V2+MANUAL[1]

CA4GA1 Engine
Service Handbook
Chief Editor: Feng Yong

Editor: Xiao Yang, Yue Xinli, Yan Meilan
Approver: Gao Jin
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Chapter One: Engine Technical Parameters and Service
Standby Parameters
Section one: Engine Technical Parameters
Section two: Service Standby
Section three: General Service Parameters
Section four: Engine Maintenance
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Section one: Engine Technical Parameters
Engine model: CA4GA1
Type: 4-stroke water-cooled EFI gasoline engine, intake VCT
Discharge capacity: 1.339 L
Position mounted: Front
Cylinder number and arrangement: four-cylinder, inline,transverse engine
Combustion chamber type: pentroof, with spark plug in the center
Valve mechanism: silent chain transmission, dual overhead camshaft
Cylinder diameter×stroke: 73×80mm
Compression ratio: 10:1
Compression pressure: 13.5 Kpa/350rpm,the pressure difference between two cylinders is less
than 100Kpa
Rated power/ revolution: 67kW/6000r/min
Maximum torque/ revolution: 120N.m/4400r/min
Working sequence: 1–3–4–2
Fuel specification: gasoline with an octane number more than 93#
Lubricating oil specification: API: SL grade is more than 5W/40
Engine dimension (length×width×height): 420X577X624 (mm)
Note: length refers to the distance between back face of the cylinder body to foremost end of the
crankshaft pulley;
Width refers to the distance between left and right ends of the engine in the upright state.
Height refers to the distance between the hignest and lowest points of the engine in the upright state.
Engine net weight (excluding air conditionor compressor, power steering pump and the combined
support): 97Kg.
Piston ring number: two compression rings and one group of oil ring
Valve timing: intake valve open, BTDC (before top dead center) 38.6°～ -6.4°
Intake valve closed, ABDC (after bottom dead center) 13.4°～ 58.4°
Exhaust valve open, BBDC (before bottom dead center) 45.3°
Exhaust valve closed, ATDC (after top dead center) 4.7°
Valve clearance(room temperature): intake valve clearance is within 0.2±0.03mm.
Exhaust valve clearance is within 0.3±0.03mm.
Idling speed: 700±50 r/min
Positive crankcase ventilation (PCV): closed PCV
Lubrication system:
Lubrication manner: pressure and splash lubrication
Oil pump type: rotor type
Oil filter: full flow type, paper filter
Lubricating oil capacity: total capacity is 3.5L, 3.0L while changing oil, and 3.5L while changing
oil filter
Cooling system: water-cooled, electric fan
Coolant capacity: 5.3L
Water pump: centrifugal V-belt transmission
Thermostat: pellet type
Air filter: paper filter
Gasoline pump type: integratedly motor, wet installation
Ignition coil: epoxy resin coil (ignition device is integrated with the coil)
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Ignition manner: electronically control each cylinder and independent ignition timing
Spark plug:
Manufacture DENSO
Model K20R-U11
Spark plug clearance（mm） 1.0～1.1
Alternator: three-phase AC rectifier 12V, 65A
Regulator type: integrated circuit
Starter: electromagnetic attraction, output is 11.5V, 1KW.
Injector assembly: needle valve electromagnetic
Fuel rail assembly: made of stainless steel, with ripple damper but without fuel return line
Crankshaft position sensor assembly: magnetoelectric
Camshaft position sensor assembly: magnetoelectric
Knock sensor assembly: non-resonant piezoelectric crystal vibration sensor
Exhaust control: dual oxygen sensor air-fuel ratio feedback control
Oxygen sensor: heat
Coolant temperature sensor: negative temperature coefficient thermistor
Throttle body assembly: electronic integrated (consisting of throttle body, position sensor and
driving motor)
Intake temperature pressure sensor assembly: integrated
Three-way catalysis: Pd-Rh
Section two: Service Standby

1. Service considerations
(1) To keep vehicle clean and prevent from damage, please use baffle plate, base and floor pad.
(2) To make assembly simple and quick, keep the removed parts in a suitable order while
removing.
(3) While repairing electrical system, abide by the following operations to keep potential safety
risks away.
① Before repairing electrical appliances, make sure to disconnect the negative cable (-) from the
battery.
② When there is a need to disconnect the connecting line from the battery while repairing or
checking, make sure to disconnect the negative cable (-),which connects the vehicle body to be the
ground line from the battery.
③ To protect the battery terminal, lossen fixed nut of the cable, lift the cable upward, and do not
twist or skid downward.
④ When cleaning terminals of the battery and cable, use special mops and do not scratch them
with files or other rough articles.
⑤ Loosen nuts when connecting cable terminal and battery terminal, tighten the nuts after fixation.
Do not use a hammer to beat cable terminal on battery terminal.
⑥ Make sure to cover the positive end cap (+) well.
(4) Check hose and conductor joints to make sure the connection is firm and correct.
(5) Replace the following non-reusable parts.
① For cotter pin, rubber gasket, O-ring, etc, make sure to replace with new parts in case failure
occurs.
② For metal gasket, T-oil seal, etc, whether to replace them depending on travelling mileages and
conditions of the parts.
③ Non-reusable parts are indicated with the sign“◆”in parts drawings.
(6) Pay attention to the precoated parts which have been coated with sealants in the production.
① If re-tightened, lossened or changed in any manner, the precoated parts will need to be coated
with specified sealants and assembled again.
② When reuse the precoated parts, clear all the original sealants, blow all the residuals on nut or
screw with compressed air, and then assemble.
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(7) Coat sealants on the gasket and sealing ring if necessary.
(8) Abide by all the specifications on bolts tightening torque, and make sure to tighten with torque
spanner.
(9) May use special service tools and materials according to the service property. Make sure to use
the special service tools and materials in the specified situations and with correct operations.
(10) When replacing fuse, check whether the rated current of the new fuse are appropriate, and do
not use fuse with higher or lower rated value.
(11) Be careful when lifting the vehicle with jack, and make sure to lift the vehicle in a suitable place.
① For safety, if only lifting the front or the rear of the vehicle with jack, make sure to choke the
wheel at the other end.
② The vehicle must be supported with stand after being lifted. If only lifting the vehicle with jack,
doing a simple and quick thing can be extremely dangerous.
(12) To protect the parts, please abide by the following requirement:
① Do not open cover and housing of the electronic control module unless necessary, if touch the
pins of the integrated circuit with hand, the integrated circuit may damage for static electricity.
② When pulling out the vacuum hose, hold the hose end and do not pull the central part to prevent
damage.
③ When pulling the circuit joints, pull the joints not the wire to prevent damage.
④ Be careful not to drop the electric components (such as sensor and relay) on a hard ground, if
dropped, the electric components must be replaced immediately and not used again.
⑤ When cleaning the engine with steam, take appropriate measures to protect ignition circuit, air
filter and various sensors to prevent damage for water.
⑥ Using pneumatic impact spanner to remove or assemble crankshaft position sensor assembly,
camshaft position sensor assembly and other sensor parts is not allowed.
⑦ When checking whether the conductor joints are conducted, insert the probes of the tester
carfully to prevent the terminal from bending.
⑧ When using the vacuometer, use a step joint and do not cover the hose onto an oversized
connecting hose with force. Once the hose has been stretched, leakage may occur.
(13) Mark the hose before removing to make sure correct connections when reassembling.
(14) All the resistances are measured at a room temperature of 20℃～30℃ unless special
situations. Because the resistance measured at the room temperature may exceed the requirement
of the specification, particularly in the case that measure immediately after running. Measurement
should be done after the vehicle has cooled down.
(15) If the vehicle is mounted with mobile communication system, such as wireless
communication equipment and cellular phone, please abide by the following considerations:
① The communication antenna should be mounted away from ECUs and sensors of the vehicle
electronic system.
② Antenna and feeder should be mounted a distance more than 20cm away from ECUs and
sensors of the vehicle electronic system.
③ Do not twist antenna, feeder and other connecting lines together, and try to layout antenna and
feeder in a different way from other wiring device.
④ Make sure antenna and feeder are adjusted correctly.
⑤ Do not mount mobile communication equipment with higher power.
2. Service standby items
(1) Engine mechanical parts
① Special service tools
No. Name Parts to be used
1 Valve guide dismantling tool Valve guide
2 Valve stem seal dismantling tool Valve stem seal
3 Valve clamp pressing tool Valve clamp
4 Connection accessory
5 Cylinder head bolt spanner joint Cylinder head bolt
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6 Crankshaft pulley dismantling clamp Crankshaft pulley
7 Body Piston pin
Piston pin dismantling Spring
clamp “C”bushing
“M”guide rod
“N”guide rod
8 Crankshaft rear oil seal dismantling tool Crankshaft rear oil
seal
9 Crankshaft front seal dismantling tool Crankshaft front seal
10 Oil filter dismantling tool Oil filter
11 Valve clearance adjusting Valve tappet pressing tong Valve clearance
tool kit Feeler
12 Crankshaft pulley fixing clamp Crankshaft pulley
13 Hose plug Various hoses
14 Fuel pressure meter Fuel pressure
15 Water pump dismantling Water pump bearing Water pump
tool dismantling tool
Water pump sealing
dismantling tool
Water pump rotor
dismantling tool
Water pump bearing
accepting tool
Water pump bearing plate
16 Engine overhaul bracket Engine
17 Engine overhaul connector Engine
18 Flywheel stopper Flywheel
19 Cylinder head dismantling clamp Cylinder head
20 Engine hanger Engine
21 Piston tool Piston
22 Sealant gun Various sealants
23 Clutch housing and pressure plate dismantling tool Clutch housing and
pressure plate
24 Oil dish dismantling tool Oil dish，rear oil seal
seat assembly etc
25 (Slotted and Phillips) screwdrivers
26 Scraper Remove sealant,
carbon etc
27 Radiator cap tester Radiator cap
28 Cylinder diameter measuring tool Cylinder diameter
29 Cylinder bore chamfering reamer Cylinder bore
② Tools recommended
No. Name Parts to be used
1 Spark plug spanner Spark plug
2 Engine adjusting tool kit
3 Packaged hose plug various hoses
4 Packaged expander various hoses
5 Extension rod kit Crankshaft pulley
bolt etc
③ Devices
No. Name
1 Connecting rod aligning tool
2 Graduated cylinder
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3 Centimeter
4 Dye penetrant
5 Heater
6 Magnetic bar
7 Micrometer
8 Piston ring expander
9 Piston ring compressor
10 Plastic clearance gauge
11 Precision straight edge
12 Soft brush
13 Spring testing tool
14 Steel square
15 Thermometer
16 Torque spanner (large, medium and small)
17 Valve reamer
18 Slide caliper
19 Calliper
20 CO/HC（carbon monoxide / hydrocarbon）tester
21 Pressure meter
22 Revolution meter
23 Cylinder bore reamer
④ Special sealants
No. Applying parts name Types of sealants Remarks
1 Stud bolt-mounting front bracket TB1322 Glue on cylinder head ends
of engine
2 Cylinder body sand hole TB1386D Glue on plug edges
bowl-shaped tabular plug
3 Cylinder body main oil gallery TB1386D Glue on plug edges
4 Hexagon head tapered screw TB1110B Glue on thread of the plug.
plug –cylinder body plug hole
5 Cylinder head sand hole TB1386D Glue on plug edges
6 Crankshaft rear oil seal seat TB1280E Glue on crankshaft rear oil seal seat plane
assembly
7 Stud bolt –intake manifold TB1322 Glue on cylinder head ends
8 Stud bolt –exhaust manifold TB1322 Glue on cylinder head ends
9 Engine oil dish assembly TB1280E Glue on cylinder body base plane, and
diameter depends on the tests
10 Joint surface of oil dipstick pipe TB1280E Glue on the head of oil dipstick pipe
and cylinder body locating hole
11 Joint-oil filter TB1110B Glue on oil filter ends
12 Stud bolt–mounting idler TB1322 Glue on cylinder head ends

assembly
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13 Chain chamber cover cap TB1280E Glue on chain chamber cover cap
assembly
14 Engine water inlet pipe seat TB1280E Glue on engine water inlet pipe seat plane
assembly
15 Engine water outlet pipe TB1280E Glue on engine water outlet pipe plane
16 Stud bolt-mounting engine water TB1110B Glue on thread

inlet pipe seat assembly
17 Coolant temperature sensor TB1110B Glue on thread
assembly
18 Oil pressure alarm assembly TB1110B Glue on thread
19 Pressure-limiting valve assembly TB1110B Glue on thread
20 Stud bolt-chain tightener assembly TB1322 Glue on thread
21 Chain lubricating nozzle TB1110B Glue on thread
22 Cylinder gasket assembly TB1280E Glue on top surface of cylinder body front
ends
23 Oil drain plug assembly TB1280E Glue on the thread of oil drain plug
assembly.
Note: 1. Chemical products from ThreeBond are recommended by the sealant provider.
2. The first two loops of the thread are not coated with sealant.
3. Do not squeeze sealant into water duct or oil duct when coating them to prevent the water and
oil ducts from being blocked.
(2) Electronic fuel injection
Refer to “CA4GA1 engine service handbook (electric control parts)” for details.
Section three: General Service Parameters

1. Mechanical parts
(1) Service data
Cylinder head Joint surface deformation
Cylinder body side specified value 0.05
accepted limit 0.10
Maximum repair-amount 0.16
Inlet and exhaust manifolds side specified value 0.08
accepted limit 0.16
Valve seat width
Intake side 1.3±0.2
Exhasut side 1.3±0.2
Valve seat contact angle 45°±30′
Valve seat accepted lower limit 1.1
First camshaft bearing seat
Intake φ32(＋0.055, ＋0.030)
Exhasut φ26(＋0.021,0)
Second to fifth camshaft bearing seats
hole standard value φ23(＋0.021,0)
Oil nozzle hole diameter
Standard φ12
Limit φ12.5
First camshaft Intake side Locating slot width 3(＋0.05,0)
bearing cap Exhasut side Bearing cap width 21(＋0.05,0)
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Valve guide Valve guide diameter
Intake valve φ5（＋0.022,＋0.010）
Exhasut valve φ5（＋0.022,＋0.010）
Valve guide protrusion height 15.1±0.2
Valve Taper angle 45°30′

Valve stem external diameter
Intake valve specified value φ5（－0.010,－0.028）
Limit φ4.962
Exhasut valve specified value φ5（－0.020,－0.038）
Limit φ4.952
Valve oil clearance
Standard Intake 0.02～0.05
Exhasut 0.03～0.06
Limit Intake 0.07
Exhasut 0.09
Edge thickness
Standard Intake 1.40
Exhasut 1.45
Limit Intake 0.9
Exhasut 1.0
Valve spring Free height Standard value 45.2

Limit value 46.2
Mounting height Standard value 37
Spring pressure Standard value 160(N)
Limit value 419(N)
Verticality deviation（reference） 0.15
Tappet Tappet diameter φ28(－0.025,－0.038)

Oil clearance
Standard value 0.025～0.059
Limit value 0.09
Intake camshaft Shaft diameter Standard value
First camshaft diameter φ32(0,－0.016)
Second to fifth camshaft diameter φ23(－0.035,－0.051)
Cam height Standard value 40.5
Limit value 40.35
First shaft diameter oil clearance
Limit value 0.10
Fifth shaft diameter oil clearance
Limit value 0.11
Radial runout Standard value 0.03
Limit value 0.04
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Exhasut camshaft Shaft diameter Standard value
First camshaft diameter φ26(－0.035,－0.051)
Second to fifth camshaft diameter φ23(－0.035,－0.051)
Cam height Standard value 40.4
Limit value 40.25
Shaft diameter oil clearance
Limit value 0.11
Radial runout Standard value 0.03
Limit value 0.04
Cylinder body Top surface deformation Standard value 0.05
Maximum value 0.10
Cylinder bore diameter(standard) GradeA φ73～φ73.01
Grade B φ73.01～φ73.02
Grade C φ73.02～φ73.03
Wear limit 0.08
Amplified 0.25mm φ73.25～φ73.28
Oil pump hole diameter Standard φ55.1(＋0.06, ＋0.03)
Limit φ55.3
Piston Piston diameter Standard Grade 1 φ72.97～φ72.98

Grade 2 φ72.98～φ72.99
Grade 3 φ72.99～φ73.00
Wear limit
Amplified 0.25mm φ73.25
Amplified 0.50mm φ73.50
Piston oil clearance Standard value 0.02～0.04
Limit value 0.06
Piston ring Piston ring thickness

First compression ring 1.2
Second compression ring 1.2
Oil ring 2.8
Piston ring gap clearance (standard)
First compression ring 0.20～0.30
Second compression ring 0.40～0.55
Oil ring 0.20～0.70
Limit value First compression ring 0.5
Second compression ring 0.7
Oil ring 1.0
Piston ring groove clearance (Standard)
First compression ring 0.04～0.09
Second compression ring 0.02～0.06
Limit value First 0.13
Second 0.08
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Piston pin Piston pin External diameter φ18(＋0.034, ＋0.028)
Clearance between piston and piston pin
Standard 0.005～0.011
Limit 0.016
Value of interference with connecting rod 0.017～0.034
Connecting rod Flexural deformation Limit 0.03
Torsional deformation Limit 0.03
Connnecting rod big end clearance
Limit 0.052
Connnecting rod axial clearance
Limit 0.50
Crankshaft Spindle diameter Standard φ46(0,－0.018)
Spindle clearance
Limit 0.068
Connecting rod shaft diameter
Limit 0.052
Crank pin diameter
Standard φ40(0,－0.018)
Flywheel Radial runout 0.12
Joint surface runout 0.08
Dynamic unbalance ≤25gcm
VCT controller Internal diameter Standard φ32(＋0.045,＋0.014)
assembly Limit φ32.06
Intake manifold Protrusion height from the cylinder head
joint surface Standard 2±0.1mm
Limit 1.8mm
Exhaust manifold Joint surface between exhasut manifold
and cylinder head Standard 0.15
Limit 0.25
Valve clearance Cold Intake valve 0.2±0.03mm
Exhasut valve 0.3±0.03mm
Compression If 350rpm, Standard 13.5 bar
pressure of cylinder Pressure difference between two cylinders ≤1.0 bar
Timing chain Flexibility limit Flexivity 4mm [when applying a force
of 127N]
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V-belt New V-belt Flexibility 7 ～ 9mm [when
applying a force of 10kgf]
Old V-belt Flexibility 11.5 ～ 13.5mm
[when applying a force of
10kgf]
Chain chamber OCV control valve hole diameter
cover cap Standard φ18(＋0.018,0)
Limit φ18.045
Joint surface deformation Standard 0.10
Limit 0.25
Crankshaft pulley Crankshaft pulley and shock absorber
and shock assembly diameter Standard φ144
absorber assembly Limit φ140
Dynamic unbalance ≤5gcm
Clutch lid assembly Separation fingertip runout Standard ≤0.5
Limit 0.7
Residual unbalance ≤15gcm
Clutch driven plate Average thickness Standard 8.0～8.4
assembly Limit 7.8
Residual unbalance ≤30gcm
Note: in millimeter
⑵ Specifications of tightening torque
No. Name Quantity Specification Tightening Remarks
torque (N.m)
1 Bolt and nut of engine front 2+2 M10 50±10
bracket
2 Cylinder head bolt 10 M9X1.25 34±3+120° Dip oil
3 Cylinder head cover cap bolt 11+2 M6 11±2
4 Connecting rod bolt 8 M8X1 22±2.5+90° Dip oil
5 Main bearing bolt 10 M10X1.25 60±5 Dip oil
6 Flywheel bolt 6 M10X1.25 78±5
7 Crankshaft pulley bolt 1 M14X1.5 200±10
8 Rear oil seal seat assembly 4 M6 8±2
9 Camshaft bearing cap 20 M6 12.5±2
10 Stud bolt for connecting intake 5+5 M8 6±1.2
and exhaust manifolds and
cylinder head
11 Nut for tightening intake 5 M8 19±4
manifold
12 Nut for tightening exhaust 5 M8 23±5
manifold
13 Bolt and nut of oil dish 14+2 M6 8±2
14 Oil drain plug assembly 1 M16X1.5 30±5
15 Oil pump assembly 3 M6 9±1.8
16 Pressure-limiting valve 1 M22X1.5 40±5
assembly
17 Oil filter joint 1 M20X1.5 44±9
18 Idler assembly 1 M10 44±9
19 VCT controller assembly 1 M10 47±7
20 OCV control valve assembly 1 M6 8±2
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21 OCV control valve filter bolt 1 M14X1.5 24.5±5
22 Exhaust camshaft sprocket 3 M6 8±1.6
23 Chain tensioner arm bolt 1 M10 19±3.8
24 Chain guide assembly 2 M6 8±2
25 Bolt and nut of chain tightener 1+1 M6 9±1.8
assembly
26 Chain mounting bracket 2 M6 8±2
27 Chain chamber cover cap 10 M6 12±2.4
assembly
28 Inlet pipe seat 3 M8 22±4
29 Outlet pipe 2 M8 22±4
30 Water pump assembly 5 M6 9±1.8
31 Coolant temperature sensor 1 M12X1.5 20±2
assembly
32 Intake temperature and 2 M6 5±1
pressure sensors assembly
33 Camshaft position sensor 1 M6 7±1
assembly
34 Knock sensor assembly 1 M8 20±5
35 Front and rear oxygen sensor Both 1 M18X1.5 45±5
assemblies
36 Electronic throttle body 4 M6 10±2
assembly
37 Rod ignition coil assembly 4 M6 8±2
38 Spark plug assembly 4 M14X1.25 18±3.5
39 Oil pressure alarm switch 1 NPT 1/8 15±5
assembly
2．Service data for cooling system

Water pump Type Centrifugal
Pump lift ≥147KPa
Flow rate ≥135l/min
Cooling fan Type Suction

Rotate mode Right handed rotation
Thermosistor Temperature (℃) when valve opens 80±2
Temperature (℃) when valve fully opens 95
Valve lift mm ≥8
3. Service data for lubricating oil

Oil pump Rotor axial clearance Standard 0.033～0.065
Limit 0.10
External rotor top clearance Standard 0.7～0.8
Limit 1.3
Internal and external rotor side clearance
Limit 0.18
Driven rotor and cylinder body clearance
Limit 0.4
Oil pump sprocket Tooth number 25
Oil filter Filter area (cm2) 860

Bypass valve opening pressure (kgf/cm2) 0.1±0.02MPa(1.0±0.2)
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4. Ignition system service data
Ignition 1-3-4-2
sequence
Spark plug Model K20R-U11
Electrode gap 1.0—1.1
5. Fuel system service data refer to “CA4GA1 engine service handbook (electric control parts)”.
6. Electric control system service data refer to “CA4GA1 engine service handbook (electric
control parts)”.
Section four: Engine Maintenance

Running-in of the engine
Considerations
(1) CA4GA1 engine is a high compression ratio engine, the gasoline needed must be motor
gasoline more than RON93#, and low grade gasoline is not allowed.
(2) Check whether engine oil pressure is correct, under normal condition, when power switch (key)
turns to “ON” position, at the function of oil pressure sensor, the oil low pressure indicator is on
(red), which indicates there is no pressure in lubrication system. Then turn the switch to “START”
position, the engine starts and runs idly, the oil low pressure indicator goes out automatically,
which indicates that the oil pressure in lubrication system is normal, now the engine can be used.
It should be noted that the engine can be used only after oil pressure has been confirmed to be
normal, otherwise, severe failure and economic damage of the engine may be caused.
(3) Check of the coolant. Firstly open the filler cap on the top of the water tank, fill up with
coolant, tighten the filler cap, and observe the fluid reservoir at the back of the water tank. When
the engine is cold, the coolant level should be close to “FULL”line of the fluid reservoir, then
the cooling system is normal and the engine can be used. If coolant level is much too low, and
close to “LOW”line, open the fluid reservoir cap, add coolant with specified desingnation and
concentration to “FULL”line.
After adding, cover the fluid reservoir cap tightly, and tighten the pawl. The engine is not allowed
to use when the coolant is insufficient. Check the coolant height of the fluid reservoir twice a week,
keeping it at “FULL”line all the time.
(4) Check of the water temperature. When the water temperature of the engine is more than or
close to danger area of the water thermometer, stop the vehicle to clear the failure, and the engine
can be used again. Otherwise, cylinder head may be deformed and the engine may be damaged.
The pointer of the water thermometer under normal running is in the central position or slightly to
the right, and not beyond 100℃.
(5) New engine is not allowed to stop suddenly while running at high speed and high load. The
engine can be stopped after running at a low speed for 3 to 5 minutes, this will help the engine
reduce failure and extend service life.
(6) When the engine is mounted on minicar to do running-in, it’s better to run on cement or
asphalt road surface, not on muddy or sandy road surface as much as possible.
(7) The vehicle with our product has a miximun speed of 80Km/h in the running-in period.
(8) The load is not allowed to exceed 50% of the maximum load within the first half of the
running-in period, and 75% of the maximum load within the second half of the running-in period.
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(9) Other requirements of the engine on running-in period should be strictly followed under the
running-in specification of the finished vehicle.
2. Engine Maintenance
(1) It is necessary to check the amount of the engine lubricating oil every day, if there is abnormal
consumption on lubricating oil, check the engine carefully to determine whether oil seals (various)
leak oil or piston ring (or piston) has failures.
(2) Because the cooling system of the engine is closed, make sure not to open water tank cover
immediately after stopping in the hot state, otherwise, human may get burnt by the liquid injected
under high pressure.
(3) Maintenance should be done according to the contents of considerations pasted on two sides of
the door and realized.
(4) Take care whether the display on each meter and failure indicator light is normal during
running, if it is abnormal, stop the vehicle immediately and restart the engine only after the failure
has been cleared.
(5) Check connecting hoses of the engine regularly to make sure the connection reliable, otherwise,
the engine may work abnormally.
(6) Pay special attention to the oil pressure alarm indicator, if the indicator is on, the oil pressure
of the engine is much too low, stop the vehicle immediately to check the lubrication system, and
restart the engine only after the failure has been solved.
(7) The engine oil should be replaced every 5000 km.
Air filter should be cleaned every 5000 km on the asphalt road and every 2500 km on the dusty
road, and replaced every 15000 km.
Electronic throttle body assembly should be checked every 10000km.
Gasoline tank should be cleaned every 20000 km.
Each bolt should be tightened to specidied torque before the vehicle runs on the road.
(8) The oil filter assembly should be replaced every 2000 km during the new vehicle running, then
every 8000 km later on. A layer of oil must be coated on the sealing ring during every
replacement.
(9) If feeling the power and economic performances of the engine have been reduced significantly,
stop the engine to check, not allowing the engine to work with failures.
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Chapter Two: Engine Structures
Section one: Cylinder Body, Cylinder Head and Crank-link Mechanism
Section two: Valve Timing Mechanism
Section three: Lubrication System
Section four: Cooling System
Section five: Intake and Exhaust Systems
Section six: Fuel System
Section seven: Ignition System
Section eight: Other Sensors and Actuating Mechanisms
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Section one: Cylinder Body, Cylinder Head and Crank-link Mechanism
Cylinder Body
Cylinder body has four cylinders, five main-bearing journals, equal bore spacing, a gantry
structure, and is integrated with crankcase. Being made of alloy cast iron, the mass is less than
28.7kg, general wall thickness is 3.5mm, no more than 4.5mm at most.
Cylinder Body
Water jackets are provided on two sides of each cylinder to keep a good cooling effect, the water
jackets on two side walls are 4 mm thick, and 97mm high, which is slightly more than the stroke
size.
The main bearing cap is made of iron based powder metallurgical material, and all the main
bearing supports of the same body are connected in brace type, having a reliable rigidity and
strength. The main bearing cap is marked with forward arrow and serial number, and needs to be
mounted according to the number.
To reduce noise and vibration, side wall and main bearing support are provided with stiffening ribs
in the periphery to form a structure with a higher rigid.
Cylinder body is punched with match grouping code of cylinder hole and match grouping codes of
main bearing bore and bush at the bottom surface.
Dimensions of the cylinder body
Total height ×full length ×total width（mm） 246×355.5×317
Cylinder diameter（mm） 73
Bore spacing（mm） 80
Main bearing bore diameter（mm） φ50
- 17 -
Cylinder Head and Combustion Chamber
Cylinder head, with a structure of dual overhead camshaft, is made of alloy cast aluminum, and
water jackets are equipped to cool the cylinder head. Combustion chamber is pentroof type, with
spark plug in the center, which can make flame transmission uniform.
Valve seat bore inclines slightly, the incline angle of intake valve seat bore is 14°30′ while that of
exhaust seat bore is 15°12′, and the valve seat bore is pressed into the cylinder head. Two rows of
camshaft bearing seats are arranged on the cylinder head, the first camshaft bearing seat of which
is siamesed. The bigger the cylinder head, the higher the rigidity. Lubricating oil sump is cast in
the siamesed camshaft bearing seat, cylinder head bolt seat surface is arranged in a deeper position,
and oil nozzle is mounted on the cylinder head.
Cylinder Head and Combustion Chamber
- 18 -
First Camshaft Bearing Seat
Intake inlet is cyclone type, which can cause the gas entered into the combustion chamber to turn,
thus combustion efficiency and volumetric efficiency can be improved.
Piston, piston pin and piston ring
Piston material is made of cast aluminum alloy, and a big pit is cast on the top to increase the
capacity of the combustion chamber. Piston is provided with two avoidance pits at intake side of
the top to prevent collision with the intake valve. With 3-ring short skirt type, the piston is printed
with graphite coating, the first ring groove and part of ring land (including piston top surface) are
oxidized, ensuring safety and durability, resisting severe thermal loads and mechanical loads, and
also reducing weight. Select piston and cylinder body to match the clearance. The weight
difference of 4 pistons of the same engine should be no more than 3 grams. Piston top is marked
with forward label (arrow), and printed with external diameter grouping codes (A, B, C). Piston
pin hole is distinguished with red and yellow. Barrel-type line of piston skirt uses hyperbolic
cosine function, barrel-type skirt surface and cylinder wall form a two-way wedge-shaped oil film,
making the skirt portion with higher carrying capacity and good lubrication. In addition, tapper
load can be avoided when piston tilts in the moving, reducing impact to cylinder wall.
To ensure the surface hardness of the piston pin, the internal and external surfaces of the piston pin
are carburized. Piston diameter label is marked with red and yellow, and applied on piston pin end
surface.
To reduce mechanical loss, the first and second piston rings are thin rings, and oil ring is a
combined ring with two side rings and one bushing ring.
The first piston ring is barrel-type, and the contact surface with cylinder is plated with hard
chromium layer to reduce abrasion, the second piston ring is tapered, and the surface is
phosphated. The contact surface between blade of combined oil ring and cylinder is plated with
hard chromium layer, and the rest is under manganese phosphating treatment. Bushing ring is
soft-nitriding.
Place the marked surface upward when mounting piston ring, and the ring openings shall be
separated by 120 °.
- 19 -
plated with hard chromium
label

label
soft-nitriding piston and piston ring
piston and piston ring
Connecting rod and connecting rod bush

Connecting rod is made from forged chrome steel, and has a higher rigidity. Forward labels of
connecting rod and connecting rod cap should be in the same side and in the front of engine when
assembling. The weight difference of 4 connecting rods of the same group should be no more than
3 grams. Grouping labels (1, 2) of connecting rod big end are two, and printed at the side of
connecting rod body. Connecting rod mass grouping labels (A, B, C, D, E) are five and printed on
the connecting rod cap.
- 20 -
Connecting rod
Connecting rod bushes are of two pieces, the upper one is mounted on connecting rod body, and
the lower one is on connecting rod cap. (Upper and lower) connecting rod bushes are divided into
four groups within specified thickness tolerance. Any two end faces of the bush are painted with
colors. Connecting rod bush locating lug is in the side. To match with the clearance, select and
assemble according to the size groupings of each parts.
Upper connecting rod bush

Connecting rod bush locating lug
Lower connecting rod
connecting rod bush

Crankshaft and bush
Crankshaft is made of ductile cast iron, and has five main journals, eight balance weights. With a
crank angle of 180°, crankshaft is symmetrically arranged on the same plane. Although crankshaft
is already in dynamic balance, in order to bear inner moment, so that crankshaft can achieve inner
balance, two groups of balancing blocks with different masses are arranged.
The third crankshaft main journal bears axial thrust, and two thrust pads made of aluminum-tin
alloy are mounted on two sides of cylinder for supporting the third main journal.
Balance weights eliminate the inherent vibration of the engine.
Crankshaft front balance weight is printed with connecting rod journal match grouping code in the
side surface, while rear balance weight is printed with main journal match grouping code in the
side surface.
- 21 -
Crankshaft main journal and crankshaft connecting rod journal use fillet rolling to improve fatigue
strength.
Crankshaft main journal diameter (mm) 46

Crankshaft connecting rod journal diameter (mm) 40
The first and fifth main bushes of the crankshaft are all made of aluminum-tin alloy, upper bush is
opened with one oil slot and one oil hole, and with bush locating lug in the side.
Crankshaft bush
Flywheel
Crankshaft is mounted with timing sprocket and crank pulley at the front, respectively driving
camshaft, water pump and engine.
Flywheel with gear ring is mounted on the rear end of crankshaft with six bolts, and flywheel body
is provided with signal gear, which can output engine revolution signal. The specifications are as
follows:
External diameter(mm) 242

Mass (kg) 6.45
Gear ring teeth 103
Gear ring modulus 2.54
Pressure plate diameter (mm) 205
- 22 -
revolution signal teeth 30 teeth
Dynamic unbalance weight is less than 25gcm
Crank pulley
To reduce torsional vibration of crankshaft, the engine is designed with radial V-belt crank pulley
and mounted with shock absorber, reducing radiated noise on engine front end, thus reducing
noise of the whole vehicle significantly and the weight.
crank pulley specifications
External diameter of crank pulley（mm） 144
V-belt slot angle 40°
V-belt slot number 6
Dynamic unbalance weight is less than 5gcm
Crankshaft oil seal

Crankshaft front oil seal and crankshaft rear oil seal is of T-type structure with spiral lines (spiral
slots), the purpose is to prevent oil from leaking. T-type oil seal has a significant sealing property,
and can force oil to flow back to the engine when crankshaft runs, at the oil pumping of spiral slot.
Crankshaft rear oil seal
Crankshaft front oil seal

oil seal specifications
Item Internal diameter External diameter Thickness
Front oil seal（mm） φ33.8 φ49 6

Rear oil seal（mm） φ72.1 φ89 8.5
Cylinder head cover cap assembly
- 23 -
Cylinder head cover cap assembly is die-cast by aluminum alloy, and has many curved surfaces.
There is a ventilation baffle, so that blow-by gas can enter intake manifold through the crankcase
ventilation valve assembly to burn, after the oil containing in the gas is removed.
Cylinder head cover cap assembly

Section two: Valve Timing Mechanism
CA4GA1 engine valve driving mechanism adopts dual overhead camshafts with intake VCT
controller assembly driven by the timing chain, camshaft is fixed on top of cylinder head, and
supported by five bearing seats to drive two intake valves and two exhaust valves, which is a
typical valve direct-drive mode. With a high rigidity and good follow-up within the whole
working range, approximate in-line arrangement intake and exhaust valve can get almost smooth
torque curves, improving air flow to go through.
Timing chain assembly and sprocket
Timing chain
Pitch circumference Pitch(mm) Segment Width (mm)
(mm)
1003 6．35 158 11．5
The engine drives exhaust camshaft with timing chain to keep stable running and low noise. This
kind of timing chain is very sensitive to bending, and has significantly reduced strength if bent,
- 24 -
therefore, try to avoid bending timing sprocket. Keep water or other chemical liquids away from
the timing chain, because these contaminants will rust the chain. There are two groups and one
piece yellow chain as the timing labels.
Timing chain
Sprocket
There are four types of sprockets, one is exhaust camshaft sprocket mounted on exhaust camshaft;
one is crankshaft sprocket mounted on crankshaft; one is sprocket on oil pump; and one is
sprocket on VCT controller assembly. Each sprocket is marked with engaging label (except the
sprocket on oil pump), match the labels on chain at assembling.
Exhaust camshaft crankshaft Oil pump VCT controller
sprocket sprocket sprocket assembly sprocket
Teeth 42 21 25 42
External 83 40．5 48．6 83
diameter
Chain tensioner assembly and chain tensioner arm assembly
By releasing chain tensioner spring, tensioning ball of chain tensioner is ejected to provide a
proper tensioning force for chain tensioner assembly, ensuring a reliable transmission, and
improving service life of the timing chain. Parts of the tensioner do not need maintenance.
Chain tensioner assembly
Chain tensioner arm assembly
Chain tensioner assembly and chain tensioner arm assembly

Camshaft
- 25 -
Intake and exhaust camshafts are made of chilled alloy cast iron, and the camshaft angle is 90°.
Exhaust camshaft assembly drives the intake camshaft assembly. Intake camshaft assembly has
phase advance and delay oil lines on the first journal.
Intake and exhaust camshaft assemblies

Camshaft specifications
Item 1st journal size（mm） Other journal size Lobe tip height（mm）
（mm）
exhaust camshaft 26 （－ 0.035 ～－ 23 （－ 0.035 ～－ 40.4
0.051） 0.051）
intake camshaft 32(0,－0.016) 23 （－ 0.035 ～－ 40.5
0.051）
3. Intake camshaft assembly is driven by exhaust camshaft assembly through the exhaust camshaft
sprocket drives sprocket on VCT controller and the intake camshaft sprocket assembly, which are
fixed on intake camshaft assembly.
4. Intake valve, exhaust valve and valve spring
Full length (mm) Valve head diameter Valve stem diameter
(mm) (mm)
Intake valve 88.1 27 5.0
Exhaust valve 88.65 23 5.0
Intake and exhaust valves are made of chromium silicon steel, valve head diameter is big in size,
improving intake and exhaust efficiency. Valve spring is made of chromium silicon steel, and has a
higher follow-up property and inherent frequency.
Valve spring specification in free state
Free length (mm) Spring mean Steel wire Total coils Effective coils
diameter (mm) diameter (mm)
45.2 16.6 3.2 9 7
- 26 -
Valve spring in assembling state
Length (mm) Load (N)
37 160±8
29.5 399±20
Spring rigidity: 31.9N/mm
4.Valve tappet
Valve tappet is designed to be cylinder-type to ensure that valve has a uniform force during
running and higher follow-up property. Valve tappet surface is under carbonitriding treatment, the
measured thickness of the tappet is printed on the inner top surface. To ensure valve clearance is
within the specified valve, match integral tappet with corresponding thickness during assembling
based on actual measured results.
5. VCT controller and intake camshaft sprocket assembly
VCT controller and intake camshaft sprocket assembly are means to control lobe phase of intake
camshaft assembly by the engine oil pressure difference. The intake angle of intake camshaft can
be changed in accordance with the working condition of the engine to save fuel.
VCT controller assembly

Section three: Lubrication System
The engine is lubricated by combination of pressure and splash to force-feed and full-flow
filtration.
Oil is pumped from oil pan through suction filter by oil pump to oil filter, then to main oil gallery,
and is distributed into each main journal, connecting rod journal, camshaft bearing seat, OCV
control valve assembly, VCT controller assembly and etc.
- 27 -
Exhaust camshaft supplies oil to lubricate exhaust bearing seat through the oil gallery, intake
camshaft supplies oil to intake bearing seat through the oil gallery to keep a good lubricating on
secondary friction surface.
Other parts of the engine, such as camshaft lobe, piston, piston ring and cylinder wall, crankshaft
thrust pad, timing chain, and oil pump driving sprocket are lubricated by splash.
Cylinder head oil

gallery
Connecting rod
Main bearing holes
Intake camshaft Exhaust camshaft OCV control

first bearing seat first bearing seat valve filter
First main
Other main
bearing cap
bearing caps
OCV control valve
assembly
on off
Main oil gallery

Intake camshaft (rear)
Intake Exhaust
camshaft camshaft first bearing seat Chain lubrication
bearing seat bearing seat nozzle
Oil filter
VCT controller
assembly
Pressure
Main oil gallery
limiting
(front)
assembly
Intake camshaft
first bearing seat Oil pump
OCV control valve Oil coarse filter

filter
Oil pan
lubrication system flowchart

(1) Oil pump assembly
Rotor oil pump assembly is mounted on cylinder body and driven by crankshaft sprocket through
- 28 -
timing chain. External and internal rotors of oil pump are mounted on cylinder body. Pressure
limiting valve is mounted on cylinder oil gallery, when oil pump reaches oil supply pressure,
pressure limiting valve drains oil, the drainage lubricating oil returns to oil pump. Oil pump is
mounted with driving sprocket for driving oil pump to rotate.
oil pump assembly

oil pump assembly specification
Type Cycloidal gear
More than 4.5(output pressure is 150KPa, oil pump revolution is
588r/min)
More than 14(output pressure is 400KPa，oil pump revolution is
Output flow（L/min）
1680r/min)
More than 41(output pressure is 450KPa，oil pump revolution is
5040r/min)
Pressure limiting valve is integrated in structure, spring is compressed in plunger and housing.
Pressure limiting valve in free state Pressure limiting valve assembling state
Free Spring Steel Tota Effectiv Length (mm) Load (N)
lengt mean wire l e coils 30.9 50.85
h diamete diamete coils 24.6 76.2
(mm) r (mm) r (mm)
43.6 9.8 1.4 12 10
Spring rigidity：4N/mm
- 29 -
oil pump sprocket teeth
oil pump sprocket teeth oil pump sprocket external diameter (mm)
25 48．6
Lubricating of valve driving mechanism

After flowing through each camshaft bearing seat, lubrication oil of valve driving mechanism
immerses tappet and valve assembly for ensuring sufficient lubrication and heat dissipation.
valve cotter
Lubricating of valve driving mechanism

Oil filter
Oil filter is a cartridge filter, pressure limiting bypass valve is mounted in the closed structure,
when the pressure difference achieves the specified value, bypass valve open. Leakage and
damage cannot occur within two minutes when oil filter is under 2MPa.
Oil filter
Filter area 860 cm2
Opening pressure of bypass valve 0.1±0.02MPa(1.0±0.2 kgf/cm2 )
Oil filter should be replaced every 2000km for a new vehicle, and later every 8000 km.
Oil pan
Oil pan is used to store lubricating oil, made of pressed steel, and welded with oil baffle. To
prevent lubricating oil from leaking, the joint surface between oil pan and cylinder body is applied
with a loop of sealant. Drainage plug assembly has magnetic core for absorbing metal crumbs and
is mounted at the lowest end of oil pan.
engine oil capacity
Oil capacity（L） Oil pan maximum capacity Oil pan minimum capacity
（L）（L）
4.0 3.5 2.0
Maintenance of lubrication system
Classified by lubricating oil API (American Petroleum Institute)
Gasoline engine SC，SD，DE，SF，SJ，SL, etc
Recommended lubricating oil viscosity SL grade
Recommended lubricating oil desingnation SL 5W/30 or 10w/30
Depending on the area of the user, it is very important to select proper lubricating oil viscosity for
keeping a good performance in the running state. Especially in cold area, lubricating oil viscosity
- 30 -
is more important, because lubricating oil influences the starting revolution directly.
When there is a need to add or replace lubricating oil, select proper lubricating oil depending on
the climate of the running area. When engine is continually in high speed running, make sure to
use SL 5W/30 or 10w/30 lubricating oil.
replacing period of engine lubricating oil
Item API classification replacing period
Gasoline engine lubricating oil More than SL every 8000km or every half year
Note: calculated by the first expired mileage or the date.
Make sure whether engine lubricating oil and oil filter are valid when doing maintenance.
Section four: Cooling System

Cooling system of the engine is a closed, forced water-cooled circulating system, consisting of
water pump, thermosistor assembly, water temperature sensor, cylinder body, various water
jackets of cylinder head and electronic throttle body, and water pipes for connecting these
members.
Cylinder water channel

Water outlet pipe
Cylinder head
Water pump
water jacket
Cylinder head longitudinal water jacket

Electronic throttle body
assembly
Thermosistor OFF Engine water inlet seat assembly Heater
Thermosistor ON
Radiator
Cooling system flowchart

Water pump assembly
Water pump assembly is of centrifugal type, and mounted on cylinder front end. Pump body is
made of aluminum alloy, and has a reduced weight. Water pump impeller is made of metal and has
a diameter of 59mm.
Water pressure is 0.138 MPa, time is 1 min, and leakage is less than 3ml/min.
Flow characteristics of water pump assembly
Item
Temperature ℃ Pump lift (kPa) Flow rate (l/min)
Revolution
7200r/min 80±2 ≥147 135
Thermosistor assembly
The engine has wax type thermosistor assembly, and is equipped with anti-push rod and water
baffle, opening temperature is marked on the edge of thermosistor assembly, this kind of
thermosistor assembly is almost free from the influence of internal pressure of cooling channel.
When the temperature reaches over 80℃, wax expands to open the valve, coolant enters the
internal cooling recirculation system of the engine; when the temperature is lower than 80℃, and
- 31 -
the valve is closed, only keeping internal recirculation of the engine.
First opening temperature of the thermosistor assembly valve ℃ 80±2

Full opening temperature of the thermosistor assembly valve ℃ 95
Full lift of the valve (mm) ≥8
Coolant temperature sensor
The engine uses thermistor-type, coolant temperature sensor with negative temperature coefficient, which
is mounted on intake seat on cylinder head rear end. Coolant temperature sensor transmits inductive
signal to the control computer, so as to optimally control the oil injection, ignition of the engine, and
simultaneously displays the cooling temperature and controls running of the electric fan.
Coolant temperature
Performance parameter between A, C pins：
Temperature range（℃） Resistance value(KΩ)
－20±0.1 13.71～16.49
25±0.1 1.825～2.155
80±0.1 0.303～0.326
110±0.1 0.1383～0.1451
Resistance between B-pin and sensor
Temperature range（℃） Resistance value(Ω) Combined with standard resistance（℃）
55 220.5（＋48.6,－38.7） ±5
60 181.8（＋38.7,－27.7） ±5
112 33.8（＋5.1,－4.07） ±5
117 29.8（＋4,－3） ±5
Section five: Intake and Exhaust Systems

Fresh air, inhaled from the air filter, enters the electronic throttle body assembly through the intake
hose, flows into the intake manifold, and cylinder head air path in turn, and the gas in the
combustion chamber after combustion exhausts from the exhaust manifold.
1. Intake system
Electronic throttle body assembly
Electronic throttle body assembly consists of throttle body, position sensor, and driving motor.
Electronic throttle body assembly is mounted on the air intake of intake manifold with four long
bolts. Driving motor on the electronic throttle body assembly controls throttle opening
- 32 -
automatically. Refer to “CA4GA1 engine service handbook (electric control parts)” for details.
Electronic throttle body assembly

Basic parameters of electronic throttle body assembly
Throttle body Hole diameter（mm） φ45
Inlet diameter × length（mm） φ55×25
Contact angle 6°
Working angle（Max） 99°
Driving motor Shaft locking current (A) 9．4±3．2（25℃，12V）
Position sensor Output voltage when valve is fully 0.6±0.1

closed（V）
Intake valve angle 90％response(full close→full open)(ms) 150
90％response (full open→full 120
close)(ms)
Intake manifold assembly
Intake manifold assembly is made of engineering plastics, with updraft structure, and manifold
assembly joint surface and electronic throttle body form an angle of 68 °. Intake manifold
assembly is equipped with electronic throttle body assembly and intake temperature and pressure
sensor. Air enters intake manifold balanced case through the throat of the electronic throttle body,
and eliminates intake fluctuation in the balanced case. Steady, uniform air flows respectively into
four air paths of the cylinder, and then goes into the combustion chamber. Two connectors on the
balanced case are connected to carbon canister control valve and brake booster pump. Intake
sealing gasket is made of silicone rubber material, and the color is red.
Performance parameter for intake manifold assembly
Intake manifold assembly bursting pressure（MPa） ≥0.5
Intake manifold assembly leakage（mL） ≤70
Intake manifold assembly pulling force（KN） ≥2
- 33 -
Intake temperature pressure sensor assembly
Intake temperature pressure sensor assembly can simultaneously complete tests for detecting
absolute pressure and air temperature of the engine intake manifold. Intake temperature pressure
sensor assembly is an important component of air quality in engine control system.
Performance parameter for intake temperature pressure sensor assembly
Intake temperature pressure Supply voltage（V） 5±0.25
sensor assembly Working temperature（℃）－30～＋120
Pressure sensor Working pressure（KPa） 13．3～120
Accuracy（25℃）（KPa） ±1．06
Temperature sensor Temperature Resistance Test current
property（KΩ） value
－20℃ 16.2 －
20℃ 2.45±0.24 Max100uA
80℃ 0.322±0.032 Max1000uA
Intake temperature pressure sensor assembly

2. Exhaust system
（1）Exhaust manifold assembly
Exhaust manifold assembly is made of chromium steel pipe, reducing exhaust resistance. Exhaust
manifold assembly is equipped with two oxygen sensors to detect the oxygen content of exhaust
gases, and transmit signals to ECU, so that ECU controls oil injecting quantity, and air-fuel ratio
within the target range.
- 34 -
Exhaust manifold sub-assembly
（2）Front and rear oxygen sensor assemblies
Front and rear oxygen sensor assemblies are used to detect oxygen content in combustion gas
exhausted from the engine, so as to determine the actual conditions of air-fuel ratio. Front and rear
oxygen sensor assemblies are heated type and cannot be exchanged, because they have different
lengths.
Performance parameter of front oxygen sensor Performance parameter of rear oxygen sensor
Item Performance Item Performance
parameter parameter
service temperature（℃）－30～900 service temperature（℃）－30～900
Working temperature（℃） 300～900 Working temperature（℃） 300～900
Max. temperature change －50～＋75 Max. temperature change －50～＋75
（℃/s）（℃/s）
Insulation resistance（MΩ） 1 Insulation resistance 1
Heating resistance（Ω） 5.6 （MΩ）
Total length 321.5 Heating resistance（Ω） 13.0
Total length 371.5
1- zirconium
dioxide ceramic
body coating
2- electrode
3- contact
4- housing contact
5- exhaust pipe
6- porous ceramic
protective layer
7- exhaust
8- air
Front and rear oxygen sensor assemblies
（3）Three-way catalytic converter
Three-way catalytic converter is connected to exhaust manifold rear end, converting harmful gases
exhausted by the engine to harmless gases with three-way catalysts. Leaded gasoline is not
allowed to use to prevent catalyst invalidation for “lead poisoning”. Catalytic converter core has a
- 35 -
mesh density of 620×103/m2, a capacity of 1.083L, and cross-sectional area of 333.1cm2.
Section six: Fuel System

Fuel system uses electronic control fuel injection system (EFI), including electric fuel pump,
gasoline filter and fuel inlet hose, fuel rail assembly, and oil injector.
Gasoline filter
Refer to “CA4GA1 engine service handbook (electric control parts)” for details of gasoline filter.
Fuel rail assembly

Fuel rail assembly consists of fuel rail sub-assembly, pulse damper assembly and four oil injector
assemblies. Fuel rail assembly is secured on cylinder head with two hexagon head flange bolts, oil
injector is inserted into oil injector hole on cylinder head, injecting oil to each oil injector hole
with a certain pressure. Oil injector is an important actuator of EFI, and injects fuel accurately by
ECU injecting signals.
Fuel rail assembly

1. Fuel rail sub-assembly
Fuel rail sub-assembly is non-return pipeline type, and made of stainless steel materials. Major
components include the oil injector fuel delivery pipeline, pipeline connector, oil injector
mounting seat, and etc.
Performance parameter for fuel rail sub-assembly
Working temperature（℃）－30～120
Bursting pressure（PSI/min） 300
Leakage（ml/min） 2.5
Cleanliness (mg) 2.0
2．Pulse damper assembly
Pulse damper assembly absorbs fuel pulse energy in the fuel rail sub-assembly, keeping a constant
pressure of fuel in the fuel rail sub-assembly. Pulse damper assembly is non-removable. Axial
force should be less than 20KN during mounting, to avoid deformation and damage of the thread.
3．Oil injector assembly
Oil injector assembly is an electromagnetic control component, consisting of electromagnetic coil,
needle-type valve needle and housing. It is featured by light weight, and high oil sealing. Oil injector
assembly ejects fuel in the specified time under the command of ECU, supplying fuel to the engine to
make it atomization. Oil injector assembly is provided with two O-ring sealing gaskets.
Suggestions: (1) Clean thoroughly to the oil injector every 20000KM with special cleaning
analyzer.
(2) Testing to the oil injector should be done in the appointed maintenance center,
and testing without permission is not allowed to prevent damage.
Note: Refer to “CA4GA1 engine service handbook (electric control parts)” for detail descriptions
to parts of electronic control fuel injection system.
- 36 -
Oil injector assembly
Main technical parameters for oil injector assembly
Working voltage（V） 14
Fuel pressure（KPa） 250～350
Coil resistance（Ω） 12±0.5（20℃）
Injection angle 20°
Section seven: Ignition System
Ignition system mainly consists of engine control unit assembly, rod-like ignition coil assembly,
and spark plug assembly.
Rod-like ignition coil assembly
Rod-like ignition coil assembly converts the input low voltage into high voltage through primary
and secondary coils, and ignites the mixture gas through spark plug assembly. Being integrated,
eliminates the need for high-voltage lines, and reduces the ignition failures and electromagnetic
interference. Refer to “CA4GA1 engine service handbook (electric control parts)” for details,
Main technical parameters for rod-like ignition coil assembly

Rated voltage（V） 12
Supply voltage（V） 5～6
Working ambient temperature（℃） Coil：-30～130
Ignition device：-40～120
Rod-like ignition coil assembly

（2）Spark plug assembly
Rod-like ignition coil assembly produces high voltage, and mixture gas is ignited by electric spark
produced by the high voltage. K20R-U11 type spark plug is used, the spark plug clearance is
1.0-1.1 mm. Tighten with the specified torque during dismantling.
Technical parameters for spark plug assembly
Full length（mm） 75.9±1
Thread diameter（mm） M14—1.25
Clearance（mm） 1.0—1.1
(3) Engine control unit assembly

Engine control unit assembly has functions of continuous monitoring and controlling the normal
running of the engine. Engine control unit assembly can calculate the required mixture ratio of air
and fuel, and ignition advance angle based on measured data input in each sensors. Engine control
unit assembly directly control the fuel injection quantity, fuel injection timing, ignition coil input
closed angle, engine ignition advance angle, the electronic throttle valve opening angle, vehicle
combustion emissions control, fuel supply system control as well as the cooling fan control and
vehicle air-conditioning system control, etc of the engine in various operating conditions. Engine
control unit assembly is provided with OBD system. Refer to “CA4GA1 engine service handbook
(electric control parts)” for details.
- 37 -
Engine grounding
Engine grounding
(numbers)
Camshaft position sensor Engine grounding
Crankshaft position sensor Starter
Knock sensor Ignition coil 1
Front oxygen sensor Ignition coil 2
Rear oxygen sensor Ignition coil 3
Coolant temperature sensor Ignition coil 4
Intake temperature Main relay

pressure sensor
Oil pump relay
Air-conditioner evaporator
Engine control
temperature sensor Oil injector 1
unit assembly
Oil injector 2
Electronic throttle
￣body sensor motor
Oil injector 3
Acceleration pedal sensor Oil injector 4
Carbon canister
Speed sensor
solenoid valve
Revolution meter Oil control valve
OBD connector Failure indicator
Electric fan relay

Combined switch
AC Compressor clutch relay

Power steering pressure
switch
AC compressor magneto
clutch
Air conditioner pressure switch
Radiator fan motor

Blast motor
- 38 -
CAN bus
Engine control unit assembly schematic
Section eight: Other Sensors and Actuating Mechanisms
（1）Crankshaft position sensor assembly
Crankshaft position sensor assembly is a magneto-electric type, and the sensor is cut by signal
wheel to produce magnetic line, and then produce voltage, to determine the position of crankshaft.
Crankshaft position sensor assembly outputs frequency signals.
Crankshaft position sensor assembly

Item Performance parameter Test condition
Air gap（mm） 2.5±0.5
Resistance（V） 1100±150 20℃
Insulation resistance （Ω） MIN10MΩ DC 500V Resistance meter,
between terminal and other
conduct portions
（2）Camshaft position sensor assembly
Camshaft position sensor assembly is a magneto-electric type, and the sensor is cut by signal
wheel to produce magnetic line, and then produce voltage, to determine the position of intake
camshaft. Camshaft position sensor assembly outputs frequency signals.
Item Performance parameter Test condition
Air gap（mm） 0.8±0.35
Resistance（V） 2150±300 20℃
Insulation resistance （V） MIN10MΩ DC 500V Resistance meter,
between terminal and other
conduct portions
Camshaft position sensor assembly

(3) Knock sensor assembly
- 39 -
Knock sensor assembly is a non-resonant piezoelectric crystal vibration sensor, which is mounted
in the engine cylinder body side, to test the vibration situation in the process of engine running,
having features of compact structure, light weight and easy layout.
Technical parameters for knock sensor assembly
Item Test condition
Initial period After endurance
Working temperature（℃） 15～35
Output voltage（mV） 26±8 14.4～40.8
DC resistance Ro(KΩ) 200±40％ 200±40％
Insulation resistance R∞（MΩ） Min 2 Min 1
Knock sensor assembly

（4）Carbon canister solenoid valve assembly
Carbon canister solenoid valve assembly is an electromagnetic element for controlling carbon
canister.
Technical parameters for carbon canister solenoid valve assembly
Rated voltage, working voltage range 12V, 10～16V
Working temperature（℃） -40～+120
Maximum reset voltage（-60KPa,120℃） 0.7V(min)
Coil resistance（20℃） 24.5±1.5Ω
Insulation resistance （Ω）
（DC 500VResistance meter） Min10MΩ
Valve sealing leakage（-60KPa,20℃） 70cm3/minMAX
Body leakage（-60KPa,20℃） 1cm3/minMAX
- 40 -
Carbon canister solenoid valve assembly
- 41 -
Chapter three: Engine Adjustment and Maintenance
Section one: Engine Adjustment
Section two: Engine Maintenance in the Finished Vehicle
Section three: Engine Adjustment and Maintenance
- 42 -
Section one: Engine Adjustment
1. Instrument connecting method and operating instructions
1) Engine analyzer
Engine analyzer is connected under requirements on engine diagnosis of “CA4GA1 engine service
handbook (electric control parts)”.
2) Analyzer is operated to read state parameters on revolution, water temperature, ignition angle,
and etc.
3) Do not dismantle battery electrode terminals when the engine is running (if ignored, abnormal
pulse signal can be input into the transistor, or even transistor and other electrical instruments will
be damaged).
4) Keep all the electrical components away from water or water vapor during cleaning.
5) The instrument for measuring exhaust emissions must be adjusted and calibrated prior to use,
and also be operated as follows:
(1) Preheating;
(2) zero adjustment;
(3) Range adjustment.
2. Checking oil height of the engine
Stop engine after preheating, several minutes
later, pull oil dipstick out to check the oil
height.
Oil height should be kept between the lowest
and highest levels, and close to the highest
level.
Engine oil capacity Correct
Maximum 3.5L oil level
Minimum 2.0L
Note: when oil level is lower than the
specified value, add oil with specified
desingnation to the highest oil level (when oil
level is lower than the specified value, check
whether there is any leakage).
3. Checking coolant level

⑴ Check fluid reservoir level, ensuring
coolant is kept between the lowest and highest
levels.
⑵When fluid reservoir level is lower than the
specified value, add water to the highest level.
⑶When coolant level is lower than the lowest
level, open radiator cover to check the coolant
level of the radiator.
⑷If coolant level is always lower than the
specified value, use radiator cover detector to
check whether there is any water leakage.
Note: ① Do not open radiator cover when the
engine is running or the coolant is not cooled.
② Cooling water capacity in the engine:
1.76L
③ coolant is water and glycol-based.
Coolant comparison table (volume %)
Glycol content Corresponding water content Protecting temperature to be

achieved
- 43 -
Minimum 35％ 65％－20℃
40％ 60％－24℃
Maximum 45％ 55％－31℃
4. Checking air filter cartridge
(1) Check whether the cartridge is blocked, polluted or damaged.
Note: replace the cartridge when necessary.
(2) Cleaning the cartridge with compressed air

Blow and brush the cartridge from the inner side or upper side with compressed air. Improper
cleaning methods, such as collision, blowing with strong airflow are not allowed.
5. Checking spark plug

(1) Check whether there is any damage or fracture on spark plug.
Note: replace the cartridge when necessary.
(2) Clean the spark plug.
(3) Check and adjust spark plug clearance.
Specified value for spark plug clearance
Manufacturer DENSO
Type K20R-U11
Clearance 1.0—1.1
6. Checking V-belt
(1) Check whether there is any damage, fracture or abrasion on V-belt.
Note: replace the V-belt when necessary.
(2) Tighten the belt, and rotate crankshaft more than 2 circles with of a specified tensioning force
of (650±50) N.
- 44 -
7. Checking valve clearance
Stop the engine: when cooling water achieves ambient temperature, check and adjust valve
clearance.
Specified valve clearance (in cold state):
Intake valve clearance: 0.2±0.03mm,
Exhaust valve clearance: 0.3±0.03mm.
Note: when the first cylinder piston is at TDC (top dead center) of compressed stroke, or TDC of
intake and exhaust stroke, check and adjust valve clearance. Adjust corresponding valve clearance
based on the piston position of the first cylinder referring to the table below.
Adjustment comparison table

crank angle cylinder 1 2 3 4
when the first cylinder piston Intake √ ╳ √ √
is at TDC of compressed Exhaust √ ╳ √ √
stroke
when the third cylinder Intake ╳ √ ╳ ╳
piston is at TDC of Exhaust ╳ √ ╳ ╳
compressed stroke
╳ means not adjustable, √ means adjustable
8. Checking compressed pressure
The pressure is no less than 1350kPa（13.5kgf/cm²）, and pressure difference between each
cylinder is less than 100Kpa (1.05kgf/cm²), when the engine is at the revolution of 350 r/min.
Note: all the spark plugs should be dismantled to check, and throttle is kept in the full open
position.
- 45 -
The compressed pressure measurement should be done within short time, and the measuring time
of each cylinder should be the same.
If the specified pressure is not achieved, check whether the clearance between cylinder and piston
satisfies the requirement, or check the abrasion conditions of piston ring.
9. Checking oil injector, fuel working pressure, and relay: Refer to “CA4GA1 engine service
handbook (electric control parts)” for details.
10. Checking fuel working pressure: Refer to “CA4GA1 engine service handbook (electric control
parts)” for details.
11. Checking relay: Refer to “CA4GA1 engine service handbook (electric control parts)” for details.
12. Checking idling emission

(1) 1. Initially check and adjust the preheated engine and testing equipment→2. Mount testing
equipment→3. Check idling revolution→4. Check idling emission
(2) Considerations
The following considerations should be observed before checking idling or during the operation.
① Preheat the engine thoroughly.
② Do not check idling when the fan motor is still working.
③ Additional loads such as front head light, rear window defroster are not allowed to use when
checking idling.
④ Air filter must be mounted.
⑤ Electronic throttle body, ECU, harness and etc should be in good condition.
⑥ Make sure there is no air leakage in the intake system.
⑦Make sure there is no air leakage in the exhaust system.
⑧ Refer to “TA1 engine service handbook (electric control parts)” for adjusting the electric
control parts.
（3）Initially check and adjust idling emission
① Preheat the engine till the cooling water achieves 80~90℃. (it is considered to achieve this
value when the fan stops running. Idling cannot be adjusted when the fan motor is running.)
②Preheat exhaust analyzer.
③ Check whether there is any damage on throttle body surface, and whether bypass water pipe is normal.
（4）Mount engine revolution analyzer on the engine. Refer to “TA1 engine service handbook
(electric control parts)” for more details.
（5）Check engine idling revolution, and measure the concentration values of carbon monoxide
and hydrocarbon (after catalysis).
The concentration values of carbon monoxide and hydrocarbon are: CO＜0.5; HC＜100PPM,
respectively, when the revolution is 700±50rpm. Oil pressure should be no less than 0.9bar.
Note: Refer to “TA1 engine service handbook (electric control parts)” for more details.
13. Checking high idling emission
Check engine high idling revolution, and measure the concentration values of carbon monoxide
and hydrocarbon (after catalysis).
The concentration values of carbon monoxide and hydrocarbon are: CO＜0.3; HC＜100PPM,
respectively, when the revolution is 2000±50rpm.
Note: 1. Refer to idling emission (1), (2), (3) of item 12 for checking high idling emission.
2. Refer to “TA1 engine service handbook (electric control parts)” for more details of electric
control parts.
- 46 -
Section two: Engine Maintenance in the Finished Vehicle
2-1 Maintenance operation
1）this section illustrates the dismantling steps for removable parts only when the engine is
mounted on the vehicle.
2）it is for operations of the timing chain, intake and exhaust camshafts, VCT controller assembly,
crankshaft front oil seal, chain chamber cover cap assembly and cylinder head gasket. The first
cylinder piston must be kept at TDC of compressed stroke before operation.
Note: TDC of compressed stroke can be determined by observing VCT controller assembly and
timing label of exhaust camshaft gear after dismantling cylinder head cover cap assembly.
2-2 Timing chain and water pump
Dismantling
1）Empty the engine coolant
2）Dismantle the connection between engine front support and frame.
Oil pan should be supported by the jack before dismantling the connection between engine front
support and frame.
Note: ① be very careful not to deform the oil pan. Oil pan deformation may block the engine oil
path.
② Be careful not to damage drain plug.
3）disconnect each plug of engine harness, actuator and sensor.
4）Dismantle hose on intake manifold for connecting carbon canister solenoid valve assembly, and
dismantle vacuum assisted air pipe.
5) Loosen the combined bolt on intake manifold support
hexagon head
flange bolt
intake manifold
support
combined bolt
6）Dismantle carbon canister solenoid valve support and carbon canister solenoid valve
- 47 -
Phillips flat and carbon canister
round combined solenoid valve
screw support
carbon canister solenoid valve

assembly
7) Loosen engine assembly adjusting bolt, adjusting nut, and hexagon head flange bolt. Loosen
water pump pulley hexagon head flange bolt
8) Dismantle V-belt
9) Dismantle water pump pulley
10) Dismantle crankshaft pulley
When unscrewing crankshaft pulley bolt, lock crankshaft pulley with tools like screwdriver to
prevent crankshaft from rotating.
11) Dismantle engine front support
- 48 -
12) Dismantle idler assembly
Idler assembly is mounted on stud bolt on front of cylinder body. Loosen hexagon nut, dismantle
hexagon nut, spring gasket and gasket, and then dismantle idler assembly.
Note: each dismantled component should be kept well in case of loss.
13) Dismantle rod-like ignition coil assembly

Loosen hexagon head flange bolt, and dismantle rod-like ignition coil assembly.
Note: in the process of dismantling rod-like ignition coil assembly, do not use sharp tools such as
screwdriver to skid rod-like ignition coil assembly, preventing insulation sleeve of rod-like
ignition coil assembly from being damaged.
14) Dismantle cylinder head cover cap assembly and oil filler cap
15) Dismantle chain chamber cover cap assembly
16) Dismantle chain mounting bracket
- 49 -
17) Dismantle tensioner assembly
Note: 1. Before dismantling tensioner, make the timing labels of exhaust camshaft sprocket and
VCT controller assembly sprocket face upward. Crankshaft sprocket key way also face upward.
The first cylinder piston is at TDC of compressed stroke.
2. Before dismantling tensioner, tensioner top pillar is secured with snap spring on the tensioner to
prevent top pillar ejecting.
18) Dismantle timing chain

Note: ① Do not use tools like screwdriver to skid and twist timing chain when dismantling timing
chain.
② Do not bend timing chain sharply, otherwise, pin and sliver of the timing chain will be
damaged.
③ Timing chain is not allowed to touch water, otherwise the service life of timing chain will be
shortened.
19) Take out crankshaft key on crankshaft small end, and then dismantle crankshaft sprocket.
20) Dismantle water pump assembly
Mounting
1) Mounting water pump assembly
The water pump body and water pump gasket are mounted on the corresponding position of
cylinder body front end with hexagon head flange bolts (three) and hexagon flange nuts (two), and
the tightening torque is 9±1.8N.m.
Note: 1. The elasticity and condition of water pump gasket must be checked to determine whether
to replace with new one.
2. The pump impeller of water pump assembly can be rotated flexibly after tightening bolts and nuts.
- 50 -
2) Check the abrasion condition on the tensioning surface of chain tensioner arm assembly, if there
are deep scratches, grooves, or burrs, replace the chain tensioner arm assembly. The chain
tensioner arm assembly is mounted on the front end of cylinder body and cylinder head. Do not
screw down chain tensioner arm bolt.
3) Mounting crankshaft sprocket

Crankshaft sprocket key way is mounted outwards on front end of crankshaft to coincide with
crankshaft key way. Crankshaft key is mounted in the key way by hand not other tools.
Crankshaft sprocket
Crankshaft key
4) Mounting chain rail assembly

Chain rail assembly is mounted on the front end of cylinder body and cylinder head, if there are
- 51 -
deep scratches, grooves, or burrs, replace the chain rail assembly. The tightening torque of
hexagon head flange bolt is 8±2N.m.
5) Mounting chain tensioner arm and tensioner assembly

(1) Chain tensioner arm assembly is mounted on the front end of cylinder body and cylinder head.
Do not screw down the bolts.
(2) Mount chain tensioner assembly, and the tightening torques of bolt and nut are 9±1.8N.m.
Hexagon head
flange bolt
Hexagon
flange nut
Chain tensioner
assembly
Chain tensioner
assembly
Chain tensioner
bolt
6) Chain lubricating nozzle is applied with anaerobic sealant on the thread portion, and mounted
on cylinder front end, and tightened to make nozzle hole face downward.
Chain lubricating
nozzle
7) Mounting timing chain

Rotate intake camshaft to make cylindrical pin upward, and make sure timing label on chain of
VCT controller assembly face upward, so that intake camshaft is at TDC of compressed stroke.
- 52 -
(2) Rotate exhaust camshaft to make cylindrical pin upward, and make sure timing label on chain of
exhaust camshaft sproket face upward, so that exhaust camshaft is at TDC of compressed stroke.
exhaust camshaft
assembly
cylindrical pin
upward
exhaust camshaft
sprocket
timing label
upward
(3) Mounting timing chain

Checking timing chain
Check whether there are defects such as abrasion, broken teeth, warping on slivers of the timing
chain. Check teeth numbers between yellow labels on timing chain, there are five slivers (10 teeth)
between two groups of double yellow slivers, and there are 34 slivers (68 teeth) between single
yellow slivers and double yellow slivers.
② As shown in the drawing, timing chain is mounted to align the timing labels.
(4) Tensioning timing chain

Nip the snap spring on chain tensioner by hand to eject tensioned plunger, and tension the timing
chain.
Note: ① Check whether the label positions of timing chain and sprocket are coincided, before
nipping snap spring on chain tensioner.
② Check whether the ejecting length of plunger is in the range of about 9-12mm, and do not
tighten bolt with gasket excessively.
(5) Rotate crankshaft about two circles in normal rotation direction, check whether timing labels
of VCT controller assembly sprocket and exhaust camshaft sprocket face upward, and check
whether crankshaft sprocket key way face upward.
- 53 -
Note: ① Do not use tools like screwdriver to skid and twist timing chain when dismantling timing
chain to prevent damaging slivers of timing chain.
② Do not bend timing chain sharply, otherwise, pin and sliver of the timing chain will be
damaged.
③ Timing chain is not allowed to touch water, otherwise the service life of timing chain will be
shortened.
④ Apply force on crankshaft to rotate engine after timing chain has been mounted.
⑤ if old timing chain is used, check pin and sliver of timing chain carefully during mounting, in
case there is fracture in the timing chain.
⑥ it is recommended that timing chain should be checked or replaced before the vehicle has
running for 50000km.
8) Tighten chain tensioner arm assembly bolt with a tightening torque of 19±3.8N.m.
chain tensioner
arm bolt
9) Mounting chain mounting bracket

Chain mounting bracket is fastened on cylinder front end with hexagon head flange bolt, and the
tightening torque of bolt is 8±2N.m.
10) Mounting chain chamber cover cap assembly

(1) Mounting front oil seal assembly
New front oil seal assembly is pressed into chain chamber cover cap hole with special tools, and
the pressing depth is 0±0.5mm from cylinder joint surface.
(2) Mounting seal gasket
- 54 -
Chain chamber cover cap seal gasket is applied with proper lubricating oil, and pressed into
groove of OCV control valve. Be careful not to drop off.
(3) Assembling chain chamber cover cap assembly

① The chain chamber cover cap assembly is applied uniformly with anaerobic sealant on jointing
portion with cylinder body, and pressed into locating pin hole on front end of cylinder body.
Tapping with wood or rubber hammers is allowed.
Note: assemble within 3 minutes after applying glues, and tighten within 15 minutes.
② fasten with hexagon head flange bolts (10), tightening torque is 12±2.4N.m. Engine harness
support I and cover cap use the same one bolt.
hexagon head flange bolt (4)
support I-to fix

engine harness
hexagon head flange

bolt (1)
hexagon head flange

bolt (5)
11) Mounting cylinder head cover cap assembly

Put cylinder head cover cap seal gasket into seal gasket groove of cover cap, and glue on the seam
of cylinder head and timing chain cover cap. Note: assemble within 3 minutes after applying glues,
and tighten within 15 minutes.
Apply sealant here
(2) Tighten each bolt and hexagon head flange bolt
- 55 -
① Use bolt M6×20 for positions ⑥, ⑦ in the drawing.
② Use stud bolt M6×55 and hexagon head flange bolt M6 for positions ⑿, ⒀in the drawing.
③ Use bolt M6×25 for the remaining positions, and tightening torque is 9-13 N.m (target value is
11).
④ Carbon canister solenoid valve support and cylinder head cover cap use bolt M6×25 together of
position ①in the drawing.
⑤ Engine harness support II and cylinder head cover cap use bolt M6×25 together of position ⑧
in the drawing.
⑥Engine harness support I and cylinder head cover cap use bolt M6×20 together of position ⑦ in
the drawing.
(3) Oil filler cap is rotary-mounted on cylinder head cover cap.

12) Mounting rod-like ignition coil assembly
Rod-like ignition coil assembly is inserted into spark plug hole of cylinder head cover cap, to the
bottom.
Tighten hexagon head flange bolts with a tightening torque of 8±2N.m.
Note: The rod-like ignition coil assembly surface is allowed to tap with rubber hammer when
mounting the rod-like ignition coil assembly.
13) Mounting idler assembly

Idler assembly is mounted on stud bolt at cylinder front end and fastened with nuts, and the
tightening torque of nut is 44±9N.m.
14) Mounting engine front support
- 56 -
Engine front support is mounted on front end of timing chain cover cap, and tightened with two
combined bolts and two hexagon nuts. The tightening torque of nut is 51±10N.m.
15) Mounting coupling bolt of engine front support and frame.

16) Mounting crankshaft pulley and shock absorber assembly
(1) Timing chain cover cap is applied with proper lubricating grease on front oil seal assembly lug;
(2) Key way aligning keys of crankshaft pulley and shock absorber assembly are inserted in the
crankshaft front end, journal is inserted into front oil seal assembly of timing chain cover cap. The
tightening torque is 200±10N.m.
17) Mounting water pump pulley

The tightening torque of bolt:11.5±2.5N.m
18) Mounting engine assembly and V-belt

Engine assembly is mounted on cylinder body front end and engine adjusting support with bolts
and adjusting nuts, bolts are not fastened temporarily.
(2) Mount V-belt according to the drawing, adjust the adjusting bolt on engine support to tension
the belt, and rotate crankshaft more than 2 circles with of a specified tensioning force of (650±50)
N. Measuring position is shown by the arrow in the drawing.
- 57 -
19) Mounting carbon canister solenoid valve support and carbon canister solenoid valve
20) Mounting combined bolt on intake manifold support
Mount hose on intake manifold for connecting carbon canister solenoid valve assembly, and
mount vacuum assisted air pipe
Mount each plug of engine harness, actuator and sensor.
21) Mount the connection of engine mounting support and frame, tighten bolts, and dismantle jack
supporting oil pan.
22) Fill up with cooling water
2-3 Intake and exhaust camshafts

Dismantling
1) After dismantling timing chain as described in chapter “dismantling timing chain and water
pump”, dismantle the camshaft.
2) Dismantle air filter assembly.
3) Dismantle intake manifold balance case support, harness etc.
4) Dismantle VCT controller assembly.
Loosen combined bolt, and dismantle VCT controller assembly.
Note: 1. When dismantling VCT controller assembly, clamp intake camshaft S24 hexagon head
with opening spanner, to prevent intake camshaft rotating and damaging the components.
2. VCT controller assembly should be kept properly in special instruments to prevent oil hole from
being polluted and gear from being damaged.
- 58 -
5) Dismantle exhaust camshaft sprocket
Clamp exhaust camshaft S24 hexagon head with opening spanner, to prevent exhaust camshaft
rotating and damaging the components. Loosen combined bolt of exhaust camshaft sprocket.
6) Loosen intake and exhaust camshafts first to fifth cam bearing cap bolts (20 in all).
Note: 1. Camshaft first cam bearing cap is a combined bearing cap of and exhaust camshafts.
2. Clean camshaft first to fifth cam bearing caps and remove all the sealant after dismantling.
3. The dismantled camshaft first to fifth cam bearing caps should be placed regularly in the special
instrument, and locating pin sleeve should be kept well.
7) Dismantle intake and exhaust camshafts

Note: Do not try to skid or forcibly dismantle intake and exhaust camshafts with tools during
dismantling to prevent camshaft from being damaged.
Mounting
1) Camshaft mounting step is opposite with the dismantling step.
2) Valve clearance adjusting refers to 7) of section 3.5 mounting cylinder head
3) Assembling intake and exhaust camshafts after adjusting valve clearance
(1) when cylinder piston is at TDC of compression, rotate crankshaft for 90° (crankshaft angle).
- 59 -
(2) Drip several drops of lubricating oil on cylinder head camshaft seat hole and valve tappet top
surface.
(3) intake and exhaust camshafts are placed with cylindrical pins of intake and exhaust camshafts
face upward.
(4) Cam bearing cap is fastened with combined bolts, and tightening torque is 12.5±2N·m.
Note: Check the clearance of valve and tappet again.
2-4 Cylinder head gasket

Dismantling
1) After dismantling intake and exhaust camshafts as described in chapter “dismantling intake and
exhaust camshafts”, dismantle the cylinder head gasket.
2) Empty engine oil.
3) Dismantle exhaust manifold.
4) Dismantle various hoses.
5) Dismantle cylinder head bolts and washers.
6) Dismantle cylinder head assembly.
7) Dismantle cylinder head gasket.
Mounting
1) Mount cylinder head gasket.
Sealant is applied at two places of cylinder head gasket: the seams of cylinder body front top
surface and cylinder gasket front bottom surface, with timing chain cover cap.
Cylinder head gasket assembly is placed on cylinder body top surface with two pin holes aligned
with locating holes on cylinder body.
Note: check the thickness and defect of cylinder head gasket, and replace with new one when
necessary.
The compression thickness of cylinder head gasket should be more than 0.3mm.
2) Mounting cylinder head assembly
① Clean bottom and front end surfaces of cylinder head, and carefully place cylinder head
assembly on cylinder head gasket with the locating pin hole aligned with locating holes on
cylinder body.
② Cylinder head is applied with a layer of lubricating oil on the thread portion and inserted into
cylinder head bolt hole.
- 60 -
Tightening torque: 34±2N.m, then 120°
2-5 Dismantling and mounting oil pump

After dismantling timing chain and water pump as described in chapter “dismantling timing chain
and water pump”, dismantle the oil pump.
Dismantling oil pump
Loosen hexagon head flange bolt, dismantle oil pump, and check abrasions of oil pump inner and
external rotors.
Mounting oil pump
Fill lubricating oil in the clearance between oil pump inner and external rotors.
Fill lubricating oil at the lower side of rotor mounting hole on cylinder body.
③ Label on external rotor faces outside of cylinder body.

④ Oil pump is located with locating pin and fastened on cylinder body front end with bolts and
gaskets. The tightening torque is 9±1.8N·m.
Note: Rotate oil pump sprocket more than one circle so that the whole circle of rotor will be
applied with lubricating oil. And rotating should be smooth, without clamping stagnation.
- 61 -
Section three: Engine Adjustment and Maintenance
3.1 Fuel rail assembly and oil injector
Dismantling
1) Dismantle plugs for connecting engine harness and oil injector to dismantle the harness.
Note: 1. Engine harness should be disposed properly after dismantling and should not be bent at a
small angle.
2. Plugging connector of engine harness should not be damaged.
2) Dismantle intake manifold support for connecting intake manifold assembly.
Note: Hexagon head flange bolt for connecting intake manifold support should be dismantled first
during dismantling.
3) Dismantle fuel connecting pipe.
fuel rail pipe joint
4) Dismantle two hexagon head flange bolts for fastening fuel rail assembly (with oil injector),
and remove fuel rail assembly and engine harness supports (two).
Note: ① if it is difficult to dismantle with the hand, use soft sticks to skid fuel rail assembly
evenly, and do not skid forcibly against damaging the fuel rail assembly.
② Do not skid fuel rail assembly directly with wood stick against damaging fuel rail and oil
nozzle.
- 62 -
5) Dismantle oil injector clamps to remove oil injector.
Dismantle oil injector clamps with the hand. Hold fuel rail, rotate oil injector and pull upwards to
remove oil injector.
Note: oil injector and fuel rail are disposed at clean and neat places respectively to prevent from
pollution and collision.
Note: pulse damper assembly is assembled with fuel rail, and not dismantled as much as possible.
If it is necessary, follow the operations below.
1. Fasten guide assembly with special clamps, and dismantle pulse damper assembly with special
tools. Fuel rail assembly cannot suffer from axial forces, otherwise, it will be deformed.
2. Make sure to measure leakage of fuel rail assembly after dismantling pulse damper assembly.
Checking
1) Check oil injector
① there is no damage on oil injector surface.
② there is no dirt to block oil hole.
③ Measure connector resistance of oil injector with ohmmeter
(Refer to “CA4GA1 engine service handbook (electric control parts)” for details)
2) Check fuel rail assembly (including pulse damper assembly)

①There is no crack, scratch, groove, corrosion, etc on fuel rail surface.
②There is no crack, scratch, groove, corrosion, etc on pulse damper assembly. There is no
deformation or damage on thread surface.
③Two support boards of fuel rail assembly should be in one plane.
- 63 -
④Measure fuel rail assembly pressure (including pulse damper assembly)
There is no leakage under a pressure of 490KPa.
⑤Measure oil injector size of cylinder head assembly: less than 13.2mm.
3) Check there is no damage or fracture on plugs of engine harness body, oil injector and other
electrical components.
4) Refer to “cylinder head” for measuring oil injector hole on cylinder head.
Mounting
1) Mount pulse damper assembly on fuel rail
Pulse damper assembly and fuel rail are assembled as the following requirements.
1. Fasten guide assembly with special clamps, and mount pulse damper assembly with special
tools. Fuel rail assembly cannot suffer from axial forces, otherwise, it will be deformed.
2. Make sure to measure leakage of fuel rail assembly after mounting pulse damper assembly.
100% dry air is used to do experiments, and leakage rate does not exceed 2.5ml/min.
3. The torque of mounting pulse damper assembly is 30±6Nm.
2) Mount oil injector on fuel rail assembly.

Apply a thin layer of engine lubricating oil on new O-rings.
Two new O-rings are replaced for oil injector and disposed in O-ring slot of oil injector.
Oil injector is inserted into fuel rail injector hole while rotating laterally, and oil injector harness
connector faces upward.
Oil injector is jammed with a clamp.
- 64 -
upward
rotate
Clamp
press
New O-ring
Note: 1. The assembled fuel rail and oil injector assembly are disposed at a clean place, and oil
- 65 -
injector should be kept from collision and pollution.
2. There is no clamping stagnation when rotating oil injector with the hand.
3) Mounting fuel rail assembly
① Put oil injector and fuel rail assembly in cylinder head oil injector hole.
Note: Rotate oil injector gently to avoid forcibly inserting, to prevent from damaging oil injector
O-ring.
② after inserting oil injector, dispose fuel rail assembly on cylinder head, and fasten fuel rail
assembly and engine harness support together with two hexagon head flange bolts.
Tightening torque: 23±5N.m
Note: if fuel rail assembly is disposed improperly, tap with soft stick.
4) Mounting plugs for connecting engine harness and oil injector to mount harness in place.
3.2 Intake system
Dismantling
Dismantle air filter intake connecting hoses and cylinder head cover cap connecting hoses.
Dismantle
Dismantle vacuum assisted air connecting hose and carbon canister control valve communicating
hose.
3) Dismantle support for connecting intake manifold assembly.
To dismantle intake manifold support, dismantle hexagon head flange bolt for connecting intake
manifold first, to prevent from damaging plastic intake manifold.
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hexagon head
flange bolt
intake manifold
support
combined bolt
4) Dismantle bolt for fastening throttle valve body and intake manifold.
Note: throttle valve body should be kept well, and the terminals should especially be kept away
from grease or water.
5) Dismantle intake manifold assembly and seal ring.
Loosen hexagon head flange bolt of intake manifold assembly, then dismantle intake manifold
assembly. Be very careful not to damage intake manifold assembly.
6) Dismantle intake pressure temperature sensor.
Checking
1) Check intake pressure sensor.
①There is no damage on surface
②Plug pin does not fall off, air hole is not blocked.
③shaking intake pressure sensor gently by hand causes no abnormal sound.
2) Checking intake manifold assembly

①Check deformations of intake manifold assembly and cylinder head joint surface, and intake
manifold assembly and electronic throttle body joint surface.
Measure diagonal deformation, if deformation exceeds the accepted limit, grinding cannot be used,
use non-grinding method to adjust.
Accepted limit: 0.50mm
② Check intake seal washer and throttle valve body seal ring.
Intake seal washer and throttle valve body seal ring are made of silicon rubber, and in red color.
Obvious scratch, fracture or burr is not allowed, if any, replace with new seal ring.
③protruding joint surface between intake seal washer and throttle valve body seal ring is
2±0.1mm, no less than 1.8mm at least.
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④Check pulling force of copper nut M8: more than 2.7KN.
M6: more than 2.0KN.
⑤Check whether there is impurity on internal and external surfaces of intake manifold, and if
there is any, clean with detergent.
⑥ Check intake manifold leakage rate.
Under pressure of 0.11Mpa, maintain the pressure for 8 seconds, leakage rate: ≤70mL
3) Check whether there is impurity on internal and external surfaces of electronic throttle body,
and if there is any, clean with detergent.
Note: 1. There is no corrosion, damage on electronic throttle body assembly plug, and plug
connector is fastened.
2. Electronic throttle body assembly is disposed at clean and neat places to prevent from
pollution and collision.
Refer to “CA4GA1 engine service handbook (electric control parts)” for specific checking
method.
Mounting
1) Mount intake seal washer and throttle valve body seal ring of intake manifold.
Intake seal washer and throttle valve body seal ring are mounted on corresponding grooves of
intake manifold, and it is allowed to apply a thin layer of lubricating oil on the protruding part of
seal ring.
2) Mount intake temperature pressure sensor.
Intake temperature pressure sensor is mounted on intake manifold, and tightening torque of
hexagon head flange bolt is 5-7(target value is 6)Nm.
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3) Mount intake manifold assembly
One thread portion of five double end studs is applied with lock glues, and double end studs are
screwed into cylinder head intake side bolt holes and tightened.
Intake manifold assembly is covered on double end studs, and fastened with 5 nuts in the
tightening sequence: starting from the middle, to the two ends in sequence from left and right
sides in turns. Tightening torque is 19±4N.m.
electronic throttle body
combined bolt
4) Mount electronic throttle body assembly

Electronic throttle body assembly is tightened with 4 combined bolts, and tightening torque is
10±0.2Nm.
5) Mount intake manifold support
①Tightening torque of bolt (one) for connecting intake manifold support and intake manifold is
23±5N.m.
②Tightening torque of bolts (two) for connecting intake manifold support and cylinder body is
50±10N.m.
hexagon head
flange bolt
intake manifold
support
combined bolt
6) Mount vacuum assisted air connecting hose and carbon canister control valve communicating
hose.
7) Mount air filter intake connecting hose and cylinder head cap connecting hose.
3.3 Exhaust manifold
Dismantling
1) Dismantle upper and lower heat shields on exhaust manifold.
Dismantle harness connectors of front and rear oxygen sensors.
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Loosen four M6 hexagon head flange bolts of upper heat shield on exhaust manifold.
Loosen four M6 hexagon head flange bolts of lower heat shield on exhaust manifold.
Dismantle upper and lower heat shields on exhaust manifold.
2) Dismantle front and rear oxygen sensors.

Note: ① Absolutely not skid or beat oxygen sensors with tools.
② Sensors are kept properly to away from contacting impurities, such as oil and water.
3) Dismantle exhaust manifold support
Loosen one M8 hexagon head flange bolt, then loosen one M10 combined bolt, and dismantle
exhaust manifold support.
Note: M8 hexagon head flange bolt should be dismantled first.
4) Dismantle exhaust manifold

Loosen five M8 hexagon flange nuts and dismantle exhaust manifold
Note: exhaust manifold should not be disposed at will to prevent from collision and damaging the
catalyst.
Checking
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1) Check exhaust manifold
Check deformation on exhaust manifold flange surface. Accepted limit: 0.15mm
If deformation exceeds accepted limit, use grinding to adjust, but grinding should not exceed
0.25mm.
2) Check there is no crush or fracture on exhaust manifold catalytic converter. If the catalytic
converter has been damaged, replace the whole exhausts manifold.
3) Check exhaust manifold gasket assembly
①Check whether substrate thickness of exhaust manifold gasket assembly is 0.6mm.
②Check whether the protruding height at two sides of exhaust manifold gasket assembly is more
than 0.25mm.
③Check five connecting pins of exhaust manifold gasket assembly are in good conditions.
Mounting
1) Mount exhaust manifold sub-assembly
(1) Mount exhaust manifold gasket.
(2) Mount exhaust manifold sub-assembly.
Tightening torque of hexagon flange nuts is 23±5N.m.
Note: The tightening sequence is: starting from the middle, to the two ends in sequence from left
and right sides in turns.
2) Mount front and rear oxygen sensors

①Oxygen sensors are screwed into exhaust manifold holes by hand
Note: front and rear oxygen sensors are different, and the front is short while the rear is long.
②Tighten oxygen sensors
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③Oxygen sensor plugs are connected to harness and tightened with clamps.
3) Mount upper and lower heat shields on exhaust manifold
Tighten 8 hexagon head flange bolts with a tightening torque of 8±2N.m.
3.4 V-belt and timing chain

Composition of timing chain
Dismantling
1) Dismantle V-belt
Loosen hexagon head flange bolt, but not too loose.
Loosen engine adjusting bolts.
Dismantle V-belt.
Note: Mark the running direction (arrow) of V-belt with chalks on V-belt back during dismantling.
2) Dismantle water pump pulley

Dismantle crankshaft pulley
⑴When loosening crankshaft pulley bolt, use special service tools to prevent flywheel from
rotating.
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⑵Because tightening torque of crankshaft pulley bolt is big, extended torque spanner can be used.
4) Dismantle engine front mounting support
Loosen hexagon head nuts and combined bolts. Do not loose spring gaskets.
Dismantle hexagon head nuts. Do not loose gaskets and spring gaskets.
6) Dismantle oil filler cap assembly
7) Dismantle rod-like ignition coil assembly
Loosen four hexagon head flange bolts and dismantle rod-like ignition coil assembly.
Note: if it is difficult to dismantle rod-like ignition coil assembly, do not use screwdrivers to skid
parts of rod-like ignition coil assembly, otherwise, rod-like ignition coil assembly will be
damaged.
8) Dismantle cylinder head cover cap assembly

Loosen hexagon head flange nuts on positions ⑿, ⒀, and bolts on positions ⑥, ⑦, and loosen
bolts of the rest positions. Dismantle cylinder head cover cap assembly. Note: carbon canister
solenoid valve support (position ①), engine harness support II (position ⑧), engine harness
support I (position ⑦) and cylinder head cover cap seal gasket are disposed in special instruments.
9) Dismantle chain chamber cover cap assembly

Note: Anaerobic sealant is applied on jointing portion of chain chamber cover cap assembly and
cylinder body. It is allowed to skid with screwdriver or tap with wood or rubber hammers during
dismantling.
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10）Dismantle chain mounting bracket
11) Dismantle chain tensioner assembly
Timing labels of VCT controller assembly and exhaust camshaft sprocket face upward.
Note: at this time, timing label of timing chain does not necessarily coincide with that of VCT
controller assembly and exhaust camshaft sprocket.
Crankshaft timing sprocket key way is rotated to face upward.

Note: at this time, timing label of timing chain does not necessarily coincide with that of
crankshaft timing sprocket.
③ Loosen hexagon head flange bolt and hexagon flange nut. Nip snap spring on chain tensioner
with the hand to fasten tensioning plunger, and dismantle chain tensioner assembly.
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hexagon head
flange bolt
snap spring
Hexagon flange nut
chain tensioner
Note: ① After chain tensioner is dismantled, crankshaft and camshaft cannot be rotated anyway.
Otherwise, piston and valve are easy to collide with each other and these parts are easy to damage.
②After chain tensioner is dismantled, snap spring on tensioner cannot be loosened to prevent
hurting people.
12) Dismantle timing chain
Note: ① When dismantling timing chain, do not bend the chain sharply with a small radius.
②When dismantling chain, do not skid with tools like screwdriver to prevent from damaging
slivers of timing chain.
13) Dismantle exhaust camshaft sprocket
14) Dismantle VCT controller assembly
Note: Clamp intake camshaft S24 hexagon head with opening spanner, to prevent intake camshaft
rotating.
15) Dismantle chain guide assembly and chain tensioner arm assembly.
16) Dismantle OCV control valve assembly
Checking
1) Check timing chain.
Check every parts of the chain, if there are damages as follows, replace the chain.
①Warping or deformation on chain slivers
② Chain pin deformation or crack
③ Deformation or abrasion on slivers of the same row
Note: in the following cases, even if there is no external damage, replace the timing chain.
① Water pump leaks water, or in other cases, timing chain contact with water constantly.
② Plenty of oil adheres to the chain, causing adhesion of chain slivers.
③ Because camshaft is jammed, chain may suffer from excessive forces.
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2) Check chain tensioner assembly
Chain tensioner assembly has smooth lubricating oil hole, without oil stain.
②Tensioning force of chain tensioner assembly is in good conditions and snap spring has no
damages.
3) Check chain guide assembly

If there are deep scratches, grooves or burrs on chain guide surface, replace the chain guide
assembly.
4) Check chain tensioner arm assembly
If there are deep scratches, grooves or burrs on chain tensioner arm surface, replace the chain
tensioner arm assembly.
5) Check exhaust camshaft sprocket
Abrasion limit of exhaust camshaft sprocket: 82.7mm.
6) Check VCT controller assembly sprocket

Abrasion limit of VCT controller assembly sprocket: 82.7mm.
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7) Check chain chamber cover cap assembly
Check front oil seal assembly
Check front oil seal assembly lugs, if there are fractures, wrinkles or cracks, replace front oil seal
assembly.
Check front oil seal assembly springs, if there are fractures, elongations or jump wires, replace
front oil seal assembly.
Replace new chain chamber cover cap seal gasket
③Check each sealing surface of chain chamber cover cap assembly is in good conditions, without
cracks, voids or warpings, otherwise, replace chain chamber cover cap assembly.
8) Refer to relevant contents in section 3.1 for checking V-belt.
9) Check OCV control valve assembly
Measure minimum valve diameter of OCV control valve assembly is more than φ17.7mm. If it is
less than minimum valve diameter, replace OCV control valve assembly.
②Check oil feed gallery hole, oil drain gallery hole, phase advance gallery hole, phase delay
gallery hole of OCV control valve assembly, and if there are foulings, replace OCV control valve
assembly.
Note: Refer to “CA4GA1 engine service handbook (electric control parts)” for details of OCV
control valve assembly.
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Mounting
1) Mount VCT controller assembly
Fasten intake camshaft with special tools, drip several drops of lubricating oil at the top front end
of intake camshaft journal, and align pin holes on VCT controller assembly with cylindrical pins
on camshaft.
After insertion, twist sprocket gently to check whether locating pin is inserted in the locating hole.
Fasten VCT controller assembly to camshaft with combined bolts, and tightening torque is 47±7N.
2) Mount exhaust camshaft sprocket

①Fasten exhaust camshaft with special tools, and align pin holes on exhaust camshaft sprocket
with pins on camshaft, and cover sprocket on exhaust camshaft.
Note: After insertion, twist sprocket gently to check whether locating pin is inserted in the locating hole.
Fasten sprocket to camshaft with combined bolts, and tightening torque is 8±1.6N.
3) Mount crankshaft sprocket

①Fasten crankshaft with special tools, mount crankshaft sprocket key way outwardly to make
sprocket key way coincide with crankshaft key way.
②Mount crankshaft key
4) Mount chain lubricating nozzle
Chain lubricating nozzle is applied with anaerobic sealant on the thread portion, and mounted on
cylinder front end, and tightened to make nozzle hole face downward.
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5) Mount chain guide assembly
Chain guide assembly is assembled on front ends of cylinder body and cylinder head, and
6) Mounting tensioner assembly

Double end studs are mounted on front end of cylinder head.
Mount chain tensioner assembly, and tightening torques of stud and bolt are 9±1.8Nm.
7) Mounting chain tensioner arm

Chain tensioner arm assembly is mounted on front ends of cylinder body and cylinder head, and
tightening torque of chain tensioner arm bolt is 19±3.8N.m.
Note: Chain tensioner arm can be moved freely after chain tensioner arm bolt is fastened.
Chain tensioner arm

assembly
Chain tensioner arm bolt
- 79 -
8) Mounting timing chain
Timing labels of VCT controller assembly sprocket and exhaust camshaft sprocket face upward,
and crankshaft sprocket key way also face upward after crankshaft is rotated.
Mount timing chain to align timing labels (yellow slivers) with labels on sprocket.
Note: Timing labels of VCT controller assembly sprocket and exhaust camshaft sprocket are
separated by 14 slivers on timing chain, timing labels of VCT controller assembly sprocket and
crankshaft sprocket are separated by 72 slivers on timing chain, and timing labels of exhaust
camshaft sprocket and crankshaft sprocket are separated by 72 slivers on timing chain.
③ Timing chain should not be twisted excessively during mounting to prevent from being
damaged.
9) Tensioning tensioner assembly
Nip the snap spring on chain tensioner by hand to eject tensioned plunger, and tension the timing
chain.
Rotate crankshaft for two circles in normal direction (clockwise) to check whether each sprocket
returns to the mounting position.
Note: ① Check whether the label positions of timing chain and sprocket are coincided, before
nipping snap spring on chain tensioner.
② Check whether the ejecting length of plunger is in the range of about 9-12mm.
③ Timing chain does not suffer from any force when crankshaft is rotated.
10) Mounting chain mounting bracket
Chain mounting bracket is mounted on cylinder front end and fastened with hexagon head flange
bolts, and tightening torque of chain tensioner arm bolt is 8±2N.m.

① Mounting front oil seal assembly
Front oil seal assembly is cleaned and pressed into chain chamber cover cap hole with special
tools, and the pressing depth is 0±0.5mm from cylinder joint surface.
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② Mounting seal gasket
Chain chamber cover cap seal gasket is applied with proper lubricating oil, and pressed into
groove of OCV control valve. Be careful not to drop off.
③Assembling chain chamber cover cap assembly

(1) One thread portion of 2 double end studs is applied with lock glues, and screwed into cylinder
head front end.
(2) The chain chamber cover cap assembly is applied uniformly with anaerobic sealant on jointing
portion with cylinder body, and pressed into locating pin hole on front end of cylinder body.
Tapping with wood or rubber hammers is allowed.
(3) Fasten with hexagon head flange bolts, tightening torque is 12±2.4N.m. Engine harness
support I and cover cap use the same one bolt.
(4) One thread portion of a double end stud is applied with lock glues, and screwed into cylinder
body front end.
One thread portion of two double end studs is applied with lock glues, and screwed into cylinder
head front end.
support I-to fix engine harness
stud bolt (2)
stud bolt (2)

Idler assembly is mounted on cylinder body front end and fastened with double end studs, and
Tightening torque of nut: 44±9N.m.
13) Mounting engine front support

Engine front support is mounted on front end of timing chain cover cap. Tightening torque of bolt:
51±10N.m
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14) Mounting water pump pulley
Tightening torque of bolt: 11.5±2.5N.m

①Mounting crankcase ventilation valve seal seat
Crankcase ventilation valve is applied with proper lubricating oil on seal seat surface and then
pressed into corresponding hole on cover cap.
②Mounting crankcase ventilation valve assembly
Crankcase ventilation valve assembly is applied with proper lubricating oil on the surface and then
inserted into seal seat- crankcase ventilation valve.
③ Mounting cylinder head cover cap assembly and harness support

(1) Put cylinder head cover cap seal gasket into gasket slot, and apply sealant on the seams of
cylinder head with timing chain cover cap (2 places). Note: assemble within 3 minutes after
applying glues, and tighten within 15 minutes.
(2) Use bolt M6×20 for positions ⑥, ⑦ in the drawing.
(3) Use stud bolt M6×55 and hexagon head flange bolt M6 for positions ⑿, ⒀in the drawing.
(4) Use bolt M6×25 for the remaining positions, and tightening torque is 9-13 N.m (target value
is 11).
(5) Carbon canister solenoid valve support and cylinder head cover cap use bolt M6×25 together
of position ①in the drawing.
(6) Engine harness support II and cylinder head cover cap use bolt M6×25 together of position
⑧ in the drawing.
(7) Engine harness support I and cylinder head cover cap use bolt M6×20 together of position ⑦
in the drawing.
④Oil filler cap is rotary-mounted on cylinder head cover cap.
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16) Refer to chapter “ignition system” for mounting rod-like ignition coil assembly.
17) Mounting OCV control valve assembly
OCV control valve assembly is mounted on the corresponding hole of chain chamber cover cap,
and tightening torque of bolt is 8±2N·m.
18) Mounting oil filler cap assembly

Oil filler cap is applied with lubricating oil on the rubber gasket and then rotary-mounted on
cylinder head cover cap.
19) Mounting engine assembly
Engine adjusting support is fastened on cylinder body, and tightening torque of bolt is 24±5N.m.
Note: Make sure engine lugs can slide along slots of engine adjusting support.
Engine assembly is mounted on cylinder body front end and engine adjusting support with bolts
and adjusting nuts, bolts are not fastened temporarily.
engine adjusting hexagon head
Adjusting nut support flange bolt
hexagon head
flange bolt
adjusting bolt-engine
engine assembly
position limiting
support assembly
hexagon head
flange bolt
20) Refer to corresponding sections of “cylinder body” for mounting V-belt.

3.5 Cylinder head
Composition of cylinder head
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Dismantling
Dismantle rod-like ignition coil assembly.
Dismantle spark plug.
Dismantle cylinder head cover cap assembly, gasket and harness supports Ⅰ, Ⅱ.
Dismantle carbon canister solenoid valve support and carbon canister solenoid valve.
Dismantle camshaft position sensor.
Dismantle the first to fifth camshaft bearing caps. Loosen and dismantle 20 bolts uniformly in 2 or
3 times.
The loosening method is as follows: 1. loosen the first camshaft bearing cap bolt. Loosen 2 bolts
in the inner side, then another 2, and dismantle the first camshaft bearing cap.
2. Loosen other camshaft bearing caps, and the loosening sequence is alternately from outside to inside.
Note: 1. Do not lose locating pin bush on the camshaft bearing cap.
2. Camshaft bearing cap cannot be beaten or skidded with hard articles during dismantling,
otherwise, it will be damaged.
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3. Camshaft bearing cap should be disposed in process instruments in sequence after dismantling.
7) Dismantle intake and exhaust camshafts
(1) Clamp hexagon parts of intake or exhaust camshaft with S24 opening spanner, and rotate
camshaft to make camshaft lobe apart from tappet surface.
(2) Shake and dismantle camshaft by hand.
Note: 1. If camshaft cannot be lifted straightly, the third camshaft bearing cap bolt should be
fastened again. Shake camshaft by hand to loosen it. Loosen the third camshaft bearing cap bolt to
dismantle camshaft.
2. Camshaft cannot be skidded or dismantled forcibly with tools or other things, otherwise,
camshaft will be broken.
8) Dismantle valve tappet.
9) Loosen water inlet and outlet pipes
10) Loosen water inlet pipe support, thermosistor, and coolant temperature sensor.
Dismantle coolant temperature sensor with opening spanners. Do not dismantle with impact tools.
11) Dismantle OCV control valve filter

Loosen bolts to remove gasket and OCV control valve filter. OCV control valve filter should be
disposed in special instruments to prevent from being damaged.
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12) Loosen cylinder head bolts
Loosen cylinder head bolts gradually in two or three times in the sequence shown in the drawing.
(2) Remove cylinder head bolts and gaskets with a magnetic bar.
13) Dismantle cylinder head assembly
Dismantle cylinder head, secure cylinder on special service tools, and secure the special tools on
the bench clamp.
Note: Be careful not to scratch joint surface of cylinder head and gasket.
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14) Dismantle valve lock clamp.
Valve spring is compressed with special tools to dismantle valve lock clamp.
Note: The following item 15 to item 18 parts to be dismantled should be disposed in groups by
valve or cylinder, so as to know the mounting positions beforehand.
15) Dismantle valve spring retainer.

16) Dismantle valve spring.
17) Dismantle valve.
18) Dismantle valve stem guide oil seal.
19) Dismantle valve spring gasket.
Note: The dismantled parts are cleaned with detergent and dried with compressed air. Do not wipe
the parts with cloth or the like.
20) Remove cylinder head from the special service tool.
Checking
Checking cylinder head
(1) Check whether there is crack, damage or deformation. If there is crack or damage, replace
cylinder head when necessary.
Check deformations on the following three surfaces of cylinder head.
1. Deformation on joint surface of cylinder head and cylinder gasket assembly
Maximum limit: 0.05mm
If deformation on joint surface exceeds the maximum limit, adjust the surface, but the height
cannot be less than a limit of 112.9 mm.
2. Deformation on joint surface of intake manifold

Intake manifold forms an angle of 68° with the bottom surface.
- 87 -
3. Deformation on joint surface of exhaust manifold
If deformation on joint surface of exhaust manifold exceeds the maximum limit, adjust the surface,
but the distance from the bottom locating pin hole cannot be less than a limit of 124.8 mm.
Exhaust manifold joint surface
(2) Check valve seat

Valve seat is applied with a thin layer of read lead oil.
Let valve fall on valve seat two or three times by self-weight. Remove the valve, and measure the
width of valve seat contact surface. The specified contact width value: 1.1～1.5 mm.
Note: if the contact surface between valve and valve seat is against the requirement or is cracked
and rough, cylinder head should be adjusted, and replaced when necessary.
1. Adjust valve seat surface. Adjust valve seat with valve seat reamer.
Adjusting steps of intake valve seat
Adjust rough contact surface of valve seat with 45°reamer.
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Adjust valve seat with 30°reamer to make the perimeter adjusted by 45°reamer be φ26.4±0.1 mm.
Adjust valve seat with 70°reamer to make the perimeter adjusted by 45°reamer be 1.1～1.5 mm.
Scrape burrs caused by adjustment of 30°and 70°reamers.
Adjusting steps of exhaust valve seat

Adjust rough contact surface of valve seat with 45°reamer.
Adjust valve seat with 30°reamer to make the perimeter adjusted by 45°reamer be φ22.3±0.1 mm.
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Adjust valve seat with 70°reamer to make the perimeter adjusted by 45°reamer be 1.4 mm.
Scrape burrs caused by adjustment of 30°and 70°reamers.
2. Checking valve sinkage

After adjusting valve seat, dispose a new valve. Measure the distance between the joint surface of
cylinder body and cylinder head (contact surface with cylinder head gasket) and valve peak. Make
sure the distance within the following limits.
Maximum limits: intake valve: 2.855 mm
Exhaust valve: 3.01 mm
Note: if sinkage exceeds the maximum limit, replace cylinder head.
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Checking camshaft bearing cap
1. Check whether camshaft bearing cap and camshaft bearing cap seat are spalling or burnt, if
there is any damage, replace camshaft bearing cap and cylinder head together.
2. Check the lateral locating slot width of the first bearing cap intake camshaft: 3～3.05mm. If it
doesn’t meet the requirement, replace the whole cylinder head assembly.
3. Check the lateral thrust surface width of the first bearing cap exhaust camshaft: 21～21.05mm.
If it doesn’t meet the requirement, replace the whole cylinder head assembly.
Check valve tappet

1. Check whether valve tappet top surface has scratch, if there is deep scratch or sinter, replace
valve tappet.
2. Check whether valve tappet cylindrical surface has scratch, if there is deep scratch or sinter,
replace valve tappet.
3. Check valve tappet thickness is within 5.20～5.80mm, otherwise, replace valve tappet.
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Note: the checked valve tappet should be marked and disposed neatly in sequence.
Checking valve
Check valve stem to observe whether there is clamping stagnation or damage. If valve stem has
damages, replace valve and valve guide together.
Checking valve stem rear part

Check whether valve stem rear part has any abnormal abrasion.
If valve stem has abnormal abrasions, adjust the rear part with valve grinder.
Make sure the minimum value of valve full-length:
Intake valve: 87.9mm
Exhaust valve: 88.45mm
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Checking valve tip
① Check roughness and damage on contact surface of valve and valve seat, and remove deposited
carbon on the tip.
If there are damages on contact surface of valve and valve seat, grind contact surface with valve
grinder.
Valve tapered angle: 45.5°
After grinding valve tip, measure margin thickness of valve tip.

Minimum limits
intake valve 0.9mm
exhaust valve 0.9 mm
Note: if margin thickness of valve tip is less than the limited value, replace with new valve.
When replacing with new valve, check the oil clearance with valve guide.
Checking valve stem and valve guide clearance

Checking the clearance
Check the oil clearance between valve guide and valve stem.
Oil clearance=valve guide internal diameter-valve stem external diameter
Specified value: intake valve: 0.050—0.020 mm
Exhaust valve: 0.060—0.030 mm
Note: if the measured clearance exceeds the specified value, replace valve guide and valve
together.
①Measure valve guide internal diameter. Six positions are measured.
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Measure valve stem external diameter. Six positions are measured.
(2) Replacing valve guide

Note: when replacing valve guide, replace valve together.
Exhaust valve side
Valve guide is punched toward combustion chamber with special tools.
New valve guide is pressed with special tools.

Protruding height of valve guide: 15.1±0.2mm
Note: after valve guide is pressed, burrs are removed with an adjustable reamer. The specified
clearance between valve guide and valve stem is guaranteed.
Intake valve side

Valve guide is pressed from one side of combustion chamber with special tools.
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New valve guide is pressed with special tools.
Protruding height of valve guide: 15.1±0.2mm
Note: after valve guide is pressed, burrs are removed with an adjustable reamer. The specified
clearance between valve guide and valve stem is guaranteed.
Checking valve spring

Check verticality of valve spring with an angle square.
Measure the free length of valve spring with spring tester, and the pressure of spring at mounting
length.
Minimum free length: 44.2 mm
Spring pressure: minimum limit/mounting length: 160N/37mm
Checking camshaft
(1) Checking exhaust camshaft
1. Checking exhaust camshaft axial locating clearance
Check whether exhaust camshaft has cracks or abnormal abrasions. In addition, check locating
size of exhaust camshaft.
Locating size of exhaust camshaft: 21.1～21.2mm
- 95 -
2. Checking radial runout of camshaft
Support two ends of bearing with V-block, place micrometer on the middle point of camshaft
middle journal, rotate camshaft one circle, and camshaft has no axial movement. Record the
reading of micrometer while camshaft is rotating, and compute maximum radial runout, that is, the
difference between maximum reading and minimum reading.
Maximum radial runout: 0.03mm
3. Checking cam protruding height

Minimum limit: 39.45 mm
If the measured height is less than the minimum limited value, replace the camshaft.
4. Check clearance between exhaust camshaft journal and cylinder head bearing hole
①Measure external diameter of camshaft journal
②Measure internal diameters of cylinder head five camshaft bearing seat holes. Measure each
bearing hole in two perpendicular directions.
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Clearance
First camshaft bearing clearance 0.035～0.072 mm
Second and fifth camshaft bearing clearances 0.035～0.072 mm
If clearance exceeds the specified value, replace the parts to make clearance satisfy the specified
value. Refer to the specified sizes of camshaft journal and cylinder head camshaft bearing hole.
Specified sizes
First journal Second and fifth journals
External diameter of 25.965～25.949 22.965～22.949
camshaft journal (mm)
Internal diameter of head 26.000～26.021 23.000～23.021
camshaft bearing hole (mm)
(2) Checking intake camshaft
Check whether intake camshaft has cracks and abnormal abrasions, oil hole is blocked, and if any,
replace intake camshaft.
Check phase advance and delay oil path axial sizes on intake camshaft front end
Phase advance oil path axial size 21.4～21.6
Phase delay oil path axial size 29.9～30.1
3. Checking radial runout of camshaft

Support two ends of bearing with V-block, place micrometer on the middle point of camshaft
middle journal, rotate camshaft one circle, and camshaft has no axial movement. Record the
reading of micrometer while camshaft is rotating, and compute maximum radial runout, that is, the
difference between maximum reading and minimum reading.
Maximum radial runout: 0.03mm
- 97 -
3. Checking cam protruding height
Minimum limit: 39.45 mm
If the measured height is less than the minimum limited value, replace the camshaft.
4. Check clearance between exhaust camshaft journal and cylinder head bearing hole
①Measure external diameter of camshaft journal
②Measure internal diameters of cylinder head five camshaft bearing seat holes. Measure each
bearing hole in two perpendicular directions.
Clearance
First camshaft bearing clearance 0.035～0.072 mm

Second and fifth camshaft bearing clearances 0.035～0.072 mm
If clearance exceeds the specified value, replace the parts to make clearance satisfy the specified
value. Refer to the specified sizes of camshaft journal and cylinder head camshaft bearing hole.
Specified sizes
First journal Second and fifth journals
- 98 -
External diameter of camshaft journal (mm) 25.965～25.949 22.965～22.949
Internal diameter of head camshaft bearing 26.000～26.021 23.000～23.021
hole (mm)
Manually grind valve.
After the completion of all checks, manually grind valve before assembling.
Apply a thin layer of abrasive on valve and valve seat, and grind with valve grinding tools.
After grinding, clean valve and cylinder head with detergent and dry with compressed air.
9) Checking cylinder head bolt
(1) Check there is no crack, wrinkling, or pit on cylinder head bolt and screw surfaces, otherwise,
replace them.
(2) Check cylinder head bolt and screw lengths are no more than 87mm, otherwise, replace them.
(3) Check cylinder head bolt and screw diameters. Standard diameter: 8.1mm
Minimum diameter: 8.0mm
If the diameter is less than minimum diameter, replace the bolt.
10) Refer to “CA4GA1 engine service handbook (electric control parts)” for checking coolant
temperature sensor and camshaft position sensor.
11) Checking cylinder head cover cap
Check cylinder head cover cap, if there is any damage, replace the whole.
12) Checking OCV control valve filter
OCV control valve filter should have no damage, or oil deposit, if any, replace it.
13) Checking cylinder gasket assembly

Check the compressed thickness of cylinder gasket assembly is 0.4mm, minimum thickness is
- 99 -
0.37mm. if the thickness is less than minimum thickness, replace cylinder gasket assembly.
14) Refer to chapter “ignition system” for checking spark plug assembly.
Mounting
Mount cylinder head on the special service tool.
1) Mount valve spring retainer gasket
Mount valve guide oil seal assembly. New valve guide oil seal assembly is applied with engine oil
and then inserted in valve guide with special service tools.
Pictorial drawing: No. 1 on page 119 of 4GB
Note: New valve guide oil seal assembly should not be pressed excessively to prevent from
damaging inner wall rubber.
Mounting intake and exhaust valves
Intake and exhaust valves are applied with clean lubricating oil on small end and stem portions,
and then inserted into corresponding valve guides from one side of combustion chamber. Be
careful not to damage valve stem oil seal.
Note: valve cannot be pulled out after insertion. If it is necessary to do so, check the new valve
stem oil seal assembly has no damage first.
Mounting valve spring
5) Mount valve spring retainer.
6) Mount valve lock clamp. Mount valve lock clamp with special service tools below.
After mounting valve lock clamp, tap valve spring retainer with a plastic hammer to make sure
valve lock clamp is mounted firmly.
Note: make sure valve spring retainer and valve lock clamp do not eject when checking valve lock clamp.
7) Mount valve tappet and adjust valve clearance.
(1) Mount the checked tappet on cylinder head.
Note: 1. there should be no clamping stagnation when rotating tappet by hand after mounting.
2. It is easy to remove tappet with a magnetic bar or by hand.
Grouping table for valve tappet
Label Thickness Label Thickness Label Thickness Label Thickness
(t) (t) (t) (t)
20 5.20 36 5.36 52 5.52 68 5.68
22 5.22 38 5.38 54 5.54 70 5.70
24 5.24 40 5.40 56 5.56 72 5.72
26 5.26 42 5.42 58 5.58 74 5.74
28 5.28 44 5.44 60 5.60 76 5.76
30 5.30 46 5.46 62 5.62 78 5.78
- 100 -
32 5.32 48 5.48 64 5.64 80 5.80
34 5.34 50 5.50 66 5.66
Note: 1. The label numbers are printed on valve tappet inner top surface.
2. Tappets are selected or replaced based on the data in grouping table for valve tappet.
(2) Adjust intake side valve clearance
1. Intake camshaft assembly is cleaned, applied with proper lubricating oil on the journal, and
disposed gently on camshaft hole of cylinder head assembly.
2. Second, third, fourth, fifth camshaft bearing caps, which have been machined with cylinder
head camshaft bearing holes are mounted on cylinder head bearing seat by the labels.
3. Bolt heads are applied with new engine oil and fastened with 8 combined bolts, the tightening
torque is 12.5±2N·m, and tightening sequence is alternately from inside to outside.
4. Rotate hexagon head of camshaft with S24 opening spanner, check clearance between tappet
top surface and cam with a feeler, dismantle camshaft, and replace tappet by the recorded data to
guarantee the valve clearance.
Intake valve clearance is 0.2±0.03mm.
5. Loosen 8 combined bolts opposite the tightening sequence, and dismantle the second, third,
fourth, fifth camshaft bearing caps.
(3) Adjust exhaust side valve clearance
1. Exhaust camshaft assembly is cleaned, applied with proper lubricating oil on the journal, and
disposed gently on camshaft hole of cylinder head assembly.
2. Second, third, fourth, fifth camshaft bearing caps, which have been machined with cylinder
head camshaft bearing holes are mounted on cylinder head bearing seat by the labels.
3. Bolt heads are applied with new engine oil and fastened with 8 combined bolts, the tightening
torque is 12.5±2N·m, and tightening sequence is alternately from inside to outside.
4. Rotate hexagon head of camshaft with S24 opening spanner, check clearance between tappet
top surface and cam with a feeler, dismantle camshaft, and replace tappet by the recorded data to
guarantee the valve clearance.
Exhaust valve clearance is 0.3±0.03mm.
5. Loosen 8 combined bolts opposite the tightening sequence, and dismantle the second, third,
fourth, fifth camshaft bearing caps.
8) Assembling engine water inlet pipe seat assembly
Engine water inlet pipe seat assembly joint surface is cleaned and then applied with sealant, bolts
are applied with sealant on the thread portion and secured on cylinder head rear end, and
9) Assembling thermosistor assembly and engine water inlet pipe
- 101 -
(1) Thermosistor assembly with seal ring is put into water inlet pipe seat assembly, rocker valve
faces upward.
(2) Engine water inlet pipe is glued on joint surface and secured on engine water inlet pipe seat
assembly with hexagon head flange bolts, and tightening torque of bolt is 8±2N.m.
10) Assembling coolant temperature sensor and water outlet pipe

(1) Assembling coolant temperature sensor
Coolant temperature sensor is glued on thread portion and secured on engine water inlet pipe seat
assembly with hexagon head flange bolts, and tightening torque is 20±4N.m.
coolant temperature sensor assembly
water
outlet pipe
(2) Assembling engine water outlet

Tightening torque of bolt: 9±2N.m for M6 bolt
11) Assembling cylinder head assembly
(1) Dismantle cylinder head with special tools.
- 102 -
Assembling cylinder gasket assembly
① Sealing surface of cylinder gasket cannot be applied with lubricating oil.
②Glue 2 places on cylinder gasket: seams of cylinder body front end top surface with cylinder
gasket front bottom surface, and with timing chain cover cap.
③Two pin holes of cylinder gasket assembly are aligned with locating rings on cylinder body and
disposed on cylinder top surface.
(3) Check whether there is any oil, water or other thing in cylinder head bolt mounting hole on
cylinder body, and dried with compressed air.
12) Tightening cylinder head bolt
(1) Cylinder head bolt gasket is put in cylinder head bolt hole with special tools.
(2) Cylinder head bolt is applied with a layer of oil on thread and bolt head portions, and put in
cylinder head bolt hole.
(3) 10 cylinder head bolts are tightened twice in the sequence shown in the drawing.
Tightening torque: 34±2N.m, then 120° . Final tightening torque is no less than 65Nm, and
tightening sequence is shown in the drawing.
- 103 -
Note: 1. If final tightening torque exceeds this range, replace the bolts.
2. If final tightening torque is still less than 65Nm after replacing, rotating angle can be increased
properly to make torque more than 65Nm.
3. Cylinder head bolts can be reused no more than three times.
11) Mounting intake and exhaust camshafts
(1) Mounting exhaust camshaft
1. Engine oil is applied on tappet and cylinder head camshaft bearing seat (especially the first
camshaft bearing seat of cylinder head).
2. Exhaust camshaft is disposed on cylinder head, and intake and exhaust camshafts are disposed
with camshaft cylindrical pin facing upward.
Note: Because thrust clearance of camshaft is small, camshaft must be mounted horizontally, if
camshaft cannot be kept horizontally, cylinder head will suffer from axial thrust force, and
camshaft will deform or fracture or even break.
Mounting intake camshaft
1. Intake camshaft position sensor target disc is mounted and pressed to the bottom.
2. Engine oil is applied on tappet and cylinder head camshaft bearing seat (especially the first
camshaft bearing seat of cylinder head).
3. Intake camshaft is disposed on cylinder head, and intake and exhaust camshafts are disposed
with camshaft cylindrical pin facing upward.
- 104 -
Note: Because thrust clearance of camshaft is small, camshaft must be mounted horizontally, if
camshaft cannot be kept horizontally, cylinder head will suffer from axial thrust force, and
camshaft will deform or fracture or even break.
12) Tighten camshaft bearing cap.
1) After camshaft is disposed well, second to fifth intake and exhaust camshaft bearing caps are
cleaned and mounted on cylinder head. Bolt is applied on head portion with a layer of engine oil
and tightened twice.
Tightening torque: 12.5±2N·m
2) The first camshaft bearing cap is mounted on cylinder head. Bolt is applied on head portion
with a layer of engine oil and tightened twice.
Note: tightening sequence of camshaft bearing cap is alternately from inside to outside.
Tightening torque: 12.5±2N·m
13) Mounting camshaft position sensor, carbon canister solenoid valve
(1) Mounting camshaft position sensor
①Camshaft position sensor is applied with clean oil on O-ring, and fastened with hexagon head
flange bolt.
- 105 -
Tightening torque:6-8N.m
camshaft position sensor is mounted here
(2) Mounting carbon canister solenoid valve

Carbon canister solenoid valve and engine harness support Ⅳ are secured with the same Phillips
flat and round combined screw.
Tightening torque is 6±2N.m.
Phillips flat and round combined screw, carbon canister solenoid valve support,
carbon canister solenoid valve assembly,
Camshaft position sensor hexagon head flange bolt
14) Mounting OCV control valve filter

OCV control valve filter is inserted into holes at intake side of cylinder head. Bolts and gaskets are
assembled in the corresponding screw holes.
Tightening torque is 24.5±5N.m.
15) Mounting exhaust camshaft sprocket

Fasten hexagon head of exhaust camshaft with S24 opening spanners, and align pin holes on
- 106 -
exhaust camshaft sprocket with pins on camshaft, and cover sprocket on exhaust camshaft.
Note: After insertion, twist sprocket gently to check whether locating pin is inserted in the locating hole.
Fasten sprocket to camshaft with combined bolts, and tightening torque is 8±1.6N.m.
16) Mounting VCT controller assembly

Fasten intake camshaft with S24 opening spanners, drip several drops of lubricating oil at the top
front end of intake camshaft journal, and align pin holes on VCT controller assembly with
cylindrical pins on camshaft. After insertion, twist sprocket gently to check whether locating pin is
inserted in the locating hole.
Fasten VCT controller assembly to camshaft with combined bolts, and tightening torque is
47±7N.m.

(1) Mounting crankcase ventilation valve seal seat
Crankcase ventilation valve is applied with proper lubricating oil on seal seat surface and then
pressed into corresponding hole on cover cap.
(2) Mounting crankcase ventilation valve assembly
Crankcase ventilation valve assembly is applied with proper lubricating oil on the surface and then
inserted into seal seat- crankcase ventilation valve.
(3) Mounting cylinder head cover cap assembly, oil filler cap and harness support
(1) Put cylinder head cover cap seal gasket into gasket slot, and apply sealant on the seams of
cylinder head with timing chain cover cap (2 places).
- 107 -
Sealant is applied here
②Carbon canister solenoid valve support is mounted to cylinder head cover cap (position ①in the
drawing) with bolt M6×25.
③ Engine harness support II is mounted to cylinder head cover cap (position ⑧ in the drawing)
with bolt M6×25.
④Engine harness support I is mounted to cylinder head cover cap (position ⑦ in the drawing)
with bolt M6×20.
⑤Use bolt M6×20 for positions ⑥, ⑦ in the drawing. Use stud bolt M6 and hexagon head flange
bolt M6 for positions ⑿, ⒀in the drawing. Use bolt M6×25 for the remaining positions, and
tightening torque is 9-13 N.m (target value is 11).
19) Mounting oil filler cap

Oil filler cap is applied with lubricating oil on the rubber gasket and then rotary-mounted on
cylinder head cover cap.
20) Refer to chapter “ignition system” for mounting spark plug assembly.
21) Refer to chapter “ignition system” for mounting rod-like ignition coil assembly.
3.6 Cylinder body
Composition of cylinder body
- 108 -
Dismantling
1) Dismantle engine assembly
2) Dismantle oil filter assembly
3) Dismantle oil filter connector
4) Dismantle oil pressure alarm assembly
Do not use an impact torque spanner to dismantle oil pressure alarm assembly to avoid damage.
- 109 -
Dismantle knock sensor assembly
Do not use an impact torque spanner to dismantle knock sensor assembly to avoid damage.
6) Dismantle oil dipstick assembly
8) Dismantle air-cooled compressor assembly
9) Dismantle combined support of air-cooled compressor and power steering pump
10) Dismantle water pump assembly
Loosen hexagon head flange bolts (three) and hexagon flange nuts (two) to dismantle water pump
body and water pump gasket.
11) Dismantle chain mounting bracket

12) Dismantle crankshaft sprocket
After retaining the crankshaft, take crankshaft key out with screw driver, then take crankshaft
sprocket out.
13) Dismantle chain lubricating nozzle
14) Dismantle oil pump assembly
Loosen hexagon head flange bolts, dismantle hexagon head flange bolts and gaskets. Dismantle oil
pump assembly.
Note: When dismantling oil pump assembly, put external rotor and internal rotor together to avoid loss.
internal rotor
external rotor
- 110 -
15) Dismantle clutch cover assembly and clutch driven plate assembly
Insert clutch housing and pressure dismantling tool into spline of the clutch driven plate assembly,
loosen six M8 coupling bolts of the clutch cover assembly and flywheel, and dismantle clutch
cover assembly and clutch driven plate assembly.
Note: Properly dispose the dismantled clutch cover assembly and clutch driven plate assembly in a
special apparatus to protect them from impact and bump, otherwise, the dynamic balance of the
clutch cover assembly will be broken.
16) Dismantle flywheel supplementary gear ring assembly
⑴ Loosen bolts of flywheel supplementary gear ring assembly evenly in two or three times, and
then dismantle the bolts.
⑵ Dismantle the flywheel supplementary gear ring assembly.
Note: The flywheel supplementary gear ring assembly is heavy, and operation should be very
careful.
17) Dismantle oil pan assembly
Loosen bolts and nuts of oil pan with special tools, gently lift oil pan with screwdriver and oil pan
dismantling tool, then dismantle the oil pan assembly.
Note: ① Do not apply excessive forces to the oil pan in avoid of deformation.
② The sealant should be dismantled clearly after dismantling the oil pan with the oil pan
dismantling tool.
18) Dismantle the baffle of the clutch housing

19) Dismantle rear oil seal seat assembly
Loosen the bolts of rear oil seal seat assembly with special tools, gently lift the rear oil seal seat
assembly with screwdriver and oil pan dismantling tool, then dismantle the rear oil seal seat
assembly.
Note: ① Do not apply excessive forces to the rear oil seal seat assembly in avoid of damage.
② The sealant should be dismantled clearly after dismantling the rear oil seal seat assembly.
20) Dismantle oil collector assembly and gasket

Loosen assembling bolts (two), and dismantle oil collector assembly and gasket.
Note: Lock glues are applied on the thread portion of the assembling bolts, and the lock glues
should be dismantled clearly after dismantling.
- 111 -
21) Loosen connecting rod cap bolt to dismantle connecting rod cap.
⑴ Rotate crankshaft till connecting rod cap to one side of the oil pan.
⑵ Loosen connecting rod bolt evenly in two or three times, and dismantle connecting rod nut.
Note: ① Deposit the dismantled connecting rod cap in process apparatus in sequence, so as to
know its mounting position beforehand.
② Do not damage the thread portion of the connecting rod bolt.
③ Do not touch bush surface by hand.
④ Do not let connecting rod bolt damage the crankshaft.
22) Dismantle main bearing cap

Loosen main bearing bolt in a sequence as shown in the drawing, and dismantle main bearing cap.
Note: ① Put the dismantled main bearing bolt and the corresponding main bearing cap together,
and do not mix them up.
② Tapping main bearing cap with wood stick or copper hammer is allowed to separate it from
main bearing seat.
③ Dispose the dismantled crankshaft assembly in a special apparatus to protect them from
damage and bump.
23) Dismantle crankshaft assembly

Note: Lift the crankshaft horizontally during dismantling, this can protect crankshaft journal from
being damaged, and the cylinder body can not prevent crankshaft from being dismantled.
⑴ Dismantle thrust pad
Thrust pad is arranged on the two sides of the third main journal.
- 112 -
⑵ Dismantle upper and lower main bushes
Upper and lower main bushes are dismantled as follows: push bush by hand at the side without
locating spigot to lift the other end, thus can dismantle bush. Do not touch the working face and
back of the bush by hand during dismantling.
Note: ① Deposit the dismantled bush in sequence, so as to know its mounting position
beforehand.
② The dismantled parts can be cleaned with detergent, and then dried with compressed air.
This method is not suitable for rubber parts.
24) Dismantle piston connecting rod assembly

⑴ If carbon is deposited on top of cylinder body to form protrusion, dismantle it with cylinder
reamer or similar tools.
⑵ Pull out piston connecting rod assembly at one side of the cylinder head.
⑶ Properly dispose the dismantled piston connecting rod assembly in special apparatus.
Note: Dismantling piston connecting rod assembly must be very careful to protect cylinder wall,
crankshaft journal and piston connecting rod assembly from being damaged.
- 113 -
25) Dismantle upper and lower bushes of the connecting rod
They should be properly disposed in special apparatus and not mixed up after dismantling.
Upper and lower bushes are dismantled as follows: push bush by hand at the side without locating
spigot to lift the other end, thus can dismantle bush. Do not touch the working face and back of the
bush by hand during dismantling.
Note: ① Deposit the dismantled bush in sequence, so as to know its mounting position
beforehand.
② The dismantled parts can be cleaned with detergent, and then dried with compressed air.
This method is not suitable for rubber parts.
Upper connecting rod bush

Connecting rod bush locating lug
Lower connecting rod bush
26) Dismantle piston ring

⑴ Dismantle piston upper compression ring, middle compression ring, and combined oil ring
assembly. Upper compression ring and middle compression ring are dismantled with piston
expander or similar tools, and cannot be damaged. Deposit the dismantled compression ring in
special apparatus, so as to know its mounting position beforehand.
Note: Do not exceed the desired range and expand the piston ring uselessly.
⑵ Dismantle combined oil ring assembly
Dismantle combined oil ring assembly by hand, and deposit the dismantled combined oil ring
assembly in special apparatus, so as to know its mounting position beforehand.
Note: Do not exceed the desired range and expand the combined oil ring assembly uselessly.
27) Dismantle piston pin
⑴ Put forward label on top of the piston downward, apply appropriate lubricating oil, and extrude
piston pin from piston pin hole with special tools.
⑵ Deposit the dismantled piston pin in special apparatus, so as to know its mounting position
beforehand.
28) Dismantle pressure limiting valve assembly
- 114 -
Sealant is applied on the thread portion of the pressure limiting valve assembly, and the sealant
should be dismantled clearly after dismantling.
29) Dismantle hexagon head tapered plug

Note: Anaerobic sealant is applied on the thread portion of the hexagon head tapered plug, and the
anaerobic sealant should be dismantled clearly after dismantling.
30) Take cylinder body from the special service tool.
Checking
?????????????
⑴ Check whether there is any damage or crack.
⑵ Check the deformation from cylinder head gasket joint surface.
Note: Check in the six directions. Maximum deformation limit: 0.1mm
If the surface deformation exceeds maximum deformation limit, the surface should be repaired.
The repair should be within a grinding limit of 0.3mm. In addition, the distance between cylinder
head gasket joint surface and oil pan mounting surface should be no less than 222mm.
⑶ Measuring cylinder diameter

Measure the cylinder diameter of each cylinder in six directions.
Note: After checking or repairing cylinder, put cylinder diameter measuring tool in the cylinder
and measure the cylinder diameter of each cylinder at a distance of over 40mm from cylinder top
mounting surface.
- 115 -
Make sure the difference between maximum cylinder diameter and minimum cylinder diameter is
no more than 0.1mm.
Note: Record the measuring results.
Pictorial drawing: No. 4 on page 83.
If the difference between maximum value and minimum value is more than the specified value
(0.1mm), make boring and grinding to the cylinder.
The specified value for cylinder diameter after grinding
When using standard piston φ73.00～φ73.03
When using oversized 0.25mm piston φ73.25～φ73.28
When using oversized 0.50mm piston φ73.50～φ73.53
Pictorial drawing: No. 1 on page 84.
After cleaning and checking to the cylinder body, calculate the clearance between cylinder and
piston. The difference between measured minimum cylinder diameter and measured maximum
cylinder diameter is used in the calculation
The clearance between cylinder and piston: 0.02～0.04mm
Note: if the calculated clearance is more than the specified value, make boring and grinding to the
cylinder as prescribed in ②. However, if oversized piston is used and the clearance between
cylinder and piston is more than the specified value, replace cylinder body and piston.
Knock sensor surface of the cylinder body is level and clean, and without damage, the thread is
pretty sound.
⑷ Measure oil pump hole
Measured oil pump hole diameter: φ55.1(＋0.06,＋0.03)
Oil pump hole diameter limit: φ55.3mm
If the diameter exceeds the specified value, replace cylinder body.
oil pump hole
2) Checking crankshaft
⑴ Check radial runout of the main journal
Rotate crankshaft with special clamp by hand, and measure runout of the main journal with
centimeter.
Maximum radial runout limit: 0.06mm
Note: Be careful not to scratch the journal.
⑵ Check abrasion of crankshaft

Check whether there is scratch or abrasion on main journal and connecting rod journal.
⑶ Check main journal and connecting rod journal
- 116 -
Pick four points on each main journal and connecting rod journal to measure the external diameter.
② Based on each measuring result of main journal and connecting rod journal, calculate the
difference between maximum value and minimum value.
Ovality and conicity limit: 0.01mm
Note: ① Measurement should be done on the whole surface of each journal to avoid oil hole on
the journal.
② Record the measuring results.
③ Be careful not to scratch crankshaft.
⑷ Check main journal clearance

Mount main bush on main bearing and main bush cap, do not touch the working face and back of
the main bush, and mounting surface of the main bearing and main bush cap during checking.
Note: upper main bush and lower main bush can not be reversed. Upper main bush (on cylinder
body) has oil slot and oil hole while lower main bush (on bearing cap) has no oil slot or oil hole.
Mount crankshaft on cylinder body.

Note: ① Be careful not to scratch crankshaft and main bush.
② Do not apply lubricating oil on crankshaft and main bush.
- 117 -
Mount plastic clearance gauge
Mount main bearing cap. Tighten twice with a specified tightening torque of 60±5N.m, and the
tightening sequence is shown in the drawing.
Note: Do not rotate crankshaft by hand after tightening.

Dismantle main bearing cap, and read the clearance value. Main journal clearance: 0.025-0.043mm.
If the clearance exceeds the specified value, grind or replace crankshaft according to the main
journal value listed in the table below, to make the clearance meet the specified value.
Note: When grinding main journal, finely process on each main journal to keep fillet radius at
R1.3mm.
Main bush size Main journal diameter
Standard size φ46(0,－0.018)
Reduced 0.25mm φ45.75～φ45.57
Reduced 0.50mm φ45.50～φ45.32
⑸ Check crankshaft axial clearance
① Mount main bush on main bearing and main bush cap, do not touch the working face and back
of the main bush, and mounting surface of the main bearing and main bush cap during checking.
Note: upper main bush and lower main bush can not be reversed. Upper main bush (on cylinder
body) has oil slot and oil hole while lower main bush (on bearing cap) has no oil slot or oil hole.
- 118 -
upper main bush
lower main bush
② Mount crankshaft on cylinder body
Note: Be careful not to scratch crankshaft and main bush.
③ Push two crankshaft thrust pads into two sides of the third main bearing seat, to make oil slot
surface face outward, that is, oil slot is in the crankshaft side.
Note: Do not apply lubricating oil on crankshaft thrust pad.
④ Mount main bearing cap. Tighten twice with a specified tightening torque of 60±5N.m.
⑤ Lift crankshaft balancing iron with flat-blade screwdriver, making crankshaft leap forward, and
measure crankshaft axial clearance with centimeter.
Axial clearance: 0.04～0.20mm.
Note: Record the measuring results.
⑥ If the axial clearance exceeds the specified value, determine to use thrust pad or replace the
thrust pad based on the calculation below.
Measured axial clearance: A
Thickness sum of left and right crankshaft thrust pads: B
Specified axial clearance: C
Required crankshaft thrust pad thickness: D＝｛﹙A＋B｝－C｝÷2
Based on the calculation result of D value, select appropriate crankshaft thrust pads from the given
data in the table below.
Crankshaft thrust pad size Crankshaft thrust pad Remark
thickness (mm)
Standard size 2.15～2.18 Using when maximum D value ≤2.18
Oversized 0.125 2.275～2.305 Using when maximum D value＞2.18
Oversized 0.250 2.40～2.43 Using when maximum D value＞2.305
For example, measured axial clearance: A＝0.53mm

Thickness sum of left and right crankshaft thrust pads: B＝4.2mm
Specified axial clearance: C＝0.04～0.20mm
Required crankshaft thrust pad thickness: D＝？
D＝｛﹙A＋B｝－C｝÷2
＝｛﹙0.53＋4.2｝－0.04～0.20｝÷2＝2.275～2.345mm, in this case, use oversized 0.125 mm
crankshaft thrust pad. However, if minimum D value exceeds 2.43 mm, replace crankshaft and
crankshaft thrust pad at the same time.
3) Checking piston and piston ring
- 119 -
⑴ Cleaning piston
Dismantle deposited carbon on top of piston with tools such as scraper.
Dismantle deposited carbon on piston ring groove with broken piston ring or other ring groove
cleaning tools.
Clean piston with soft brush and detergent. Be careful not to scratch piston surface.
Check whether there is any crack, damage, or stagnation.
⑵ Measure the thicknesses of the upper compression ring, lower compression ring and combined
oil ring with a thickness gauge.
Standard thickness for upper compression ring: 1.2mm
Standard thickness for middle compression ring: 1.2mm
Standard thickness for combined oil ring: 2.8mm
⑶ Check side clearance of piston ring groove
Measure side clearance of piston ring groove in the whole circle with a feeler or thickness gauge,
the measured maximum value is considered to be the side clearance of the piston ring groove.
Side clearance of upper compression ring: standard value: 0.04～0.09mm
Limit value: 0.13mm
Side clearance of middle compression ring: standard value: 0.02～0.06mm
Limit value: 0.08mm
If the measured side clearance exceeds the specified value, measure the thickness of the piston
ring with micrometer. In accordance with the following standard thickness of the piston ring,
replace piston ring, piston or the two at the same time.
⑷ Check whether there is any damage on combined oil ring assembly.

Note: if any of the upper compression ring, middle compression ring and combined oil ring
assembly is defective in a cylinder, replace all the piston ring together.
⑸ Measure external diameter of the piston
Measure external diameter of the piston at the specified position, i.e., a certain distance away from
the lowest part of the piston.
Position for measuring external diameter of the piston: 8mm away from the lowest part of the
piston.
Note: Record the measuring results. (The measuring results are necessary data for calculating the
clearance between cylinder and piston.)
Insert No. 1 on page 86 of the “3GA2 service handbook”
⑹ Check piston pin clearance
① Measure internal diameter of piston pin hole.
② Measure external diameter of piston pin hole.
③ Calculate the clearance between piston pin hole and piston pin.
Accepted limit:
Note: If the clearance exceeds the specified value, replace piston and piston pin together.
⑺ Measure opening clearance of the piston ring
After checking or repairing cylinder, put piston ring in the cylinder and measure the opening
clearance of the piston ring at a distance of over 40mm from cylinder top mounting surface with a
feeler.
Opening clearance between upper compression ring and ring groove: 0.04～0.09mm.
Opening clearance between middle compression ring and ring groove: 0.02～0.06mm.
Opening clearance between oil ring and ring groove: 0.03～0.11mm.
Note: ① Apply lubricating oil on the outside of the piston ring before putting piston ring in the
cylinder.
② If the opening clearance exceeds the specified value, replace piston and piston pin together.
Check the connecting rod
⑴ Check whether there is any damage or crack on the connecting rod.
⑵ Check whether there is any deformation or distortion on the connecting rod.
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Maximum deformation limit: 0.03mm
Maximum distortion limit: 0.03mm
⑶ Measure hole clearance of connecting rod big end
① Mount upper and lower bushes of the connecting rod on connecting rod body and connecting
rod cap, respectively.
② Mount plastic clearance gauge on crankshaft on crankshaft connecting rod journal, fasten the
connecting cap with a specified torque after mounting connecting rod bush cap.
Tightening torque: 22±2.5N.m, then torque for 90°±10°.
③ Dismantle connecting rod cap, and measure the clearance.
The clearance between connecting rod bush and crankshaft connecting rod journal is 0.017～
0.035mm. If the clearance exceeds the specified value, grind or replace crankshaft according to the
crankshaft connecting rod journal value listed in the table below, to make the clearance meet the
specified value.
Connecting rod bush size Crankshaft connecting rod journal
Standard size φ40.000～φ39.982
Reduced size 0.25 φ39.750～φ39.732
Reduced size 0.50 φ39.500～φ39.482
Note: When grinding crankshaft connecting rod journal, finely process on each crankshaft
connecting rod journal to keep fillet radius at R1.3mm.
⑷ Check connecting rod axial clearance
① Measure the axial clearance between connecting rod and crankshaft with a thickness gauge.
Axial clearance: 0.20～0.47mm
Note: When measuring the axial clearance, press the connecting rod to any side of the crankshaft
in axial direction, and measure the clearance with a thickness gauge at the other side.
② If the clearance exceeds the specified value, replace connecting rod, crankshaft or the two
together according to the axial widths of the connecting rod big end and connecting rod journal.
Axial width of the Axial width of the connecting rod journal
connecting rod big end
18.80～18.73mm 19.00～19.13mm
Reference
drawing
Axial width of the crankshaft connecting rod journal

5) Check clutch cover assembly
⑴ Check the abrasion and scratch conditions of clutch cover assembly pressure plate surface, and
the abrasion limit is less than 0.3mm.
⑵ Check runout of clutch cover assembly within φ70 of the diaphragm spring center, and the
runout limit is less than 0.7mm.
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6) Check clutch driven plate assembly
⑴ Check whether the average thickness of the two friction surfaces of the driven plate assembly
within the range of 8.0～8.4mm, the average thickness limit of the two friction surfaces is 7.8mm.
⑵ The friction plate of the clutch driven plate assembly is not allowed to fracture, and is free of
oil and impurities.
7) Check flywheel supplementary gear ring assembly

⑴ Make sure there is no abrasion or damage on the contact surface of gear ring and clutch plate of
the flywheel supplementary gear ring assembly.
⑵ Check the radial runout of the flywheel supplementary gear ring assembly.
Fasten flywheel bolt to a specified torque.
Tightening torque: 73.3～82.7N.m
Note: prior to check, make sure to fasten crankshaft main bush cap to the specified torque.
Measure the radial runout of the flywheel supplementary gear ring assembly with centimeter.
The radial runout limit of the flywheel supplementary gear ring assembly is 0.12mm.
Note: If the measured radial runout exceeds the limit value, replace the flywheel supplementary
gear ring assembly.
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8) Refer to chapter “lubrication system” for checking pressure limiting valve assembly.
9) Checking other parts
⑴ Check whether there is any damage or crack on other parts, if necessary, replace them.
⑵ Refer to “lubrication system” for checking oil pump assembly in details.
⑶ Refer to “cooling system” for checking water pump assembly in details.
Mounting
(Considerations)
⑴ Clean all the parts thoroughly.
⑵ Prior to mounting, apply new lubricating oil on all the moving members and rotating members.
⑶ Replace defective seal gaskets, and dismantle all the original sealants.
⑷ Sealant can be used when necessary to prevent water leakage and oil leakage.
⑸ Use appropriate bolts, nuts and gaskets. Fasten bolts and nuts with specified torque, and do not
fasten excessively the stud bolt on aluminium alloy parts.
⑹ If marks have been made during dismantling, reassemble should be done in accordance with
these marks. Make sure piston and other parts are assembled correctly in accordance with
specified clearance.
When cylinder body is mounted on engine overhaul support, fasten it with bolts to make sure
safety.
2) Assembling cylinder body locating pin

⑴ Cylinder head locating rings (two) are pressed into two holes on top surface of cylinder body,
extending a length of 5.5～6mm.
⑵ Clutch housing locating pins (two) are pressed into two holes on cylinder body rear end surface,
extending a length of 12～12.5mm.
⑶ Cylindrical pins (two) are pressed into two holes on rear oil seal mounting surface at cylinder
body rear end, extending a length of 6～6.5mm.
⑷Hexagon head tapered plug is applied uniformly with anaerobic sealant on the thread portion,
and then is assembled.
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cylinder head locating ring
clutch housing locating pin
Hexagon head tapered plug
cylindrical pin
⑸ Press oil pump locating pins (two) into two holes on front end of cylinder body, extending a
length of 4～4.2mm.
⑹ Press cylindrical pins (two) into two holes on front end surface of cylinder body, extending a
length of 6～6.5mm.
⑺ Press combined supports locating rings (two) into two holes of exhaust side, extending a length
of 5～5.5mm.
cylinder body front

end surface
locating pin
locating ring
cylindrical pin
3) Refer to chapter “lubrication system” for mounting pressure limiting valve assembly.
4) Assembling crankshaft assembly
⑴ Assembling crankshaft locating pin
Assemble locating pin with special tools on flange surface, where flywheel is mounted at the rear
end of the crankshaft, and locating pin extends a length of 6～7mm from flange surface.
Note: ① The grouping label of main journal is marked on the 8th crank arm
② The grouping label of connecting rod journal is marked on the 1st crank arm
③ Main journal is divided into three groups, and the grouping sizes of main journal diameter are
listed in the table below.
④ Connecting rod journal is divided into three groups, and the grouping sizes of connecting rod
journal diameter are listed in the table below.
locating pin
main journal size grouping
connecting rod journal size grouping
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main journal diameter grouping
Symbol actual size
3 >-0.006～0
2 >-0.012～0.006
1 >-0.018～0.012
connecting rod journal diameter grouping
Symbol actual size
3 >-0.006～0
2 >-0.012～0.006
1 >-0.018～0.012
⑵ Match wall thickness of main bush
The wall thickness grouping of main bush is marked on the back of the bush, upper main bush has
oil hole, while lower main bush has no oil hole.
Note: the thickness grouping of main bush is listed in the table below.
Main bush grouping by wall thickness
Grouping code color mark grouping size
5 Cyan
4 black
3 brown
2 green
1 yellow
⑶ Matching of main bush

Select appropriate main bush to assemble in accordance with main bearing hole grouping code and
crank main journal grouping code of cylinder body
Matching bush code=7-(hole code + bearing code)
The assembling relationship of main bearing seat, journal and main bush is listed in the table
below:
seat hole grouping
bush grouping
main bearing bush

bush bush bush
clearance code code clearance code
clearance
bush bush bush

clearance code clearance code clearance code
bush bush bush

clearance code clearance code clearance code
⑷ Mounting main bush
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With cylinder base plane facing upward, main bearing seat surface is cleaned with silks, five upper
main bushes corresponding to crankshaft journal and seat hole are applied with lubricating oil and
placed on main bearing seat. Locating lug on bush back should fall into the corresponding slots
and bush back should be against the main bearing cap seat. Each upper main bush should be
applied with lubricating oil on the working surface.
Lower main bush is mounted on main bearing bush cap, bush locating lug should fall into the
corresponding slots and bush back should be against the main bearing seat surface. Each lower
main bush should be applied with lubricating oil on the working surface.
Note: ① Oil or other foreign matters are not allowed on the surface between bush back and main
bearing seat surface, and oil hole on the bush should be communicated with oil hole on
the seat surface.
② Bush locating lug cannot be loose after pressed into locating slot of the connecting rod
bearing seat.
③ Do not touch working surface and back surface of connecting rod bush and bush
mounting surface of connecting rod during assembling.
④ Clean lubricating oil on each connecting rod bush back surface.

⑸Assembling crankshaft
① before assembling crankshaft, lubricating oil gallery hole should be cleaned and blown
carefully and foreign matters in each journal are not allowed.
② drip 3-5 drops of lubricating oil on the inner surface of the fixed main bush, lift the cleaned
crankshaft, place main journal gently on main bearing seat, and rotate gently for two circles.
③ Mounting thrust pad
Two thrust pads are pushed into two sides of the third main bearing seat respectively, with oil slot
facing outward, that is, oil slot is in the crankshaft side.
Note: pushing position is top side of the third main journal.
④ Mounting main bearing cap

Lower main bushes corresponding to the five main bushes of crankshaft journal and seat hole are
applied with lubricating oil and placed on main bearing cap seat. Locating lug on bush back
should fall into the corresponding slots and bush back should be against the main bearing cap seat.
Five main bearing caps are pointed to the front of cylinder by the arrow, and mounted on main
bearing seat in sequence from cylinder front. Tapping main bearing seat with wood stick or copper
hammer is allowed to fasten it on the main bearing seat. Tighten with main bearing bolts for twice.
Initial tightening torque: 20±5Nm.
Final tightening torque: 60±5N.m and the tightening sequence is shown in the drawing.
Note: ① Be careful not to scratch each crankshaft journal when mounting main bearing bush cap.
② Make sure crankshaft can rotate flexibly after initial tightening and each further tightening of
main bearing cap.
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⑤ Suck cylinder body with magnetometer and measure crankshaft axial clearance with
centimeter.
Axial clearance: 0.04～0.2mm
5) Mounting rear oil seal seat assembly
⑴ Rear oil seal seat assembly is cleaned and pressed into rear oil seal seat hole with special tools.
Pressing depth from rear oil seal seat joint surface is 2.5±0.3mm, that is, oil seal cannot exceed oil
seal seat end surface.
⑵ lug is applied with proper lubricating oil, and rear oil seal seat joint surface is cleaned and
applied uniformly with sealant.
Note: ① it only can be used after checking there is no paint, dirt, and scratch on rear oil seal seat.
② assemble within 3 minutes after applying glues, and tighten within 15 minutes.
⑶ the locating pin hole on oil seal seat is aligned with locating pin on cylinder, and it is allowed
to tap oil seal seat external surface by hand or rubber hammer. Crankshaft rear flange journal is
inserted into oil seal lug, and oil seal seat is against cylinder rear end surface. Tighten hexagon
head flange bolt in the sequence shown in the drawing.
Tightening torque of bolt: 8±2N·m
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Note: oil seal surface cannot be damaged when assembling rear oil seal seat assembly.
6) Assembling connecting rod, piston and connecting rod bush

⑴ Matching piston pin external diameter grouping
Piston pin external diameter grouping is applied on end surface of pin with red and yellow colors.
⑵ Matching piston pin hole grouping and piston skirt grouping

Piston pin hole is divided into two groups, red and yellow colors are labeled on the piston pin seat.
Piston skirt is divided into three groups, A, B, C are labeled on piston top surface.
⑶ Assemble piston pin with special piston pin dismantling clamps.

① Insert spring into the special piston pin dismantling clamp body
Insert long rod into body.
Mount chock on the body, and the surface with notch faces upward.
Mount piston on the body, and align with notch of the chock.
Note: lubricating oil is filled in piston pin hole.
② Insert piston pin into piston pin hole.
Note: lubricating oil is applied on piston pin.
Align connecting rod small end with piston pin hole.
Note: Keep forward labels of piston and connecting rod in the same direction.
③ Small rod is inserted into the central hole of piston pin and laid flat. Piston pin is inserted into
piston pin hole and connecting rod small end with special pressing tools.
Pressing load of piston pin: 100N.m
Pressing depth: the distance between piston and piston pin is 0±0.5mm when connecting rod end
surface adheres close to inner flange of the piston.
Note: ① Forward label on piston top and connecting rod forward label should be in the same side,
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the pressed piston pin has the same color with piston pin seat.
② parts should be cleaned and applied with proper lubricating oil.
⑷ Matching connecting rod assembly grouping

The printing positions for connecting rod forward label, big end grouping label and mass grouping
label are shown in the drawing.
Connecting rod assembly is divided into five groups by mass, and A, B, C, D, E are labeled on the
big end.
Connecting rod big end diameter is divided into two groups, and 1, 2 are labeled on the big end.
⑸ Matching connecting rod bush

Based on crankshaft upper connecting rod journal grouping label, select piston connecting rod
assembly and connecting rod bush according the above assembling relationship table.
Note: upper and lower bushes are divided into four groups by the wall thickness, and the colors of
black, brown, green, and yellow are applied on back of the bush.
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⑹ Assembling relationship of seat hole, axle hole, and connecting rod journal
Select proper connecting rod bush to assemble based on grouping codes of crankshaft connecting
rod journal and connecting rod big end.
Bush code=6-(hole code +axle code)
⑺ Assembling upper and lower bushes

Mount connecting rod upper bush into the connecting rod bush seat hole, making locating lug in
the corresponding slot of bush seat, and bush back against connecting rod big end hole seat
surface.
Mount connecting rod lower bush into the connecting rod bush cover hole, making locating lug in
the corresponding slot of bush seat, and bush back against connecting rod bush cover hole seat
surface.
Note: ① connecting upper bush has oil hole and lower bush has no oil hole.
② Oil or other foreign matters are not allowed on the surface between bush back and
connecting rod bearing seat, and oil hole on the bush should be communicated with oil
hole on the seat surface.
③ Bush locating lug cannot be loose after pressed into locating slot of the connecting rod
bearing seat.
④ Do not touch working surface and back surface of connecting rod bush and bush
mounting surface of connecting rod during assembling.
⑤ Clean lubricating oil on each connecting rod bush back surface.
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7) Assembling piston ring
⑴ Piston ring slot should be cleaned, and there is no foreign matter in the ring slot.
⑵ Insert the combined oil ring assembly into oil ring slot first, then assemble middle compression
ring and upper compression ring in sequence with hand or special tools.
Note: ① Upward mark of piston ring should face upward.
② Be careful not to scratch the piston surface with opening end of piston ring.
⑶ Piston ring can be rotated flexibly after assembling into the ring slot.
8) Assembling piston connecting rod assembly
⑴ Rotate crankshaft to make the first and fourth connecting rod journals be on top dead center
(TDC) position.
⑵ Apply proper lubricating oil on the inner surface of the bush; apply proper lubricating oil on the
whole circle of cylinder body within 10mm from top surface.
⑶ The openings of the piston ring should be interlaced as shown in the drawing, and each opening
of ring is shown in the drawing below:
⑷ Forward label of piston connecting rod assembly is pointed to the engine front, and piston
connecting rod assembly is pushed into cylinder with special tools. When connecting rod bush is
fixed with connecting rod journal, assemble the connecting rod big end of fixed connecting rod
lower bush (inner surface is applied with proper lubricating oil) into connecting rod.
Note: Forward label of connecting rod cover and mark of connecting rod body should be in the
same side.
⑸ The thread portion of connecting rod bolt is applied uniformly with proper lubricating oil.
⑹ Tighten connecting rod bolt
Tightening torque: 22±2.5N.m, then tighten to plastic region: 90°±10°
⑺Rotate crankshaft to make the second and third connecting rod journals be on top dead center
(TDC) position, and complete the assembling of other two piston connecting rod assemblies by
repeating the above steps.
⑻ Check rotation torque of crankshaft should be less than 5～15N.m.
Note: ① connecting rods with the same mass grouping label should be used for the same engine.
② The thread portion of connecting rod bolt should not be damaged during dismantling of
connecting rod assembly.
③ the connecting rod cover locating pin should be aligned with connecting rod body locating pin,
and tapped into the mounting position during assembling of connecting rod assembly.
9) Refer to chapter “lubrication system” for assembling oil collector assembly
10) Assembling oil pan assembly
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⑴ Wash oil pan assembly clearly.
⑵ Apply Φ3mm sealant on base planes of cylinder, timing chain cover cap, rear oil seal seat and
the surrounding portion of thread hole (as shown in the drawing), fasten oil pan, and tighten the
nuts and bolts with a tightening torque of 8±2N·m.
Tightening sequence: Tighten two nuts in the front first, then the middle, and tighten 14 bolts to
the two ends in sequence from left and right sides in turns.
Note: Assemble within 3 minutes after applying glues, and tighten within 15 minutes.
⑶ Assembling drain plug assembly

Note: The thread portion of drain plug assembly can be applied with sealant.
11) Assembling clutch housing baffle
Clutch housing baffle is flat and without warping. The tightening torque of hexagon head bolt is
5～10N.m.
12) Assembling flywheel supplementary gear ring assembly

⑴ Clutch pressure plate locating pins (three) are pressed into flywheel locating pin holes with
special tools, extending a length of 7～8mm.
⑵ Crankshaft is fixed with special tools to prevent flywheel from clockwise rotation. The locating
pin holes of flywheel gear ring assembly is aligned with crankshaft rear end locating pin, inserted
on crankshaft rear end spigot, and fastened with flywheel bolts, the tightening sequence is as
shown in the drawing.
Tightening torque: 73.3～82.7N.m
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Note: Red mark points on flywheel are important positions of the flywheel, and flywheel without
red mark does not need to mount.
13) Assembling clutch driven plate assembly and clutch cover assembly
⑴ Insert clutch housing and pressure plate dismantling tools into crankshaft rear end holes, apply
splines of clutch driven plate assembly with lithium lubricating grease, and mount clutch driven
plate assembly in the direction shown in the drawing.
Note: lithium lubricating grease or other grease or water cannot be applied on friction plate of
clutch driven plate assembly during mounting.
Clutch driven plate assembly

⑵ Mount clutch housing assembly on flywheel, and tighten the bolt for fixing clutch housing
assembly and flywheel in the diagonal line direction for three times. Tightening torque:
19.1±1.2Nm
Note: Red mark points on flywheel are important positions of the flywheel, the important positions
of clutch housing assembly and flywheel should be interlaced when assembling clutch housing
assembly.
14) Refer to chapter “lubrication system” for assembling oil pump assembly
15) Assembling crankshaft sprocket
Crankshaft is fixed with special tools, and sprocket key way is mounted outward to coincide
sprocket key way with crankshaft key way.
16) Assembling chain lubricating nozzle
Chain lubricating nozzle is applied with anaerobic sealant on the thread portion, and mounted on
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cylinder front end, and tightened to make nozzle hole face downward so that the ejected
lubricating oil can flow directly on timing chain.
Note: The thread portion of chain lubricating nozzle is applied with anaerobic sealant, not
blocking the oil holes.
17) Refer to chapter “V-belt and timing chain” for assembling timing chain
18) Refer to chapter “V-belt and timing chain” for assembling chain mounting bracket
19) Assembling water pump assembly
⑴ Two stud bolts are applied with glues on the thread portions first, and twisted into the
corresponding positions of cylinder body front end surface.
⑵ Water pump body and water pump gasket are mounted on the corresponding positions of
cylinder body front end surface with hexagon head flange bolts (three) and hexagon flange nuts
(two), and tightening torque is 9±1.8N.m.
Note: water pump gaskets should be sound and resilient; otherwise, new water pump gasket
should be replaced.
20) Mounting combined support of idler assembly and air-cooled compressor assembly
Mount combined support of idler assembly and air-cooled compressor assembly on cylinder body,
and tighten hexagon head flange bolt. The tightening torque is 50±10N.m.

The tightening torque of bolt is 44±9N.m.
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22) Assembling air-cooled compressor assembly
Air-cooled compressor assembly is fixed on the combined support with bolts. The tightening
torque of bolts (four) is 24±5N.m.
23) Assembling oil dipstick assembly

⑴ The oil dipstick assembly is applied with sealant at one end, inserted into oil dipstick hole of
cylinder body, and fixed at intake side of cylinder head with hexagon head flange bolt. The
tightening torque is 22±4N.m.
⑵ Oil dipstick assembly is inserted into oil dipstick pipe.
24) Assembling knock sensor assembly

Knock sensor assembly is fixed at the intake side of cylinder body with hexagon head flange bolts,
forming an angel of 45° with the horizontal direction. The tightening torque is 20±5N.m.
Note: ① There is no damage on the knock sensor assembly surface, and the joint surface is flat.
②Do not use an impact torque spanner to tighten knock sensor assembly.
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Knock sensor assembly
hexagon head flange bolt
25) Assembling oil pressure alarm switch assembly

The second or third thread portion of oil pressure alarm switch assembly is applied with sealant
(sealant should not be squeezed into the main oil gallery), screwed into main oil gallery bypass
hole of cylinder, and tightened with special tools. The tightening torque is 15±5N.m.
Note: Do not use an impact torque spanner to tighten knock sensor assembly oil pressure alarm
switch assembly.
26) Assembling oil filter connector and oil filter assembly

⑴ The oil filter connector is cleaned, and applied with sealant on the thread portion, screw into
cylinder body till contact with cylinder body surface, and tighten with special tools. The tightening
torque is 34-54N.m.
⑵ The sealing gasket of oil filter assembly is applied uniformly with a layer of lubricating oil;
screw oil filter into oil filter connector with a special torque spanner and screw into 3/4 loops till
the sealing gasket contacts with cylinder sealing surface.
27) Refer to chapter “V-belt and timing chain” for assembling engine assembly
28) Assembling V-belt
Mount V-belt as the drawing, adjust the adjusting bolt on engine support to tighten the belt.
Rotate crankshaft for more than two loops, and the specified value of belt tensioning force is
650±50N. Measuring position is the position shown by the arrow in the drawing.
Tighten hexagon head flange bolt on the adjusting nut with a tightening torque of 23±4N.m, and
tighten hexagon head flange bolt on the position limiting support assembly with a tightening
torque of 50±10N.m.
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Note: ① If the original V-belt is used again, the rotating direction of V-belt during assembling is
the same with that marked on the back of the V-belt during dismantling.
② Do not bend the V-belt sharply with a very small radius, if so, the core wire will be broken.
③ Keep the V-belt away from oil, grease or water.
④ Do not skid the V-belt with screwdriver or the like during assembling.
⑤ Checking or replacing V-belt within 20000 km is recommended, and it is necessary to replace
when reaching 50000 km.
3.7 Ignition System
Ignition system includes: rod-like ignition coil assembly and spark plug
Dismantling
1) Refer to the chapter of “timing chain and water pump” for dismantling rod-like ignition coil
assembly and spark plug
2) Dismantling spark plug
Dismantle spark plug with special tools. Taking out the spark plug must be very careful in case of
clash.
Checking
1) Checking spark plug
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⑴ Check there is no porcelain falling or damage on the body of the spark plug assembly.
⑵ Check there is no carbon deposit or damage on the electrode, thread and body of the spark plug
assembly, if any, remove with special detergents.
⑶ Check spark plug clearance
Bend the outer electrode carefully to obtain correct spark plug clearance, which falls within the
range of 1.0 to 1.1mm.
Refer to “CA4GA1 engine service handbook (electric control parts)” for checking rod-like
ignition coil assembly.
Mounting
1) Mount spark plug assembly.
Mount 4 spark plug assemblies with special tools on corresponding bolt holes of the cylinder head.
Tightening torque: 18±3.5N
Note: The spark plug should be placed gently and carefully in the spark plug hole of cylinder head
with special tools. Do not drop the spark plug from spark plug guide hole, if so, the spark plug will
be damaged.
2) Mounting rod-like ignition coil assembly

(1) Insert pen-like ignition coil into spark plug hole of the cylinder head, to the bottom as
required.
(2) Tighten hexagon head flange bolt. Tightening torque: 8±2N.m
Note: Press rod-like ignition coil assembly gently (tapping with a rubber hammer is allowed), to
joint rod-like ignition coil assembly and spark plug tightly till make a sound of “click”.
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3.8 Lubrication System
Note: Check running condition after assembling oil pump assembly to determine the sealing
property of the oil pump. Checking should be done very carefully to make sure various clearances
are in normal range.
Checking
Checking oil pump assembly
⑴ Appearance checking of oil pump assembly
Damages, such as deformation, cracking, warping on oil pump assembly sprocket, internal and
external rotors and housing are not allowed, if any, replace with a new one.
⑵ Top clearance of oil pump external rotor
Check clearance between top of the external rotor and front face of cylinder body with a feeler:
0.7～0.8mm. Clearance limit: 1.3mm.
⑶ Side clearance between internal rotor and external rotor
Check side clearance between internal rotor and external rotor with a feeler: 0.05～0.10mm.
Clearance limit: 0.18 mm.
Internal rotor,
External rotor,
Side clearance between internal

rotor and external rotor
⑷ Clearance between driven rotor and cylinder head

Check clearance between driven rotor and cylinder head with a feeler: 0.19～0.27mm. Clearance
limit: 0.4 mm.
Checking pressure limiting valve assembly
Press plunger of the pressure limiting valve by hand, and make sure the plunger can be
compressed.
Check length of pressure limiting valve assembly: 36mm.
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Mounting
1) Mounting pressure limiting valve
Apply sealant on the thread of the pressure limiting valve, then screw in thread hole. Note: Make
sure there is no foreign matter in the mounting hole.
2) Mounting oil collector assembly

Place a new oil collector gasket on the flange face of the oil collector assembly, and tighten the
combined bolt.
Tightening torque of the bolt: 6～11N.m
3) Mounting oil pump assembly

⑴ Fill lubricating oil aiming at the clearance between internal and external rotors.
⑵ Fill lubricating oil at the lower side of rotor mounting hole of the cylinder body.
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⑶ Make label on external rotor face outside of cylinder head, and mount external rotor in the rotor
mounting hole of the cylinder head.
⑷ Fasten it on the front face of the cylinder head with bolt and washer, and the tightening torque
needed is 9±1.8N·m.
Note: ① Rotate oil pump sprocket for one more circle to make full circle of the rotor is applied
with lubricating oil.
② Rotating oil pump sprocket should be smooth, without clamping stagnation.
3.9 Cooling System

Radiator
Check the cooling system of the vehicle in the following steps, and fasten loose bolts or replace
defective parts.
⑴ Dismantle radiator cover and fill cooled water in the cooling system. Mount radiator cover
tester.
⑵ Apply a pressure of 117.6KPa (1.2kgf/cm2) on the cooling system with the radiator cover tester,
and then check the following items in sequence:
① Radiator leakage
② Water pump leakage
③ Hose connector leakage
④ Hose overexpansion
Note: Do not deform water inlet of the radiator cover when dismantling the radiator cover tester or
during the test.
Pictorial drawing: No. 3 on page 123 of the“3GA2 service handbook”
⑶ Checking water inlet of the radiator
① Deformation or depression of the sealing face
②Deformation of the edges
Note: If water inlet is deformed, radiator cover cannot be covered tightly, causing reduction of the
cooled water.
Radiator cover
Checking
⑴ Check the following parts and replace defective parts.
① Bent or deformed sealing gasket
② Deformed or depressed valve and valve seat
Incrustation deposits between valve and valve seat
- 141 -
Note: Incrustation deposited between valve and valve seat must be cleared.
⑵ Checking sealing pressure and working conditions of vacuum relief valve
Limit value for opening pressure of relief valve: 58.8KPa (0.6kgf/cm2).
Standard value for opening pressure of relief valve: 73.5～102.9KPa(0.75～1.05kgf/cm2).
Thermosistor assembly
Checking
⑴ Immerse the thermosistor assembly into water, heat the water gradually and check the opening
temperature of the valve.
⑵ If the valve can not be tightly open or closed at normal temperature, replace the thermosistor
assembly.
First opening temperature of the thermosistor assembly valve: 80±2℃
Full opening temperature of the thermosistor assembly valve: 95℃
Full lift of the valve (mm): ≥8
Water pump assembly
Dismantling
1) Press pulley disk of the water pump assembly out.
Press pulley disk of the water pump assembly out with water pump dismantling tool.
2) Press water pump bearing out.
Press water pump bearing out with water pump dismantling tool.
3) Dismantle water pump impeller and seal assembly.
Press water pump impeller and seal assembly out with water pump dismantling tool.
Checking
Check whether there is any damage or abrasion on water pump impeller and seal assembly, if any,
replace with new ones.
Check whether there is any damage, abnormal noise or improper rotation on water pump bearing,
if any, replace with new ones.
Assembling
1) Press bearing on the water pump impeller with special tools.
2) Press water pump impeller and seal assembly on specified position with special tools.
Pictorial drawing: the amended No. 2 on page 127 of the“3GA2 service handbook”
3) Press water pump impeller on specified position with special tools.
4) Press water pump bearing on water pump pulley seat.
5) After assembling, make sure the water pump impeller can rotate freely.
- 142 -
CA4GA1 Engine Service Handbook
Chief Editor: Feng Yong

Editor: Xiao Yang, Yue Xinli, Yan Meilan
Approver: Gao Jin
- 143 -

V2+MANUAL[1]

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CA4GA1 Engine

Chief Editor: Feng Yong

Section one: Engine Technical Parameters

Section two: Service Standby

Section three: General Service Parameters

Section four: Engine Maintenance

Section two: Service Standby

12 Stud bolt–mounting idler TB1322 Glue on cylinder head ends

16 Stud bolt-mounting engine water TB1110B Glue on thread

Section three: General Service Parameters

Valve Taper angle 45°30′

Valve spring Free height Standard value 45.2

Tappet Tappet diameter φ28(－0.025,－0.038)

Piston Piston diameter Standard Grade 1 φ72.97～φ72.98

Piston ring Piston ring thickness

2．Service data for cooling system

Cooling fan Type Suction

3. Service data for lubricating oil

Oil filter Filter area (cm2) 860

Section four: Engine Maintenance

Section one: Cylinder Body, Cylinder Head and Crank-link Mechanism

Section two: Valve Timing Mechanism

Section three: Lubrication System

Section four: Cooling System

Section five: Intake and Exhaust Systems

Section six: Fuel System

Section seven: Ignition System

Section eight: Other Sensors and Actuating Mechanisms

Cylinder Head and Combustion Chamber

plated with hard chromium

soft-nitriding piston and piston ring

plated with hard chromium

piston and piston ring

Connecting rod and connecting rod bush

Upper connecting rod bush

connecting rod bush

Crankshaft main journal diameter (mm) 46

External diameter(mm) 242

Crankshaft oil seal

Crankshaft rear oil seal

Crankshaft front oil seal

Front oil seal（mm） φ33.8 φ49 6

Cylinder head cover cap assembly

Cylinder head cover cap assembly

Chain tensioner assembly

Chain tensioner arm assembly

Chain tensioner assembly and chain tensioner arm assembly

Intake and exhaust camshaft assemblies

VCT controller assembly

Cylinder head oil

Intake camshaft Exhaust camshaft OCV control

Main oil gallery

OCV control valve Oil coarse filter

lubrication system flowchart

oil pump assembly

Lubricating of valve driving mechanism

Lubricating of valve driving mechanism

Section four: Cooling System

Cylinder water channel

Cylinder head longitudinal water jacket

Thermosistor OFF Engine water inlet seat assembly Heater

Cooling system flowchart

First opening temperature of the thermosistor assembly valve ℃ 80±2

Section five: Intake and Exhaust Systems