Haima S5 User manual

Type
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 sensors 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 -1426(BTDC)
Intake
OFF 6626(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(°) 310 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 112.9113.1
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 0.180.26
valve clearance(engine in cold
condition)(mm)
Exhaust 0.260.34
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 89.3189.91
Intake
Min. 89.11
Standard 90.6391.23
Valve length (mm)
Exhaust
Min. 90.43
Standard 4.9654.980
Intake
Min. 4.915
Standard 4.9554.970
Valve stem
diameter(mm)
Exhaust
Min. 4.905
valve guide’s inside diameter (mm) Standard 5.05.012
Intake 12.713.3
valve guide’s protrusion height (mm)
Exhaust 12.713.3
Valve seat
Width of valve seat’s contact surface (mm) 1.11.5
Intake 43.544
Angle of valve seat (°)
Exhaust 43.544
Intake 30.4
Valve seat sinking (valve protrusion
height)(mm)
Exhaust 34.6
Valve spring
Intake H1: 33.4mm 142.2161.8{14.5116.51kgf}
valve spring height H
pressure (N{kgf})
Exhaust H2: 24.9mm 293.4324.4{29.9433.10kgf}
Verticality(mm) 1.50mm
Valve oil seal
Depth L(mm)
Intake 15.716.3
Engine block 1A-3
Exhaust 15.716.3
Tappet
Tappet hole’s diameter(mm) Standard 31.00031.025
Tappet diameter(mm) Standard
30.96430.980
Standard
0.0200.061
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
25.94525.960
Journal diameter(mm)
Min. 25.915
Journal clearance(mm) Standard
0.0400.076
Standard
0.080.20
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
74.874.815
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
74.7874.79
Standard
0.0100.035
Clearance between piston and cylinder bore
(mm)
Max. 0.10
Piston ring
Top ring Standard
0.0300.070
Second Ring Standard
0.0200.060
Oil Ring Standard
0.0400.120
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
0.150.30
Engine block 1A-4
Second Ring
0.200.40
Oil Ring
0.100.40
cylinder](mm)
Max. 1.0
Piston pin
Piston pin’s diameter(mm) Standard
18.00118.005
Piston pin hole’s inside diameter (mm) Standard
18.01018.014
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
0.0050.013
Connecting rod
Length [center to center](mm)
GN16-VF
Standard
135.3135.4(132.9133.0)
Inside diameter of connecting rod’s small end
(mm)
Standard
17.97417.985
Standard
0.1000.350
Connecting rod’s end gap(mm)
Max. 0.40
Connecting rod bearing
Connecting rod bush size (mm) Standard
1.4851.496
Standard
0.0140.058mm
Connecting rod bearing clearance (mm)
Max. 0.10
Crankshaft
Crankshaft radial run-out(mm) 0.03
Main journal diameter(mm) Standard
46.00446.029
Standard
0.0140.034
Main journal clearance (mm)
Max. 0.1
Main bearing bush size (mm) Standard
1.9711.996
Crank pin diameter(mm) Standard
39.98040.000
Thrust bearing size (mm) Standard
3.2053.255
Standard
0.090.273mm
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])
400588{4.16.0}[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)
0.51.5
Thermostat
Opening temperature ( )
8084
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 0.060.20
Clearance between inner rotor’s prong
and outer rotor (mm)
Max. 0.22
Standard 0.2500.325
Clearance between outer rotor and pump
body (mm)
Max. 0.35
Standard 0.0300.090
Backlash (mm)
Max. 0.14
Compression spring’s length (mm)[pressure:97.7
107.4N{9.9610.96kgf}]
33.50
Front-end oil seal’s driving distance (mm)[from oil pump
body’s rim]
00.5
Engine block 1A-6
Rear oil seal
Rear oil seal’s driving distance (mm)[from crankshaft bac
k
cover’s rim]
00.5
Plastic fixing bolt’s length
Cylinder head bolt(mm) Standard 136.8144.2
Standard 74.1574.85
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 6.99.8
Clutch pressure plate 18.6 1.9 18.625.5
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°(04°)
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{2.13.1kgf·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: 3041N·m{3.14.2kgf·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
–3037 SAE5W30
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:13.015.0N·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{3.14.2kgf·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 Generators
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 .
2. Loosen the power generator’s fixing nut .
Use the adjusting bolt , and adjust the belt
tension and belt difference to the specified value.
3. Tighten the power generator pivot bolt’s nut
: tightening torque:4360N·m
4. Tighten the power generator’s fixing nut :
tightening torque:37.352N·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.
Power
Generator Belt
Power
Generator
Adjust the bolt
power generator’s
fixing nut power
generator’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
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:0.51.5mm
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

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User manual

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