FAW CA4, GA5 Repair Manual

Tianjin FAW
		CA4GA5 Engine Maintenance Manual
	Contents
Chapter 1 Technical Parameters and Maintenance Preparation Data of Engine ......................			2
Section 1	Technical Parameters of Engine ......................................................................		3
Section 2	Maintenance Preparation .................................................................................		5
Section 3	General Maintenance Parameters ....................................................................		8
Section 4 Engine Maintenance ......................................................................................			14
Chapter 2 Engine Structure ...........................................................................................................			16
Section 1	Cylinder block, cylinder head and crank connecting rod mechanism ...........		17
Section 2 Valve actuating mechanism ...........................................................................			24
Section 3	Lubrication System........................................................................................		29
Section 4 Cooling System..............................................................................................			33
Section 5	Intake and Exhaust Systems ..........................................................................		35
Section 6 Fuel System ...................................................................................................			38
Section 7	Ignition System ..............................................................................................		40
Section 8	Other sensors and other actuating mechanism...............................................		42
Chapter 3 Engine Adjustment and Maintenance.........................................................................			44
Section 1 Engine Adjustment ........................................................................................			45
Section 2	Engine Maintenance When Engine is Installed on the Vehicle.....................		49
Section 3 Engine Adjustment and Maintenance ............................................................			62

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Tianjin FAW

CA4GA5 Engine Maintenance Manual

	Chapter 1
	Technical Parameters and Maintenance
	Preparation Data of Engine
Section 1	Technical Parameters of Engine ...............................................................................................................	3
Section 2	Maintenance Preparation ..........................................................................................................................	5
Section 3	General Maintenance Parameters .............................................................................................................	8
Section 4	Engine Maintenance ...............................................................................................................................	14

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Tianjin FAW

CA4GA5 Engine Maintenance Manual

Section 1 Technical Parameters of Engine

Engine model: CA4GA5

Displacement: 1.497 L

Bore ×stroke: 73×89.4 mm

Compression ratio: 10.2: 1,

Rated power/rotating speed: 75kW/6000r/min

Maximum net torque/rotating speed: 135N.m/4400r/min

Fuel specification: octane number above 93# unleaded gasoline or 93# ethanol gasoline and above. Engine dimension (L*W*H): 421*554*637 (mm)

Note: The length refers to the distance from rear end of cylinder block to front end of crank pulley;

The width refers to the distance from the outermost end of left side to that of right side when the engine is in upright state.

The height refers to the distance from the highest point to the lowest point of the engine when the engine is in upright state.

Net weight of engine (cooling compressor power steering pump and combination bracket are excluded): 104Kg Valve timing

Intake valve opening: 38°before TDC~12°after TDC.

Intake valve closing: 22°~72°after BDC.

Exhaust valve opening: 48.5°before BDC.

Exhaust valve closing: 5.5°after TDC

Lubrication system volume

Total volume of lubrication system: 4.0L.

High level oil volume of engine oil pan: 3.5L.

Low level oil volume of engine oil pan: 2.5L

Cooling system:

Use the coolant containing water (at 20 , PH is 6.5-8.5) and ethylene glycol. Pure water is not allowed. Coolant volume percentage

Ethylene glycol content	Corresponding water content	Protection temperature
Min. 35%	65%	-20
40%	60%	-24
Max. 45%	55%	-31

The maximum allowed temperature of engine coolant: 110 .

Coolant alarm temperature: 115 .

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		Tianjin FAW				CA4GA5 Engine Maintenance Manual
	Temperature regulation range of thermosistor:
	Opening temperature: (82±2) ; full-open temperature: 95 .
	Maximum lift of the thermosistor: ≥8mm.
	Alternator:
	Generator type: integrated alternator.
	Voltage (V): 13.5±0.1.
	Output current (refer to the table):
				Generator output current
		Output current (A)					Engine speed (r/min)
		Cold state			Hot state
		≥35			24~27		1800
		≥45			31~34		2000
		≥77			≥65		6000
	Engine speed: 1000~18000(r/min).

Operating temperature of the generator: -40 ~105 .

Generator weight: 4.1kg.

Note:

Cold state: the state when the generator starts to work.

Hot state: the state after the generator works for 30 minutes.

Multi-wedge belt (belt pulley slot type): 6PK

Starter

Electromagnetic operation forced engagement.

Rated voltage: 12V;

Nominal power: 1.1kW (20 ).

Operating temperature of the starter: -40 ~120 .

Emission control standard: National III and IV

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CA4GA5 Engine Maintenance Manual

Section 2 Maintenance Preparation

1.Maintenance Notes (refer to CA4GA1 Engine Maintenance Manual)

2.Maintenance preparation notes

(1) Mechanical part of the engine

Special maintenance tools

	No.	Description		Location
			Main body
		Special fixture for installing	Spring
	1		“C” bushing	Piston rod
		and removing piston pin
			“M” guide rod
			“N” guide rod
	2	Piston tool		Piston
	3	Adjustment tool for spark plug		Spark plug clearance
	Recommended tools
	No.	Description		Location
	1	Disassembling tool for valve guide pipe		Valve guide pipe
	2	Disassembling tool for valve stem oil seal		Valve stem oil seal
	3	Press-mounting tool for valve lock clamp		Valve lock clamp
	4	Attachment
	5	Cylinder head bolt wrench joint		Cylinder head bolt
			Fixing tool for crankshaft and
	6	Disassembling fixture for crank	flywheel	Crank pulley
		pulley	Disassembling bar for crank
			pulley
			Main body
			Spring
	7	Special fixture for piston pin	“C” bushing	Piston rod
			“M” guide rod
			“N” guide rod
	8	Disassembling tool for rear oil seal of crankshaft		Rear oil seal of crankshaft
	9	Disassembling tool for front oil seal of crankshaft		Front oil seal of
				crankshaft
	10	Disassembling tool for engine oil filter		Engine oil filter
	11	Valve clearance adjustment tool	Valve tappet pressure clamp	valve clearance
		kits	Feeler gauge
	12	Fixing fixture for crank pulley		Crank pulley
	13	Hose plug		All hoses
	14	Fuel pressure gauge		Fuel pressure
			Disassembling tool for water
			pump bearing
			Disassembling tool for water
		Disassembling tool for water	pump seals
	15		Disassembling tool for water	Water pump
		pump
			pump rotor
			Receiving tool for water pump
			bearing
			Water pump bearing base plate
	16	Engine overhaul bracket		Engine
	17	Engine overhaul connection bracket		Engine
	18	Flywheel locking tool		Flywheel
	19	Disassembling fixture for cylinder head		Cylinder head

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CA4GA5 Engine Maintenance Manual

20

Engine slings

Engine

21

Piston tool

Piston

22

Sealant gun

All kinds of sealant

23

Disassembling tool for clutch housing and pressure plate

Clutch housing and

pressure plate

24

Stainless steel wire wiper

Remove sealant and

25

Scraper knife

carbon deposit etc.

26

Disassembling tool for engine oil pan

Engine oil, rear oil seal

seat assembly etc.

27

Screwdriver (flat head screwdriver, Phillips screwdriver)

28

spark plug wrench

Spark plug

29

Radiator cover tester

Radiator cover

30

Measuring tool for cylinder bore

Cylinder bore

31

Chamfering reamer for cylinder hole

Cylinder hole

32

All kinds of casing heads

Bolt and nut

Equipments

No.

Description

1

Straightening tool for connecting rod

2

Expanding tool for piston ring

3

Compressing tool for piston ring

Special sealant

No.

Location

Sealant type

Remark

1

Stud – install engine front support

TB1322

Apply the sealant on the end connecting

bracket

with cylinder head

2

Cylinder block sand outlet hole bowl-

TB1386D

Apply the sealant on the edge of the plug

type plug

3

Cylinder block main oil channel bowl-

TB1386D

Apply the sealant on the edge of the plug

type plug

4

Hexagon head tapered screw plug-at

TB1110B

Apply the sealant on plug screw thread

drainage hole of cylinder block

5

Cylinder head sand outlet hole bowl-

TB1386D

Apply the sealant on the edge of the plug

type plug

6

Rear oil seal seat assembly for

TB1280E

Apply the sealant on rear oil seal seat

crankshaft

surface of crankshaft

7

Stud - intake manifold

TB1322

Apply the sealant on the end connecting

with cylinder head

8

Stud – exhaust manifold

TB1322

Apply the sealant on the end connecting

with cylinder head

Apply the sealant on the bottom of cylinder

9

Engine oil pan assembly

TB1280E

block, applied diameter is determined by

testing

10

Joint surface of engine oil dipstick pipe

TB1280E

Apply the sealant on the head of engine oil

and cylinder block location hole

gauge pipe

11

Joint – engine oil filter

TB1110B

Apply the sealant on the end connecting

engine oil filter

12

Stud - install idler assembly

TB1322

Apply the sealant on the end connecting

with cylinder head

13

Chain chamber cover assembly

TB1280E

Apply the sealant on chain chamber cover

surface

14

Engine water inlet pipe seat assembly

TB1280E

Apply the sealant on engine water inlet pipe

seat surface

15

Engine water outlet pipe

TB1280E

Apply the sealant on engine outlet pipe

surface

16

Studinstall engine water inlet pipe seat

TB1110B

Apply the sealant on threads

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				Tianjin FAW			CA4GA5 Engine Maintenance Manual
			assembly
	17		Coolant temperature sensor assembly			TB1110B	Apply the sealant on threads
	18		Engine oil pressure alarm assembly			TB1110B	Apply the sealant on threads
	19		Relief valve assembly			TB1110B	Apply the sealant on threads
	20		Studchain tensioner assembly			TB1322	Apply the sealant on threads
	21		Chain lubrication nozzle			TB1110B	Apply the sealant on threads
	22		Cylinder gasket assembly			TB1280E	Apply the sealant on cylinder block front
							end top surface edge
	23		Drain plug assembly			TB1280E	Apply the sealant on drain plug assembly
							thread.
	(Note)		1. Sealant manufacturer recommends using products Three Bond Chemical Industry Co., Ltd..

2.When applying sealant on the threads, do not apply it on the first two threads.

3.When applying sealant on sealed oil channel and water channel, do not squeeze sealants into water channel or oil channel to prevent them from being blocked.

Comparison of CA4GA5 and CA4GA1 Engine Changing Parts

	No.	Part description	Changing point	Remark
	1	Cylinder block	1. Height increase
			1. Crank arm lengthened	Crankshaft diameter
	2	Crankshaft	2. Connecting rod shaft diameter
				unchanged
			enlarged
	3	Piston	Top pit enlarged
	4	Connecting rod	Big end hole enlarged
	5	Upper bearing shell for	Connecting rod shaft diameter
		connecting rod	enlarged
	6	Lower bearing shell for	Connecting rod shaft diameter
		connecting rod	enlarged
			1. Intake valve seat
	7	Cylinder head assembly	2. Exhaust valve seat
			3. Lift changing
	8	Spark plug	Heat value changing	Model and clearance
				changing
	9	Intake valve	Dimension enlarged
	10	Exhaust valve	Dimension enlarged
	11	Intake camshaft assembly	Lift changing
	12	Exhaust camshaft assembly	Lift changing
	13	Chain guide rail assembly	Length changing	Engine block heightened
	14	Chain tension arm assembly	Length changing	Engine block heightened
	15	Timing chain	Number of teeth increasing	Engine block heightened
	16	Chain tooth cover assembly	Enlarging	Engine block heightened
	17	Engine oil dipstick assembly	Lengthening	Engine block heightened
	18	Engine oil dipstick pipe	Lengthening	Engine block heightened
		assembly
	19	Intake manifold assembly	Change to central updraught type
	20	Hexagon flange nut		Install intake manifold
	21	Intake manifold bracket	Lengthening	Engine block heightened
	22	Exhaust manifold assembly	Appearance changing
	23	Canister solenoid valve exhaust	Lengthening	Position change
		pipe
	24	Electronic throttle valve water	Lengthening	Position change
		inlet/outlet pipe

(2) Electronic control fuel injection

Refer to CA4GA1 Engine Maintenance Manual (electronic control)

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CA4GA5 Engine Maintenance Manual

Section 3 General Maintenance Parameters

1. Mechanical Part

(1) Maintenance Data

Cylinder head	Joint surface deformation
	Cylinder block side	Specified value	0.05
		Allowed limit	0.10
	Maximum repairing and fitting quantity		0.16
	Intake/exhaust manifold side	Specified value	0.08
		Allowed limit	0.16
	Valve seat opening label and width
		Intake side	1.3±0.2
		Exhaust side	1.25±0.2
	Valve seat opening contact angle		45°±30′
	Allowed lower limit of valve seat opening	Intake side	0.49
		Exhaust side	0.46
	1st camshaft bearing support		φ32(+0.055, +0.030)
		Intake	φ26(+0.021,0)
		Exhaust	φ23(+0.021,0)
	2nd ~5th camshaft bearing support hole standard value
	Fuel spray nozzle hole diameter
		Standard	φ12
		Limit	φ12.5
1st camshaft bearing cover	Intake side	Locating slot width	3(+0.05,0)
	Exhaust side	Bearing cap width	21(+0.05,0)
Valve guide pipe	Valve guide pipe diameter
	Intake valve		φ5(+0.022,+0.010)
	Exhaust valve		φ5(+0.022,+0.010)
	Protruding height of valve guide pipe		15.1±0.2
Valve	Conical surface angle		45°30′
	Valve stem outer diameter
	Intake valve	Specified value	φ5(-0.010,-0.028)
		Limit	φ4.962
	Exhaust valve	Specified value	φ5(-0.020,-0.038)

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		Tianjin FAW			CA4GA5 Engine Maintenance Manual
					Limit	φ4.952
			Valve clearance
			Standard		Intake	0.02~0.05
					Exhaust	0.03~0.06
			Limit		Intake	0.07
					Exhaust	0.09
			Edge thickness
			Standard		Intake	1.40
					Exhaust	1.45
			Limit		Intake	0.9
					Exhaust	0.9
	Intake camshaft		Shaft diameter standard value		1st camshaft diameter	φ32(0,-0.016)
					2nd ~ 5th camshaft diameter	φ23(-0.035,-0.051)
			Cam height		Standard value	41.2
					Limit value	40.95
			1st shaft diameter oil clearance		Standard value	0.03~0.071
					Limit value	0.10
			5th shaft diameter oil clearance		Standard value	0.035~0.072
					Limit value	0.11
			Radial runout		Standard value	0.03
					Limit value	0.04
	Exhaust camshaft		Shaft diameter standard value		1st camshaft diameter	φ26(-0.035,-0.051)
					2nd ~ 5th camshaft diameter	φ23(-0.035,-0.051)
			Cam height		Standard value	41.1
					Limit value	40.04
			Shaft diameter oil clearance		Standard value	0.035~0.072
					Limit value	0.11
			Radial runout		Standard value	0.03
					Limit value	0.04
	Cylinder block		Top surface deformed
					Standard value	0.05
					Maximum value	0.10
			Cylinder bore diameter (standard)
					Grade A	φ73~φ73.01
					Grade B	φ73.01~φ73.02
					Grade C	φ73.02~φ73.03

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						Wear limit	0.08
						Enlarging 0.25mm type	φ73.25~φ73.28
						Enlarging 0.50mm type	φ73.50~φ73.53
			Engine oil pump hole diameter
						Standard	φ55.1(+0.06, +0.03)
						Limit	φ55.3
	Piston		Piston diameter		Standard	Grade A	φ72.97~φ72.98
						Grade B	φ72.98~φ72.99
						Grade C	φ72.99~φ73.00
					Wear limit
						Enlarging 0.25mm type	φ73.25
						Enlarging 0.50mm type	φ73.50
			Piston oil clearance
						Standard value	0.02~0.04
						Limit value	0. 06
			Piston top pit diameter				φ60.4
	Piston ring		Piston ring thickness			1st compression ring	Less than 1.2
						2nd compression ring	Less than 1.2
						Oil ring	Less than 2.0
			Piston ring opening clearance (Standard)
						1st compression ring	0.20~0.30
						2nd compression ring	0.40~0.55
						Oil ring	0.20~0.70
			Limit value			1st compression ring	0.5
						2nd compression ring	0.7
						Oil ring	1.0
			Piston ring groove clearance(Standard)
						1st compression ring	0.04~0.09
						2nd compression ring	0.02~0.06
			Limit value			1st compression ring	0.13
						2nd compression ring	0.08
	Piston pin		Piston pin		Clearance between outer ring and piston		φ18(+0.034, +0.028)
						Standard	0.005~0.011
						Limit	0.016
			Interference fit with connecting rod				0.017~0.034
	Connecting rod		Bent and deformed			Limit	0.03

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		Tianjin FAW			CA4GA5 Engine Maintenance Manual
			Bent and deformed		Limit	0.03
			Connecting rod big end clearance		Standard	0.017~0.029
					Limit	0.046
			Connecting rod axial clearance		Standard	0.20~0.40
					Limit	0.50
	Crankshaft		Main shaft diameter
					Standard	φ46(0,-0.018)
					Enlarging 0.25mm type	φ45.75~φ45.57
					Enlarging 0.50mm type	φ45.5~φ45.32
			Main shaft diameter clearance
					Standard	0.025~0.043
					Limit	0.068
			Connecting rod shaft diameter clearance
					Standard	0.017~0.035
					Limit	0.052
			Crank pin diameter
					Standard	φ44(0,-0.018)
					Enlarging 0.25mm type	φ39.75~φ39.57
					Enlarging 0.50mm type	φ39.50~φ39.32
	Intake manifold		Seal groove depth			4±0.1mm
			Seal ring protruding height		Standard	2±0.1mm
					Limit	1.8mm
	Exhaust manifold		Flange deformation
					Standard	0.25
					Limit	0.40
	Valve clearance		Cold state		intake valve	0.2±0.03mm
					Exhaust valve	0.3±0.03mm
	Timing chain		Flexibility limit			4mm [with 127N applied]
	Chain chamber cover		OCV Control valve hole diameter		Standard	φ18(+0.018,0)
					Limit	φ18.045
			Joint surface deformation		Standard	0.10
					Limit	0.25
	Upper and lower connecting		Shell width			14.5(0,-0.2)
	rod bearing shell		Free opening width			47( +1.5,+0.5)
			Central thickness			1.5(+0.009,-0.003)

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(Note) Unit: mm

(2) Tightening torque specifications

	No.	Name	Qty.	Spec.	Tightening torque	Remark
					(N.m)
	1	Bolt and nut for engine front support	2+2	M10	50±10
	2	Cylinder head bolt	10	M9×1.25	34±3+120°	Dipping
						oil
	3	Cylinder head cover bolt	11+2	M6	11±2
	4	Connecting rod bolt	8	M8X1	22±2.5+90°	Dipping
						oil
	5	Main bearing bolt	10	M10×1.25	60±5	Dipping
						oil
	6	Flywheel bolt	6	M10×1.25	78±5
	7	Crankshaft belt pulley bolt	1	M14×1.5	200±10
	8	Rear oil seal seat assembly	4	M6	8±2
	9	Camshaft bearing cover	20	M6	12.5±2
	10	Stud for connecting intake and exhaust	5+5	M8	6±1.2
		manifold and cylinder head
	11	Nut for tightening intake manifold	5	M8	19±4
	12	Nut for tightening exhaust manifold	5	M8	23±5
	13	Bolt and nut for engine oil pan	14+2	M6	8±2
	14	Drain plug assembly	1	M16×1.5	30±5
	15	Engine oil pump assembly	3	M6	9±1.8
	16	Relief valve assembly	1	M22×1.5	40±5
	17	Engine oil filter joint	1	M20×1.5	44±9
	18	Idler assembly	1	M10	44±9
	19	VCT controller assembly	1	M10	47±7
	20	OCV control valve assembly	1	M6	8±2
	21	OCV control valve filter bolt	1	M14×1.5	24.5±5
	22	Exhaust camshaft sprocket wheel	3	M6	8±1.6
	23	Chain tensioning arm bolt	1	M10	19±3.8
	24	Chain guide rail assembly	2	M6	8±2
	25	Bolt and nut for chain tensioner	1+1	M6	9±1.8
		assembly

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	26		Mounting bracket for chain		2	M6	8±2
	27		Chain chamber cover assembly		10	M6	12±2.4
	28		Water inlet pipe seat		3	M8	22±4
	29		Water outlet pipe		2	M8	22±4
	30		Water pump assembly		5	M6	9±1.8
	31		Coolant temperature sensor assembly		1	M12×1.5	20±2
	32		Intake temperature pressure sensor		2	M6	5±1
			assembly
	33		Camshaft position sensor assembly		1	M6	7±1
	34		Knock sensor assembly		1	M8	20±5
	35		Front/rear oxygen sensor assembly		1,	M18×1.5	45±5
					each
	36		Electronic throttle valve body assembly		4	M6	10±2
	37		Bar type ignition coil assembly		4	M6	8±2
	38		Spark plug assembly		4	M14×1.25	18±3.5
	39		Engine pressure alarm switch assembly		1	NPT 1/8	15±5

2. Cooling system maintenance data

Water pump	Type	Centrifugal
	Lift	≥147KPa
	Flow	≥135L/min
Cooling fan	Type	Inhaling type
	Rotating type	Rotate right
Thermosistor	the temperature , when the valve is opened	80±2
	the temperature , when the valve is fully opened	95
	Valve lift mm	≥8

3.Lubricating oil maintenance data (refer to CA4GA1 Engine Maintenance Manual)

4.Ignition system maintenance data

Spark plug	Model	XU22EPR-U
	Electrode gap	0.8—0.9

5.For fuel system maintenance data, please refer to CA4GA1Engine Maintenance Manual (Electronic Control)

6.For electronic system maintenance data, please refer to CA4GA1Engine Maintenance Manual (Electronic Control)

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Section 4 Engine Maintenance

1. Engine running-in

Notes

(1)CA4GA5 engine is an engine with high compression ratio. The gasoline used shall be above RON93#. Gasoline below this grade is not allowed.

(2)Check if the engine oil pressure is correct. Under normal circumstances, when power switch (key) is turned to “ON”, low pressure indicator lamp (red) of the engine oil pressure is light with the function of engine oil pressure sensor. It means no pressure is in the lubrication system. Turn the switch to “Start”, and the engine starts and runs idly. Now, low pressure indicator lamp of engine oil pressure goes out automatically. It means engine oil pressure in the lubrication system is normal. Now the engine can be used.

Note: the engine can be used only after confirming engine oil pressure is normal. Otherwise, the engine will have a serious fault and lead to economic loss.

(3) Check the coolant. First open the filler cap on the top of water tank. After filling the coolant, tighten the filler cap. Then observe the liquid storage tank. When the engine is in cold state, the coolant level shall be close to “FULL” scale of liquid storage tank, and now the cooling system is in normal and the engine can be used. If coolant level is too low and below “LOW” scale, first open liquid storage tank cover and then fill coolant with specified model and concentration to “FULL”.

After filling the coolant, tighten the liquid storage tank fixedly. Align the anti-rotating claw and tighten it. Do not operate the engine without enough coolant. Check the coolant level of liquid storage tank once every two weeks to keep the level at “FULL” all the time.

(4) Check the water temperature. When the engine water temperature is higher than or close to danger area of water temperature gauge, the vehicle shall be stopped to check. After troubleshooting, the engine can go on running. Otherwise, cylinder head will be deformed to damage the engine. At the time of normal driving, water temperature gauge pointer shall be in the middle or deflect to the right a little. The temperature does not exceed 100 .

(5)When a new engine is running at high speed with high load, it is not allowed to stop the engine suddenly. The engine shall run at low speed for 3~5 minutes and then stop. In this way, it is helpful to reduce engine faults and prolong service life.

(6)When the engine is installed on a mini vehicle or minicar for running-in, it is better to drive on a cement or asphalt road and avoid driving on muddy or sandy road.

(7)For a vehicle with this engine, the highest speed in the running-in period shall be less than 80Km/h.

(8)During 1/2 mileage in running-in period, the load shall not exceed 50% of the maximum load. It shall not exceed 75% of the maximum load during the latter half of mileage.

(9)Other requirements of the engine in running-in period shall strictly observe running-in specifications of the vehicle.

2. Engine Maintenance

(1)It is necessary to check the engine lubricating oil. If the lubricating oil consumption is abnormal, it is necessary to check the engine in details to find out (all kinds of) oil seal leakage, piston ring fault or piston fault.

(2)Cooling system of the engine is closed. When stopping in hot state, do not open water tank cover. Otherwise, the liquid sprayed in high pressure will cause personal hurt.

(3)Make maintenance and achieve it according to engine notes on both sides of the door.

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(4)During the course of driving, check if all kinds of instruments in instrument panel and fault indicator are normal. If any of them is abnormal, it is necessary to stop and check. After troubleshooting, restart the engine.

(5)It is necessary to check all pipes of the engine frequently to keep connection normal and reliable. Otherwise, the engine will work abnormally.

(6)Pay special attention to engine oil alarm lamp. If the lamp is light, it means the engine oil pressure is too low. The vehicle shall be stopped immediately to check lubrication system. After troubleshooting, restart it.

(7)Replace engine oil once every 5,000km.

Clean the air filter once every 5,000km when driving on an asphalt road, clean it every 2,500km when driving on an earth road and replace it every 15,000km.

Check electronic throttle valve assembly once every 10,000km.

Clean gasoline tank every 20,000km.

After various bolts are tightened according to specified torque, the vehicle can start driving.

(8)Replace engine oil filter assembly every 2,000Km initially, then replace it every 8,000Km. Apply engine oil on seal ring every time.

(9)If you find the engine dynamic property and economical efficiency reduce greatly; you shall check the engine and not allow the engine to run with a fault.

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		CA4GA5 Engine Maintenance Manual
	Chapter 2 Engine Structure
Section 1 Cylinder block, cylinder head and crank connecting rod mechanism ....................................................			17
Section 2 Valve actuating mechanism ....................................................................................................................			24
Section 3	Lubrication System.................................................................................................................................		29
Section 4 Cooling System.......................................................................................................................................			33
Section 5	Intake and Exhaust Systems ...................................................................................................................		35
Section 6 Fuel System ............................................................................................................................................			38
Section 7	Ignition System.......................................................................................................................................		40
Section 8	Other sensors and other actuating mechanisms ......................................................................................		42

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Section 1 Cylinder block, cylinder head and crank connecting rod mechanism

Cylinder block

The cylinder block has four cylinders, five main bearing supporting crankshaft main journals, equal cylinder center distance and gantry structure. Cylinder block and crankcase are integrated. Material is alloy cast iron. The weight is less than 28.7kg. The wall thickness is 3.5mm and the maximum wall thickness shall be not more than 4.5mm.

Cylinder block

Water jackets are provided on both sides of each cylinder to ensure a good cooling result. Water jacket thickness on both side walls is 4mm. Water jacket height is 110mm, which is a little higher than the stroke.

Main bearing cap material is iron-based powder metallurgy, which is integrated with main bearing seat of engine block. They are fully-support type structure, with reliable rigidity and strength. There is a forward arrow and number on main bearing cap. When assembling, the number shall be checked and followed.

In order to reduce the noise and vibration, reinforced rib is provided on side wall and around main bearing to form a rigid structure.

There are grouping numbers of cylinder hole, and grouping numbers of main bearing hole and main bearing shell on the bottom of engine block.

Cylinder block dimensions

Total height ×full length ×total width	(mm)	270.2×355.5×326.5
Cylinder bore	(mm)	73
Cylinder center distance	(mm)	80
Main bearing hole diameter	(mm)	φ50

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Main bearing hole grouping mark

Character font is No. 4 printing form

Stamp horizontally

Front
end	Cylinder hole grouping mark

Character font is No. 4 printing form

Stamp horizontally

Cylinder head and combustion chamber

The cylinder head adopts aluminum alloy casting, double top-mounted camshaft structure and is provided with water jacket to cool cylinder head. Combustion chamber is like a roof ridge and spark plug is installed at the center of combustion chamber to keep flame spread uniform.

The valve seat opening is a little declined type The intake valve seat opening inclination is 14°30′ and exhaust valve seat opening inclination is 15°12′. The cylinder head is pressed into valve seat opening. There are two lines of camshaft bearing supports on the cylinder head. The first camshaft bearing support is combined. The cylinder head height is enlarged and rigidity is increased. Combined camshaft bearing support is provided with lubricating oil slot. The cylinder head bolt head seat is position in deep place. Fuel injector is installed on the cylinder head.

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Exhaust		Intake

Exhaust

Combustion

chamber

Rotational

flow inlet

Intake

Cylinder head and combustion chamber

1st camshaft bearing support

In order to increase combustion efficiency, air inlet adopts spiral-flow type to rotate gases in combustion chamber so as to increase the charging efficiency. The cylinder head is provided with longitudinal water channel.

Piston, piston rod and piston ring

Piston is made of aluminum casting alloy. There is a φ60.4 pit on the top (Note: piston top pit diameter of 1.3L engine is different from that of 1.5L engine) to enlarge combustion volume. There are two pits on the air intake side on the top of the piston to prevent it from colliding with intake valve. Piston is of three-ring short skirt type. Graphite coating is printed on the surface of piston. The first ring groove and some ring edges (including piston top) is oxidized to ensure safety and durability, resist heat load and mechanical load, and reduce the weight at the same time. Piston and cylinder block shall be matched to ensure fit clearance. The weight difference among four pistons of the same engine shall not be more than 6g. There is a forward mark (arrow) and piston outer diameter grouping number (A, B, C) printed on the top of the piston. Piston pin hole grouping adopts red and yellow. Piston skirt barrel line adopts hyperbolical cosine function. Barrel skirt and cylinder wall formed bidirectional wedge oil film make the skirt have higher bearing capacity and good lubrication. In addition, inclination in piston motion can avoid load on closed angle to reduce impact of the piston on cylinder wall.

In order to endure surface hardness of piston pin, inner and outer surfaces of the piston pin are carburized. Piston pin diameter adopts red and yellow marks on piston pin end face.

In order to reduce mechanical loss, 1st and 2nd piston rings shall be thin rings. Oil ring adopts two side rings and one grommet.

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1st piston ring is barrel surface ring. The surface that contacts the cylinder is plated with hard chromium coat to reduce surface wear. 2nd piston ring is taper-face ring, which is treated by phosphorization. The surface of scraper blade in combination oil ring, which contacts the cylinder, is plated with hard chromium. Other surfaces are treated by phosphorization. Grommets go through tufftriding.

When installing piston ring, the surface with a mark shall be upward. Opening for each ring shall be separated by 120°.

Hard chrome plating

Mark

Hard chrome plating

Mark

Tufftriding

Hard chrome plating

Piston and piston ring

Connecting rod and connecting rod bearing shell

Connecting rod is forged by chrome steel, with high rigidity. When assembling connecting rod cap, forward marks shall be on the same side. When installing it on the engine, this surface shall face engine front. The weight difference among four connecting rods of four cylinders in the same group shall be no more than 3g. Connecting rod big end grouping marks (1 and 2) have two groups, which are printed on connecting rod body side. Connecting rod quality grouping mark (A, B, C, D, E) have five groups, which are printed on connecting rod cover.

Big end grouping mark

Forward mark

Quality grouping mark

Connecting rod

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Connecting rod bearing shell includes upper half and lower half. Upper half is installed on connecting rod body and lower half on connecting rod cap. Connecting rod bearing shell (upper and lower half) is divided into four groups within specified thickness tolerance. The bearing shell is colored on both ends. Connecting rod bearing positioning lip is on the side. When assembling, in order to ensure fit clearance, select and assemble according to grouping dimension of related parts.

Connecting rod upper bearing shell

Connecting rod bearing shell location lip

Connecting rod lower bearing shell

Connecting rod bearing shell

Crankshaft and bearing shell

Crankshaft is made of nodular cast iron, which consists of five main journals, eight pieces of balance weights, crank throw included angle 180°, with symmetrical plane. It has dynamic balance itself. But it bears inner bending moment to make crankshaft reach inner balance. Two groups of different balance weights are prepared.

The third main journal bears axial thrust. Two thrust shims made of mock silver are installed on both sides of cylinder block supporting the third main journal.

Balance weight removes all inherent vibration of the engine.

Connecting rod journal grouping code is stamped on the side of front balance weight. Main bearing journal grouping code is stamped on the side of rear balance weight.

Location pin

Main bearing journal and connecting rod journal of crankshaft adopt rolling fillet to increase fatigue strength.

Main bearing journal diameter of crankshaft mm	46
Connecting rod journal diameter of crankshaft mm	44

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1st ~5th main bearing shells of crankshaft adopt the same aluminum-tin alloy bearing shell. Upper bearing shell is provided with one oil groove and oil hole. Positioning lip for bearing shell is on the side.

Crankshaft upper bearing shell

Bearing shell location lip

Crankshaft lower bearing shell

Crankshaft bearing shell

Flywheel

Crankshaft front end is provided with timing sprocket and crank shaft belt pulley. They are used to drive camshaft, water pump and generator, respectively.

			Crankshaft belt pulley
					Belt pulley bolt
		Crankshaft sprocket
Crankshaft

Flywheel

Location pin

Flywheel bolt

Semi-circle key

Pressure plate location pin

The flywheel with ring gear is installed on rear end of crankshaft by 6 bolts. The flywheel body has signal teeth used to output the engine speed signal. The specifications as follows:

Outer diameter mm	242
Mass kg	6.45
Gear ring tooth number	103
Gear ring modulus	2.54

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	Pressure plate surface diameter mm			205
	Rotating speed signal tooth number			30 teeth
	Dynamic unbalance less than			25gcm

Crank pulley

In order to reduce torsional vibration, the engine adopts spoke type V-belt crank pulley with shock absorber to reduce radiation noise on front end of the engine so as to reduce noise of complete machine and reduce weight.

	Crank pulley specifications
Crank pulley outer diameter (mm)		144
V-belt groove angle		40°
V-belt groove number		6
Dynamic unbalance is less than		5gcm

Crankshaft oil seal

Front and rear oil seals of crankshaft are T structure with spiral line (spiral groove) in order to prevent oil leakage. T oil seal applies spiral groove oil pump. When crankshaft is running, oil is forced to return to the engine. T oil seal has obvious sealing characteristics.

Rear oil seal assembly

Rear oil seal seat assembly

			Rear seal oil of crankshaft
	Chain chamber
	cover assembly
					Chain chamber
					cover assembly
					Front oil seal
	Front oil seal
					assembly
	assembly

Front seal oil of crankshaft

Oil seal specification

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	Item				Inner diameter	Outer diameter	Thickness
	Front oil seal (mm)			φ33.8		φ49	6
	Rear oil seal (mm)			φ72.1		φ89	8.5

Cylinder head cover assembly

Cylinder head cover assembly is cast by aluminum alloy, with many arc surfaces. A ventilation baffle is used to separate the engine oil in blow-by gas and then oil flows into intake pipe through crankshaft case vent valve assembly for combustion.

Cylinder head cover assembly

Section 2 Valve actuating mechanism

Valve actuating mechanism of CA4GA5 engine adopts double top-mounted camshafts with intake VCT controller assembly driven by timing chain drive belt. The camshaft is fastened on the upper part of cylinder head, which is supported by five bearing supports to drive two intake valves and two exhaust valves. This is a typical direct drive of valve. It has high rigidity and good follow-up characteristics within the whole working range. Similarly in-line intake and exhaust valves can get an almost smooth torque characteristic curve and increase passing capacity of air flow to ensure thorough intake and exhaust.

Timing chain assembly and sprocket

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	Timing chain
	Pitch circumference			Pitch mm		Pieces		Width mm
	length mm
	1054			6. 35		166		11. 5

For this engine, timing chain drives exhaust camshaft to ensure stable running and low noise. When timing chain is bent, it will reduce strength greatly. Therefore, timing sprocket shall not be bent. Do not make water or other chemical liquids contact timing chain during the course of using. These contaminants will corrode chain link pieces. Timing chain has two groups and one yellow link piece which is timing mark.

Timing mark

Timing mark

Timing mark

Timing chain

Sprocket

There are four sprockets. The first is exhaust camshaft sprocket installed on exhaust camshaft; the second is crankshaft sprocket installed on crankshaft; the third is a sprocket installed on engine oil pump; the fourth is a sprocket installed on VCT controller assembly. Each sprocket has engagement mark (except the sprocket on engine oil pump). When assembling, it shall align with the mark on the chain.

	Exhaust camshaft	Crankshaft sprocket	Engine oil	VCT controller assembly
	sprocket		pump sprocket	sprocket
Number of teeth	42	21	25	42
Outer diameter	83	40. 5	48. 6	83

Chain tensioner assembly and chain tension arm assembly

Open the chain tensioner spring to eject tensioning ball of chain tensioner to provide appropriate tension for chain tensioner assembly so as to ensure reliable drive and prolong service life of timing chain. Parts for tensioner are free of maintenance.

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Chain tensioner assembly

Chain tension arm assembly

Chain tensioner assembly and chain tension arm assembly

Camshaft

Intake and exhaust camshaft are made of cold shock alloy cast iron. Cam included angle is 90°. Exhaust camshaft assembly drives intake camshaft assembly. The first journal of intake camshaft assembly has phase advance and delayed oil line.

Target wheel

Intake camshaft

Exhaust camshaft

VCT controller assembly

Exhaust camshaft sprocket

Intake and exhaust camshaft assembly

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					Camshaft specifications
		Item			1st journal dimension	Other journal dimension	Tip height (mm)
					(mm)	(mm)
	Exhaust camshaft			26(-0.035~-0.051)		23(-0.035~-0.051)	41.1
	Intake camshaft			32(0,-0.016)		23(-0.035~-0.051)	41.2

3.Intake camshaft assembly is driven by exhaust camshaft assembly, that is, exhaust camshaft sprocket drives VCT controller and sprocket on the intake camshaft sprocket assembly. VCT controller and intake camshaft sprocket assembly are fixed on intake camshaft assembly.

4.Intake valve, exhaust valve and valve spring

	Full length mm	Valve head diameter mm	Valve stem diameter mm
Intake valve	88.1	27.5	5.0
Exhaust valve	88.65	23	5.0

Intake valve and exhaust valve are made of chrome-silicon steel. Head diameter is designed to be larger so as to increase intake and exhaust efficiency. Valve spring is made of chrome-silicon steel. At high speed, it has high follow-up performance and natural frequency.

Free state specifications of valve spring

	Free length mm	Mean diameter of	Steel wire diameter	Total number of	Effective number
		spring mm	mm	turns	of turns
	45.2	16.6	3.2	9	7

	Assembled state of valve spring
Length mm		Load N
37		160±8
29.5		399±20
Spring rigidity: 31.9N/mm

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Valve tappet

Valve spring

Valve spring

Gasket

Intake valve

Exhaust valve

4. Valve tappet

Valve tappet is cylindrical to ensure uniform force when the valve moves, and has high follow-up performance. Tappet surface is carbonitriding. After carbonitriding, actual thickness of tappet is stamped on the inner top. In order to keep valve clearance within specified range, select integrated tappet with corresponding thickness according to actual measuring result when installing the engine.

5. VCT controller and intake camshaft sprocket assembly

VCT controller and intake camshaft sprocket assembly control cam peach-shaped phase position of intake camshaft assembly by using engine oil pressure difference, and change intake camshaft intake angle with engine working conditions changing so as to save fuel.

VCT controller assembly

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Section 3 Lubrication System

The engine adopts pressure and splash lubrication types, forced oil supply and full-flow filter.

Engine oil pumped from oil pan by oil pump goes through oil catcher and goes into engine oil filter, main oil duct and then goes to each main bearing journal of crankshaft, connecting rod journal, camshaft bearing support, OCV control valve assembly and VCT controller assembly. Exhaust camshaft supplies oil to exhaust bearing support by its oil line for lubrication. Intake camshaft supplies oil to each bearing support on the intake side by its oil line to lubricate friction pair surface enough.

Other parts of the engine, such as clearance between camshaft peach, piston, piston ring and cylinder wall; crankshaft thrust shim, timing chain and engine oil pump drive sprocket adopt splash lubrication.

Cylinder head oil channel

1st bearing support

1st bearing support

OCV control valve

for intake camshaft

for exhaust

filter

camshaft

OCV control valve

assembly

On

Off

Each cam bearing

Each cam bearing

1st bearing support

support for intake

support for exhaust

for intake camshaft

VCT controller assembly

1st bearing support for intake camshaft

OCV control valve filter

Oil pan

Main bearing holes for all connecting rods

1st main bearing cap		Other main bearing
		caps

Main oil channel

Chain lubrication nozzle

Engine oil filter

Relief valve
		Main oil channel
assembly

Engine oil pump

Engine oil coarse strainer

Lubrication system block diagram

(1) Engine oil pump assembly

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Rotor engine oil pump assembly is installed on the cylinder block, driven by crankshaft sprocket through timing chain. Outer and inner rotors of engine oil pump are installed on cylinder block. The relief valve is installed on cylinder block oil line. When engine oil pump reaches the oil supply pressure, the relief valve will work and drain oil. Drained lubrication oil returns to the engine oil pump. The engine oil pump is provided with drive sprocket used to drive engine oil pump.

		Engine oil pump assembly
		Engine oil pump assembly specifications
Type	Cycloid curve
	4.5	(Output pressure 150KPa, engine oil pump speed 588r/min)
Output flow (L/min)	14	(Output pressure 400KPa, engine oil pump speed 1680r/min)
	41	(Output pressure 450KPa, engine oil pump speed 5040r/min)

Relief valve is an integral structure. Spring is compressed in plunger and housing.

Free state specifications of relief valve spring

	Free length mm	Mean diameter of	Steel wire diameter		Total number of	Effective number of
		spring mm	mm		turns	turns
	43.6	9.8	1.4		12	10
		Assembled state of relief valve spring
		Length mm			Load N
		30.9			50.85
		24.6			76.2

Spring rigidity: 4N/mm

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