3 - SFG15T Engine

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SFG15T Engine

Section I Technology Specification for Electric Fuel Injection Gasoline Engine


2
Section II Main Checking and Adjusting Specification and Torque ..............................4
I. Main Checking and Adjusting Specification.....................................................................4
II. Main Tightening Torque........................................................................................................5
Section III Parts Structure, Repairing and Adjustment of Electric Fuel Injection
Gasoline Engine...........................................................................................................................9
一、Valve and cylinder head......................................................................................................9
II. Cam Shaft and Valve Tappet.............................................................................................13
III. Position Connecting Rod....................................................................................................15
IV. Crank and Crankcase..........................................................................................................21
V、Timing Transmission System............................................................................................25
VI. Lubricating System..............................................................................................................26
VII. Cooling System....................................................................................................................29
VIII、Fuel Supply System.........................................................................................................31
IX. Electronic Fuel Injection System.....................................................................................28
X. Electric System........................................................................................................................32
XI. Clutch.......................................................................................................................................35
Section IV Starting, Operation and Parking of Gasoline Engine ...............................37
I. Preparation before Starting.................................................................................................37
II. Steps of Starting.....................................................................................................................37
III. Inspection in Operation Period........................................................................................37
IV. Parking....................................................................................................................................38
Section V. Debugging of Gasoline Engine............................................................................39
I. Gasoline engine cannot start or is hard to start.............................................................39
II. Gasoline engine is powerless or the acceleration is powerless .................................40
III. Gasoline engine is powerless.............................................................................................41
IV. Backfire, Blasting and Detonation of Gasoline Engine.............................................41
V. Idling speed of gasoline engine is too high.....................................................................42
VI. Strange noise exists in gasoline engine..........................................................................42
VII. Gasoline consumption is too much................................................................................43
VIII. Oil consumption is too much.........................................................................................43
IX. Gasoline engine is too hot..................................................................................................44
X. It does not extinguish after turning off ignition switch..............................................44
XI. Pressure of engine oil is too low.......................................................................................44
XII. Fault indicating lamp of gasoline engine is constant on.........................................45
XIII. Discharge is not qualified...............................................................................................45
XIV. Fault of clutch system......................................................................................................45
SFG15T Engine

XV. Fault of transmission system...........................................................................................47


XVI. VVT does not work...........................................................................................................48
Appendix I. Fault Code List.....................................................................................................49

3-1
SFG15T Engine

Section I Technology Specification for Electric Fuel

Injection Gasoline Engine

Type SFG15T

In-line four-cylinder and four-stroke, water cool, double


overhead camshaft, 16- valve, electronic-control sequential
Model
multi-point fuel injection, silent chain transmission, DVVT,
Turbocharged.
Displacement (L) 1.498

Compression Ratio 9.2:1


Rated Power
110/5600
kW/(r/min)
Maximum Torque
220/1800~4000
N.m/(r/min)
Minimum Idling
750±50
Speed(r/min)
Minimum Fuel
2000rpm2barBMEP≤400;4000rpm10barBMEP≤270
Consumption(g/kW•h)
Fuel Grade 93# or above unleaded gasoline (GB17930-2 0 1 3 )

Engine SM 5W/30

6MT
Fuel Grade 75W/90 GL-4
Transmission
CVT Mobil Esso EZL799(A)、
Transmission IDEMITSU CVTF-EX1

With gearbox 173(6MT)


Net Weight (kg)
Without gearbox 128

With gearbox 1070×580×680


Dimension (Length ×
Width × Height),mm
Without gearbox 558×580×680

Gearbox Ratio Gear I 3.727


Gear II
2.045
(6MT)
Gear III 1.393 Gear IV 0.975

3-2
SFG15T Engine

Gear V 0.761 Gear VI 0.646


Main
Gear R 3.538 reduction 4.353
ratio

Driving range 0.443-2.416 Gear R 2.684

Gear ratio (CVT) Main


reduction 5.576 /
ratio

Section II Main Checking and Adjusting Specification

and Torque

I. Main Checking and Adjusting Specification

Intake valve
0.2±0.03
Clearance of Cold-state Valve(mm)

Exhaust valve 0.3±0.03

Compression pressure of cylinder when it is ≥850(Pressure difference of any two cylinders is


400rpm (kPa ) not more than 90kPa)

Vacuum of Idling Inlet Pipe (kPa)


≥70

Clearance of Spark Plug (mm)


0.7~0.8

750rpm ≥90
Engine Oil Pressure (kPa)

4000rpm ≥300

Lubricating Oil Capacity (L)


4.2~4.7

Lubricating Oil Capacity of Transmission

2.0~2.2
(L)

Idling Speed (rpm)


750±50

3-3
SFG15T Engine

Idling Oil Temperature (℃)


<130

Temperature of Cooling Water(℃) 82~92

Tension of air conditioning compressor


400~600
belt(N)

II. Main Tightening Torque


Tightening torque limit
No. Bolt of Parts name and Location and
Grade Tighten the process
Tightening Parts specification quantity
Spark plug
1 3707200-F00-00 Cylinder head (25±2)N•m
M12×1.25
Tensioning wheel Generator
2 1025200-F00-00 (45±5)N•m
assembly bracket
Cylinder
3 1021050-E01-00 Idler assembly (45±5)N•m
body
Oil pressure Cylinder
4 3611600-A11-00 (15±2)N•m
alarm body
Water
Outtake
5 3611200-B11-00 temperature (18±2)N•m
chamber
sensor
Cylinder head
6 1014040-F00-00 PVC valve (5±1)N•m
cover
Drive belt pulley Active Belt
7 1000909-E01-00 10.9 (30±2)N•m+(60±3)°
bolt M14×1.5×35 Pulley 1
Main bearing cap Main bearing
8 1002108-F00-00 12.9 (20±2)N•m+(90±3)°
bolt M10×1.25×60 cap 10
The connecting rod Connecting rod
9 1004101-F00-00 12.9 (20±2)N•m+(60±3)°
bolt M8×1×42 8
Cylinder head bolt Cylinder head
10 1015038-F00-00 12.9 (30±2)N•m+(90±3) °+(90±3)°
M10×1.25×99 10
Camshaft front bearing Camshaft front
11 1003107-E01-00 10.9 (23±2)N•m
cap bolts M8×40 bearing cap 3
Camshaft bearing Camshaft bearing
12 1003108-C03-00 10.9 (12±1)N•m
cover bolts M6×35.5 cover 16
Bolts - Generators
13 1000931-E01-00 8.8 Generators 2 (50±5)N•m
M10×105

3-4
SFG15T Engine

Oil pan bolt


14 1000929-E01-00 8.8 Oil pan 2 (10±1)N•m
M6×80
Tensioner rail Tensioner rail
15 1021102-C03-00 10.9 (10±1)N•m
bolt M6×1×34 1
Hexagonal flange
bolt of Intake
16 1006213-D03-00 10.9 VCP 2 (68±3)N•m
camshaft
M10×1.25×38
Flywheel bolt
17 1008315-D00-00 12.9 Flywheel 6 (74±2)N•m
M10×1.25×19
guide rail 2
Strainer 1
OCV valve 2
Hexagonal flange Heater 1 Oil
18 Q1860612 8.8 (10±1) N•m
bolt M6×12 level gauge
tube 1 Water
pump wheel 3
Fuel pipe 1

Tightening torque limit (II)

No. Bolt of Parts name and Location and


Grade Tighten the process
Tightening Parts specification quantity
fuel injection
pump 2、
Hexagonal flange
19 Q1860616 8.8 Phase sensor (10±1)N•m
bolt M6×16
seat 2 Water
pump wheel 3
Air intake
Hexagonal flange temperature
20 Q1860620 8.8 (5±1)N•m
boltM6×20 pressure
sensor 1
Thermolator
cap 2 OCV
valve seat 1
Hexagonal flange Rear-end cap
21 Q1860620 8.8 (10±1)N•m
boltM6×20 4 Oil pan 13
Water outlet
cover 2
Ignition coil 4
Hexagonal flange Rear-end cap
22 Q1860625 8.8 (10±1)N•m
boltM6×25 2 Oil pump 4

3-5
SFG15T Engine

Hexagonal flange tensioner 2


23 Q1860630 8.8 (10±1)N•m
boltM6×30 Oil pump 2
Hexagonal flange OCV valve
24 Q1860640 8.8 (10±1)N•m
boltM6×40 seat 2
Hexagonal flange Throttle valve
25 Q1860650 8.8 (10±1)N•m
boltM6×40 body 4
Hexagonal flange cylinder
26 Q1840625 8.8 (10±1)N•m
boltM6×25 cover 10
Hexagonal flange cylinder
27 Q1840650 8.8 (10±1)N•m
boltM6×50 cover 2
Hexagonal flange Intake manifold
28 Q1840816 8.8 (23±2)N•m
bolt M8×16 support frame 4

Hexagonal flange Outlet chamber


29 Q1840820 8.8 (23±2)N•m
bolt M8×20 4
Compressor
Hexagonal flange
30 Q1840823 8.8 adjustment (23±2)N•m
bolt M8×23
bracket 2
Hexagonal flange Vacuum pump
31 Q1840825 8.8 (23±2)N•m
bolt M8×25 5
Hexagonal flange Knock sensor
32 Q1840828 8.8 (23±2)N•m
bolt M8×28 1
Hexagonal flange Intake
33 Q1840830 8.8 (23±2)N•m
bolt M8×30 manifold 3
Hexagonal flange
34 Q1840832 8.8 Water pumps 4 (23±2)N•m
bolt M8×32
Hexagonal flange starter 2、
35 Q1840835 8.8 (23±2)N•m
bolt M8×35 Timing cover 6
Tightening torque limit (III)
No. Bolt of Parts name and Location and
Grade Tighten the process
Tightening Parts specification quantity
Generator
Hexagonal flange bracket 1、
36 Q1840835 8.8 (28±2)N•m
bolt M8×35 compressor
bracket 2
Generator
Hexagonal flange bracket 1、
37 Q1840842 8.8 (28±2)N•m
bolt M8×42 compressor
bracket 1
38 Q1840845 Hexagonal flange 8.8 Generator (28±2)N•m

3-6
SFG15T Engine

bracket 1、
bolt M8×45 compressor
bracket 1
Hexagonal flange Timing
39 Q1840850 8.8 (23±2)N•m
bolt M8×50 housing 2
Hexagonal flange Timing
40 Q184B1045T 10.9 (50±5)N•m
bolt M10×1.25×45 housing 4
Bolt and spring Oil strainer 2
washer Crankshaft
41 Q1420616 8.8 (10±1)N•m
component position
M6×16 sensor 1
Bolt and spring
42 Q1420816T14F2 washer component 12.9 Clutch 6 (23±2)N•m
M8×16
Rear
Hexagon bolt,
suspension 3
spring washer and
Left
43 Q146B1025T flat washer 10.9 (50±5)N•m
suspension 3
assembly, general
Right
M10×1.25×25
suspension 3
Hexagonal flange Exhaust
44 Q32008T13F19 10.9 (34±2)N•m
nut M8( Copper ) manifold 9
Intake
Hexagonal flange
45 Q32008T13 10.9 manifold 2、 (23±2)N•m
nut M8
compressor 1
Hexagonal flange Transmission
46 Q320B10T13 10.9 (50±5)N•m
nut M10 2

47 1118001-F00-00 Supercharger bolts 10.9 Supercharger (34±2)N•m

48 1118009-F00-00 Supercharger nut 10.9 Supercharger (34±2)N•m

49 1118002-F00-00 Supercharger oil 10.9 Supercharger (23±2)N•m


over bolts inlet pipe of
gasoline 1、
Supercharger
inlet pipe of
water 1、
Supercharger
return pipe of

3-7
SFG15T Engine

water 1

3-8
SFG15T Engine

Section III Parts Structure, Repairing and Adjustment of Electric

Fuel Injection Gasoline Engine

Understanding parts structure of gasoline engine as well as mastering key points of repairing and
adjustment is helpful to maintain gasoline engine and keep its performance and quality. Here is brief
description to parts structure, repairing and adjustment key point of S F G 1 5 T g a s o l i n e e n g i n e

I. Valve and Cylinder

1、Cylinder head shall be opened after it


is cooled in order. Several times to gradually
loosen the cylinder head bolts, so as not to
cause cylinder head assembly warping
deformation.
When installing the cylinder head
assembly, tighten all bolts to (30 ± 2) N • m,
then angle (90 ± 3) °, and last angle (90 ± 3) °
in the reverse order of removal.
Torque of all bolts shall be rechecked in
the order that from the front end of cylinder to
the rear end after the bolts are screwed in the
above mentioned order. The recheck is
Sketch 1-1 Side
Outtake completed when torque value is 60 ~ 75N.m.
2 、 Cylinder washers shall be replaced every
time when installing the cylinder head.
Oil Hole The coatings of cylinder washer attached
on cylinder head and cylinder body shall be
wiped out after disassembling cylinder head.
Do not scratch the contacting surface. Coatings
Intake Side of cylinder washer shall be avoided to enter
Sketch 1-2 into oil hole, cooling water hole and screw bolt.
It shall be checked that whether air bell
exists or whether sealing strip is complete
before installing new cylinder head. If the
above defects exist, it shall be replaced.
Attention shall be paid to installation
direction when installing cylinder washer,

3-9
SFG15T Engine

holes of which must align to the high-pressure


oil hole of crankcase and direct to front end of
engine (timing end), which is shown as the
Sketch 1-2.
3、Carbon in combustor shall be cleaned.
It cannot be cleaned by sharp tools. Surface of
parts cannot be damaged. Whether scratch
exists in intake hole, exhaust hole, combustor
and cylinder head shall be checked after
cleaning. Installing surface level of cylinder
head, intake manifold and exhaust manifold
shall be tested by hair ruler and filler gauge as
shown in Sketch 1-3. If the levelness is more
than limited value, cylinder head shall be
replaced.
Levelness limited value of cylinder head
Sketch 1-3 shall be 0.03mm;
Levelness limited value of installing
surface of intake manifold and exhaust
manifold shall be 0.05mm;

4、Micrometer of outer diameter and dial


gauge of inner diameter shall be adopted
(shown as Sketch1-4) to test diameter of valve
rod and inner diameter of valve conduit
respectively, and ensure that the testing points
are not less than one. If the clearance is more
than limited value, valve or valve circuit shall
be replaced.
Diameter of intake valve:(4.972~4.986)㎜
Diameter of exhaust valve:(4.952~4.964)㎜
Inner diameter of valve circuit: (5~5.012)㎜
Standard tolerance clearance:
Intake valve: (0 . 0 1 4 ~ 0 . 0 4 )mm

Exhaust valve: (0 . 0 3 4 ~ 0 . 0 6 )mm

Limited value of tolerance clearance

Intake valve: 0.07mm

Exhaust valve: 0.09mm

Sketch 1-4
5 、 Carbon in on valve shall be checked.
Whether sealing side of valve is worn, burnt or

3-10
Sketch1-5
SFG15T Engine

out of shape shall be checked. If any, valve


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

Intake valve: (2.3~2.7)mm

Exhaust valve:( 3.14~3.54)mm

Limited value of valve head:

Intake valve: 2.1mm

Exhaust valve: 2.9mm

6、Whether any dent or abrasion exists on


surface (Sketch 1-6) shall be checked. If
necessary, it can be ground by oil. If the
chamfer is worn, valve shall be replaced.

Sketch 1-6 7、Contacting surface width of valve seat


(Sketch 1-7) shall be checked: One layer of red
lead shall be applied on sealing cone of valve
equally, valve seat should be ground then and it
shall be rotated on circle at least. The mark
produced by ground sealing cone of valve must
be solid color strip, width of which must be in
the specified range.
Standard width of mark on sealing cone of
Sketch 1-7
valve (B):
Intake valve:(2.51~2.91)㎜
Exhaust valve:(2.80~3.36)㎜

Repairing of valve seat:


If the mark produced when valve seat and
valve are ground is not equal or its width is not
the specified range, it must be ground again, or
ground or ground accurately after cutting.
Ring of intake valve seat shall be cut by
ReamerValve Seat
reamer of valve seat, (shown as Sketch 1-8). It
30° 30°
shall be cut 60°for the first time,45°for the
second time, and 30°for the third time, shown
45° 45°
60° 60°
Intake Exshaust
3-11
Sketch
Sketch 1-8 1-9
SFG15T Engine

as Sketch 1-9. The second cutting must be in


accordance with the required width of cone
contacting surface.
Ring of exhaust valve seat: It shall be cut
for 60°for the first time by reamer of valve
seat, 45°for the second time, and 30°for the
third time(Sketch 1-9). The second cutting
must be accorded with requirements of
contacting width of cone.
Grinding of valve cone: The first step is
grinding by rough grinding paste; the second
step is grinding by fine grinding paste.

8 、 (Show as Sketch 1-10) Whether the


valve spring is damaged and whether its
elasticity is reduced shall be checked for the
reduction of elasticity will generate tremble and
it will lead airtightness of the valve is not good
after returning. As a result, air will leak to
lower the output power of engine
Standard free length of valve spring:

4 4 . 2 mm

Sketch1-10 Limited value for free length of valve

spring: 38.9 mm

Standard preload of valve spring: It is


34mm when it is 114N~126N;

Spring perpendicularity: Based on the


clearance between valve spring end and ruler,
the perpendicularity of valve spring shall be
checked (Sketch 1-11) by ruler and slab. If the
perpendicularity is more than limited value,
valve spring must be replaced.
Limited value of valve spring
Sketch 1-11
perpendicularity: 1.2㎜
The end with color must be upward when
installing spring valve.

3-12
SFG15T Engine

9、Oil seal of valve cannot be used again


once it is removed. The new one must be used
for installing, shown as Sketch 1-12. When
installing oil seal of valve, the delicate tool
shall be operated by hand only. Never hit the
tool by hammer or other things to avoid
breaking oil seal.

II. Cam Shaft and Valve Tappet


Sketch 1-12
1、The valve to be tested shall be rotated
to the location to be overlapped with center
line, shown as sketch 2-1.Clearnacne between
valves, which is not more than the limited
value, shall be tested.
Limited value of value clearance (cold
state):
Intake valve: 0.2±0.03mm
Sketch 2-1 Exhaust vale: 0.3±0.03mm
If clearance between intake valves is more
than limited value, the valve tappet shall be
replaced.

1 6 3 5 4 2
2 、 Bearing bolt of cam shaft shall be
removed in the order shown in Sketch 2-2. And
then the bearing cover of cam shaft and cam
shaft shall be removed. Whether neck and
cover of cam shaft is damaged shall be
checked. If any bad situation is found, the
intake cam shaft, exhaust cam shaft or cylinder
head assy. shall be replaced. As the camshaft
assembly bearing cover and cylinder head
1 6 3 5 4 2 assembly is a combination of processing, and
therefore never allow a separate replacement of
Sketch 2-2 camshaft assembly bearing cover, must replace
the cylinder cover assembly.

3、Abrasion of cam shall be checked: It is


shown as Sketch 2-3. Cam height shall be
measured by outer diameter of micrometer. If

Sketch 2-3 3-13


SFG15T Engine

the height is less than limited value, cam shaft


shall be replaced.
Height of intake cam shaft:
Standard value:(42.48~42.52)㎜
Limited value:
Height of exhaust cam shaft:
Standard value:(41.11~41.15)㎜
Limited value: 40.91㎜
Radial run-out of cam shaft neck shall be
checked: It is shown as Sketch 2-4. The cam
shaft shall be placed in between the two Vs.
Radial run-out of cam shaft shall be measured
by dial indicator. If the radial run-out is more
than limited value, the cam shaft shall be
replaced.
Limited value for radial run-out of cam
Sketch 2-4 shaft shall be 0.02 mm

4、Abrasion of cam shaft neck shall be


check:
Diameter of each cam shaft neck shall be
measured by micrometer. Inner diameter of
cam bearing of cylinder head shall be measured
inner-diameter micrometer (Sketch 2-5).
Clearance of cam shaft necks can be got
by the value of bearing hole diameter of cam
shaft neck minuses the relevant diameter value
of cam shaft.
If clearance of cam shaft neck is more
than limited value, the cam shaft shall be
replaced. If necessary, cylinder head shall be
replaced.
Sketch 2-5 Clearance of cam shaft neck:
Inner diameter of cam bearing:
φ23(0,+0.021)mm
Diameter of cam bearing:φ23(-0.051,-
0.035)mm
Standard value of clearance: ( 0.035 ~
0.072)㎜
Limited value of clearance:0.12㎜

3-14
SFG15T Engine

5 、 Valve tappet shall be taken out to


check whether there are hallow, abrasion,
scratch or damage exist on the tappet surface. If
any, it shall be replaced.

6、Installation of cam shaft


①、The cam shaft and valve tappet shall
be washed by gasoline before installing cam
shaft.
② 、 Each bearing neck, cam shaft and
hole surface of cam bearing cover shall be
lubricated by engine oil. Cam shaft shall be
placed in the corresponding order, namely the
intake cam shaft shall be placed on the intake
side while exhaust cam shaft shall be placed on
the exhaust side (Sketch 2-6)
Exhaust Camshaft Assy
The largest bearing cover (front bearing
cover) shall be installed on the shaft neck
which is near to chain of cam shaft when
installing cam bearing cover. Then the other
Intake Camshaft Assy
cam shafts shall be installed in the marked
order of cam shaft bearing. 4# bearing cover
shall be installed on the intake side which is
near to shaft neck of front bearing cover. 8#
Sketch 2-6
bearing cover shall be installed on exhaust side
which is near to front bearing cover. Arrows of
all bearing cover direct to the front end (chain
end). When screwing bolt of cam bearing, it
shall be completed for 2 to 3 times. The tighten
torque of front bearing cover of cam shaft shall
be 23±2N·m while tighten torque of front
bearing cover of cam shaft shall be
12±1N·m.

III. Position Connecting Rod

1 、 Whether abrasion or crack exist on


position connecting rod, whether carbon exist
on position head, and whether bad burnt exist
shall be checked. If any, it must be replaced.
Position diameter shall be measured on
10mm

the 10mm to position end. Measuring direction

Sketch 3-1

3-15
SFG15T Engine

shall be perpendicular to the axle direction of


position line, shown as Sketch 3-1.
Diameter of position pin:
(φ74.975±0.005)mm(RED)
(φ74.965±0.005)mm(BLUE)
Diameter of cylinder:
+0.02
Φ75+0.0101 mm(RED)MARK 1
φ75+0.01
0 mm(BLUE) MARK 2
Cooperating clearance of position and
cylinder shall be (0.03 ~ 0.05)mm. Attention
shall be paid to cooperation and choosing so
that meets requirements of cooperation
clearance when repairing。

2、Connecting Rod
Side clearance of the large end (show as
Sketch 3-2): Connecting rod shall be assembled
according to the right cooperation technology.
Side clearance of the large end shall be
checked. If it is more the specified value, the
connecting rod shall be replaced.
Standard clearance value of the large end
of connecting rod:(0.15~0.30)㎜
Limited side clearance value of large end
of connecting rod: 0.35㎜
Sketch 3-2 Axle parallelism of the large and small
end hole of connecting rod: It shall be checked
by straightener. If it is more than the specified
value: connecting rod shall be replaced.
Bending limited value of paralleslism:
0.05㎜
Distortion limited value of parallelism:
0.10㎜

3、Whether abnormal abrasion or damage


exist on position pin, small end hole of
connecting rod shall be checked. If any, the
relevant parts shall be replaced, shown as
Sketch 3-3.Cooperation clearance of hole and
position for the small end of connecting rod
shall be checked. If it is more than limited

3-16
SFG15T Engine

value, position pin or connecting rod shall be


replaced.
Small end hole of connecting rod :
(19.008~19.016)㎜
Diameter of position pin : ( 18.996 ~
19.000)㎜
Sketch 3-3
Assembling clearance of position pin :
(0.008~0.02)㎜
Limited value of cooperation clearance :
0.03㎜

4、Unequal abrasion or damage condition


connecting rod neck of crankshaft shall be
checked: Diameter of connecting rod neck shall
be checked by micrometer; if connecting rod
neck is damaged or cylindricity is more than
limited value, the crankshaft shall be changed,
shown as Sketch 3-4.
Diameter of connecting rod neck : ( 40
~40.018)㎜
Sketch 3-4 Cylindricity limited value of connecting
rod neck:0.01㎜

Diameter Grouping
5、Selection of connection rod neck:
Size Grouping ① 、 Hole diameter of the large end of
connecting rod neck shall be divided into three,
being marked as 1, 2, and 3, which are printed
on the large side, shown as Sketch 3-5。
1

Hole Diameter Grouping of


Sketch 3-5 Mark
A

Crankshaft Pin( ㎜ )
2

1 46.000~46.006
B
3

2 >46.006~46.012
C

3 >46.012~46.018
1

Connecting Rod Assy.


② Diameter of crankshaft
A

connecting rod neck shall be divided


into three groups, being marked as A, B
and C, which are printed on the board
edge in the order from the first

3-17
Sketch 3-6
SFG15T Engine

crankshaft pin to the forth crankshaft


pin, shown as Sketch 3-6.
Hole Diameter Grouping of
Mark
Crankshaft Pin ( ㎜ )

A >42.994 ~43.000

B >42.988 ~42.994

C 42.982 ~42.988

Grouping of Diameter Grouping


Connecting Rod of Crank& Crank
Bush A B C
Inner 1 1 2 3
Diamete
2 2 3 4
r
Groupin
g of
Large
3 3 4 5
End of
Connect
ing Rod
6 、 Clearance Check for Shaft Bush of
Connecting Rod:
Plastic Plug ① 、 Shaft bush and connecting rod neck
of crankshaft shall be washed by gasoline
before checking clearance of shaft bush, which
then shall be installed on connecting rod and
cover correctly;

②、A piece of plastic plug gage, width of


which is the same with connecting rod neck,

3-18
Sketch 3-7
SFG15T Engine

shall be placed on connecting rod neck,


avoiding oil hoe, shown as Sketch 3-7;
CAUTION do not rotate the
crankshaft while installing a plastic
plug.
③ 、 Installation of connecting rod cover:
Lubricating oil shall be applied on the thread of
bolt before installing; attention shall be paid to
the “raised part” (forward mark) on connecting
rod and it should direct to the belt pulley
Cover of Shaft Bush Arrow Mark (front), shown as Sketch 3-8, the screw shall be
tightened as the method specified.
Fasten Methods of Connecting Rod
Belt Bolt:
Step 1: It shall be stopped when torque
Side
is(20±2)N·m;
of Step 2: Connecting rod bolt (60°±3°) angle
Cram shall be rotated at the speed of 20rpm. (Note: the
kshaft
torque shall be 45~65 N.m);

④ 、 Connecting rod(bush) cover shall be

removed. Ruler shall be placed on plastic plug


Sketch 3-8
gauge. Thickness of plastic plug gauge on the

widest clearance shall be tested, shown as Sketch

3-9. If the clearance is more than difference, the

connecting rod bush shall be placed. It shall be

tested again according to the above mentioned

Ruler Plastic Plug Gage method until it is qualified.

Sketch 3-9 Standard value of connecting rod bush

clearance: (0.02~0.04)mm

Limited value of connecting rod bush:


0.065mm
7 、 Whether pit, burnt or flaking exists
between connecting rod bush shall be checked.
Shape of shaft bush shall be observed. If any, it
shall be replaced.

3-19
SFG15T Engine

8 、 Clearance of position ring sink:


Position ring sink shall be washed before
checking. New position rings shall be placed
into the sink. Clearance between rings shall be
Position Ring
measured by ruler, shown as Sketch 3-10. If the
clearance is more than difference, position shall
be replaced.

Thickness Gauge Clearance between position rings:


Sketch 3-10 Ring 1: Standard(0.03~0.05)mm
Ring 2:Standard(0.02~0.04)mm
Oil ring comp: Standard(0.01~0.03)mm

9 、 Clearance of position rings shall be


measured (Sketch 3-11): Position rings shall be
placed into cylinder. If the clearance is more
Clearance Gauge than difference, position shall be replaced. Top
of cylinder and position rings shall be washed
Cylinder Body
before embedding positing ring, and remove
the carbon.
Clearance of position rings:
Ring 1:
Standard: (0.2 ~ 0.32)mm, limited value
Position Ring 0.7mm
Ring 2:
Standard:( 0.35 ~ 0.45)mm; limited value
1.00mm
Sketch 3-11
1 0 、 Assembling of Position Rod:
① To ensure that the gasoline engine runs
normally, the 4 connecting rods of the same
gasoline engine must be the same quality.
Quality grouping number of connecting rod
must be on the side and be marked with
capitalized English letter, from “A” to J”, 10
groups in total。
② Before installing, the position rod assy.
shall be washed and dried. Then the position
pin, position head, position ring sink and small
hole of rod shall be lubricated by lubricating
oil. Forward mark “○” on the top of
position shall be corresponded to the forward
Manufacture Mark mark of rod ( the same side of direction). It is
ensured that the position clasps on the two ends
shall be installed rightly after installing

Manufacture Mark
3-20
Sketch 3-12
SFG15T Engine

position pin. Opening of the clasp shall be


upward or downward.
③ Installation of position ring: It is
shown as Sketch 3-12, the Ring 1 and Ring 2
are marked with manufacture’s mark. The side
with mark shall be upward when installing.
Cushion spring shall be installed at first when
installing oil ring assy. Then the two scrapers
shall be installed. Attention shall be paid to
opening of position ring, shown as Sketch 3-13,
the openings are staggered.
Note: Distinguishing of position rings .
A ) Ring 1 is nitrided steel ring, the
1. Arrow Mark
surface is smooth and shining;
2. Clearance of Upper B ) Ring 2 is phosphating cast iron ring,
6 the surface is grey
Scrapper Ring
4 2 ④ Moderate gasoline shall be applied on
7. Intake Side
the position ring, position, cylinder wall, rod
1
4. Clearance of 1st bush and crank pin before the installed position
45° rod comp is installed in the cylinder. Then the
Position Ring
45° forward mark “○”of position ring shall be
5. Clearance of Lower
aligned to the front of engine (belt pulley).
Scrapper Ring Ring shall be compressed by delicate frock.
3 5 After that, it aligns to cylinder hole. Position
6. Exhaust Side
7 top shall be knocked by plastic bar. The
Sketch 3-13 3. Clearance of 2nd
position shall be placed into cylinder slowly.
Position Ring and Scrapper Connecting rod shall be installed on the crank.
Ring ⑤ The forward mark of connecting rod
cover shall be directed to the front of engine.
Then the cover shall be installed on connecting
rod. Screw shall be tightened as the specified
way.

IV Crank and Crankcase

1 、 Straightness of crank: It is shown as


Sketch 4-1; offset of the middle axle neck shall
be measured by micrometer. Crank shall be
rotated slowly. If the straightness is more than
limited value, crank. shall be replaced
Limited value of straightens for crank
shaft neck: 0.06mm
Sketch 4-1

3-21
SFG15T Engine

2 、 Thrust clearance of crank: The main


axle bush, thrust place and rear main axle cover
shall be assembled correctly and tightened as
the specified torque of
(20±2)N•m+(90±3)°. It is shown as
Sketch 4-2 and pushed back and forth along the
axle direction. Thrust clearance of crank shall
be measured by micrometer. If it is more than
limited value, the thrust plate shall be replaced.
Standard value of thrust clearance for crank:
(0.11~0.31)㎜
Sketch 4-2
Limited value of thrust clearance for
crank: 0 . 3 3 ㎜
Standard thickness of thrust clearance for
crank:2 . 5 ㎜

3 、 Cylindricity of main axle neck:


Different diameters of different places and
different lengths in the same section shall be
measured by micrometer. The difference
reflects the unequal abrasion. If any is damaged
badly or the unequal abrasion is more than
limited value of cylindricity, the axle neck shall
be braised or the crank shall be replaced,
shown as Sketch 4-3.
Cylindricity limited value of main
crankshaft neck: 0 . 0 1 ㎜

4 、 Selection of main shaft bush


① Inner diameter of main bearing shall be
divided into three groups, which are marked
with A, B and C. Bearing holes of from the
first group to the fifth group shall be printed on
the specified side of intake side, which is near
to the fourth bearing hoe. It is shown as Sketch
4-4.
Diameter Grouping of Main Bering Hole
Grouping
Size( ㎜ )
Mark
A 53.000~53.006
B >53.0061~53.012

3-22
SFG15T Engine

C >53.0121~53.018

② Main axle diameter of crank shall be


divided into three groups, which are marked
with 1,2 and 3. It shall be printed on the edge
1

A of the fourth balance block of crank in the


2

order from the first crank to the fifth crank. It is


B

shown as Sketch 4-5.


3

Diameter Grouping of Main Axle Neck of


Groups
主轴颈组别 of Main Axle Neck
Crank
1

Grouping
Size (㎜)
Mark

1 >48.994~49.000

2 >48.988~48.9939

3 >48.982~48.9879

③ Standard main axle shaft shall be


divided into five groups, which are marked
with 1,2,3,4 and 5, printed on the back of main
shaft bush which are selected as the following
table to ensure the right cooperation clearance.

3-23
SFG15T Engine

Grouping of Diameter Grouping of Main

Main Shaft Axle for Crank

Bush 1 2 3

Inner A 1 2 3

Diameter B 2 3 4
Grouping
of Main C 3 4 5
Bearing

上主轴瓦油孔
Oil Hole of Upper Main Axle Bush

Sketch 4-6

④ Main shaft bush can be divided into


upper shaft and lower shaft, which are installed
on crankcase and main bearing cover
respectively. The upper bush (installed on the
crankcase) has oil hole, shown as Sketch 4-6.
Do not install the upper bush and lower bush
mistakenly. Thrust plate of the cranks shall be
installed on the two sides of the third main
bearing respectively. Oil sink of thrust plate
shall direct to the outside when installing
(direct to thrust plate of crank) (Sketch 4-7).
止推片油槽 Never install it upside down.
Oil Sink of Thrust Plate
5 、 Each bearing cover is casted with
Sketch
Upper 4-7of Bearing Cover
Arrow
轴承盖上箭头 sequence number and arrow mark. Main
bearing cover shall be slightly placed on the
corresponding main bearing seat ( arrow on the
main bearing cover shall direct to the front of
engine), shown as Sketch 4-8.Then bolt of
main bearing cover shall be put and screws 2~
3 teeth. Bolt of main bearing cover shall be
screwed to the specified torque value
Sketch4-8 (20±2)N•m+(90±3)°。

3-24
SFG15T Engine

Note: After tightening the main bearing


cap bolts, crank the crankshaft with a torque
not greater than 10N • m. The crankshaft
should be able to rotate smoothly.

6、Clearance of main shaft


①Shaft bush and main shaft neck shall be
cleaned at first before checking clearance of
main shaft bush. One plastic plug gauge (which
is parallel to crank) with the same width of
main shaft bush shall be placed on the main
shaft neck, avoiding oil hole. Never rotate
crank when installing the plastic plug
gauge② 、 It shall be installed on the main
bearing cover as the specified order and
screwing the bolt according to requirements.
(Sketch4-9).③ 、 Main bearing cover shall be
taken down. Thickness of the widest point of
plastic plug gauge shall be measured by ruler
(Sketch 4-10). If the clearance is more than
Sketch 4-9 limited value, the main shaft bush (the upper
and lower bush must be replaced together) shall
be replaced. The clearance shall be measured
Straightening again until it is qualified.
Plastic Bar Standard clearance of main shaft bush:
(0.02~0.04)㎜
Limited value of main shaft bush: 0.060㎜

7 、 Whether corrosion, scratch,

abrasion or damage exists on main shaft

Ruler bush shall be checked. If any, the upper

Sketch 4-10 and lower main shaft bushes shall be

replaced together.

8 、 Rear oil seal assy. of crank: Whether


abrasion or damage exists on flange of oil seal
shall be checked carefully. If any, the oil seal
shall be checked.
Ruler

3-25
SFG15T Engine

Moderate gasoline shall be applied on


Rear Oil Seal Assy
曲轴后油封总成 flange of oil seal before installing. It shall be
of Crankshaft
pressed in steadily by delicate frock so that oil seal

ending is (1.9 ~ 2.1) ㎜ , lower than oil sealing

seat, shown as Sketch 4-11. Whether defect or

Sketch 4-11 damage exists on flange of oil seal and spring of

oil seal on be back cover of crank shall be

checked. If any, it shall be checked timely.

9 、 Check of fly wheel: If gear ring is


damaged, destroyed or wore, the fly wheel
shall be replaced. If friction surface which
contacting clutch is damage for wore badly, the
fly wheel shall be replaced.
It is shown as Sketch 4-12. End face
jumping of fly wheel shall be measured by
micrometer. If it is more than limited value, the
fly wheel shall be replaced.
Limited value of fly wheel:0.2㎜
Fly wheel shall be locked by delicate
Sketch 4-12 tools when installing , shown as Sketch 4-13. It
shall be screwed by 2~3 times until it reaches
1 2
the specified torque value of (74±2)N•m。
10. It is shown as Sketch 4-14.
Deformation condition of crankcase shall be
checked by knife straight edge and plug gage.
If the flatness is more than limited value, it
shall be adjusted.
Sketch 4-13 Flatness standard value of the flat on
crankcase: 0.03mm
Flatness limited value of the flat on
crankcase: 0.05mm
3
V. Timing Transmission
1 、 Installing requirement of timing
4 transmission:
Timing Mark of Timing Sprocket (Intake) and ①When e of Cylinder 4 is on the dead point
1 、正时链轮(进气)与链条的正时标记 of compressing stroke, shown as Sketch 5-1,
Chain
Timing2 、正时链轮(排气)与链条的正时标记
Mark of Timing Sprocket (Exhaust) and locations of timing mark shall be one-to-one
Chain Sketch 4-14 correspondence.
3 、曲轴键槽和缸体上 1 、 4 缸上止点标记
Stop Mark of Crankshaft Sink and Cylinder 1 and 4
4 、曲轴链轮与链条的正时标记
Timing Mark of Crankshaft Sprocket and Chain
3、曲轴链轮(进气)与缸盖的正时 3-26
Sketch 5-1
SFG15T Engine

②Camshaft and crank cannot be moved


after removing the timing chain, otherwise the
valve will disturb position so that the valve or
position shall be damaged.
③Whether timing chain is wore badly or
chain plate cracks shall be checked. If any, the
timely chain shall be replaced.
④ Whether abrasion or crack exists on
tensioning rail of chain or guiding rail shall be
checked. If any, the new tensioning rail or guiding
rail shall be replaced.
⑤ Whether abrasion, dedendum or crack
exist chain of camshaft or chain teeth of crank
shall be checked. If any, a new one shall be
replaced.
2、Installation of Transmission:
① 、 Keyway of crankshaft chain should
align to the stop point timing mark of Cylinder
1 and 4 cylinder body when installing timing
chain of crankshaft (casting of convex
platform).
②Guiding rail and tensioning guiding
assy. shall be installed. (Note: Tensioning rail
is not fixed and guiding rail is fixed).
③ When installing timing chain, the
timing mark shall be one-to-one
correspondence.
④ Hydraulic tension assy. shall be
installed. Tensioning rail shall be fixed.
Finally, the fixing pin of hydraulic tension
assy. shall be pulled out; push tension rail
slightly to confirm that the hydraulic tension
assy. can stretch out.
VI. Lubricating System
1、Check engine Oil Quality
Whether engine oil is bad, is mixed with
water, changes color or become thick shall be
checked. If it is bad, it shall be replaced,
otherwise, performance index and service life
of the gasoline engine shall be affected. When
replacing, the oil drain bolt on engine oil plate
shall be taken down to drain lubricating oil.
After that, the oil drain plug shall be installed

Oil Drain Bolt


3-27
Sketch 6-1
SFG15T Engine

again and tightened as the specified torque of


(15~21)N•m It is shown as Sketch 6-1. When
replacing gasoline engine, oil shall be drained
in the hot state after the engine is stopped. The
adopted engine oil should be in accordance
with provisions of Instruction.
a)SM level and above 5W / 30;

1/4 2、Check Engine Oil Quantity


When measuring oil level, vehicle shall be
parked on the level place; it shall be measured five
minutes after stopped. Oil quantity shall be
measured by oil level gauge. Oil level shall be in
between the high and lower scratch of oil level
Sketch 6-2
gauge (Sketch 6-2). If it is lower than the lower
scratch, whether engine leaks shall be checked,
and oil shall be added until it is in between the
upper and lower scratch and is on the 1/4 of the
upper scratch (line of the two holes). Injecting
O-ring opening is on the cylinder cover. After injecting,
start gasoline engine. It shall be stopped after
running for 3 minutes. Oil level shall be checked
again 5 minutes later.
3、Replace Oil Filter
Delicate wrench shall be sued to take the
oil filter that needs to be replaced.
Installing surface of new oil filter shall be
Sketch 6-3 checked and cleaned. Clean engine oil shall be
applied on sealing ring of new oil filter (Sketch
6-3) It shall be screwed by hand sot that the
seal ring is close to installing surface. Then it
shall be rotated torque calibration value:
23N·m。
Note: Oil filter is disposable part, which
cannot be used repeatedly.
4、Check of Lubricating Oil Pressure
Usually, when power switch (key) is on
“connecting”, the oil pressure indicator is light
up and it means that there is not engine oil
pressure; then it is placed on “start” ( or

3-28
SFG15T Engine

“START”), the gasoline engine is in idling


state, the oil pressure indicator extinguishes,
and it means that oil pressure indicator is
normal. If oil pressure indicator does not
extinguish, pressure of oil in lubricating system
is not normal. Whether engine oil is norm,
whether oil passage leaks, whether network of
suction filter or oil filter is blocked shall be
checked.

5 、 Check Lubricating Oil of


Transmission
Lubricating oil of transmission shall be
gear oil of heavy-load vehicle 85W/90 GL-
4 ( General area ) or 75W/90 GL-4 ( Arctic
area ) It is shown as Sketch 6-4. Opening oil
Oil Inject Plug inject plug, it gear oil flows from oil hole or oil
level reaches screw hole, it means gear oil is
full. If gear oil cannot reach the
abovementioned requirement, it means gear oil
is not full, and it shall be injected fully
according to the provision. Then it shall be
sealed by oil injection plug applied with sealant
he and screw plug with torque of ( 10 ~
Oil Drain Plug 18)N.m.

6、Check Oil Pump


Sketch 6-4
①Whether defect and damage exist on
flange of oil seal shall be checked before
installing oil pump. Measure the radial
clearance between the outer rotor and the
housing with a feeler gauge. If the clearance
Internal External exceeds the limit, replace the outer rotor or
rotor rotor Shell housing . It is shown as Sketch 6-5
The radial clearance between the outer
rotor and the shell the limit:0.2mm。
The radial clearance between the outer
rotor and the inner rotor is limited to :
0.2mm。
Sketch 6-5
②The removed spare parts shall be
washed. A layer of thick oil shall be applied on
the inner rotor, outer rotor, flange of oil seal,

3-29
SFG15T Engine

inner surface of oil pump cover and cover


plate. Then inner rotor and outer rotor shall be
installed in oil pump cover of timing chain
cover. Rotor cover shall be installed and
tighten the screw
Flexibility of inner rotor and outer rotor
shall be checked by rotating by hands after
installing the cover plate

7. Installation of Oil Plate and Oil Filter:


① Cooperating surface of oil plate and
crankcase shall be cleaned. The oil and dirty oil
on it shall be cleared. It is shown as Sketch 6-
Slick and Apply 6②Oil shield plate shall be installed on main
bearing cover. Oil plate shall be installed on
Glue
crankcase and screwed according to the
specified torque of 10±1 N﹒m.
Note: The specified silicone sealant shall
be applied when installing oil plate.
③Oil drain bolt shall be installed on oil plate
and it shall be tightened by the torque of ( 15
~ 21 ) N•m 。 Installing surface of new oil
filter shall be checked and washed. Engine oil
shall be injected. Whether leakage exists on
connector shall be checked.
Sketch 6-6
④When installing oil filter, seal ring on
the connecting seat of oil filter shall be
installed on oil plate. Bolts shall be put in and
screwed by the specified torque to fixed value,
In the oil filter seal on the amount of methyl
silicone oil after hand screw into the oil pan
components, and then use a special wrench
fastening torque calibration value: 23N · m。

1 VII. Cooling System


放 1、Coolant
2
Coolant of gasoline engine adopts glycol
3 anti-freezing solution or soft water. Never use
the hard water, such as river water or well
1、Water Storage Tank
2、Mark of Full water. Refrigerant of gasoline engine adopts
3、Mark of Low Level glycol anti-freezing solution or soft water.
Never use the hard water, such as river water or

Sketch 7-1 3-30


SFG15T Engine

well water. If temperature is lower than -30℃


in winter, the mixer of 50﹪ anti-freezing
solution/antiseptic shall be used; if temperature
is more than -15℃ in winter, the mixer of 70﹪
water and 30% anti-freezing
solution/antiseptic shall be used. Even if the
temperature is not expected to reach freezing
point, for the purpose of anti-corrosion
lubrication, should also be applied to 70%
water and 30% antifreeze / preservative mixed
liquid.
2、Capacity of refrigerant in water tank shall
be checked (Sketch 7-1)
Refrigerant level in water tank shall be
checked when cooling the engine (Note: Water
tank cover and radiator cover in hot state
cannot be opened to avoid empyrosis). Normal
refrigerant level shall be in between the scratch
of “Full” and “Low” of the water tank.
Opening the tank, moderate refrigerant shall be
injected until it reaches “Full”. Then cover it,
and the cover shall align to the mark on water
tank.

3、.Check Quality of Refrigerant


①Whether refrigerant is clean shall be
checked. If it is too dirty, the clean refrigerant
shall be replaced.
②Whether rust exists around radiator cover
and radiator core shall be checked .
③ Whether oil stains exist in refrigerant
shall be checked.
4、The following parts of cooling system
shall be checked.
①Whether leakage exist in cooling system
shall be checked.
Release Valve
放气阀 ②Whether radiator and soft pipe are
调温器密封垫 damaged or distorted shall be checked.
Thermostat Gasket

③Whether clamp of soft pipe falls off shall


be checked.
5. Check Thermolator

3-31
Sketch 7-2
SFG15T Engine

①Whether exhaust valve of thermolator is


clean shall be checked, shown as Sketch 7-2. If
it is blocked, the engine will be hot.
②Whether there is foreign matter exists
on seat of thermostat valve shall be checked for
it will block the sealing of valve seat.
③Whether sealing gasket of thermolator
is damaged, aging or other damages shall be
checked.
2 ④ Thermolator shall be soaked into the
water, shown as Sketch 7-3. It is heated
gradually. Whether valve is opened in the
1 specified temperature shall be checked.
Temperature of the valve is opened at the

3 beginning: 82℃
Temperature of the valve is fully opened:
92℃
If temperature of the valve is opened at the
Sketch 7-3 beginning is higher than the specified temperature
obviously, the thermolator shall be replaced.
Otherwise, the engine will be too cold or too hot.

6、Check Water Pump (Sketch 7-4)


①Water pump shall be rotated by hands.
If it is not flexible or there is foreign matter, it
shall be replaced.
② Whether impeller of water pump is
damaged shall be checked. If necessary, it shall
be replaced.
7、Belt of Water Pump shall be Checked
Whether crack, cutting, deformation or
Sketch 7-4 abrasion exists on belt of water pump shall be
checked. If necessary, it shall be replaced.
8、Check the oil cooler
Check whether the oil cooler leakage, oil
leakage phenomenon. If necessary,it shall be
replaced。

3-32
SFG15T Engine

VIII、Supply system

1、Turbocharger theory and inspection(Sketch 8-1)



① 、 A turbocharger is an air pump that
operates with the exhaust energy of the engine
Bypass valve exhaust. When the turbocharger is rotated, a
large amount of compressed air is delivered to
the combustion chamber of the engine. By
increasing the weight of the compressed air,
more fuel can be injected into the engine, the
engine in the size of the same conditions to
generate more power. Maintenance, check the
turbocharger volute, pressure shell whether has
the crack, the exhaust valve is able to open and
close normally, check the impeller if has
Sketch 8-1 damage, while hand-held turbocharger
impeller, if the rotation is not flexible and
Axial, radial clearance increased significantly,
need to replace the turbocharger.
② 、 Exhaust gas bypass valve : The
opening and closing of the bypass valve is
controlled by the boost pressure control
solenoid valve controlled by the ECU. By
changing the opening time of the solenoid
valve, the gas pressure in the right chamber of
the pneumatic chamber is controlled, and the
opening degree of the bypass valve is changed
to precisely adjust the supercharging pressure.
The setting and checking of the preload force
of the spring in the bypass valve actuator are
carried out at the manufacturer's specially set
and calibrated equipment and can not be
adjusted or changed by the user. Do not use
parts such as push rods outside of the bypass
valve as handles to move the booster assembly
so as not to affect the sensitivity and reliability
of the bypass valve actuator。
②Turbocharger circuit failure (Sketch 8-
2): turbocharger due to oil caused by the failure
Return pipe of more, mainly by the oil spill, inadequate oil
Intake pipe or poor oil return, poor oil quality. If the oil
leakage is found to check the oil bolt torque

3-33
Sketch 8-2
SFG15T Engine

value, if necessary, replace the oil bolts, copper


gasket or supercharger

1)Oil leak
Supercharger leakage is more
common in the pressure side, mainly by
the seal ring work or bearing and shaft
clearance is too large caused by long-
term replacement of oil, will increase the
impurities in the oil, exacerbate the seal
ring wear. In addition, the non-standard
installation or supercharger temperature
is too high, so that seal deformation
failure; bearing and shaft clearance is
too large, increased vibration of the rotor
bearings, increasing the impact of
damage to the dynamic balance,
excessive rotation radius to both ends
Seal damage, damage to the
supercharger。
2 ) Insufficient oil supply or poor oil
return
Engine oil pump is not working properly,
resulting in insufficient oil or poor oil return or
oil pressure is too low, will make the bearings
and shaft damage due to poor lubrication. To
timely clean out the oil, to ensure the normal
oil supply.
3)Poor oil quality
Oil containing foreign matter such as
impurities, sediment or metal shavings can
worsen the wear of turbocharged bearings and
shafts and seal rings due to the high speed of
the shaft. It is necessary to change the oil and
clean the oil circuit in time.
Exhaust ③ 、 Supercharger air circuit failure
(Figure 8-3)
1)Foreign matter into the engine's intake
Intake
and exhaust system, will damage the turbine
blades and compressor blades, and then destroy
8--3 the supercharger shell. If the phenomenon of
leakage, the need to immediately replace the

3-34
SFG15T Engine

supercharger inlet gasket, if necessary, replace


the turbocharger,
2)、Insufficient air intake
If not clean up in time, replace the air
回水管 filter, due to blockage caused by insufficient
gas supply and reduce the speed and power.
Gas poor, air seal damage will also cause
insufficient supply。
③、Turbocharger water failure (Figure 8-
4)
Check the supercharger pipe is damaged,
install the flange surface seal, such as the
phenomenon of leakage found in the need to
进水管 check the oil bolt torque value, if necessary,
replace the oil bolts, copper gasket or
图 8-4 supercharger.

3-35
SFG15T Engine

IX. Electronic Fuel Injection System


SFG15T gasoline engine adopts closed-loop control system which adopts the advanced computer control
ignition device with function of discharge control, idling control and evaporative emission control. Focusing
on electronic control unit (ECU), the system calculates the intake air capacity according to the sensor signal
of temperature pressure. Accordingly, it confirms the fuel-injection quantity per circulation and adjusts
according to the refrigerant temperature. The ECU shall adjust fuel-injection quantity according to sensor
signal in the situation that fuel closed-loop control so that the mixing gas, made by fuel and air, keep the
theoretical equivalent air-fuel ratio. As a result, the three-way catalytic converter can purify the exhaust air to
the largest extent. Reducing the content of carbon monoxide (CO), hydrocarbon (HC) and nitrogen oxides
(NOx) in exhaust of gasoline engine.
1、Closed-loop Control Theory of Idling Rotate Speed
Idling work conditions of gasoline engine in normal temperature is close-loop control. The fuel injection
system will close the throttle fully in idling working conditions. Air intake quantity of the engine in running
shall be controlled by idle actuator on the bypass of throttle. ECU shall supervise rotate speed of gasoline
engine timely and comparison of the targeted idling rotate speed pre-set by the system. According to the
variation of rotate speed, the idling control valve and ignition leading angle shall be adjusted so that the
gasoline engine can work steadily in the specified idling rotate speed.
2、Timing Control Theory of Ignition
Based on the load and rotate speed signal, ECU will confirm value of ignition leading angle and adjust
on the basis of refrigerant temperature to get the right ignition leading angle so that confirm the correct
ignition time.
3、Sensor
①Throttle position sensor (Sketch 8-1): It
shall be installed on the outside of throttle
with the same axle of throttle, signal of
throttle position passes to ECU to judge
working conditions of engine.
②Intake temperature pressure sensor
(Sketch 8-2):
It shall be installed on the intake manifold.
Sketch 8-1 Circulation inflating volume shall be calculated
according to the intake air temperature and
pressure single. Based on it, the basic fuel
injection volume for each cylinder shall be
Sketch 8-2
judged and confirmed.。

③Sensor on crankcase(Sketch 8-3): It


shall be installed on the front of transmission
which provides rotate speed and crankcase
location signal for engine so that provide

Sketch 8-3
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SFG15T Engine

reference point for fuel injection timing and


ignition timing

④Water temperature sensor(Sketch 8-4):


It shall be installed on the thermolator assy. to
supervise refrigerant temperature and provide
reference point for air fan.

Sketch 8-4 ⑤ Oxygen sensor (Sketch 8-5): It shall be


installed on the outlet of exhaust manifold to
supervise the oxygen in exhaust air for
adjusting fuel injection volume for the closed-
loop control of air-fuel ratio.
Sketch 8-5

⑥Knocking sensor(Sketch8-6)
It shall be installed on between Cylinder 2
and 3 to supervise whether detonation takes
place in the process of burning. Once it
detonates, ingestion shall be delayed and turns
into timing closed-loop control.
⑦ Pressure alarm (Sketch 8-7)
Sketch 8-6 It shall be installed on the main oil
passage of cylinder body to supervise the oil
pressure in the passage and ensure that the
engine is lubricated reliably.

Sketch 8-7
⑧ 、 Environmental pressure sensor ( 8-
8)
Installed in the air filter to monitor the
atmospheric pressure, the input signal and
the intake air temperature pressure signal
comparison, ECU through the ambient
pressure sensor signal and the intake air
temperature and pressure sensor input signal
Sketch 8-8 to calculate the actual air into the engine
after the density, the system based on Engine
and other relevant parameters of the state,
and then calculate the actual engine into the
combustion of the actual air supply.

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SFG15T Engine

4、Electric Control Unit (Sketch 8-9)


It is installed on the vehicle to analyze and
handle the input signal of sensor, and then give
out signal to actuator.
Water shall be prevented when installing
electric control unit. It shall be installed in the
low temperature environment.
Sketch 8-9
5、Actuator
① Electric fuel pump: It shall be installed
in the oil tank. Oil pump of ECU shall be
controlled by relay. Once it stops working, the
electric fuel pump will stop rotating
automatically.
② Fuel injector and fuel guiding rail
assy. (Sketch 8-10) :the upper is fuel injector, the
fuel injection is controlled by electric control unit
and it adopts no-oil return system( fuel pressure
shall be 0.4MPa)
Sketch 8-10

③Ignition coil (Sketch 8-11)


SFG15T gasoline engine uses advanced
direct ignition technology without distributor,
which is equipped with built-in ignition driving
circuit, which sends ignition signal to primary
winding of ignition coil. The ignition coil is
respectively installed on cylinder head cover,
The spark plug of each cylinder.

④Idle actuator (Sketch 8-12)


It is installed on throttle and controlled by
Sketch 8-11 ECU to change the section area of bypass so
that to change the bypass volume when idling
and control the rotate speed of idle.

⑤ Canister Solenoid Valve


Sketch 8-12 Opening of canister solenoid valve is
controlled by ECU according to working
condition of gasoline engine. Evaporative
emission in canister entering intake manifold

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Sketch 8-13
SFG15T Engine

shall be controlled to lower the exhaust of


vehicle greatly.

⑥ OCV Control Valve (Sketch 8-14)


Direction and pressure of engine shall be
controlled by two-direction four-way valve
control to adjust the corresponding phase angle
of camshaft so as to get good distribution
effect.
Sketch 8-14
⑦VCP (Sketch 8-15)
Oil quantity shall be controlled by OCV
control valve. Opening of VCP shall be
adjusted to the intake leading angle.

Intake VCP Exhaust VCP


Sketch 8-15

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SFG15T Engine

X. Electric System

1、Ignition System
Ignition system of S F G 1 5 T gasoline engine is free-adjustment ignition system, which is without

electric and contactor parts, The ignition timing is controlled by electric controller, which can improve the

controlling accuracy of ignition time and reliability, improving ignition energy and ignition voltage greatly.

(1) Composition

The system is composed by power supply, ignition switch, electric controller,

crankshaft position sensor, ignition wire, high voltage damper and spark plug.

Note: Type of spark plug is B O S C H Y R 6 N I 3 0 2 S , screw thread is M 1 2 × 1 . 2 5 , clearance of

electrode is ( 0 . 7 ~ 0 . 8 ) m m . If the electrode is burnt, screw thread is damaged or the insulator is damaged,

the spark plug shall be replaced.

(2) Wiring, shown as(9-1)


62 01 81 04

Twin-core Shielded
双芯屏蔽线 Wire
双芯屏蔽线 IRC

C A C A C A C A

B B B B
4 3 2 1

Sketch 9-1

2 、 .Starting system, shown as( 9 - 2 )

Ignition Terminal
端子 50 50
Fuse
端子 30 30
Terminal

Battery

3-32 Starter
Sketch

9-2
SFG15T Engine

Connecting Post S
Performance test of starting
Connecting Postt M
system:
C a u t i o n : Te s t m u s t b e f i n i s h e d i n
3 ~ 5seconds to avoid burning the
coil.
(1)Attraction test
Guiding wire shall be connected
as Sketch 9-3, and whether the small
gear rotates outward shall be
Sketch 9-3 checked. If it does not move, the
electromagnetic switch shall be
replaced.
Note: The magnetic coil shall be
disconnected from binding post “M”
before testing
(2)Keep test
If small gear of the above
mentioned guiding wire moves
outside, then the negative guiding
w i r e s h a l l b e t a k e n o ff f r o m “ M ”
biding post, shown as Sketch 9-4.
Whether the small gears still rotate
outward shall be checked. Otherwise,
electromagnetic switch shall be
replaced
Sketch 9-4
(3)(3) Returning test of small
gear
It is shown as Sketch 9-5,
negative guiding wire shall be
removed, and the small gear shall
r e t r a c t i n s i d e q u i c k l y. O t h e r w i s e , t h e
electromagnetic switch shall be
replaced

(4)No-load performance test


The battery and ammeter shall be
Sketch 9-5 connected as Sketch 9-6. Whether
fault exists in engine or small gear
directs outwards shall be checked.

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Sketch 9-6
SFG15T Engine

Whether armature displays the


specified currency shall be checked.
Specified currency: It is 90A for13.5V.

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SFG15T Engine

3 、 Charge system
Type of alternating current engine in charge system shall be 1 3 . 5 V 1 0 0 A . Wiring way is shown as Sketch
9-7.

B Charge Indicator

L Fuse(SA)
Soft Wire of

Battery

Fuse Box

Sketch 9 - 7
(1)Whether wiring of engine is good shall be checked. Whether abnormal noise
exists in generator shall be checked. If any, it shall be tore for checking.
(2) Circuit of charge indicator shall be checked
Start gasoline engine. It shall be stopped after being heat. All electric accessories
shall be closed. Ignition device shall be placed on “ON”, the charge indicator is lit
up.
The charge indicator should extinguish when starting gasoline engine, otherwise,
circuit of charge indicator shall be checked.

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SFG15T Engine

XI. Clutch

1 、 Whether driven disc of clutch is wore


or damaged shall be checked. Depth of rivet in
friction disc should not less than 0.3mm.If it is
less than 0.3mm, driven disc of clutch shall be
replaced (Sketch 10-1).

Sketch 10-1

2 、 Run-out tolerance of driven


disc shall be checked. The maximum
driven disc shall be 0.8mm. If it is
more than it, the driven disc shall be
replaced.

Sketch 10-2 3 、 Whether z diaphragm spring


is wore shall be checked
We a r i n g depth and width of
diaphragm spring shall be measure by
calipers, shown as Sketch (10-3 ) . If
n e c e s s a r y, t h e c l u t c h d i s c a s s y, s h a l l
be replaced.
Sketch 10-3
Limited value: depth is 0.6mm;
width is 5.0mm.

4、4. Installation of clutch


4 Clutch shall be fixed from driven
3 5 disc to fly wheel by delicate tool as
Sketch 10-4 and 10-5. Position pin
hole of clutch disc shall align to
position pin. It shall be screwed
2 6 equally by the torque of 23±2N·m.
Alignment of the end of
Sketch 10-4
diaphragm spring shall be checked by
dial i n d i c a t o r. The maximum
inequality shall be 0.7mm. If it is too
l a rg e , i t m u s t b e a d j u s t e d .
1
Sketch 10-5
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SFG15T Engine

Section IV Starting, Operation and Parking of Gasoline


Engine
Right operation of gasoline engine does not only keep the gasoline engine runs normally, but also delay
its service life.
I. Preparation before Starting
The following items shall be inspected before staring gasoline engine:
1 、 Coolant level in radiator, fastening conditions and looseness of belt pulley shall be checked.
2 、 Whether oil volume displaced by ruler of gasoline engine is in accordance with requirement shall be
checked.
3 、 Oil volume in oil tank as well as conditions of pipelines connectors in oil supply system shall be
checked. The leakage and air in pipeline shall be discharged.
4 、 Electrolyte level in battery shall be checked.
5 、 The fastening conditions of electric equipment, such as batter, generator, starter, spark plug and
ignition coil, or the connectors on electric device shall be checked.
II. Steps of Starting
1 、 Shift lever of transmission shall be located on neutral position.
2 、 The clutch shall be stepped to reduce load of gasoline engine.
3 、 Key of ignition switch shall be rotated and placed on the starting position to start gasoline engine.
Time of power-on should not be more than 5s when starting. Starting interval is not less than 10s every time.
4 、 Key of ignition switch shall be loosed after the gasoline engine is started so
that it returns to ignition place.
If it does not make it for many times, please look into it. 。
III. Inspection in Operation Period
1、Whether any knock, blast, slap, loose or other strange noise exists.
2. Whether burning smell caused by high temperature of generator or other
electric equipment exists.
3. Whether oil leaks in oil system, cooling system and lubricating system.
4. Whether reading (indicator ) of the meters for oil pressure, water temperature,
current and oil level is normal.

IV Parking

If the gasoline engine has to be parked when running at large load, the idling speed shall be lower for 2

~3 minutes at first, and then the ignition switch shall be closed so that the gasoline engine shall be gradually

cooled equally, avoiding the distortion of spare parts and spontaneous combustion for the engine is too hot

Cooling water in gasoline engine shall be drained completely after parking in freezing season or sever
cold area. Water filling cover of radiator shall be opened when draining. The draining switch on bottom of

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SFG15T Engine

radiator shall be opened at first, and it shall be closed after draining all the water. If the cooling water is mixed
with antifreezing solution, the water cannot be drained.

Section V. Debugging of Gasoline Engine

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

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

I. Gasoline engine cannot start or is hard to start

Reason Debugging Method

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SFG15T Engine

1.Fault of starting system


Battery voltage is not enough Charge

Battery connection is bad Clean binding post, tighten the battery wire

Fuse breaks Replace the fuse

Starter breaks down Repair or replace the starter

Ignition switch breaks down Repair or replace the ignition switch

2.Fault of ignition system


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

II. Gasoline engine is powerless or the acceleration is powerless

Reason Debugging Method

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SFG15T Engine

1. Ignition system breaks down


Spark plug does not work Check or replace the spark plug
High voltage wire is damaged Replace of high voltage wire
Ignition coil is damaged Replace the ignition coil

2. Gasoline engine breaks down


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

III. Gasoline engine is powerless

Reason Debugging Method

1. Gasoline compression is bad


Valve is leaky Grind valve
Valve spring tension is inadequate or broken Replace the valve spring
Cylinder gasket is leaky Replace the cylinder gasket
Piston ring is stuck or broken Replace the piston ring
Piston or cylinder bore is worn excessively Repair or replace the parts

2. Ignition system breaks down


Ignition coil is damaged Replace the ignition coil
Spark plug does not work Clean, adjust or replace the spark plug

3. Gasoline supply is bad


Fuel injector is blocked or damaged Clean or replace of the injector
Throttle position sensor is damaged Replace the throttle position sensor
Oil pressure of electric fuel pump is not enough Repair or replace the electric fuel pump
There is fouling in oil tank Clean the tank, replace it if necessary
Gasoline pipeline is blocked Clean gasoline pipeline
Fuel filter is blocked Replace the fuel filter
Air exists in fuel system Check and fasten connectors

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SFG15T Engine

Chose gasoline according to provisions of


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

V. Idling speed of gasoline engine is too high

Reason Debugging Method


1. Throttle position sensor is damaged Replace the throttle position sensor
2. Throttle is not fully closed Adjust the cable or remove the dirt
3. Intake system is leaky Check the air intake system repair
4. Idle regulator is damaged Replace the idle speed regulator

VI. Strange noise exists in gasoline engine


Reason Debugging Method
1. Valve clearance is improper Adjust
2. Piston pin is loose Replace the piston pin
3. Pistons, piston rings and cylinder are worn Repair and replace
4. Connecting rod bush is worn Replace the connecting rod bush
5. Main shaft bush is worn Replace the main bush
6. Crankshaft thrust pad is worn Replace the crankshaft thrust piece

3-41
SFG15T Engine

7. Camshaft thrust gap is too large Replace the camshaft


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

3-42
SFG15T Engine

X. It does not extinguish after turn off ignition switch


Reason Debugging Method
Turn off the ignition switch after idling
1. Gasoline engine is too hot
gasoline engine makes the water temperature
2. Spark plug is too hot
drop below 80 ℃
3. Deposited carbon is combustion chamber is
Select the spark plug with specified type
too much
Remove deposited carbon
4. Ignition timing is improper
Adjust ignition timing
XI. Pressure of engine oil is too low
Reason Debugging Method
1. Oil leaks
See 1 Chapter VIII
2. Oil is too little or too thin
Add or replace oil
3. Oil temperature is too high
Cool gasoline engine, check cooling system
4. Oil pump valve breaks
Repair reducing valve
5. Oil pump breaks
Repair or replace oil pump
6. suction filter is blocked, oil pan leaks
Clean dredge, tighten the oil pan bolts
7. Oil pressure alarm does not work
Replace the oil pressure alarm
8. Main bearing, connecting rod bearing are
Replace the bush
excessively worn
Replace the oil filter
9. Oil filter is blocked
XII. Fault indicating lamp of gasoline engine is constant on
Reason Debugging Method
1. Electronic fuel injection system breaks It shall be diagnosed by fault diagnosis tester
(see Fault Code List)
2. Fault exists in cable Whether connectors are connected firmly and
whether the cable shorts or breaks shall be checked

XIII. Discharge is not qualified


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

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SFG15T Engine

in the dense air-fuel ratio


XIV. Fault of clutch system
Reason Debugging Method

1. Clutch slides
Free stroke of clutch pedal is improper Adjust free stroke
Clutch is worn or there is oil stain Repair or replace the clutch disc
Clutch disc, pressure plate or flywheel surface Replace the clutch disc, pressure plate or
is distorted flywheel
Diaphragm spring is weakened Replace the clutch cover
Clutch cable is corrosive Replace the cable
2. Clutch is hard to be separated
Adjust free stroke
Free stroke of clutch is improper
Replace the clutch cover
Diaphragm spring or spring is worn
Lubricate
There are rust marks on input splines
Replace the input shaft
Transmission input splines are damaged or
worn
Replace the clutch disc
Clutch plate swingings seriously
Replace the clutch disc
Clutch plates are damaged there is oil stain
3. Clutch vibration
Replace the clutch disc
Clutch plate show mirror phenomenon
Repair or replace the clutch disc
Clutch plate is with oil stain
Replace the separation bearing or clutch plates
Sliding for separation bearing on the bearing of
Lubricate or replace the bearing retainer of
input shaft is not smooth
input shaft
Shimmy or contact of clutch plate is bad
Replace the clutch disc
Torsion spring in clutch plates is weakened
Replace the clutch disc
Rivet of clutch plate is loose
Replace the clutch disc
Clutch cover or flywheel surface is distorted
Replace the clutch cover or flywheel
Mounting pad of engine becomes weak , bolts
Retighten or replace the mounting pad
or nuts are loose
4. Clutch makes noise
Separation bearing is worn or damaged Replace separation bearing
Bearing of front input shaft is worn Replace bearing of input shaft
Cooperation of transmission input shaft is too Replace clutch disc or transmission input
loose shaft
Pressing plate and diaphragm spring are loose Replace clutch cover
5. Clutch bites
Clutch plate is worn seriously
Replace the clutch disc
Exposed rivet is exposed
Replace the clutch disc
Torsion spring is weaken

3-44
SFG15T Engine

Replace the clutch disc

3-45
SFG15T Engine

XV. Fault of transmission system


Reason Debugging Method

1. Out of gear
Shift fork shaft is worn Replace
Shift fork or synchronizer sleeve is worn Replace
Elasticity of positioning spring is weakened or Replace
damaged Replace
Bearing on the input shaft or main shaft is worn Replace the cover and gear tooth
Geer sleeve or chamfer teeth is damaged or worn
Cotter spring ring dislocates or falls off Replace
2. In gear
Elasticity of synchronizer spring is weakened or Replace
broken Replace
Shift shaft or shift fork is distorted
3. Shift is difficult
Stroke of clutch pedal is incorrect Adjust
Friction disc of clutch plate is distorted or broken Replace
Clutch cover is damaged Replace the clutch cover
Synchronizer ring is worn Replace
Geer sleeve or chamfer teeth is damaged or worn Replace the gear sleeve or gear
Shift shaft is distorted Replace
4. Noise
Volume of lubricating oil is not enough or the type is
Supplement or replace
not proper
Replace
Bearing is damaged or worn
Replace
Gear is damaged or worn
Replace
Synchronizer is damaged or worn
Replace
Geer sleeve or chamfer teeth is damaged or worn

3-46
SFG15T Engine

XVI. VVT does not work

Reason Debugging Method


Oil pressure is insufficient Oil dipstick and whether oil quantity
meets the requirements shall be checked,
lubricating oil shall be injected if it is
insufficient; check pump pressure relief valve
and the oil outlet seals, replace if necessary
Lubricating oil pipeline is blocked Whether oil pipeline is smooth shall be
checked; whether OCV control valve is
blocked, whether the kerosene is cleaned or the
filter mesh is replaced shall be checked.
Open or short circuit Check the circuit and the replace damaged
components
VCP fault Replace VCP

3-47
SFG15T Engine

Appendix I. Fault Code List

No. Fault Code Fault Code Information


1 P000A Response of intake VCP phase lags
2 P0010 VVT intake control valve circuit failure
3 P0012 The intake air VVT is not in the default position at startup
4 P0016 Camshaft and crankshaft relative position is not correct
5 P0030 Front oxygen sensor heating control circuit is open (Bank1)
6 P0031 Heater of front oxygen sensor shorts to low voltage
7 P0032 Heater of front oxygen sensor shorts to high voltage
8 P0033 Discharge control valve control circuit failure
The discharge control valve control circuit voltage is too
9 P0034 low
The discharge control valve control circuit voltage is
10 P0035 too high
Rear oxygen sensor heating control circuit open
11 P0036 circuit (Bank1)
12 P0037 Heater of rear oxygen sensor shorts to low voltage
13 P0038 Heater of rear oxygen sensor shorts to high voltage
Front oxygen sensor heating resistance is
14 P0053 unreasonable (Bank1)
Rear Oxygen sensor heating resistance is
15 P0054 unreasonable (Bank1)
16 P006D Ambient pressure sensor signal circuit failure
17 P0072 Ambient temperature sensor voltage is too low
18 P0073 Ambient temperature sensor voltage is too high
19 P0101 Air flow sensor signal is unreasonable
20 P0102 Air flow sensor signal voltage is too low
21 P0103 Air flow sensor signal voltage is too high
22 P0111 Intake air temperature sensor signal unreasonable failure
23 P0112 Coil voltage of intake temperature sensor is low
24 P0113 Coil voltage of intake temperature sensor is high
25 P0116 Engine coolant temperature sensor signal unreasonable
26 P0117 Coil voltage of refrigerant temperature sensor is low
27 P0118 Coil voltage of refrigerant temperature sensor is high

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SFG15T Engine

No. Fault Code Fault Code Information


The electronic throttle position sensor 1 signal is
28 P0121 unreasonable
29 P0122 Voltage of 1# wire for throttle position is low
30 P0123 Voltage of 1# wire for throttle position is high
31 P0130 Front Oxygen sensor signal is unreasonable (Bank1)
32 P0131 Front oxygen sensor shorts to low voltage
33 P0132 Front oxygen sensor shorts to high voltage
34 P0133 Front Oxygen Sensor Aging (Bank1)
Front Oxygen sensor circuit signal circuit fault
35 P0134 (Bank1)
36 P0136 Rear Oxygen sensor signal is unreasonable (Bank1)
37 P0137 Rear oxygen sensor shorts to low voltage
38 P0138 Rear oxygen sensor shorts to high voltage
39 P0140 Rear oxygen sensor breaks
Off - line detection air - fuel ratio closed - loop
40 P0170 control self - learning unreasonable
Off - line detection air - fuel ratio closed - loop
41 P0171 control self - learning too thin
Off - line detection air - fuel ratio closed - loop
42 P0172 control self - learning too strong
43 P0201 First cylinder injector control circuit failure
44 P0202 Second cylinder injector control circuit failure
45 P0203 Third cylinder injector control circuit failure
46 P0204 Forth cylinder injector control circuit failure
47 P0219 The engine speed exceeds the maximum speed limit
The electronic throttle position sensor 2 signal is
48 P0221 unreasonable
The electronic throttle position sensor 2 signal circuit
49 P0222 voltage is too low
The electronic throttle position sensor 2 signal circuit
50 P0223 voltage is too high
51 P0234 Turbine control overcharging
The signal pressure of the turbocharger pressure
52 P0237 sensor is too low
53 P0238 Turbocharged pressure sensor signal voltage is too

3-49
SFG15T Engine

high
54 P0243 Exhaust gas control valve drive circuit failure
55 P0245 Exhaust control valve drive circuit voltage is too low
56 P0246 Exhaust control valve drive circuit voltage is too high
No. Fault Code Fault Code Information
57 P0261 Low voltage for oil injector of cylinder 1 breaks down
58 P0262 High voltage for oil injector of cylinder 1 breaks down
59 P0264 Low voltage for oil injector of cylinder 2 breaks down
60 P0265 High voltage for oil injector of cylinder 2 breaks down
61 P0267 Low voltage for oil injector of cylinder 3 breaks down
62 P0268 High voltage for oil injector of cylinder 3 breaks down
63 P0270 Low voltage for oil injector of cylinder 4 breaks down
64 P0271 High voltage for oil injector of cylinder 4 breaks down
65 P0300 Several cylinders catches fire
66 P0301 Cylinder 1 fire
67 P0302 Cylinder 2 fire
68 P0303 Cylinder 3 fire
69 P0304 Cylinder 4 fire
70 P0322 Speed sensor signal failure
71 P0327 Knock sensor signal circuit voltage is too low
72 P0328 Knock sensor signal circuit voltage is too high
73 P0341 The phase sensor signal is unreasonable
Three-way catalytic converter oxygen storage
74 P0420 capacity aging (emission overrun)
75 P0444 Carbon canister control valve control circuit failure
Carbon tank control valve control circuit voltage is too
76 P0458 low
Carbon tank control valve control circuit voltage is
77 P0459 too high
78 P0480 Cooling fan relay control circuit fault (low speed)
79 P0481 Cooling fan relay control circuit fault (high speed)
80 P0501 Vehicle speed sensor signal failure
81 P0506 Idle control speed is lower than the target idle speed
82 P0507 Idle control speed is higher than the target idle speed

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SFG15T Engine

83 P0560 System battery voltage signal is unreasonable


84 P0562 System battery voltage is too low
85 P0563 System battery voltage is too high
No. Fault Code Fault Code Information
86 P0571 Brake signal is unreasonable
87 P0604 Electronic control unit RAM failure
88 P0605 The electronic control unit ROM has failed
89 P0606 Electronic throttle safety monitoring function failure
90 P0627 Oil pump relay control circuit is open
91 P0628 Oil pump relay control circuit voltage is too low
92 P0629 Oil pump relay control circuit voltage is too high
93 P0645 The A / C compressor relay control circuit is open
94 P0646 A / C compressor relay control circuit voltage is too low
95 P0647 A / C compressor relay control circuit voltage is too high
96 P0688 The main relay output voltage is unreasonable
97 P0691 Cooling fan relay control circuit voltage is too low (idle)
98 P0692 Cooling fan relay control circuit voltage is too high (idle)
99 P0693 Cooling fan relay control circuit Low voltage (high speed)
Cooling fan relay control circuit voltage is too high
100 P0694 (high speed)
101 P0704 Clutch pedal switch signal unreasonable
102 P1297 Throttle front gas leak failure
103 P1336 Electronic throttle safety monitoring Torque limiting effect
The airbag sends an interruption or signal to the ECU
104 P1523 incorrectly
Electronic throttle actual position and target position
105 P1545 deviation is out of range
106 P1559 Electronic throttle self - learning process failure
The system voltage does not meet the electronic
107 P1564 throttle self-learning conditions
Electronic Throttle Lower Limit Position Initialization
108 P1565 Self - Learning Fault
109 P1568 Electronic throttle return position is too large
110 P1579 Electronic throttle self-learning conditions are not met
111 P1614 Authentication reply error

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SFG15T Engine

112 P1627 BCM communication failure, resulting in anti-theft lock


113 P2088 VVT Inlet control valve circuit voltage is too low
114 P2089 VVT Inlet control valve circuit voltage is too high
No. Fault Code Fault Code Information
115 P2106 Electronic throttle drive level failure
The electronic accelerator pedal position sensor 1
116 P2122 signal voltage is too low
The electronic accelerator pedal position sensor 1
117 P2123 signal voltage is too high
The electronic accelerator pedal position sensor 2
118 P2127 signal voltage is too low
The electronic accelerator pedal position sensor 2
119 P2128 signal voltage is too high
Electronic accelerator pedal position sensor signal is
120 P2138 unreasonable
Air-fuel ratio closed-loop control self-learning value
121 P2177 over the upper limit (in the load area)
Air-fuel ratio closed-loop control self-learning value
122 P2178 lower limit (middle load area)
Air-fuel ratio closed-loop control self-learning value
123 P2187 over the upper limit (low load area)
Air-fuel ratio closed-loop control self-learning value
124 P2188 lower limit (low load area)
125 P2195 Front oxygen sensor aging
126 P2196 Front oxygen sensor aging
127 P2261 Discharge control valve mechanical failure
128 P2270 Rear oxygen sensor aging

129 P2271 Rear oxygen sensor aging

130 U0001 CAN communication related diagnosis


ECU and ESP (electronic stability program control
131 U0123
module) control module communication is lost
Communication with BCM is lost or signal is
132 U0140
abnormal

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