Haima S5 User manual

Table of Contents

General Catalogue

Vo l u m e I

Chapter I Engine Body ····················································································· 1A-1

Chapter 2 Electronic Fuel Injection Control System ··················································· 1B-1

Chapter 3 Fuel System ······················································································ 1C-1

Chapter 4 Intake and Exhaust System ···································································· 1D-1

Chapter 5 Cooling System·················································································· 1E-1

Chapter 6 Engine Accessory-Belt ········································································· 1F-1

Chapter 7 Engine Suspension ·············································································· 1G-1

Chapter 8 MF515M Transmission ········································································ 1H-1

Chapter 9 Gearshift Mechanism ··········································································· 1J-1

Volume II

Chapter 10 Clutch System ··················································································· 2A-1

Chapter 11 List of tires and drive shafts ··································································· 2B-1

Chapter 12 Wheels and tires ················································································· 2C-1

Chapter 13 Suspension system ·············································································· 2D-1

Chapter 14 Steering system·················································································· 2E-1

Chapter 15 Brake system····················································································· 2F-1

Volume III

Chapter 16 A/C System ······················································································ 3A-1

Chapter 17 Airbags and Restraint System ································································· 3B-1

Chapter 18 Body and Accessories ·········································································· 3C-1

Chapter 19 Electrical System················································································ 3D-1

Table of Contents

Chapter 1 Engine Body

Table of Contents

1.1 How to use this manual ················································································ 1A-0

1.1.1

Technical Parameters ················································································· 1A-1

1.1.2

Special tools··························································································· 1A-9

1.2

Inspection and Maintenance of Complete Vehicle ················································· 1A-10

1.2.1

Inspection of Compression Pressure ..............................................................................1A-10

1.2.2

Inspection of the Engine Oil...........................................................................................1A-10

1.2.3

Inspection of Oil Pressure ..............................................................................................1A-11

1.2.4

Replacement of Engine Oil ............................................................................................ 1A-11

1.2.5

Replacement of Oil Filter ...............................................................................................1A-12

1.3

Application of Engine Maintenance Platform ······················································ 1A-12

1.3.1

Mount the Engine onto Maintenance Platform...............................................................1A-12

1.3.2

Dismantle the Engine from Maintenance Platform ........................................................1A-13

1.4

Power Generator and Starter ·········································································· 1A-13

1.4.1

Power Generator’s Dismantling/Mounting ....................................................................1A-13

1.4.2

Explanations on Inspection of Power Generator Belt.....................................................1A-13

1.4.3

Explanations on adjustment to tension of power generator and air conditioning drive belts

.................................................................................................................................................1A-13

1.4.4

Explanations on inspection of power generator .............................................................1A-13

1.4.5

Starter Dismantling/Mounting........................................................................................1A-14

1.4.6

Explanations on inspection of starter .............................................................................1A-14

1.5

Ignition, Control System··············································································· 1A-14

1.5.1

Spark Plug Dismantling/Mounting.................................................................................1A-15

1.5.2

Control System Parts Dismantling/Mounting.................................................................1A-15

1.5.3

Crankshaft position sensor’s dismantling/mounting explanations .................................1A-15

1.5.4

Explanations to inspection of crankshaft position sensor...............................................1A-15

1.5.5

Explanations on water temperature sensor dismantling/mounting.................................1A-16

1.6

Intake and Exhaust System············································································ 1A-17

1.6.1

Intake and Exhaust System Dismantling/Mounting .......................................................1A-17

1.6.2

Explanations on intake manifold dismantling .................................................................1A-18

1.6.3

Explanations on the intake manifold seal ring mounting ...............................................1A-18

1.6.4

Explanations on the throttle body seal ring mounting....................................................1A-18

1.6.5

Explanations on the exhaust manifold dismantling........................................................1A-18

1.7

Timing System ·························································································· 1A-18

1.7.1

Timing system dismantling/mounting ............................................................................1A-18

1.7.2

Explanations on timing chain tensioner assembly dismantling....................................1A-199

1.7.3

Explanations on crankshaft pulley dismantling..............................................................1A-19

1.7.4

Explanations on cylinder head hood dismantling...........................................................1A-19

Table of Contents

1.7.5 Explanations on the timing chain dismantling ...............................................................1A-19

1.7.6

Explanations on the timing chain’s tensioner assembly mounting.................................1A-19

1.7.7

Explanations on the tensioner arm assembly mounting .................................................1A-19

1.7.8

Explanations on timing chain mounting.........................................................................1A-19

1.7.9

Explanations on the cylinder head hood mounting ........................................................1A-20

1.7.10

Explanations on the crankshaft pulley mounting .........................................................1A-20

1.7.11

Explanations on water pump pulley mounting .............................................................1A-21

1.8

Lubricating System····················································································· 1A-21

1.8.1

Oil Sump Dismantling/Mounting...................................................................................1A-21

1.8.2

Explanations on the oil sump dismantling......................................................................1A-21

1.8.3

Explanations on the oil sump mounting .........................................................................1A-21

1.8.4

Oil Pump and Timing Chain Case Assembly Dismantling/Mounting............................1A-22

1.8.5

Explanations on oil pump’s oil seal dismantling............................................................1A-22

1.8.6

Explanations on oil pump’s oil seal mounting................................................................1A-22

1.8.7

Explanations on the oil filter mounting ..........................................................................1A-23

1.8.8

Explanations on oil pump disassembling/ mounting......................................................1A-23

1.8.9

Inspection of Oil Pump...................................................................................................1A-23

1.9

Cooling System ························································································· 1A-24

1.9.1

Thermostat Dismantling/Mounting ................................................................................1A-24

1.9.2

Explanations on thermostat inspection and mounting....................................................1A-24

1.9.3

Cooling water pipeline dismantling/mounting ...............................................................1A-24

1.9.4

Explanations on heater water pipe /O-ring mounting.....................................................1A-25

1.9.5

Water Pump Dismantling/Mounting...............................................................................1A-25

1.10

Cylinder Cover and Valve Mechanism ····························································· 1A-26

1.10.1

Cylinder Head Mechanism Dismantling/ Mounting.....................................................1A-27

1.10.2

Valve Mechanism Dismantling/ Mounting...................................................................1A-29

1.10.3

Cylinder Head Inspection /Repair ................................................................................1A-30

1.10.4

Inspection of Valve and Valve Guide ...........................................................................1A-31

1.10.5

Explanations on inspection of valve seat......................................................................1A-31

1.10.6

Explanations on inspection of valve spring..................................................................1A-32

1.10.7

Explanations on the inspection of camshaft .................................................................1A-33

1.10.8

Explanations on inspection of tappet hole and tappet ..................................................1A-34

1.11

Flywheel, clutch ······················································································· 1A-35

1.11.1

Flywheel and Clutch Dismantling/Mounting ...............................................................1A-35

1.11.2

Explanations on Clutch Pressure Plate/Friction Disc Dismantling...............................1A-36

1,11.3

Explanations on the clutch friction disc inspection /mounting.....................................1A-37

1.11.4

Explanations on the clutch pressure plate inspection/mounting...................................1A-37

1.12

Cylinder body, Crank Connecting Rod Mechanism·············································· 1A-38

1.12.1

Cylinder Body, Crank Connecting Rod Mechanism Dismantling/Mounting...............1A-38

1.12.2

Cylinder Body Inspection /Repair................................................................................1A-42

1.12.3

Connecting Rod Inspection ..........................................................................................1A-44

1.12.4

Inspection of Piston Connecting Rod Assembly ..........................................................1A-44

1.12.5

Crankshaft Inspection /Repair ......................................................................................1A-45

Engine block 1A-0

How to use this manual

Subject Scope

 This manual comprises procedures on engine

maintenance, and specific procedures fall into

5 basic operation steps:

I: dismantling/mounting; II disassembling

/mounting; III: resetting; IV inspection; V

adjustment.

 Simple operation may be completed by

inspecting the engine appearance, such as

dismantling/mounting of periphery parts,

parts cleaning, and appearance inspection etc.

Overhaul Steps:

1. Prior to most overhaul work, illustrative

pictures shall be observed because they will

help distinguish parts & components,

illustrate the parts fastening way, and the way

of inspecting parts appearance. In addition,

illustration explanations are attached to

dismantling/mounting procedures in need of

systematic demonstration.

2. On illustrations there are symbols of wearing

parts, tightening torque, lubricating oil, and

sealant, and also corresponding explanations

and marks are made to special tools or

equipments for dismantling or mounting.

3. Corresponding numbers are marked on

pictures for the operation sequence and parts’

major operation process. In general,

information of this kind serves as key and

core content of the diagnosis procedure. Due

to this, please refer to these materials during

the overhauling process.

Symbol

Four kinds of symbols are used in this manual to

indicate application of lubricating oil, sealant, and

special tools etc., and they imply occasions where

foresaid materials shall be applied during the

maintenance period.

Symbol Connotation Remark

Inject

lubricating oil

Inject new engine oil

Inject sealant

Inject appropriate

sealant

Replace parts

wearing parts like

O-ring and gasket

Use special Appropriate special

tools tools or equipments

Prompt signals

In this manual there are such signals as

“Warning”, “Caution”, “Attention”,

“Explanation”, and “Limit”.

Warning

 Warning is used to prompt that personal

injury may be caused due to negligence.

Caution

 Caution is used to prompt that engine damage

may be caused due to negligence.

Notice

 Notice is used to provide additional

information for completion of given

procedures.

Explanation

 Explanation is used to prompt the permissible

range for inspection or adjustment.

Limit

Limit is used to prompt the upper and lower limit

for the inspection or adjustment.

Engine block 1A-1

1.1.1 Technical Parameters

Technical Parameters of Complete Equipment

Item Parameter Remark

Model GN15-VF GN16-VF GN16-VF1

Cylinder quantity and

arrangement

In-line 4-cylinder

Combustion chamber Roof shape

Ignition sequence 1-3-4-2 By cylinder number

Rotation direction Counterclockwise

From back to front (flywheel

side taken as the back end)

Valve timing mechanism

dual overhead camshaft, timing chain

drive (silent chain), intake VVT

Valve quantity 16

Displacement (cc) 1497 1591

Bore× stroke (mm) 74.8×85.2 74.8x90.5

Compression ratio 10 10

ON -14～26(BTDC)

Intake

OFF 66～26(ABDC)

ON 39(BBDC)

Valve

timing

(°)

Exhaust

OFF 5(ATDC)

Max. power(kW/rpm) 77/6000 81.5/6000 85/6000 Net power

Max. torque(N·m/rpm) 140/4000 149/4000 153/4000 Net torgue

Air conditioning idle speed:800±50

Idle speed (rpm)

Target idle speed:750±50

Ignition advance angle(°) 3～10 Idle state

Starting mode Electrical starting

Cooling mode Water cooling forced circulation

Lubricating mode Pressure, Split, Complex

Overall dimension (mm) 573.2×615.0×606.3 573.32x724.2x6063

Net weight (kg) 94.8 96.5

Engine block 1A-2

Technical Parameters of Maintenance

Item Parameter

Cylinder head

Standard 112.9～113.1

Height (mm)

Max. grinding 0.2

Deformation at cylinder gasket’s abutment

surface (mm)

Max. 0.03

Max. 0.15

Deformation at manifold’s abutment

surface (mm)

Max. grinding 0.20

Intake 0.18～0.26

valve clearance(engine in cold

condition)(mm)

Exhaust 0.26～0.34

Valve and valve guide

Standard 1.35

Intake

Min. 0.85

Standard 1.85

Width of valve seal tape

(mm)

Exhaust

Min. 1.35

Standard 89.31～89.91

Intake

Min. 89.11

Standard 90.63～91.23

Valve length (mm)

Exhaust

Min. 90.43

Standard 4.965～4.980

Intake

Min. 4.915

Standard 4.955～4.970

Valve stem

diameter(mm)

Exhaust

Min. 4.905

valve guide’s inside diameter (mm) Standard 5.0～5.012

Intake 12.7～13.3

valve guide’s protrusion height (mm)

Exhaust 12.7～13.3

Valve seat

Width of valve seat’s contact surface (mm) 1.1～1.5

Intake 43.5～44

Angle of valve seat (°)

Exhaust 43.5～44

Intake 30.4

Valve seat sinking (valve protrusion

height)(mm)

Exhaust 34.6

Valve spring

Intake H1: 33.4mm 142.2～161.8{14.51～16.51kgf}

valve spring height H

pressure (N{kgf})

Exhaust H2: 24.9mm 293.4～324.4{29.94～33.10kgf}

Verticality(mm) 1.50mm

Valve oil seal

Depth L(mm)

Intake 15.7～16.3

Engine block 1A-3

Exhaust 15.7～16.3

Tappet

Tappet hole’s diameter(mm) Standard 31.000～31.025

Tappet diameter(mm) Standard

30.964～30.980

Standard

0.020～0.061

Clearance between tappet and tappet hole (mm)

Max. 0.180

Camshaft

Camshaft’s radial run-out(mm) Max. 0.03

Standard 44.71

Intake

Min. 44.51

Standard 44.28

Cam’s protrusion height

(mm)

Exhaust

Min. 43.58

Standard

25.945～25.960

Journal diameter(mm)

Min. 25.915

Journal clearance(mm) Standard

0.040～0.076

Standard

0.08～0.20

End gap(mm)

Max. 0.21

Cylinder body

Standard 205

Height (division surface between upper surface

and main cover)(mm)

Max. grinding 0.20

Deformation of upper surface (mm) Standard 0.1

Cylinder bore’s inside diameter

[measure inside diameter at the place 37mm

below the top surface] (mm)

Standard

74.8～74.815

Wearing limit (mm) 0.135

Piston diameter(mm)

[Measure the piston diameter at the

place19.38mm below the lower rim of oil

control ring slot along the vertical direction of

the piston pin hole’s axial line.]

Standard

74.78～74.79

Standard

0.010～0.035

Clearance between piston and cylinder bore

(mm)

Max. 0.10

Piston ring

Top ring Standard

0.030～0.070

Second Ring Standard

0.020～0.060

Oil Ring Standard

0.040～0.120

Top ring / Second

Ring

Max. 0.15

Clearance between piston

ring and ring slot (mm)

Oil Ring Max. 0.15

Opening clearance [measure inside Top ring

0.15～0.30

Engine block 1A-4

Second Ring

0.20～0.40

Oil Ring

0.10～0.40

cylinder](mm)

Max. 1.0

Piston pin

Piston pin’s diameter(mm) Standard

18.001～18.005

Piston pin hole’s inside diameter (mm) Standard

18.010～18.014

Clearance between connecting rod’s small end

hole and piston pin (mm)

Standard

-0.031～-0.016

Clearance between piston pin hole and piston

pin (mm)

Standard

0.005～0.013

Connecting rod

Length [center to center](mm)

（GN16-VF）

Standard

135.3～135.4(132.9～133.0)

Inside diameter of connecting rod’s small end

(mm)

Standard

17.974～17.985

Standard

0.100～0.350

Connecting rod’s end gap(mm)

Max. 0.40

Connecting rod bearing

Connecting rod bush size (mm) Standard

1.485～1.496

Standard

0.014～0.058mm

Connecting rod bearing clearance (mm)

Max. 0.10

Crankshaft

Crankshaft radial run-out(mm) 0.03

Main journal diameter(mm) Standard

46.004～46.029

Standard

0.014～0.034

Main journal clearance (mm)

Max. 0.1

Main bearing bush size (mm) Standard

1.971～1.996

Crank pin diameter(mm) Standard

39.980～40.000

Thrust bearing size (mm) Standard

3.205～3.255

Standard

0.09～0.273mm

Crankshaft end gap(mm)

Max. 0.30

Inspection to complete vehicle

Standard value 1170{12.0}[300]

Minimum limit 980{10.0}[300]

Compression pressure

kPa{kgf/cm2}[rpm]

Max. limit of

pressure difference

between cylinders

100{1.0}

Oil pressure (kPa{kfg/cm2}[rpm])

400～588{4.1～6.0}[2500]

Oil adding volume L Oil replacement 3.6

Engine block 1A-5

Oil and oil filter

replacement

3.8

Oil grade API engine oil grade higher than SL

Higher than –25 ℃ SAE 10W–30

Oil viscosity level

-30 ℃～37 ℃

SAE 5W–30

Starter

Voltage (V) 11

Zero-load test

Current (A)

＜95

Timing chain disassembling part

Automatic tensioner push rod’s extension strength (mm) 3

Crankshaft rotating speed sensor

Clearance between signal wheel and sensor (mm)

0.5～1.5

Thermostat

Opening temperature ( )℃

80～84

Full-opening temperature ( )℃ 95

Full-opening stroke (mm) Min. 8.5

Clutch pressure plate

Diaphragn spring’s wearing depth (mm) Max. 0.6

Diaphragn spring’s radial circle run-out (mm) Max. 0.6

Pressure plate’s flatness (mm) 0.05

Clutch friction disc

Thickness of protrusion rivet (mm) Min. 0.3

End-on circle run-out(mm) Max. 0.7

Flywheel

End-on circle run-out(mm) Max. 0.13

Oil pump

Standard 0.06～0.20

Clearance between inner rotor’s prong

and outer rotor (mm)

Max. 0.22

Standard 0.250～0.325

Clearance between outer rotor and pump

body (mm)

Max. 0.35

Standard 0.030～0.090

Backlash (mm)

Max. 0.14

Compression spring’s length (mm)[pressure:97.7 ～

107.4N{9.96～10.96kgf}]

33.50

Front-end oil seal’s driving distance (mm)[from oil pump

body’s rim]

0～0.5

Engine block 1A-6

Rear oil seal

Rear oil seal’s driving distance (mm)[from crankshaft bac

k

cover’s rim]

0～0.5

Plastic fixing bolt’s length

Cylinder head bolt(mm) Standard 136.8～144.2

Standard 74.15～74.85

Main bearing cover bolt(mm)

Max. 75.3

Engine block 1A-7

Tightening torque

Torque value

Mounting place

N•m kgf•m

Remark

Power generator

Bracket 45.1 4.6

Adjusting arm 45.1 4.6

Adjusting slider 21.6 2.2

Power generator pivot’s bolt and nut 45.1 4.6

Ignition, control system

Ignition coil 8.8 0.9

Spark plug 25 2.6

Fuel rail 21.6 2.2

Camshaft position sensor 8.8 0.9

Water temperature sensor 15 1.53

Knock sensor 21.6 2.2

Knock sensor bracket 16.8 1.7

Crankshaft position sensor 8.8 0.9

OCV valve 8.8 0.9

Intake and exhaust system

Throttle body 8.8 0.9

Intake manifold 21.6 2.2

Intake manifold bracket (manifold side) 21.6 2.2

Exhaust manifold 21.6 2.2

Exhaust manifold bracket (cylinder

body side)

21.6 2.2

Exhaust manifold bracket (manifold

side)

45.1 4.6

Exhaust manifold heat shield 8.8 0.9

Lubricating system

Oil switch 14.7 1.5

Oil filter 14.0 1.43

Oil filter adapter 21.6 2.2

Oil filter 8.8 0.9

Oil sump 8.8 0.9

Cylinder body, crank connecting rod mechanism

50±2 16.7

Crankshaft pulley

60±2°

First set the pretension torque and

then tighten the angle.

Flywheel 100 10.3

Engine block 1A-8

Transmission baffle plate 8.8 0.9 6.9～9.8

Clutch pressure plate 18.6 1.9 18.6～25.5

Crankshaft’s rear cover 8.8 0.9

35±2.5 3.5

Main bearing cover

Tightening 60°(0～ -4°)

First set the pretension torque and

then tighten the angle. Pay attention

to the bolt’s length, which has limit

value (see corresponding part)

15±2N·m

1.32～

1.74kgf·m

Connecting rod cover

90°～94°

First set the pretension torque for two

times, and then tighten the angle.

Pay attention to the bolt’s length,

which has limit value (see

corresponding part)

Cylinder head, valve train and others

24.5 2.5

Cylinder head

Tighten 90°+ 90°(0～4°)

First set the pretension torque, and

tighten the angle two times. Pay

attention to the bolt’s length, which

has limit value (see corresponding

part)

Camshaft’s front cover 20 2.04

Camshaft cover 11 1.12

Cylinder head hood 8.35 0.85

10 1.02 See corresponding part

Oil pump and timing chain case

assembly

39.5 4.03 See corresponding part

Timing chain guide rail 10 1.02

Tensioner arm 23.5 2.4

Timing chain tensioner 9.8 1.0

VVT fixing bolt 60 6.12

Front and rear hook 18.4 1.88

Cooling system

9.8 1.0 See corresponding part

Water pump

45.1 4.6 See corresponding part

Water pump pulley 9.35 0.95

Water inlet pipe seat 9.35 0.95

Heater water pipe assembly 9.35 0.95

Engine block 1A-9

1.1.2 Special tools

Oil pressure gauge

Oil seal erector

Valve spring ejector

Piston pin assembling tool set

Belt tensiometer

Gear ring stop device

Valve oil seal ejector

Oil filter sleeve Valve guide ejector / erector

Valve oil seal erector

Flywheel brake

Clutch guider

Oil sump ejector

Engine block 1A-10

1.2 Inspection and Maintenance of

Complete Vehicle

1.2.1 Inspection of Compression Pressure

Warning

 When the engine is running, the oil

temperature is extremely high. Therefore,

keep cautious during dismantling and

mounting process since there is a danger of

burn.

1. Set the vehicle into the normal pre-inspection

state: warm up the engine to a normal running

temperature; then stop the running and cool it

for 10 minutes.

2. Dismantle the fuel pump relay (see

corresponding complete vehicle maintenance

manual).

3. Disconnect ignition coil’s wiring harness joint

(see corresponding complete vehicle

maintenance manual).

4. Dismantle Cylinder 1’s ignition coil and spark

plug(see Ignition, Control System part).

5. Mount the gauge into Cylinder 1’s spark plug

hole.

6. Floor the accelerator pedal and start the

engine.

7. Record the gauge’s maximum reading.

8. Measure all cylinders’ compression pressures

according to preceding method, and inspect if

the pressure difference between cylinders is

lower than the limit value.

Limit value (maximum): 980 (kPa)

Item

Standard

value

Minimum

limit

Maximum

pressure

difference

between

cylinders

compression

pressure

kPa{kgf/cm

2}[rpm]

1170

{12.0}

[300]

980

{10.0}

[300]

100

{1.0

kgf/cm2}

Note: If one cylinder or several cylinders

encounter excessively low pressure, or pressure

difference between cylinders goes beyond the limit

value specified, some drops of engine oil shall be

added for repeated operation. Repeat the

inspection following Step5-7.

■ If the compression pressure increases, the

fault cause should be attributed to piston, piston

ring, or cylinder inner surface’s wearing or

damage, and in turn an overhaul is needed.

■ If the adjacent cylinder encounters low

pressure, the cylinder gasket may be damaged, or

the cylinder head likely suffers deformation, and in

turn an overhaul is needed.

■ If the compression pressure is still low, the

valve seat is burnt or in poor quality, and the

valve’s sealing face has poor contact. Thus, an

overhaul is needed.

9. Take off the gauge

10. Connect the ignition coil wiring

11. Mount the fuel pump relay

12. Mount the spark plug tightening torque:20～

30N·m{2.1～3.1kgf·m }

13. Connect the ignition coil wiring.

1.2.2 Inspection of the Engine Oil

1. Park the automobile on the level ground.

2. Warm up the engine to a normal running

temperature and stop the running.

3. Wait for 5 minutes.

4. Pull out the dipstick and observe the oil level

Compression Gauge

Injector

Engine block 1A-11

and oil state, inspect if the oil level ranges

between Scale F and Scale L.

5. Add or replace oil according to needs.

6. Confirm the dipstick O-ring’s installation (see

right figure).

7. Insert the dipstick again.

1.2.3 Inspection of Oil Pressure

Warning

 Wasted and used oil is cancer-causing

substance, and so skin shall be cleaned with

soap and tap water immediately after the

work.

1. Dismantle the oil pressure switch.

2. Mount the special tools onto oil pressure

switch’s mounting hole.

3. Warm up the engine to a normal running

temperature.

4. Run the engine to a fixed rotating speed, and

cast attention to the oil pressure gauge’s

reading.

5. Stop the running and cool the engine.

6. Dismantle special tools.

★ Note: if the pressure goes beyond the

specified range, inspect the cause, and repair

the engine and replace the oil according to

needs.

Notice

 Oil with different viscosities and temperatures

may vary in pressure

7. Oil pressure:400 ～ 588kPa{4.1 ～

6.0kgf/cm2}[2500rpm]

8. Smear evenly the thread sealant (A6F011)

onto the oil pressure switch thread (see the

figure).

9. Mount the oil pressure switch. Tightening

torque:14.7N·m{1.5kgf·m}.

10. Start the engine and inspect if the engine oil

suffers leakage.

1.2.4 Replacement of Engine Oil

1. Dismantle the oil cover and oil drain plug.

2. Pour the oil into appropriate vessel.

3. Mount the new oil drain plug. Tightening

torque: 30～41N·m{3.1～4.2kgf·m}.

4. Add engine oil of specified model and volume

into the engine.

5. Remount the oil cover.

6. Inspect the dipstick’s scale value.

7. Start the engine and inspect if there is

leakage.

8. Inspect the engine oil level and add the oil if

necessary (see Inspection of Engine Oil).

Notice

 In some occasions, actual oil volume that is

added according to the oil scale may differ

from the oil volume specified.

Item Oil capacity (L)

Oil replacement 3.6

Oil and oil filter replacement 3.8

 Engine Oil Grade: API Engine Oil Grade:

above SL

O-ring

Oil pressure gauge

Smearing

Sealant is needed when the bolt is reused.

Engine block 1A-12

Oil viscosity standard Oil viscosity level

Higher than–25℃ SAE10W–30

–30℃～37℃ SAE5W–30

1.2.5 Replacement of Oil Filter

1. Dismantle the oil filter with special tools.

2. Rub and clean the new oil filter with a clean

cloth.

3. Smear clean oil onto the new oil filter’s

O-ring.

4. Mount the oil filter with special tools

Tightening torque:13.0～15.0N·m{1.32～

1.52kgf·m}.

5. Start the engine and inspect if there is leakage.

Inspect the oil level and check if oil adding is

needed (see Inspection of Engine Oil).

Others

Other inspection and maintenance like power

generator inspection and starter inspection etc can

be conducted on the complete vehicle. See this

manual and corresponding complete vehicle

maintenance manual for processing procedures.

1.3 Application of Engine

Maintenance Platform

1.3.1 Mount the Engine onto

Maintenance Platform

1. Lift the engine, and align the cylinder body’s

pin hole to the maintenance platform’s

mounting dowel pin to mount the engine(see

the figure).

2. Mount the work fixture according to the

figure and lock it.

3. Adjust the fixing bolt to appropriate place and

prevent the engine mounting from getting

loose.

4. Pour the engine oil into specified vessel.

5. Mount the new oil drain plug, and tighten the

oil drain plug. tightening torque: 30 ～

41N·m{3.1～4.2kgf·m}

Smear clean oil onto the

new oil filter’s O-ring.

Fixing bolt

Engine block 1A-13

1.3.2 Dismantle the Engine from

Maintenance Platform

Dismantle the engine from the maintenance

platform according to steps reverse to “Mount

the Engine onto Maintenance Platform”.

Notice

 The engine maintenance platform’s

self-locking brake system may lose efficacy

in an unbalanced state, for instance, the

engine maintenance platform suffers

unbalance due to sudden and rapid action

resulting from the engine mounting onto and

dismantling from the platform, which will

result in danger. Due to this, to ensure the

engine and the entire maintenance

platform’s balance during the operation

process, the maintenance platform’s rotary

handle shall be held tightly in hands during

the engine tilting process.

1.4 Power Generator and Starter

1.4.1 Power Generator’s

Dismantling/Mounting

Warning

 When dismantling /mounting the power

generator on the complete vehicle, the

accumulator cable shall be dismantled firstly,

or the power generator’s Terminal B will

contact the vehicle body, which will lead to

sparks and further result in personal injury

and electric element damage.

1. Dismantle the power generator according to

the sequence illustrated in the figure.

2. Mount the power generator according to the

sequence reverse to the dismantling process.

3. Inspect the belt’s deflection /tension (see

Inspection of the Power Generator Belt).

1 Generator adjusting arm

2 Generator belt

3 Generator bolt

4 Generator

1.4.2 Explanations on Inspection of Power

Generator Belt

If necessary, inspect the power generator belt’s

deflection and tension: see complete vehicle

maintenance manual’s corresponding part.

1.4.3 Explanations on adjustment to

tension of power generator and air

conditioning drive belts

1. Loosen the power generator’s bolt nut . ①

2. Loosen the power generator’s fixing nut . ②

Use the adjusting bolt , ③ and adjust the belt

tension and belt difference to the specified value.

3. Tighten the power generator pivot bolt’s nut

: tightening ① torque:43～60N·m

4. Tighten the power generator’s fixing nut ②:

tightening torque:37.3～52N·m

Notice

 If mounting the new power generator belt or

running power generator belt for less than 5

minutes, adjustment shall be made according

to the new part’s standard value.

 If running power generator belt for more than

5 minutes, adjustment shall be made

according to old part’s standard value.

 If it fails to stay within the standard value,

readjustment shall be made from Step 1 on.

1.4.4 Explanations on inspection of power

generator

1. Confirm if the accumulator has been charged.

②Power

Generator Belt

④Power

Generator

③Adjust the bolt

②power generator’s

fixing nut power

①generator’s bolt nut

Engine block 1A-14

2. Confirm if the belt’s deflection /tension stays

within the specified range (See power

generator part: Inspection of Power Generator

Belt).

3. Turn the ignition switch to the “ON” position,

and the charge warning lamp will turn on.

4. Confirm if the charge warning lamp is off

after the engine has been put into running.

★ Note: If there is abnormal situation, see

corresponding “Complete Vehicle Fault

Diagnosis and Handling”.

1.4.5 Starter Dismantling/Mounting

Warning

 When dismantling/mounting the starter on the

complete vehicle, if the accumulator’s

positive cable fails to be loosened, the

starter’s Terminal B will connect with or

contact the body, which will lead to sparks

and further result in personal injury and

electric element damage. Due to this,

accumulator’s positive cable shall be

dismantled firstly when the following

operations are conducted:

1. Dismantle the accumulator’s positive cable.

2. Dismantle the starter according to the

sequence illustrated in the figure.

3. Mount the starter according to the sequence

reverse to the dismantling process.

1 Binding posts B cable

2 Binding posts S cable

3 Starter

1.4.6 Explanations on inspection of starter

Accompanying inspection:

1. Confirm if the accumulator is charged.

2. Start the starter to Confirm if the starter runs

stably and has no running noise.

★ Note: If there is abnormal situation, turn the

ignition switch to the “START” position, and

measure the voltage between Terminal S and

Terminal B, and the standard voltage shall be

greater than 8(V)

—If the voltage stays beyond the specified range,

overhaul the wiring harness and ignition switch.

—If the voltage stays within the specified range,

dismantle the starter and inspect the solenoid

switch and starter.

Zero-load test

1. Confirm if the accumulator is charged.

2. Connect the starter, accumulator, voltmeter

and ammeter (see right figure).

3. Run the starter and Confirm if its running is

stable.

4. During the starter running process, measure

the voltage and current.

Note: If there is abnormal situation, conduct

repair or replacement.

Standard voltage:11(V), standard current:＜95(A)

1.5 Ignition, Control System

Ignition Coil and PCV Valve

Dismantling/Mounting

Notice

 When dismantling the ignition coil and spark

plug, shield sleeve at the connecting rod can

be easily torn. Due to this, they should be

dismantled only when the replacement is

necessary and tearing and damage shall be

avoided during the dismantling process.

1. Dismantle parts according to sequence

illustrated in the figure.

Ignition switch

Accumulato

r

Terminal S

Starte

r

Engine block 1A-15

1 Ignition coil

2 Spark plug

3 PCV valve

2. Mantle parts according to sequence reverse to

the dismantling process.

1.51 Spark Plug Dismantling/Mounting

Notice

 Mount the spark plug cautiously because

strong impact will result in spark plug

damage.

PCV Valve Dismantling /Inspection

1. Dismantle the PCV valve.

2. Confirm if the air ventilation in PCV valve is

as the following table. If there is abnormal

situation, replacement shall be conducted.

Air Ventilation Condition Table

Test Condition Test Result

Blow to A

There is air outflow

from Interface B

Blow to B

There is no air outflow from

Interface A

1.5.2 Control System Parts

Dismantling/Mounting

1. Dismantle parts according to sequence

illustrated in the figure.

2. Mount parts according to sequence reverse to

the dismantling process.

1 Oil rail

2

Crankshaft position sensor (see

Inspection of Crankshaft Position

Sensor)

3 Camshaft position sensor

4 Pressure temperature sensor

5 Throttle body

6

Water temperature sensor (see

dismantling/mounting explanations)

7 Oil control valve

8 Oil pressure sensor

9 Knock sensor

Note: this part only lists different parts of

the control system’s mounting conditions

on the engine. See the complete vehicle’s

corresponding part for relevant fault

diagnosis and inspection.

1.5.3 Crankshaft position sensor’s

dismantling/mounting explanations

1. When mounting the crankshaft position

sensor, smear “LOCTITE5971” onto the

cylinder body (shade line zone).

2. When smearing the sealant, keep clean the

unit surface’s bonding part.

3. After smearing the sealant, mount the

crankshaft position sensor within 3 minutes.

1.5.4 Explanations to inspection of

crankshaft position sensor

Clearance inspection

Attentions

⑥ Not greate

r

than 15{1.53}

N

ot greater

than 29.4{3}

Engine block 1A-16

 Under-mentioned inspection shall be

conducted if necessary.

1. Confirm if the crankshaft rotating speed

sensor is correctly mounted.

2. Use the plug gauge to measure the clearance

between signal wheel protrusion platform and

crankshaft rotating speed sensor.

Notice

 If the clearance is incorrect, adjust the

crankshaft rotating speed sensor or inspect if

there is torsion and indentation in the signal

wheel’s protrusion part. (If have, replace the

crankshaft signal panel).

Standard clearance value:0.5～1.5mm

1.5.5 Explanations on water temperature

sensor dismantling/mounting

Use the sleeve to dismantle the water temperature

sensor.

Zone for smearing

the sealant

Crankshaft

p

osition senso

r

Crankshaft

signal panel

Clearance

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Haima S5 User manual

Haima S5 User manual

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