Chery DA465Q-1A2/D User manual

CheryQQServiceManual 465EngineMechanicalSystem
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Chery Automobile Co., Ltd
CONTENTS
CHAPTER 1…………………………………………………2
CHAPTER 2…………………………………………………5
CHAPTER 3…………………………………………………21
CHAPTER 4…………………………………………………31
CHAPTER 5…………………………………………………34
CHAPTER 6…………………………………………………35
CHAPTER 7…………………………………………………37
CHAPTER 8…………………………………………………39
CHAPTER 9…………………………………………………41
CHAPTER 10……………………………………………… 43
CHAPTER 11……………………………………………… 45
CHAPTER 12……………………………………………… 46
CHAPTER 13……………………………………………… 49
CHAPTER 14……………………………………………… 50
CHAPTER 15………………………………………………51
CHAPTER 16………………………………………………52

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CHAPTER 1 Technical Parameters of Engine
1 Specification
1.1 Technical specification
Model DA465Q-1A2/D
Mode Four cylinders. Four stroke. Water-cooling. Inline.
.Breadthways. Overhead camshaft. EFI
Bore 65.5mm
Stroke 78mm
Pressure ratio 9. 0: 1
Displacement 1051m1
Nominal power 38.5kW（5200 r/min）[gross power]
MAX torque 83NZm（3000～3500r/min）[gross power]
MIX fuel consumption 275g/kwZh[gross power]
Nominal RPM 5200r/min
Idle speed 850±50r/min
Emissions
Idle speed CO≤0.5% HC≤100PPm DB11/044-1999
High idle speed
CO≤0.3% HC≤100PPm DB11/044-1999
Mode CO≤2.2 g/km HC+NOX≤0.5g/km EC 96
Strays GB 14023-2000
Steering Anticlockwise ( From opposite )
Spark advance angle 6°～7° [idle model]
Spark order 1－3－4－2
Oil pressure 0.294～0.539MPa（3.0～5.5kgf/cm2）3000r/min
Dimensions
length×width×height
Inclusive transmission 776×609×656.7mm
Not inclusive transmission 396×609×656.7mm
Weight Not inclusive transmission 98kg
Fuel 90#(RON90) or more GB19730-99 unleaded gasoline
Oil Environmental temperature >－20SF15W/40
<－20SF5W/30
Coolant quantity 4.5L

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Oil quantity 3.5L
Transmission oil Base on local temperature; select GL-4、or GL-5 Transmission oil；
quantity：2.1 L
Suction filter Dry type
Spark F6RTC
Generator Silicon rectify generator
Start-mode Electric start-up
Cooling method Pump circulation water-cooling
Lubricating method Pressure and splash compound
1.2 Oil pump
3000rpm 294 - 539kpa
1.3 Specification of fastener
Application Specification
Engine Metric(N.m)
Pulley bolt 95 + (30°- 45°)
Stretching pulley accessories bolt 26±4
Camshaft bracket cover bolt 8±2
Camshaft timing pulley bolt 45±5
Connect rod bearing cap bolt 28～32
Coolant temperature sensor Max 20
Crankshaft main bearing cap bolt 43-48
Cylinder head bolt 55-60
Engine flywheel bolt 40-45
Exhaust manifold nut 18-23
Engine mounting bracket set bolt 25±2.5
Knock sensor bolt 15-25
Intake manifold nut 18-23
Oil filter 12-16
Oil pan bolt 4-5
Oil pan drain plug 20-25
Oil pressure sensor 12-15
Oxygen sensor 40-60
Oil pump bolt 8-10
Spark plug 20-30
Left overhang of connecting front frame
side member
50±5
Engine left overhang gasket of
connecting transmission
40±5

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Engine rear overhang and vehicle body 100±5
Engine rear overhang and bracket 100±5
Engine right overhang and vehicle body 50±2.5
Engine right overhang and bracket 100±5
2 Engine lubricant
Viscosity of oil is decided by outer temperature of gasoline or diesel engine, it is acceptable
for engine temperature to be much higher or lower than given temperature in a short time. It
is necessary for the user not to make the engine working at high speed for a long time and it
is necessary for the user not to make the engine overloaded, if the temperature exceeding the
limit or the user uses low-viscosity oil such as SAE 5W-30.
Regulations
C = Conventional engine oil
NT=New Technological oil
Classification of viscosity — ACEA/API grade
Engine oil SAE Scope of Temperature Grade of Quality
From To ACEA Standard API Standard
Conventional
Engine oil
5W—30 -20 +20 A1/B1 A2/B2 SH SJ/CE CF
10W—30 -20 +20 A1/B1 A2/B2 SH SJ/CD CE
10W—40 -20 >+40 A2/B2 A3/B3 SH SJ/CD CE
10W—50 -20 >+40 A2/B2 A3/B3 SH SJ/CE CF
10W—60 -20 >+40 A2/B2 A3/B3 SH SJ/CE CF
15W—40 -15 >+40 A2/B2 A3/B3 SH SJ/CE CF
15W—50 -15 >+40 A2/B2 SG/CD
20W—40 -10 >+40 A2/B2 SF SG/CD
20W—50 -10 >+40 A2/B2 SF SG/CD
NT- New
technique
10W—30 -20 >+40 A3/B3 SJ/CF
10W—40 -20 >+40 A3/B3 SJ/CF
5W—30 <-30 >+40 A3/B3 SJ/CF
5W—40 <-30 >+40 A3/B3 SJ/CF
5W—50 <-30 >+40 A3/B3 SJ/CF

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0W—30 <-30 >+40 A3/B3 SJ/CF
0W—40 <-30 >+40 A3/B3 SJ/CF
Notice:
It is applicable only under the circumstance of ACEA and API standard being listed
ACEA standard can not replace API standard, on the contrary ,API standard can take the
place of ACEA standard.
Viscosity is not equal to quality.
CHAPTER 2 Diagnosis of the Engine
I Engine pressure test.
It can make sure the condition of piston ring 、valve and cylinder head gasket to carry out
compression pressure test for the engine cylinder.
1 The storage battery must be up to the standard of normal voltage or close to the normal
voltage if you want the operational temperature of engine to be normal.
2 Turn off the engine.
3 Stop ignition.
4 Stop fuel system.
5 Remove out all spark plugs.
6 Remove out vacuum pipe in throttle valve body.
7 Lock the throttle valve to be open with a limit stop.
8 Check the cylinder pressure according to the following steps:
You shall fix the pressure gauge in spark-plug hole, while the engine working along with the
starter, you should make the testing cylinders finish 4 compression strokes at least. You shall
examine and record the readings of every stroke pressure gauge, then throw out the pressure
gauge, as to the other cylinders, repeat above-mentioned steps to carry out the pressure test.
9 Record all pressure readings of all cylinders
Standard pressure of cylinder:1.32Mpa ( Rotational speed of engine shall be no less than
300r/min), pressure of every cylinder shall be no less than 1.10Mpa，pressure difference
between any two cylinders shall be no more than 0.098Mpa.
10 Example of possible testing results are introduced as follows:
a Pressure of all cylinders shall be steadily improved to approach the stipulated pressure
promptly, when the pressure is tested to be normal
b It is probably due to piston ring if pressure of the first stroke is too low, but it is showing
a tendency to go up in the afterwards strokes but not reaching the normal standard yet ,or
the pressure goes up obviously after three times being infected with oil.

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c It is probably due to valve if pressure of the first stroke is too low and it remains low in
afterwards strokes or the pressure keep the former state after being injected with oil.
d It is probably due to cylinder head gasket if pressure of two neighboring cylinders is too
low or there is some coolant in the crankcase.
11 Remove the limit stop from throttle valve plate
12 Install vacuum pipe to throttle valve body
13 Install spark plug
II General introduction to diagnosis of engine noise
Notice: Comparing with sound of other engines, you should make sure that you are not
giving a lot of trouble to maintain the normal one, because some engines have normal special
noise out of consideration of design.
The following 4 factors shall be considered when you make diagnosis of engine noise:
●Classification of noise
●Conditions for noise to happen
●Frequency for noise to happen
●Position for noise to happen in the engine
Noise of engine is usually synchronous with engine speed(results from connecting rod or
piston)or half of engine speed(valve train).You should try to make sure frequency of the
noise.
1 Main bearing noise
Noise results from main bearing damage or wear is just like the sound of thud or knocking ,
it happens once every circle that the engine rotate, the noise comes to maximum when the
engine works with heavy load, knock of interval knocking sound which is much more
piercing than the main bearing wear noise, shows that clearance of crankshafts is too big.
The following conditions can lead to main bearing noise:
lThe pressure of oil pump is too low.
lThe oil is too thin or/and the oil filter is too dirty.
lThe clearance of main bearing is too big.
lThe end clearance of crankshaft is too big.
lThe shaft journal of crankshaft is out of round.
lBelt tension is too high.
lCrankshaft pulley is not tight enough.
lMain bearing cover is not tight enough.
lDriving belt pills.
2 Connecting rod bearing noise
Sound of knocking is generated at all speed under the condition of connecting rod bearing
being damaged or wear ,connecting rod noise and knocking sound of piston or looseness of
piston pin may be confused together easily in early stage of connecting rod bearing damage,
knocking sound of connecting rod will become louder along with engine speeding up, this
noise comes to maximum while decelerating.
The following circumstances can be the cause of noise:

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lBearing clearance is too big.
lCrankshaft connecting rod journal wear
lThe oil is too thin or/and oil filter is too dirty
lOil pressure is too low
lThe shaft journal of crankshaft connecting rod is out of round.
lConnecting rod malposition
lConnecting rod nut fixed torque is not correct
lBearing shell is not correct or bearing shell is malposition
3 Piston noise
It is hard to distinguish the noise generated by piston pin or connecting rod, loose of piston
pin may result in sharp double knocking sound, usually, it can be heard when the engine is
idling or the engine speeds up suddenly then slow down; the piston pin will be ticking
slightly if the piston is installed not properly, the noise becomes more obvious if the engine
works without heavy load; too much clearance between piston and cylinder liner will result
in sound of knocking the cylinder from inside, this kind of noise is similar to metal knocking
sound, just like the piston slap the cylinder shell from inside during the process of stroke.
Engine noise slowing down after warming up is a sign for piston to slap cylinder, there is too
much clearance between piston and cylinder liner when the engine is cold, sound of slaping
is much louder.
The following circumstance can lead to piston noise:
lPiston pin wear or too loose
lPiston pin is installed not properly.
lThere are too much clearance between piston and cylinder liner.
lLubrication is not enough.
lThe carbon deposit at piston crown knocks cylinder head.
lPiston ring groove wear or fracture
lPiston fracture
lConnecting rod malposition
lPiston ring wear or damage
lThe clearance of piston ring groove is too big.
lThe clearance of piston ring ends is not enough.
lPiston malposition is at a angle of 180 degree
lThe shape of piston skirt is not correct.
4 Flywheel noise
Check whether or not the flywheel is loose or cracked according to the following steps:
4.1 Drive the vehicle at the speed of 32 km/h.
4.2 Turn off the engine
The flywheel may be loosened or damaged if you hear the kind of pinging sound, this kind
of pinging sound comes to maximum while decelerating. Bearing knocking sound can result
from looseness of bolts. It depends on stability of idling to generated how much slapping
sound when the engine is idling at high speed, the noise can be made or can not be made if
transmission drive put into gear. Check the connecting bolts between transmission and
flywheel, crankshaft and flywheel first, before make sure whether or not there is some

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relationship between the knock and bearing.
5 Valve train noise
Valve train malfunction can be shown by means of slight slapping sound of any frequency or
frequency is equal to half of engine speed, the noise will go up along with acceleration of the
engine.
First, warm up the engine before judging the valve train noise, so as to make the engine parts
expand to normal state. Listen to engine noise under the circumstance of engine cover being
shut.
Remove out the rocker arm head ,make sure the parts of valve train which result in noise
with stethoscope, if the noise of valve train is abnormal. The cause of noise are introduced as
follows:
lValve spring fracture, resiliency of valve spring is not enough.
lValve is blocked or curved
lRocker is curved
lThe cam of camshaft is damaged or poor performance.
lLubrication of valve train is not good or oil pressure is too low.
lThe clearance of valve stem and valve guide pipe is too big.
lValve guide pipe wear
lPush rod wear
lValve rocker wear
lBolt of valve rocker fracture
lAuxiliary parts of valve rocker is too loose or wearing.
III Diagnosis of engine noise
1 Exhaust gear
Symptom Cause of malfunction/ Troubleshooting
Vibration or quack
noise of exhaust
system
Looseness or malposition of exhaust parts, you can carry out
the following procedures:
1 Align the joints.
2 Fasten the joints.
3 Check to see whether or not exhaust lifting hook , mounting
bracket and clamp are damaged.
Waste gas leak or
noise
The following conditions can result in waste gas leak or noise:
lExhaust parts joints or connection leak.
lTighten clip or connecting parts to regulated torque.
lInstallation of exhaust system is not correct or malposition.
lAlign and tighten the clip.
lThere are some cracks on the exhaust manifold.
lLeakage between exhaust manifolds or between the
cylinder heads.
lFasten the exhaust manifold on the cylinder head according

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to the regulation
lTighten or replace exhaust manifold washer.
lExhaust expansion connection parts damage or wear.
lReplace parts if necessary.
lExhaust pipe is burned or rusty.
lReplace the exhaust pipe if necessary.
lMuffler is damaged or burned.
lReplace the muffler assembly.
lExhaust clip and/or bracket are damaged or loosened.
lReplace the parts if necessary.
2 Valve train
Symptom Cause of malfunction/Troubleshooting
There is some noise while
idling, the noise becomes
lounder when the rotational
speed is much higher.
This kind of noise has nothing to do with malfunction
of tappet, it is becomes more obvious under low gear
speed of 10-15 km/h, this kind of noise sounds just
like ticktack, the following condition can result in this
kind of noise:
lValve end or Valve rocker gasket wear
lClearance of valve stem and valve guide is too
big.
lRadial run-out of valve seat is too remarkable.
lRadial run-out of valve working surface is too
remarkable.
lMalposition of valve spring
1 Rock the engine until the nosing valve depart from
the valve seat.
2 Rotate valve spring and valve
3 If the noise is corrected ,check the valve spring to
see whether or not it is in malposition. If the
malposition exceeds the limit, replace the valve
spring.
Driving at high-speed ,there is
some noise, while driving at
low-speed, the noise disappear.
High-speed driving noise may result from the
following condition:
Oil level is too high. If oil level is higher than FULL
(full mark),crankshaft balancer will stir the oil into
foams, when the foam is pumped into the tappet, the

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tappet will make noise. Make the oil being put in
correct oil level.
Oil level is too low.
If oil level is lower than ADD(add mark),the
atmosphere will be pumped in by oil pump, it will
result in tappet noise, add oil if necessary.
lOil pump filter screen is bent or too loosened.
Noise which has nothing to do
with engine speed.
Check the following circumstances:
lLubricating system of rocker.
lRocker ball wear.
lRocker is bent or damaged.
lValve rocker is too loosened or damaged.
3 Abnormal noise diagnosis of engine
Symptom Cause of malfunction/Troubleshooting
There is some knocking
sound while starting ,but
only continue several
seconds.
Oil viscosity is not suitable.
Use suitable oil viscosity according to estimated
temperature, see the maintenance and lubrication for
reference.
knocking continue 2-3
minutes while engine is cold
Engine cold start pinking sound usually disappears when
the specified cylinder secondary ignition circuits connect
the ground. Check the engine to see if it is under the
following circumstances:
lCrankshaft balancer or drive pulley is loose or
broken.
lTighten or replace parts if necessary
lClearance of piston and cylinder liner is too big.
Check the parts of piston, replace if necessary
lConnecting rod is bent

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Knocking noise while idling
heat start
Check the engine to see if it is under the following
circumstances:
lDriving belt wear
lCheck tension , replace driving belt if necessary.
lThe compressor of air condition system
lReplace parts if necessary .
lOil viscosity is not suitable.
lUse oil with suitable viscosity according to estimated
temperature, see maintenance and lubrication for
reference.
lPiston pin clearance is too big.
lReplace piston and piston pin if necessary.
lCalibrate location of connecting rod
lCheck connecting rod, replace if necessary.
lClearance of piston and cylinder liner is not enough.
lBore cylinder , install new piston
lAdjust looseness or torque of crankshaft balancer.
lReplace wearing parts
lMake sure that the direction of piston pin is right.
lInstall piston correctly.
Slight pinking sound while
heat start.
Check to see if the engine is under the following
conditions:
lDetonation or ignition knock
lSee engine control system for reference.
lExhaust manifold leak gas.
lFasten bolt or replace gasket
lClearance of connecting rod bearing is too big.
lReplace connecting rod bearing if necessary
Severe knocking sound Check to see if the engine is under the following

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while increasing the torque. circumstances:
lCrankshaft balancer or pulley nave is broken.
lReplace parts if necessary
lTransmission belt of auxiliary is too tight or there are
some scratching marks on it.
lReplace driving belt if necessary
lFlywheel is broken.
lReplace flywheel
lClearance of crankshaft main bearing is too big.
lReplace parts if necessary.
lClearance of connecting rod bearing is too big.
lReplace parts if necessary
4 Diagnosis of driving belt noise
Step Operation Yes No
The following circumstances indicate that there is whispering noise:
lThere is a high pitch noise when drive belt or pulley rotate every circle.
lIt usually happens in cold and damp morning.
lSprinkle some water on the drive belt for confirmation, the noise should stop
immediately.
1
Check to see whether or not the belt pulley is
malposition.
Check to see if there are any belt pulleys are
malposition?
To step2 To step3
2
Fix position of the belt pulley which is
malposition once again, to see whether or not
there is still any whispering noise?
To step3 System normal
3
Check to see whether or not the bracket is bent
or broken.
Are there any bent or broken bracket?
To step4 To step5
4Replace the bent or broken bracket
Is there any whispering noise? To step5 System normal
5
Check to see whether or not the fastener is
loose or lost.
Is there any loose or lost fasteners?
To step6 System normal
6Fasten any loose fasteners.
Lost fastener should be replaced immediately. To step7 System normal

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See the specification of fastener for reference.
Is there still any whispering noise?
7
Check to see whether or not the belt pulley
flange is bent.
Is there any bent belt pulley flange?
To step8 To step9
8Replace belt pulley.
Is there any whispering noise? To step9 System normal
9
Check to see if there are severe hollowness
exceeding 1/3 depth of the belt groove.
Is there any severe hollowness?
To step10 —
10
Replace driving belt.
See the “Replacement of driving belt” for
reference.
—System normal
5 Screaming noise of driving belt
Step Operation Yes No
Definition: The following circumstances indicate there are some screaming noise.
lSharp noise usually happens in the multi-rib driving belt result from driving belt
slipping.
lBlocking or sliding phenomenon of A/C system compressor connecting throttle
happens when driving belt is overloaded, there is some noise.
1
Check to see whether or not the belt pulley is
malposition.
Is there any malposition belt pulley?
To step3 To step2
2
Check to see whether or not the length of driving
belt is correct.
See “Replacement of driving belt” for reference.
Is the length of driving belt is correct or not?
To step4 To step5
3
Repair it or replace with new parts according to
the request.
Is the maintenance completed?
System
normal —
4
Make a test to see whether or not the tensioner
works normally.
Does the driving tensioner work normally?
To step3 To step5
5 Check to see whether or not the size of belt pulley
is correct.
Check to see if the size of all belt pulley is correct
or not.
To step6 To step3
6 Check to see if the bearing is blocked badly or To step3 System normal

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whether or not there are some blocked bearing.
6 Hooting noise of driving belt
Step Operation Yes No
Definition: Successive high pitch noise can be generated because of bearing malfunction.
1
Check to see whether or not there is some damage
of accessories bearing.
Is there any noise resulting from the bearing?
To step2 System normal
2Install new parts according to the request.
Is the maintenance completed?
System
normal —
7 Rumbling noise of driving belt
Step Operation Yes No
Definition: Low and deep slapping noise may be resulted from malposition of driving belt.
This kind of noise happens while idling cold .
One low-frequency noise can be heard when the driving belt rotate every one circle.
1
Check to see whether or not there is any severe hollowness.
Is there any severe hollowness exceeding 1/3 depth of the belt
rib?
To step2 System
normal
2Clean belt pulley of driving belt.
Is the maintenance completed?
System
normal To step3
3
Install new driving belt, see “replacement of driving belt” for
reference.
Is the maintenance completed?
System
normal —
8 Diagnosis of driving belt vibration
Step Operation Yes No
Definition: Vibration has something to do with the engine speed, vibration may be sensitive
to the accessories load.
1
Check to see whether or not the driving belt is wearing,
damaged, accumulated dusts or losing reinforcement.
Is there any damage or wear of the driving belt?
To step2 To step3
2
Replace the parts accordingly, see the replacement of
transmission belt” for reference. do you finish the
maintenance?
To step3 —
3 Check to see whether or not the fastener is loose or lost. To step4 To step5

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Is there any loose or lost fastener?
4Fasten it or replace new parts according to the actual request.
Is the maintenance completed?
System
normal —
5
Check to see whether or not the belt pulley is damaged or
bent.
Is there any damage of driving belt?
To step6 To step7
6Repair it or replace with new parts according to the need.
Is the maintenance completed?
System
normal —
7Check to see whether or not the tensioner works normally.
Does the tensioner work normally or not? To step9 To step8
8
Replace it accordingly, see “Replacement of tensioner of
driving belt” for reference.
Is the maintenance completed?
System
normal —
9
Check to see whether or not the bracket is loose, bent or
broken.
Is there any loose or bent or broken bracket?
To
step10
System
normal
10 Repair it or replace bracket if necessary.
Is the maintenance completed?
System
normal —
9 Diagnosis of driving belt out of position
Step Operation Yes No
Definition: The following circumstances may result in driving belt out of position.
1
Check to see whether or not the belt pulley is
malposition or bent。
Is the belt pulley malposition?
To step2 To step3
2Replace belt pulley of malposition or being bent.
Is the driving belt out of position or not? To step3 System normal
3
Check to see whether or not the bracket is bent
or broken。
Is there any bent or broken brackets?
To step4 To step5
4Replace the damaged bracket.
Is the driving belt out of position or not? To step5 System normal
5
Check to see whether or not the fastener is
loose or lost.
Is there any loose or lost fasteners?
To step6 To step7
6
Replace lost fastener , fasten it according to the
regulations.
See “Specification of fastener” for reference.
Is the driving belt still out of position or not?
To step7 System normal
7
Check to see whether or not the pulley of power
steering-wheel pump is malposition。To step8 To step9

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Is the pulley of power steering-wheel pump is
malposition or not?
8
Realign or replace pulley of power
steering-wheel pump，
See “Replacement of pulley of power
steering-wheel pump” for reference.
Is the driving belt still out of position or not?
To step9 System normal
9
Check to see whether or not the transmission
belt is damaged。
Is the driving belt damaged or not?
To step10 To step11
10 Replace driving belt
Is the driving belt still out of position? To step11 System normal
11
Check to see whether or not the tensioner of
driving belt works normally.
Is the operation of tensioner of driving belt
normal or not?
–To step12
12
Replace the tensioner of driving belt, see
“Replacement of tensioner of driving belt” for
reference.
Is the driving belt still out of position?
–System normal
10 Diagnosis of driving belt severe damage and wear
Step Operation Yes No
Definition: Driving belt outside reinforcing rib wear results from installation of driving belt is
not correct.
1
Check to see whether or not the reinforcing
driving belt accord with the guide slot of belt
pulley?
—To step2
2
Replace the driving belt.
See “Replacement of driving belt” for
reference.
Is the maintenance completed?
System normal —
11 Diagnosis of engine misfire
Check Operation

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The following diagnosis touches upon the common problems or possible causes.
You can fix a breakdown through adjustment and maintenance or replacement according to the
request, after carrying out the correct diagnosis.
This malfunction diagnosis schedule will be helpful for diagnosing engine misfire resulting
from mechanism problems such as camshaft malfunction, bearing wear or being damage and
connecting rod being bent.
This schedule doesn’t include the driving elements malfunction such as injector malfunction.
Check the motive system inside diagnosis system
You should check the initial information first, then contrast the specified classification while
carrying out the basic diagnosis of engine misfire according to this schedule.
Initial check
1.Check the following conditions with eyes:
lEngine flywheel or crankshaft pulley looseness or installation is not
correct.
lThere are some damaged or malpositioned parts of driving system.
2. Listen to the inside of engine to see whether or not there is any
abnormal noise.
3. Check to see whether or not the oil pressure of engine is suitable
4. Check to see whether or not the oil consumption is too much.
5. Check to see whether or not the coolant consumption of engine is too
much.
6. Do compression test for the engine.
Inlet manifold leak
Inlet manifold which generates vacuum leakage will cause misfire of
engine
Check the following conditions:
lVacuum hose pipe installation is not correct or damaged
lThere are something wrong with the inlet manifold or gasket or
installation is not correct
lThere are some cracks or damage in the inlet manifold, throttle or
gasket installation is not correct.
lInlet manifold warp
lThe sealing surface of cylinder head warp or being damaged.
Coolant
consumption
Coolant consumption may be but not certain result in engine over heated
Check the following circumstances:
lCoolant leak
lCylinder head gasket fault
lCylinder head warp
lThere are some cracks on the cylinder head.
lEngine body is damaged.
lThe length of cylinder head bolt is not correct.
Fuel consumption
1 Fuel consumption may be but not certain result in engine misfire.
2 Remove out spark plug and check to see whether or not there is any oil
stain in the spark plug.
3 Carry out cylinder pressure test or cylinder leakage test.

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4 Check the following conditions if the cylinder pressure test shows that
there is any damage of valve or valve guide:
lValve stem seal wear, chip or installation is not properly.
lValve guide wear
lValve stem wear
lValve or valve seat wear or burnt.
5 Check the following conditions if the test indicating piston ring wear or
being damaged:
lPiston ring fracture or installation is not correct.
lEnd clearance of piston ring is too big.
lBore wear or taper is too big.
lCylinder is damaged.
lPiston is damaged.
There is some
abnormal noise
inside the engine.
1 Make sure if the noise accords with the rotational speed of crankshaft or
camshaft while the engine is working.
2 The timing lamp sounds twice every flash ,that is the rotational speed of
crankshaft; the timing lamp sounds just once every flash ,that is the
rotational speed of camshaft.
3 Check the following circumstance if the noise is the same as the
frequency of camshaft rotational speed:
lValve train missing or loose.
lValve rocker wear or looseness
lMalfunction of valve spring
lValve being bent or being burnt
lCam of camshaft wear
lCheck to see if timing belt or pulley wear or being damaged.
4 Check the following conditions if the frequency of knock is the same as
the crankshaft rotational speed:
lThe main bearing of crankshaft or connecting rod bearing wear
lPiston or cylinder wear
lPiston or piston pin wear
lMalfunction of connecting rod.
lThere is too much Carbon deposit on piston crown
There is no
abnormal noise
inside the engine.
1 Check to see if the timing belt or pulley is wear or installed not properly.
2 Remove valve rocker cover of engine side whose cylinder is misfiring.
3 Check the following conditions:
lThe bolt of valve rocker is too loose
lPush rod is bent
lMalfunction of valve spring
lValve wear or installation is not good.
lCam of camshaft wear

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IVFuel consumption
1 General description
Engine oil consumption of engine refers to amount of oil used, never to confuse fuel
consumption and oil leakage of oil pan and cylinder head.
Engine oil is used for:
1.1 Depart the contacting surface away with oil film, prevent dry friction.
1.2 Conduct heat generated from friction
1.3 Bring the residue after burning away.
It is necessary to consume certain amount of oil in order to achieve above-mentioned
aims, in other words ,it is not realistic to find a engine without oil consumption.
Generally speaking, amount of oil consumption is small, it is ok to add a little oil during
the period of replacing oil, even through you may not add the oil. Of course, you must
add the oil if oil level is lower than the minimum mark of oil consumption indicator.
Also, you should make sure that fuel level is not higher than maximum mark, otherwise
oil consumption will be more.
Generally speaking, oil consumption becomes stable after the vehicle driving several
kilometre therefore, oil consumption measurement shall be carried out after vehicle
driving 7500 km. Before measurement, you should make sure that the engine doesn’t
lose fuel because of leakage.
Dipstick is used only for the purpose of inspection not for measurement. The engine
must be turned off at least 2 minutes before checking oil level, it may be the cause of
manufacturing tolerance if you add enough oil but the level is not reaching the maximum. It
shows that oil is overused if vehicle driving 100 km consuming more than 0.075 L oil,
causes and solutions of oil being overused are introduced as follows:
●Oil consumption indicator doesn’t have good function. Please make vehicle level, check oil
level and spend some time to make the oil subside.
●Oil viscosity is not suitable. Please use recommended SAE according to local temperature.
●Successive high-speed driving
●Heavy load drawing, such as towed vehicle. Please decrease oil mileage .
●The performance of ventilation system of crankcase is not effective.
●Oil leak. Please fasten bolts if necessary, replace gasket and seal gasket if necessary.
●Valve guide or oil seal wear or lost. Please install enlarge sized valve and/or new oil seal.
●Piston ring fracture or wear
●Piston ring or seat is installed not properly or correctly
●Installation or assembly of piston is not good.
●Cylinder head gasket and oil outlet hole is blocked.
2Measuring method of fuel consumption
2.1 Make vehicle level when checking, temperature of engine is not less than 80 .
2.2 Make engine idling before draining the engine fuel.
2.3 Turn off the engine immediately after drainage ,record the drainage time (3 minutes)
with chronograph, test should show that drainage should be completed within 3

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minutes.
2.4 Displace oil to state of guttate.
2.5 Cool the engine oil of displacement to 20 for 1 to 2 hours.
2.6 Measure oil amount after cooling with measuring graduated flask . Refill enough new
oil accordingly. You should subtract 0.25 litre fuel because the oil filter is not replaced.
2.7 These oil is enough for the driver to drive at least 500 km/350 miles. The driver should
keep his/her own normal route and driving style.
2.8 Repeat above-mentioned procedures from 1 to 4 afterwards, drainage time is the same.
2.9 Consumption amount of oil in graduated flask is oil consumption or mileage
consumption of engine.
3. Diagnosis and test of fuel pressure
The following conditions may cause low temperature of oil or oil without pressure. If oil
level is too low, fill the oil to the oil level of the indicator.
Oil pressure switch is not correct or the performance is not good. Please replace the
switch.
oil viscosity is not correct or oil being diluted
-Please use new oil with suitable viscosity according to estimated temperature.
-Please use new oil if the old one being diluted.
-Oil pump wear or too dirty ,clean or replace the oil pump.
-Oil filter is blocked. Please replace the oil filter.
-There are some holes in the connecting rod oil dipper. Please replace the connecting
rod oil dipper.
-There are too much clearance between the bearings. Please replace the bearing.
-There are some holes in the passage or the passage being blocked. Please repair or
replace the engine block.
- Oil groove plug lost or not properly installed. Please install or maintain it if
necessary.
- Pressure regulating valve is blocked. Please check the pressure regulating valve to
see whether or not it is blocked in the hole, check to see whether or not there are
some scores and fins in the hole.
- Valve guide wear. Repair if necessary.
Start the engine under the running temperature of more than 80 .
Take off the oil pressure switch.
Oil pressure test, see the arrows in screw hole.
Measure oil pressure 0.294-0.539 Mpa (3000 r/min)
Take off oil manometer and adaptor.
Install oil pressure switch properly.
Fill enough oil to maximum of oil gauge.
Notice: Oil temperature is decided by corresponding engine load, the temperature can be
150 under extremely heavy load.