Foton Operation and Miantenance Manual for View Series Light Bus Operating Manual

福田风景系列轻型客车

使用与维修手册

OPERATION AND MAINTENANCE MANUAL

FOR FOTON VIEW SERIES LIGHT BUS

北汽福田汽车股份有限公司

BEIQI FOTON MOTOR CO.,LTD.

内 容 简 介

BRIEF INTRODUCTION

福田风景系列轻型客车是北汽福田汽车股份有限公司生产的主导产品，本《福田风景系

列轻型客车使用与维修手册》较详细地介绍了风景系列轻型客车的技术维护，BJ491EQ1、
BJ483ZQB、BJ486ZQ、YC4F90-21、2RZ-E、4G64S4 等发动机构造、使用、维修、故障排除，
汽车底盘、电器与仪表构造、保养及故障排除、部分车辆主要技术参数等内容。

本书可供风景系列轻型客车使用、维护、修理人员参考。

FOTON VIEW series light bus is the leading product of Beiqi Foton Motor Corporation. This
Operation and Maintenance Manual for FOTON VIEW Series Light Bus introduces in details the
technical maintenance of VIEW series light bus; structure, operation, maintenance and
troubleshooting of BJ491EQ1, BJ483ZQB, BJ486ZQ，YC4F90-21，2RZ-E，4G64S4 engines; main
technical parameters for structure, maintenance and troubleshooting of automobile chassis,
electricals and instruments etc.

This manual offers a reference for user and service personnel of VIEW series light bus.

北汽福田汽车股份有限公司

BEIQI FOTON MOTOR CO., LTD.

福田风景系列轻型客车

使用与维修手册

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW

SERIES LIGHT BUS

北汽福田汽车股份有限公司编

COMPIlED BY BEIQI FOTON MOTOR CO., LTD.

Printed by Chengshun Paper and Plastic Printing House of Langfang City

开本:889mm×1194mm(大 16 开) 22 印张 字数 76.89 千字

Format: 889mm×1194mm (big 16 format) Printing Papers Words Kiloword

2006 年 8 月北京第一版 2006 年 8 月第一次印刷

August , 2006 First Edition, Beijing August, 2006 First Print

印数 0～1000 册

Impression 0~1000 copies

前 言

PREFACE

福田风景系列轻型客车是北汽福田汽车股份有限公司在引进日本技术的基础上，根据用
户需求进一步研制开发的系列轻型客车。该系列轻型客车采用 BJ491EQ1、BJ483ZQB、
BJ486ZQ、YC4F90-21、2RZ-E、4G64S4 等汽、柴油发动机；采用了平、半高顶、高顶车身；

淡化仿桃木豪华内饰、动力转向、电动窗、遥控锁、电动后视镜、后照地灯、后组合尾灯、
钻石前大灯、内外温度显示器、高位刹车灯、后暖风、CD/调频一体机、VCD 机、中控锁、
高靠背可调座椅、分体空调等；尾气排放达排放法规的要求，特别适用于各地区城乡使用。

VIEW series light bus has been developed to meet the demands of our customers based on the
technology introduced from Japan. The light buses adopts BJ491EQ1,BJ483ZQB、BJ486ZQ,
YC4F90-21，2RZ-E，4G64S4 gasoline and diesel engines; the buses among the series adopts
flat/half high/ high roof bodies, they equip with peach wood imitated luxury interior trim, power
steering, power window, remote lock, power rear view mirrors, rear floor lamps, rear combination
tail lamps, diamond headlamps, interior and exterior temperature display, high mount brake lamp,
rear warm wind, combination of CD/FM, VCD player, central lock, high back adjustable seat and
individual A/C etc. The vehicles complies with emission regulations, they are ideal vehicles for city
and rural areas.

风景系列轻型客车具有良好的安全性、动力性、经济性、舒适性、操作稳定性和环保性，
自投放市场以来深受广大用户的欢迎。

VIEW series light bus features safety, strong power, economy and comfortability. They also
have good performances such as stable operation and environment friendship. They have been very
popular since the day they were put into market.

汽车性能的保持、发挥以及使用寿命的长短、可靠性等，一方面取决于汽车设计和制造

过程中的质量，另一方面取决于用户的正确使用和精心维护、汽车维修厂正确的修理。为了

使广大用户和维修单位对风景系列轻型客车使用与维修有一个较全面的了解，掌握该车的使

用、维护与修理方法，延长车辆的使用寿命，我们特编写这本《福田风景系列轻型客车使用

与维修手册》。本手册系统地介绍了风景系列轻型客车整车技术性能；几种发动机构造、使用、
维护、修理和故障排除；底盘、电气设备的维护和检修；汽车维护保养制度等。

Maintaining and implementation of vehicle performance and service life / reliability depend on
its orignal quality during design and manufacturing, as well as correct operation and careful

maintenance or repair by the user and service garage. This Operation and Maintenance Manual for
VIEW Series Light Bus tends to make the operation and maintenance of VIEW series light bus
known to the users and service stations, so that they could master vehicles’ operation, maintenance
and repair methods to prolong service life of the vehicle. This manual introduces systmatically
VIEW series light bus’s technical performance. It includes the structure, operation, maintenance,
repair and troubleshooting of several engine models; also in this manual are maintenance and repair
of chassis and electrical equipment as well as maintenance system of the vehicle.

本书可供风景系列轻型客车使用、维护、修理人员参考。

This manual offers a reference for user and service personnel of VIEW series light bus.

由于编写时间仓促，资料缺乏，书中难免有不足之处，恳请广大读者批评指正。

Any comment to this manual is highly appreciated.

编 者

Author

2006 年 8 月

August, 2006

TABLE OF CONTENTS

·1·

目 录

TABLE OF CONTENTS

第一章 风景系列轻型客车主要数据资料

Chapter1 Main data and specification of View series light-bus…………………………………1

1.1 风景系列轻型客车主要数据与规格

1.1 Main data and specification of VIEW series light-bus……………………………………………………… 1

1.2 BJ491EQ1 发动机技术资料

1.2 Technical data of BJ491EQ1 gasoline engine……………………………………………………………… 23

1.3 BJ486ZQ 柴油发动机技术资料

1.3 Technical specification of BJ486ZQ diesel engine………………………………………………………… 29

1.4 YC4F90-21 发动机技术资料

1.4 Technical specification of YC4F90-21 diesel engine……………………………………………………… 31

1.5 2RZ-E 发动机技术资料

1.5 Model 2RZ-E Engine Technical specification………………………………………………………………33

1.6 4G64S4 发动机技术资料

1.6 Technical data of 4G64S4 engine……………………………………………………………………………43

第二章 汽车技术维护

Chapter 2 Vehicle Technical Maintenance………………………………………………………51

2.1 日常维护

2.1 Routine Maintenance………………………………………………………………………………………… 51

2.2 一级维护

2.2 First level maintenance……………………………………………………………………………………… 52

2.3 二级维护

2.3 Second level maintenance…………………………………………………………………………………… 54

2.4 走合期维护

2.4 Run-in maintenance……………………………………………………………………………………………60

2.5 换季维护

2.5 Seasonal Maintenance…………………………………………………………………………………………60

2.6 全车润滑

2.6 Vehicle lubrication…………………………………………………………………………………………… 61

第三章 BJ491EQ1 汽油机构造与调整维修

Chapter 3 Structure, Adjustment and Service of BJ491EQ1 Gasoline Engine…………… 63

3.1 气缸盖部件

3.1 Cylinder head parts ………………………………………………………………………………………… 63

3.2 气缸体部件

3.2 Cylinder block parts ………………………………………………………………………………………… 71

3.3 曲柄连杆机构

3.3 Crank-connecting rod mechanism ……………………………………………………………………………76

3.4 配气机构

3.4 Valve train …………………………………………………………………………………………………… 79

3.5 润滑系统

·2·

3.5 Lubrication system ……………………………………………………………………………………………84

3.6 冷却系统

3.6 Cooling system ……………………………………………………………………………………………… 85

3.7 起动系统

3.7 Starting system ……………………………………………………………………………………………… 88

3.8 充电系统

3.8 Charging system ………………………………………………………………………………………………90

3.9 曲轴箱通风装置

3.9 Crankcase ventilator ………………………………………………………………………………………… 91

3.10 离合器

3.10 Clutch ……………………………………………………………………………………………………… 91

FOTON OPERATION AND MAINTENANCE MANUAL FOR VIEW SERIES LIGHT BUS

第四章 BJ491EQ1 汽油机的燃油喷射系统

Chapter 4 BJ491EQ1 Gasoline Engine Fuel Injection System …………………………… 94

4.1 德尔福电控燃油喷射系统简介

4.1 Introduction of Delphi Electronic Control Fuel Injection (EFI) System………………………………………94

4.2 德尔福电控燃油喷射系统零部件

4.2 Parts and Components of Delphi EFI System ……………………………………………………………… 96

第五章 BJ491EQ1 汽油机的使用

Chapter 5 Application of BJ491EQ1 Gasoline Engine ……………………………………112

5.1 安全操作规定

5.1 Regulations for safe operating………………………………………………………………………………112

5.2 油料和冷却液

5.2 Fuel, oil and cooling fluids …………………………………………………………………………………112

5.3 起动前的准备

5.3 Preparations before Startup …………………………………………………………………………………114

5.4 起动步骤

5.4 Startup Proedures ……………………………………………………………………………………………114

5.5 怠速及暖机

5.5 Idle Speed & Warm-up ………………………………………………………………………………………115

5.6 运转期间的检查

5.6 Check during Running ………………………………………………………………………………………115

5.7 停车

5.7 Shutdown ……………………………………………………………………………………………………115

5.8 零件保护

5.8 Component Protection ………………………………………………………………………………………115

5.9 跛行回家

5.9 Limp in ………………………………………………………………………………………………………116

5.10 使用注意事项

5.10 Precautions during Operation ………………………………………………………………………………116

第六章 BJ491EQ1 汽油机的技术保养

Chapter 6 Technical Maintenance of BJ491EQ1 Gasoline Engine ……………………… 117

6.1 技术保养周期

6.1 Technical maintenance interval …………………………………………………………………………… 117

6.2 技术保养内容

TABLE OF CONTENTS

6.2 Content of technical maintenance ………………………………………………………………………… 117

6.3 润滑系统的技术保养

6.3 Technical maintenance for lubrication system …………………………………………………………… 118

6.4 冷却系统的技术保养

6.4 Technical maintenance for cooling system …………………………………………………………………119

6.5 燃油系统的技术保养

6.5 Technical maintenance for fuel system………………………………………………………………………119

6.6 进气系统的技术保养

6.6 Technical maintenance for air intake system ……………………………………………………………… 120

·3·

第七章 BJ491EQ1 汽油机故障与排除方法

Chapter 7 BJ491EQ1 Gasoline Engine Faults and Troubleshooting …………………… 121

7.1 汽油机故障排除常识

7.1 Gasoline engine troubleshooting summary …………………………………………………………………121

7.2 汽油机电控燃油喷射系统故障诊断基础

7.2 Diagnosis basics -- gasoline engine electronic fuel injection system…………………………………………121

7.3 汽油机电控燃油喷射系统故障诊断注意事项

7.3 Notes to diagnosis - gasoline engine electronic fuel injection system ………………………………………121

7.4 汽油机故障排除方法

7.4 Gasoline engine troubleshooting procedures ……………………………………………………………… 122

第八章 BJ486ZQ 柴油机的构造与调整维修

Chapter 8 Structure, Adjustment and Service of BJ483ZQB Diesel Engine …………… 131

8.1 柴油机维护调整须知

8.1 Precautions on Service and Adjustment of Diesel Engine ………………………………………………… 131

8.2 柴油机维护与调整

8.2 Service and Adjustment of Diesel Engine ………………………………………………………………… 131

第九章 柴油机故障与排除方法

Chapter 9 Diesel Engine Faults and Troubleshooting………………………………………145

9.1 柴油机起动困难

9.1 Hard start-up…………………………………………………………………………………………………145

9.2 柴油机低温起动困难

9.2 Hard start-up at low temperature…………………………………………………………………………… 146

9.3 柴油机功率不足

9.3 Insufficient power……………………………………………………………………………………………146

9.4 柴油机运转时有异常杂音

9.4 Abnormal noise during operation……………………………………………………………………………147

9.5 柴油机排气烟色不正常

9.5 Abnormal exhaust gas color…………………………………………………………………………………148

9.6 柴油机机油压力不足

9.6 Lower oil pressure……………………………………………………………………………………………148

9.7 柴油机冷却系统冷却液温度失常.缺液

9.7 Abnormal coolant temperature or coolant short…………………………………………………………… 149

9.8 柴油机增压系统故障

9.8 Supercharging system fault …………………………………………………………………………………150

9.9 起动电机不运转.起动无力.发出噪音

·4·

9.9 Starter does not run, weak start up or noise…………………………………………………………………151

9.10 发电机不发电.充电电流小或充电电流过大

9.10 Alternator does not work, lower or higher charging current………………………………………………151

9.11 蓄电池容量不足.自放电过大

9.11 Lower battery volume, higher self-discharging……………………………………………………………152

9.12 冷起动预热系统故障

9.12 Cold-start preheating system faults…………………………………………………………………………152

9.13 水泵电磁风扇离合器故障

9.13 Water pump electro-magnetic fan clutch fault………………………………………………………………153

FOTON OPERATION AND MAINTENANCE MANUAL FOR VIEW SERIES LIGHT BUS

第十章 底盘构造与修理

Chapter 10 Chassis Structure and Service …………………………………………………156

10.1 离合器

10.1 Clutch ………………………………………………………………………………………………………156

10.2 变速器

10.2 Transmission ……………………………………………………………………………………………… 163

10.3 传动轴

10.3 Propeller shaft ………………………………………………………………………………………………179

10.4 后桥

10.4 Rear Axle ………………………………………………………………………………………………… 182

10.5 前桥

10.5 Front Axle ………………………………………………………………………………………………… 190

10.6 转向机构

10.6 Steering Mechanism ……………………………………………………………………………………… 199

10.7 悬架

10.7 Suspension …………………………………………………………………………………………………208

10.8 制动系统

10.8. Brake System ………………………………………………………………………………………………214

10.9 车轮

10.9 Wheel ………………………………………………………………………………………………………225

第十一章 电器及仪表结构.使用与修理

Chapter 11 Structure, Application and Serice of Electrical Devices & Instruments …… 232

11.1 电器系统概述

11.1 Electrical System Overview ……………………………………………………………………………… 232

11.2 保险盒

11.2 Fuse Box ……………………………………………………………………………………………………232

11.3 电器系统的故障及修理

11.3 Troubleshooting ……………………………………………………………………………………………232

11.4 电器配件

11.4 Electrical Devices ………………………………………………………………………………………… 235

11.5 组合仪表与辅助电器

11.5 Complex Instrument and Auxiliary Electrical Devices ……………………………………………………259

11.6 汽车空调

11.6 Air Conditioner ……………………………………………………………………………………………262

TABLE OF CONTENTS

附录

Appendices

附录 1：匹配 BJ491EQ1 德尔福Ⅲ发动机豪华型整车电气原理图
Appendix：1 Vehicle (Luxury type) Circuit Diagram, with Delphi III BJ491EQ1 engine
附录 2：匹配 BJ483ZQB 发动机经济型整车电气原理图
Appendix：2: Vehicle (Economy type) Circuit Diagram, with BJ486ZQs engine
附录 3：匹配 2RZ-E 发动机整车电气原理图
Appendix3：Vehicle Circuit Diagram, with 2RZ-E engine
附录 4：匹配 BJ483ZQB 发动机整车电气原理图
Appendix4：Vehicle Circuit Diagram, with BJ483ZQB engine
附录 5：匹配 BJ491EQ1 德尔福Ⅲ发动机新电喷系统整车电气原理图
Appendix5；Vehicle (new EFI) Circuit Diagram, with Delphi III BJ491EQ1 engine
附录 6：匹配 BJ486ZQ 发动机整车电气原理图
Appendix6：Vehicle Circuit Diagram, with BJ486ZQ engine
附录 7：匹配 4YC4F90-21 发动机整车电气原理图
Appendix7：Vehicle Circuit Diagram, with 4YC4F90-21engine
附录 8：匹配 4G64S4 发动机整车电气原理图
Appendix8：Vehicle Circuit Diagram, with 4G64S4 engine
附录 9：匹配 4G64S4 发动机经济型整车电气原理图
Appendix 9：Vehicle (Economy type) Circuit Dirgram, with 4G64S4 engine

·5·

Chapter 1 Main Data and Specification of VIEW Series Light-bus

Overall length

Overall width

rall hight

Wheel track

Min ground

Wheel base

Rear extension

Min turning

Chapter 1 Main data and specification

of VIEW series light-bus

1.1 Main data and specification of VIEW series light-bus

1.1.1 Main data and specification of VIEW BJ6486、BJ6516

Table 1-1 General data

Model

Drive type 4×2 rear axle drive

BJ6486

FB

BJ6486

HFB

BJ6486

J1F1B

BJ6486

H2F1

BJ6486

J1F2B

BJ6486

H2F2

BJ6486

HJ1F2B

BJ6486

B1DWA

BJ6486

J1FB

·1·

BJ6486

H1F

Seats (include
driver)

(mm)

(mm)
Ove

(mm)

(front
/rear)(mm)

clearance
(mm)

(mm)
Front

extension
(mm)

9~12 ← ← ← ← ← ← 6~15 ← 9~12

4900 ← 4970 ← ← ← ← ← ← 4900

1690 ← ← ← ← ← ← ← ← ←

1935 2205 1935 1995 1935 1995 2225

1450/14

30

165 ← ← ← ← ← ← ← ← ←

2590 ← ← ← ← ← ← ← ← ←

1200 ← 1270 ← ← ← ← ← ← 1200

←

1460/14

40

← ← ← ← ←

1935/19

95

1935 1995

1450/14

30

←

(mm)

diameter (m)
Approach

angle (°)
Departure

angle(°)

1110 ← 1110 ← ← ← ← ← ← ←

≤11.5

21 ← 20 ← ← ← ← ← ← 21

20 ← 20 ← ← ← ← ← ← ←

← ← ← ← ← ← ← ← ←

·2·

include

Overall length

Overall width

Overall hight

Wheel track

Min Ground

Wheel base

Min Turning

included

← Overall length

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Table 1-2 General data

Model

BJ648

HJ1FB

BJ648

H2F

BJ648

H2FB

BJ648J

1FC

BJ648

HJ1FC

BJ648

B1DW

A-8

BJ648

B1DW

A-6

Drive type 4×2 rear axle drive

BJ648
B1DX

A

BJ648
B1DX

A-1

BJ648
B1DX

A-2

BJ648
H1FB

Seats (
driver)

(mm)

(mm)

(mm)

(front/rear)
(mm)

clearance(mm)

(mm)
Front
extension
(mm)
Rear extension
(mm)

6~15 9~12

4970

1690

← ← ← ← 4900 4970

← ← ← ← ← ← ← ← ← ←

2205 1995

1450/1

430

← ← ← ←

← ← ← 6~15 6~12 6~15

← ← ← 4900

1935 2225 1935 2050

1460/1

440

← ← ← ← ←

2225 1995

← ← 9~12

165 ← ← ← ← ← ← ← ← ← ←

2590

1270

1110

← ← ← ← ← ← ← ← ← 1200

← ← ← ← ← ← ← ← ← ←

← ← ← ← ← ← ← ← ← ←

diameter(m)
Approach
angle (°)
Departure
angle (°)

≤11.5 ← ← ← ← ← ← ← ← ← ←

20 ← ← ← ← ← ← ← ← ← 21

20 ← ← ← ← ← ← ← ← ← 20

Note：“←”same as indicated value

Table1-3 General data

Model

BJ648

B1DW

A-1

BJ648

B1DW

A-2

BJ648

B1DW

A-3

BJ648

B1DW

A-4

BJ648

B1DW

A-5

BJ648

B1DW

A-7
Drive type 4×2rear axle drive
Seats (

driver )

(mm)

6~15 6~12 ← ← ← 6~15 6~9 6~15 10~15

4970 ← ← ← ← ← ← ← 5085 ←

BJ648

B1DW

A-9

BJ648

B1DW

C

BJ648

B1DW

A

BJ648

B1DW

A-1

Chapter 1 Main Data and Specification of VIEW Series Light-bus

Overall width

Overall hight

Wheel track

Min grond

Min Turning

Approach angle

included

Overall length

Overall width

Overall hight

Wheel track

n Ground

·3·

Model

(mm)

(mm)

front/rear) (mm)

clearance(mm)

BJ648

B1DW

A-1

1690 ← ← ← ← ← ← ← ← ←

2225 1935 1995 2225 1995 2050 1935 1935 2050

1460/14

40

165 ← ← ← ← ← ← ← ← ←

BJ648

B1DW

A-2

BJ648

B1DW

A-3

BJ648

B1DW

A-4

BJ648

B1DW

A-5

BJ648

B1DW

A-7

BJ648

B1DW

A-9

BJ648

B1DW

C

BJ648

B1DW

A

← ← ← ← ← ← ← ← ←

BJ648

B1DW

A-1

Wheel base (mm) 2590 ← ← ← ← ← ← ← ← ←
Front

extension(mm)
Rear
extension(mm)

diameter(m)

1270 ← ← ← ← ← ← ← 1320 ←

1110 ← ← ← ← ← ← ← 1175 1110

≤11.5

← ← ← ← ← ← ← ← ←

(°)
Departure
angle(°)

20 ← ← ← ← ← ← ← ← 16

20 ← ← ← ← ← ← ← ← ←

Table 1-4 General data

Model

BJ6516

B1DW

A-2

BJ6516

B1DW

A-3

BJ6516

B1DW

A-4

BJ6516

B1DXA

BJ6516

B1DXA

-1

BJ6516

B1DXA

-2
Drive type 4×2rer axle dtive
Seats (

driver )

(mm)

(mm)

(mm)

← 6~9 10~15

← ← ← ← 6~9 10~15 6~9

← 5085 5085 ← ← ← ← ← ← ←

← ← ← ← ← ← ← ← ← ←

1935 ← ← 1935 ← 2050 ← 1995 ← ←

BJ6516

B1DXA

-3

BJ6516

B1DXA

-4

BJ6516

B1DXA

-5

BJ6516

B1DXA

-6

(front/rear)
(mm)

Mi
clearance(mm)

← ← ← ← ← ← ← ← ← ←

← ← ← ← ← ← ← ← ← ←

·4·

Wheel base

Min turning

Curb weight

Front axle

Max total

Front axle

Min stable speed in D gear

full load at

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Model

(mm)
Front
extension(mm)
Rear
extension(mm)

dismeter(m)
Approach angle
°)
Departure
angle(°)

Model

BJ6516

B1DW

A-2

BJ6516

B1DW

A-3

BJ6516

B1DW

A-4

BJ6516

B1DXA

BJ6516

B1DXA

-1

BJ6516

B1DXA

-2

BJ6516

B1DXA

-3

BJ6516

B1DXA

-4

BJ6516

B1DXA

-5

← ← ← ← ← ← ← ← ← ←

← ← ← ← ← ← ← ← ← ←

← 1175 1175 1110 ← ← ← ← ← ←

← ← ← ← ← ← ← ← ← ←

← ← ← 20 ← 16 ← ← ← ←

← ← ← ← ← ← ← ← ← ←

Table 1-5 Mass data

BJ6486

FB

BJ6486

HFB

BJ6486

J1F1B

BJ6486

H1F1

BJ6486

J1F2B

BJ6486

H2F2

BJ6486

HJ1F2B

BJ6486

B1DWA

BJ6486

J1FB

BJ6516

B1DXA

-6

BJ6486

H1F

(kg)

(kg)
Rear axle (kg) 750 760 762 760 700 765 770 700/715

mass (kg)

(kg)

1640 1700 1665 1710 1660 1715 1720 1660/1690 1670 1660

890 940 903 950 960 950 950 960/975

965 960

705 700

2516 2576 2541 2586 2536 2591 2596 2635/2665 2450 2440

1270 1300 1283 1310 1280 1310 1310 1105/1115 1025 1020

Rear axle (kg) 1246 1276 1258 1276 1256 1281 1286 1530/1550 1425 1420

Table 1-6 Operation data

Max speed ≥120 ← ≥130 ← ≥125 ← ← ≥120 ← ←

≤20 ← ← ← ← ← ← ← ← ←

Max climbing slope (%)
Brake distance (

50km/h) (m)

≥30 ← ← ← ← ← ← ← ← ←

≤22 ← ← ← ← ← ← ← ← ←

Fuel consumption
(L/100km)

≤9.5 ← ← ← ← ← ← ← ← ←

(average speed 50km/h)

Model

Rear axle

Max total

Front axle

Rear xale

Min stable speed in D

full

Curb weight

Max tatal mass

Curb
weight (kg)
Front
axle(kg)

Chapter 1 Main Data and Specification of VIEW Series Light-bus

·5·

Table 1-7 Mass data

BJ6486

HJ1FB

BJ6486

H2F

BJ6486

H2FB

BJ6486

1FC

BJ6486

HJ1FC

BJ6486

B1DW

A-8

BJ6486

B1DW

A-6

BJ6486

B1DX

A

BJ6486

B1DX

A-1

BJ6486

B1DX

A-12

BJ6486

H1FB

1670 1680 1700 1680 1700 1660 1670 1660 1665 1740 1660

965 980 990 980 990 960 965 960 938 1000 960

(kg)

mass (kg)

(kg)

(kg)

705 700 710 700 710 700 705 700 727 740 700

2405 2556 2576 2556 2576 2635 2450 3635 2640 2715 2440

1025 1086 1096 1086 1096 1150 1070 1335 1300 1315 1020

1425 1470 1480 1470 1480 1530 1380 1300 1340 1400 1420

Table 1-8 Operation data

Max speed ≥120 ← ← ← ← ← ← ≥125 ≥130 ← ≥120

gear

≤20 ← ← ← ← ← ← ← ← ← ←

Max climbing slope (%) ≥30 ← ← ← ← ← ← ← ← ≥38 ≥30
Brake distance (m) (
load at speed 50km/h)

≤22 ← ← ← ← ← ← ← ← ≤19 ≤22

Fuel cansumption
(L/100km)

≤9.5 ← ← ← ← ← ← ← ← ← ←

(average speed 50km/h)

Note ：“←” same as indicated value

Table 1-9 Mass data

Model

BJ6486

B1DW

A-1

BJ6486

B1DW

A-2

BJ6486

B1DW

A-3

BJ6486

B1DW

A-4

BJ6486

B1DW

A-5

BJ6486

B1DW

A-7

BJ6486

B1DW

A-9

BJ6486

B1DW

C

BJ6516

B1DW

A

BJ6516

B1DW

A-1

(kg)

1740 1660 1670 1740 1670 1670 1660 1740 1690 1690

Front axle (kg) 1110 960 965 985 965 965 960 985 975 970
Rear axle (kg) 730 700 705 755 705 705 700 755 715 720

(kg)

2715

Front axle (kg) 1145

Rear axle (kg) 1570

2050~2

440

860~11

05

1190~1

530

2060~2

450

865~11

10

1195~1

535

2130~2

520

895~11

40

1235~1

575

2050~2

645

865~11

10

1195~1

535

2615 2227 2715 2665 ←

1110 1140 1120 1135

1505 1575 1545 1530

·6·

Min stable speed in D

Max climbing slope

full

average

Curb weight

Max total mass

Min stable speed in

Max climbing slope

full

average speed

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Table 1-10 Operation data

Max Speed ≥120 ← ← ← ← ← ← ← ← ←

gear

（％）
Brake distance（
load at 50km/h）（ m ）

≤20

≥30

≤22

← ← ← ← ← ← ← ← ←

← ← ← ← ← ≥38

← ← ←

← ← ← ← ← ← ← ← ←

Fuel consuption

（L/100km）(

≤9.5

← ← ← ← ← ← ← ← ←

speed 50km/ h)

Table 1-11 Mass data

(kg)

Modle

BJ6516

B1DW

A-2

1700 1730 1730 1690 1695 1700 1705 1735 1735 1730

BJ6516

B1DW

A-3

BJ6516

B1DW

A-4

BJ6516

B1DXA

BJ6516

B1DXA

-1

BJ6516

B1DXA

-2

BJ6516

B1DXA

-3

BJ6516

B1DXA

-4

BJ6516

B1DXA

-5

BJ6516

B1DXA

-6

Front axle (kg) 980 900 900 980 978 980 980 905 905 905
Rear axle kg) 720 830 830 720 717 720 725 830 830 830

(kg)

2675 2297 2675 2665 2670 2645 2650 2302 2680 2297

Front axle (kg) 1140 1200 1405 1120 1123 1115 1110 1102 1280 1097
Rear axle (kg) 1530 1097 1270 1545 1547 1530 1540 1200 1400 1200

Table 1-12 Operation data

Max speed ← ← ← ≥125 ≥130 ≥125 ≥130

D gear （km/h）

（％）
Brake distance（
load at 50km/h (m)

← ← ← ← ← ← ≤22 ← ← ←

← ← ← ← ← ≥38 ← ← ← ←

← ← ← ← ← ← ≤19 ← ← ←

← ← ←

Fuel consumption

（L/100km）
（

← ← ← ← ← ← ← ← ← ←

50km/h）

Chapter 1 Main Data and Specification of VIEW Series Light-bus

Engine cooling

Transmission oil

Engine cooling

Table 1-13 Volume data

BJ64

BJ64

Model

86

B1D

XA-1

86

B1D

XA-2

BJ64

86

J1F1

B

BJ64

86

H2F1

BJ65

16

BDX

A-1

BJ65

16

BDX

A-3

BJ64

86

J1F2

B

BJ64

86

HJ1F

2B

Fuel tank（L） 65

BJ64

86

H2F2

BJ64

86

B1D

XA

BJ65

16

B1D

XA

BJ65

16

B1D

XA-2

BJ65

16

B1D

XA-4

BJ65

16

B1D

XA-5

·7·

BJ65

16

B1D

XA-6

Used fuel （#）

Better than 93# non-lead gasoline

Engine
lubricating

4.3 5.2

system（L）
Oil SF class 10W/30 or 15W/40

system （L）

10.1

Anti -freezer Ethy lene anti –frezer （or anti –corrosive anti freezer ，do not use alcoholic anti freezer ）
Transmission（L）

type

Gear oil GL-5 80W/90 in north （cold ）China ，85W/90 for other regions

2.0

Rear axle（L） 1.6

Table 1-14 Volume data

Model

BJ6486

FB

BJ6486

HFB

BJ6486

H1F

BJ6486

H2F

BJ6486

H2FB

BJ6486

HFB

BJ6486

HJ1FB

BJ6486

J1FB

BJ6486

J1FC

BJ6486

HJ1FC

Fuel tank （L）
Used fuel （#）

Better than 93#non-lead gasoline

65

Engine
lubricating

4.2

system（L）
Oil SE class 10W/30 or 15W/40

system（L）

10.1

Anti -freezer Ethylene anti-freezer（or anti- corrosive anti-freezer，do not use alcoholic anti-freezer ）
Transmission

（L）
Transmission
oil type

Rear axle （L）

Gear oil GL-5 80W/90 in north （cold ）China，85W/90 for other area

2.0

2.2

·8·

Engine cooling

Rear axle

discharged, max current

Model

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Table 1-15 Volume data

BJ64

BJ64

BJ64

BJ64

BJ64

BJ64

BJ64

BJ64

BJ64

86

B1D

WA

86
B1D
WA-

1

86
B1D
WA-

2

86
B1D
WA-

3

86
B1D
WA-

4

86
B1D
WA-

5

86
B1D
WA-

6

86
B1D
WA-

7

86
B1D
WA-

8

BJ64

86
B1D
WA-

9

BJ65

16

B1D

WA

BJ65

16
B1D
WA-

1

BJ65

16
B1D
WA-

2

BJ65

16
B1D
WA-

3

BJ65

16
B1D
WA-

4

BJ64

86

B1D

WC

Fuel tank （L）

65

Fuel （#） Better than 93# non lead gasoline
Engine

lubrication

4.2

system （L）
Oil SE class 10W/30or 15W/40

system （L）

10.1

Coolant Ethylene anti-freezer（or anti corrosive anti frezer，do notuse alcoholic anti freezer area）
Transmission

（L）
Transmission
oil type

Rear axle（L）

Gear oil GL-5 80W/90 in north （cold） china，85W/90for other area

2.0 6.5

2.2

Table 1-16 Volume data

BJ6

Model

486

B1D

XA-

1

BJ64
86B1
DXA

-2

BJ64

86J1F

1B

BJ64

86H2

F1

BJ65

16BD

XA-1

BJ65
16BD
XA-3

BJ64

86J1F

2B

BJ64
86HJ

1F2B

BJ64

86H2

F2

BJ64
86B1
DXA

BJ64
86B1
DXA

BJ65
16B1
DXA

-2

BJ65
16B1
DXA

-4

BJ65
16B1
DXA

-5

BJ65
16B1
DXA

-6

oil
Brake
system (L)

Brake fluid

Battery

Refrigerant
(g)
Refrigerant
type

Gera GL-5 80W/90in north （cold ）china ,85W/90for other area

1

V -3 –QC/T670 – 2000

At 20℃: concentration 1.28 （full charged）；1.16（charged 50%）；1.06（
15A during quick charging; 5A during slow charging

1400 1150

R134a

Chapter 1 Main Data and Specification of VIEW Series Light-bus

discharged, max current

WA

Rear axle

discharged, max current

Refrigerant

Refrigerant

Spark plug

deflection

Table 1-17 Volume data

Model

BJ6486

FB

BJ6486

FB

BJ6486

H1F

BJ6486

H2F

BJ6486

H2FB

BJ6486

FB

BJ6486

HJ1FB

BJ6486

J1FB

BJ6486

J1FC

Gear oil Gear oil GL-5 80W/90in north （cold china,85W/90 for other aera

·9·

BJ6486

HJ1FC

Brake
system (L)

Brake fluid

Battery

Refrigerant
(g)
Refrigerant
type

Model

oil
Brake
system（L）

1

JG3# composed brake fluid

At 20℃: concentration 1.28 （full charged）；1.16（charged 50%）；1.06（
15A during quick charging; 5A during slow charging

1500

R134a

Table 1-18 Volume data

BJ648

6

B1D

BJ648

6

B1D

WA-1

BJ648

6

B1D

WA-2

BJ648

6

B1D

WA-3

BJ648

6

B1D

WA-4

BJ648

6

B1D

WA-5

BJ648

6

B1D

WA-6

BJ648

6

B1D

WA-7

BJ648

6

B1D

WA-8

BJ648

6

B1D

WA-9

Rear oil GL-5 80W/90,innorth (cold )china 85W/90 other area

1

BJ651

6

B1D

WA-2

BJ651

6

B1D

WA-3

BJ651

6

B1D

WA-4

BJ648

6

B1D

WC

Brake fluid

Battery

At 20℃: concentration 1.28 （full charged）；1.16（charged 50%）；1.06（
15A during quick charging,5A during slow charging

(g)

type

Model

clearance (mm)
Belt

(mm)

BJ648

6

B1DX

A-1

BJ64

86

B1D

XA-2

BJ64

86

J1F1

B

V-3-QC/T670-2000

1500

R134a

Table 1-19 Adjustment data

BJ65

BJ65

BJ65

BJ64

86

H2F1

16

BDX

A-1

16

BDX

A-3

BJ651

16

BDX

A-5

6

BDX

A-4

BJ64

86

J1F2

B

BJ64

86

HJ1F

2B

BJ64

86

H2F2

0.7~0.8 1.1

5~7 ←

BJ64

86

B1D

XA

BJ65

16

B1D

XA

BJ651

6

B1D

XA

·10·

brake

Free angle of

Free travel of clutch

Free travel of brake

Steering wheel free

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Model

Free travel -­clutch pedal (mm)
Free travel-­pedal (mm)

steering wheel (°)

BJ648

B1DX

6

A-1

BJ64

86

B1D

XA-2

BJ64

86

J1F1

B

BJ64

86

H2F1

BJ65

16

BDX

A-1

BJ65

16

BDX

A-3

BJ65

16

BDX

A-5

BJ651

6

BDX

A-4

BJ64

86

J1F2

B

BJ64

86

HJ1F

2B

BJ64

86

H2F2

5~15 ←

1~3 ←

≤20(from center to left) ←

BJ64

86

B1D

XA

Toe-in (mm) 3±1 ←
Camber (°) -0°20’ ±30’ ←

Kingpin
inclination

10°50’ ±30’ ←

Caster (°) 1°15’ ±30’ ←

Engine

Model 4G64S4M 2RZ-E

BJ65

16

B1D

XA

BJ651

6

B1D

XA

Type

Bore × stroke(mm
×mm)

In-line, water cooling ,four cylinders,four strokes, electronic control multi-point injection

gasoline engine

86.5×100 95×86

Displacement 2.350 2.438

Table 1-20 Adjustment data

Model

Spark plug clearance
（mm)

Belt deflection(mm)

pedal (mm)

pedal (mm)

angle (°)
Toe-in (mm)

BJ6486

FB

BJ6486

HFB

BJ6486

H1F

BJ6486

H2F

BJ6486

H2FB

BJ6486

0.8~1.0

5~7

5~15

1~3

≤20(From center to left)

3±1

HFB

BJ6486

HJ1FB

BJ6486

J1FB

BJ6486

J1FC

BJ6486

HJ1FC

Camber(°)
Kingpin inclination
Caster(°)

-0°20’ ±30′

10°50’ ±30′

1°15’ ±30′

Engine

Chapter 1 Main Data and Specification of VIEW Series Light-bus

Spark plug clearance

Free travel of clutch

Steering wheel free

Kingpin incliniation

point Injection

Spark plug clearance

·11·

Model

BJ6486

FB

BJ6486

HFB

Model

Vertical ,in-line water cooling .four cylinder ,four strokes, electronic control one-point

Type
Bore×stroke(mm×

mm)
Displacement（L）
Note :“←” same as indicated value

Model

BJ6486

B1DWA

(mm)
Belt deflection (mm)

pedal (mm)
Free travel of brake
pedal(mm)

BJ6486

H1F

Table1-21 Adjustment data

BJ6486

B1DWA-1

BJ6486

H2F

BJ6486

B1DWA-2

BJ6486

H2FB

BJ6486

HFB

BJ6486

HJ1FB

491EQ

injection gasoline engine

91×86

2.237

BJ6486

B1DWA-3

BJ6486

B1DWA-4

0.8~1.0

5~7

5~15

1~3

BJ6486

J1FB

BJ6486

B1DWA-5

BJ6486

J1FC

BJ6486

B1DWA-6

BJ6486

HJ1FC

BJ6486

B1DWA-7

angle (°)
Toe in (mm)

Camber (°)

(°)
Caster (°)

Model

Type
Bore×stroke

(mm×mm)
Displacement（L）

Model

≤20(from center to lift)

3±1

-0°20’ ±30′

10°50’ ±30′

1°15’ ±30′

Engine

491EQ1

In-line, water cooling, four cylinders, four strokes, electronic control multi –

gasoline engine

91×86

2.237

Table1-22 Adjustment data

BJ6486

B1DWA-8

BJ6486

B1DWA-9

BJ6516

B1DWA

BJ6516

B1DWA-1

BJ6516

B1DWA-2

BJ6516

B1DWA-3

BJ6516

B1DWA-4

BJ6486

B1DWC

(mm)
Belt deflection (mm)

0.8~1.0

5~7

·12·

Free travel of clutch

Free travel of brake

Steering wheel free

Rated power

Max torque

Idle speed

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Model

pedal (mm)

pedal (mm)

angle (°)

BJ6486

B1DWA-8

BJ6486

B1DWA-9

BJ6516

B1DWA

BJ6516

B1DWA-1

BJ6516

B1DWA-2

5~15

1~3

≤20(from center to left)

Toe- in (mm) 3±1
Camber (°) -0°20’ ±30′
Kingpin inclination

10°50’ ±30′

Caster (°) 1°15’ ±30′

Engine

Model 491EQ1

Type

Bore ×strok
(mm×mm)

In-line, water cooling, four cylinders, four strokes, electronic control multi –point Injection

gasoline engine

91×86

BJ6516

B1DWA-3

BJ6516

B1DWA-4

BJ6486

B1DWC

Dispencement（L）

Note :“←” same as indicated value

BJ64

BJ64

BJ64

86

86

Model

B1D

XA-1

B1D

XA-2

86

J1F1

B

Compression
ratio

(kW)(r/min)

(N.m)(r/min)

(r/min)

During

Lubri

Idle

catin

speed

g oil

press

During

ure

runnin

(kPa)

g

2.237

Table1-23 Adjustment data

BJ65

BJ65

BJ65

BJ65

BJ64

86

H2F1

16

BDX

A-1

16

BDX

A-3

16

BDX

A-4

BJ648

16

BDX

A-5

6

J1F2

B

BJ64

86

HJ1F

2B

BJ64

86

H2F2

BJ64

86

B1D

XA

9.5 9.0

95/5250 88/5000

196/2750 198/2600

750±50 800/±50

≥20.4

≥170

BJ65
16B1
DXA

BJ65
16B1
DXA

-2

BJ65
16B1
DXA

-6

Drive system

Chapter 1 Main Data and Specification of VIEW Series Light-bus

Transmission

Drive

BJ64

BJ64

Model

86

B1D

XA-1

86

B1D

XA-2

BJ64

86

J1F1

B

BJ64

86

H2F1

BJ65

16

BDX

A-1

BJ65

16

BDX

A-3

BJ65

16

BDX

A-4

BJ65

16

BDX

A-5

BJ648

6

J1F2

B

BJ64

86

HJ1F

2B

BJ64

86

H2F2

BJ64

86

B1D

XA

Clutch Single disc, dry diaphram spring，hydraulic operation

Mechanic 5+1,gears with synchronizers

BJ65
16B1
DXA

BJ65
16B1
DXA

-2

·13·
BJ65

16B1
DXA

-6

Ⅰgear
Ⅱgear

ratio

Ⅲgear

Model

Compression ratio
Rated power

[kw（r/min）]
Max torque
[N.m(r/min)]

Idle speed(r/min)

Lubricati

ng oil

pressure

(kPa)

During

Idle

speed

During

running

BJ6486

FB

BJ6486

HFB

3.967 4.452

2.136 2.619

1.36 1.517

Table 1-24 Adjustment data

BJ6486

H1F

BJ6486

H2F

BJ6486

H2FB

BJ6486

HFB

BJ6486

HJ1FB

BJ6486

J1FB

8.8

70/4600

178/3200

780±50

≥20.4

≥170

BJ6486

J1FC

BJ6486

HJ1FC

Drive system

Clutch Single disc，dry disphram spring，hydraulic operation

Transmission Mechanic 5+1 gears with synchronizer

Ⅰgear

4.452

Drive

ratio

Ⅱgear
Ⅲgear

2.619

1.517

Note :“←” same as indicated value

Table 1-25 Adjustment data

Model

Compression ratio
Rated power /rpm

（kw(r/min)）

BJ6486B1

DWA

BJ6486B1

DWA-1

BJ6486B1

DWA-2

BJ6486B1

DWA-3

76/4300~4600

BJ6486B1

DWA-4

8.8

BJ6486B1

Max roque 193/3200

DWA-5

BJ6486B1

DWA-6

BJ6486B1

DWA-7

·14·

Rated power /

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Model

BJ6486B1

DWA

BJ6486B1

DWA-1

BJ6486B1

DWA-2

BJ6486B1

DWA-3

BJ6486B1

DWA-4

BJ6486B1

DWA-5

BJ6486B1

DWA-6

BJ6486B1

DWA-7

[N.m(r/min)]

Idle speed (r/min)

Lubrica

tion oil
pressur

e（kPa）

During

Idle speed

During

running

800±50≥

≥20.4

≥170

Drive system

Torque converter

ratio

Clutch Single disc，dry diaphram spring，hydraulic operation

/ 2.3

/

Transmission Mechanic 5+1 gears with synchronizer Torque converter＋Planet gears

Drive

ratio

Ⅰgear

Ⅱgear

4.452 Ⅰgear 2.450
Ⅱgear 1.450

Ⅲgear 1

O/Dgear 0.688

2.619

Planet

Gears

ratio

Ⅲgear

Modle

Compression ratio

Rpm
(kW(r/min)）
Max torque
(N.m(r/min))

Idle speed(r/min)
Lubrica

ting oil
pressur

e（kPa）

During

Idle speed

During

running

Torque converter

ratio

BJ6486B1

DWA-8

BJ6486B1

DWA-9

1.517

Table 1-26 Adjustment data

BJ6516B1

DWA

BJ6516B1

DWA-1

BJ6516B1

DWA-2

BJ6516B1D

WA-3

8.8

76/4300~4600

193/3200

800±50

≥20.4

≥170

Drive system

/ 2.3

Rgear 2.222

BJ6516B
1DWA-4

BJ6486B1

DWC

Clutch Single disc，dry diaphram spring ，hydraulic operation

/

Transmission Mechanic 5+1 gears with synchronizers Torque converter＋Planet gears

Chapter 1 Main Data and Specification of VIEW Series Light-bus

Planet gears

Propeller shaft

Front

·15·

Drive

ratio

Driv

e

ratio

Modle

Ⅰgear

Ⅱgear 2.619

Ⅳgear 1.517

Model

Ⅳ gear
Ⅴ gear

R gear

BJ6486B1

BJ648

6B1D

XA-1o

r -2

DWA-8

BJ64

86

J1F1

B

BJ6486B1

DWA-9

BJ6516B1

DWA

BJ6516B1

DWA-1

BJ6516B1

DWA-2

4.452 Ⅰgear

Table 1-27 Adjustment data

BJ65

BJ65

BJ65

BJ64

86

2F1

16

BDX

A-1

16

BDX

A-3

16

DXA-

4

BJ65

16

DXA-

5

BJ64

86

1F2B

BJ64

86

J1F2

B

1.000 1.000

0.856 0.854

3.578 4.473

BJ6516B1D

WA-3

ratio

BJ64

BJ64

2F2

86

86

1DX

A

BJ6516B
1DWA-4

BJ6486B1

DWC

2.450
Ⅱgear
Ⅲgear

1.450

1

O/Dgear 0.688

Rgear 2.222

BJ65

BJ65

BJ65

16

16

B1D

B1D

B1D

XA

XA-2

XA-6

16

type

Rear axle

Final drive
Final drive

ratio

Differntial

Half shaft

Suspen

tion

Tire

Tire
pressur
e (kPa)

Model

front

rear

rear

BJ6486H

FBor FB

Tubular，exposed needle bearing, universal joint

Integrated banjo type or tubular type

Single hyperbolic bevel gear

4.1 4.27

Symmetric bevel gear type

Semi-floating

Running system

Torsion bar spring，double cross arm independent suspention

Longitudinal leaf spring; non-independent suspension

195/70R15C 195/70R15C or 205/70R15

325 325/250
450 450/250

Table 1-28 Adjustment data

BJ6486H

1F

BJ6486H

2F

BJ6486H

2FB

BJ6486H

FB

BJ6486H

J1FB

BJ6486J

1FB

BJ6486J

1FC

BJ6486H

J1FC

Drive

ratio

Ⅳ gear
Ⅴ gear

R gear

1.000

0.854

4.473

·16·

pressure

Drive

ension

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Model

Prepoller shaft

type

Rear axle

Final drive

Final drive ratio

Differential

Half shaft

Suspens

ion

Front

Rear

Tire

Tire

(kPa)

Front

Rear

Model

BJ64

86B

1DW

A

BJ6486H

FBor FB

BJ64

BJ64

86B1

86B1

DWA

DWA

-1

BJ6486H

1F

BJ6486H

2F

BJ6486H

2FB

BJ6486H

FB

BJ6486H

J1FB

Tubular，exposed needle bearing, universal joint

Integrate bonjo type or tubular type

Single hyperholic bevel rear

4.556

Symmetric bevel gear type

Semi-floating

Running system

Torsion bar spring，double cross arm independent suspension

Longitudinal leaf spring; non-independent suspension

185R14

325
450

Table 1-29 Adjustment data

BJ64

BJ64

BJ64

BJ64

BJ64

-3

86B1

DWA

-4

86B1
DWA

-5

86B1

DWA

-6

86B1

DWA

-7

86B1

DWA

-8

BJ64

86B1

DWA

-9

BJ65

16B1

DWA

BJ65
16B1

DWA

-1

BJ6486J

1FB

BJ65

16B1

DWA

-2

BJ6486J

BJ65

16B1

DWA

-3

1FC

BJ6516

B1DWA

-4

BJ6486H

J1FC

BJ64

86B1

DWC

Ⅳgear
Ⅴgear

ratio

R gear

Propeller

shaft type

Rear axle

Final drive

Tubular，exposed，needle bearing universal joint

Whole banjo type of tubular type

Single hyperbolic bevel gear

Final drive

ratio

Differential

Symmetric bevel gear type

Half shaft

Running system

Susp

Front

Rrear

Torsion bar spring, double cross arm independent suspension

Longtudinal leaf spring non-independent suspension

Tire 185R14 195/70R15C

Tire

Pa)

Front

Rear

press
ure(k

1.000 /

0.854 /

4.473 /

4.556

Semi -floating

185R14

325

450

Chapter 1 Main Data and Specification of VIEW Series Light-bus

Max Wheel

body

Wire harness

Table 1-30 Steering gear and brake

Model

BJ648

6B1D

XA-1o

r-2

BJ648

6J1F1

B

BJ648

6H2F

1

BJ651

6XA-

1or -2

BJ651

6XA-

3

BJ648
6J1F2

B

BJ648

6HJ1

F2B

BJ648

6H2F

Steering gear Rack and pinion

Drive ratio 36.42

·17·

BJ65

BJ648

2

6B1D

XA

BJ651

6B1D

XA

BJ651

6B1D

XA-4

16B1
DXA

-5

BJ65

16B1

DXA-

6

Left

37°±0.3°

turning

angle

Right

Steering Wheel

position

34°±0.3°

Left

Service brake Hydraulic，vacuum boosting，dual circuits brake，front disk/rear drum brake

Wire hauness

Vehi

Rated voltage

cle

and

elect

ric

devi

ce

Starter model

Vehicle body

（V）

Battery

model

Alternator

model

Compressor

90A Japanese

Japanese QDY1218（Japanese）

10PC15 10PA17C

Unibody

Negative ground

12

N50Z

Table 1-31 Steering gear and brake

Model

BJ6486

HFB0rFB

BJ6486

H1F

BJ6486

H2F

BJ6486

2FB

BJ6486

HFB

BJ6486

HJ1FB

BJ6486

J1FB

BJ6486

J1FC

BJ6486

HJ1FC

Steering gear Rack and pinion

Drive ratio 36.42

Max wheel

Left 37°±0.3°

truning

angle

Steering wheel position

Right 34°± 0.3°

Left

Running brake Hydraulic, vacuum boosting，dual circuits brake, front disc/rear drum brake

Vehicle

body and

electric

device

Vehecle

body

Ratded

voltage (V)

Unibody

Negative ground

12

·18·

Alternator

e body

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Model

BJ6486

HFB0rFB

BJ6486

H1F

BJ6486

H2F

BJ6486

2FB

Battery

model

Alternator

model

Starter

model

Compressor

Table 1-32 Steering gear and brake

Model

BJ6486B

1DWA

BJ6486B

1DWA-1

BJ6486B

1DWA-1

or-2or-3

BJ6486B

1DWA-4

or –5or-6

BJ6486B1

DWA-7or-8

or-9

Steering gear Rear and rack

Transmission

ratio

Max

Lifut 37°±0.3°

36.42

Wheel

turning

Right 34°± 0.3°

angle

Steering wheel

position

Left

BJ6486

HFB

N50Z

65A

QD121

V50

BJ6486

HJ1FB

BJ6516

B1DWA

BJ6486

J1FB

BJ651

6B1DWA

-10r-2

BJ6486

J1FC

BJ6516

B1DWA-

30r-4

BJ6486

HJ1FC

BJ6486

B1DWC

Running brake

Vehicle

Harness

Rated

Vehicl

and

electri

voltage

Battry
model

c

device

model

Stater

model

compress

body

(V)

or

Hydraulic，vacuum booating ，daul circuits brake ，front disc ，rear drum brake

All load –brearing metal body

Negative prond

12

N50Z

65A

QD121

V50

Chapter 1 Main Data and Specification of VIEW Series Light-bus

turbocharger

1.1.2 Main data and specification of VIEW BJ6536

Table1-33

Vehicle model BJ6536B1DBA-2 BJ6536B1DBA-4 BJ6536B1DDA-4

BJ6536B1DW

A-2

Drive Type 4×2 rear axle drive

Persons in cab 6～9 7-9 7-9 6-9 10-12

BJ6536B1DW

·19·

A-1

Overall

dimensions

（mm）

Wheel base （mm）

Wheel

L 5320 5320、5385 5320、5385 5320 5320

W

1690 1690 1690 1690 1690

H 2050 2050、2225 2050、2225 2050 2050

2590 2890 2890 2890 2890

Front 1460 1460 1460 1460 1460

track

（mm）

Max Speed

（km/h）

Max Climbing slope

Min ground

clearance（mm）

Curb weight（kg）
Total weight（kg）

Rear 1440 1440 1440 1440 1440

≥95 ≥100 ≥110 ≥110 ≥120

（%）

≥22 ≥22 ≥30 ≥30 ≥38

≥160 ≥160 ≥160 ≥165 ≥160

1785 1785、1825 1840、1865 1695
2484 2484 2425、2450 2628

Engine BJ483ZQB BJ486ZQ YC4F90-21 BJ491EQ1 BJ491EQ1

Type

Four cylinders，in-line， water

cooling，direct injection，

diesel engine

Four cylinders，

in-line water

cooling，Turbo

charger diesel

engine

In-line，water cooling，four

cylinders，four strokes，

electronic control multi-point

injection gasoline engine

Bore×Stroke（mm）

Compression ratio
Reted power/Rpm

（kw/rpm）

Max torque/Rpm

（N.m/rpm）

83×100 86×100 92×100 91×86 91×86

17．5 18.1 17．5 8.8 8.8

46/3300 52/3300 65/3400 76/4300-4600 76/4300-4600

150/2200 175/1900-2300 215/1900-2200 193/2000-2600 193/2000-2600

Diaplacement(L) 2.164 2.324 2.66 2.237 2.237

Engine Lubricating

system (L)

Engine coolanting

system (L)

Fuel tank volume(L)

4.5 4．5 7．5 4.2 4.2

10．1

65 65/70 65/70 65 65

·20·

Fuel consumption(at

alignment

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Vehicle model BJ6536B1DBA-2 BJ6536B1DBA-4 BJ6536B1DDA-4

50km/h,full

payload,good road)

≤9 ≤8.5 ≤9.5 ≤ ≤9.5

L/100km)

Transm

ission

Model ZSY08 ZSY08 035H 5RYA

Type Mechanic 5+1 gears with synchronizer

Clutch Single plate, dry type diaphragm spring

Type Whole banjo type, punch axle housing

Rear

axle

Steerin-

g gear

Final drive

ratio

Rear axle

(L)

4.1 4.556 4.1

2．2（85W/90）

Type Pinion and rack

Transmissi

on (L)

1

BJ6536B1DW

A-2

Final drive

ratio

BJ6536B1DW

A-1

4．556

Sevice brake Hydraulic,vacuum boosting , dual circuits front disk,rear drum brake，

King

–pin

inclinati

Front

wheel

on

Caster 1°15′±30′ 1°15′±30′ 1°15′±30′

Camber 0°20′±30′ 0°20′±30′ 0°20′±30′

Toe-in

Max Wheel turning

angle（°）

Free travel of brake

pedal（mm）

Parking brake type

Suspenti

Front

on

system

Rear

-10°50′±30′ -10°50′±30′ -10°50′±30′

1～5 mm 1～5 mm 1～5 mm 1～5 mm 3±1 mm

34～37 34～37 34～37 34～37 34～37

1～3 1～3 1～3 1～3 1～3

Steel cable（Wheel brake）

Torsion bar spring，double crose arm independent suspension，hydraulic two –way

telescopic shock absorber

Longitudinal half –elliptic leaf spring ，non –independent suspension

Hydraulic two –way telescopic shock absorber

-10°50′±
30′

1°15′±30′ 1°15′±30

0°20′±30′ 0°20′±30

-10°50′±
30′

′

′

Electrica

l device

Type Negative ground

Rated

voltage

12V

Type of Tire and 185R14: 325 185R14C:325 185R14C:325 185R14C:325 185R14C：325

Chapter 1 Main Data and Specification of VIEW Series Light-bus

dimensions

·21·

Vehicle model BJ6536B1DBA-2 BJ6536B1DBA-4 BJ6536B1DDA-4

Tire pressure (kPa)

Type of Tire and

Tire pressure（kPa）

185R14:450

195/70R15:250 195/70R15:250 195/70R15:250

185R14C:450

195/70R15:300

185R14C:450

195/70R15:300

BJ6536B1DW

A-2

185R14C:450

195/70R15:300

185R14C：450

Type of Rim 7JJ×15

Table1-34

Vehicle model BJ6536B1DBA-1 BJ6536B1DBA-5

BJ6536B1DDA

-5

BJ6536B1DBA-4

BJ6536B1DDA

Drive Type 4×2 Rear axle drive

Persons in cab 10～12 10-14 10-15 6-9 6-9

Over all

L 5320 5320、5385 5320、5385 5320、5385 5320、5385

W 1690 1690 1690 1690 1690

（mm）

Wheel base （mm）

H 2050 2050、2225 2050、2225 2050、2225 2050、2225

2890 2890 2890 2890 2890

BJ6536B1DW

A-1

-4

Wheel

front 1460 1460 1460 1460 1460

track

（mm）
Max Speed（km/h）
Max Climbing slope

Min ground

clearance（mm）

Curb weight（kg）
Gross weight（kg）

rear 1440 1440 1440 1440 1440

≥95 ≥100 ≥110 ≥100 ≥110

（%）

≥22 ≥25 ≥30 ≥25 ≥30

≥160 ≥160 ≥160 ≥160 ≥160

1785 1785、1825 1865、1890 1785、1825 1840、1865
2718 2952 3032、3057 2484 2425、2450

Engine BJ483ZQB BJ486ZQ YC4F90-21 BJ486ZQ YC4F90-21

Type

Four cylinders，

in-line， water

cooling，

supercharging，

diesel engine、

Four cylinders，

in-line， water
cooling，direct

injection，diesel

engine

Four cylinders，

in-line， water

cooling，direct

injection，diesel

engine

Four cylinders，

in-line， water
cooling，direct

injection，diesel

engine

Four ylinders，

in-line， water
cooling，direct

injection，diesel

engine

Bore×Stroke（mm） 83×100 86×100 92×100 86×100 92×100

Compression ratio
Reted power/Rpm

（kw/rpm）

Max torque/Rpm

（N.m/rpm

17．5 18.1 17．5 18.1 17．5

46/3300 52/3300 65/3400 52/3300 65/3400

150/2200 175/1900-2300 215/1900-2200 175/1900-2300 215/1900-2200

Diaplacement 2.164（L） 2.324（L） 2.66（L） 2.324（L） 2.66（L）

·22·

Fuel consumption(at

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Vehicle model BJ6536B1DBA-1 BJ6536B1DBA-5

BJ6536B1DDA

-5

BJ6536B1DBA-4

BJ6536B1DDA

Engine oil (L) 4.5 4．5 7．5 4．5 7．5

Engine coolant (L)

10．1 10．1 10．1 10．1 10．1

Fuel tank (L) 65 65/70 65 65 65

50km/h,full

payload,good road)

≤9 ≤8.5 ≤9.5 ≤8.5 ≤9.5

L/100km)

Transm

ission

Model

Type Mechanic 5+1 gears with synchronizer

Clutch Single disc dry, diaphram spring, hydraulic operration

Type Whole banjo type , punch axle housing

Rear

axle

Final drive

ratio

Rear axle

(L)

4.1 4.556 4.1 4．556 4．1

2．2（85W/90） 2．2（85W/90） 2.2（85W/90） 2.2（85W/90） 2.2（85W/90）

-4

Steerin

g gear

Type Rear and rack

Transmissi

on (L)

Brake system

King

–pin

inclinati

Front

on

wheel

alignment

Caster 1°15′±30′ 1°15′±30′ 1°15′±30′ 1°15′±30′

date

Camber 0°20′±30′ 0°20′±30′ 0°20′±30′ 0°20′±30′

Toe-in

Max Wheel turning

angle（°）

Free travel of brake

pedal（mm）

1

Hydraulic,vacuum boosting ,dual circuits front

disk,rear drum brake

-10°50′±30′ -10°50′±30′

-10°50′±30
′

-10°50′±30′

-10°50′±

1°15′±30

0°20′±30

1～5 mm 1～5 mm 1～5 mm 1～5 mm 1～5 mm

34～37 34～37 34～37 34～37 34～37

1～3 1～3 1～3 1～3 1～3

30′

′

′

Parkong brake type

Suspenti

Front

on

system

Rear

Steel cable （Wheel brake）

Torsion bar spring，double cross arm independent suspension, hydraulic two –way

telescopic shack absorber

Longitudinal half –elliptic leaf spring，non –independent suspension,

hydraulic two –way telescopic shack absorber

Chapter 1 Main Data and Specification of VIEW Series Light-bus

Type of Tire andTire

·23·

Vehicle model BJ6536B1DBA-1 BJ6536B1DBA-5

Electrica

l device

pressure (kPa)

Type of Tire and

Tire pressure (kPa)

Type Negative ground

Rated

voltage

185R14: 325

185R14:450

185R14C:325

195/70R15:250

185R14C:450

195/70R15:300

BJ6536B1DDA

-5

12V

185R14C:325

195/70R15:250

185R14C:450

195/70R15:300

BJ6536B1DBA-4

185R14C:325

195/70R15:250

185R14C:450

195/70R15:300

BJ6536B1DDA

-4

185R14C:325
195/70R15:25

0
185R14C:450
195/70R15:30

0

1.2 Technical data of BJ491EQ1 gasoline engine

1.2.1 General structure of gasoline engine

Gasoline engine is a type of complicated machine that transforms heat energy of fuel into mechanical

operation. A gasoline engine contains the following mechanisms and systems:

1.2.11 Crank-connecting rod mechanism

The function of crank-connecting rod mechanism is to change reciprocating motion of piston into rotation
movement of crankshaft, and change gas pressure on top of piston into torque, producing output through
crankshaft.

Crank-connecting rod mechanism contains piston / connecting rod assemblies and crankshaft/flywheel
assemblies.

1.2.1.2 Cylinder block and cylinder head

Cylinder block and cylinder head form piston motion space and gasoline engine combustion chamber in
which air-fuel mixture is burning. The cylinder block and cylinder head are the framework of a gasoline engine,
on which all moving parts and auxiliary systems are supported and installed.

1.2.1.3 Valve train

Valve train discharges exhaust gas and sucks in air at specified timing to help combustion inside the engine.

Valve train includes valves and driving assemblies (tappet, push rod, rocker arm, rocker arm shaft, camshaft,
timing chain sprocket and timing chain etc.)

Air intake/exhaust system is composed of air cleaner, intake/exhaust manifolds/pipes, throttle body, muffler
and three-way catalytic converter etc.

1.2.1.4 Fuel supply system

Fuel supply system turns gasoline into combustible mixture according to the working requirement of gasoline
engine, and continuously supplies cylinder to meet the needs during combustion process.

Fuel supply system is mainly composed of fuel tank, electric fuel pump, fuel filter, fuel injector, pressure
regulator and fuel pipeline etc.

1.2.1.5 Lubrication system

Lubrication system is to deliver engine oil (lubricant) to friction surfaces of moving parts to perform
antifriction, cooling, cleaning and antirust functions, so as to reduce friction resistance and wear, take away the
heat generated during friction that ensure normal working of gasoline and prolong its service life.

BJ491EQ1 multi point electronic fuel injection gasoline engine combines to use pressure and splash
lubrication methods.

The lubrication system is mainly composed of oil strainer, oil pump, oil filter and lubricant oil passages etc.

·24·

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

1.2.1.6 Cooling system

Cooling system is to radiate heat from excessive heat parts, so as to ensure a normal working temperature of
engine and avoid damage to its mechanical parts and other adverse influences.

BJ491EQ1 multi point electronic fuel injection gasoline engine adopts a forced water-cooling method.

The cooling system is mainly composed of cylinder block and water jacket in cylinder head, water pump, fan,
radiator, thermostat and silicon oil fan clutch etc.

1.2.1.7 Ignition system

Ignition system is to generate electric sparks to ignite the air-fuel mixture inside cylinder timely.

The ignition system is composed of battery, spark plug, ignition coil and high resistance cable.

1.2.1.8 Starting system

Starting system is to rotate crankshaft to a certain speed so as to suck combustible mixture into cylinder to
enable ignition and combustion.

The starting system is composed of starter, battery and other devices.

1.2.1.9 Electronic control fuel injection system

Through various sensors, electronic fuel injection system input signals of air intake volume, crankshaft
rotation / position and other auxiliary components to ECM. ECM processes these singals and commads auctators
to get uptimum air-fuel ratio and proper ignition timing, and ignite the combustible mixture to obtain an ideal
engine power performance, economical efficiency and emission index.

1.2.2 Specifications of gasoline engine

Description BJ491EQ1

Type

4-stroke ，in-line,water cooling,wedge combustion chamber，

EFI

Number of Cylinders 4
Cylinder bore ［mm］ 91
Piston stroke ［mm］ 86
Displacement［L］ 2.237
Rated output［kW/(r/min)］ 76/4600~4600
Idle rpm ［r/min］ 800±50
Max torque［N·m/(r/min)］ 193/2000~2600
Fuel rate RON93 or better ，non-leaded super gasoline
Min fuel consumption ［g/(kW·h)］ ≤275
Oil rate SF or better 10W/30or 15W/40，and 5W/30 in winter
Oil /fuel consumption rate ［%］ ＜0.8
Average piston speed ［m/s］ 13.19
Rotating direction of crankshaft Counter- clockwise
Compression ratio 8.8：1
Anti-freezer Ethylene anti-freezer
Oil volume (dry)［L］ 4.2

Chapter 1 Main Data and Specification of VIEW Series Light-bus

Description BJ491EQ1

Coolant volume ［L］ 7.9（With out worm pipe capacity）

·25·

Firing sequence

Intake open advance angle 12ºBTDC
Intake close delayed angle 48ºABDC

Valve timing

Exhaust open advance 54ºBBDC
Exhaust close delayed angle 10ºATDC

Coolant type
Lubricating
Starting type
Net weight [kg]
Spark plug clearance[mm]
Max oil temperature [℃]
Coolant temperature [℃]

At idle ≥30

Oil pressure [kPa]

2000r/min ≥170
3000r/min 245~490

1-3-4-2

Forced cooling

Combine to use pressure and splash lubrication

Electric starting

145

1.1±0.1
110

85~105（For high pressure cooling system ）

1.2.3 Specifications of gasoline engine main components

Description Type Specifications

ECM ITMS-6F

O2 sensor 25327985 Heat style
Spark plug F6RTC or F5RTC M14×1.25， 3~9kΩ resistance
Starter QDY1253 U=12V，P=1kW
Alternator U=14V，I=65A/90A
Fuel injector 25343351
Oil pump Rotor type
Water pump Centrifugal type

Thermostat

Oil pressure sensor ZM10，Alarm pressure 39.2kPa
Oil filter Paper element

491-FT01 for van；491-FT02 for pick-up；
491-FT03for SUV

Valve opening temperature ；76℃，or more at 88℃，valve
lift≥8mm

Ignition coil 19005252
Clutch Diaphragm spring type

·26·

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

1.2.4 The fitting clearance of main components

Description Data
Warpage -- cylinder block side 0.15mm

Warpage -- manifold side 0.10mm

Culinder head

Valve guide

bushing

Valve

Refacing angle

Intake 45º，75º

Exhaust 45º

Valve seat

Connecting angle 45º
Connecting width 1.2~1.4mm

Inner diameter（mm） 8.010~8.030

STD（mm） 13.040~13.051

Outer dirmeter

O/S0.05（mm） 13.090~13.101

Intake 108.2

Overall length STD（mm）

Exhaust 108.5

Intake 44.5º

Valve face angle

Exhaust 44.5º

Intake（mm） 7.970~7.985

Stem diameter

Exhaust（mm） 7.965~7.980

Intake 0.025~0.060

STD（mm）

Exhaust 0.030~0.065

Stem oil clearance

Intake 0.10

Limit （mm）

Exhaust 0.12

Valve spring

Rocker arm and

shaft

Valve lifter and

lifter hole

Valve stem end face

polishing limit（mm）

Margin thickness

Limit（mm）

Installed tension at 40.6mm（N） 292~336

Squareness（mm）

Oil clearance

（mm）

Oil clearence

（mm）

Intake 0.5

Exhaust 0.5

Intake 1.0～1.4

STD

Exhaust 1.3～1.7

Intake 0.5

Limit

Exhaust 0.8

Free length （mm） 47

Limit 2.0

STD 0.02~0.051

Limit 0.08

STD 0.017~0.056

Limit 0.10

Leak down test at196N 7~50s/1mm

Chapter 1 Main Data and Specification of VIEW Series Light-bus

Description Data

Manifold Warpage Limit（mm） 0.4

Chain slackness at 98N Limit（mm） 13.5

·27·

Timing chain and

timing sprocket

Chain tensioner

and vibration

damper

Camshaft

Camshaft

Chain elongation Limit（mm） 291.44

Cranshaft sprocket wear Limit（mm） 59（Measure with chain）

Camshaft sprocket wear Limit（mm）

Tensioner head thickness Limit（mm） 12.5

Damper thinckness Limit（mm） 5

Thrust clearance（mm）

Journal oil clearance

（mm）

Journal diameter STD

（mm）

Out of round limit（mm） Limit 0.06

114（Measure with

chain）

STD 0.07~0.22

Limit 0.3

STD 0.025~0.111

Limit 0.14

No.1 46.459~46.475
No.2 46.209~46.225
No.3 45.959~45.975
No.4 45.709~45.725
No.5 45.459~45.475

Cylinder block

Piston and piston

ring

Cam lobe height

（mm）

Top surface warpage（mm） 0.05

Bore diameter（mm）

Diameter of piston

（mm）

Piston oil clearance（mm） 0.032~0.092

STD

Intake 38.620~38.720

Exhaust 38.629~38.729

Intake 38.26

Limit

Exhaust 38.27

STD 91.00~91.03

Limit 91.23

O/S 0.5（mm） 91.73
O/S0.75（mm） 91.98
O/S1.00（mm） 92.23

STD 90.938~90.968

O/S 0.5（mm） 91.438~91.468
O/S0.75（mm） 91.688~91.718
O/S1.00（mm） 91.938~91.968

·28·

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Description Data

NO.1 0.27~0.39

Piston ring end gap

（mm）

Piston ring groove clearance 0.03~0.07

Thrust clearance（mm） 0.160~0.312

Connecting –rod

Flyweel Runout （mm） 0.10

Thrust clearence（mm）

Crankshft

Benting per 100mm Limit 0.05
Twisting per100mm Limit 0.05

Thrust washer

thickness

（mm）

Main jounral oil

clearence（mm）

Main journal diameter

（mm）

NO.2 0.40~0.55

Oil side rail 0.20~0.70

STD 0.02~0.20

Limit 0.35

STD 2.450~2.490
O/S0.125mm 2.565~2.615
O/S0.250mm 2.69~2.89

STD 0.020~0.051

limit 0.10

STD 57.985~58.00

Crank pin oil

clearence（mm）

Crank pin diameter （mm） STD 47.985~48.00

Circle runout（mm） Limit 0.06

Main journal taper and out –of round（mm）

Crank pin taper and out –of round（mm）

STD 0.020~0.051

Limit 0.10

Limit 0.02
Limit 0.02

1.2.5 Tightening torque of main fasteners

1.2.5.1 Tightening torque for mechanical parts of gasoline engine

Parts

Rocker arm shaft×Cylinder head 25~32 Water pump ×cylinder block 39~48

Cylinder head

bolts

Manifold ×cylinder head 49~55 Connecting cap ×rod 49~55

Spark plug ×cylinder head 25~30

M12 93~105

M8 20~25

Tightening torque

（N.m）

Parts

Chain case 20~25

Mainbearing cap × cylinder

block

Tightening torque

（N.m）

78~88

Chain sprocket ×camshaft 90~100 Crankshaft pilley ×crankshaft 155~165

Chapter 1 Main Data and Specification of VIEW Series Light-bus

·29·

Parts

Camshaft thrust washer ×cylinder

block

Water pump×chain case 20~25 Oil pan ×cylinder block 10~13

Oil pan drain plug 38~45 Head cover ×cylinder head 6~8

1.2.5.2 Tightening torque for EFI parts

NO Parts

1 Throttle body 10~15 5 Ignition coil 10~15
2 MAP sensor 7~12 6 O2 sensor 38~46
3 Coolant temperature sensor 20~25 7 Upper and lower ports 20~25
4 Crankshaft 7~9

1.2.5.3 Tightening torque for other parts

NO Parts

Tightening torque

（N.m）

20~25 Flywheel×crankshaft 83~90

Tightening

torque（N.m）

Tightening torque

（N.m）

Parts

NO Parts

NO Parts

Tightening torque

（N.m）

torque（N.m）

Tightening torque

（N.m）

Tightening

1 M6 9~11 3 M10 41~591
2 M8 20~25 4 M12 73~

1.3 Technical specification of BJ486ZQ diesel engine

1.3.1 Technical specification of BJ486ZQ diesel engine

No Description Unit Specifications

1 Type

2 Shape of combustion chamber
3 Cylinder number 4
4 Cylinder bore mm 86
5 Piston stroke mm 100
6 Compression ratio 18
7 Diplacement L 2.324
8 Firing sequence 1-3-4-2
9 Output /rpm Kw/r/min 52/3300

DI A type

4-stroke ,water cooling ,in line、DI

supercharging，diesel engine

10 Max torque /rpm N．m/r/min 175/1900～2300
11 Min fuel consumption rate G/kw/h 225
12 Adjustable velocity % ≤10

·30·

8º,Intake valve closes(after

No Description Unit Specifications

13 Idle rpm r/min 800～850
14 Smoke m-1 ≤1.8

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

15

16 Method of lubrication Pressure and splash
17 Starting method Electric
18 Net weight Kg ≤215
19 Overall dimensions mm 754×592×671

Rotating directon of

crankshaft

Clockwise(see from front of diesel engine)

1.3.2 Main technical parameters of BJ486ZQ diesel engine

Description Parameters

Intake valve opens（before T.D.C）

B.D.C)44º

Exhaust valve opens (before BDC) 44º ;

Exhaust valve closes (after TDC) 8º

Intake valve 0.35mm, Exhaust valve 0.35mm

≤550℃

≤95℃(use high pressure water tank ≤105℃)

0.30～0.42MPa

Valve timing

Advance angle 8º～10ºCA(before T.D.C)

The range of

temperature and

pressure

Intake valve

Exhaust valve

Valve clearance

(cold)

Exhaust gas temperature

Coolant outlet

temperature

Oil temperature 80℃～105℃

Idling oil pressure ≥0.07MPa

Nominal speed oil

pressure

Camshaft gear bolt 45～55

Main bearing cap bolt 160～180

Tightening

torque(N.m)

Connecting –rod nut 55～65

Cylinder head bolt

Flywheel bolt 80～90

Crankshaft pulley bolt 250～280

170～190(bolt，Cylinder head)55～65(Small bolt，Cylinder

1.3.3 Main fitting specification of BJ486ZQ diesel engine

Description Specifications

Type of oil pump Gear type

Lubrication system

Type of oil filter Integral canister type

Alarm oil pressure 80kPa

head)

Chapter 1 Main Data and Specification of VIEW Series Light-bus

Description Specifications

Fuel filter Rotor type

Fuel pump Piston

·31·

Fuel supply sistem

Cooling system

Electronic sistem

Type of fuel injection

pump

Type of injector “P”multi –hole type ，ZP20 type

Injector open pressure 22～23MPa

Water pump Centrifugal type

Water pump flow ≥130L/min/4800r/min

Thermostat Wax type

Fan Silicon oil clutch and plastic fan

Glow plug relay 12V

Starter 12V,2.8kw

Alternator 14V,900W

Alternator rotating

direction

Type SJ44 or JP40S

BHF4P090213 type

Clockwise (viewing from front)

Turbeocharger

Max rpm 18000r/min

Rated rpm 15000r/min

1.4 Technical specification of YC4F90-21 diesel engine

1.4.1 The technical specifications

NO Description Specifications

1 Engine type 4-stroke ，water cooling，in line，supercharging
2 Shape of combustion chamber DI ω shape
3 Cylinder bore × Piston stroke （mm）
4 Displacement（L） 2.66
5 Compression ratio 17.5:1
6 Rated power/rpm kW（r/min） 65±5%/3400
7 Max torque /rpm （N.m/rpm） 210/1900~2200
8 Min fuel consumption〔g/（kW.h）〕

4-92×100

≤215

9 （Oil/fuel ）consumption rate ≤0.2%

·32·

full load

Transmission connecting

e end face to transmission connecting

release lever:

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

NO Description Specifications

10 Max rpm ( r/min) ≤3630
11 Min steady idle rpm 700~800
12 Firing order 1-3-4-2
13 Rotating direction of crankshaft Clockwise（viewing from front of diesel engine）
14 Starting method Electric

15 Starting performance

Startup at -10℃ w/o glow plug device, startup at-35℃ with

glow plug device; successful startup after 3 crankings

16 Smoke at free acceleration ( Rb) ≤2.0

Maximum smoke under

17

FSN

≤3.5

18 Noise (dB) (A) ≤116
19 Oil pan volume 7.5（L）
20 Oil temperature 90～115℃

Oil pressure at steady idling speed:>0.1MPa

21 Lubricating oil pressure

Working pressure: 0.3-0.6MPa
22 Coolant temperature 80～95℃
23 Exhaust gas temperature ≤650℃
24 Net weight（kg） 260（excl. clutch）

Overall dimensions

25

（L×W×H）mm

723.6×568.3×666

1.4.2 Main components specifications

NO Description Specifications

1 Type of fule injection pump BHF4PL090
2 Type of injector CKBAL63P967
3 Turbocharger JP50
4 EGR controller (ECU) Max environment temperature＜80℃

Fraction face of flywheel and clutch to transmission connecting plate :

5

plate

6 Type of clutch

52mm ; Input shaft bearing
plate : 25mm

ф225 diaphragm spring clutch，ajusting height of clutch

36.4mm; Clutch is of involute spline type

7 Flywheel 108teeth，speed signal output from flywheel
8 Speed sensor Mounting location aligns with flywheel gear ring center,
9 Input shaft bearing 6201 bearing，Input shaft front φ12mm

Chapter 1 Main Data and Specification of VIEW Series Light-bus

intake

ront fuel tank

Cleanness from air filter to

ment

NO Description Specifications

10 Oil pan volume 7.5L，Engine w/o oil from factory
11 Starting motor DC reducer motor QDJ1303/3kW/12V
12 Generator 14V/90A，built-in voltage regulator
13 Air filter flow ≥600m3/h
14 Air filter resistance ≤2.5 kPa, with double stage elements

Air intake resistance –

15

system

16 Radiating area -- radiator ≥16M2
17 Expansion tank ≥15% of total cooling system volume
18 Fuel filter flow ≥0.7L/min，particles after filter＜0.005mm

Cleanness of f

19

to fuel pump inlet pipe

≤4 kPa，Negative pressure alarm on air filter assembly

＜10mg

·33·

20

engine intake manifold

21 Catalytic converter Clear with compressed air after every 10000km
22 Battery V /Capacity 12V/80Ah

23 Engine oil

24 Injection pump & oil 5W/30，CF rate diesel engine oil
25 Fuel Choose fuel according to environment temperature

＜10mg

Should be higher than APL CF-4 rate according to environ
temperature

1.5 Model 2RZ-E Engine Technical specification

1.5.1 Technical specification

Model 2RZ - E

Type

No. of cylinder 4
Cylinder bore (mm) 95
Piston stroke (mm) 86

In line, four cylinders, four strokes, water-cooling,
multi-point EFI

Total displacement (L) 2.438
Rated power / Rpm 85KW/5000rpm
Min. idle stablized Rpm 800 ±50 rpm
DP Rpm 2000 rpm
Max torque / Rpm 193N.m / 2600rpm
Fuel rating 95# or above unlead fuel (GB17930)

·34·

Oil rating SF 10W/30 or 15W/40 (GB11121)

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Model 2RZ - E

Crankshaft turing direction (viewing from flywheel end
to gasoline engine front end)

Compression ratio 9
Igniting sequence 1-3-4-2
Cooling Forced water-cooling
Lubrication Pressure and splashing
Starting Power startup

Counter-clockwise

1.5.2 Main component specification

Description Type Specification

EFI system

Spark plug P16R：BPR5EP11
Starter U=12V P=1.4Kw
Alternator U=13.9～15.1V, I=60A
Distributor （mm） ( type 11 A) Singnal generator clearance: 0.2～0.4

Toyota computer control system
(TCCS)

Signal generator (sensing
coil ) resistance（Ω）

Ignition coil

Oil pump Rotary
Water pump Centrifugal

Thermostat

Oil filter

Clutch Diaphragm spring type

280～360

U=12V primary coil resistance 0.4～0.5Ω;
secondary coil resistance 10.0～14.0 KΩ

Wax type, valve opening temperature 80～
84°C, 95℃fully open travel ≥ 8mm
Fully flow type with limit valve, spin-on
type with paper element

1.5.3 Parameters for check and adjustment

Valve clearance (cool engine)（mm）

Ignition advance angle 5°BTDC (at 800rpm)
Ignition sequence 1-3-4-2

Intake valve 0.2～0.3
Exhaust valve 0.25～0.35

Primary coil resistance（Ω） 0.4～0.5
Secondary coil resistance（KΩ） 10.0～14.0

Chapter 1 Main Data and Specification of VIEW Series Light-bus

·35·

Distributor signal generator (sensing
coil ) resistance（Ω）

280～360

Compress pressure（KPa） 1226
Min. pressure（KPa） 883

Compress pressure difference among
cylinders（KPa）

98

Intake pipe vacuum (at idle)（KPa） Larger than 53.3
Pollutant emission at idle CO ≤0.5%
Spark plug clearance（mm） 1.1

Idle (800rpm) 29.4KPa

Oil pressure

Mid-high rpm (3000rpm) 245～490KPa
Oil temperature ≤110℃
Oil volume ( fill at dry) 5.2L

(oil filter contains oil) 3.6
Refill after draining （L）

(oil filter contains no oil) 4.1
Fan belt tension (pressure 10kg, the

deflection under 98 N)
Coolant volume (use softened water
or antifreezer) without heater

New belt: 5～7mm

Used belt: 7～8 mm

8L

With front heater 9L
With front and rear heater 10L

Radiator Relieve valve opening
pressure（KPa）

Standard 74～103

Limit 59
Battery fluid gravity under 20°C 1．25～1．27

Rated output current 60 A

Rotor coil resistance 2.8～3.0Ω

Alternator

Brush exposed length（mm）

Sliding ring diameter（mm）

Alternator regulator Regulator Voltage

Rated voltage and output power 12V, 1.4Kw

Idle property

Starter motor

Brush length（mm）

Standard 10.5
Limit 1.5
Standard 14.2～14.4

Limit 12.8
At 25℃ 13.9～15.1V
At 115℃ 13.5～14.3V

Amp 90 A or less at 11.5V
Rpm 3000 rpm or more
Standard 15.5
Limit 8.5

Spring mounting load Standard 18～24N

·36·

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Pump body clearance（mm）

Standard 0.100～0.175
Limit 0.30
Standard 0.11～0.24

Oil pump

Side clearance（mm）

Limit 0.35
Standard 0.03～0.09

Radial clearance（mm）

Limit 0.15

Fuel pressure 2.7～3.1 bar

1.5.4 Fitting sizes of main parts

Description Data

Warpage (contacting face with block)（mm） Limit 0.15

Cylinder head

Warpage (contacting face with intake /
exhaust manifolds)（mm）

Cone angle

Valve

seat

Contacting angle 45°

Limit 0.20

Intake valve seat 30°45°60°
Exhaust valve seat 30°45°60°

Valve guide

Valve

Contacting width（mm） 1.2～1.6

Inner diameter（mm） 8.01～8.03
Outer

diameter

Standard（mm） 13.040～13.051
Enlarge 0.05mm（mm） 13.090～13.091

Projecting height（mm） 18.2～18.6

Intake valve 102.00

Valve length（mm） Standard

Exhaust valve 102.25

Intake valve 44.5°

Valve cone angle

Exhaust valve 44.5°

Valve stem diameter
（mm）

Intake valve 7.970～7.985

Exhaust valve 7.965～7.980

Intake valve 0.025～0.06

Standard

Valve stem clearance
（mm）

Exhaust valve 0.030～0.065

Intake valve 0.08

Limit

Exhaust valve 0.10

Valve stem end face
grinding limit（mm）

Valve top edge
thickness limit（mm）

Intake valve 0.5

Exhaust valve 0.5

Intake valve 0.5

Exhaust valve 0.8

Chapter 1 Main Data and Specification of VIEW Series Light-bus

Intake/exhaust

Timing chain

Damper plate

and sliding

Main bearing hole diameter at the main bearing inner hole

Description（mm） Data

Free length（mm） 47.31

·37·

Valve spring

manifolds

and sprocket

plate

Camshaft

Mounting tension（N） 238～265
Un-verticality （mm） 2.0
Sealing face warpage—intake（mm） Limit 0.2
Sealing face warpage—exhaust （mm） Limit 0.7
16 links chain length（mm） Limit 146.6
Allowable wear on crankshaft sprocket diameter（mm） Limit 59.4
Allowable wear on camshaft sprocket diameter（mm） Limit 113.8
Wear of damper plate（mm） Limit 1.0

Wear of sliding plate （mm） Limit 1.0

Standard 0.08～0.18

Axial clearance（mm）

Limit 0.25
Standard 0.025～0.066

Radial clearance（mm）

Limit 0.10
Shaft journal diameter（mm） Standard 33.959～33.975
Center shaft journal runout （mm） Limit 0.06
Cam lub height（mm） Standard 47.84～47.94
Top plane warpage（mm） Limit 0.05
Cylinder bore（mm） Limit 94.99～95.00
Fit with piston of standard size, allowable bore wear（mm） 95.06
Fit with enlarged (0.5mm) piston, allowable bore wear （mm） 95.56

Cylinder
block

Taper and out of round（mm） Limit 0.01

Standard No1 64.000～64.008
Main bearing hole on cylinder block（mm ）

No 2 64.009～64.016

No 3 64.017～84.024

reduction(0.25mm) non-grouping （mm）

64.000～64.024

Description Data (mm)
Piton and ring

Piston diameter
（mm）

Standard 94.95～94.96
Enlarge 0.50mm 95.45～95.46

Clearance between piston and cylinder（mm） 0.03～0.05
Piston ring open clearance

（mm）

Top ring

Standard 0.22～0.35
Limit 0.95

·38·

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Description Data (mm)
Piton and ring

Connecting rod and
bearing

Second ring

Standard 0.03～0.43
Limit 1.03
Standard 0.45～0.60

Oil ring

Limit 1.2

Side clearance between ring
groove and ring（mm）

Standard 0.03～0.08

Limit 0.2

Piston pin mounting temperature 80°C
Connecting rod axial clearance

（mm）

Standard 0.160～0.312
Limit 0.35
Standard No1 56.000～56.008

Inner diameter -- connecting
rod big end（mm）

Standard No2 56.009～56.016
Standard No3 56.017～56.024

Connecting rod big end inner diameter at bearing inner hole
reduction (0.25mm), non-grouping（mm）

56.000～56.024

Standard No1 1.481～1.485

Center wall thickness -- connecting rod bearing
（mm）

Standard No2 1.486～1.489
Standard No3 1.490～1.493

Center wall thickness at bearing inner hole reduction (0.25mm),
non-grouping（mm）

1.601～1.607

Bearing clearance（mm）

Standard 0.030～0.059
Limit 0.1
Standard 0.005～0.011

Clearance between piston pin and bushing（mm）

Limit 0.015
Piston pin diameter（mm） Standard 24.000～24.009
Bushing inner diameter（mm） 24.008～24.017
Bending & distortion at each 100mm（mm） Limit 0.05
Twisting at each 100mm（mm） Limit 0.15

Flywheel End face run-out （mm） Limit 0.1
Crankshaft

Axial clearance （mm）

Standard 0.02～0.022

Limit 0.3
Thrust plate thickness（mm） Standard 2.400～2.440

Standard 0.020～0.049
Main journal radial clearance（mm）

Limit 0.1

Chapter 1 Main Data and Specification of VIEW Series Light-bus

Description Data (mm)

·39·

Crankshaft

Main journal diameter（mm） 59.987～60.000
Main journal min. diameter（mm） 59.745～59.755

Standard No1 1.986～1.990

Standard No2 1.991～1.994

Standard No3 1.995～1.998

Center wall
Main bearing center wall thickness（mm）

thickness at

main bearing

inner hole

1.601～1.607
reduction
(0.25),
non-grouping

Crank pin diameter（mm） Standard 52.987～53.000
Crank pin min. diameter (at connecting rod

bearing reduction of 0.25mm)（mm）

52.745～52.755

Run-out （mm） Limit 0.03
Taper and out of round –main journal（mm） Limit 0.005

Taper and out of round—crank pin journal
（mm）

Limit 0.005

Outer diameter（mm） Standard 37.922～37.932

Valve tappet

Standard 0.028～0.053

Clearance （mm）

Limit 0.1

1.5.5 The specification of tightening torque

1.5.5.1 Tightening torque of main fastener
Tightened parts N-m

Cylinder head x camshaft bearing cap 16
Cylinder head x chain tensioner 21
Cylinder head x spark plug 18
Cylinder head x exhaust manifold 49
Cylinder head x fuel pump 20

Nut 12

Cylinder block x oil filter bracket

Joint bolt 67

Cylinder block x water plug 25

·40·

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

First 44

Cylinder block x cylinder head

Second 90° turning

Third 90° turning

First 44

Cylinder block x crankshaft main bearing cap

Second 90° turning

First 25

Connecting rod x connecting rod bearing cap

Second 90° turning
Crankshaft x crankshaft pulley 245
Camshaft x distributor drive gear 74
Crankshaft x flywheel 88
Crankshaft x drive plate 74
Oil pan x oil plug 25
Alternator x bracket 59
Engine mounting isolator x engine mounting bracket 44
Intake manifold x TVSV 25
Coolant bypass flange x thermostat 25
EGR valve x intake manifold 20
EGR valve x EGR pipe 20
Exhaust manifold x EGR pipe 20
Fuel outlet pipe x intake manifold 20
Fuel outlet pipe x injector cover 4.4
NO 1 fuel supply pipe x fuel outlet pipe 29
No 1 fuel supply pipe x fuel filter 29
Cold start injector pipe x cold start injector 20
Cold start injector pipe x fuel outlet pipe 20
Pressure regulator x fuel outlet pipe 25

Chapter 1 Main Data and Specification of VIEW Series Light-bus

·41·

1.5.5.2 Bolt standard tightening torque

Mark grade Mark grade
Hex bolt

Hex flange bolt w. washer
Hex head bolt

No. mark on bolt head

4- 4T
5- 5T
6- 6T
7- 7T
8- 8T
9- 9T
10- 10T
11- 11T

W/o mark 4T

W/o mark 4T

Stud
W/o mark

4T

With slot

6T

Hex bolt

Hex flange bolt w. washer

Hex head bolt

Two projecting lines 5T

Two projecting lines 6T

Welding bolt

4T

Hex bolt

Two projecting lines 7T

Hex bolt

Four projecting lines 8T

·42·

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Specified tightening torque – standard bolts

Specified torque

Rating Diameter (mm) Pitch (mm)

4T

6 1 5 6

8 1.25 12.5 14
10 1.25 26 29
12 1.25 47 53
14 1.5 74 84
16 1.5 115 --

5T

6 1 6.5 7.5

8 1.25 15.5 17.5
10 1.25 32 36
12 1.25 59 65
14 1.5 91 100
16 1.5 140 --

6T

6 1 8 9

8 1.25 19 21
10 1.25 39 44

Hex bolt Hex flange bolt

N-m N-m

7T

8T

9T

10T

11T

12 1.25 71 80
14 1.5 110 125
16 1.5 170 --

6 1 10.5 12

8 1.25 25 28
10 1.25 52 58
12 1.25 95 105
14 1.5 145 165
16 1.5 230 --

8 1.25 29 33
10 1.25 61 68
12 1.25 110 120

8 1.25 34 37
10 1.25 70 78
12 1.25 125 140

8 1.25 38 42
10 1.25 78 88
12 1.25 140 155

8 1.25 42 47
10 1.25 87 97
12 1.25 155 175

Chapter 1 Main Data and Specification of VIEW Series Light-bus

1.6 Model 4G64 Engine main technical specification

1.6.1 Model 4G64 S4 MPI engine performance curve

·43·

·44·

In line, four cylinders, roof type combustion

chamber, SOHC 16 valves, four strokes, water

PON93 or above superior unleaded gasoline

imited operation (L/100km)

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

1.6.2 Engine main technical parameters

SN Description Parameters

1 Model Mitsubishi 4G64 S4 MPI

2 Type

cooling, multi-point EFI gasoline engine

3 No.of cylinder 4
4 Cylinder bore (mm) 86.5
5 Piston stroke(mm) 100
6 Total displacement (L) 2.351
7 Compression ratio 9.5
8 Fuel injection and ignition sequence 1-3-4-2

9 Fuel rating

(GB17930)

10 Oil rating SE or above 10W-30 or 15W-40 (GB11121)
11 Oil volume (L) 4.3 (with 0.3L in oil filter)
12 Coolant volume (L) 8 (8.5 L with rear heater)

intake valve open 18° BTDC

Port timing

13

(Crankshaft turning angle)

Intake valve close 53° ABDC
Exhaust valve open 50° BBDC

Exhaust valve close 18° ATDC
14 Spark plug clearance (mm) 1±0.1
15 Cooling method Forced close water cooling
16 Rated power / rated rpm (kw/rpm) 93/5250
17 Max torque/max torque rpm (N-m/rpm) 190.12/2750
18 Min. fuel consumption (g/kw/h) 258.4

Fuel consumption at l

19

(for light bus)

8.54

20 Idle rpm 750±50

at idle ≥96

21 Oil pressure(KPa)

At 200 rpm ≥205
At 3000 rpm ≥386

CO% 1.0±0.5

22 Pollutant emission

HC(ppm) 2.≤500comply with GB18352.2

23 System fuel pressure (KPa) 300 ± 20

Chapter 1 Main Data and Specification of VIEW Series Light-bus

Total mass (with engine, water pump, without clutch

SOHC, 16 valves (2 intake/exhaust valves for

SN Description Parameters

24 Dimension (L×W×H) (mm) 695×635×632

·45·

25

and housing) (kg)

161.8

26 Thermostat opening temperature （℃） 82 (100 at fully open)
27 Ignition advance angle 5°± 2°BTDC
28 Lubrication method Pressure and splashing
29 Crankshaft turning direction Counter-clockwise (viewing from engine front)
30 Cylinder sleeve type W/o sleeve
31 Fuel supply method Multi-point EFI

32 Valve train

33 Drive belt deflection (under 98N.m) (mm)

each cylinder)
Alternator

Power steering pump
AC compressor pump

Check value 5.5～8.5
new belt 5.5～7.5
used belt 7.5～8.5

34 Tensioner projection（mm） 3.8～4.5

1.6.3 Fitting sizes of engine main parts

Description Standard Limit

Alternator belt

Camshaft

Cylinder head

Valve

Tensioner arm projection (mm) 12 -­Tensioner arm press-in ( 98～196N-m) (mm) ≤1 --

Cam height (mm)

Intake 37.39 36.89

Exhaust 36.83 36.33
Shaft diameter (mm) 45
Lower plane flatness (mm) 0.03 0.2

Surface grinding limit ★total grinding amount (block
and head) (mm)

★0.2

Total height (mm) 119.9～120.1
Length of cylinder head bolt (mm) 97.4 ≤99.4

Intake 1.0 0.5

Top edge thickness (mm)

Exhaust 1.2 0.7

Valve stem diameter (mm) 6.0
Radial clearance—valve stem and

guide (mm)

Intake 0.02～0.05 0.10
Exhaust 0.03～0.07 0.15

Top cone angle (degree) 45～45.5 --

Height (mm)

Intake 112.30 111.80

Exhaust 114.11 113.61

·46·

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Description Standard Limit

Free height 51 50.5

Valve spring

Operating pre-tension / operating height (N/mm) 267/433 -­Verticality (degree) ≤2 ≤4
Contacting width (mm) 0.9～1.3 -­Inner diameter (mm) 6 --

Valve guide

Outer diameter (mm) 11 -­Press-in height (mm) 14 -­Valve stem projection (mm) 49.3 49.8

Description Standard Limit

Drive gear 0.08～0.14 --

Oil pump Side clearance (mm)

Driven gear 0.06～0.12 --

Piston Piston clearance (mm) 0.02～0.04

Top ring 0.02～0.06 0.1

Side clearance (mm)

Second ring 0.02～0.06 0.1

Piston ring

Top ring 0.25～0.35 0.8

End clearance (mm)

Second ring 0.4～0.55 0.8
Oil ring 0.10～0.40 1.0

Outer diameter (mm) 22.0 --

Piston pin

Press-in force (N) 7399～17150 --

Press-in temperature

Room
temperature

--

Radial clearance – connecting rod journal (mm) 0.02～0.05 0.1
Radial clearance – main journal (mm) 0.02～0.04 0.1

Crankshaft

Main journal (mm) 57 -­Connecting rod journal (mm) 45 -­Axial clearance – crankshaft (mm) 0.05～0.18 0.25

Connecting rod Big end side clearance (mm) 0.10～0.25 0.4

Flatness—upper surface (mm) 0.05 0.1

Cylinder block

Grinding limit (mm) – upper surface ▲ total
grinding of cylinder block and head (mm)

Total height (mm) 290±0.1 --

-- ▲ 0.2

Inner diameter – bore (mm) 86.5～86.53 -­Bore cylindricality (mm) 0.01 --

Chapter 1 Main Data and Specification of VIEW Series Light-bus

Enlarged and second

Description Standard Limit

processed size (mm) –
valve guide hole
(intake/exhaust)

·47·

0.05OS 11.05～11.07

0.25OS 11.25～11.27

0.50OS 11.50～11.52

Cylinder head

Enlarged and second

0.30OS 34.435～34.455

processed size (mm) –
intake valve seat ring
Enlarged and second

0.60OS 34.735～37.755

0.30 OS 31.935～31.955

processed size (mm) –
exhaust valve seat ring

0.60OS 32.235～32.255

Alternator Rotor winding resistance (Ω) 3～5 --

1.6.4 Tightening torque of engine bolts

Tightening torque for main bolts

S.N. Tightening location Torque (N-m)

Rocker arm cap bolt 3.84

Rocker arm and camshaft

Cylinder head bolt 1.96+90°~ +90°

Bolt-rocker arm and camshaft assembly 31.4
Thrust cap bolt 18.6

Drain plug 44.1
Oil pan 6.86
Oil strainer bolt/nut 18.62
Oil pressure switch 9.8
Oil discharge plug 44.1

Oil pump front cover

Bracket bolt – oil filter 18.62
Front cover bolt 23.52
Plug 23.52
Flange bolt 36.26
Bolt – oil pump cover 15.68
Screw – oil pump cover 9.8

Connecting rod nut 19.6 +90°~ +90°

Flywheel bolt 132.3
Rear cover plate mounting bolt 10.78

Crankshaft, cylinder block and
flywheel

Bell cover mounting bolt 8.82
Oil seal cover mounting bolt 10.78
Main bearing cap bolt 24.5 +90°~ +90°

·48·

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

S.N. Tightening location Torque (N-m)

Bracket bolt 4.9

Throttle body

Alternator, ignition system

Throttle position sensor 3.43
Idle air valve bolt 3.43
Mounting nut – idle speed adjusting screw 2.94
Cooling fan bolt 10.78
Fan clutch bolt 10.78
Alternator fixing bolt 23.52
Brace bolt 23.52
Pivot nut 22.54
Crankshaft pulley bolt 24.5
Spark plug 24.5
Distributor bolt 12.74
Ignition coil bolt 23.53
Locating bushing bolt – camshaft pulley 9.8
Bolt -- front lower cover 10.78
Bolt – tensioner 48.02

Timing belt

Fuel system

Bolt – tensioner arm 21.56
Bolt – auto tensioner 23.52
Bolt—center pulley 35.28
Brace bolt – tensioner 48.02
Bolt – timing belt rear cover 10.78
Timing belt indicator 8.82
Fixing bolt – oil pump pulley 53.9
Bolt – crankshaft pulley 117.6
Fixing bolt – tensioner “B” 18.62
Fixing bolt – balance shaft pulley 45.08

Bolt – camshaft pulley 88.2
Fixing bolt – balance shaft pulley 45.08
Throttle 18.62
EGR valve 21.56
Injector and distribution pipe 11.76
Fuel return pressure regulator 8.82
Intake manifold 8.82

Chapter 1 Main Data and Specification of VIEW Series Light-bus

S.N. Tightening location Torque (N-m)

Engine lug bolt 18.62
Engine coolant temperature sensing plug 29.4

·49·

Intake manifold

Coolant outlet pipe joint bolt 19.6
Intake manifold bolt 19.6
Coolant temperature sensor 10.78
Intake manifold bracket 13.72
Bolt – exhaust manifold cover 13.72
Joint bolt – coolant inlet pipe 23.52
Exhaust manifold nut (M8) 29.4
Exhaust manifold nut (M10) 49

Exhaust manifold

Joint bolt – coolant bypass pipe 23.52
Bolt – coolant pipe sets 12.74
Bolt – thermostat case 23.52
Water pump bolt 13.72

Tightening toque for ordinary bolts
Tightening torque for bolts and nuts

Torque ( N-m)

Bolt diameter

Pitch

Bolt (with spring washer) Flange bolt

Head mark 4 Head mark 7 Head mark 10 Head mark 4 Head mark 7
M6 1.0 -- 8.82 12.74 -- 10.78
M8 1.25 10.78 17.64 29.4 13.72 23.52

M10 1.25 19.6 33.32 58.8 29.4 49
M12 1.25 35.28 60.76 105.84 53.9 88.2

Bevel pitch tightening torque

Torque ( N-m)

Pitch size

Light alloy Cast iron, steel

NPTF 1/16 4.9～7.84 7.84～11.76

PT 1/8 7.84～11.76 14.7～21.56

PT1/4 19.6～29.4 34.3～44.1

NPTF 1/4 19.6～29.4 34.3～44.1

PT 3/8 39.2～53.9 53.9～73.5
PT 1/2 68.6～98 117.6～156.8

·50·

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Plastic area tightening method (bolt)

▲ The method is used on following bolts:

1. Cylinder head bolts

2. Main bearing cap bolts

3. Connecting rod bolts

▲ Tightening methods

Tightening the bolt for another 90～100 ° (two 90° for a cylinder head) after it has been tightened with

specified torque. Tightening method varies in different area. Observe the indicated methods in this book.

1.6.5 Sealant application

(1) Sealant

Sealant is used on relevant part of an engine. Special care should be taken to sealant applying amount,
applying location and state of applying face so as to obtain a good sealing. Insufficient applying will lead to poor
sealing and leaking, while over applying will lead to sealant overflow to block coolant / oil ducts. Correct sealant
applying requires consistent and even application on connecting surface, ensuring the whole connecting surface
has a layer of flat sealant.

(2) Remove sealant on connecting surface

It is usually easy to remove the sealant-combined parts. In some case, the process can apply a wood stick or
same tool to knock slightly to break the sealant on connecting surface. A flat and smooth sealant scraper can also
be used for removing (insert it into connecting surface), but be sure not to injure the surface. Use oil pan special
tool (MD998727) to remove engine oil pan.

(3) Clean the connecting surface

Clear dirt on the surface with a sealant scraper or a wire brush to make sure the surface is flat and smooth,
free from oil stain and dirt. Note to remove the sealant on mounting holes and thread holes.

(4) Applying tips

Apply sealant evenly on specified diameter to circle the mounting hole. Mount parts while sealant is still wet
(with 15 minutes). Leave enough time for sealant to harden after parts-mounting (around 1 hour). Do not apply oil
on applying area or run the engine during the period.

(5) Sealant application location

Location Sealant rating
Coolant outlet pipe joint MD970389 or equivalent
Coolant bypass pipe joint MD970389 or equivalent
Coolant temperature unit 3MATD No. 8660 or equivalent
Oil pan MD970389 or equivalent
Oil seal cover MD970389 or equivalent
Oil pressure switch 3MATD No. 8660 or equivalent
Coolant temperature sensor 3M NUT LOCKING NO.4171 or equivalent

Chapter 2 Vehicle Technical Maintenance

·51·

Chapter 2 Vehicle Technical Maintenance

With the improvement of vehicle technology and quality, vehicle maintenance becomes more important.

Vehicle maintenance should be performed regularly based on preventive and forcible principles.

Vehicle maintenance procedures are arranged according to gradual changes of vehicle technical conditions,
and they should be preformed before these conditions become deteriorated. Therefore, vehicle maintenance is of
preventive nature. To perform forced maintenance according to maintenance interval and technical requirements
will keep vehicle clean and tidy, pinpoint and remove timely potential faults so as to prolong vehicle service life.

2.1 Routine maintenance

Vehicle parts tend to become loose, worn-out and damaged during vehicle’s operation, which harm vehicle’s
performance. Routine maintenance carried out by driver will reverse these effects and keep vehicle in a proper
working condition. Driver keeps watching vehicle’s technical conditions by means of routine maintenance is very
important to drive safely and avoid accident.

2.1.1 Routine maintenance procedures

a. Before, within and after using vehicle, check safety mechanism and fittings for fastening;
b. Keep oil, air, fuel filters and battery surface clean;
c. Avoid fuel, water, air and electricity from leaking.

These steps will keep vehicle in a clean look and good working condition.

Figure 2-1 Vehicle routine maintenance procedures

Category

External 1. Check and clean mirrors outside driver cab, windshield and window glasses;

2. Check vehicle appearance, paint and corrosion on body;

3. Check tyre adjustment and wheel lugs’ fastening.

4. Check and adjust windshield wiper;

5. Check and lubricate door hinges and engine hood;

6. Check and adjust battery fluid level or check battery gravity indication.

Interior 7. Check vehicle for any leaks;

8. Check and adjust vehicle lights and signals;

9. Check and adjust horn;

10. Check wiper and windshield washer;

11. Check windshield defroster;

12. Check and adjust rear view mirrors and sun-shield;

13. Check steering wheel free travel and its operation.

14. Check gas pedal performance;

15. Check clutch/brake pedals free travels and their travel smoothness at depressing and releasing;

16. Check brake performance;

17. Check parking brake performance.

Engine

compartme

nt

18. Check and add engine oil;

19. Check and add engine coolant;

20. Check and add windshield washer fluid;

21. Check and add fluid to brake master cylinder and clutch master cylinder.

22. Check and clean air filter element.

23. Check engine intake / exhaust systems for fastening.

Procedures

·52·

proof capability, add coolant or adjust coolant concentration

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

2.1.2 Procedures for routine vehicle maintenance

Before, within and after using vehicle, it is suggested to perform routine maintenance procedures indicated
with following flow chart (figure 2-1):

Check and clean

Fastening and

Figure 2-1 Routine maintenance flow chart

Check before driving

Checking during driving

Check after driving

Replenish fuel, air,

lubricating

coolant and electricity

Back to normal operation condition

Remove faults

2.2 First level maintenance

For 1st level maintenance, the interval or mileage are 6 months or 7500km－15000km respectively, whoever
comes first will override. First maintenance is carried out by service technician, it focuses on cleaning, fastening
and lubricating procedures beside these have made in routine maintenance procedures, and also includes checks
on safety-related devices such as brake and operating mechanisms.

2.2.1 Procedures for 1st level maintenance (see chart 2-2)

Chart 2-2 Procedures for 1st level maintenance

1. Check lubricating, cooling, exhaust and fuel systems for leakage or damage;

2. Replace engine oil and oil filter element;

Engine

Chassis

3. Check coolant level and its frozen­if necessary;

4. Clean air filter, replace filter element if necessary.

5. Check drive belt condition and tension, adjust belt tension or replace belt if necessary.

6. Check clutch pedal travel;

7. Check transmission for leakage or damage;

8. Check UJ boot for damage;

9. Check tie rod ball joint for fastening and clearances, and check if boot is damaged;

10. Check brake system for leakage or damage;

11. Check brake fluid level, add fluid if necessary;

cabin and

cargo body

Electrical

system

Road test

Chapter 2 Vehicle Technical Maintenance

12. Check brake pad lining’s thickness;

13. Check and adjust manual brake devices;

14. Check tyre for pressure, wear or damage;

15. Check wheel lugs torque;

16. Check tyre tread depth.

17. Check door hinges and limit arms;

18. Check for any crack and loosening,

19. Check performances of headlights, alarm lights, turning lights and horn;

20. Check and adjust headlight beams;

21. Check windshield wiper and washer, add fluid if necessary;

22. Check battery fluid level, add distilled water if necessary;

23. Check and test vehicle technical performance.

·53·

2.2.2 Requirements to First Level Maintenance

1. All exposed nuts and bolts at following units are complete, fastened and crack-free: engine FR/RR
suspensions, intake/exhaust manifolds, assisted exhaust brake system, heating and A/C systems, engine radiator,
tyres, propeller shaft, vehicle body, accessory brackets;

2. Steering arm, steering tie rod and brake controls operate well with complete fittings; no free plays on tie
rod ball joints, steering cross bearings and propeller shaft cross bearings;

3. Fluid levels of steering gear, transmission, transaxle should be 0-15mm under inspection doors (check
when engine is cold), vent hole should not be blocked; and flange nuts on transmission, final drive are fastened.

4. Lubricating fluid nozzles are complete and on their right mounting positions; all lubricating spots are fed
without being ignored,

5. Air filter element is clean and effective,

6. Tyre pressure is up to standard, no stone or other hard objects embedded in tyre.

7. Free travel of clutch and brake pedals comply with technical standards.

8. Lights, meters, horn and signals are complete and work well.

9. Battery fluid level is 10-15mm higher than plates, and battery vent hole unclogged and connectors
fastened.

10. No free play on wheel hub bearings,

11. Test run vehicle to check maintenance result. During test, there should be no abnormal noise on engine
and chassis, each control mechanism should meet technical demands; steering and braking system are sensitive
and reliable, and no loosening on fittings. After test run, check engine and chassis for oil, fluid, air and electricity
leakages.

2.2.3 Flow chart of 1st level maintenance

Flow chart of 1st level maintenance is indicated as follow:

·54·

Workshop

check

Service

operation

Material

and labor time

calculation

Maintenance schedule

Process

check

Finish

check

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Delivery

Fill out technical files

Chart 2-2 Flow chart of 1st level maintenance

2.3 Second level maintenance

After being used for a longer period of time or mileage (30000km or 12 months), vehicle should be checked
and adjusted thoroughly to retrieval its safety, power and fuel economy. For these purpose, vehicle is required to
be serviced completely with Second Level maintenance. Second level maintenance mainly focuses on checks and
adjustments besides these have made during first level maintenance, it also dismantles tyres to check and rotate.
To avoid vehicle’s early damage, vehicle will be diagnosed and analyzed technically before starting this
maintenance, and additional services or repairs based on diagnosed results may be added to maintenance
procedures. Professional service technician performs 2nd level maintenance.

2.3.1 Vehicle’s Technical judgment before 2nd level maintenance

Before 2nd level maintenance, there should be checks both with instruments and manually. These checks will
diagnose possible faults and assass vehicle’s technical condition, so as to determine additional procedures to 2nd
maintenance’s basic procedures.
Basic methods to assass vehicle’s technical condition:

1. To know how the vehicle is driving. Service technician will ask driver how the vehicle is running (includes

engine power, abnormal noise, steering and braking performance, and oil consumption).

2. Review vehicle’s technical records that include records on driving, maintenance, check/test, assembly

repair and minor repairs during maintenance cycles.

3. Analyze results from instrumental check/test and manual check to pinpoint faults.

2.3.2 Diagnosing procedures before 2nd level maintenance

1. Engine check and test: performances at acceleration and deceleration, and possible engine’s smoke

emission and leakage;

2. Power-train check and test: clutch performance, transmission internal coordination, sealing conditions of
transmission and final drive. And also check transmission and final drive’s working temperature, and check for
any abnormal noise in the system.

3. Brake system: performances of main brake system, parking brake system, exhaust assisted brake system.
And check systems for any leakage.

4. Steering system check/test: steering wheel free travel, system performance, and check for any leakage.

Chapter 2 Vehicle Technical Maintenance

,

Piston ring wear, top and

side gap increase, piston

Cylinder worn, large

clearance between

cylinder

cylinder, select piston,

ring stuck, ring

ring and piston,

head burnt, bore

piston (adjust

advance angle of

cooling

between crankshaft

/connecting rod bearing,

Remove to check, adjust

clearance, check

crankshaft journal wear,

its roundness and

cylindrical. Cut if

nd

check camshaft

fitting clearance

and abnormal sound

piston, piston pin and

connecting rod cooper

Remove to check

clearances among them,

oil pressure,

d due to

bearing

to check, repair if

s power is 75%

Cylinder pressure is 80%

outputs

Excessive crankshaft case

value is low and

Higher cylinder leakage,

air pressure drops up to 0.25

7. Oil consumption increases

Piston top burnt, cylinder

Crankshaft bearing

valve clearance,

valve clearance,

check valve mechanism,

repair or replace if

·55·

5. Drive line system check/test: abnormal tyre wear, suspension bushes wear, and check bolts on body for
any loosening, rust and distort, also check body surface for corrosion and paint peel-offs.

6. Electrical devices check/test: dashboard gauges’ indication, oil pressure, coolant temperature, alternator
charging indication, A/C, and heating device’s operation.

Checking methods: with check/test equipment, vehicle tester and by experience.

2.3.3 Technical performance assassment and additional service before 2nd level maintenance

Basis for additional service Description to 2nd level maintenance, details see chart 2-3.

Chart 2-3. Basis for additional service procedures to 2nd level maintenance

Category Location Check results Faults Additional services

Poor valve seal Adjust valve clearance

grind valve

Replace piston ring

ring breakage;

Check and measure

pistons and

bore cylinder if necessary
walls;
Piston
bank broken

Replace

check cylinder

Replace
Piston
scratched

injection), check

system.
Larger fitting clearance

abnormal sound

measure

necessary.
Worn-out camshaft a
its timing gear

remove to

and timing gear
Larger

instrument

al check

engine

1. Engine’
lower than rated value;

2.
lower than rated value.

3. Uneven power
among cylinders;

4.
gas leakage

＞40L/min（1000r/min）
＞70L/min（2000r/min）

5. Vacuum
unstable;

6.

Mpa;

(＞0.3L/100km);

8. Low oil pressure;

9.
scratched;

10.
whining;

11. Piston pin whining;

12. Cylinder knock;

13. Valve noise.

--

bush
Low
abnormal soun
larger crankshaft
clearance
Larger
worn valve mechanism

replace if necessary

Remove

necessary

Adjust

necessary

·56·

camshaft bearing

to check camshaft

valve

crankshaft axial

crankshaft thrust

pump shaft

bearing damaged or

to check water

pump, replace bearing or

k, remove

skipping, worn

friction plate,

incomplete release,

to check clutch,

replace friction plate or

clutch

sound or frequent

or broken shaft,

to check

meshing clearance or

s

gear face or larger

meshing clearance,

differential,

final drive, axle case

(frequent

gear meshing

to check final

meshing

clearance, worn gear,

ball groove worn to stick

steering wheel free

travel, remove to check

and free

shaft counter

play or bearing

to check counter

failure (adjustment does

to check or

deformed, serious paint

axle distorted,

kingpin

front wheel

alignment, remove to

check or replace kingpin

or bush, correct or replace

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Category Location Check results Faults Additional services

manual

check

Abnormal sound ­mechanism

Valve spring broken Replace valve spring
Noise--

Remove

bearing
Worn timing gear Replace timing gear

Engine

Larger
clearance

Worn
washer

Replace thrust washer

Oil leak at crankshaft oil seal Oil seal failure Replace oil seal
Abnormal sound-- water pump Water

Remove

Clutch

Transmission

Axle

Steering

gear

Others

shaft broken

water pump

Engine over heated Radiator pipe restricted Remove to chec

pipe restrictions.

Clutch failure Clutch

Remove

return spring
unstable engagement

Abnormal sound －

Bearing damaged Replace release bearing

release bearing
Abnormal
repair--transmission
Enlarged
abnormal sound－final drive’
drive/driven gears

Worn
gear, bush

Worn
meshing clearance

Remove

transmission

Adjust

check gear fitting.

abnormal sound-

temperature ＞ 60 ℃

Incorrect
or tooth broken

Remove

drive and differential

minor repair)
steering wheel free travel＞10

Larger

Adjust

º, stuck or heavy

steering gear

Abnormal
play-propeller
bearing
Brake
not work)
Body
peel-off
tyre side wear

Radial
worn to stick

Worn-out brake pad

Remove

bearing

Remove

replace pad / shoe

Metal crack, rust Repair, weld and paint

Perform
Front
steering knuckle
play, axle parts distorted

distorted parts

Chapter 2 Vehicle Technical Maintenance

leakage at oil seals on

transmission, steering gear, axle

oil seal, poor

power and reliability

decreased, fuel and oil

consumption increased. Chassis

and body conditions turn to

service or

·57·

Category Location Check results Faults Additional services

Serious

Aged

Replace oil seal
sealing

case.

General

comments

Engine

Engine or

vehicle

Engine passably

overhaul vehicle

worse

2.3.4 Basic service procedures during 2nd level maintenance

Professional technician performs the 2nd level maintenance that includes these services in 1st level
maintenance, mainly focuses on check and adjustment, and also on check tyres rotation. The basic service items
see chart 2-4.

Chart 2-4 Basic service procedures of 2nd level maintenance

Category Description

1. Check lubrication, fuel and cooling systems for leakage

Engine and

clutch

Drive system

Steering

system

2. Check exhaust system for leakage or damage

3. Replace engine oil or oil filter

4. Check coolant level and coolant performance, add coolant or adjust concentration if necessary

5. Check belt tension and condition, adjust tension or replace it if damaged

6. Clean air filter, replace element if necessary

7. Replace fuel filter

8. Check clutch pedal free travel, adjust if necessary

9. Check and clean fuel injector

10. Check advanced angle of injection, adjust if necessary

11. Check transmission for leakage

12. Check propeller shaft and UJ

13. Check tie rod ball joint for fastening and clearance, adjust if necessary

14. Check brake system for leakage or damage

15. Check pad lining thickness, replace pad if necessary

Brake system

and wheel

16. Check and adjust parking brake unit

17. Check assisted exhaust brake system performance

18. Check tyre pressure

19. Check tyre for tread depth and wear

20. Check wheel lug torque

·58·

Delivery

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Category Description

21. Check performances of headlights, alarm light, turning lights and horn

22. Check performances of windshield wiper and washer devices

Electrical

system

23. Check windshield fluid level, add if necessary

24. Check battery fluid level, add distilled water if necessary

25. Check air filter

A/C system 26 check A/C’s performance and refrigerant amount

Heating unit 27. Check heating fan performance, and any leaks at pipeline and connectors

Road test 28. Check performances of speedometer, brake, shift mechanism and steering mechanism.

2.3.5 Flow chart of 2nd level maintenance

Workshop check

Collect owner’s brief

Check before maintenance

Instrument test

Decide additional operation

Description

Manual check

Fill out technical files

Service operation

Process check

Finish check

Material and labor time
calculation

Figure 2-3 Flow chart of 2nd level maintenance

2.3.6 Requirements to 2nd level maintenance

1. Engine’s three filters (air, fuel and oil) are clean, engine starts easily and runs smoothly, exhausts normally,
temperature and oil pressure are within normal range; engine is sensitive to rpm changes without abnormal noise;
all drive belts are complete with proper tension and without abnormal wear.

2. Clutch pedal free travel is up to standard; clutch operates easily and releases completely, engages smoothly
and reliable; no leakages at pipelines on hydraulic operating systems; there is proper amount of fluid in reservoir
and fluid is clean and clear.

3. Parts in transmission, axle and UJ drive unit are lubricated and connected well, no abnormal noise and
overheating; no jump-gear and shift difficulties; their exterior surfaces are clean and no sign of fluid leaks.

4. Steering wheel free travel and wheel toe-in are up to standards, steering maneuver is light, flexible and
reliable; front wheels do not dive or incline to one side.

Chapter 2 Vehicle Technical Maintenance

ylinder leak and

bearing, rod bearing, pistons, piston pins and valve

index, water content, flash point, PH value and

on engine (oil/water), FR/RR crankshaft, radiator, water

and

performance, transmission, final drive housing surface

sounds from

, differential, final drive, bearing on propeller

·59·

5. Brake pedal free travel and brake clearance are up to standards; brake, parking brake and assisted exhaust
brake all work well without lagging and misalignment; no air leak in brake systems; inertia proportional valve
works well.

6. Tyres are mounted correctly with right pressure; shock absorber system is clean and well, fixed tightly;
wheel hub bearing with right torque and gets well lubricated.

7. Battery is clean and works well, fixed tightly; battery fluid level, gravity and load voltage are up to
standards.

8. Alternator, starter, gauges, lights, signals, switch/button and all other accessories are complete and work
well; all circuit is complete and well and fastened tightly.

9. Vehicle is clean, vehicle body’s pose is sound with well paint; no oil, water, air and electricity leaks. All
lubricating spots are well fed and all connections are tight and reliable.

10. A/C/heating fan work well, their connecting pipelines have no water or fluid leakages.

2.3.7 Required check and diagnosis before 2nd level maintenance

Required check and diagnosing Description before 2nd level maintenance see following chart 2-5.

Chart 2-5 Required check and diagnosing Description before 2nd level maintenance

Category

Parts

tested

Parts

checked

No. Description Check items

1 Engine power No load power, power output balance among cylinders

2

3 Cylinder sealing

Parameters of starting

system

Starting current and voltage

Cylinder pressure, crankshaft case leak, c
vacuum

4 Port timing Open and close angles of inlet/exhaust valves

5 Engine noise

6

Cylinder surface

condition

7 Engine oil lab test

1 Engine

2 Steering system

Crankshaft
mechanism

Cylinder scratch, piston head burnt, coke and piston side wear

Contaminated
motional viscosity
Seals
pump, water jacket; crankshaft axial play and abnormal sound
Steering wheel free travel, steering gear performance
sealing; road test steering stability (if necessary)
Clutch

3 Transmission system

conditions and their oil seals; road test; abnormal
transmission
shaft; case temperatures on transmission and final drive.

4 Drive line Tyre side wear, leaf spring bracket, pin and bush
5 Meters and signals Correct indication
6 Others

·60·

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

2.4 Run-in maintenance

2.4.1 Vehicle during run-in period

To prolong vehicle’s operating year, it is required to let vehicle “break in “ when it is first put into use. Only

after break- in period can a vehicle be put into normal use.

Requirements during run-in period:

1. Run-in mileage: 1500-2000 km;

2. Select better road to drive vehicle with moderate speed, and vehicle’s load and speed should be less than
rated values.

3. Driver should comply with operation rules, keep engine in normal working temperature;

4. Keep vehicle’s routine maintenance checks and fasten outside bolts/nuts regularly; watch closely
temperature changes of each assembly and their sound; and make proper adjustment timely.

5. When run-in period is finished, vehicle should be sent vehicle for run-in service.

2.4.2 Maintenance services during run-in period

Newly purchased or overhauled vehicle must have run-in period. To keep vehicle’s reliable operation and
prolong its operation year, there must be a forced service. BJ1049, BJ1043 vehicle in its “Maintenance Manual
“ enlists detailed requirements to maintenance.

A forced maintenance to find and remove faults after run-in period, which includes complete checks,
fastening and lubricating is crucial to drive vehicle safely.

Vehicle run-in period maintenance includes following cleaning, checks, fastening and lubricating services:

① Change engine oil, transmission and rear axle fluids;

② Change oil filter and fuel filter elements;

③ Check transmission, rear axle, steering gear and engine for leakages, fasten half shaft bolts, steering

drop arm nuts, tie rod ball joint nuts;

④ Check engine coolant and windshield washer fluid levels;

⑤ Check propeller shaft and FR-RR suspension systems, fasten propeller shaft bolts and suspension

U-bolts.

⑥ Check tyre for pressure and technical conditions, fasten wheel lugs;

⑦ Check brake system performance, add brake fluid, check and adjust brake pad clearance;

⑧ Check and adjust engine valve clearance.

Note: Detailed content please see “Maintenance Manual”

2.5 Seasonal Maintenance

Weather conditions affect vehicle’s operation. In the area where lowest temperature drops under 0℃ in a
year, there must be seasonal maintenance before summer and winter. In-using vehicle’s seasonal maintenance is
usually performed by driver, and can also be sent to service workshop for help. Main services for seasonal
maintenance include oil, coolant (according to seasonal temperature requirements) changes, and adjustment on
fuel supply system & power supply system.

1 Change lubrication oil

BJ1049, BJ1043 engine& chassis use multi-level oil that can be applied both in summer and winter. This
makes oil change easy at seasonal maintenance by just selecting relevant oil with same viscosity and by following
changing interval requirement.

Chapter 2 Vehicle Technical Maintenance

Chart 2-6 Viscosity and ambient temperature

Engine oil viscosity rate

5W、5W/30 -32 70W -55
10W、10W/40 -23 75W -40
20W、20W/50 -12 80W -26

85W -12
90、140、250 above 0℃

Chassis gear fluid is mainly used on transmission and final drive assemblies. To change lubrication oil, one
can only adjust its viscosity, and obey all quality and rate requirements in owner’s manual. No alteration is
allowed.

2 Change engine coolant

One can formulate coolant by him or buy it with relevant brand/specification from market. Ethylene
glycol/water coolant is commonly seen. It is rated by icing point as -18℃、-35℃and -45℃. One should select
coolant with rated temperature is 5℃ lower that actual environment temperature.

3 Clean fuel system and select diesel of right rate

Before winter, fuel system should be cleaned thoroughly. Clean all filtering grids, clean and change filter
element and turn to use right-rated diesel. According to their quality, vehicle diesel is rated into three levels as
premium, 1st class and qualified, and classified into 6 rates as 10、0、-10、-20、-35、-50 according to their icing
points. One should select diesel whose rated temperature is 5℃ lower than actual environment temperature to
keep diesel from freezing (paraffin seeping out).

4 Battery maintenance

Before winter, one should clean battery, add distilled water or adjust battery fluid gravity. Right gravities
according to local temperature are as follows:

Below 0℃: 1.24 above -20℃: 1.27 above -30℃: 1.28 above -40℃: 1.29 below -40℃: 1.31

Use battery sulphate with a gravity of 1.853 (15℃) and clean distilled water to adjust a battery gravityIf
battery capacity becomes low due to longer operation, it should be recharged as follows:

Constant current charging: Current: 0．1C20 (C20：20hours capacity). When end voltage reaches 14.4V, go
on charging for 5 hours.

Constant voltage charging: Voltage: 14.4±0.1V, allowed max. current 0.5 C20, keep charging for 16 hours.
Perform these operations could be difficult in cold winter, it is suggested to do some of those works before winter,
which include adjustments, fastening and cleaning on various locations. A thoroughly maintenance may let a
vehicle pass through winter safely.

Lowest operation temp.

（℃）

Gear fluid viscosity rate

Lowest operation temp.

（℃）

·61·

2.6 Vehicle lubrication

▲ Follow these rules to lubricate assemblies and parts:

1. Clean and remove dirt on oil cap, plug and nozzle to avoid them from entering parts.

2. Use grease gun to inject grease till parts interior is full and grease overflow at seam is seen.

3. Use standard grease that can be used year round.

Assemblies& parts lubrication mileage and requirements see chart 2-7

·62·

as per engine manual

as per engine manual

Between FR/RR leaf

shaft

er shaft

Steering knuckle pin

as per engine manual

and local temperature (same

wheel hub

wheel hub

input

as per engine manual

motor and

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Chart 2-7 Assemblies& parts lubrication mileage and requirements

No. Lub. location Lub. rate

1 Engine oil

2 Transmission

Select
and local temperature
Select
and local temperature

Run-in

maintenance

（1500～

2000km）

Change Change Change

Change Add Change

1st level

maintenance

（7500～15000

km or 6 month）

maintenance

（30000km or

12 month）

3 Rear leaf spring pin No.2 lithium grease Add Change

4

springs

Lithium grease
(molybdenum disulfide)

Add Change

5 Propeller shaft UJ No.2 lithium grease Add Change

Propeller

6

spline
Mid propell

7

bricking bearing

No.2 lithium grease Add Change

No.2 lithium grease Add Change

8 Battery terminals Industrial Vaseline
9

General lithium grease Add Change
10 Alternator bearing General lithium grease Add Change
11 Drag link ball joint General lithium grease Add Change
12 Tie rod ball joint General lithium grease Add Change

Select
13 Steering gear

Add Change

as that of transmission)
14 FR leaf spring pin No.2 lithium grease Add Change

Front

15

16

bearing
Rear
bearing

General lithium grease Change

General lithium grease Change

17 Water pump bearing General lithium grease Add Add

Transmission

18

shaft FR bearing

General lithium grease

19 Oil filter (element) Change Change Change

20 Rear axle

Select

or local temperature

Change Add Change

21 Door hinges Engine oil

Wiper

22

driving rod pin

Engine oil

2nd level

add 3～4

drops

add 3～4

drops

Chapter 3 Structure, Adjustment and Service of BJ491EQ1 Gasoline Engine

·63·

Chapter 3 Structure, Adjustment and Service of

BJ491EQ1 Gasoline Engine

Knowledge of structures of the gasoline engine parts, master of adjustment and maintenance essentials and
correct service, and maintenance to the gasoline engine can let the gasoline engine maintain its performance and
quality in long term. Following is a brief description of structures, adjustment and maintenance essentials for parts
of BJ491EQ1 multi point electronic fuel injection gasoline engine.

3.1 Cylinder head parts

The cylinder head parts of BJ491EQ1 multi-point electronic fuel injection gasoline engine is as shown in
Figure 3-1.

Figure 3-1 Cylinder Head Parts of BJ491EQ1 Multi Point Electronic Fuel Injection Gasoline Engine

1-PVC; 2-Valve keeper; 3-Intake valve spring top cap; 4-Exhaust valve spring top cap; 5-Valve spring; 6-Valve oil seal; 7- valve
spring bottom cap; 8-Valve; 9-Rear engine lug; 10-Rear cover of cylinder head; 11-Cylinder head; 12-Cylinder gasket; 13-Hydraulic
valve tappet; 14- Engine front lug; 15-Engine front water pipe assembly; 16-Exhaust pipe connector and gasket; 17-Valve guide;
18-Valve rocker arm shaft; 19-Valve push rod; 20-Spark plug cover; 21-Spark plug; 22-Valve rocker arm and spring; 23-Cylinder
head cover

·64·

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

3.1.1 In order to prevent gas and water leakage from cylinder gasket, operator should check tightening torques

of cylinder head bolts with a torque wrench at every 500km and 2000km (for a new vehicle). The tightening
torques: 10 M12 bolts-- 93~105N·m; 3 M8 bolts--20~25N·m.

Tighen the bolts after the gasoline engine has cooled down. The tightening sequence is as shown in Figure

3-2.

Front

Figure 3-2 Tightening Sequence of Cylinder Head Bolts

● Note: A cylinder head bolt can only be used twice. If the bolt has been used twice, replace with a new one.

3.1.2 Follow the sequence indicated in figure 3-3 to disassemble the rocker arm shaft, unscrew the bolts and

nuts of rocker arm shaft in 2~3 times to avoid breaking off of rocker arm shaft and damage the bolts.

Follow a sequence that is reversed to these indicated in figure 3-3 to assemble the rocker arm shaft assembly,

tighten the bolts and nuts in 2~3 times. The final tightening torque is 25~32N·m.

After a new vehicle has driven 500km and 2000km, its bolts and nuts on rocker arm shaft should be tighened

as per above torque requirements.

Figure 3-3 Sequence for Disassembly of Rocker Arm Bolts

3.1.3 After the gasoline engine has cooled down, follow the sequence that is reversed to these indicated in

figure 3-2 to disassemble the cylinder head. Unscrew the bolts of cylinder head step by step in 3 times to avoid
distortion of cylinder head.

3.1.4 When to mount a cylinder gasket, apply high temperature resistant sealant on surfaces of its both sides so

as to ensure sealing performance. The gasket must be replace each time cylinder head has been dismantled (see
figure 3-4).

Chapter 3 Structure, Adjustment and Service of BJ491EQ1 Gasoline Engine

New cylinder gasket

Front

·65·

Figure 3-4 Installation of Cylinder Gasket

3.1.5 After a cylinder head has been dismantled, clear gasket leftovers embedded on surfaces of cylinder head /

block with a cutter. Be careful not to scratch contact surface and prevent entry of gasket leftover into tappet hole,
water jacket hole and bolt hole (see Figure 3-5).

Figure 3-5 Clearing of Cylinder Head / Block

3.1.6 Check cylinder head for crack, and follow procedures indicated in figure 3-6 to measure warpages of

cylinder head base and sides where intake and exhaust manifold are installed.

Figure3-6 Cylinder Head warpage Mesurement

Maximum warpage:
Cylinder head base: 0.15mm;

·66·

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Manifold side: 0.10mm.
If its warpage exceeds the maximum value, cylinder head.should be replaced.

3.1.7 Check the fitting clearance between valve stem and valve guide hole (see Figure 3-7, Figure 3-8)

Diameter of valve guide inner hole: Φ8.010~Φ8.030mm;
Diameter of intake valve stem: Φ7.970~Φ7.985mm;
Diameter of exhaust valve stem: Φ7.965~Φ7.980mm.
Nominal fitting clearances:
Intake valve: 0.025~0.060mm;
Exhaust valve: 0.030~0.065mm;
Maximum fitting clearances:
Intake valve: 0.10mm;
Exhaust valve: 0.12mm.
If the clearance exceeds the maximum value, replace the valve and valve guide.

Figure 3-7 Check Diameter of Valve Guide

Figure 3-8 Check Diameter of Valve Stem

3.1.8 Check valve cone and plate for depression, groove and carbon deposit. If necessary, grind to correct the

valve cone angle (correct angle is 44.5º). The grinding extent should be as small as possible.(see Figure 3-9).

Nominal edge thickness of intake valve: 1.0~1.4mm;
Nominal edge thickness of exhaust valve: 1.3~1.7mm;
Minimum edge thickness of intake valve: 0.5mm;

Chapter 3 Structure, Adjustment and Service of BJ491EQ1 Gasoline Engine

·67·

Minimum edge thickness of exhaust valve: 0.8mm.

Figure 3-9 Check and Grind Valve Cone

If the edge thickness of valve head is less than minimum value, valve should be replaced. (see Figure 3-10).
Nominal length of intake valve: 108.2mm;
Nominal length of exhaust valve: 108.5mm;
Minimum length of intake valve: 107.7;
Minimum length of exhaust valve: 108.0mm.
If total length of valve is less than the minimum value, valve should be replaced.

Edge thickness

Figure 3-10 Check the Edge Thickness of Valve Head

3.1.9 Check valve seat for wear, damage and carbon deposit. If necessary, grind and clean the valve seat. The

grinding extent should be as small as possible.

Coat a thin layer of Prussian blue (or white lead) on the valve cone, install the valve, gently press and turn
the valve to check its seating condition. If the valve cone along 360º is covered with blue, the valve must be
coaxial; otherwise replace the valve. If the valve along 360º is covered with blue, the valve guide and valve seat
must be concentric; otherwise grind the valve seat. The contact annulus should be at the middle of valve cone with
a width of 1.2~1.4mm (see figure 3-11).

·68·

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Width

Figure 3-11 Check of Wear Status of Valve Seat

If the contact annulus fails to comply with above requirements:

(1) If the contact annulus is on top of the valve cone, grind the valve seat with 30º and 45º mill (see figure 3-12).

Width

Figure 3-12 Grinding the Valve Seat with 30º and 45º mill

(2) If the contact annulus is at the bottom of the valve cone, grind the valve seat with 60º and 45º mill (see
figure 3-13).

(3) Grind the valve and valve seat with valve grinding compound to make them join closely without gas
leaking (see figure 3-14). After grinding, clean the valve, valve seat and inner hole of valve guide thoroughly.

Width

Figure 3-13 Grinding the Valve Seat with 45º and 60º Mill

Chapter 3 Structure, Adjustment and Service of BJ491EQ1 Gasoline Engine

·69·

Figure 3-14 Grinding of Valve and Valve Seat

3.1.10 Measure the free length of valve spring with a caliper, the reading should be 47mm ± 0.5mm; measure

perpendicularity of valve spring with a surface plate and a square, the reading should be less than or equal to 2mm.
If free length or perpendicularity of valve spring exceeds the specified limit, replace the valve spring.

Measure the elastic force of valve spring at nominal installation length 40.6mm with a spring tester, the
reading should be 292~336N. If the elastic force of valve spring at nominal installation length does not comply
with the specified value, replace the valve spring (see figure 3-15).

Figure 3-15 Measue elastic force of valve spring

3.1.11 Check valve rocker arm and rocker arm shaft:

(1) Check for wear on contact surface between valve rocker arm and valve, if necessary, polish this surface
or replace the rocker arm.

(2) Push and turn the rocker arm by hand along the direction shown in figure 3-16, if a relative movement
margin is felt, disassemble and check the fitting clearance between the valve rocker arm and the rocker arm shaft.

·70·

Up

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Figure 3-16 Check Valve Rocker Arm and Rocker Arm Shaft

Inner diameter of valve rocker arm: Φ18.500~Φ18.515mm；

Diameter of rocker arm shaft: Φ18.474~Φ18.487mm;

Nominal fitting clearances: 0.02~0.051 mm;

Maximum fitting clearance: 0.08mm.

If the clearance exceeds the maximum value, replace the valve rocker arm and rocker arm shaft.

(3) Make sure the direction of rear end boss (valve rocker arm shaft) is correct, and follow figure 3-17 to
assemble valve rocker arm and spring. Use special tools to install and clamp during assembly.

Special tool

Forward

Heave

With heave

Figure 3-17 Installation of Valve Rocker Arm

3.1.12 Check push rod

(1) Follow figure 3-18 to check run-out at middle of push rod. The maximum value is 0.30mm. If the value
exceeds the maximum, replace the push rod.

(2) Check oil passage hole of push rod for clogging. If clogging is present, use compressed air to clear up.

Chapter 3 Structure, Adjustment and Service of BJ491EQ1 Gasoline Engine

Figure 3-18 Check Run-out at Middle of Push Rod

·71·

3.1.13 Use special tools (figure 3-19) to disassemble and assemble the valve. The valve spring end with white

paint faces down at mounting.

Special tool

Figure 3-19 Disassembly and Installation of Valve Spring

3.2 Cylinder block parts

See Figure 3-20 for cylinder block parts and crank-connecting rod mechanism parts in BJ491EQ1 multi point
electronic fuel injection gasoline engine.

·72·

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Figure 3-20 Cylinder Block Parts and Crank-connecting Rod Mechanism Parts -- BJ491EQ1 Multi Point

Electronic Fuel Injection Gasoline Engine

1-Piston ring; 2-Piston; 3-Connecting rod and connecting rod cap; 4-Connecting rod bearing sleeve; 5-Rear oil seal gasket;
6-Rear oil seal cover; 7-Drain switch; 8-Main bearing shell of crank; 9-Crankshaft thrust plate; 10-Main bearing cap; 11-Engine oil
strainer; 12-Oil pan assembly; 13-Engine oil pump; 14-Crank; 15-Sprocket chamber gasket; 16-Sprocket chamber cover gasket;
17-Crank pulley; 18-Sprocket chamber cover; 19-Timing chain and sprocket; 20-Sprocket chamber casing

Chapter 3 Structure, Adjustment and Service of BJ491EQ1 Gasoline Engine

No. 3 bearing cap

No. 1,2,4 and 5 bearing caps

·73·

3.2.1 Check axial clearance between big end of connecting rod and end surface of crank-connecting rod journal

with a feeler or a dial indicator. Nominal clearance: 0.160~0.312mm; maximum axial clearance: 0.35mm. If the
clearance exceeds the maximum value, replace the connecting rod (see Figure 3-21).

Figure 3-21 Check End Clearance of Connecting Rod Big End

3.2.2 Check end clearance of crank with a dial indicator. Nominal clearance: 0.02~0.22mm, maximum end

clearance: 0.35mm. If the clearance exceeds the maximum value, replace with a new set of thrust plates. Nominal
thickness of thrust plate: 2.440~2.490mm.

3.2.3 The main bearing caps are not interchangeable, and their directions (front and rear) must be correct. In

order to prevent misplacement or adverse installation, the main bearing cap is marked with sequence number
and cast a “forward” arrow (see Figure 3-22).

Forward Forward

Figure 3-22 Marks on Main Bearing Cap

Figure 3-23 Assemble a Thrust Plate

·74·

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

3.2.4 Thrust plates are installed respectively on both sides of 3rd main bearing seat / cap of cylinder block.

●Note:
(1) When to install a thrust plate, its side with oil groove should be outward. Never install it in adverse

direction (see Figure 3-23).

(2) There are oil grooves and oil holes on the main bearing cover that is installed on cylinder block. The

upper and lower covers can not be installed adversely.

3.2.5 Check cylinder block for crack and damage, and follow Figure 3-24 to check warpage on top deck of

cylinder block with a fine ruler and a feeler (the value should be less than 0.05mm). If the warpage exceeds the
specified limit, use surface grinder to grind the top deck of the cylinder block. Or replace the unserviceable
cylinder block.

Figure 3-24 Check Warpage on Top deck of Cylinder Block

3.2.6 Measure inner diameter of each cylinder bore. Measuring position and direction see Figure 3-25. Nominal

diameter of cylinder bore is Φ91.00~Φ91.03mm. See Table 3-1 for diameters of cylinder bore groups..

Table 3-1 Diameters of Cylinder Bore Groups

First group Φ91.00mm≤D＜Φ91.01mm

Second group Φ91.01mm≤D＜Φ91.02mm

Third group Φ91.02mm≤D＜Φ91.03mm

Lateral

Front

Longitudinal

Middle

Figure 3-25 Measurement of Cylinder Bore Diameter

Maximum cylinder bore diameter: Φ91.23mm.
If diameter exceeds the maximum value, re-bore the four cylinders.

Chapter 3 Structure, Adjustment and Service of BJ491EQ1 Gasoline Engine

·75·

3.2.7 If deep longitudinal score or burn-out is present on cylinder wall, re-bore the four cylinders. The increased

diameter of cylinder bore during repairing (+0.50mm) is Φ91.50~Φ91.53mm. After repair, the wear limit of
cylinder bore is Φ91.73mm.If the value exceeds this limit, replace the cylinder block.

3.2.8 Diameter of gasoline engine piston falls into three groups (see Table 3-2) , each matches the cylinder bore

in the same group. The grouping mark is on top of piston.

Table 3-2 Piston Diameter Group

First group Φ90.938mm≤D＜Φ90.948mm

Second group Φ90.948mm≤D＜Φ90.958mm

Third group Φ90.958mm≤D＜Φ90.968mm

Measuring position for piston diameter: at skirt section, 24mm from top along the direction vertical to piston

pin (see Figure 3-26).

The increased piston diameter for repair is Φ91.438~Φ91.468mm.
The fitting clearance between piston and cylinder is 0.052~0.072mm. Follow the following formula to

calculate the required re-boring dimension.

Cylinder re-boring dimension = piston diameter + cylinder fitting clearance with piston – boring margin
The boring margin should be less than 0.02mm, because excessive boring may destroy finely machined

roundness and cylindricity.

Figure 3-26 Measurement of Piston Diameter

3.2.9 The main bearing hole dimensions fall into three groups. The grouping numbers for first to fifth holes are

marked on rear end of bottom plane of cylinder block. The main bearing shells also fall into three groups. During
assembly, select the main bearing shell with the same grouping number as main bearing hole, and install it into
corresponding main bearing hole (see Figure 3-27).

Check for fitting clearance between crankshaft main journal and main bearing shell. The nominal clearance is

0.020~0.051mm, the maximum value is 0.1mm. If the clearance exceeds the maximum, replace the main bearing
shell, or replace the crankshaft if necessary.

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OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

1, 2 or 3

Front

Figure 3-27 Matching of Main Bearing shell

3.2.10 Follow Figure 3-28 to check run-out of main journal at middle of crankshaft (the maximum run-out is

0.06mm). If the run-out exceeds the maximum value, replace the crankshaft.

Nominal diameter of crankshaft main journal is Φ57.985~Φ58.000mm; nominal diameter of connecting rod
journal is Φ47.985~Φ48.000mm; cylindricity limit of main journal and connecting rod journal is 0.020mm.
Replace the crankshaft if it is out of these range.

Figure 3-28 Check Crankshaft

3.3 Crank-connecting rod mechanism

The crank-connecting rod mechanism of BJ491EQ1multi point electronic fuel injection gasoline engine is as
shown in Figure 3-20.

3.3.1 Check fitting clearance between crank-connecting rod journal and connecting rod shell. The nominal

clearance is 0.020~0.051mm, and the maximum value is 0.100mm. If the fitting clearance exceeds this maximum
value, replace the connecting rod shell or replace the crankshaft if necessary,

3.3.2 Both connecting rod big end holes and connecting rod bearing shells fall into three groups with marks as 6,

7, 8. Assembly should be made within same group.

Mating numbers are marked on sides of connecting rod body and connecting rod cap. Interchanged assembly
is prohibited. The semicircle heaves on connecting rod body and connecting rod cap should be on the same side
with that of piston that has a depression mark on top. They should all face engine front (see Figure 3-29).

Chapter 3 Structure, Adjustment and Service of BJ491EQ1 Gasoline Engine

Depression

Semicircle heave part

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Figure 3-29 Semicircle Heaves on Connecting Rod Body and Connecting

Rod Cap and Depression Mark on Top of Piston

3.3.3 Check bending extent (see Figure 3-30) and distortion (see Figure 3-31) of connecting rod with a

connecting rod corrector. Maximum bending extent: 0.05mm for every 100mm; maximum distortion: 0.05mm for
every 100mm. If bending extent or distortion exceeds the maximum value, replace the connecting rod.

Figure 3-30 Check Bending Extent of Connecting Rod with a Connecting Rod Corrector

Figure 3-31 Check Distortion of Connecting Rod

●Note: When to replace the connecting rod, its cover and bearing shell should be replaced at the same time.

3.3.4 Check piston and piston ring groove for wear. Replace piston if necessary.

●Note: If piston has to be replaced, the ring on it should also be replaced.

The clearance between piston and piston ring (ring groove clearance) is 0.03~0.07mm. If the ring groove
clearance does not comply with the specified value, replace the piston.

Install piston ring into cylinder bore, use piston to press it to the position where is 110mm from top of

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OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

cylinder block, and then measure ring opening clearance (end clearance) with a feeler. Nominal end clearances:
first ring 0.27~0.39mm; second ring 0.40~0.55mm; oil ring: 0.20~0.70mm. Maximum end clearance: first ring:

1.11mm; second ring: 1.07mm; oil ring: 1.10mm (see Figure 3-32).

Figure 3-32 Check Piston Ring Opening Clearance

3.3.5 Use special tools to disassemble and assemble piston and connecting rod assemblies. The usage for

special disassembling tools are as shown in Figure 3-33. The usage for special assembling tools are as shown in
Figure 3-34.

Figure 3-33 Special Tools to Dismantle Piston and Connecting Rod Assemblies

1-Special tools; 2-Piston pin

Figure 3-34 Special Tools to assemble Piston and Connecting Rod Assemblies

1-Special tools; 2-Piston pin

3.3.6 After three piston rings are installed onto ring grooves, their opening positions should be interleaving as

shown in Figure 3-35 with marks on first ring and second ring facing upwards.

Chapter 3 Structure, Adjustment and Service of BJ491EQ1 Gasoline Engine

First ring and oil ring

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Second ring

Front

Oil ring lower blade

Oil ring upper blade

bushing spring

Figure 3-35 Opening Positions of Piston Rings

3.3.7 Check for fitting clearance between bearing hole and journal of camshaft. Inner diameters of bearing

holes (counting from front end) are as follows:

First hole: Φ46.500~Φ46.570mm;

Second hole: Φ46.250~Φ46.320mm;

Third hole: Φ46.000~Φ46,070mm;

Fourth hole: Φ45.750~Φ45.820mm;

Fifth hole: Φ45.500~Φ45.570mm;

Nominal fitting clearances: 0.025~0.111mm;

Maximum fitting clearance: 0.140mm.

If the clearance exceeds the maximum value, replace the camshaft bearing, and replace the camshaft when
necessary.

3.3.8 Measure diameter of hydraulic tappet hole. The value should be Φ21.417~Φ21.443 mm. Nominal fitting

clearance between tappet hole and tappet is 0.017~0.056mm, the maximum value is 0.100mm. If the clearance
exceeds the maximum, replace the tappet.

3.4 Valve Train

3.4.1 Using a wire, follow the procedures in figure 3-36 to take out the valve tappet.

Figure 3-36 Take out Valve Tappet

● Note: Place orderly the valve tappets with heads up for easy re-assembly.

3.4.2 Using a spring scales to pull the timing chain with a force of 98N (Figure 3-37). Measure the clearance

“△” between chain tensioner plug and support, the value should not exceed 13.5mm. Otherwise replace with new
timing chain and sprocket.

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OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Figure 3-37 Check timing chain slackness

3.4.3 Measure journal run-out at middle of camshaft (Figure 3-38), the maximum value should be 0.06mm.

Otherwise replace the camshaft.

Figure 3-38 Measure Journal Run-out at Middle of Camshaft

Check cam height, the nominal heights of cams should be as follows:

Intake cam: 38.620~38.720mm;

Exhaust cam: 38.629~38.729mm;

Minimum cam height:

Intake cam: 38.26mm;

Exhaust cam: 38.27mm;

If cam height is less than the minimum value, replace the camshaft.

Check camshaft journal, the nominal diameters are (count from front end):

First journal: Φ46, 459~Φ46.475mm;

Second journal: Φ46.209~Φ46.225mm;

Third journal: Φ45.959~Φ45.975mm;

Fourth journal: Φ45.709~Φ45.725mm;

Fifth journal: Φ45.459~Φ45.475mm.

If journal dimension of is not within the specified range, follow the procedures indicated in 3.3.7 of this
chapter to check the fitting clearance between camshaft bearing hole and journal.

3.4.4 Install the thrust plate and camshaft sprocket onto camshaft, tighten the fixing bolts of camshaft sprocket

with a 90N.m tightening torque, and then measure axial clearance between thrust plate and first journal thrust
surface with a feeler (see Figure 3-39). The nominal axial clearance is 0.07~0.22mm. The maximum axial

Chapter 3 Structure, Adjustment and Service of BJ491EQ1 Gasoline Engine

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clearance is 0.30mm. If the clearance exceeds the maximum value, replace the camshaft bearing. Or replace the
camshaft if necessary.

Figure 3-39 Measure Camshaft Axial Clearance

3.4.5 Check length of timing chain. Using a spring scales( Figure 3-40) to pull (49N) the chain.The maximum

chain length is 291.4mm. Select 3~4 measurement points at random to measure. If chain length exceeds the
maximum value, chain should be replaced.

3.4.6 Using a caliper (Figure 3-41) to measure diameters of crankshaft timing sprocket and camshaft timing

sprocket ( with chain). Minimum diameters are:

Crankshaft sprocket of: Φ59mm;

Camshaft sprocket: Φ114mm;

If sprocket diameters are less than the minimum value, replace the chain and two sprockets.

Figure 3-40 Check Timing Chain Length

Figure 3-41 Measure Diameters of Crankshaft Timing Sprocket and Camshaft

Timing Sprocket (with Chain)

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OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

3.4.7 Use a caliper to check the thickness of rubber damper. The damper is on the head of chain tensioner plug

(see Figure 3-42). The nominal thickness is 15.0mm, and minimum thickness is 12.5mm.

Figure 3-42 Check the Thickness of Chain Tensioner Rubber Damper

If the thickness is less than the minimum value, replace the plug or chain tensioner assembly. When to
replace or re-instal the plug, operator should first apply a layer of engine oil onto chain tensioner body hole and
plug’s sliding surface.

3.4.8 Check thickness of rubber layer on damper. The nominal thickness is 6.6mm and minimum thickness is

5mm. If the thickness is less than minimum value, replace the damper.

3.4.9 Check outer diameter of valve tappet. The value should be 21.387~21.404mm. Otherwise check fitting

clearance between tappet hole of cylinder block and valve tappet by following procedures in 3.3.8 of this chapter .

3.4.10 Before installing valve tappet onto gasoline engine, discharge the air its inner chamber first and recheck

to ensure air is discharged completely. The methods are as follows (see Figure 3-43):

Figure 3-43 Discharge air from tappet

1-Push rod support; 2-Plunger

Dip the plunger into an engine oil pan, depress push several times to discharge air from tappet inner chamber.
Then fill the chamber with engine oil. Depress push rod again, if push rod is very hard or even fail to move the
plunger, this indicates tappet is in good condition; if plunger is easy to be pressed down, that indicates the tappet is
leaking and should be replaced.

● Note: Tappet body and plunger are precise coupler, which are not allowed to disassemble or interchange at

will. Be sure to use clean oil to perform these procedures.

3.4.11 Leak down test for valve tappet: if possible, use a leak down tester to check tappet leak down(Figure 3-44).

The test oil is industrial alcohol or special test oil. Apply a pressure (196N) on the plunger, and measure the time
required for another 1mm plunger leak down after the plunger has dropped by 2mm (the value should be 7~50s).

Chapter 3 Structure, Adjustment and Service of BJ491EQ1 Gasoline Engine

Mark

(testing ambient temperature is 20℃).

Figure 3-44 Valve Tappet Leak down test

3.4.12 Installation tips for timing sprocket and timing chain:

(1) When to install camshaft thrust plate, its side with two depressions should direct to engine front;

(2) Rotate the crankshaft to move sprocket key to the top, let the key on camshaft top and align with the
depression mark on thrust plate (see Figure 3-45).

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Figure 3-45 Installation of Timing Sprocket and Timing Chain

1-Aligning key of sprocket on camshaft; 2-Aligning key of sprocket on crankshaft

(3) Put the timing chain onto the timing sprockets on camshaft and on crankshaft, and let the two bright
white nodes on the chain respectively align with the depressions on two sprockets.

(4) Let key notches on two sprockets respectively align with the aligning keys on crankshaft and camshaft,
and then install the two sprockets and timing chains evenly and simultaneously (see Figure 3-46).

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OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Figure 3-46 Installation of Sprocket and Chain

3.5 Lubrication system

3.5.1 Check quality of engine oil

Check engine oil in lubrication system for deterioration, moisture, color change or thinning. Change any
inferior oil. Inferior oil may affect the performance and service life of a gasoline engine.

● Note:

(1) Dispose properly changed oil to protect environment.

(2) The engine oil used in lubrication system should comply with the specification in this manual (see

3.2.2)

3.5.1 Check volume of engine oil

Check the volume of engine oil in oil pan with the dipstick. The oil level should be within upper and lower
scales of the dipstick. If the oil level is below the lower mark (L), check for leakage and fill with engine oil till the
oil level reaches upper scale (F) (see Figure 3-47).

Figure 3-47 Check Oil Volume in Oil Pan with the Dipstick

● Note: The oil level could not be higher than the upper scale (F) on dipstick. Otherwise, oil consumption

would become high and the service life of three-way catalytic converter would be shortened as well.

Chapter 3 Structure, Adjustment and Service of BJ491EQ1 Gasoline Engine

3.5.3 Replace engine oil filter

Use special wrench to remove the oil filter. Check and clean the installation surface on filter seat. Coat clean
engine oil on new oil filter gasket (see Figure 3-48).

As shown in Figure 3-49, spin on the new filter onto the filter seat by hand until some resistance is felt, and
then use a special wrench to rotate for 3/4 turn.

● Note: Engine oil filter is one-time service part, which can not be used repeatedly. Dispose the used engine

oil and engine oil filter properly to protect environment.

3.5.4 Check engine oil pump

The engine oil pump is installed on lower front right side of cylinder block and is driven by a impeller.

·85·

Figure 3-48 Replace Engine Oil Filter

Special tool

Figure 3-49 Installation of Engine Oil Filter

(1) Dip the oil strainer into engine oil, rotate the pump shaft clockwise. Engine oil should flow out from oil
outlet of oil pump.

(2) Block the oil pump outlet with thumb and rotate the pump shaft with a slotted point screwdriver. It
should be hard to be rotated.

3.6 Cooling system

3.6.1 Check coolant volume in reservoir

The level of coolant in reservoir should be within upper and lower scales. Add coolant if necessary.

3.6.2 Check coolant quality

(1) Check coolant for cleanness. Change any dirty coolant.

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OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

(2) Check if rust is present around radiator cap and radiator opening.

(3) Check coolant for smear.

3.6.3 Check cooling system

(1) Check cooling system for leakage.

(2) Check radiator and hose for damage and distortion.

(3) Check hose clamps for looseness.

3.6.4 Check fan belt

(1) Check fan belt for crack, extending, deterioration or serious wear. Replace if necessary.

(2) As shown in Figure 3-50, make sure the fan belt engages correctly into pulley.

Correct Incorrect

Incorrect

Figure 3-50 Check Engagement of Fan Belt into Pulley

(3) Check and adjust fan belt tension (see Figure 3-51): Use a force of 98N to press the belt at middle spot
between alternator and water pump. If the deflection is 7~8mm (for a new belt 5-7mm), belt tension is nominal;
otherwise adjust it.

Figure 3-51 Check and Adjust Fan Belt Tension

(4) In cold region, replace with low temperature proof belt in winter.

3.6.5 Check thermostat

Dip the thermostat into water under heating. Gradually to heat up water while checking its opening
temperature and valve stroke (see Figure 3-52).

Chapter 3 Structure, Adjustment and Service of BJ491EQ1 Gasoline Engine

Figure 3-52 Check Thermostat

Opening temperature of the valve: 76℃;

Stroke of the valve: more than 8mm at 88℃.

If the opening temperature and stroke do not comply with specification, replace the thermostat.

The oscillating valve on the thermostat should be turn to upper left position during thermostat installation
(see Figure 3-53).

·87·

Oscillating valve

Figure 3-53 Installation of Thermostat

3.6.6 Check water pump

Check water pump and timing sprocket chamber body for crack; check fitting surface for damages, and check
water pump bearing for free rotation and noise (see Figure 3-54).

● Note: Observe if there is coolant leaking trace from overflow opening.

3.6.7 Check silicon oil fan clutch

Check silicon oil fan clutch (excl. rigid coupling fan) for damage and silicon oil leak. If any, replace the
silicon oil clutch. See Figure 3-55.

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OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Figure 3-54 Check Water Pump

Figure 3-55 Check Silicon Oil Fan Clutch

3.7 Starting system

See figure 3-56 for the starting system of BJ491EQ1 multi point electronic fuel injection gasoline engine.

Ignition switch

Fuse

Terminal 30

Battery

Figure 3-56 Starting System of Gasoline Engine

Terminal 50

Starter

Chapter 3 Structure, Adjustment and Service of BJ491EQ1 Gasoline Engine

·89·

3.7.1 Attraction test for starter

Disconnect excitation coil from C terminal (see Figure 3-57); connect the battery to solenoid, the pinion should
extend out at the moment. If the pinion does not act, replace the solenoid assembly.

Terminal C

Terminal 50

Figure 3-57 Attraction Test for Starter

3.7.2 Maintenance test for starter

As per procedures, when the pinion is in extended position, disconnect negative lead and the pinion should
still be in extended out position. If the pinion retracts, replace solenoid assembly (see Figure 3-58).

Figure 3-58 Maintenance Test for Starter

3.7.3 Check retraction of starter pinion

As shown in Figure 3-59, disconnect negative lead from the solenoid switch body, and the pinion should
retract inwards. If the pinion does not retract, replace the solenoid switch assembly.

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OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Figure 3-59 Check retraction of Starter Pinion

3.7.4 No-load performance test for starter

As shown in Figure 3-60, connect battery and an vlotage meter, and the pinion should extend out. Check if
the starter rotates freely and stably. Check the current, the value should be less than 90A.

Terminal 50

Terminal 30

Figure 3-60 No-Load Performance Test for Starter

3.8 Charging system

Model 65A/90A alternator with regulator is used in BJ491EQ1 engine’s charging system. Its connection is as
shown in Figure 3-61.

3.8.1 Check alternator connection for any abnormal noise during engine running. Dismantle to check if any.

● Warning: Never connect or disconnect wiring during engine running to avoid accident.

3.8.2 Check charging indicator lamp circuit. Start the engine and shut it down after it has warmed up. Turn off

all electrical accessories. Turn the ignition switch to “ON”, the charging indicator lamp should lit then.

Chapter 3 Structure, Adjustment and Service of BJ491EQ1 Gasoline Engine

Soft

Charging

connection
of battery

indicator lamp

Fuse (5A)

Fuse box

Figure 3-61 Charging System Circuit

The charging indicator lamp should extinguis after engine has started. Otherwise check circuit of charging
indicator lamp.

3.9 Crankcase ventilation

·91·

BJ491EQ1 multi point electronic fuel injection gasoline engine is equipped with positive crankcase
ventilation device, which sucks the exhaust gas leaking into the crankcase to intake manifold and then into the
combustion chamber (via vent valve) to burn again. This design tends to protect oil from contaminatded by fuel,
and protect component surface from corrosion due to anhydride formed from exhaust gas and water vapor.
Therefore, never remove the crankcase ventilation device.

The crankcase ventilation system is mainly composed of the positive crankcase ventilation device (PCV) that
is installed on the cylinder head cover, a vent pipe that connects vent valve to intake pipe, and a short pipe that
connects valve cover to air filter pipe.

● Note: During operation, be sure to prevent the vent valve from being clogged. No damage and gas leak on

connecting hose are allowed.

3.10 Clutch

BJ491EQ1 multi point electronic fuel injection gasoline engine adopts diaphragm spring clutch.

3.10.1 Check driven plate of clutch for wear or damage. Measure the depth of rivet head in friction plate. The

depth should not be less than 0.3mm, otherwise replace the driven plate (see Figure 3-62).

If necessary, replace plate and cover assembly of a clutch.

3.10.2 Check for run-out tolerance on the edge of driven plate (see Figure 3-63). The maximum run-out

tolerance is 0.8mm. If it exceeds this value, replace the driven plate.

3.10.3 Check diaphragm spring for wear. As shown in Figure 3-64, measure depth and width of wear on

diaphragm spring with a caliper. The maximum value: depth 0.6mm, width 5.0mm.