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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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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Ethylene glycol content

Corresponding water content

Protection temperature

Min. 35%

65%

-20℃

40%

60%

-24℃

Max. 45%

55%

-31℃

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

The maximum allowed temperature of engine coolant: 110℃. Coolant alarm temperature: 115℃.

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Output current (A)

Engine speed (r/min)

Cold state

Hot state

≥35

24~27

1800

2000

6000

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

≥45 31~34 ≥77 ≥65

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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No.

Description

Location

Special fixture for installing

and removing piston pin

Main body

Piston rod

Spring

“C” bushing

“M” guide rod

“N” guide rod

Piston tool

Piston

Adjustment tool for spark plug

Spark plug clearance

No.

Description

Location

Disassembling tool for valve guide pipe

Valve guide pipe

Disassembling tool for valve stem oil seal

Valve stem oil seal

Press-mounting tool for valve lock clamp

Valve lock clamp

Attachment

Cylinder head bolt wrench joint

Cylinder head bolt

Disassembling fixture for crank

pulley

Fixing tool for crankshaft and flywheel

Crank pulley

Special fixture for piston pin

Piston rod

Spring

Disassembling tool for rear oil seal of crankshaft

Rear oil seal of crankshaft

Disassembling tool for front oil seal of crankshaft

Front oil seal of

crankshaft

Disassembling tool for engine oil filter

Engine oil filter

Valve clearance adjustment tool

kits

valve clearance

Feeler gauge

Fixing fixture for crank pulley

Crank pulley

Hose plug

All hoses

Fuel pressure gauge

Fuel pressure

Disassembling tool for water

pump

Disassembling tool for water

pump bearing

Water pump

Disassembling tool for water

pump seals

Disassembling tool for water

pump rotor

Receiving tool for water pump

bearing

Water pump bearing base plate

Engine overhaul bracket

Engine

Engine overhaul connection bracket

Engine

Flywheel locking tool

Flywheel

Disassembling fixture for cylinder head

Cylinder head

CA4GA5 Engine Maintenance Manual

Section 2 Maintenance Preparation

1. Maintenance Notes (refer to

2. Maintenance preparation notes

(1) Mechanical part of the engine

Special maintenance tools

①

Recommended tools

②

CA4GA1 Engine Maintenance Manual

)

Disassembling bar for crank pulley Main body

“C” bushing “M” guide rod “N” guide rod

Valve tappet pressure clamp

18 19

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Engine slings

Engine

Piston tool

Piston

Sealant gun

All kinds of sealant

Disassembling tool for clutch housing and pressure plate

Clutch housing and pressure plate

Stainless steel wire wiper

Remove sealant and carbon deposit etc.

Scraper knife

Disassembling tool for engine oil pan

Engine oil, rear oil seal seat assembly etc.

Screwdriver (flat head screwdriver, Phillips screwdriver)

spark plug wrench

Spark plug

Radiator cover tester

Radiator cover

Measuring tool for cylinder bore

Cylinder bore

Chamfering reamer for cylinder hole

Cylinder hole

All kinds of casing heads

Bolt and nut

Equipments

Description

Straightening tool for connecting rod

Expanding tool for piston ring

Compressing tool for piston ring

No.

Location

Sealant type

Remark

Stud – install engine front support bracket

TB1322

Apply the sealant on the end connecting with cylinder head

Cylinder block sand outlet hole bowltype plug

Apply the sealant on the edge of the plug

Cylinder block main oil channel bowltype plug

Apply the sealant on the edge of the plug

Hexagon head tapered screw plug-at drainage hole of cylinder block

Apply the sealant on plug screw thread

Cylinder head sand outlet hole bowltype plug

TB1386D

Apply the sealant on the edge of the plug

Rear oil seal seat assembly for crankshaft

TB1280E

Apply the sealant on rear oil seal seat surface of crankshaft

Stud - intake manifold

Apply the sealant on the end connecting with cylinder head

Stud – exhaust manifold

TB1322

Apply the sealant on the end connecting with cylinder head

Engine oil pan assembly

TB1280E

Apply the sealant on the bottom of cylinder block, applied diameter is determined by testing

Joint surface of engine oil dipstick pipe and cylinder block location hole

TB1280E

Apply the sealant on the head of engine oil gauge pipe

Joint – engine oil filter

TB1110B

Apply the sealant on the end connecting engine oil filter

Stud - install idler assembly

TB1322

Apply the sealant on the end connecting with cylinder head

Chain chamber cover assembly

TB1280E

Apply the sealant on chain chamber cover surface

Engine water inlet pipe seat assembly

TB1280E

Apply the sealant on engine water inlet pipe seat surface

Engine water outlet pipe

Apply the sealant on engine outlet pipe surface

Stud- install engine water inlet pipe seat

Apply the sealant on threads

③

No.

CA4GA5 Engine Maintenance Manual

Special sealant

④

TB1386D

TB1110B

TB1322

15 16

TB1280E TB1110B

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assembly

Coolant temperature sensor assembly

TB1110B

Apply the sealant on threads

Engine oil pressure alarm assembly

TB1110B

Apply the sealant on threads

Relief valve assembly

TB1110B

Apply the sealant on threads

Stud- chain tensioner assembly

TB1322

Apply the sealant on threads

Chain lubrication nozzle

TB1110B

Apply the sealant on threads

Cylinder gasket assembly

TB1280E

Apply the sealant on cylinder block front end top surface edge

Drain plug assembly

TB1280E

Apply the sealant on drain plug assembly thread.

No.

Part description

Changing point

Remark

Cylinder block

Crankshaft

Crankshaft diameter unchanged

Piston

Top pit enlarged

Connecting rod

Big end hole enlarged

Upper bearing shell for connecting rod

Connecting rod shaft diameter enlarged

Lower bearing shell for connecting rod

Cylinder head assembly Spark plug

Model and clearance changing

Intake valve

Dimension enlarged

Exhaust valve

Dimension enlarged

Intake camshaft assembly

Exhaust camshaft assembly

Chain guide rail assembly

Engine block heightened

Chain tension arm assembly

Engine block heightened

Timing chain

Number of teeth increasing

Engine block heightened

Chain tooth cover assembly

Enlarging

Engine block heightened

Engine oil dipstick assembly

Lengthening

Engine block heightened

Engine oil dipstick pipe assembly

Lengthening

Engine block heightened

Intake manifold assembly

Change to central updraught type

Hexagon flange nut

Install intake manifold

Intake manifold bracket

Lengthening

Engine block heightened

Exhaust manifold assembly

Appearance changing

Canister solenoid valve exhaust pipe

Lengthening

Position change

Electronic throttle valve water inlet/outlet pipe

Lengthening

Position change

CA4GA5 Engine Maintenance Manual

(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

⑤

11 12 13 14

1. Height increase

1. Crank arm lengthened

2. Connecting rod shaft diameter enlarged

Connecting rod shaft diameter enlarged

1. Intake valve seat

2. Exhaust valve seat

3. Lift changing Heat value changing

Lift changing Lift changing Length changing Length changing

(2) Electronic control fuel injection Refer to CA4GA1 Engine Maintenance Manual (electronic control)

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Cylinder head

Valve guide pipe

1. Mechanical Part

(1) Maintenance Data

CA4GA5 Engine Maintenance Manual

Section 3 General Maintenance Parameters

Joint surface deformation Cylinder block side Specified value Allowed limit Maximum repairing and fitting quantity Intake/exhaust manifold side Specified value Allowed limit Valve seat opening label and width Intake side Exhaust side Valve seat opening contact angle Allowed lower limit of valve seat opening Intake side Exhaust side 1st camshaft bearing support Intake Exhaust 2nd ~5th camshaft bearing support hole standard value

0.05

0.10

0.16

0.08

0.16

1.3±0.2

1.25±0.2 45°±30′

0.49

0.46

φ32(+0.055, +0.030) φ26(+0.021,0) φ23(+0.021,0)

1st camshaft bearing cover Intake side Locating slot width

Valve Conical surface angle

Fuel spray nozzle hole diameter Standard Limit

Exhaust side Bearing cap width

Valve guide pipe diameter Intake valve Exhaust valve Protruding height of valve guide pipe

Valve stem outer diameter Intake valve Specified value Limit Exhaust valve Specified value

φ12 φ12.5

3(+0.05,0) 21(+0.05,0)

φ5(+0.022,+0.010) φ5(+0.022,+0.010)

15.1±0.2

45°30′

φ5(-0.010,-0.028) φ4.962 φ5(-0.020,-0.038)

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Exhaust camshaft

CA4GA5 Engine Maintenance Manual

Limit Valve clearance Standard Intake Exhaust Limit Intake Exhaust Edge thickness Standard Intake Exhaust Limit Intake Exhaust

Intake camshaft Shaft diameter standard value 1st camshaft diameter

2nd ~ 5th camshaft diameter Cam height Standard value Limit value 1st shaft diameter oil clearance Standard value

φ4.952

0.02~0.05

0.03~0.06

0.07

0.09

1.40

1.45

0.9

φ32(0,-0.016) φ23(-0.035,-0.051)

41.2

40.95

0.03~0.071 Limit value 5th shaft diameter oil clearance Standard value Limit value Radial runout Standard value Limit value

Shaft diameter standard value 1st camshaft diameter 2nd ~ 5th camshaft diameter Cam height Standard value Limit value Shaft diameter oil clearance Standard value Limit value Radial runout Standard value Limit value

Cylinder block Top surface deformed

Standard value Maximum value

0.10

0.035~0.072

0.11

0.03

0.04

φ26(-0.035,-0.051) φ23(-0.035,-0.051)

41.1

40.04

0.035~0.072

0.11

0.03

0.04

0.05

0.10 Cylinder bore diameter (standard) Grade A Grade B Grade C

φ73~φ73.01 φ73.01~φ73.02 φ73.02~φ73.03

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Piston

Piston ring

Piston pin

Bent and deformed Limit

0.03

CA4GA5 Engine Maintenance Manual

Wear limit Enlarging 0.25mm type Enlarging 0.50mm type Engine oil pump hole diameter Standard Limit

Piston diameter Standard Grade A Grade B Grade C Wear limit Enlarging 0.25mm type Enlarging 0.50mm type Piston oil clearance Standard value Limit value Piston top pit diameter

0.08

φ73.25~φ73.28 φ73.50~φ73.53

φ55.1(+0.06, +0.03) φ55.3

φ72.97~φ72.98 φ72.98~φ72.99 φ72.99~φ73.00

φ73.25 φ73.50

0.02~0.04

0. 06

φ60.4

Piston ring thickness 1st compression ring 2nd compression ring Oil ring Piston ring opening clearance (Standard) 1st compression ring 2nd compression ring Oil ring Limit value 1st compression ring 2nd compression ring Oil ring Piston ring groove clearance(Standard) 1st compression ring 2nd compression ring Limit value 1st compression ring 2nd compression ring

Piston pin Clearance between outer ring and piston

Less than 1.2 Less than 1.2 Less than 2.0

0.20~0.30

0.40~0.55

0.20~0.70

0.5

0.7

1.0

0.04~0.09

0.02~0.06

0.13

0.08

φ18(+0.034, +0.028) Standard Limit Interference fit with connecting rod

Connecting rod

0.005~0.011

0.016

0.017~0.034

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Crankshaft

Valve clearance Timing chain

Flexibility limit

4mm [with 127N applied]

Chain chamber cover

CA4GA5 Engine Maintenance Manual

Bent and deformed Limit Connecting rod big end clearance Standard Limit Connecting rod axial clearance Standard Limit

Main shaft diameter Standard Enlarging 0.25mm type Enlarging 0.50mm type Main shaft diameter clearance Standard Limit Connecting rod shaft diameter clearance Standard Limit Crank pin diameter

0.03

0.017~0.029

0.046

0.20~0.40

0.50

φ46(0,-0.018)

φ45.75~φ45.57

φ45.5~φ45.32

0.025~0.043

0.068

0.017~0.035

0.052

Standard Enlarging 0.25mm type Enlarging 0.50mm type

Intake manifold Seal groove depth

Seal ring protruding height Standard Limit

Exhaust manifold Flange deformation

Standard Limit

Cold state intake valve Exhaust valve

OCV Control valve hole diameter Standard Limit

φ44(0,-0.018)

φ39.75~φ39.57

φ39.50~φ39.32

4±0.1mm

2±0.1mm

1.8mm

0.25

0.40

0.2±0.03mm

0.3±0.03mm

φ18(+0.018,0)

φ18.045

Upper and lower connecting rod bearing shell

Joint surface deformation Standard Limit

Shell width Free opening width Central thickness

0.10

0.25

14.5(0,-0.2)

47( +1.5,+0.5)

1.5(+0.009,-0.003)

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No.

Name

Qty.

Spec.

Tightening torque

(N.m)

Remark

Bolt and nut for engine front support

2+2

M10

50±10

Cylinder head bolt

M9×1.25

34±3+120°

Dipping

oil

Cylinder head cover bolt

11+2

11±2

Connecting rod bolt

M8X1

22±2.5+90°

Dipping

oil

Main bearing bolt

M10×1.25

60±5

Dipping

oil

Flywheel bolt

M10×1.25

78±5

Crankshaft belt pulley bolt

M14×1.5

200±10

Rear oil seal seat assembly

8±2

Camshaft bearing cover

12.5±2

Stud for connecting intake and exhaust manifold and cylinder head

5+5

6±1.2

Nut for tightening intake manifold

19±4

Nut for tightening exhaust manifold

23±5

Bolt and nut for engine oil pan

14+2

8±2

Drain plug assembly

M16×1.5

30±5

Engine oil pump assembly

9±1.8

Relief valve assembly

M22×1.5

40±5

Engine oil filter joint

M20×1.5

44±9

Idler assembly

M10

44±9

VCT controller assembly

M10

47±7

OCV control valve assembly

8±2

OCV control valve filter bolt

M14×1.5

24.5±5

Exhaust camshaft sprocket wheel

8±1.6

Chain tensioning arm bolt

M10

19±3.8

Chain guide rail assembly

8±2

Bolt and nut for chain tensioner assembly

9±1.8

CA4GA5 Engine Maintenance Manual

(Note) Unit: mm (2) Tightening torque specifications

11 12

14 15

5 5

1 3

1+1

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Mounting bracket for chain

8±2

Chain chamber cover assembly

12±2.4

Water inlet pipe seat

22±4

Water outlet pipe

22±4

Water pump assembly

9±1.8

Coolant temperature sensor assembly

M12×1.5

20±2

Intake temperature pressure sensor assembly

5±1

Camshaft position sensor assembly

7±1

Knock sensor assembly

20±5

Front/rear oxygen sensor assembly

each

M18×1.5

45±5

Electronic throttle valve body assembly

10±2

Bar type ignition coil assembly

8±2

Spark plug assembly

M14×1.25

18±3.5

Engine pressure alarm switch assembly

NPT 1/8

15±5

Thermosistor Spark plug

CA4GA5 Engine Maintenance Manual

2. Cooling system maintenance data

Water pump Type

Lift Flow

Cooling fan Type

Rotating type the temperature ℃, when the valve is opened

the temperature ℃, when the valve is fully opened Valve lift mm

3. Lubricating oil maintenance data (refer to CA4GA1

4. Ignition system maintenance data

Model Electrode gap

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)

Engine Maintenance Manual

Centrifugal

≥147KPa ≥135L/min

Inhaling type Rotate right

80±2 95 ≥8

)

XU22EPR-U

0.8—0.9

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CA4GA5 Engine Maintenance Manual

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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CA4GA5 Engine Maintenance Manual

(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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Total height ×full length × total width (mm)

270.2×355.5×326.5

Cylinder bore (mm)

Cylinder center distance (mm)

φ50

CA4GA5 Engine Maintenance Manual

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

Main bearing hole diameter (mm)

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CA4GA5 Engine Maintenance Manual

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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CA4GA5 Engine Maintenance Manual

Intake

Exhaust

Rotational

flow inlet

Cylinder head and combustion chamber

Exhaust

Intake

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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CA4GA5 Engine Maintenance Manual

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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Main bearing journal diameter of crankshaft mm

Connecting rod journal diameter of crankshaft mm

onnecting rod lower bearing shell

CA4GA5 Engine Maintenance Manual

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 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.

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Outer diameter mm

242

Mass kg

6.45

Gear ring tooth number

103

Gear ring modulus

2.54

CA4GA5 Engine Maintenance Manual

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

Flywheel bolt

Flywheel

Location pin

Crankshaft

Crankshaft sprocket

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:

Semi-circle key

Pressure plate location pin

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Pressure plate surface diameter mm

205

Rotating speed signal tooth number

30 teeth

Dynamic unbalance less than

25gcm

Crank pulley outer diameter (mm)

144

V-belt groove angle

40°

V-belt groove number

Dynamic unbalance is less than

5gcm

CA4GA5 Engine Maintenance Manual

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

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.

Chain chamber

cover assembly

Rear oil seal assembly

Rear oil seal seat assembly

Front oil seal

assembly

Rear seal oil of crankshaft

Chain chamber cover assembly

Front oil seal

assembly

Front seal oil of crankshaft

Oil seal specification

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Inner diameter

Outer diameter

Thickness

Front oil seal (mm)

φ33.8

φ49 6 Rear oil seal (mm)

φ72.1

φ89

8.5

CA4GA5 Engine Maintenance Manual

Item

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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Pitch circumference length mm

Pitch mm

Pieces

Width mm 1054

6. 35

166

11. 5

Exhaust camshaft sprocket

Crankshaft sprocket

Engine oil pump sprocket

VCT controller assembly sprocket

Number of teeth

Outer diameter

40. 5

48. 6

CA4GA5 Engine Maintenance Manual

Timing chain

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 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.

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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CA4GA5 Engine Maintenance Manual

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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Item

1st journal dimension

(mm)

Other journal dimension

(mm)

Tip height (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

Full length mm

Valve head diameter mm

Valve stem diameter mm

Intake valve

88.1

27.5

5.0

Exhaust valve

88.65

5.0

Free length mm

Mean diameter of spring mm

Steel wire diameter mm

Total number of turns

Effective number of turns

45.2

16.6

3.2 9 7

Length mm

Load N

160±8

29.5

399±20

CA4GA5 Engine Maintenance Manual

Camshaft specifications

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

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.

Spring rigidity: 31.9N/mm

Free state specifications of valve spring

Assembled state of valve spring

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CA4GA5 Engine Maintenance Manual

Valve tappet

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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pump

CA4GA5 Engine Maintenance Manual

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

Main bearing

holes for all

connecting rods

1st bearing support

for intake camshaft

Each cam bearing support for intake

1st bearing support

for exhaust

camshaft

Each cam bearing

support for exhaust

OCV control valve

filter

OCV control valve

assembly

Off

1st bearing support

for intake camshaft

VCT controller

assembly

1st bearing support

for intake camshaft

1st main bearing cap

Chain lubrication

nozzle

Relief valve

assembly

Other main bearing

caps

Main oil channel

Engine oil filter

Main oil channel

Engine oil

(1) Engine oil pump assembly

OCV control

valve filter

Engine oil coarse

strainer

Oil pan

Lubrication system block diagram

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Cycloid curve

＞

4.5 (Output pressure 150KPa, engine oil pump speed 588r/min)

＞

14 (Output pressure 400KPa, engine oil pump speed 1680r/min)

＞

41 (Output pressure 450KPa, engine oil pump speed 5040r/min)

Free length mm

Mean diameter of

spring mm

Steel wire diameter

Total number of

turns

Effective number of

turns

43.6

9.8

1.4

Length mm

Load N

30.9

50.85

24.6

76.2

CA4GA5 Engine Maintenance Manual

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

Output flow (L/min)

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

Free state specifications of relief valve spring

Assembled state of relief valve spring

Spring rigidity: 4N/mm

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