PDF Engine Manual FAW V-5 Truck - 887 KB
This technical manual provides detailed service and repair information for the engine used in the FAW V-5 truck.
It is a vital resource for mechanics performing engine diagnostics, complex repairs, and complete overhauls.
The guide includes specifications, tolerances, and step-by-step procedures.
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Tianjin FAW
CA4GA5 Engine Maintenance Manual
Contents
Chapter 1 Technical Parameters and Maintenance Preparation Data of Engine ...................... 2
Section 1 Technical Parameters of Engine ...................................................................... 3
Section 2 Maintenance Preparation ................................................................................. 5
Section 3 General Maintenance Parameters .................................................................... 8
Section 4 Engine Maintenance ...................................................................................... 14
Chapter 2 Engine Structure ........................................................................................................... 16
Section 1 Cylinder block, cylinder head and crank connecting rod mechanism ........... 17
Section 2 Valve actuating mechanism ........................................................................... 24
Section 3 Lubrication System ........................................................................................ 29
Section 4 Cooling System .............................................................................................. 33
Section 5 Intake and Exhaust Systems .......................................................................... 35
Section 6 Fuel System ................................................................................................... 38
Section 7 Ignition System .............................................................................................. 40
Section 8 Other sensors and other actuating mechanism............................................... 42
Chapter 3 Engine Adjustment and Maintenance......................................................................... 44
Section 1 Engine Adjustment ........................................................................................ 45
Section 2 Engine Maintenance When Engine is Installed on the Vehicle ..................... 49
Section 3 Engine Adjustment and Maintenance ............................................................ 62
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Tianjin FAW
CA4GA5 Engine Maintenance Manual
Bent and deformed Limit 0.03
Connecting rod big end clearance Standard 0.017~0.029
Limit 0.046
Connecting rod axial clearance Standard 0.20~0.40
Limit 0.50
Crankshaft Main shaft diameter
Standard φ46(0,-0.018)
Enlarging 0.25mm type φ45.75~φ45.57
Enlarging 0.50mm type φ45.5~φ45.32
Main shaft diameter clearance
Standard 0.025~0.043
Limit 0.068
Connecting rod shaft diameter clearance
Standard 0.017~0.035
Limit 0.052
Crank pin diameter
Standard φ44(0,-0.018)
Enlarging 0.25mm type φ39.75~φ39.57
Enlarging 0.50mm type φ39.50~φ39.32
Intake manifold Seal groove depth 4±0.1mm
Seal ring protruding height Standard 2±0.1mm
Limit 1.8mm
Exhaust manifold Flange deformation
Standard 0.25
Limit 0.40
Valve clearance Cold state intake valve 0.2±0.03mm
Exhaust valve 0.3±0.03mm
Timing chain Flexibility limit 4mm [with 127N applied]
Chain chamber cover OCV Control valve hole diameter Standard φ18(+0.018,0)
Limit φ18.045
Joint surface deformation Standard 0.10
Limit 0.25
Upper and lower connecting Shell width 14.5(0,-0.2)
rod bearing shell
Free opening width 47( +1.5,+0.5)
Central thickness 1.5(+0.009,-0.003)
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Tianjin FAW
CA4GA5 Engine Maintenance Manual
Connecting rod bearing shell includes upper half and lower half. Upper half is installed on connecting rod body
and lower half on connecting rod cap. Connecting rod bearing shell (upper and lower half) is divided into four
groups within specified thickness tolerance. The bearing shell is colored on both ends. Connecting rod bearing
positioning lip is on the side. When assembling, in order to ensure fit clearance, select and assemble according to
grouping dimension of related parts.
Connecting rod upper bearing shell
Connecting rod bearing shell location lip
Connecting rod lower bearing shell
Connecting rod bearing shell
Crankshaft and bearing shell
Crankshaft is made of nodular cast iron, which consists of five main journals, eight pieces of balance weights,
crank throw included angle 180°, with symmetrical plane. It has dynamic balance itself. But it bears inner bending
moment to make crankshaft reach inner balance. Two groups of different balance weights are prepared.
The third main journal bears axial thrust. Two thrust shims made of mock silver are installed on both sides of
cylinder block supporting the third main journal.
Balance weight removes all inherent vibration of the engine.
Connecting rod journal grouping code is stamped on the side of front balance weight. Main bearing journal
grouping code is stamped on the side of rear balance weight.
Location pin
Main bearing journal and connecting rod journal of crankshaft adopt rolling fillet to increase fatigue strength.
Main bearing journal diameter of crankshaft mm 46
Connecting rod journal diameter of crankshaft mm 44
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CA4GA5 Engine Maintenance Manual
Relief valve
assembly
Engine oil pump sprocket tooth number
Tooth number of engine oil pump sprocket Outer diameter of engine oil pump sprocket (mm)
25 48. 6
Lubrication for Valve Actuating Mechanism
Lubricating oil required for valve actuating mechanism goes through camshaft bearing support to submerge tappet
and valve components in lubricating oil to ensure sufficient lubrication and heat dissipation.
Valve module Valve spring seat Spark plug assembly
Valve spring
Valve guide pipe
oil seal
Valve spring shim
Lubricating oil
Intake valve
Exhaust valve
Valve actuating mechanism lubrication
Engine oil filter
Engine oil filter has an element. There is a relief valve in closed structure. When inlet/outlet pressure
difference reaches the specified value, bypass valve is opened. At 2 MPa, engine oil filter shall not leak and
be damaged within 2 minutes.
Engine oil filter
Filtering area 860 cm2
Opening pressure of bypass-valve 0.1±0.02MPa(1.0±0.2 kgf/cm2 )
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CA4GA5 Engine Maintenance Manual
Engine ground Engine ground (digit)
Camshaft position sensor
Engine ground
Crankshaft position
sensor Starter
Denotation sensor Ignition coil 1
Front oxygen sensor Ignition coil 2
Rear oxygen sensor Ignition coil 3
Engine control
Coolant temperature unit assembly Ignition coil 4
sensor
Intake temperature/ Main relay
pressure sensor
Fuel pump relay
Air conditioner
evaporator temperature
sensor Fuel injector 1
Electronic throttle valve
Fuel injector 2
body sensor motor
Fuel injector 3
Acceleration pedal
sensor
Fuel injector 4
Speed sensor Canister solenoid valve
Tachometer Engine oil control valve
OBD connector MIL
Combination switch
Fan relay
Air compressor clutch relay
Power-assisted steering
switch
Air compressor
Air conditioner pressure electromagnetic clutch
switch
Radiator fan motor
Blower motor
CAN assembly
Functional block diagram for engine control unit assembly
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CA4GA5 Engine Maintenance Manual
11) Remove crank pulley.
Before loosening crank pulley bolt, use a
screwdriver to lock crank pulley in order to prevent
the crankshaft from rotating. Crankshaft
assembly
Crank pulley
assembly
Crank pulley bolt
Hexagon nut
Spring washer
2) Remove front engine support.
Front mount of
engine
Combination bolt
Washer
13) Remove idler assembly.
Spring washer
Idler assembly is installed on the stud of cylinder block front
end. Loosen hexagon nut and take down hexagon nut, spring
Hexagon nut
washer and washer. Then take down idler assembly.
Note: keep all removed parts in a safe place to avoid Idler assembly
them from being lost.
14) Remove bar type ignition coil assembly
Loosen hexagon head flange bolt and remove bar type ignition
coil assembly.
Note: when removing bar type ignition coil assembly, it is not
allowed to use a screwdriver to pry bar type ignition coil
assembly to avoid bar type ignition coil assembly insulation
sheath from being damaged.
15) Remove cylinder head cover assembly and engine oil filler
cap.
16) Remove chain chamber cover assembly
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CA4GA5 Engine Maintenance Manual
Align two pin holes of cylinder head gasket with locating ring on
cylinder block and place it on cylinder block top surface.
(Note) Check cylinder head gasket thickness and if there is any
defect. If necessary, replace with a new gasket.
Rear Front
Installation compression thickness of cylinder head gasket is
more than 0.3mm.
2) Install cylinder head assembly
① Clean cylinder head bottom and front end, align locating pin
hole with locating ring on cylinder block and place it on cylinder
head gasket carefully.
② Cylinder head bolt thread is applied by lubricating oil and
then inserted into cylinder head bolt hole.
Tightening torque: 34±2N.m, then rotate by 120°.
Fill oil within
this range
2-5 Remove and install engine oil pump
After removing timing chain and water according to “Remove
Timing Chain and Water Pump” section, remove engine oil Inner rotor
pump.
Remove engine oil pump
Loosen hexagon head flange bolt and remove engine oil pump. Outer rotor
Check wear conditions of inner and outer rotors of engine oil
pump. Oil filling
Install engine oil pump
Fill lubricating oil into the clearance between inner and outer
rotors of engine oil pump.
Fill lubricating oil from lower side of rotor mounting hole on
cylinder block.
③ The mark on outer rotor faces to the outside of cylinder block. Location pin
④ Locate the bolt and washer with locating pin, and tighten
them on front end of cylinder block. Tightening torque is Hexagon head
9±1.8N·m. flange bolt
(Note) Rotate engine oil pump sprocket by at least one turn to Washer
lubricate the rotor completely and run flexibly.
Engine oil pump
assembly
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CA4GA5 Engine Maintenance Manual
Remove
1) Remove V-belt
Loosen hexagon head flange bolt, but do not make it too loose.
Loosen adjusting bolt of the generator.
Remove V-belt.
Note: before removing, mark the running direction of V belt on
the back of V belt with chalk (an arrow).
2) Remove water pump belt pulley.
Remove crank pulley
(1) When loosening crank pulley bolt, use a special maintenance
tool to prevent the flywheel from rotating.
(2)Because tightening torque of crank pulley bolt is large,
extended torque wrench can be used.
4) Remove engine front mounting bracket.
Loosen hexagon nut and combination bolt. Do not lose spring
washer.
5) Remove idler assembly.
Bar type ignition coil Hexagon head
Remove hexagon nut. Do not lose washer and spring washer. assembly flange bolt
6) Remove engine oil filler cap assembly
7) Remove bar type ignition coil assembly
Loosen four hexagon head flange bolts and then take out bar
type ignition coil assembly.
Note: When taking out bar type ignition coil assembly, if it is not
easy to take out bar type ignition coil assembly, it is not allowed
to use a screwdriver to pry bar type ignition coil assembly.
Otherwise, bar type ignition coil assembly will be damaged.
Bracket II–fastening Bracket I –fastening
8) Remove cylinder head cover assembly engine wire harness engine wire harness
Loosen hexagon head flange nut at ⑿ and ⒀ positions and bolts
at ⑥ and ⑦ positions, and loosen bolts at other positions.
Remove cylinder head cover assembly. (Note) put canister
solenoid valve bracket (No. 1 position), engine wire harness
bracket II (No. 8 position), engine wire harness bracket I (No. 7
position) and cylinder head cover gasket in a special container.
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CA4GA5 Engine Maintenance Manual
Remove
Remove bar type ignition coil assembly.
Remove spark plug.
Remove cylinder head cover assembly, liner and wire harness Intake camshaft
Combination bolt
bracket I and II. assembly
Remove canister solenoid valve bracket and canister solenoid 1st camshaft
valve. bearing cap
Remove camshaft position sensor.
Remove 1st ~ 5th camshaft bearing caps. Loosen 20 bolts twice or
three times uniformly and then remove them.
Loosening method as follows: 1. Loosen 1st camshaft bearing Exhaust camshaft
cap bolt. First loosen 2 bolts inside and then loosen other two assembly
bolts, remove 1st camshaft bearing cap.
2. Loosen other camshaft bearing caps. Loosening sequence of
camshaft bearing cap is from outside to inside alternatively.
Note: 1. Do not lose location pin bush on camshaft bearing cap.
2. When removing camshaft bearing cap, do not knock or pry
with a hard object. Otherwise, it may damage camshaft bearing
cap.
3. After removing camshaft bearing cap, put it into the container
in order.
7) Remove intake/exhaust camshaft
(1). Use S24 open spanner to hold exhaust or intake camshaft
hexagon, rotate camshaft to keep camshaft peach away from
tappet surface.
(2) Shake camshaft by hand to remove it.
(Note) 1. If camshaft can not be lifted straight, it is necessary to Engine water inlet Hexagon head
tighten 3rd camshaft bearing cap bolt again. Shake camshaft by pipe flange bolt (2)
hand to loosen it. Loosen 3rd camshaft bearing cap bolt again and
remove camshaft.
2. Do not use a tool or other objects to pry camshaft or take it
down forcedly. Otherwise, it may be broken.
8) Remove valve tappet.
9) Loosen water inlet and outlet pipes.
Engine water Hexagon head
outlet pipe flange bolts (2)
10) Loosen water inlet seat, thermosistor and coolant Coolant temperature
temperature sensor. sensor assembly
Engine water inlet pipe
Use an open spanner to remove coolant temperature sensor. Do seat assembly
not use any impact tool.
Combination bolt
Hexagon head flange
nuts (2)
Studs (2)
Thermosistor
assembly with seal
ring
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CA4GA5 Engine Maintenance Manual
3. Check radial runout of camshaft.
Use V block to support both ends of camshaft. Place dial gauge
on the center of middle journal of camshaft, rotate camshaft by
one turn to ensure camshaft does not move axially. When
camshaft rotates, take down reading on dial gauge and calculate
the maximum radial runout, i.e. the difference between the
maximum reading and the minimum reading.
Maximum radial runout: 0.03mm
3. Check protruding height of cam.
Minimum limit: 39.45mm
If the height measured is less than the minimum limit value,
replace the camshaft.
Intake camshaft
4. Check the clearance between camshaft journal and cylinder journal dimension
head bearing hole.
① Measure outer diameter of camshaft journal.
② Measure inner diameter of five camshaft bearing seat holes on Camshaft
cylinder head. Measure each hole at two directions which are journal hole
perpendicular to each other.
Clearance
1st camshaft bearing clearance 0.030~0.071mm
2nd ~5th camshaft bearing clearance 0.035~0.072 mm
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CA4GA5 Engine Maintenance Manual
19) Install engine oil filler cap.
After applying lubricating oil on rubber seal ring of engine oil
filler cap, install engine oil filler cap on cylinder head cover by
rotating.
20) For installing spark plug assembly, refer to related section of
ignition system.
21) For installing bar type ignition coil assembly, refer to related
section of ignition system.
3.6 Cylinder block
Cylinder block composition
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CA4GA5 Engine Maintenance Manual
⑷Check if combination oil ring assembly is damaged.
Note: for one cylinder, if any of upper compression rings, middle
compression ring and combination oil ring assembly are defective,
replace piston ring as a whole group.
⑸ Measure outer diameter of the piston
Measure outer diameter of the piston at a distance from the lowest
end of the piston
Measuring position for outer diameter of piston pin: 8mm away
from lower end
Note: record measuring result. (When calculating the clearance
between cylinder and piston, this measured result is required data.)
⑹Check piston pin clearance.
① Measure inner diameter of piston pin hole.
② Measure outer diameter of piston hole.
③ Calculate the clearance between piston pin hole and piston pin.
Allowable limit:
Note: If the clearance exceeds specified value, replace piston and
piston rod in group.
⑺ Measure opening clearance of piston ring
After checking or repairing the cylinder, place piston ring into the
cylinder until it is above 40mm from top installation surface of
cylinder block. Measure piston ring opening clearance with a plug
gauge.
Lateral clearance between upper compression ring and ring groove:
0.04~0.09mm.
Lateral clearance between middle compression ring and ring
groove: 0.02~0.06mm.
Backlash between oil ring and ring groove: 0.03~0.11mm.
Piston ring
Note: ①Before placing, apply lubricating oil on outside of piston
ring.
②If opening clearance exceeds specified limit, replace piston ring
in group.
Check connecting rod
(1)Check if connecting rod is damaged or cracked.
(2)Check if connecting rod is bent and twisted.
Maximum bending limit: 0.03mm
Maximum torsion limit: 0.03mm Bent
Twisted
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CA4GA5 Engine Maintenance Manual
Grouping according to thickness of connecting rod
bearing shell
Grouping No. color mark. Grouping size
Black
Dark brown
Green
Yellow
⑹Assembling relations of support hole, shaft hole, connecting
rod journal
According to crankshaft connecting rod journal grouping code
and connecting rod big end diameter grouping code, select
Oil
appropriate connecting rod bearing shell. Connecting rod upper hole
bearing shell
Bearing shell code =6-(hole code + bearing code)
Table of assembling relation of support hole, bearing
shell, connecting rod journal
support hole grouping
bearing shell grouping Upper bearing shell
main shaft split shaft
location lip
Bearing shell Bearing shell
Clearance code clearance code
Clearance Bearing shell clearance Bearing shell
code code
Clearance Bearing shell clearance Bearing shell
code code
Connecting rod lower
bearing shell
Bearing shell Hole code Bearing code
code
⑺ Install connecting rod upper/lower bearing shells
Bearing shell location lip
Install connecting rod upper bearing shell into connecting rod
bearing shell seat hole, make location lip in corresponding slot of
bearing shell seat and make shell back lean against connecting
rod big end hole seat surface reliably.
Install connecting rod lower bearing shell into connecting rod
bearing shell seat hole, make location lip in corresponding slot of
bearing shell seat and make shell back lean against connecting
rod big end hole seat surface reliably.
Note: ① Connecting rod upper bearing shell is provided with oil
hole, but connecting rod lower bearing shell is not provided with
oil hole.
② Oil or other foreign matters are forbidden between bearing
shell back and connecting rod bearing support surface. Oil hole
on the shell and oil hole on the support face shall be interlinked.
③ After bearing shell location lip is pressed into location slot of
connecting rod bearing support, it will not become loose.
④ When installing, do not touch working surface and back face
of connecting rod bearing shell, and installation surface of
connecting rod bearing shell.
⑤ Wipe off lubricating oil on the back of each connecting rod
bearing shell.
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