SFG18 Gasoline Engine

Content
SECTION I TECHNOLOGY SPECIFICATION FOR ELECTRIC FUEL INJECTION GASOLINE ENGINE...........................4

SECTION II MAIN CHECKING AND ADJUSTING SPECIFICATION AND TORQUE...........................................................5

I. MAIN CHECKING AND ADJUSTING SPECIFICATION...................................................................................................................5

II. MAIN TIGHTENING TORQUE....................................................................................................................................................6

SECTION III PARTS STRUCTURE, REPAIRING AND ADJUSTMENT OF ELECTRIC FUEL INJECTION GASOLINE

ENGINE..........................................................................................................................................................................................9

II. CAM SHAFT AND VALVE TAPPET..........................................................................................................................................14

III. POSITION CONNECTING ROD...............................................................................................................................................16

IV. CRANK AND CRANKCASE.....................................................................................................................................................20

VI.LUBRICATING SYSTEM..........................................................................................................................................................24

VII. COOLING SYSTEM.............................................................................................................................................................. 27

VIII. ELECTRONIC FUEL INJECTION SYSTEM.............................................................................................................................29

IX. ELECTRIC SYSTEM...............................................................................................................................................................33

X. CLUTCH.................................................................................................................................................................................36

SECTION IV STARTING, OPERATION AND PARKING OF GASOLINE ENGINE...............................................................38

I. PREPARATION BEFORE STARTING............................................................................................................................................38

II. STEPS OF STARTING...............................................................................................................................................................38

III. INSPECTION IN OPERATION PERIOD......................................................................................................................................38

IV. PARKING.............................................................................................................................................................................. 39

SECTION V. DEBUGGING OF GASOLINE ENGINE..............................................................................................................40

I. GASOLINE ENGINE CANNOT START OR IS HARD TO START......................................................................................................40

II. GASOLINE ENGINE IS POWERLESS OR THE ACCELERATION IS POWERLESS.............................................................................41

III. GASOLINE ENGINE IS POWERLESS........................................................................................................................................41

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IV. BACKFIRE, BLASTING AND DETONATION OF GASOLINE ENGINE

V. IDLING SPEED OF GASOLINE ENGINE IS TOO HIGH

VI. STRANGE NOISE EXISTS IN GASOLINE ENGINE

VII. GASOLINE CONSUMPTION IS TOO LARGE

VIII. OIL CONSUMPTION IS TOO LARGE

IX. GASOLINE ENGINE IS TOO HOT

X. IT DOES NOT EXTINGUISH AFTER CLOSING IGNITION SWITCH

XI. PRESSURE OF ENGINE OIL IS TOO LOW

XII. FAULT INDICATING LAMP OF GASOLINE ENGINE IS CONSTANT ON

XIII. DISCHARGE IS NOT QUALIFIED

XIV. FAULT OF CLUTCH SYSTEM

XV. FAULT OF TRANSMISSION SYSTEM

APPENDIX I. FAULT CODE LIST

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 Section I Technology Specification for Electric Fuel Injection Gasoline Engine

Type SFG18

In-line four-cylinder and four-stroke, water cool, double overhead camshaft, 16- valve, electronic-control
Model
sequential multi-point fuel injection, silent chain transmission, VGIS, double VVT

Displacement (L) 1.798

Compression Ratio 10.2:1

Rated Power KW/(r/min) 102/5600

Maximum Torque
187/3600-4400
N.m/(r/min)
Minimum Idling
750±50
Speed(r/min)
Minimum Fuel
≤260
Consumption(g/kw•h)

Fuel Grade 93# or above unleaded gasoline (G B 1 7 9 3 0 - 2 0 1 3 )

Engine SM 5W/30

Fuel Grade

Transmission 75W/90 GL-4

With gearbox 152

Net Weight (kg)
Without gearbox 112
Dimension (Length ×
With gearbox 844×723×648
Width × Height),mm

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 Gear Ⅰ Gear Ⅱ
3.545 2.158

Gearbox Ratio Gear Ⅲ Gear Ⅳ

1.346 1.030

Gear Ⅴ Gear R
0.912 3.133

Section II Main Checking and Adjusting Specification and Torque

I. Main Checking and Adjusting Specification

Intake valve
0.23±0.03
Clearance of Cold-state Valve(mm)
Exhaust valve
0.32±0.03
Compression pressure of cylinder when it is
≥9 8 0 Pressure difference of any two cylinders is not more than 98kPa)
400rpm (kPa )

Vacuum of Idling Inlet Pipe (kPa) ≥65

Clearance of Spark Plug (mm) 0.8±0.1

Idling speed ≥60

Engine Oil Pressure (kPa)
3000rpm ≥294

Lubricating Oil Capacity (L) 3.8

Lubricating Oil Capacity of Transmission (L)

2.0~2.2

Idling Speed (rpm)

750±50
Idling Oil Temperature (℃)
130
Temperature of Cooling Water(℃) 82～95

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 II. Main Tightening Torque

No. Bolt of Tightening Parts Tightening Torque Value (N﹒m)

1 Cylinder head bolt 80±4

2 Drive belt pulley bolt 160±5

3 Main Bearing Cover Bolt 60±2

4 Upper and lower cylinder mounting bolt 30±2

5 Cam bearing cap bolt 12±2

6 Connecting rod bolt 48±2

7 Flywheel assembly bolt 88±5

8 Clutch bolt 23±2

9 Tension wheel bolt 50±5

10 Idler wheel bolt 35±5

11 The idler wheel component mounting bolt 50±5

12 Intake manifold component nut 23±2

13 Exhaust manifold nut 28±2

14 Exhaust manifold bracket bolt 50±5

15 Fuel rail bolt 10±1

16 Oil drain plug 40±5

17 The engine left hook 50±5

18 Pump bolt 10±1

19 Starter bolt 50±5

20 Air compressor bolt 25±2

21 Generator bracket 50±5，23±2

22 Knock sensor bolt 23±2

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23 Left and right, rear suspension bracket bolt 50±5

24 Generator assembly bolt 50±5，23±2

25 Transmission assembly 50±5，70±5

26 VCP bolt 70±5

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Section III Parts Structure, Repairing and Adjustment of Electric Fuel Injection Gasoline

Engine

Understanding parts structure of gasoline engine as well as mastering key points of repairing and adjustment is helpful to maintain gasoline

engine and keep its performance and quality. Here is brief description to parts structure, repairing and adjustment key point of S F G 1 8 g a s o l i n e

engine.

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 ** Expression is faulty **. Valve and Cylinder
1. Cylinder head shall be opened after it is cooled in order (shown

in Sketch 1-1). All the bolts with no more than 20rpm speed to

preload 20N - m, and with no more than 25rpm speed to preload

Front side
40N m, finally, with no more than 25rpm speed to (80 + 3) N - m

According to the above steps to tighten the bolts, with 80N - M

moment according to order from the front to back all the check cylinder

head bolts, check bolts shall be no rotation.

When removing the cylinder head, should be in reverse order to

assembly, several times to gradually loosen the cylinder head bolts, so as

1-1
to cause the cylinder head warping deformation.

2. Cylinder washers shall be replaced every time when installing the

cylinder head.

The coatings of cylinder washer attached on cylinder head and

Exhaust Side cylinder body shall be wiped out after disassembling cylinder head. Do

not scratch the contacting surface. Coatings of cylinder washer shall be

Front side avoided to enter into oil hole, cooling water hole and screw bolt.

It shall be checked that whether air bell exists or whether sealing strip

is complete before installing new cylinder head. If the above defects exist,

Sketch 1-2. Intake Side it shall be replaced.

When installing the cylinder gasket, attention should be paid to the

installation direction, as shown in Figure 1-2.

3 Carbon in combustor shall be cleaned. It cannot be cleaned by

sharp tools. Surface of parts cannot be damaged. Whether scratch

exists in intake hole, exhaust hole, combustor and cylinder head

shall be checked after cleaning. Installing surface level of cylinder

head, intake manifold and exhaust manifold shall be tested by hair

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 ruler and filler gauge as shown in Sketch 1-3. If the levelness is

more than limited value, cylinder head shall be replaced.

Levelness limited value of cylinder head shall be 0.04mm;

Levelness limited value of installing surface of intake manifold

1-3
and exhaust manifold shall be 0.05mm;

4.Micrometer of outer diameter and dial gauge of inner diameter

shall be adopted (shown as Sketch1-4) to test diameter of valve rod

and inner diameter of valve conduit respectively, and ensure that the

testing points are not less than one. If the clearance is more than

limited value, valve or valve circuit shall be replaced.

Diameter of intake valve: (5.47～5.485)mm

Diameter of exhaust valve: (5.465～5.48)mm

Inner diameter of valve circuit: (5.51~5.53)mm

Standard tolerance clearance:

Intake valve: (0.025～0.06)mm

Exhaust valve: (0.03～0.065)mm

1-4
Limited value of tolerance clearance

Intake valve: 0.07mm

Exhaust valve: 0.08mm

1-5

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 5. Carbon in on valve shall be checked. Whether sealing side of valve is worn,

burnt or out of shape shall be checked. If any, valve shall be replaced.

If head thickness of valve (Sketch 1-5) is less than limited value, it shall be

replaced.

Standard thickness of valve head (T):

Intake valve: (2.5～2.9)mm

Exhaust valve:( 2.6～3.0)mm

Limited value of valve head:

Sketch 1-5 Intake valve: 2.05mm

Exhaust valve: 1.99mm

6. Whether any dent or abrasion exists on surface (Sketch 1-6) shall be

checked. If necessary, it can be ground by oil. If the chamfer is worn, valve

shall be replaced.

7. Contacting surface width of valve seat (Sketch 1-4) shall be checked: One

layer of red lead shall be applied on sealing cone of valve equally, valve

seat should be ground then and it shall be rotated on circle at least. The

mark produced by ground sealing cone of valve must be solid color strip,

width of which must be in the specified range.

Standard width of mark on sealing cone of valve (B):

Intake valve: (1.513～2.088 mm

Exhaust valve: (1.768～2.354)mm

Repairing of valve seat:

If the mark produced when valve seat and valve are ground is

not equal or its width is not n the specified range, it must be ground

again, or ground or ground accurately after cutting.

Ring of intake valve seat shall be cut by reamer of valve seat,

Reamer of Valve Seat (shown as Sketch 1-8). It shall be cut 60°for the first time,45°for

the second time, and 30°for the third time, shown as Sketch 1-9.

The second cutting must be in accordance with the required

Sketch 1-8
width of cone contacting surface.

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 8. (Show as Sketch 1-10) Whether the valve spring is damaged and

whether its elasticity is reduced shall be checked for the reduction of

elasticity will generate tremble and it will lead air tightness of the valve

Intake
30° 30°
Exhaust is not good after returning. As a result, air will leak to lower the output
45° 45°
60° 60° power of engine.

Standard free length of valve spring: 4 5 . 2 mm

1-9
Standard preload of valve spring: It is 33.88mm when it is （153～

169）

Spring perpendicularity: Based on the clearance between valve

spring end and ruler, the perpendicularity of valve spring shall be

checked (Sketch 1-11) by ruler and slab. If the perpendicularity is more

than limited value, valve spring must be replaced.

Limited value of valve spring perpendicularity: 1.0mm

Sketch 1-10 The end with color must be upward when installing spring valve

9. Oil seal of valve cannot be used again once it is removed. The new

one must be used for installing, shown as Sketch 1-12. When installing

oil seal of valve, the delicate tool shall be operated by hand only. Never

hit the tool by hammer or other things to avoid breaking oil seal.

Sketch1-11

Sketch 1-12

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 ** Expression is faulty **. Cam Shaft and Valve
Tappet
1. The valve to be tested shall be rotated to the location to be

overlapped with center line, shown as sketch 2-1.Clearnacne between

valves, which is not more than the limited value, shall be tested.

Limited value of value clearance(cold state):

Intake valve: 0.23±0.03mm

Exhaust vale: 0.32±0.03mm

Sketch 2-1
If clearance between intake valves is more than limited value, the

valve tappet shall be replaced.

2. Bearing bolt of cam shaft shall be removed in the order shown in

Sketch 2-2. And then the bearing cover of cam shaft and cam shaft shall
12 4 16 8 1 Front
13 5 17 9 be removed. Whether neck and cover of cam shaft is damaged shall be
3
14 6 18 10
15 7 19 11 2
checked. If any bad situation is found, the intake cam shaft, exhaust cam

shaft or cylinder head assy. shall be replaced.

Sketch 2-2

3. Abrasion of cam shall be checked: It is shown as Sketch 2-3. Cam

height shall be measured by outer diameter of micrometer. If the height

is less than limited value, cam shaft shall be replaced.

Height of intake cam shaft:

Standard value: (44.583～44.657)mm

Limited value: 44.56mm

Height of exhaust cam shaft:

Standard value: (43.763～43.837)mm

Limited value: 43.74mm

Sketch 2-3

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 Radial run-out of cam shaft neck shall be checked: It is shown as
Sketch 2-4. The cam shaft shall be placed in between the two Vs. Radial
run-out of cam shaft shall be measured by dial indicator. If the radial
run-out is more than limited value, the cam shaft shall be replaced.
Limited value for radial run-out of cam shaft shall be 0.02 mm.
4. Abrasion of cam shaft neck shall be check:
Diameter of each cam shaft neck shall be measured by
micrometer. Inner diameter of cam bearing of cylinder head shall be
measured y inner-diameter micrometer (Sketch 2-5).
Clearance of cam shaft necks can be got by the value of bearing
Sketch 2-4
hole diameter of cam shaft neck minuses the relevant diameter value of
cam shaft.
If clearance of cam shaft neck is more than limited value, the cam
shaft shall be replaced. If necessary, cylinder head shall be replaced.
Clearance of cam shaft neck:
Inner diameter of cam bearing: φ23(0,+0.021)
Diameter of cam bearing: φ23(-0.056,-0.035)
Standard value of clearance: (0.035～0.077)mm
Limited value of clearance: 0.03mm
5. Valve tappet shall be taken out to check whether there are hallow,
abrasion, scratch or damage exist on the tappet surface. If any, it shall be
replaced.
6. Installation of cam shaft:
Sketch 2-5
** Expression is faulty **The cam shaft and valve tappet shall be
washed by gasoline before installing cam shaft.
** Expression is faulty ** Each bearing neck, cam shaft and hole
surface of cam bearing cover shall be lubricated by engine oil. Cam shaft
Intake Cam Shaft Assy.
shall be placed in the corresponding order, namely the intake cam shaft
shall be placed on the intake side while exhaust cam shaft shall be placed
on the exhaust side (Sketch 2-6)
The largest bearing cover (front bearing cover) shall be installed
on the shaft neck which is near to chain of cam shaft when installing
cam bearing cover. Then the other cam shafts shall be installed in the
marked order of cam shaft bearing. 4# bearing cover shall be installed on
the intake side which is near to shaft neck of front bearing cover. 8#
Exhaust Cam Shaft Assy.
bearing cover shall be installed on exhaust side which is near to front
bearing cover. Arrows of all bearing cover direct to the front end (chain
end). When screwing bolt of cam bearing, it shall be completed for 2 to
3 times. The tighten torque of front bearing cover of cam shaft shall be
（ 12±1 ） N·m, while tighten torque of front bearing cover of cam
shaft shall be （23±2）N·m。

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 ** Expression is faulty **. Position Connecting
Rod
12mm 1. Whether abrasion or crack exist on position connecting rod,
whether carbon exist on position head, and whether bad burnt exist shall
be checked. If any, it must be replaced.
Position diameter shall be measured on the 10mm to position end.
Measuring direction shall be perpendicular to the axle direction of

Sketch 3-1 position line, shown as Sketch 3-1.

Diameter of position pin: (φ79.25±0.0075) mm

Diameter of cylinder: φ79.3（0，0.013）mm

Cooperating clearance of position and cylinder shall be (0.0425～
0.0705)mm. Attention shall be paid to cooperation and choosing so that
meets requirements of cooperation clearance when repairing.
2. Connecting Rod
Side clearance of the large end (show as Sketch 3-2): Connecting rod
shall be assembled according to the right cooperation technology. Side

3-2 clearance of the large end shall be checked. If it is more the specified
value, the connecting rod shall be replaced.
Standard clearance value of the large end of connecting rod: （0.16

～0.342）㎜
Limited side clearance value of large end of connecting rod:
0.35mm
Axle parallelism of the large and small end hole of connecting rod: It
shall be checked by straightened. If it is more than the specified value:
connecting rod shall be replaced.
Bending limited value of paralleslism:0.04mm
Distortion limited value of parallelism: 0.10mm

3-3 3. Whether abnormal abrasion or damage exist on position pin, small

end hole of connecting rod shall be checked. If any, the relevant parts
shall be replaced, shown as Sketch 3-3.Cooperation clearance of hole
and position for the small end of connecting rod shall be checked. If it is
more than limited value, position pin or connecting rod shall be
replaced.
Small end hole of connecting rod: (19.974～19.985)㎜
Diameter of position pin: (20.003～20.006)㎜

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 Assembling clearance of position pin: (-0.032～-0.018)㎜ m m
Limited value of cooperation clearance: 0.01mm
4. Unequal abrasion or damage condition connecting rod neck of
crankshaft shall be checked: Diameter of connecting rod neck shall be
checked by micrometer; if connecting rod neck is damaged or
cylindricity is more than limited value, the crankshaft shall be changed,
shown as Sketch 3-4.
Diameter of connecting rod neck: （43.982～44.000）m m
Sketch 3-4 Cylindricity limited value of connecting rod neck: 0.01mm
5. Selection of connection rod neck:
** Expression is faulty **. Hole diameter of the large end of
connecting rod neck shall be divided into three, being marked as 1, 2, and
Gross weight
3, which are printed on the large side, shown as Sketch 3-5.
Hole Diameter Grouping of the Large
Mark Mark
End of Connecting Rod Neck (mm)
1 47.000～47.008
2 ＞47.008～47.016
3 ＞47.016～47.024
Batch number
s
** Expression is faulty **Diameter of crankshaft connecting
rod neck shall be divided into three groups, being marked as 1
Sketch 3-5 2 and 3 which are printed on the board edge in the order from
the first crankshaft pin to the forth crankshaft pin, shown as
Sketch 3-6.

Hole Diameter Grouping of Crankshaft Pin

Mark
(mm)
1 ＞43.994～44.000
2 ＞43.988～43.994
3 ≥43.982～43.988

** Expression is faulty **Thickness of connecting rod bush shall be

divided into three, being marked as 1, 2 and 3, which are printed on shaft
bush. The bush shall be selected according to the following table to
Connecting rod ensure the cooperation clearance is right.
Main shaft diameter diameter number
number Sketch 3-6 Diameter Grouping of
G r o u p i n g o f Connecting
Crank& Crank
Rod Bush
1 2 3
Inner Diameter 1 2 3 4
Grouping of 2 3 4 5
L a rg e E n d o f
Connecting 3 4 5 6
Rod

15
16
 6. Clearance Check for Shaft Bush of Connecting Rod

** Expression is faulty ** Shaft bush and connecting rod neck of

Plastic Plug Gage
crankshaft shall be washed by gasoline before checking clearance of shaft

bush, which then shall be installed on connecting rod and cover correctly;

** Expression is faulty **A piece of plastic plug gage, width of

which is the same with connecting rod neck, shall be placed on

connecting rod neck, avoiding oil hoe, shown as Sketch 3-7;

Sketch 3-7 ** Expression is faulty **Installation of connecting rod cover:

Lubricating oil shall be applied on the thread of bolt before installing;

attention shall be paid to the “raised part” (forward mark) on connecting

rod and it should direct to the belt pulley (front), shown as Sketch 3-8, the

screw shall be tightened as the method specified.

Fasten Methods of Connecting Rod Bolt:

Step 1: It shall be stopped when torque is(20±2)N·m; At the speed of

20rpm.
3-8
Step 2: It shall be rotated at the speed of 20rpm. when torque

is(50±2)N·m

** Expression is faulty ** Connecting rod(bush) cover shall be

removed. Ruler shall be placed on plastic plug gauge. Thickness of plastic

plug gauge on the widest clearance shall be tested, shown as Sketch 3-9.

If the clearance is more than difference, the connecting rod bush shall be

placed. It shall be tested again according to the above mentioned method

until it is qualified.

Standard value of connecting rod bush clearance: ( 0 . 0 0 9 ～

0 . 0 2 2 ) ㎜ )mm

Limited value of connecting rod bush: 0.025mm

7. Whether pit, burnt or flaking exists between connecting rod bush

Sketch 3-9 shall be checked. Shape of shaft bush shall be observed. If any, it shall be

replaced.

17
 8. Clearance of position ring sink: Position ring sink shall be washed
before checking. New position rings shall be placed into the sink.
Clearance between rings shall be measured by ruler, shown as Sketch 3-
10. If the clearance is more than difference, position shall be replaced.
Clearance between position rings:
Ring 1: Standard(0.04～0.08)mm
Ring 2:Standard(0.02～0.07)mm
1. Position Ring
Oil ring comp: Standard(0.06～0.15)mm
2. Thickness Gauge

9. Clearance of position rings shall be measured (Sketch 3-11): Position

Sketch 3-10 rings shall be placed into cylinder. If the clearance is more than
difference, position shall be replaced. Top of cylinder and position rings
shall be washed before embedding positing ring, and remove the carbon.
Clearance of position rings:
Ring 1:
Standard: (0.02～0.30)mm, limited value 0.5mm
Ring 2:
Standard:( 0.4～0.55)mm; limited value 0.9mm

10. Assembling of Position Rod

1. Cylinder Body
** Expression is faulty **To ensure that the gasoline engine runs
2. Clearance Gauge
3. Position Ring normally, the 4 connecting rods of the same gasoline engine must be the
same quality. Quality grouping number of connecting rod must be on the

Sketch 3-11 side and be marked with capitalized English letter, from “A” to H”, 8
groups in total.
** Expression is faulty ** Before installing, the position rod assy.
Shall be washed and dried. Then the position pin, position head, position
ring sink and small hole of rod shall be lubricated by lubricating oil.
Forward mark “○” on the top of position shall be corresponded to the

Manufacture Mark forward mark of rod ( the same side of direction). It is ensured that the
position clasps on the two ends shall be installed rightly after installing
position pin. Opening of the clasp shall be upward or downward.
** Expression is faulty ** Installation of position ring: It is shown
as Sketch 3-12, the Ring 1 and Ring 2 are marked with manufacture’s

Manufacture Mark mark. The side with mark shall be upward when installing. Cushion
spring shall be installed at first when installing oil ring assy. Then the
two scrapers shall be installed. Attention shall be paid to opening of
Sketch 3-12
position ring, shown as Sketch 3-13, the openings are staggered.

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 Note: Distinguishing of position rings
A) Ring 1 is nitride steel ring, the surface is smooth and shining;

1. Arrow Mark B) Ring 2 is phosphate cast iron ring, the surface is grey.
2. Clearance of 1st Position Ring ** Expression is faulty ** Moderate gasoline shall be applied on
3. Clearance of 2nd Position
Ring and Scrapper Ring the position ring, position, cylinder wall, rod bush and crank pin before
5. Clearance of Upper Scrapper
Ring the installed position rod comp is installed in the cylinder. Then the
6. Clearance of Lower Scrapper
Ring forward mark “○”of position ring shall be aligned to the front of engine
7. Intake Side
(belt pulley). Ring shall be compressed by delicate frock. After that, it
8. Exhaust Side
aligns to cylinder hole. Position top shall be knocked by plastic bar. The
position shall be placed into cylinder slowly. Connecting rod shall be
installed on the crank.
Sketch 3-13
** Expression is faulty **The forward mark of connecting rod
cover shall be directed to the front of engine. Then the cover shall be
installed on connecting rod. Screw shall be tightened as the specified
way.

** Expression is faulty **. Crank and Crankcase

1. Straightness of crank: It is shown as Sketch 4-1; offset of the middle
axle neck shall be measured by micrometer. Crank shall be rotated
slowly. If the straightness is more than limited value, crank. shall be
replaced
Limited value of straightens for crank shaft neck: 0.01mm
2. Thrust clearance of crank: The main axle bush, thrust place and rear
Sketch 4-1 main axle cover shall be assembled correctly and tightened as the
specified torque of 60±2N.m. It is shown as Sketch 4-2 and pushed back
and forth along the axle direction. Thrust clearance of crank shall be
measured by micrometer. If it is more than limited value, the thrust plate
shall be replaced.
Standard value of thrust clearance for crank: (0.06～0.24)mm
Limited value of thrust clearance for crank: 0.3mm
Standard thickness of thrust clearance for crank: 2.5 mm
3. Cylindricity of main axle neck: Different diameters of different places
and different lengths in the same section shall be measured by
micrometer. The difference reflects the unequal abrasion. If any is
damaged badly or the unequal abrasion is more than limited value of
cylindricity, the axle neck shall be braised or the crank shall be replaced,
shown as Sketch 4-3.

Sketch 4-2

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 Cylindricity limited value of main crankshaft neck:0.01mm
4.Selection of main shaft bush
** Expression is faulty ** Inner diameter of main bearing shall be
divided into three groups, which are marked with A, B and C. Bearing
holes of from the first group to the fifth group shall be printed on the
specified side of intake side, which is near to the fourth bearing hoe. It is
shown as Sketch 4-4.
Diameter Grouping of Main Bering Hole
Grouping Mark Size (mm)
A 52.005～52.011
Sketch 4-3
B 52.0111～52.017
C 52.0171～52.021
** Expression is faulty **Main axle diameter of crank shall be
divided into three groups, which are marked with 1,2 and 3. It shall be
printed on the edge of the fourth balance block of crank in the order
from the first crank to the fifth crank. It is shown as Sketch 4-5.

Marking Place of Grouping Number Diameter Grouping of Main Axle Neck of Crank

4-4 Grouping Mark Size (mm)

1 ＞47.994～48.000
2 ＞47.988～47.994
3 ≥47.982～48.988
** Expression is faulty **Standard main axle shaft shall be
divided into five groups, which are marked with 1,2,3,4 and 5, printed
on the back of main shaft bush which are selected as the following table
to ensure the right cooperation clearance
Grouping of Main Shaft Bush Diameter Grouping of Main
Axle for Crank
1 2 3
Inner Diameter Grouping of A 3 4 5
Main Bearing B 4 5 6
Sketch 4-5
C 5 6 7
** Expression is faulty ** Main shaft bush can be divided into
upper shaft and lower shaft, which are installed on crankcase and main
bearing cover respectively. The upper bush (installed on the crankcase)
has oil hole, shown as Sketch 4-6. Do not install the upper bush and
lower bush mistakenly. Thrust plate of the cranks shall be installed on
the two sides of the third main bearing respectively. Oil sink of thrust
4-6
Oil Hole of Upper Main Axle Bush
plate shall direct to the outside when installing (direct to thrust plate of
crank) (Sketch 4-7). Never install it upside down.

20
21
 5. Each bearing cover is casted with sequence number and arrow
mark. Main bearing cover shall be slightly placed on the corresponding
main bearing seat ( arrow on the main bearing cover shall direct to the
front of engine), shown as Sketch 4-8.Then bolt of main bearing cover
shall be put and screws 2～3 teeth. Bolt of main bearing cover shall be
screwed to the specified torque value 30±2N.m Then bolt of main shaft
torque value 60±2N.m
Oil Sink of Thrust Plate

6.Clearance of main shaft

** Expression is faulty ** Shaft bush and main shaft neck shall be
cleaned at first before checking clearance of main shaft bush. One
plastic plug gauge (which is parallel to crank) with the same width of
Sketch 4-7 main shaft bush shall be placed on the main shaft neck, avoiding oil
hole. Never rotate crank when installing the plastic plug gauge.

** Expression is faulty **It shall be installed on the main bearing

cover as the specified order and screwing the bolt according to
requirements. (Sketch4-9)

** Expression is faulty ** Main bearing cover shall be taken

down. Thickness of the widest point of plastic plug gauge shall be
measured by ruler (Sketch 4-10). If the clearance is more than limited
4-8
value, the main shaft bush (the upper and lower bush must be replaced
together) shall be replaced. The clearance shall be measured again until
it is qualified.
Standard clearance of main shaft bush: (0.0019～0.0039)mm
Limited value of main shaft bush: 0.050mm

4-9

22
 7. Whether corrosion, scratch, abrasion or damage exists on

main shaft bush shall be checked. If any, the upper and lower main shaft

bushes shall be replaced together.

8. Rear oil seal assy. of crank: Whether abrasion or damage

exists on flange of oil seal shall be checked carefully. If any, the oil seal

shall be checked.

Moderate gasoline shall be applied on flange of oil seal before

Sketch 4-11 installing. It shall be pressed in steadily by delicate frock so that oil seal

4-10 ending is 0 m m ～ 0 . 5 ㎜ lower than oil sealing seat, shown as Sketch 4-

Front oil seal 11. Whether defect or damage exists on flange of oil seal and spring of
Rear oil seal
oil seal on be back cover of crank shall be checked. If any, it shall be

checked timely.

9. Check of fly wheel: If gear ring is damaged, destroyed or

wore, the fly wheel shall be replaced. If friction surface which

contacting clutch is damage for wore badly, the fly wheel shall be

replaced.
4-12
It is shown as Sketch 4-12. End face jumping of fly wheel shall be

measured by micrometer. If it is more than limited value, the fly wheel

shall be replaced.

Limited value of fly wheel: 0 . 1 m m

Fly wheel shall be locked by delicate tools when installing , shown

as Sketch 4-13. It shall be screwed by 2 ～ 3 times until it reaches the

specified torque value of (88±5)N·m。

Sketch 4-13
10. It is shown as Sketch 4-14. Deformation condition of crankcase
shall be checked by knife straight edge and plug gage. If the flatness is
more than limited value, it shall be adjusted.
Flatness standard value of the flat on crankcase: 0.03mm
Flatness limited value of the flat on crankcase: 0.05mm

Sketch 4-14

23
24
 ** Expression is faulty **.Timing Transmission
Exhaust VCP Intake VCP
1. Installing requirement of timing transmission:
** Expression is faulty **When e of Cylinder 4 is on the dead point
of compressing stroke, shown as Sketch 5-1, locations of timing mark
shall be one-to-one correspondence.
** Expression is faulty **Camshaft and crank cannot be moved
after removing the timing chain, otherwise the valve will disturb position
so that the valve or position shall be damaged.
** Expression is faulty **Whether timing chain is wore badly or
chain plate cracks shall be checked. If any, the timely chain shall be

Timing chain replaced.

tension rail Timing chain ** Expression is faulty ** Whether abrasion or crack exists on
guide rail tensioning rail of chain or guiding rail shall be checked. If any, the new
tensioning rail or guiding rail shall be replaced.
** Expression is faulty ** Whether abrasion, dedendum or crack
exist chain of camshaft or chain teeth of crank shall be checked. If any, a
new one shall be replaced.
Timing chain 2. Installation of Transmission:
tensioner
Crankshaft ** Expression is faulty **Keyway of crankshaft chain should
timing chain align to the stop point timing mark of Cylinder 1 and 4 cylinder body
wheel when installing timing chain of crankshaft (casting of convex platform).
** Expression is faulty **Guiding rail and tensioning guiding
assay shall be installed. (Note: Tensioning rail is not fixed and guiding
rail is fixed).
Sketch 5-1 ** Expression is faulty ** When installing timing chain, the
timing mark shall be one-to-one correspondence.
** Expression is faulty ** Hydraulic tension assy. shall be
installed. Tensioning rail shall be fixed. Finally, the fixing pin of
hydraulic tension assy. shall be pulled out; push tension rail slightly to
confirm that the hydraulic tension assy. can stretch out.
** Expression is faulty **.Lubricating System
1. Check engine Oil Quality
Whether engine oil is bad, is mixed with water, changes color or
become thick shall be checked. If it is bad, it shall be replaced,
otherwise, performance index and service life of the gasoline engine
Oil drain bolt
shall be affected. When replacing, the oil drain bolt on engine oil plate
6-1 shall be taken down to drain lubricating oil. After that, the oil drain
plug shall be installed again and tightened as the specified torque of 25
～ 3 0 N . m . It is shown as Sketch 6-1. When replacing gasoline engine,
oil shall be drained in the hot state after the engine is stopped. The
adopted engine oil should be in accordance with provisions of
Instruction.

25
 a)15W/40:(oil for the temperature of -20℃～40℃);
b)10W/30:( oil for the temperature of -25℃～30℃);
Sketch 6-1 c) 0W/30：(oil for the temperature of -35℃～30℃)

2. Check Engine Oil Quantity

1/4 When measuring oil level, vehicle shall be parked on the level
place; it shall be measured five minutes after stopped. Oil quantity shall
be measured by oil level gauge. Oil level shall be in between the high and
lower scratch of oil level gauge (Sketch 6-2).If it is lower than the lower
scratch, whether engine leaks shall be checked, and oil shall be added
until it is in between the upper and lower scratch and is on the 1/4 of the
upper scratch (line of the two holes). Injecting opening is on the cylinder
Sketch 6-2
cover. After injecting, start gasoline engine. It shall be stopped after
running for 3 minutes. Oil level shall be checked again five minutes later.
O-ring
3. Replace Oil Filter
Delicate wrench shall be sued to take the oil filter that needs to be
replaced.
Installing surface of new oil filter shall be checked and cleaned.
Clean engine oil shall be applied on sealing ring of new oil filter (Sketch
6-3). It shall be screwed by hand sot that the seal ring is close to installing
surface. Then it shall be rotated for 3/4 circle by delicate wrench.
Note: Oil filter is disposable part, which cannot be used
repeatedly.
4. Check of Lubricating Oil Pressure
Usually, when power switch (key) is on “connecting”, the oil
pressure indicator is light up and it means that there is not engine oil
Sketch 6-3
pressure; then it is placed on “start” ( or “START”), the gasoline engine is
in idling state, the oil pressure indicator extinguishes, and it means that oil
pressure indicator is normal. If oil pressure indicator does not extinguish,
pressure of oil in lubricating system is not normal. Whether engine oil is
norm, whether oil passage leaks, whether network of suction filter or oil
filter is blocked shall be checked.

26
 5. Check Lubricating Oil of Transmission
Lubricating oil of transmission shall be gear oil of heavy-load

vehicle GL-4 75W/90. It is shown as Sketch 6-4. Opening oil inject

plug, it gear oil flows from oil hole or oil level reaches screw hole, it
means gear oil is full. If gear oil cannot reach the abovementioned
requirement, it means gear oil is not full, and it shall be injected fully
according to the provision. Then it shall be sealed by oil injection plug

applied with sealant he and screw plug with torque of （ 15 ～

20）N.m.
Oil Inject Plug Oil Drain Plug 6. Check Oil Pump
** Expression is faulty **Whether defect and damage exist on
6-4 flange of oil seal shall be checked before installing oil pump. If
necessary, it shall be replaced. Moderate engine oil shall be applied on
flange of oil seal and it shall be pressed into oil seal so that surface of

oil seal is (0.06 ～ 0.18)mm lower than oil seal seat surface before
installing. It is shown as Sketch 6-5.
** Expression is faulty **Whether severe abrasion exists on inner
rotor, outer rotor, rotor cover and oil pump cover shall be checked.
Clearance between plug gauge and cover of outer rotor shall be
checked. If it is more than limited value, rotor or cover shall be
replaced.
Clearance limited value of outer rotor and cover shall be 0.31mm.
Side clearance shall be tested by knife straight edge and plug
gauge, Limited value of side clearance shall be 0.15mm.
Sketch 6-5
** Expression is faulty ** The removed spare parts shall be
washed. A layer of thick oil shall be applied on the inner rotor, outer
rotor, flange of oil seal, inner surface of oil pump cover and cover plate.
Then inner rotor and outer rotor shall be installed in oil pump cover of
timing chain cover. Rotor cover shall be installed and tighten the screw.
Flexibility of inner rotor and outer rotor shall be checked by
rotating by hands after installing the cover plate.
7. Installation of Oil Plate and Oil Filter:
** Expression is faulty **Cooperating surface of oil plate and
crankcase shall be cleaned. The oil and dirty oil on it shall be cleared.
It is shown as Sketch 6-6.

27
 ** Expression is faulty ** Oil shield plate shall be installed on
main bearing cover. Oil plate shall be installed on crankcase and
Mating surface
screwed according to the specified torque of 10±1 N﹒m.
Note: The specified silicone sealant shall be applied when
installing oil plate.
** Expression is faulty **Oil drain bolt shall be installed on oil
plate and it shall be tightened by the torque of 40N.m. Installing surface
of new oil filter shall be checked and washed. Engine oil shall be
injected. Whether leakage exists on connector shall be checked.
** Expression is faulty **When installing oil filter, seal ring on
the connecting seat of oil filter shall be installed on oil plate. Bolts shall

be put in and screwed by the specified torque of (10±1) N﹒m.

Installing surface of oil filter shall be checked and washed. Clean engine

Sketch 6-6 oil shall be applied on the seal ring of oil filter, which shall be screwed
by hand so that the seal ring close to installing surface. Then it shall be
rotated for 3/4 circle by delicate wrench.

** Expression is faulty **. Cooling System

1. Refrigerant
Refrigerant of gasoline engine adopts glycol anti-freezing solution or
soft water. Never use the hard water, such as river water or well water. If
temperature is lower than -30℃ in winter, the mixer of 50 ﹪ anti-
freezing solution/antiseptic shall be used; if temperature is more than -
15℃ in winter, the mixer of 70﹪ water and 30% anti-freezing
solution/antiseptic shall be used.
2. Capacity of refrigerant in water tank shall be checked (Sketch 7-1)
Refrigerant level in water tank shall be checked when cooling the engine

1. Water Storage Tank (Note: Water tank cover and radiator cover in hot state cannot be opened
2. Mark of Full to avoid empyrosis). Normal refrigerant level shall be in between the
3. Mark of Low Level
scratch of “Full” and “Low” of the water tank. Opening the tank,
moderate refrigerant shall be injected until it reaches “Full”. Then cover
it, and the cover shall align to the mark on water tank.
3.Check Quality of Refrigerant
Sketch 7-1
** Expression is faulty **Whether refrigerant is clean shall be checked.
If it is too dirty, the clean refrigerant shall be replaced.

28
 ** Expression is faulty ** Whether rust exists around radiator

Release Valve cover and radiator core shall be checked .

** Expression is faulty ** Whether oil stains exist in refrigerant
Thermostat Gasket
shall be checked.
4. The following parts of cooling system shall be checked.
** Expression is faulty **Whether leakage exist in cooling system
shall be checked.
** Expression is faulty **Whether radiator and soft pipe are
damaged or distorted shall be checked.
Sketch 7-2 ** Expression is faulty **Whether clamp of soft pipe falls off
shall be checked.
5.Check Thermolator
** Expression is faulty **Whether exhaust valve of thermolator is
2
clean shall be checked, shown as Sketch 7-2. If it is blocked, the engine
will be hot.
1 ** Expression is faulty **Whether there is foreign matter exists
on seat of thermostat valve shall be checked for it will block the sealing
3
of valve seat.
** Expression is faulty **Whether sealing gasket of thermolator is
damaged, aging or other damages shall be checked.
** Expression is faulty ** Thermolator shall be soaked into the
water, shown as Sketch 7-3. It is heated gradually. Whether valve is
opened in the specified temperature shall be checked.
Temperature of the valve is opened at the beginning: 82℃
Sketch 7-3 Temperature of the valve is fully opened: 95℃
If temperature of the valve is opened at the beginning is higher
than the specified temperature obviously, the thermolator shall be
replaced. Otherwise, the engine will be too cold or too hot.
6.Check Water Pump (Sketch 7-4)
** Expression is faulty **Water pump shall be rotated by hands.
If it is not flexible or there is foreign matter, it shall be replaced.
** Expression is faulty ** Whether impeller of water pump is
7-4
damaged shall be checked. If necessary, it shall be replaced.
7.Belt of Water Pump shall be Checked
Whether crack, cutting, deformation or abrasion exists on belt of
water pump shall be checked. If necessary, it shall be replaced

29
 ** Expression is faulty **. Electronic Fuel Injection System
SFG18 gasoline engine adopts closed-loop control system, which adopts the advanced computer control ignition device with function of

discharge control, idling control and evaporative emission control. Focusing on electronic control unit (ECU), the system calculates the intake air

capacity according to the sensor signal of temperature pressure. Accordingly, it confirms the fuel-injection quantity per circulation and adjusts

according to the refrigerant temperature. The ECU shall adjust fuel-injection quantity according to sensor signal in the situation that fuel closed-loop

control so that the mixing gas, made by fuel and air, keep the theoretical equivalent air-fuel ratio. This can make the three way catalytic converter

exhaust purification to maximize the reduction of gasoline engine exhaust of carbon monoxide (CO), hydrocarbons (HC) and nitrogen oxide (N0x)

content.

1. Closed-loop Control Theory of Idling Rotate Speed

Idling work conditions of gasoline engine in normal temperature is close-loop control. The fuel injection system will close the throttle fully in

idling working conditions. Air intake quantity of the engine in running shall be controlled by idle actuator on the bypass of throttle. ECU shall

supervise rotate speed of gasoline engine timely and comparison of the targeted idling rotate speed pre-set by the system. According to the variation

of rotate speed, the idling control valve and ignition leading angle shall be adjusted so that the gasoline engine can work steadily in the specified

idling rotate speed.

2. Timing Control Theory of Ignition

Based on the load and rotate speed signal, ECU will confirm value of ignition leading angle and adjust on the basis of refrigerant temperature

to get the right ignition leading angle so that confirm the correct ignition time.

3. Sensor

** Expression is faulty **Throttle position sensor (Sketch 8-1): It

shall be installed on the outside of throttle with the same axle of throttle,

signal of throttle position passes to ECU to judge working conditions of

engine.

8-1

30
 ** Expression is faulty **Intake temperature pressure sensor

(Sketch 8-2):

It shall be installed on the intake manifold. Circulation inflating

8-2
volume shall be calculated according to the intake air temperature and

pressure single. Based on it, the basic fuel injection volume for each

cylinder shall be judged and confirmed.

8-3
** Expression is faulty **Sensor on crankcase(Sketch 8-3): It

shall be installed on the front of transmission which provides rotate

speed and crankcase location signal for engine so that provide reference

point for fuel injection timing and ignition timing.

8-4
** Expression is faulty ** Water temperature sensor(Sketch 8-4):

It shall be installed on the thermolator assy. to supervise refrigerant

temperature and provide reference point for air fan.

** Expression is faulty ** Oxygen sensor (Sketch 8-5): It shall be

8-5

installed on the outlet of exhaust manifold to supervise the oxygen in

exhaust air for adjusting fuel injection volume for the closed-loop

control of air-fuel ratio.

** Expression is faulty ** Knocking sensor(Sketch8-6)

It shall be installed on between Cylinder 2 and 3 to supervise

8-6

whether detonation takes place in the process of burning. Once it

detonates, ingestion shall be delayed and turns into timing closed-loop

control.

31
.

** Expression is faulty **. Electric System

1. Ignition System

Ignition system of S F G 1 8 gasoline engine is free-adjustment ignition system, which is without electric and contactor parts, The

ignition timing is controlled by electric controller, which can improve the controlling accuracy of ignition time and reliability, improving

ignition energy and ignition voltage greatly.

(1) Composition

The system is composed by power supply, ignition switch, electric controller, crankshaft position sensor, ignition wire, high voltage

damper and spark plug.

Note: Type of spark plug is K L 6 R T C , screw thread is M 1 4 × 1 . 2 5 ,clearance of electrode is ( 0 . 7 ~ 0 . 9 ) mm. If the electrode is

burnt, screw thread is damaged or the insulator is damaged, the spark plug shall be replaced.

( 2 ) Wi r i n g , s h o w n a s S k e t c h 9 - 1

7
3ECU

Twin-core Shielded Wire

Ignition insurance

Ignition Coil

Spark
plug
9-1

2.Starting system, shown as Sketch 9-2

Ignition Switch
Terminal 50
Fuse
Terminal 30

Battery

Starter Motor

32
Sketch 9-2

33
 The common faults are: starter does not work, powerless running,

driving gear not run very well, dysfunctional starter does not stop

working, idle starter etc.

1) As shown in Figure 9-3 when the maintenance, first check the

battery, to confirm the adequacy of its electricity.

- +
Connecti Provisions: pull in voltage > 9V.
Connecting Post S
(2) then check the starting system circuit fault: check the connection

接线柱 S of the wire, the switch work.

9-3
线柱 M
(3) Judge the fault in the electromagnetic switch on the motor (or

warning: each test must be in the (0 ~ 5) seconds, to avoid

damage), short circuit on the starter screwdriver metal part two

main terminal, if the motor running, fault in the electromagnetic

- +
接线柱
S 接线柱 switch. Otherwise, the fault is in the motor.
B
① 、Switching performance test. As shown in Figure 9-2, the

9-4 connection wire and check whether the small gear outward

rotation, if the pinion does not move, then the

electromagnetic switch should be replaced.

+ -
② No-load performance test

The battery and ammeter shall be connected as Sketch 9-5.

9-5 Whether fault exists in engine or small gear directs outwards shall be

checked. Whether armature displays the specified currency shall be

checked.

Specified currency: It is 90A for11V.

34
3.Charge system

Type of alternating current engine in charge system shall be1 4 V 1 0 0 A . Wiring way is shown as Sketch 9-7.

Soft Wire of Battery Charge Indicator

Fuse (SA)

Fuse Box

Sketch 9-7
(1) Whether wiring of engine is good shall be checked. Whether abnormal noise exists in generator shall be checked. If any, it shall be tore for

checking.

(2) Circuit of charge indicator shall be checked

Start gasoline engine. It shall be stopped after being heat. All electric accessories shall be closed. Ignition device shall be placed on “ON”, the

charge indicator is lit up.

The charge indicator should extinguish when starting gasoline engine, otherwise, circuit of charge indicator shall be checked.

35
 ** Expression is faulty **. Clutch
1. Whether driven disc of clutch is wore or damaged shall be checked.

Depth of rivet in friction disc should not less than 1.3mm.If it is less

than 1.3mm, driven disc of clutch shall be replaced (Sketch 10-1)

Sketch 10-1

2. Run-out tolerance of driven disc shall be checked. The maximum

driven disc shall be 0.5mm. If it is more than it, the driven disc shall be

replaced.

3. Whether z diaphragm spring is wore shall be checked

Sketch 10-2 Wearing depth and width of diaphragm spring shall be measure by

calipers, shown as Sketch (10-3）. If necessary, the clutch disc assy,

shall be replaced.

Limited value: depth is 0.6mm; width is 5.0mm.

4. Installation of clutch

Sketch 10-3 Clutch shall be fixed from driven disc to fly wheel by delicate tool

as Sketch 10-4 and 10-5. Position pin hole of clutch disc shall align to

position pin. It shall be screwed equally by the torque of 30±5N·m.

Sketch 10-4

36
 Alignment of the end of diaphragm spring shall be checked by

dial indicator. The maximum inequality shall be 0.6mm.If it is too large, it

must be adjusted.

Sketch 10-5

37
 Section IV Starting, Operation and Parking of Gasoline Engine
Right operation of gasoline engine does not only keep the gasoline engine runs normally, but also delay its service life.

I. Preparation before Starting

The following items shall be inspected before staring gasoline engine:
1. Refrigerant level in radiator, fastening conditions and looseness of belt pulley shall be checked
2. Whether oil volume displaced by ruler of gasoline engine is in accordance with requirement shall be checked.
3. Oil volume in oil tank as well as conditions of pipelines connectors in oil supply system shall be checked. The leakage and air in pipeline shall
be discharged.
4. Electrolyte level in battery shall be checked.
5. The fastening conditions of electric equipment, such as batter, generator, starter, spark plug and ignition coil, or the connectors on electric
device shall be checked.

II. Steps of Starting

1. Shift lever of transmission shall be located on neutral position.
2. The clutch shall be stepped to reduce load of gasoline engine.
3. Key of ignition switch shall be rotated and placed on the starting position to start gasoline engine. Time of power-on should not be more than 5s
when starting. Starting interval is not less than 10s every time.
4. Key of ignition switch shall be loosed after the gasoline engine is started so that it returns to ignition place.
If it does not make it for many times, please look into it.

III. Inspection in Operation Period

1. Whether any knock, blast, slap, loose or other strange noise exists.
2. Whether burning smell caused by high temperature of generator or other electric equipment exists.
3. Whether oil leaks in oil system, cooling system and lubricating system.
4. Whether reading( indicator ) of the meters for oil pressure, water temperature, current and oil level is normal.

38
 IV. Parking
If the gasoline engine has to be parked when running at large load, the idling speed shall be lower for 2 ～ 3 minutes at first, and then the

ignition switch shall be closed so that the gasoline engine shall be gradually cooled equally, avoiding the distortion of spare parts and spontaneous

combustion for the engine is too hot

Cooling water in gasoline engine shall be drained completely after parking in freezing season or sever cold area. Water filling cover of radiator

shall be opened when draining. The draining switch on bottom of radiator shall be opened at first, and it shall be closed after draining all the water. If

the cooling water is mixed with antifreezing solution, the water cannot be drained.

39
 Section V. Debugging of Gasoline Engine

The gasoline engine may break down when work, if it does not debug in time, the engine cannot work normally or the parts may be damaged.

To debug, observe and analyze it at first, and then debug referring the following methods. Never disassemble it blindly.

I. Gasoline engine cannot start or is hard to start

Reason Debugging Method
1.Fault of starting system
Battery voltage is not enough Charge
Battery connection is bad Clean binding post, tighten the battery wire
Fuse breaks Replace the fuse
Starter breaks down Repair or replace the starter
Ignition switch breaks down Repair or replace the ignition switch

2．Fault of ignition system

Ignition coil is loose Cable is inserted firmly
Ignition coil is damaged Replace ignition coil
Sensor cable of crankshaft position is loose Cable is inserted firmly
Sensor of crankshaft position is damaged Replace sensor of crankshaft position
High voltage wire is loose or leaky Insert or replace the high voltage wire
Spark plug electrode clearance is not proper Adjust the electrode clearance
Spark plug is damped or carbon deposits on the electrode Dry or remove deposited carbon
Spark plug insulator breaks Replace spark plugs
Cable of electronic controller wire is loose Cable is inserted firmly
Electronic controller is damaged Replace the electronic controller
3. Fault of fuel system
Oil supply of electric fuel pump is not enough Repair or replace the electric fuel pump
Fuel injector is damaged or blocked Replace or clean fuel injector
Sensor of crankshaft position is damaged or cable is loose Replace or insert the sensor of crankshaft position
Fuel pump relay is damaged Replace fuel pump relay
Cable is short or broken Inspect or repair cable
Electronic controller is damaged Replace electronic controller
Fuel filter is blocked Replace gasoline filter
Gasoline pipeline is blocked or air-resisted Wash pipeline or exclude air resistance
4.Condition of gasoline engine is not good
Valve is leaky or burnt Repair or replace valve
Cylinder gasket is damaged Replace
Piston, piston ring and cylinder are worn Repair or replace
Intake manifold is leaky Check the intake manifold and gasket, tighten nut
Valve clearance is adjusted improperly or damaged Adjust, repair or replace

40
 II. Gasoline engine is powerless or the acceleration is powerless
Reason Debugging Method
1. Ignition system breaks down
Spark plug does not work Check or replace the spark plug
High voltage wire is damaged Replace of high voltage wire
Ignition coil is damaged Replace the ignition coil

2. Gasoline engine breaks down

Repair or replace valve
Valve is leaky or burnt
Repair or replace parts
Cylinder compression is poor
Replace the cylinder gasket
Cylinder gasket is leaky
Check the intake manifold and gasket, and tighten
Intake manifold is leaky
the nut

III. Gasoline engine is powerless

Reason Debugging Method

1. Gasoline compression is bad
Valve is leaky Grind valve
Valve spring tension is inadequate or broken Replace the valve spring
Cylinder gasket is leaky Replace the cylinder gasket
Piston ring is stuck or broken Replace the piston ring
Piston or cylinder bore is worn excessively Repair or replace the parts
2. Ignition system breaks down
Ignition coil is damaged Replace the ignition coil
Spark plug does not work Clean, adjust or replace the spark plug
3. Gasoline supply is bad
Fuel injector is blocked or damaged Clean or replace of the injector
Throttle position sensor is damaged Replace the throttle position sensor
Oil pressure of electric fuel pump is not enough Repair or replace the electric fuel pump
There is fouling in oil tank Clean the tank, replace it if necessary
Gasoline pipeline is blocked Clean gasoline pipeline
Fuel filter is blocked Replace the fuel filter
Air exists in fuel system Check and fasten connectors
Chose gasoline according to provisions of
4. Gasoline specification is not qualified
instructions
5. Intake manifold is leaky
Check the intake manifold and gasket
6. Air filter is blocked
Clean the shell and blow filter element
7. Gasoline engine is too hot
See Chapter IX

41
 IV. Backfire, Blasting and Detonation of Gasoline Engine
Reason Debugging Method
1. Ignition system breaks down
Ignition system wire is loose Check and tighten all fittings
Spark plug does not work Clean, adjust or replace the spark plug
heat value of spark plug is improper Replace the spark plug with appropriate heat
value
2. Improper mixture ingredients
Gasoline supply is poor See 3 in Chapter III
Intake manifold is leaky Tighten the nut or replace gaskets
3. Valve mechanism breaks down
Valve is leaky or stuck Grind or replace the valve
Valve spring force is insufficient Replace the valve spring
4. Cylinder head state is bad
Carbon is deposited in combustor Remove deposited carbon
Cylinder head is too hot or the cooling is bad Exclude water in cooling water jacket
The cylinder head is damaged Replace the cylinder head

V. Idling speed of gasoline engine is too high

Reason Debugging Method

1. Throttle position sensor is damaged Replace the throttle position sensor
2. Throttle is not fully closed Adjust the cable or remove the dirt
3. Intake system is leaky Check the air intake system repair
4. Idle regulator is damaged Replace the idle speed regulator
VI. Strange noise exists in gasoline engine
Reason Debugging Method

1. Valve clearance is improper Adjust

2. Piston pin is loose Replace the piston pin
3. Pistons, piston rings and cylinder are worn Repair and replace
4. Connecting rod bush is worn Replace the connecting rod bush
5. Main shaft bush is worn Replace the main bush
6. Crankshaft thrust pad is worn Replace the crankshaft thrust piece
7. Camshaft thrust gap is too large Replace the camshaft

42
 VII. Gasoline consumption is too large
Reason Debugging Method
1. Gasoline pipeline leaks Tighten fittings and throughout, clips
2. Air filter is blocked Check and clean the air filter
3. Ignition system breaks down
Ignition coil breaks down Replace the ignition coil
Spark plug breaks down Check or replace the spark plug
4. Gasoline compression is bad See 1 in Chapter ** Expression is faulty **
5. Clutch slips Check and adjust the clutch
6. Tire pressure is improper Adjust the tire inflation pressure
VIII. Oil consumption is too large
Reason Debugging Method
1. Oil leaks
Oil drain plug of oil pan is loose Tighten the oil drain plug
Bolts of oil pan are loose Tighten bolts
Coating of oil pan is uneven Re-glue
Oil pump seal is damaged Replace the oil pump gasket
Front and rear crankshaft oil seal are damaged Replace the seals
Oil pressure alarm is loose Tighten the oil pressure alarm
2. The piston ring is worn or damaged excessively Replace the piston ring
3. Piston and cylinder are worn Replace the piston or cylinder boring
4. Position of piston ring is not right Adjust the opening position of the piston ring
5. Valve seal is damaged the oil seal of valve
6. The valve rod or valve guiding pipe are worn badly Replace the valve or guiding pipe of valve
7. Ventilation device of crankcase is blocked Check, clean and clear
IX. Gasoline engine is too hot
Reason Debugging Method
1. Cooling water is short
Add cool water
2. Water pump belt is loose or damaged
Adjust the belt tension or replace belt
3. Water pump breaks
Repair or replace the water pump
4. Thermostat breaks
Replace the thermostat
5. Radiator, water jacket of the cylinder and pipeline is
Clean, repair or replace the parts
blocked or leaky

43
6. Deposited carbon is combustion chamber is too much Remove deposited carbon
7. Oil is too little or the viscosity is too low Add or replace oil
8. The exhaust system is not smooth Clean or replace exhaust system parts

X. It does not extinguish after closing ignition switch

Reason Debugging Method
Turn off the ignition switch after idling gasoline engine
1. Gasoline engine is too hot
makes the water temperature drop below 80 ℃
2. Spark plug is too hot
Select the spark plug with specified type
3. Deposited carbon is combustion chamber is too much
Remove deposited carbon
4. Ignition timing is improper
Adjust ignition timing
XI. Pressure of engine oil is too low
Reason Debugging Method
1. Oil leaks See 1 Chapter ** Expression is faulty **
2. Oil is too little or too thin Add or replace oil
3. Oil temperature is too high Cool gasoline engine, check cooling system
4. Oil pump valve breaks Repair reducing valve
5. Oil pump breaks Repair or replace oil pump
6. suction filter is blocked, oil pan leaks Clean dredge, tighten the oil pan bolts
7. Oil pressure alarm does not work Replace the oil pressure alarm
8. Main bearing, connecting rod bearing are excessively worn Replace the bush
9. Oil filter is blocked Replace the oil filter

XII. Fault indicating lamp of gasoline engine is constant on

Reason Debugging Method
1. Electronic fuel injection system breaks It shall be diagnosed by fault diagnosis tester (see Fault Code List)
2. Fault exists in cable Whether connectors are connected firmly and whether the cable shorts or
breaks shall be checked

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 XIII. Discharge is not qualified
Reason Debugging Method
1.Leaded gasoline is adopted so that oxygen sensor and catalytic converter are damaged Use the unleaded petrol and replace the oxygen
2. Ignition system fault causes that it lacks fire for a long time which damages the oxygen sensor sensor and catalytic converter
and catalytic converter. Check and replace ignition system, replace
3. Exhaust system leaks, electronic controller cannot get the correct oxygen sensor signal, resulting oxygen sensors and catalytic converters
in the dense air-fuel ratio Exhaust system shall be checked

XIV. Fault of clutch system

Reason Debugging Method
1. Clutch slides
Free stroke of clutch pedal is improper Adjust free stroke
Clutch is worn or there is oil stain Repair or replace the clutch disc
Clutch disc, pressure plate or flywheel surface is distorted Replace the clutch disc, pressure plate or flywheel
Diaphragm spring is weakened Replace the clutch cover
Clutch cable is corrosive Replace the cable
2. Clutch is hard to be separated
Free stroke of clutch is improper Adjust free stroke
Diaphragm spring or spring is worn Replace the clutch cover
There are rust marks on input splines Lubricate
Transmission input splines are damaged or worn Replace the input shaft
Clutch plate swingings seriously Replace the clutch disc
Clutch plates are damaged there is oil stain Replace the clutch disc
3. Clutch vibration Replace the clutch disc
Clutch plate show mirror phenomenon Repair or replace the clutch disc
Clutch plate is with oil stain Replace the separation bearing or clutch plates
Sliding for separation bearing on the bearing of input shaft is not smooth Lubricate or replace the bearing retainer of input shaft
Shimmy or contact of clutch plate is bad Replace the clutch disc
Torsion spring in clutch plates is weakened Replace the clutch disc
Rivet of clutch plate is loose Replace the clutch disc
Clutch cover or flywheel surface is distorted Replace the clutch cover or flywheel
Mounting pad of engine becomes weak , bolts or nuts are loose Retighten or replace the mounting pad

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4. Clutch makes noise
Separation bearing is worn or damaged Replace separation bearing
Bearing of front input shaft is worn Replace bearing of input shaft
Cooperation of transmission input shaft is too loose Replace clutch disc or transmission input shaft
Pressing plate and diaphragm spring are loose Replace clutch cover

5. Clutch bites
Clutch plate is worn seriously Replace the clutch disc
Exposed rivet is exposed Replace the clutch disc
Torsion spring is weaken Replace the clutch disc
XV. Fault of transmission system
Reason Debugging Method

1. Out of gear
Shift fork shaft is worn Replace
Shift fork or synchronizer sleeve is worn Replace
Elasticity of positioning spring is weakened or damaged Replace
Bearing on the input shaft or main shaft is worn Replace
Geer sleeve or chamfer teeth is damaged or worn Replace the cover and gear tooth
Cotter spring ring dislocates or falls off Replace

2. In gear
Elasticity of synchronizer spring is weakened or broken Replace
Shift shaft or shift fork is distorted Replace

3. Shift is difficult
Stroke of clutch pedal is incorrect Adjust
Friction disc of clutch plate is distorted or broken Replace
Clutch cover is damaged Replace the clutch cover
Synchronizer ring is worn Replace
Geer sleeve or chamfer teeth is damaged or worn Replace the gear sleeve or gear
Shift shaft is distorted Replace

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4. Noise
Volume of lubricating oil is not enough or the type is not proper Supplement or replace
Bearing is damaged or worn Replace
Gear is damaged or worn Replace
Synchronizer is damaged or worn Replace
Geer sleeve or chamfer teeth is damaged or worn Replace

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 Appendix I. Fault Code List
No. Fault Code Fault Code Information
1 P0030 Upstream oxygen sensor heating control circuit open circuit (Bank1)
2 P0031 Upstream oxygen sensor heating control circuit to ground short circuit (Bank1)
3 P0032 Upstream oxygen sensor heating control circuit for short circuit of power supply (Bank1)
4 P0036 Downstream oxygen sensor heating control circuit open circuit (Bank1)
5 P0037 Downstream oxygen sensor heating control circuit to ground short circuit (Bank1)
Downstream oxygen sensor heating control circuit for short circuit of power supply
6 P0038 (Bank1)
7 P0053 Upstream of the oxygen sensor heater resistance unreasonable (Bank1)
8 P0054 The lower the oxygen sensor heater resistance unreasonable (Bank1)
9 P0105 Air inlet pressure sensor signal without fluctuation
10 P0106 Inlet pressure sensor signal is not reasonable
11 P0107 Intake pressure sensor signal circuit voltage is too low
12 P0108 Intake pressure sensor signal circuit voltage is too high
13 P0111 Inlet temperature sensor signal is not reasonable
14 P0112 Intake air temperature sensor signal circuit voltage is too low
15 P0113 Intake air temperature sensor signal circuit voltage is too high
16 P0116 Engine coolant temperature sensor signal is not reasonable
17 P0117 Engine coolant temperature sensor circuit voltage is too low
18 P0118 Engine coolant temperature sensor circuit voltage is too high
19 P0122 Throttle position sensor 1 signal circuit voltage is too low
20 P0123 Throttle position sensor 1 signal circuit voltage is too high
21 P0130 Upstream oxygen sensor signal is not reasonable (Bank1)
22 P0131 Upstream oxygen sensor signal circuit voltage is too low (Bank1)
23 P0132 Upstream oxygen sensor signal circuit voltage is too high (Bank1)
24 P0133 Aging (Bank1) of the upstream oxygen sensor
25 P0134 Upstream oxygen sensor circuit signal fault (Bank1)
26 P0136 Downstream oxygen sensor signal is not reasonable (Bank1)
27 P0137 Downstream oxygen sensor signal circuit voltage is too low (Bank1)
28 P0138 Downstream oxygen sensor signal circuit voltage is too high (Bank1)
29 P0140 Downstream oxygen sensor circuit signal fault (Bank1)
Off line detection of air fuel ratio closed loop control self learning is not reasonable
30 P0170 (Bank1)
31 P0171 Off line detection of air fuel ratio closed loop control over self learning (Bank1)
32 P0172 Off line detection of air fuel ratio closed loop control over self learning (Bank1)
33 P0201 A cylinder injector control circuit fault
34 P0202 Two cylinder injector control circuit fault
35 P0203 Three cylinder injector control circuit fault
36 P0204 Four cylinder injector control circuit fault
37 P0261 A cylinder injector control circuit voltage is too low
38 P0262 A cylinder injector control circuit voltage is too high

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39 P0264 Two cylinder injector control circuit voltage is too low
40 P0265 Two cylinder injector control circuit voltage is too high
41 P0267 Three cylinder injector control circuit voltage is too low
42 P0268 Three cylinder injector control circuit voltage is too high
43 P0270 Four cylinder injector control circuit voltage is too low
44 P0271 Four cylinder injector control circuit voltage is too high
45 P0300 Multi cylinder fire
46 P0301 A cylinder is on fire
47 P0302 Two cylinder fire
48 P0303 Three cylinder fire
49 P0304 Four cylinder fire
50 P0321 The crank gear is not reasonable.
51 P0322 Speed sensor signal fault
52 P0327 Knock sensor signal circuit voltage is too low
53 P0328 Knock sensor signal circuit voltage is too high
54 P0420 Aging of oxygen storage capacity of three element catalyst (emission limit)
55 P0444 Control circuit fault of carbon canister control valve
56 P0458 Carbon tank control valve control circuit voltage is too low
57 P0459 Carbon tank control valve control circuit voltage is too high
58 P0480 Cooling fan relay control circuit fault
59 P0501 Vehicle speed signal fault
60 P0506 Idle speed control speed is lower than the target idle speed
61 P0507 Idle speed control speed is higher than the target idle speed
62 P0508 Step motor drive circuit voltage is too low
63 P0509 Step motor drive circuit voltage is too high
64 P0511 Stepper motor driver circuit fault
65 P0537 Air conditioning evaporator temperature sensor circuit voltage is too low
66 P0538 Air conditioning evaporator temperature sensor circuit voltage is too high
67 P0560 Battery voltage signal is not reasonable
68 P0562 System battery voltage is too low
69 P0563 System battery voltage is too high
70 P0627 Oil pump relay control circuit fault
71 P0628 Oil pump relay control circuit fault
72 P0629 Oil pump relay control circuit voltage is too high
73 P0645 A/C compressor relay control circuit fault
74 P0646 A/C compressor relay control circuit fault
75 P0647 A/C compressor relay control circuit voltage is too high
76 P0650 MIL lamp driver circuit fault
77 P0691 Cooling fan relay control circuit fault
78 P0692 Cooling fan relay control circuit voltage is too high
Air fuel ratio closed loop control over the upper limit of self learning value (middle load
79 P2177 area)

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80 P2178 Air fuel ratio closed loop control self learning value super lower limit (middle load area)
81 P2187 Air fuel ratio closed loop control over the upper limit of self learning value (low load area)
82 P2188 Air fuel ratio closed loop control over limit of self learning value (low load area)
83 P2195 Before the oxygen sensor is concentrated to dilute reaction (partial dilute Bank1)
Before the oxygen sensor dilute to the concentration of the reaction (partial concentration
84 P2196 of Bank1)
85 P2270 After the oxygen sensor is concentrated to dilute reaction slow (partial dilute Bank1)
After the oxygen sensor diluted to the concentration of the reaction (partial concentration
86 P2271 of Bank1)

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61 P 0563 Voltage of the system is high
62 P 0646 Clutch relay wire of air conditioner shorts to low voltage or breaks
63 P 0647 Clutch relay wire of air conditioner shorts to high voltage
64 P 0650 Fault indictor lamp breaks down
65 P 0685 Main relay breaks
66 P 0685 Main relay breaks
67 P 1167 Front oxygen is too thick when accelerating oil-break
68 P 1171 Front oxygen is too thin when accelerating or thinning
69 P 1336 Deviation of 58 gear is not learnt
70 P 2187 Oil system in idling working condition is too thin
71 P 2188 Oil system in idling working condition is too thick

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