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BYD AUTO

BYD Suri Maintenance & Repair Manual

Engine & Transmission Contents Chapter 1 BYD473Q Engine ............................................................................................................ 3 Part 1 Engine............................................................................................................................. 4 Section 1 Introduction ........................................................................................................ 4 Section 2 Cylinder Head ...................................................................................................11 Section 3 Cylinder Block .................................................................................................. 38 Part 2 Lubricating System ....................................................................................................... 57 Part 3 Intake Manifold and Exhaust System ........................................................................... 63 Part 4 Engine Cooling System ................................................................................................ 64 Part 5 Fuel and Exhaust System ............................................................................................ 67 Chapter 2 476ZQA Engine ............................................................................................................. 70 Part 1 Engine........................................................................................................................... 71 Section 1 Overview .......................................................................................................... 71 Section 2 Belt Driving Device .......................................................................................... 76 Section 3 Crankshaft Rear Oil Seal Component ............................................................. 78 Section 4 Timing Chain .................................................................................................... 80 Section 5 Detection of the Sparkplug and Cylinder Compression Pressure ................... 82 Section 6 Engine .............................................................................................................. 84 Part 2 Lubrication System ......................................................................................................119 Section 1 Schematic Diagram of Engine Lubrication Circuit ..........................................119 Section 2 Inspection of Oil Pressure ............................................................................. 120 Section 3 Engine Oil ...................................................................................................... 121 Section 4 Oil Sump ........................................................................................................ 122 Section 5 Oil Pump ........................................................................................................ 123 Part 3 Cooling System .......................................................................................................... 124 Section 1 Schematic Diagram of Engine Cooling System ............................................ 124 Section 2 Thermolator.................................................................................................... 125 Section 3 Water Pump ................................................................................................... 126 Part 4 Clutch.......................................................................................................................... 128 Section 1 Clutch Device................................................................................................. 128 Section 2 Flywheel ......................................................................................................... 131 Chapter 3 Transmission ............................................................................................................... 132 Section 1 Structural parameters .................................................................................... 133 Section 2 Service Guidelines ......................................................................................... 134 Section 3 Service of transmission ................................................................................. 136 Section 4 Differential ...................................................................................................... 165 Chapter 4 6T25 Manual Transmission ......................................................................................... 170 Section 1 Introduction of Transmission ......................................................................... 171 Section 2 Transmission Operating Mechanism ............................................................. 175 Section 3 Transmission mechanism .............................................................................. 179

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BYD AUTO

BYD Suri Maintenance & Repair Manual

Section 4 Transmission Assembly ................................................................................. 193 Chapter 5 BYD6DT25 Dual Clutch Transmission ........................................................................ 204 Section 1 Introduction of Transmission ......................................................................... 205 Section 2 Dual Clutch .................................................................................................... 207 Section 3 Operating Mechanism and Housing .............................................................. 216 Section 4 Gear and Drive Shaft ..................................................................................... 229

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BYD AUTO

BYD Suri Maintenance & Repair Manual

Chapter 1 BYD473Q Engine Contents Part 1 Engine .................................................................................................................................... 4 Section 1 Introduction ............................................................................................................... 4 Section 2 Cylinder Head .......................................................................................................... 11 Section 3 Cylinder Block ......................................................................................................... 38 Part 2 Lubricating System .............................................................................................................. 57 Part 3 Intake Manifold and Exhaust System .................................................................................. 63 Part 4 Engine Cooling System ....................................................................................................... 64 Part 5 Fuel and Exhaust System .................................................................................................... 67

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BYD AUTO

BYD Suri Maintenance & Repair Manual

Part 1 Engine Section 1 Introduction 1.1 Main Technical Parameters BYD473QB/QE engine uses the electronic fuel injection (EFI) system developed by our company and it has advanced self-diagnosis function. The injection system uses the multi-point sequential injection which features high power per liter, low fuel consumption, low noise, less pollution and compact structure. Under any working conditions, BYD473QB/QE engine can operate with the best performance and the complete vehicle equipped with this kind of engine can ensure reliable safety, driving comfort, fuel economy and perfect environmental performance. Main technical parameters of BYD473QB/QE Engine are listed in the following table. Model BYD473QB BYD473QE Type 4-stroke, water-cooled, inline, SOHC and EFI Number of Cylinders 4 Cylinder Bore (mm) 73 Piston Stroke (mm) 88.9 89.4 Compression Ratio 10.2 10.6 Firing Order 1-3-4-2 Nominal Power (kW) 79 (5800r/min) 79 (5800r/min) Max. Torque (Nm) 144 (4800 r/min) 144 (4650r/min) Nominal Speed (r/min) 5800 Min.Spec Fuel Consumption (g/kW h) 245 236 Oil Pressure (kPa) 340~490 (3000r/min±50r/min) Min. Stable Speed (idle speed (r/min) 780±50 Total Displacement (L) 1.488 1.497 Oil and Fuel Consumption Ratio (%) 0.26 Dimension (mm) 587×543×700 587×543×700 (length×width×height) Net Weight (kg) 92 97 CO≤0.15% HC≤40ppm (780±50r/min) Emissions at Idle Speed CO≤0.15% HC≤40ppm (2500±50r/min) GB18285-2005 The vehicle uses 93# unleaded gasoline Fuel (GB17930-1999) SG 10W/30 (All seasons in southern China and Lubricant Oil spring, summer and autumn in northern China) SG 5W/30 (Winter in northern China) (GB11121) Coolant Glycol Cooling Fluid dry-type, single disc, diaphragm spring, constant Type pressure Clutch Clutch plate assembly φ200×8.9 mm (Free State) Dimensions (mm) Clutch cover assembly φ255×40.4 mm Weight (kg) 4.314 with synchromesh unit, five forward gears and one Transmission Type reverse gear 3 1st gear 3.308 2nd gear 1.826 Transmission Gear Ratio 3rd gear 1.207 4th gear 0.939

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BYD AUTO

BYD Suri Maintenance & Repair Manual

Final Drive Ratio Dimensions (mm) Lubricant Oil

5th gear 0.730 reverse gear 3.231 4.471 (length×width×height) 504×382×363mm medium duty gear oils for vehicles (GL-4 SAE 80W/90)

1.2 Technical Specifications for Maintenance Engine Cylinder Head Name

Measuring Item

Cylinder Head

Warpage Height Axial Clearance Oil Film Clearance between Camshaft and Bracket Total Runout

Camshaft

Cam Lobe Height Clearance (cold state) Valve

Valve Tappet O.D. Clearance between Valve Tappet and Guide Width

Valve Seat

Valve Spring

Valve Tappet Mounting Height Free Length I.D.

Valve Guide Mounting Height Rocker Arm

Clearance between Rocker Arm and Rocker Shaft

Measuring Condition

Standard Value

Overhaul Limit 0.08 mm

119.9~120.1 mm 0.07~0.25 mm

0.5 mm

0.025~0.046 mm

0.1 mm

Max. 0.03 mm 35.37 mm 30.565 mm 35.39 mm 0.18~0.22 mm 0.23~0.27 mm 5.470~5.485 mm 5.455~5.470 mm 0.025~0.060 mm

0.04 mm

Intake Variable Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust

0.04~0.075 mm

0.11 mm

Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake

0.85~1.15 mm 1.25~1.55 mm 46.1~46.5 mm 46.2~46.6 mm 50.5 mm 57.2 mm 5.51~5.53 mm 5.51~5.53 mm 15.85~16.35 mm 15.85~16.35 mm 0.02~0.054 mm

1.60 mm 2.00 mm 46.8 mm 46.9 mm

Exhaust

0.02~0.054 mm

0.08 mm

Measuring Condition

Standard Value

Overhaul Limit

Max.0.07 mm 73~73.019 mm ----

0.10 mm 73.07 mm 0.05 mm

----

0.25 mm

72.955~72.975 mm

72.945 mm

5.45 mm 5.42 mm 0.08 mm

5.55 mm 5.55 mm

0.08 mm

Engine Cylinder Block Name

Cylinder Block

Piston

Measuring Item Warpage Cylinder Bore Cylinder Bore Taper Cylinder Reboring Limit Distance from Bottom of Piston Skirt to

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BYD Suri Maintenance & Repair Manual

Piston O.D. 13 mm Clearance with Cylinder Piston Ring Groove Width Clearance between Piston Ring and Groove Piston Ring Piston Ring End Gap

Piston Pin

Connecting Rod

Crankshaft

Crankshaft Bearing

O.D. Clearance between Piston Pin and Piston Pin Bore Clearance between Pin and small-end hole of Connecting Rod Diameter of small-end hole of Connecting Rod Diameter of big-end hole of Connecting Rod Installed on End Clearance of Crankshaft Diameter of Main Journal Diameter of Connecting Rod Journal Connecting Rod/Main Journal Taper Connecting Rod/Out of Roundness of Main Journal End Clearance Runout Oil Film Clearance between Main Shaft Bearing and Journal Clearance between Connecting Rod Bearings

Engine Lubrication Name Measuring Item

0.035~0.054 mm

0.06 mm

First Air Ring

1.02~1.04 mm

1.07 mm

Second Air Ring Multi-piece Oil Ring First Air Ring

1.21~1.23 mm

1.25 mm

2.01~2.03 mm

2.05 mm

0.03~0.07 mm

0.15 mm

Second Air Ring First Air Ring

0.02~0.06 mm

0.13 mm

0.20~0.35 mm

0.6 mm

Second Air Ring Multi-piece Oil Ring

0.35~0.5 mm

0.65 mm

0.2~0.7 mm

0.8 mm

17.996~18 mm 0.005~0.015 mm

0.015~0.037 mm 17.963~17.981 mm Normal

43~43.015 mm

0.15~0.3 mm

0.4 mm

49.937~49.955mm 39.940~39.955 mm

Measuring

0.005 mm

0.01 mm

0.005 mm

0.01 mm

0.1~0.35 mm Max. 0.03 mm

0.45 mm 0.04 mm

0.028~0.049 mm

0.055 mm

0.022~0.050 mm

0.055 mm

Standard Value

Overhaul Limit

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BYD AUTO

Engine Oil

Oil Pump

Relief Valve

BYD Suri Maintenance & Repair Manual

Capacity

Clearance between Internal and External Rotor Clearance between Pump Housing and External Rotor Clearance between Pump Housing and External Rotor Shaft Relief Valve, Oil Pressure when oil temperature is 80°C

Condition Engine overhaul Replace oil, including oil filter Replace oil, excluding oil filter

4.0 L 3.3 L

2.9 L 0.075 mm~0.15 mm

0.18 mm

0.06 mm~0.136 mm

0.18 mm

0.028 mm~0.065 mm

0.085 mm

idle speed

Min. 30 kPa

3000 rpm/min

Min. 300 kPa

Engine Cooling Name

Radiator Reservoir Radiator Cap

Measuring Item Coolant volume (including engine, heater, hoses and radiator) Coolant Volume

Measuring Condition Engine Overhaul Coolant Replacement

Functioning Temperature Valve Lift at full-open

Thermo Switch

Switching Temperature

Overhaul Limit

4.7 L 3.6 L 0.4 L

Opening Pressure

Thermolator

Standard Value

93 kPa~123 kPa Just open Full open ON OFF

76°C~80°C 90°C 8 mm 91~95°C Subtract 3~8°C of the temperature when the switch is ON

1.3 BYD473QE/QB Tightening Torque Table of Gasoline Engine Serial No.

Tightened Parts/Components

1

Cylinder Head

2

Main Bearing Cap

3 4 5 6 7 8

Connecting Rod Cap Flywheel Sparkplug Labyrinth Gland Knock Sensor Oil Pressure Switch

Bolt size Cylinder Head Bolt and Gasket Unit Main Bearing Cap Bolt and Gasket Unit Connecting Rod Bolt Flywheel Bolt M14×1.25 Bolt M6×12 Bolt M8×30 R2 1/8

Tightening (Nm)

Torque

29 and corner 130° 25 and corner 40° 9.8 and corner 90° 95 20 12 25 15

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BYD AUTO

BYD Suri Maintenance & Repair Manual

9

Cylinder Threaded Plug

Head

10

Tensioning Link Plate

11

Camshaft Sprocket

12 13

Guide Link Plate Tensioner Seat

14

Oil Pump Assembly

15

Water Pump

16

Oil Collector

17

Oil Sump

18

Oil Filter

20

Welded Dipstick Tube Assembly Water Outlet Tube

21

Intake Manifold

19

22 23

Fuel Distributor Assembly Intake Temperature Pressure Sensor

24

Intake Valve Assembly

25

Throttle Wire Bracket

26

Exhaust Manifold

37

Exhaust Manifold Heat Shield Exhaust Manifold Bracket Front Lambda Sensor Thermolator Cap Camshaft Phase Sensor Coolant Temperature Sensor Cylinder Head Cover Ignition Coil Charcoal Canister Control Valve Bracket Crankshaft Damper Pulley Water Pump Pulley

38

Generator

39

Clutch

27 28 29 30 31 32 33 34 35 36

Cover

Bolt M10×1.25×12 Tensioning Link Plate Bolt Shaft Camshaft Sprocket Bolt Assembly Bolt M6×16 Bolt M6×30 Bolt M6×25

30 22 56 12 12 10

Bolt M6×35 Bolt M6×35 Bolt M6×12 Nut M6 Bolt M6×30 Bolt M8×35 Bolt M6×50 Oil Filter Threaded Connecting Pipe

10 12 10 10 12 25 12 12 20

Bolt M6×12

10

Bolt M6×12 Bolt M8×50 Nut M8

10 25 25

Bolt M6×12

10

Cross Recessed Pan Head Screw M5×16 Bolt M6×30 Bolt M6×35 Bolt M6×12 Bolt M10×1.25×20 Bolt M10

5 12 12 12 44 44

Bolt M6×25

10

Bolt M8×20 Nut M8×25 M18×1.5-6e Bolt M6×20

25 25 45 10

Bolt M6×16

10

M12×1.5-6g

15

Cylinder Head Cover Bolt Unit Bolt M6×25

12 10

Bolt M6×12

10

Pulley Bolt and Gasket Unit

37 plus corner 90°

Bolt M6×12 Bolt M8×70 Bolt M8×25 Hexagon Socket Head Cap

14 25 25 25

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BYD AUTO

BYD Suri Maintenance & Repair Manual

Assembly 40

Transmission

41

Starter

42

Intake Manifold Bracket Assembly

43

Timing Cover

44

Clutch Baffle Camshaft Thrust Cover Camshaft Target Wheel Cylinder Head Threaded Plug EGR Valve Seat EGR Valve OCV Valve Assembly

45 46 47 48 49 50

Screw Bolt M12×1.25×60 Bolt M12×1.25×65 Bolt M12×1.25×95 Bolt M10×1.25×45 Bolt M10×1.25×20 Bolt M6×16 Intake Manifold Bracket Big Gasket Bolt M6×30 Hexagon Fit Bolt Bolt M8×50 Bolt M8×80 Bolt M6×30 Bolt M12×1.25×12 Bolt M6×12

65 65 65 44 44 12 12 25 25 25 10 20 10

Bolt M6×20

10

Hexagon Socket-head Cap Bolt

34

M16×1.5-6h

45

M8 Nut M8 Nut Bolt M6×55

25 25 12

1.4 BYD473Q List of Different Elements of Gasoline Engine Model Part Number

BYD473QB

BYD473QE

BYD473QA-1003400 BYD473QB-1005021 BYD473QA-1003060 BYD473QA-1006010 BYD473QA-1008020 BYD473QA-1003601 BYD473QA-1003054 BYD473QA-1121010 BYD473QA-1130020 BYD473QA-1130015 BYD473QA-1303200 BYD473QA-1132020 BYD473QA-3611030 BYD473QA-3611040 BYD473QA-3611050 BYD473QA-3611060

BYD473QE-1003400 BYD473QD-1005021 BYD473QE-1003060 BYD473QE-1006010 BYD473QE-1008020 BYD473QE-1003601 BYD473QE-1003054 BYD473QE-1121010 BYD473QE-1026300 BYD473QE-1130015 BYD473QE-1303200 BYD473QE-1132110 BYD473QE-3611700 BYD473QE-3611400 BYD473QE-3611200 BYD473QE-3611100

BYD473QA-3611070

BYD473QE-3611500

Name Cylinder Head Assembly Processing Crankshaft Rocker Arm Mechanism Camshaft Assembly Intake Manifold Assembly Intake Manifold Bracket Intake Manifold Stud Fuel Distributor Assembly Charcoal Canister Control Valve Charcoal Canister Control Valve Bracket Water Outlet Tube Welding Unit II Throttle Body Throttle Valve Position Sensor Knock Sensor Crankshaft Position Sensor Coolant Temperature Sensor Intake Air Temperature and Pressure Sensor

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Front Lambda Sensor Idle Stepper Motor Ignition Coil Assembly Engine Harness Bracket Ⅹ Engine Harness Bracket Ⅻ EGR Control Valve EGR Valve Seat EGR Valve Gasket EGR Valve Seat Gasket EGR Valve Stud EGR Valve Seat Branch Pipe Intake Manifold Transition Gasket Intake Manifold Gasket OCV Valve Unit Cylinder Head Threaded Plug Cylinder Head Threaded Plug Gasket EGR Backwater Hose

BYD Suri Maintenance & Repair Manual

BYD473QA-3611080 BYD473QA-3611090 IB5-3705100 IB5-1024217 None None None None None None None None None None None None None

BYD473QE-1211100 BYD473QE-1026200 BYD473QE-3705010 IB5-4016214 IB5-4016215 BYD473QE-3615100 BYD473QE-1003501 BYD473QE-1003507 BYD473QE-1003502 BYD473QE-1003506 BYD473QE-1003505 BYD473QE-1008021 BYD473QE-1008024 BYD473QE-1003700 BYD473QE-1003055 BYD473QE-1003056 BYD473QE-1303016

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BYD Suri Maintenance & Repair Manual

Section 2 Cylinder Head 2.1 Valve Lash Control Note: The valve can be adjusted only when the temperature of the cylinder head is below 38°C. 2.1.1 Remove the cylinder head cover. 2.1.2 Turn the crankshaft and place 1 cylinder piston on the top dead center (TDC). Marker "UP" on the camshaft sprocket should be on the top, and the top dead center groove of the camshaft sprocket should be aligned with the upper edge of the cylinder head.

2.1.6 Tighten the adjusting lock nut and recheck the clearance; if necessary, repeat the procedure mentioned above.

2.1 3.Select appropriate feeler gauges for valves which need inspection. BYD473QB Engine: intake valve lash:0.25 mm ± 0.02 mm exhaust valve lash: 0.29 mm ± 0.02 mm BYD473QE Engine: intake valve lash: 0.20 mm ± 0.02 mm exhaust valve lash: 0.25 mm, 0.02 mm

2.1.7 Turn the crankshaft clockwise. Align the top dead center groove of the No.3, No.4, and No.2 pistons on the camshaft sprocket with the upper edge of the cylinder head successively; inspect the valve lash with a feeler gauge, and adjust it if necessary. 2.1.8 Install the cylinder head cover.

2.1 4 Insert a feeler gauge between the adjusting screw and the end of the valve lever, and then slide it back and forth; slight resistance should be felt. 2.1.5 If the resistance is too big or small, loosen the adjusting lock nut and rotate the adjusting screw until appropriate resistance can be felt when sliding the feeler gauge back and forth.

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BYD Suri Maintenance & Repair Manual

2.2 Removal and Installation of Crankshaft Damper Pulley Removal Remove bolts on the crankshaft damper pulley using a ratchet wrench, an extension rod and a 19 mm sleeve. Installation 2.2.1 Clean the crankshaft damper pulley (A), crankshaft (B), bolt (C) and washer (D), and lubricate them as shown in the illustration below.

2.3.3 Remove the idler unit.

2.3.4 Turn the crankshaft damper pulley and align its top dead center (TDC) marker with the pointer. 2.2.2 Install the crankshaft damper pulley and bolts on the crankshaft pulley and then tighten bolts to 37 Nm with a torque wrench and a 19mm sleeve. Don’t use an impact wrench. If bolts on the pulley or the crankshaft are new, tighten the bolts to 177 Nm and then loosen them and tighten them to 37 Nm. 2.2.3 Tighten the bolts on the pulley to 90°.

2.3 Removal and Installation of Timing Chain Note: Keep the timing chain away from the magnetic field.

2.3.5 Remove the water pump pulley.

Removal

2.3.6 Remove the cylinder head cover.

2.3.1 Remove the belt. 2.3.2 Remove the assembling bolt 1 on the generator’s adjusting arm and then loosen generator's assembling bolt 2.

2.3.7 Remove the crankshaft damper pulley. 2.3.8 Remove the oil sump.

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BYD Suri Maintenance & Repair Manual

2.3.9 Support the engine from the cylinder block's bottom with a jack and a wood block. 2.3.10 Keep the generator away from the timing cover and remove the timing cover.

2.3.11 Apply engine oil on the surface of the timing chain tensioner seat. Pry up holes on the timing chain tensioner seat with a screwdriver and remove bolt 1 and loosen bolt 2.

2.3.13 Remove the Chain tension plate and the chain guide plate.

2.3.14 Remove the timing chain. Installation

2.3.12 Remove the timing chain tensioner seat.

Note: Keep the timing chain away from the magnetic field. 2.3.14.1 Place the crankshaft on the top dead center (TDC) Align the TDC marker on the crankshaft sprocket with the pointer on the oil pump.

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2.3.14.2 Place No.1 piston on the top dead center. Marker "UP" on the camshaft sprocket should be on the top and the top dead center groove of the camshaft sprocket should be aligned with the upper edge of the cylinder head.

2.3.14.3 Install the timing chain on the crankshaft sprocket and the color chip should be aligned with TDC marker on the crankshaft sprocket.

2.3.14.4 Install the timing chain on the camshaft sprocket and the pointer should be aligned with the three color chips.

BYD Suri Maintenance & Repair Manual

2.3.14.5 Apply engine oil on the threads of the chain tension plate bolts, and install the tensioning chain plate unit and guide chain plate unit.

2.3.14.6 Install the tensioner seat and then slightly tighten the bolt.

2.3.14.7 Apply engine oil on the sliding surface of the tensioner seat.

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2.3.14.8 Turn the tensioner seat clockwise to press against the chain tension plate, install the remaining bolts and tighten them.

BYD Suri Maintenance & Repair Manual

2.3.14.13 Install the timing cover.

2.3.14.9 Check the crankshaft front seal of the timing cover for any damage. If the oil seal is damaged, replace the crankshaft front seal. 2.3.14.10 Remove the old flange sealant on the timing cover's mating surface, bolts and bolt holes. 2.3.14.11 Clean the timing cover's mating surface and dry it. 2.3.14.14 Install the oil sump. 2.3.14.12 Apply flange sealant evenly on the mating surface of the timing cover and cylinder block as well as the inner thread of each hole.

2.3.14.15 Install the crankshaft damper pulley. 2.3.14.16 Install the cylinder head cover.

Note:

2.3.14.17 Install the water pump pulley.

Apply 2 mm~3 mm wide flange sealant along the dotted lines.

2.3.14.18 Install the idler unit.

Apply 3 mm~4 mm wide flange sealant on the upper surface of the cylinder block on the timing cover.

2.3.14.19 Install the generator’s adjusting arm assembling bolts.

The parts should be installed within 4 minutes after the flange sealant is applied on them. If not, clean the old residue, reapply the flange sealant and install the parts.

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2.3.14.20 Install and adjust the belt.

BYD Suri Maintenance & Repair Manual

34.5 mm -35.2 mm

2.4 Installation of Crankshaft Front Seal Special tools needed: Guide rod for removal and installation

2.5 Removal of Cylinder Head Cover 2.5.1 Remove the intake manifolds.

2.4.1 Using SST, tap a new oil seal into the timing cover directly at the specified mounting height.

2.5.2 Remove 4 ignition coils. 2.5.3 Remove the cylinder head cover.

2.4.2 Measure the distance between the timing cover’s surface (contacting surface with the cylinder block) and the oil seal. Oil seal mounting height 34.5 mm~35.2 mm

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BYD Suri Maintenance & Repair Manual

2.6 Removal of Cylinder Head Note: a

Use a fender cover to avoid damaging the paint.

b

To avoid damage, hold the connectors and carefully pull out the wire harness connectors.

c

To avoid damaging the cylinder head, loosen the cylinder head bolts only when the engine coolant temperature is below 38°C (100°F).

d

To avoid wrong connection, do mark on all wire harnesses and hoses. Make sure they do not contact with other wires and hoses or interfere with other parts.

e

Keep the timing chain away from the magnetic field.

2.6.5 Remove heater hoses.

2.6.1 Drain engine coolant. 2.6.2 Remove the air cleaner housing. 2.6.3 Remove inlet and outlet hoses of the throttle body.

2.6.6 Remove the belt. 2.6.7 Remove the intake manifolds. 2.6.8 Remove the exhaust manifolds. 2.6.9 Remove the engine wire harness connectors and harness retainers from the cylinder head. 4 injector connectors 2.6.9.1 Engine coolant temperature sensor connector 2.6.9.2 Camshaft phase sensor connector

2.6.4 Remove inlet and outlet hoses of the radiator.

2.6.9.3 Oil pressure switch connector 2.6.9.4 Knock sensor 2.6.10 Remove the connected wire harnesses, bolts and harness brackets. 2.6.11 Remove the water outlet tube connecting pipe and the positive crankcase ventilation (PCV) hose.

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BYD AUTO

BYD Suri Maintenance & Repair Manual

2.6.12 Remove the cylinder head cover. 2.6.13 Remove the assembling bolts on the generator's mounting bracket and loosen the generator's assembling bolts.

2.6.22 Install the crankshaft damper pulley loosely.

2.6.14 Remove the idler unit.

2.6.23 Apply engine oil on the sliding surface of the timing chain tensioner seat through the oil return hole on the cylinder head.

2.6.15 Turn the crankshaft damper pulley and align its top dead center (TDC) marker with the pointer. 2.6.16 Remove the water pump pulley. 2.6.17 Remove the crankshaft damper pulley. 2.6.18 Support the engine from the bottom of the oil sump with a 300×300×25mm wood block and a jack. Note: Do not place the jack on the center of the oil sump to avoid damaging it. 2.6.19 Remove the ground cable and then remove engine front support. 2.6.20 Keep the engine away from the timing cover and remove the timing cover.

2.6.21 Make a reference marker on the camshaft sprocket and the timing chain.

2.6.24 Fix the crankshaft damper pulley and put a socket wrench on the camshaft sprocket bolt.

2.6.25 Turn the camshaft clockwise, press the chain tension plate, and install a M6 × 1.0 mm bolt into the bolt hole of the cylinder

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BYD Suri Maintenance & Repair Manual

block through the chain tension plate. 2.6.26 Hold the camshaft with an open-end wrench and remove the camshaft sprocket.

The order of loosening the cylinder head bolt unit. 2.6.29 Remove the cylinder head.

2.7 Removal and Installation of Camshaft Sprocket Removal 2.6.27 Remove the bolt on the tensioning chain guide plate.

Note: Keep the timing chain away from the magnetic field. 2.7.1 Remove the cylinder head cover. 2.7.2 Make a reference marker on the camshaft sprocket and the timing chain.

2.7.3 Apply engine oil on the sliding surface of the tensioner seat through the oil return hole on the cylinder head.

2.6.28 Remove the cylinder head bolt unit. To avoid warp age and deformation, loosen the bolts by turning 1/3 circle each time in order and repeat the procedure until all bolts are loose.

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BYD Suri Maintenance & Repair Manual

Note: Hang the timing chain with a steel wire.

2.7.4 Remove the sight glass cover.

Installation Note: Keep the timing chain away from the magnetic field.

2.7.5 Remove the bolt M12×1.25×12 on the timing cover and the gasket, fix the crankshaft damper pulley and put a socket wrench on the camshaft sprocket bolt.

2.7.7.1 Align the reference marker and install the timing chain on the camshaft sprocket; install the camshaft sprocket on the camshaft.

2.7.7.2 Hold the camshaft with an open-end wrench and tighten the bolt. 2.7.6 Turn the camshaft clockwise, press the chain tensioning plate, and install a M6 × 1.0 mm bolt into the bolt hole of the cylinder block through the M12 bolt hole on the timing cover and then the chain tensioning plate.

Specialized torque: 75 Nm

2.7.7 Grip the camshaft with an open-end wrench and remove the Camshaft Sprocket Bolt Assembly.

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BYD Suri Maintenance & Repair Manual

2.7.7.5 Turn the camshaft clockwise, press the timing chain tensioning plate and take out the bolt M6×1.0mm. 2.7.7.6 Install the bolt M12×1.25×12 with a new washer. 2.7.7.7 Install a new sight glass cover.

2.7.7.3 Apply engine oil on the sliding surface of the tensioner seat through the oil return hole of the cylinder head.

2.7.7.8 Install the cylinder head cover.

2.8 Replacement of Camshaft Target Wheel (BYD473QB Engine) Removal 2.8.1 Remove the air cleaner. 2.8.2 Remove connected wire harnesses, bolts and harness brackets. 2.8.3 Remove the cylinder head. 2.7.7.4 Fix the crankshaft damper pulley and put a socket wrench on the camshaft sprocket bolt.

2.8.4 Remove the camshaft thrust cover.

2.8.5 Fix the camshaft with an open-end wrench and loosen the hexagon socket-head cap bolt.

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2.8.6 Remove the camshaft target wheel.

BYD Suri Maintenance & Repair Manual

2.8.6.4 Install the cylinder head cover. 2.8.6.5 Install harness brackets, wire harnesses, bolts and so on. 2.8.6.6 Install the air cleaner.

2.9 Inspection of Cylinder Head’s Warp age 2.9.1 Remove the cylinder head cover. 2.9.2 Inspect the camshaft.

2.8.6.1 Install the camshaft target wheel.

2.9.3 Check the cylinder head for warp age. Measure the length of each side and the length along the direction coming through the center.

2.8.6.2 Hold the camshaft with an open-end wrench and then tighten the bolt to 34 Nm.

2.9.3.1 If the warp age is less than 0.08 mm, the cylinder head needs no repair.

Installation

2.9.3.2 If the warp age is between 0.08 mm and 0.2 mm, the cylinder head needs repair 2.9.3.3 The overhaul limit for a 120 mm high cylinder head is 0.2 mm. 2.9.3.4 Standard cylinder head height:119.9 mm~120.1 mm

2.8.6.3 Install the camshaft thrust cover using a new O-ring seal.

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BYD Suri Maintenance & Repair Manual

2.10.4 Remove the rocker shaft hollow bolts and then the rocker arm assembly. Note: When disassembling the rocker arm, remove the dowel pin first and then the rocker arm from the rocker shaft's timing chain side.

2.11 Disassembly and Assembly of Rocker Arm and Rocker Shaft 2.10 Removal of Rocker Arm Assembly 2.10.1 Remove the cylinder head cover. 2.10.2 Loosen the rocker arm adjusting screws. Rocker arm adjusting screws

BYD473QB Engine Note: 2.11.1 To make sure each part is installed in place, mark on each part when removing. 2.11.2 Do remove or install the rocker arms from the rocker shaft's timing chain side. 2.11.3 Inspect the rocker shaft and the rocker arm. 2.11.4 If the rocker arm is to be reused, it must be installed on the former position.

2.10.3 Turn 2 circles each time in the order as the illustration shown and loosen the rocker shaft hollow bolts.

2.11.5 Before assembling, clean all parts with the solvent, dry them and then apply grease on all contact points.

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BYD Suri Maintenance & Repair Manual

BYD473QE Engine

2.11.8 Inspect the rocker shaft and the rocker arm.

Note: 2.11.6 To make sure each part is installed in place, mark on each part when removing.

2.11.9 If the rocker arm is to be reused, it must be installed on the former position.

2.11.7 Do remove or install the rocker arm from the rocker shaft's timing chain side.

2.11.10 Before assembling, clean all parts with the solvent, dry them and then apply grease on all contact points.

2.12 Inspection of Rocker Arm and Rocker Shaft 2.12.1 Remove the rocker arm assembly. 2.12.2 Measure the diameter of the rocker shaft of the first rocker arm.

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BYD Suri Maintenance & Repair Manual

2.12.3 Turn the I.D. dial gauge to 0 according to the diameter of the axle.

2.12.5 Repeat the procedure for all rocker arms and rocker shafts. If the clearance is beyond the limit, replace the rocker shaft and rocker arms whose clearance is beyond the limit.

2.13 Removal of Camshaft 2.13.1 Remove the air cleaner. 2.12.4 Measure the rocker arm’s I.D. with an I.D. dial gauge and check its out of roundness.

2.13.2 Remove the camshaft sprocket. 2.13.3 Remove the rocker arm assembly.

Clearance between the rocker arm and the rocker shaft:

2.13.4 Remove the connected wire harness bolts and wire harnesses.

Standard: 0.019 mm~0.058 mm Overhaul limit: 0.08 mm

2.13.5 Disconnect the camshaft phase sensor connector and remove the camshaft phase sensor. 2.13.6 Remove the camshaft thrust cover and pull out the camshaft.

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2.14.6 Support the camshaft with a V-block and check its total runout.

2.14 Inspection of Camshaft 2.14.1 Remove the camshaft sprocket. 2.14.2 Remove the rocker arm assembly. 2.14.3 Place the rocker shaft on the cylinder head and tighten the bolts to the specified torque.

If the total runout is beyond the overhaul limit, replace the camshaft and recheck the oil film clearance between the camshaft and seat hole. If the oil film clearance is still beyond the overhaul limit, replace the cylinder head. Camshaft's total runout

Specified Torque: 29 Nm Standard: Max. 0.03 mm Apply engine oil on the bolts’ thread and flange.

Overhaul limit: 0.04 mm

2.14.4 Push the camshaft toward the back of the cylinder head in place. 2.14.5 Hold the dial gauge's pointer against the end of the camshaft and turn the dial gauge to zero. Push the camshaft back and forth and read the axial clearance. If the axial clearance is beyond the overhaul limit, replace the thrust cover and make another inspection. If it is still beyond the overhaul limit, replace the camshaft. Camshaft's axial clearance: Standard: 0.07 mm~0.25 mm Overhaul limit: 0.5 mm

2.14.7 Measure the cam lobe height. Standard cam lobe height: Intake: 35.38 mm Variable Intake: 30.565 mm Exhaust: 35.39 mm

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2.15 Removal of Valve, Valve Spring and Valve Stem Seal

C Overhaul limit: 5.42 mm

When removing the valve and valve spring, mark to install them on the former position. 2.15.1 Remove the cylinder head cover. 2.15.2 Remove the camshaft. 2.15.3 Using an appropriate sleeve and a plastic hammer, tap the valve spring upper seat slightly and loosen the valve collet. Remove the valve collet, valve spring, valve and valve stem seal.

2.17 Inspection of Valve Tappet and Valve Guide Clearance 2.17.1 Remove the valve. 2.17.2 Slide the valve from the valve guide for about 10 mm, then shake the valve tappet (shaking method) on the normal thrust direction, measure the I.D. of the valve guide with an I.D. dial gauge, measure the O.D. of the valve tappet with a micrometer and thus the clearance between the two can be calculated. 

2.16 Inspection of Valve Remove the valve Measure the following items of the valve Intake valve: A

Standard: 27.4 mm~27.6 mm

B

Standard: 118.1 mm~118.7 mm

If the measurement is beyond the overhaul limit, use a new valve and make another inspection.



If the measurement is within the overhaul limit, reassemble with a new valve. If the measurement is still beyond the overhaul limit after using a new valve, go to step 3. Clearance between intake valve tappet and valve guide: Standard: 0.04 mm~0.10 mm Overhaul limit: 0.16 mm

C Standard: 5.470 mm~5.485 mm C Overhaul limit: 5.44 mm

Clearance between exhaust valve tappet and valve guide:

Exhaust valve:

Standard: 0.10 mm~0.16 mm

A

Standard: 22.9 mm~23.1 mm

Overhaul limit: 0.22 mm

B

Standard: 117.3 mm~117.9 mm

C Standard: 5.455 mm~5.470 mm

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above operation. 2.18.3 Select appropriate and replaceable valve guides and freeze them in a refrigerator's freezing chamber for about 1 hour. 2.18.4 Heat the cylinder head to 150°C with a platen heater or an oven. Monitor the temperature with a thermometer. The cylinder head's temperature should not be over 150°C. Overheating may lead to looseness of the valve seat. 2.17.3 Subtract the valve tappet O.D. measured by a micrometer out of the guide I.D. measured by a bore micrometer. Measure along the valve tappet and valve guide on three different locations. The D-value of max. measurements and min. measurements of the guide should not be beyond the overhaul limit. Clearance between intake valve tappet and valve guide: Standard: 0.02 mm~0.05 mm Overhaul limit: 0.08 mm

2.18.5 Start work from one side of the camshaft and using a punch and an air hammer, eject the valve guide towards the direction of the combustion chamber for about 2 mm.

Clearance between exhaust valve tappet and valve guide:

This could tap some carbon out and makes the removal easier.

Standard: 0.050 mm~0.080 mm

When holding the air hammer, keep it and the valve guide paralleled to avoid damaging the punch.

Overhaul limit: 0.11 mm

2.18 Replacement of Valve Guide Special tools needed: a

Valve guide replacer

b

Valve guide reamer

2.18.6 Turn the camshaft over and tap out the valve guide toward the cylinder head's camshaft side.

2.18.1 Inspect the clearance between the valve tappet and the valve guide. 2.18.2 As shown in the figure below, use the pneumatic valve guide punch which is available on the market and modified in accordance with the diameter of valve guide. In most cases, using this special tool and a regular hammer will finish the

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2.18.7 If the valve guide cannot move, drill a hole with an 8 mm drill and try again. Using the drill is the last resort. If the valve guide bursts, the cylinder may get damaged. 2.18.8 When necessary, take out one new valve guide from the freezing chamber each time. 2.18.9 Apply a thin layer of engine oil on the outer surface of the new valve guide. Install the valve guide from the cylinder head’s camshaft side; using SST, tap the valve guide to the specialized height. If 16 valve guides need to be installed, it may be necessary to reheat the cylinder head. Valve guide's mounting height: 15.70 mm~16.30 mm

2.18.12 Turn the reamer clockwise continuously until it comes out of the valve guide’s hole. 2.18.13 Clean valve guides thoroughly with cleaner and water to remove all cuttings. 2.18.14 Check the clearance of a valve. Make sure that there is no resistance when the valve is sliding in the intake and exhaust valve guides.

2.19 Overhaul of Valve Seat 2.19.1 Inspect the clearance between the valve tappet and guide. If the valve guide is worn, replace it when cutting the valve seat. 2.19.2 Repair the valve seat in the cylinder with a valve seat reamer.

2.18.10 Apply cutting oil on the reamer and the valve guide. 2.18.11 Turn the reamer clockwise within the range of the valve guide hole.

2.19.3 Cut a 45°seat carefully and only cut away redundant material to make sure the valve seat is smooth and concentric.

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2.19.4 Mill the superior angle and under horn according to the angle shown in the illustration. Check the width of the valve seat and make the corresponding adjustment.

Inlet: 67.5° Outlet: 60°

2.19.5 Ream again slightly with a 45°reamer to remove possible burr caused by other reamers. Width of valve seat Intake: Standard: 0.850 mm~1.150 mm Overhaul limit: 1.60 mm Exhaust: Standard: 1.250 mm~1.550 mm Overhaul limit: 2.00 mm 2.19.6 After adjusting the surface of the valve seat, check the valve seat for smoothness: Apply Prussian blue on the valve's surface, and insert the valve in its former place in the cylinder head. Then lift the valve and push it against the valve seat. Repeat the operation for several times.

2.19.7 As shown in the illustration, the valve seat's surface with Prussian blue must be aligned with the center of the valve seat. 2.19.7.1 If it is too high (close to the valve tappet), it is necessary to ream it again with a 67.5°reamer (inlet) or 60° reamer (outlet) to make it lower and then ream it again with a 45°reamer to restore the valve seat's width. 2.19.7.2 If it is too low (close to the edge of the valve), it is necessary to ream it again with a 30°reamer to make it higher and then ream it again with a 45°reamer to restore the valve seat's width. Note: Make sure that a 45°milling cutter is used for the last milling. 2.19.8 Insert the intake valve and exhaust valve in the cylinder head and measure the mounting height (A) of the valve tappet Mounting height of intake valve tappet: Standard: 46.1 mm~46.5 mm Overhaul limit: 46.8 mm Mounting height of Exhaust valve tappet: Standard: 46.2 mm~46.6 mm Overhaul limit: 46.9mm

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2.19.9 If the mounting height of the valve tappet is beyond the overhaul limit, replace the valve and make another inspection. If it is still beyond the overhaul limit, replace the cylinder head; because the valve seat of the cylinder head is too deep.

2.20 Installation of Valve, Valve Spring and Valve Stem Seal Special tools needed: a b

Valve tappet stem seal replacer Valve spring compressor

2.20.1 Apply a layer of engine oil on the valve tappet and install the valve into the valve guide.

2.20.5 Install the valve spring. Orient the valve spring with more winding toward the cylinder head.

2.20.2 Check whether it's smooth for the valve to move up and down.

2.20.6 Install the spring upper seat.

2.20.3 Install the spring lower seat on the cylinder head.

2.20.7 Install the valve spring compressor. Press the spring and install the valve collet.

2.20.4 Apply grease on the valve guide and install a new valve stem seal with a valve guide stem seal replacer. Note: Exhaust valve stem seal is marked as "EX" and intake valve stem seal as "IN" and they are not exchangeable.

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2.21.2 Install the camshaft phase sensor with a new O-ring seal and connect the camshaft phase sensor connector. (BYD473QB Engine) 2.21.3 Install harness brackets and bolts. 2.21.4 Install the camshaft sprocket. 2.20.8 Tap each valve tappet 2 to 3 times slightly with a plastic hammer to make sure that valves and valve collets are installed in place. Only tap along the axial direction of valve tappets to avoid deformation of the valve tappets.

2.21.5 Install the rocker arm assembly. 2.21.6 Install the air cleaner.

2.22 Installation of Rocker Arm Assembly 2.22.1 Install the rocker arm assembly with dowel pins. Note: When reassembling the rocker arm, install the rocker arm from the rocker shaft's timing chain side.

2.21 Installation of Camshaft 2.21.1 Install the camshaft on the cylinder head and then the camshaft thrust cover with a new O-ring seal.

2.22.2 Tighten each bolt by turning 2 circles each time following the order shown in the illustration. Specified Torque: 29 Nm.

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Apply engine oil on the threaded and flange part of the bolts.

BYD Suri Maintenance & Repair Manual

cylinder head. 2.23.6 Tighten the bolts on the cylinder head to 29 Nm following the order shown in the illustration. Use a beam torque wrench to tighten bolts and if a preset torque wrench is used, make sure that bolts are tightened slowly and do not over tighten them. If noise occurs when tightening the bolt, loosen it and tighten it again from the first step.

2.22.3 Adjust the valve lash. 2.22.4 Install the cylinder head cover.

2.23 Installation of Cylinder Head Install the cylinder head in the reverse order of removal: 2.23.1 Clean the contacting surface of the cylinder head and the cylinder block. 2.23.2 Install the cylinder head gasket and dowel pins on the cylinder head. Be sure to use a new cylinder head gasket.

2.23.7 Tighten all bolts on the cylinder head to 130°. 2.23.8 Install the assembling bolt on the timing chain's guide chain plate.

2.23.3 Make sure that the key slot of the crankshaft is positioned upward. 2.23.4 Install the cylinder head on the cylinder block.

2.23.9 Install the timing chain on the camshaft sprocket, align the reference markers and install the camshaft sprocket on the camshaft.

2.23.5 Apply engine oil on the thread and the bottom of the bolt head of all bolts on the

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2.23.10 Fix the camshaft with an open-end wrench and tighten the bolt. Specified Torque: 56 Nm

2.23.13 Fix the crankshaft damper pulley and put a socket wrench on the camshaft sprocket bolt.

2.23.11 Install the crankshaft damper pulley loosely. 2.13.12 Apply engine oil on the sliding surface of the timing chain tensioner seat through the oil return hole on the cylinder head.

2.23.14 Turn the camshaft clockwise, press the timing Chain tension plate and take out a bolt M6×1.0 mm. Note: When turning the camshaft, the torque should not be over 56 Nm. Don't turn the camshaft anticlockwise. 2.23.15 Check the crankshaft front seal for damage. If the seal is damaged, replace with a new one.

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2.23.16 Remove the old flange sealant on the timing cover's mating surface, bolts and bolt holes.

BYD Suri Maintenance & Repair Manual

applied on them. If not, clean the old residue, reapply the flange sealant and install the parts.

2.23.17 Clean and dry the timing cover's mating surface. 2.23.18 Apply flange sealant evenly on the mating surface of the timing cover and the cylinder block as well as the inner thread of each hole. Note: 

Apply 2 mm~3 mm width flange sealant along the dotted lines.



Apply 3 mm~4 mm width flange sealant on the upper surface of the cylinder block on the timing cover.

2.23.20 Put the edge of the timing cover and the edge of the oil sump together and then install the timing cover on the cylinder block. Note: When installing the timing cover, don't slide the undersurface of the oil sump's assembling surface.

2.23.19 Apply flange sealant evenly on the mating surface of the timing cover and the oil sump as well as the inner thread of each hole. Note: 

Apply 2 mm~3 mm width flange sealant along the dotted lines.



Apply 5.00 mm width flange sealant on the shaded area.



The parts should be installed within 4 minutes after the flange sealant is

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2.23.21 Install the harness brackets. 2.23.22 Install the crankshaft damper pulley. 2.23.23 Install the cylinder head cover. 2.23.24 Install the water pump pulley. 2.23.25 Install the idler unit. 2.23.26 Install assembling bolts on the generator's adjusting arm and adjusting bracket.

2.23.34 Install the inlet and outlet hoses of the radiator.

2.23.27 Install the belt and adjust the belt by adjusting the adjusting bolt on the generator. 2.23.28 Install the water outlet tube unit and use a new water outlet tube O-ring.

2.23.35 Install the inlet and outlet hoses of the throttle body.

2.23.29 Install the positive crankcase ventilation (PCV) hose. 2.23 30 Install the harness brackets and mounting bolts. 2.23.31 Install the exhaust manifold. 2.23.32 Install the intake manifold. 2.23.33 Install the heating hose.

2.23.36 Install the air cleaner. 2.23.37 After installation, check whether all guides, hoses and connectors are installed in place. 2.23.38 Check for fuel leakage. When the ignition switch is switched ON (don't start the starter), run the fuel pump for about 2 seconds and pressurize the fuel pipe. Repeat the procedure 2 to 3 times and

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then check the fuel pipe for leakage. 2.23.39 Refill the radiator with engine coolant and bleed the air out of the cooling system when the heater valve is open. 2.23.40 Inspect the idle speed. 2.23.41 Inspect the ignition timing.

2.24 Installation of Cylinder Head Cover 2.24.1 Clean the washer and groove of the cylinder head cover thoroughly. 2.24.2 Install the cylinder head cover washer into the groove of the cylinder head cover. 2.24.3 Make sure that the mating surface is clean and dry. 2.24.4 Apply 3.0 m width flange sealant on the mating area of the timing cover. Note: The parts should be installed within 4 minutes after the flange sealant is applied on them. If not, clean the old residue, reapply the flange sealant and install the parts. 2.24.5 When the cylinder head cover is installed on the cylinder head, slide the cylinder head cover back and forth slightly to ensure that the cylinder head cover washer is installed in place.

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Section 3 Cylinder Block Parts location (a)

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Parts location (b)

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3.1 Inspection of Axial Clearance of Connecting Rod and Crankshaft 3.1.1 Remove the oil pump. 3.1.2 Measure the connecting rod axial clearance between the connecting rod and the crankshaft with a feeler gauge. Connecting rod axial clearance: Standard value: 0.15 mm ~0.30 mm Overhaul limit: 0.40 mm 3.1.5 If the axial clearance is beyond the tolerance zone, replace the thrust plate and make another inspection. If it is still beyond the tolerance zone, replace the crankshaft.

3.2 Replacement of Crankshaft Bearing Shell Inspection of Main Bearing Shell Clearance

3.1.3 If the connecting rod axial clearance is beyond the tolerance zone, install a new connecting rod and make another inspection. If it is still beyond the tolerance zone, replace the crankshaft. 3.1.4 Push the crankshaft away from the dial gauge, place the dial gauge against the crankshaft's end and turn it to zero. Then pull back the crankshaft tightly against the gauge: the reading should not exceed the overhaul limit. Crankshaft axial clearance: Standard value: 0.10 mm ~ 0.35 mm Overhaul limit: 0.45 mm

3.2.1 Before inspecting the oil film between the main bearing shell and the journal, remove the crankshaft main bearing cap and the bearing shell first. 3.2.2 Clean each main journal and bearing shell with a clean piece of maintenance cloth. 3.2.3 Put a plastic clearance gauge between the two adjacent main journals. 3.2.4 Reinstall the bearing shell and the crankshaft main bearing cap and tighten the bolt to 25 Nm +40°. Note: Don’t turn the crankshaft during inspection. 3.2.5 Remove the crankshaft main bearing cap and the bearing shell again and measure the widest area of the plastic clearance gauge. Oil film clearance between the main bearing shell and the journal: Standard value: 0.018 mm~0.036 mm Overhaul limit: 0.050 mm

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3.2.6 If the clearance measured by the plastic clearance gauge is too wide or too narrow, remove the crankshaft and the upper bearing shell. Install a complete and new bearing shell with the same grouping code and inspect the clearance again. Don’t adjust the clearance by filing, gap-filling, grinding the bearing shell or bearing cap.

BYD Suri Maintenance & Repair Manual

Location of Main Journal's Grouping Codes 3.2.7.2 The main journal's grouping codes are stamped on the crankshaft.

3.2.7 If the clearance measured by the plastic clearance gauge is still not correct, try to use a bigger or smaller bearing shell (select the color above or below it in the table), and then make another inspection. If the clearance is still ont correct after using an appropriate bearing shell, replace the crankshaft and restart the inspection. Selection of Main Bearing Shell Location of Crankshaft Holes' Grouping Codes 3.2.7.1 Grouping letters distinguishing 5 main journals are stamped on the end of the crankshaft. Write down the crankshaft holes’ grouping codes. If the codes are unreadable due to dirt and dust, clean the parts only with the solvent or cleaner, instead of the wire bush or scraper.

Fifth gear journal

3.2.7.3 Select a proper bearing shell for replacement from the following table by using the grouping codes on the crankshaft hole and crankshaft journal. Note: Grouping codes are on the edge of the main bearing shell. Assembling table for main shaft hole, main bearing shell and main journal

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Journal becoming larger

Main shaft hole becoming larger

3.3 Replacement of Connecting Rod Bearing Shell Inspection of Connecting Rod Bearing Clearance 3.3.1 Inspect the oil film clearance between the connecting rod bearing and the journal. Remove the main bearing cap. 3.3.2 Remove the connecting rod cap and the connecting rod bearing shell.

3.3.6 Remove the connecting rod cap and the bearing shell and then measure the widest area of the plastic clearance gauge. Oil film clearance between the connecting rod bearing shell and the journal: Standard value: 0.020 mm ~0.038 mm Overhaul limit: 0.050 mm

3.3.3 Clean the crankshaft connecting rod journal and the bearing shell with a clean piece of maintenance cloth. 3.3.4 Place a plastic clearance gauge on the connecting rod journal. 3.3.5 Reinstall the bearing shell and the connecting rod cap and tighten the bolt. Tightening Torque: 9.8 Nm + 90°corner. Note: Don’t turn the crankshaft during inspection.

3.3.7 If the clearance measured by the plastic clearance gauge is too wide or too narrow, remove the upper bearing shell. Install a

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complete and new bearing shell with the same grouping code and inspect the clearance again. Don't adjust the clearance by filing, gap-filling, grinding the bearing shell or bearing cap. 3.3.8 If the clearance measured by the plastic clearance gauge is still not correct, try to use a bigger or smaller bearing shell (select the color above or below it in the table), and then make another inspection. If the clearance is still not correct after using an appropriate bearing shell, replace the crankshaft and restart the inspection. Selection of Connecting Rod Bearing Shell 3.3.8.1 Check each connecting rod for cracks or thermal deterioration.

Location of Connecting Rod Journal's Grouping Codes 3.3.8.3 Connecting rod journal's grouping codes are stamped on the crankshaft. Location of Connecting Rod Journal's Grouping Codes

Location of Connecting Rod Big End Hole Code 3.3.8.2 The tolerance zone for each connecting rod should be between 0 to 0.015 mm with an increment of 0.008 mm according to the size of the big end hole on the connecting rod. The range is indicated by stamped numbers or bar codes. All kinds of number and bar code combinations can be found on the engine (half of them are stamped on the bearing cap and the other half are stamped on the connecting rod). If the codes are unreadable due to dirt and dust, clean the parts only with the solvent or cleaner, instead of the wire bush or scraper. Standard hole size: 43.0 mm

3.3.8.4 Select a proper bearing shell for replacement from the following table by using the codes on the big end hole and connecting rod journal. Note: Grouping codes are on the edge of the bearing shell.

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Assembling table of seat hole, connecting rod bearing shell and connecting rod journal

3.4 Removal of Oil Sump 3.4.1 Drain engine oil.

3.4.3 Remove the clutch baffle and then the 2 bolts (A) for tightening the transmission.

3.4.2 Move the dipstick tube.

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3.4.4 Remove the bolt for tightening the oil sump. 3.4.5 Place a straight screwdriver as shown in the illustration and remove the oil sump from the cylinder block.

3.5.7 Remove the main bearing cap. 3.5.8 Remove the connecting rod cap/bearing shell and place them carefully in order. 3.4.6 Remove the oil sump and place it carefully with its contacting surface with the cylinder block upwards.

3.5 Removal of Crankshaft and Piston

3.5.9 Remove the crankshaft from the cylinder block and make sure that it has no contact with the cylinder block and don't damage the journal.

3.5.1 Remove the engine. 3.5.2 Remove the transmission. 3.5.3 Remove the timing chain. 3.5.4 Remove the cylinder head. 3.5.5 Remove the oil collector and then the oil pump.

3.5.10 Remove the upper bearing shell from the connecting rod and place it with the corresponding bearing shell cap.

3.5.6 Remove the main bearing cap bolt. To avoid warpage and deformation, turn 1/3 circle each time to remove bolts in the order shown in the following illustration. Repeat this procedure until all bolts are loose.

3.5.11 Observe the top of the cylinder liner's inner wall carefully and if metal projection or carbon deposit is found, remove it with a reamer following the instruction of the reamer supplier. The projection may damage the piston when the piston is pulled out.

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3.6.2 Clean the pipeline of the crankshaft with pipeline cleaner or an appropriate brush. 3.6.3 Clean the key slot and thread. 3.6.4 Measure the roundness at the orthogonal part of the center of each connecting rod journal and main journal. The D-value of each journal's measurement should not be beyond the overhaul limit. 3.512 Tap out the piston with the hammer's wooden handle. Hold the piston by one hand when tapping.

Out of roundness of the journal: Standard value: Max. 0.005 mm Overhaul limit: 0.010 mm

3.513 Install the main bearing cap and bearing shells on the cylinder block in the correct order. 3.5.14 After removing all piston rings and the connecting rod assembly, reinstall the connecting rods and connecting rod caps. 3.5.15 Mark each piston/connecting rod assembly with its cylinder number to ensure they are installed in place. Note: The marker on the connecting rod indicates the dimension of the connecting rod hole instead of its position in the engine.

3.6 Inspection of Crankshaft Out of roundness and taper 3.6.1 Remove the crankshaft from the cylinder block.

3.6.5 Measure the taper at the edge of each connecting rod and main journal. The D-value of every journal's measurement should not be beyond the overhaul limit.

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Journal's taper: Standard value: Max. 0.005 mm

Diameter of the piston: Standard value: 72.955 mm~72.975 mm Overhaul limit: 72.945 mm

Overhaul limit: 0.010 mm Verticality 3.6.6 Place the cylinder block on the surface table. 3.6.7 Clean the bearing shell and install it on No.1 and No.5 journals of the cylinder block. 3.6.8 Lower the crankshaft and install it into the cylinder block. 3.6.9 Measure all main journals' runout. Turn the crankshaft for 2 rounds. The difference between each journal's measurement should not be beyond the overhaul limit. Total runout of the crankshaft: Standard value: Max. 0.03 mm Overhaul limit: 0.04 mm

The diameter of the piston with an enlarged dimension: 0.25: 73.205 mm~73.225 mm

3.7 Inspection of Cylinder Block and Piston 3.7.1 Remove the crankshaft and piston. 3.7.2 Check the piston for deformation or cracks. 3.7.3 Measure the piston's diameter at the point shown in the illustration bellow the piston skirt.

3.7.4 Check the wear and measure the taper from the direction of X and Y at 3 different heights of each cylinder as shown in the illustration. If the measurement of any cylinder is beyond the overhaul limit of the cylinder hole with an enlarged dimension, replace the cylinder block. If the cylinder block needs reboring, see step 7 after reboring. Cylinder hole dimension: Standard value: 73.00 mm ~73.019 mm Overhaul limit: 73.07 mm An enlarged dimension: 0.25: 73.25 mm~73.269 mm Reboring limit: Max. 0.25 mm

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BYD Suri Maintenance & Repair Manual

Taper of the hole: Limit: (difference of the 1st and 3rd measurement) 0.05 mm

3.7.5 Grind the cylinder if it is scratched or scraped. 3.7.6 Check the top of the cylinder block for warp age and deformation. As shown in the illustration, do the measuring along the cylinder block's edge and diagonal lines. Warp age of the engine: Standard value: Max. 0.05 mm Overhaul limit: 0.10 mm

3.7.7 Measure the D-value between the cylinder hole diameter and piston diameter. If the clearance is close to or beyond the overhaul limit, check the piston and cylinder for over wear. Clearance between the piston and the cylinder: Standard value: 0.010 mm~0.040 mm Overhaul limit: 0.05 mm

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Cylinder's grinding Grinding is only necessary when the cylinder hole is scratched or scraped.

BYD Suri Maintenance & Repair Manual

3.8.2 Remove the piston pin using SST. Inspection 3.8.2.1 Measure the diameter of the piston pin.

3.7.7.1 Measure the cylinder hole Diameter of the piston pin: If the cylinder block is to be reused, the cylinder needs grinding and the cylinder hole needs to be measured again.

Standard value: 17.996 mm~18.000 mm

3.7.7.2 Using grinding oil and a fine grinding stone (particle size 400), grind the cylinder hole with a 60°checker plate. Only grinding stones of particle size—400 or finer stones such as Sunnen, Ammco or the equivalent—can be used. A grinding stone which is worn or broken should not be used. 3.8.2.2 Turn the I.D. dial gauge to zero according to the diameter of the piston pin.

3.7.7.3 After grinding, clean all metal particles in the engine thoroughly. Clean the cylinder hole with warm soap water. Dry it and then apply engine oil on it immediately to avoid rust. A solvent should not be used because solvents could make metal particles spread on the cylinder wall again. 3.7.7.4 If the scratch or scrape still exists after the cylinder block is grinded to its repair limit, rebore the cylinder block. The minor vertical scratch and scrape are acceptable as long as they are not deep enough to block a fingernail and they are shorter than the cylinder hole.

3.8 Replacement of Piston, Piston Pin and Connecting Rod Disassembly 3.8.1 Remove the piston from the cylinder block.

Replacement of Piston, Piston Pin and Connecting Rod 3.8.2.3 Measure the clearance between the piston pin and the small-end hole of connecting rod. Clearance between the piston pin and small-end hole of connecting rod: Standard value: -0.037 mm~-0.015 mm

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BYD Suri Maintenance & Repair Manual

3.8.2.4.2 Press the piston pin into the piston with SST. Replacement of Piston Ring 3.8.2.4 Inspect the D-value between the piston pin diameter and the piston hole diameter. Clearance between the piston pin and piston hole

3.8.2.4.2.1 Remove the piston from the cylinder block. 3.8.2.4.2.2 Remove the used piston ring using a piston ring expander.

Standard value: 0.005 mm~0.015 mm

Reassembly 3.8.2.4.1 Install the piston and connecting rod. The arrow and the connecting rod marker should face the same direction.

3.8.2.4.3 Clean all piston ring grooves thoroughly with a split ring without a cutting angle or groove cleaner with a cutting edge matching the piston ring groove. The groove width of the first air ring is 1.0 mm. The groove width of the second air ring is 1.2 mm. The groove width of the multi-piece oil ring is 2.0 mm. If necessary, the cutting edge can be trimmed. Don't use a wire brush to clean the groove and don't deepen the groove with a

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BYD Suri Maintenance & Repair Manual

cleaner. Note: If the piston is to be separated from the connecting rod, don't install a new piston ring. 3.8.2.4.4 Push a new piston ring into the cylinder hole with a piston. The distance from the piston ring to the bottom should be 15 mm-20 mm.

3.8.2.4.5 Measure the close clearance of the piston ring with a feeler gauge. Overhaul limit

First air ring

Standard close clearance 0.20 mm~0.35 mm

Second air ring

0.35 mm~0.50 mm

0.75 mm

Multi-piece oil ring

0.20~0.70 mm

0.80 mm

0.79 mm

If the measurement is beyond the maximum close clearance, replace the piston ring. If the measurement is still beyond the maximum close clearance after installing a new piston ring, replace the cylinder block. 3.8.2.4.6 Install the first air ring (A) and the second air ring (B) shown in the illustration. Make sure that the surface with the marker (C) made by the piston ring manufacturer is upward when installing.

3.8.2.4.7 Turn the piston ring in the groove and make sure that there is no clamping stagnation. 3.8.2.4.8 The direction of its end clearance should be as shown in the illustration when installing the piston ring:

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BYD Suri Maintenance & Repair Manual

3.8.2.4 9 After installing a new piston ring, measure the clearance of every groove. Clearance of first air ring Standard value: 0.075 mm~0.100 mm Overhaul limit: 0.17 mm Clearance of second air ring Standard value: 0.030 mm~0.055 mm Overhaul limit: 0.13 mm

Installation of Piston If the crankshaft is installed 3.8.2.4.9.1 Set the crankshaft of each cylinder to the lower dead center successively. 3.8.2.4.9.2 Remove the connecting rod cap, install the piston ring compressor and make sure that the bearing shell is firmly installed in place. 3.8.2.4.9.3 Orient the mark on the piston to the engine's timing chain side (front end).

3.8.2.4.9.4 Put the piston in the cylinder and tap it with the wooden handle of a hammer (A) or the equivalent wooden bar. Before installing it into the cylinder hole, maintain downward pressure on the piston ring compressor (B) to avoid the piston ring expanding.

3.8.2.4.9.5 Stop when the piston ring compressor bounces and before pushing the piston back into place, check whether the connecting rod and the crankshaft journal are aligned. 3.8.2.4.9.6 Inspect the clearance of the connecting rod bearing shell with a plastic clearance gauge. 3.8.2.4.9.7 Inspect the connecting rod bolt. 3.8.2.4.9.8 Apply engine oil on the threads of the bolt. Then install the connecting rod cap with the bearing shell. Tighten the bolt to 9.8 Nm + 90°corner. If the crankshaft is not installed

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BYD Suri Maintenance & Repair Manual

bearing with a plastic clearance gauge. 3.8.2.4.9.8.1 Remove the connecting rod cap, install the piston ring and make sure that the bearing shell is fixed in position. 3.8.2.4.9.8.2 Orient the mark on the piston to the engine's timing chain side (front end). 3.8.2.4.9.8.3 Put the piston in the cylinder and tap it with the wooden handle of a hammer (A) or the equivalent wooden bar. Before installing it into the cylinder hole, maintain downward pressure on the piston ring compressor (B) to avoid the piston ring expanding. 3.8.2.4.9.8.4 Set all pistons to the top dead center.

3.10.3 Inspect the connecting rod bolt. 3.10.4 Install a bearing shell on the cylinder block and the connecting rod. 3.10.5 Apply a layer of engine oil on the main bearing shell and the connecting rod bearing shell. 3.10.6 Hold the crankshaft, place No.2 and No.3 journals vertically and upward and then put the crankshaft in the cylinder block. 3.10.7 Install a thrust plate on No.4 journal of the cylinder block.

3.9 Inspection of Connecting Rod Bolt 3.9.1 Measure the diameter of the connecting rod bolt at point A and point B in the illustration with a dial gauge.

3.10.8 Apply engine oil on the thread and flange of the connecting rod bolt.

3.9.2 Calculate the difference of measurements at point A and point B. Diameter difference = diameter A diameter B. Technical specification for diameter difference: 0~0.05 mm 3.9.3 If the diameter difference is beyond the tolerance zone, replace the connecting rod bolt.

3.10 Installation of Crankshaft 3.10.1 Inspect the clearance of the connecting rod bearing with a plastic clearance gauge. 3.10.2 Inspect the clearance of the main

3.10.9 Put the connecting rod journal into No.1 and No.4 connecting rod. Align the markers on the connecting rod and the connecting rod cap and then tighten the connecting rod cap and bolt by hand. 3.10.10 Turn the crankshaft clockwise and fix the journal between No.2 and No.3 connecting rods. Align the markers on the connecting rod and the connecting rod cap and then tighten the connecting rod cap and bolt by hand. 3.10.11 Tighten the connecting rod bolt to 9.8 Nm. 3.10.12 Tighten the connecting rod bolt to 90° corner. 3.10.13 Install the crankshaft rear seal. Apply grease on the inner groove of the oil seal before installing and then install the oil seal on the crankshaft.

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BYD Suri Maintenance & Repair Manual

3.10.14 Measure the distance between the crankshaft and the oil seal.

flange of the main bearing cap bolts.

Mounting height of oil seal: 7 mm~8 mm

3.10.21 Tighten the bearing cap bolts to 25 Nm in the order shown in the illustration.

3.10.22 Tighten the main bearing cap bolt to 40°corner. 3.10.23 Remove redundant flange sealant on the cylinder block. 3.10.15 Install the main bearing cap and be aware of the marker's orientation. 3.10.16 Remove the old flange sealant on the mating surface of the main bearing cap's rear end.

3.10.24 Install the dowel pin (A) and a new O-ring (B) on the oil pump (C), then align the inner rotor with the crankshaft and install the oil pump.

3.10.17 Clean and dry the mating surface of the main bearing cap's rear end. 3.10.18 Apply 3 mm width flange sealant along the dotted lines. Note: The parts should be installed within 4 minutes after the flange sealant is applied on them. If not, clean the old residue, reapply the flange sealant and install the parts.

3.10.25 Install the oil collector (D) with a new washer (E). 3.10.26 Install the cylinder head. 3.10.27 Install the timing chain. 3.10.19 Place the main bearing cap on the cylinder block.

3.10.28 Install the transmission.

3.10.20 Apply engine oil on the thread and

3.10.29 Install the engine.

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Note: If the crankshaft or connecting rod bearing shell is replaced, run the engine at idle speed after reassembling until it reaches normal operating temperature and then run it for about 15 minutes.

3.11 Installation of Oil Sump 3.11.1 Remove the old flange sealant on the oil sump's mating surface, bolt and bolt hole. 3.11.2 Clean and dry the mating surface of the oil sump and the cylinder block.

3.11.5 Install oil sump A using dowel pin B and a new O-ring.

3.11.3 Install a new crescent seal on the oil sump.

3.11.4 Apply specialized flange sealant on the oil sump's mating surface with the cylinder block and the inner wall of the bolt hole. Note: Apply 2 mm-3 mm width flange sealant along the dotted line A in the following illustration. Apply 5.0 mm width flange sealant on the shaded area B in the illustration.

3.11.6 Tighten bolts in 2 to 3 steps Tightening torque: (refer to markers in the following illustration) Marked as A: 25 Nm Marked as B: 12 Nm

The parts should be installed within 4 minutes after the flange sealant is applied on them. If not, clean the old residue, reapply the flange sealant and install the parts.

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BYD Suri Maintenance & Repair Manual

3.11.7 Install the clutch baffle and then tighten the 2 bolts for fixing the transmission. Tightening torque for each bolt is shown in the illustration.

10 Nm

10. Nm

3.11.9 Wait for at least 30 minutes after installation and then fill the engine oil.

3.11.8 Install dipstick tube (A) using a new O-ring (B).Tightening torque shown in the illustration.

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Part 2 Lubricating System

1.1 Inspection of Oil Pressure Switch 1.1.1 Remove the oil pressure switch connector (A) on the engine oil pressure switch (B).

1.1.2 Inspect the continuity between the positive terminal (C) and the engine

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(grounding). The circuit should be continuous when the engine stops; the circuit is open when the engine runs. 1.1.3 If the on-off action of the oil pressure switch is abnormal, check the oil level; if the oil level is normal, check the oil pressure; if the oil pressure is normal, replace the oil pressure switch.

BYD Suri Maintenance & Repair Manual

Min. 340 kPa 1.2.4 If the oil pressure is not within the range, check the following items: Check the oil collector for blocking Check the oil pump

1.3 Replacement of Engine Oil 1.2 Oil Pressure Test 1.3.1 Warm up the engine. If the oil pressure warning light remains ON when the engine is running, check the oil level; if the oil level is normal:

1.3.2 Remove the drain bolt (A) and drain the engine oil.

1.2.1 Remove the oil pressure switch and connect the oil pressure gauge and oil pressure switch mounting hole together using a specialized connector.

1.3.3 Reinstall the drain bolt using a new washer (B). 1.3.4 Refill with new engine oil. When replacing: 2.9 L; When replacing (including oil filter): 3.3 L; 1.2.2 If the oil pressure gauge doesn't display oil pressure when the engine starts, turn the engine off. Troubleshoot before going to the next step. 1.2.3 When the engine reaches the operating temperature (the fan starts twice at least), the oil pressure should be: Oil temperature: 80°C Oil pressure: Idle speed: Min.70 kPa; When the engine runs at 3000r/min;

The engine is overhauled: 4.0 L. 1.3.5 Keep the engine running for over 3 minutes and then check for oil leakage.

1.4 Replacement of Engine Oil Filter 1.4.1 Remove the oil filter using a wrench for oil filter removal. 1.4.2 Inspect the thread (A) and rubber seal (B) of the new oil filter, clean the oil sump base and apply a thin layer of engine oil on the rubber seal of the oil filter. Be sure to use the oil filter with a built-in bypass system.

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1.4.3 Install the oil filter by hand.

BYD Suri Maintenance & Repair Manual

1.5.3 Tighten the oil filter screwed tube on the oil sump to 20 Nm and then remove the oil filter screwed tube nut.

1.4.4 Tighten the oil filter clockwise using SST after the rubber seal is installed in place. Tightening: 3/4 circle to 1 circle clockwise. Tightening Torque: 12 Nm

1.4.5 After installation, fill the engine with engine oil to the oil level required, keep the engine running for over 3 minutes and then check for oil leakage.

1.5 Replacing Screwed Tube of Oil Filter 1.5.1 Remove the oil filter. 1.5.2 Install 2 M20×1.5 mm bolts (A) on the new oil filter screwed tube. Hold the nut using a wrench and then tighten the nut.

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BYD Suri Maintenance & Repair Manual

1.6 Overhaul of Oil Pump Breakdown drawing

Removal a b

Remove the timing chain. Remove the oil collector (A) and then remove the oil pump (B).

Radial clearance between the internal rotor and the external rotor: Standard: 0.075 to 0.15 mm Overhaul limit: 0.18 mm

Inspection a

Remove the oil pump cap

b

Inspect the radial clearance of the internal

rotor (A) and the external rotor (B). If the radial clearance is beyond the overhaul limit, the oil pump should be replaced.

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BYD Suri Maintenance & Repair Manual

Overhaul limit: 0.18 mm. c

Inspect the radial clearance of the rotor (A) and the pump housing (B). If the radial clearance of the housing and the rotor is beyond the overhaul limit, the oil pump should be replaced. Radial clearance of the pump housing and the rotor:

e

Check the internal rotor, external rotor and the pump housing for scratch or other damage, replace it if necessary.

f

Install the oil pump cap.

Installation Standard: 0.028~0.065 mm. a Overhaul limit: 0.085 mm.

Install the dowel pin (A) and a new O-ring on the oil pump (C). Then align the internal rotor and the crankshaft and install the oil pump.

d

b

Install the oil collector (D) using a new washer (E).

c

Install the timing chain.

Inspect the radial clearance of the external rotor (A) and the pump housing (B). If the radial clearance of the housing and the external rotor is beyond the overhaul limit, the oil pump should be replaced. Radial clearance between the pump housing and the external rotor: Standard: 0.06~0.136 mm.

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BYD Suri Maintenance & Repair Manual

1.7 Installation of Labyrinth Gland 1.7.1 Clean and dry the labyrinth gland's mating surface, bolts and bolt holes. 1.7.2 Apply 2 mm~3 mm width flange sealant along the dotted line (A). Note: The parts should be installed within 4 minutes after the flange sealant is applied on them. If not, clean the old residue, reapply the flange sealant and install the parts.

1.8 Replacement of Oil Pressure Switch 1.8.1 Disconnect the oil pressure switch connector (A) and then remove the oil pressure switch (B).

15 Nm

1.8.2 Apply anaerobic adhesive on the threaded part of the oil pressure switch, then install the oil pressure switch and the tightening torque is 15 Nm. 1.7.3 Install the labyrinth gland.

6×1.0 mm 12 Nm

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BYD Suri Maintenance & Repair Manual

Part 3 Intake Manifold and Exhaust System 1.1 Removal and Installation of Intake Manifold Removal 1.1.1 Remove the intake manifold cover. 1.1.2 Remove the air cleaner. 1.1.3 Remove the breather pipe (A), brake booster vacuum hose (B) and the positive crankcase ventilation (PCV) hose (C)).

1.1.10.2 Install the intake manifold bracket. 1.1.10.3 If the inlet and outlet hoses of the throttle body have been removed, they must be installed in place. 1.1.10.4 If the throttle body has been removed, install it in place using a new throttle valve seal washer. 1.1.10.5 Install the charcoal canister control valve connecting hose. 1.1.10.6 Install harness brackets and bolts. 1.1.10.7 Install the throttle valve wire and adjust it.

1.1.4 Remove the throttle wire.

1.1.10.8 Install the breather pipe, brake booster vacuum hose and the positive crankcase ventilation (PCV) hose.

1.1.5 Remove harness brackets and bolts.

1.1.10.9 Install the air cleaner.

1.1.6 Remove the charcoal canister control valve connecting hose.

1.1.10.10 Install the intake manifold cover.

1.1.7 Remove the throttle body when replacing the intake manifold.

1.1.10.11 After installation, check whether all guides, hoses and connectors are installed in place.

1.1.8 If the engine coolant has been drained, remove the inlet and outlet hoses of the throttle body. 1.1.9 Remove the engine wire harness connectors and harness retainers and etc. on the intake manifold. 1.1.10 Remove the intake manifold bracket and then remove the intake manifold.

1.1.10.12 If the engine coolant has been drained, refill the radiator with engine coolant. Open the heater valve when refilling in order to bleed the air out of the cooling system.

1.2 Removal and Installation of Exhaust Manifold

Installation

1.2.1 Remove the exhaust manifold heat shield and the exhaust manifold bracket and then remove the exhaust manifold.

1.1.10.1 Install the intake manifold with a new intake manifold seal washer, tighten bolts and nuts in 2 to 3 steps in an intersectional way starting from the inside bolts. The tightening torque is 25 Nm.

1.2.2 Install the exhaust manifold and tighten bolts and nuts starting from the inside bolts in 2 to 3 steps and in an intersectional way. 1.2.3 Install other parts in the reverse order of removal.

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BYD Suri Maintenance & Repair Manual

Part 4 Engine Cooling System Parts location

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1.1 Inspection of Thermolator If the thermolator turns on by itself in the room temperature, replace the thermolator. Inspect the closed thermolator : 1.1.1 Hang the thermolator (A) in a container with water and don't let the thermometer (B) contact the bottom and inner wall of the container. 1.2.3 Rotate the water pump pulley anticlockwise and check whether the water pump can turn freely. 1.2.4 Check the seal for leakage. It is normal that the discharge orifice "leaks" a little.

1.1.2 Fill water, measure the temperature with the thermometer and inspect the temperature when the thermolator turns on and is on. 1.1.3 Measure the lifting height when the thermolator is on. Standard thermolator:

1.3 Replacement of Water Pump 1.3.1 Remove the belt.

Lifting height: over 8.0 mm

1.3.2 Drain engine coolant.

Start to turn on: 76°C~80°C

1.3.3 Remove the water pump pulley.

Being on: 90°C

1.3.4 Remove the 5 bolts for tightening the water pump and then remove the water pump.

1.2 Inspection of Water Pump 1.2.1 Remove the belt. 1.2.2 Remove the water pump pulley.

1.3.5 Inspect and clean the O-ring groove and its mating surface with the cylinder block. 1.3.6 Install the water pump with a new O-ring in the reverse order of removal. 1.3.7 Remove the overflowed engine coolant. 1.3.8 Refill the radiator with engine coolant and open the heater valve when refilling in order to bleed the air out of the cooling system.

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1.4 Replacement of Thermolator Removal 1.4.1 Remove the thermolator cap (A) and then remove the thermolator (B).

M6x 1.0 mm 10 Nm

4. Install the thermolator cap (D). Installation 1. Remove the used flange sealant on the thermolator's mating surface, bolts and bolt holes. 2. Apply 2 mm~3 mm width flange sealant along the dotted line (A).

Note: Refill the engine with coolant at least 30 minutes after installation.

1.5 Replacement of Coolant Temperature Sensor 1.5.1 Drain engine coolant. 1.5.2 Disconnect the coolant temperature sensor connector and then remove the coolant temperature sensor. 1.5.3 Install the coolant temperature sensor. 1.5.4 Remove the overflowed engine coolant.

3. Install the thermolator seal ring (A) on the thermolator (B) and then install the thermolator with the pin (C) facing upward.

1.5.5 Refill the radiator with engine coolant and open the heater valve when refilling in order to bleed the air out of the cooling system.

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Part 5 Fuel and Exhaust System Arrangement of Vacuum hoses: BYD473QB Engine

Camshaft phase (CMP) sensor (EMS but no such sensor in Delphi system) The CMP sensor detects No.1 cylinder's position and offers references for each cylinder's injection successively.

BYD473QE Engine

Engine coolant temperature sensor (ECT)

PGM-FI System The Programmed Fuel Injection (PGM-FI) System is a multipoint sequential injection system.

The ECT sensor is a resistor varying with the temperature (thermistor).The thermistor's resistance decreases when the temperature of the engine coolant is higher.

Crankshaft position (CKP) sensor The CKP sensor detects engine speed and makes sure of ignition timing and fuel injection timing of each cylinder.

Idle Stepper Motor

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BYD Suri Maintenance & Repair Manual

The idle stepper motor (IMA) is a carefully-chosen resistance device for controlling the concentration of mixed gas at idle speed.

System description: Throttle body

Knock sensor The knock control system can make the knock lowest by adjusting the ignition timing. Positive Crankcase Ventilation (PCV) System The PCV valve inhales the piston's air leakage into the intake manifold to avoid releasing it into the atmosphere.

Throttle valve position (TP) sensor The TP sensor is a potentiometer connected to the throttle valve shaft. When the throttle threshold varies, the sensor changes the signal voltage to the ECM/PCM. TP sensor and the throttle body must be replaced as a unit.

Parts location of idle speed control system Engine idle speed is controlled by the idle stepper motor a

When the engine starts, keep the solenoid valve on for a certain amount of time. Increasing air quantity could increase the idle speed.

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b

BYD Suri Maintenance & Repair Manual

quality of bypass air is controlled by the temperature of the engine coolant.

When the temperature of the engine coolant is low, open the solenoid valve to achieve proper high idle speed. The

Parts location of the intake system The system supplies the engine with the air needed. When the air is inhaled into the system, the resonance chamber in the intake manifold can reduce noise.

d

Pinch the PCV valve and intake manifold slightly by the fingers or pliers at idle speed and make sure a click sound occurs from the PCV valve. If no click sound is heard, check the PCV valve retainer for cracks or damage. If the retainer is ok, replace the PCV valve and make another inspection.

PCV system c

Check the connection parts of the PCV valve (A) and hose (B) for leakage or clamping stagnation.

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BYD Suri Maintenance & Repair Manual

Chapter 2 476ZQA Engine Contents Part 1 Engine .................................................................................................................................. 71 Section 1 Overview ................................................................................................................. 71 Section 2 Belt Driving Device.................................................................................................. 76 Section 3 Crankshaft Rear Oil Seal Component .................................................................... 78 Section 4 Timing Chain ........................................................................................................... 80 Section 5 Detection of the Sparkplug and Cylinder Compression Pressure .......................... 82 Section 6 Engine ..................................................................................................................... 84 Part 2 Lubrication System .............................................................................................................119 Section 1 Schematic Diagram of Engine Lubrication Circuit .................................................119 Section 2 Inspection of Oil Pressure..................................................................................... 120 Section 3 Engine Oil.............................................................................................................. 121 Section 4 Oil Sump ............................................................................................................... 122 Section 5 Oil Pump ............................................................................................................... 123 Part 3 Cooling System.................................................................................................................. 124 Section 1 Schematic Diagram of Engine Cooling System.................................................... 124 Section 2 Thermolator ........................................................................................................... 125 Section 3 Water Pump .......................................................................................................... 126 Part 4 Clutch ................................................................................................................................. 128 Section 1 Clutch Device ........................................................................................................ 128 Section 2 Flywheel ................................................................................................................ 131

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Part 1 Engine Section 1 Overview The BYD476ZQA engine adopts the advanced technologies of exhaust gas turbocharging, gasoline in-cylinder direct injection, hydraulic tappet, all-aluminum engine body, intake VVT, etc., and has the characteristics of high power per liter, low fuel consumption, little noise, low pollution, compact structure. The BYD476ZQA engine can operate at its optimum states in various working conditions, and ensure the reliable safety, comfortable driving, best economic efficiency and perfect environment-friendly performance of the loaded complete vehicle.

1.1 Major Technical Parameters 1. The main specifications of BYD473QB/QE Engine are listed in the following table. Parameters

Model BYD476ZQA

Items Type Nominal power Maximum torque/rotating speed Cylinder diameter × route Engine displacement Compression ratio Valve structure Type of fuel Mode of fuel supply Ignition sequence Engine oil exhaust emission system Supercharging Camshaft regulation Cylinder block material

Inline four-cylinder, water-cooled, dual-overhead camshaft, 16-valve and 4-stroke electronically-controlled fuel injection engine 113 KW (5200 r/min) 240 N·m (1750 r/min-3500 r/min) 76.5 mm×81.4 mm 1.497 L 10:1 Silent chain drive, dual-overhead camshaft, 16-valve 93# unleaded gasoline (GB17930-1999) or above used for vehicle Electronically-controlled direct fuel injection 1—3—4—2 Special oil designated and approved by the Department Three-way catalytic converter Exhaust gas turbo-charging Intake VVT Aluminum alloy

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2. Table of BYD476ZQA Engine Tightening Torque Serial No.

Tightened Parts/ Components

Bolt size

Pieces/ Set

1

Cylinder head bolt

M11×1.5 internal dodecagonal lobular socket head bolt

10

2

Main bearing cap bolt

M10×1.25 dodecagona socket lobular socket flange bolt

10

3

Connecting rod bolt

4

Flywheel bolt

5

Crank pulley bolt

6 7

Sparkplug Fuel pressure sensor Fuel inlet fitting of the high-pressure fuel rail

8

M10×1

4 1

Tightening Torque (Nm) 20 Nm for the first time 70 Nm for the second time 90 ºrotation angle 20 Nm for the first time 50 Nm for the second time 90 ºrotation angle 30 Nm + 90 º rotation angle 60 Nm + 90 º rotation angle 150 Nm + 180 º rotation angle 25 Nm 20 Nm

M20×1.5

1

80 Nm

Hex socket head blot M6×45 Hex socket head blot M6×65 M12×1.25-LH internal dodecagonal lobular socket flange blot

5 10

10 Nm + 90 º rotation angle

1

50 Nm + 90 º rotation angle

M8×1 dodecagonal lobular socket flange blot M10×1 internal dodecagonal lobular socket head blot M14×1.5 dodecagonal lobular socket flange blot

8 6 1

9

Camshaft housing bolt

10

VVT component bolt

11

Exhaust camshaft sprocket

M10×1.25 hex head bolt

1

50 Nm + 90 º rotation angle

12

Oil pump sprocket

M8 hex lobular socket pan-head bolt

1

30 Nm

M8

9

20 Nm

1

35 Nm

13 14 15 16 17 18

Exhaust manifold screw cap Cylinder block threaded plug I Cylinder block threaded plug II Oil-return hole cover plate Crankshaft rear oil seal component Cylinder block

2

20 Nm

M6×12 hex flange bolt

6

10 Nm

M6×20 hex flange bolt

6

10 Nm

M14×1.5

1

35 Nm

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30 31 32 33

threaded plug assembly Fixing and supporting plate assembly Engine front lifting hook Engine rear lifting hook Exhaust manifold Camshaft rear end cover Intake fitting bolt assembly Three-way catalytic converter screw nut Intake manifold Exhaust manifold heat shield Semi-circular clamping block Oil drain plug assembly Oil sump Oil rule conduit tube Oil collector Oil pump

34

Oil cooler

19 20 21 22 23 24 25 26 27 28 29

41 42

Oil cooler water tube assembly PCV four-way component PCV breather tube assembly I Chain tension plate Chain guide plate Threaded tube for mounting the oil filter Oil filter OCV valve

43

Timing cover

44

Gas-oil separation

35 36 37 38 39 40

M10×16 hex flange bolt

1

44 Nm

M8×20 hex flange bolt

2

24 Nm

M8×20 hex flange bolt

2

24 Nm

Stud

9

10 Nm

M6×16 hex flange bolt

4

10 Nm

M6 hex socket head cap screw

2

7 Nm

6

20 Nm

M8×35 hex socket head bolt

5

24 Nm

M6×12 hex flange bolt

2

10 Nm

Cross recessed pan-head tapping screw 63

2

7 Nm

1

25 Nm

M6×20 hex flange bolt M6×12 hex flange bolt M6×20 hex socket head bolt M8×50 hex flange bolt M8×20 hex lobular socket head blot M6×20 hex socket head bolt M8×16 hex socket head bolt

20 1 2 3

10 Nm 10 Nm 10 Nm 24 Nm

5

24 Nm

1 1

10 Nm 24 Nm

M6×20 hex socket head bolt

1

10 Nm

M6×20 hex socket head bolt

1

10 Nm

M8 chain plate fixing stud M8 chain plate fixing stud

1 3

20 Nm 20 Nm

1

35 Nm

1 1 7 7 3 3 1 5

15 Nm 5 Nm 24 Nm 24 Nm 24 Nm 44 Nm 10 Nm 5 Nm

M5×12 hex flange bolt M8×50 hex flange bolt M8×25 hex flange bolt M8×20 hex flange bolt M10×80 hex flange bolt Stud M5×16 hex flange bolt

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device Tension pulley assembly Supercharger oil inlet pipe component Supercharger oil return pipe component Supercharger water inlet pipe component Supercharger water outlet pipe component Supercharger stud Supercharger heat shield Solenoid valve for limiting supercharged pressure

53

Intercooler

54

High-pressure fuel rail

61

Oil inlet tube component High-pressure fuel pump Throttle valve screw Dual pipe component Water inlet pipe assembly for the electrically-driven water pump Thermolator component Water pump pulley

62

Water pump

55 56 57 58 59

60

63 64 65 66 67

Motor-driven water pump support Motor-driven water pump Camshaft phase sensor Knock sensor Intake air temperature and pressure sensor

M10×80 hex flange bolt

1

44 Nm

Hollow bolt M12×1.5 Hollow bolt M10×1 M6×12 hex flange bolt M6×12 hex socket head bolt M6×16 hex flange bolt Hollow bolt M12×1.5 M6×12 hex flange bolt Hollow bolt M12×1.5 M6×12 hex flange bolt

1 1 1 2 2 1 1 1 2 6

35 Nm 30 Nm 10 Nm 10 Nm 10 Nm 35 Nm 10 Nm 35 Nm 10 Nm 10 Nm

M6×12 hex flange bolt

3

10 Nm

Cross recessed pan-head tapping screw 55

2

5 Nm

6

7 Nm

3 2 2 1

24 Nm 24 Nm 17 Nm 10 Nm

M6×20 hex socket head bolt

2

10 Nm

M8×12 hex flange bolt

4 1

7 Nm 24 Nm

M6×12 hex flange bolt

2

10 Nm

M6×25 hex flange bolt

4

10 Nm

M8×12 hex flange bolt M8×40 hex lobular socket head bolt M8×16 hex flange bolt M10×16 hex flange bolt

3

24 Nm

5

24 Nm

1 1

24 Nm 44 Nm

M6×20 hex socket head bolt

1

10 Nm

M6×16 hex flange bolt

1

10 Nm

M8×30 hex flange bolt Cross recessed pan-head tapping screw 55

1

20 Nm

4

5 Nm

Cross recessed pan-head tapping screw 63 M8×75 hex flange bolt M8×60 hex flange bolt Screw nut M14×1.5 M6×16 hex flange bolt

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Generator Ignition coil Chain tensioner Oil pressure switch

M8×90 hex flange bolt M6×30 hex flange bolt M6×35 hex flange bolt

2 4 2 1

24 Nm 10 Nm 10 Nm 18 Nm

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Section 2 Belt Driving Device 2.1 Driving Belt 2.1.1 Disassembly of the driving belt Rotate the tension pulleys counterclockwise with a tool to loosen the belt, and then disassemble the driving belt. Right

Wrong

2.1.3 Assembly of the Belt Rotate the tension pulleys counterclockwise with a tool, assemble the belt in a winding manner shown in Figure 1.1, and then slowly loosen the tension pulley to tension the belt slowly.

2.2 Belt Pulley and Driven Accessories 2.2.1 Crankshaft belt pulley

Figure 1.1

Disassembly of the crankshaft belt pulley: position the flywheel with a special tool, screw off the crankshaft belt pulley bolts and take off the crankshaft belt pulley;

2.1.2 Inspection and adjustment of the belt Appearance inspection of the driving belt

2.1.2.1 Visually inspect its appearance, and change the belt if the wear is severe. 2.1.2.2 Inspection of the tension capacity As Figure 1.1 shows, inspect the tension pulleys with a tool, and replace the belt if the tension pulley is in its ultimate state. 2.1.2.3 Inspection of the belt assemble conditions Reinstall the belt if any error in the following figure occurs.

Installation of the crankshaft belt pulley: position the flywheel with a special tool, screw up the crankshaft belt pulley bolt with the tightening torque of a 150 Nm + 180ºrotating angle. 2.2.2 Electric generator Disassembly of the electric generator: hold the generator gently by hand, screw off the fixing bolts of the generator and remove the generator;

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Installation of the electric generator: aim the mounting holes on the generator at those on the timing cover, and make sure the belt pulley is facing the front end of the engine, then gently hold the generator and screw down bolts A and B as shown in the following figure with a tightening torque of 24 Nm. 2.2.3 Idler pulley Disassembly of the idler pulley: screw off the idler pulley bolts and take down the idler pulley; Installation of the idler pulley: train on the mounting holes on the timing cover and then screw up the idler pulley bolt. Tightening torque: 44 Nm

Idler pulley bolt

2.2.5 Air conditioner compressor and tension pulley Disassembly: Unscrew the mounting bolts of the air conditioner compressor and remove the AC compressor, then screw off the tension pulley mounting bolts and remove the tension pulley, after that, unfasten the tension pulley support mounting bolts and remove the tension pulley support; Installation: 2.2.5.1 Install the tension pulley support on the cylinder block and screw up the bolts 2.2.5.2 Assemble the tension pulley into the support seat hole from the front end, making sure the Dowel pin on the tension pulley is well matched and positioned with the pinhole inside the support, and then screw up the mounting bolts from the back end with a tightening torque of 44 Nm. Dowel pin

pinhole

2.2.4 Water pump belt pulley Disassembly of the water pump belt pulley: unscrew the bolts of the water pump belt pulley, and remove the water pump belt pulley; Assembly of the water pump belt pulley: Closely attach the belt pulley to the mounting surface of the water pump, then rotate and aim at the mounting holes, and screw down the bolts with a tightening torque of 24 Nm.

Note: The compress surfaces between all belt pulleys and the bolts must be clean and free from grease and other impurities.

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Section 3 Crankshaft Rear Oil Seal Component 3.1 Disassembly of the Crankshaft Rear Oil Seal Component 3.1.1 Make sure the flywheel and oil sump are already taken off before disassembling the crankshaft rear oil seal component, making sure the flywheel and oil sump are already taken off; Uniformly (1/2 circle maximum each time) screw M6×35 bolts into three positions pointed by the arrows in the right figure, and then press out the crankshaft back end cover component and the sensor wheel all together.

Tightening torque: 30 Nm 3.2.2 Insert the Dowel pin on the positioning tool into the pinhole of the signal wheel; Pinhole

3.2 Assembly of the Crankshaft Rear Oil Seal Component

Dowel pin

3.2.1 Screw the cylinder block threaded plug components off the cylinder block, screw in the crankshaft positioning tool, and fix the crankshaft to the top dead centers of the first and the fourth cylinders;

3.2.3 Fix the positioning tool and the crankshaft rear oil seal component with three M6×20 bolts shown by arrows in the right figure; Tightening torque: 3 Nm, and closely attach the tool and crankshaft rear oil seal component.

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Note: Clean the mounting surface of the crankshaft with a piece of silk cloth before installation, and do not apply any grease on the surface; The oil seal lip will be damaged if the seal support ring, a protective tool for the oil seal lip during transportation and assembly, is removed early. a= 0.5

3.2.4 As the figure shown, insert the dowel pin into the threaded hole at the rear end of the crankshaft, then screw up two hex socket head bolts A to fix the positioning tool and crankshaft rear oil seal component onto the crankshaft; Tightening torque: 15 Nm

Crankshaft Rotating Speed Signal Wheel

3.2.6 Screw up the fixing bolts of the crankshaft back end cover component according to the sequence shown in the figure. Tightening torque: 10 Nm

Dowel pin

3.2.5 Carefully screw up the nuts shown in the figure and take down the assembly tool. Note: Check whether the dimensions shown in the figure meet the requirement: 0.3 mm≤a≤0.7 mm

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Section 4 Timing Chain 4.1 Disassembly of the Timing Chain 4.1.1 Rotate the crankshaft clockwise to the adjacency of the top dead centers of the first and the fourth cylinders, and then revolve the crankshaft 45 º. Then screw the cylinder block threaded plug component off the cylinder block, screw in the crankshaft positioning tool, and rotate clockwise to fix the crankshaft to the top dead centers of the first and the fourth cylinders.

shown in the figure, and lock the tensioner with a lock pin;

Tightening torque: 30 Nm

Positioning Tool

Lock Pin 4.1.4 Disassemble the timing chain and other accessories.

4.2 Assembly of the Timing Chain 4.1.2 Position the exhaust camshaft sprocket and the chain tension with the positioning tool, and then unscrew the exhaust camshaft sprocket bolt as well as the VVT component bolt (left-handed thread);

4.2.1 Locate the crankshaft on top dead centers of the first and the fourth cylinders with the crankshaft positioning tool. For details, refer to the first item in the disassembly of the timing chain; 4.2.2 Before the installation of the camshaft housing, it is necessary to position the camshaft to the top dead center for compression of the first cylinder with the camshaft positioning tool;

Positioning Tool

4.1.3 Press the plunger towards the A direction

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contacting with the chain. Install the chain tensioner and apply a proper amount of oil to the friction surface. Pull out the tensioner lock pin (pointed out by the arrow) and tension the chain;

4.2.3 Assemble the exhaust camshaft sprocket onto the exhaust camshaft, screw the exhaust sprocket bolt in the position 2mm away from the abutted surface, keep the sprocket rotating freely and prevent it from falling off; Assemble the VVT component onto the intake camshaft, screw the VVT component bolt in the position 2mm away from the abutted surface, keep the sprocket rotating freely and prevent it from falling off;

4.2.5 Keep the camshaft at the top dead center of cylinder 1 and fix the exhaust camshaft sprocket with the special tool shown in the figure. Then tighten the bolts of the VVT components and exhaust camshaft sprocket to the specified torque.

Hang the timing chain guide plate in place, and apply a proper amount of lubricating oil to the part contacting with the chain. Hang the timing chain onto the exhaust camshaft sprocket, the VVT component sprocket and the crankshaft sprocket with the guide plate;

Tightening torque: 50 Nm+90ºrotating angle

Positioning Tool

Disassemble the special tool at the top dead center of the camshaft and install the camshaft back end cover. Protect the seal ring of the camshaft back end cover. Tighten the bolts to the specified torque.

4.2.4 Hang the tensioning chain plate in place and apply a proper amount of oil to the part

Remove the camshaft positioning tool and assemble the cylinder block threaded plug component back to the original position

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Section 5 Detection of the Sparkplug and Cylinder Compression Pressure The oil temperature shall be at least 30 º;

5.1 Disassembly and Assembly of the Sparkplug Disconnect the ignition coil plug, screw off four mounting bolts and remove the ignition coil; Remove the sparkplug with the special wrench; The installation is in the reverse order of the removal. The tightening toque of the sparkplug is 25 Nm, and the tightening torque of the mounting bolts of the ignition coil is 10 Nm.

5.2 Inspection of the Sparkplug

5.2.2.5 Go onto the following steps if dampness is found on the sparkplug.

5.2.1 As shown in the figure, measure the electrical resistance with an ohmmeter and check whether the resistance is greater than 10 MΩ. Go on to the fifth step if the resistance is lower than 10 MΩ. Ohmmeter

5.2.2.6 Check if there is any damage on the threaded or insulated parts of the sparkplug, Ground Connection

5.2.2 Inspect the sparkplug with the simple method below if an ohmmeter is not available. 5.2.2.1 Quickly speed the revolution of the engine to 4000 r/min and leave at this speed for five minutes; 5.2.2.2 Remove the sparkplug; 5.2.2.3 Observe the sparkplug electrode; 5.2.2.4 It shows the sparkplug is normal if dryness on the electrode is detected;

5.2.2.7 If any, change the sparkplug; 5.2.2.8 Check the sparkplug electrode gap; The range of the sparkplug electrode gap is 1.0-1.2 mm. Note: If the gap of a new sparkplug electrode needs adjusting, only the root part of the lateral electrode can be adjusted rather than the head; the adjustment of a used sparkplug is not permitted.

5.3 Inspection of Compression Pressure Pull out the plug from the fuel pump control unit before the inspection

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5.3.1 Heat the engine to the normal operating temperature and then flame out; 5.3.2 Remove the connection plug of the ignition coil of the first cylinder; 5.3.3 Remove the ignition coil of the first cylinder;

5.3.5.5 Measure the compression pressure of the cylinder; 5.3.6 Take away the pressure gauge and install the sparkplug with a tightening torque of 25 Nm; 5.3.7 Assemble the ignition coil;

5.3.4 Loosen the sparkplug of the first cylinder; 5.3.5 Check the compression pressure of the first cylinder; 5.3.5.1 Internally connect a pressure gauge to the sparkplug hole of the first cylinder; 5.3.5.2 Ignite to run the engine; 5.3.5.3 Record the maximum reading figure of the pressure gauge; Item

Standard Value Maximum Limit of Pressure Difference among Cylinders

Compression Pressure MPa (≥400r/min) 1.0-1.5 MPa ≤0.3 MPa

5.3.5.4 When the pressure inside the air cylinder is too low or the pressure difference among the cylinders greatly exceed the maximum limit, put a few drops of oil into the cylinders through the sparkplug hole and measure the compression pressure of the cylinders again.

5.3.8 Connect connecting plug of the ignition coil; Note: Following the steps of 2-7 and sequentially measure the compression pressure of the second and the third cylinders; The measurement should be completed as soon as possible. If the compression pressure increases after the oil is dropped, the piston, the piston ring or the cylinder wall may be worn and an overhaul is required; If the compression pressure remains low, it indicates the valve may be stuck or the sealing surfaces do not contact tightly, and an overhaul is required; and if pressure of adjacent cylinders is low, it indicates the cylinder head gasket may be damaged or the cylinder head is deformed, thus an overhaul is required.

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Section 6 Engine 6.1 Disassembly of the Engine 6.1.1 Disassembly of the driving belt See P4 for counterclockwise rotation of the tension pulley.

6.1.3.2 Take off the water pump and the water pump gaskets.

6.1.2 Disassembly of the front end pulley train

6.1.4 Disassemble the crankcase ventilation device 6.1.2.1 Screw off the mounting bolts of the idler pulley, and take down the idler pulley; 6.1.2.2 Screw off the engine mounting bolts, and take down the engine; 6.1.2.3 Secure the water pump pulley with a pulley fixing tool, remove the mounting bolts and take off the water pump pulley;

6.1.2.4 Screw off four mounting bolts of the air conditioner compressor, and remove the air conditioner compressor; 6.1.2.5 Position the flywheel with a special tool and screw off the crankshaft belt pulley bolt component. 6.1.3 Disassemble the water pump

6.1.4.1 Screw off the fixing bolt A, and remove the PCV breather tube assembly I; 6.1.4.2 Screw off the fixing bolt B of the PCV four-way component; 6.1.4.3 Remove the PCV breather tube assembly II from the connector of the intake manifold; 6.1.4.4 Pull out the four-way component from the rubber sleeve of the intake fitting; 6.1.4.5 Pull out the camshaft housing connection hose and the one-way check valve from the camshaft housing connector; 6.1.4.6 And take off the camshaft housing ventilation device.

6.1.3.1 Screw off five mounting bolts of the water pump;

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6.1.6.1 Screw off the tapping screw that fixes the semi-circular clamping block, and then remove the semi-circular clamping block; 6.1.6.2 Carefully unfasten the main intake pipe from the throttle valve clamping seat and then remove it.

6.1.5 Disassemble the fuel evaporate emission control system 6.1.5.1 Pull out the charcoal canister vacuum pipe component from the PCV four-way component; 6.1.5.2 Take off the charcoal canister vacuum pipe component from the intake manifold; 6.1.5.3 And then remove the charcoal canister vacuum pipe component, charcoal canister connection hose, and charcoal canister control valve.

6.1.7 Disassemble the throttle valve Screw off four throttle valve fixing bolts, and then remove the throttle valve. Throttle Valve Mounting Screws

One-way Valve

6.1.8 Disassemble the intake manifold 6.1.8.1 Pinch off the clamp and pull out the water inlet hose of the intercooler from the intercooler water inlet;

Camshaft Housing Connection Hose

6.1.8.2 Screw off five bolts for mounting the intake manifold, and remove the intake manifold.

6.1.6 Disassemble the main intake pipe

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6.1.11.1 Screw off the fixing bolts and remove the supercharger heat shield; 6.1.11.2 Screw off the fixing bolts and take off the exhaust manifold heat shield.

6.1.9 Disassemble the oil inlet tube component 6.1.9.1 Screw off the support plate fixing bolts; 6.1.9.2 Screw off two union nuts, then take off the oil inlet tube component. Note: The oil inlet tube component must be placed in a clean and dust-free sealed bag, and the connection between the high-pressure fuel pump and the fuel inlet of the high-pressure fuel rail must be sealed immediately with a clean cover.

6.1.12 Disassemble the supercharger water outlet tube assembly 6.1.12.1 Screw off two support plate fixing bolts; 6.1.12.2 Screw off the hollow bolts and remove the pipe assembly. Note: Two gaskets are required to be replaced. 6.1.13 Disassemble the supercharger oil inlet pipe component 6.1.13.1 Screw off the support plate fixing bolts; 6.1.13.2 Screw off two hollow bolts, and remove the pipe component. Note: Two gaskets are required to be replaced.

6.1.10 Disassemble the high-pressure fuel rail 6.1.10.1 Slowly screw off the five mounting bolts of the high-pressure fuel rail; 6.1.10.2 Hold the high-pressure fuel rail with both hands and remove it along the direction of the fuel injector.

6.1.14 Disassemble the supercharger water inlet tube assembly 6.1.14.1 Pinch off the clamp connected between the supercharger water inlet tube and the supercharger water inlet hose;

6.1.11 Disassemble the heat shield

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6.1.14.2 Screw off the support plate fixing bolts; 6.1.14.3 Screw off the hollow bolts and remove the pipe assembly. Note: Two gaskets are required to be replaced. Note: The removed pipe should be placed in a sealed and clean condition, and no impurities are allowed in all connectors of the supercharger pipes.

6.1.16 Disassemble the exhaust manifold 6.1.16.1 Screw off nine exhaust manifold screw caps; 6.1.16.2 Remove the fixed plate I and II; 6.1.16.3 Slightly and vertically knock the exhaust manifold with a rubber mallet in an alternating way, until the exhaust manifold is completely separated from the cylinder block, and then slowly remove the exhaust manifold. 6.1.15 Disassemble the supercharger and the supercharger oil return pipe component 6.1.15.1 Screw off the two bolts connecting the supercharger oil return pipe and the cylinder block; 6.1.15.2 Screw off the three nuts connecting between the supercharger and the exhaust manifold; 6.1.15.3 Remove the supercharger and the supercharger oil return pipe component.

6.1.17 Disassemble the water inlet pipe of the motor-driven water pump 6.1.17.1 Screw off the bolts connected among the water inlet pipe of the water pump, oil sump and cylinder block;

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6.1.17.2 Remove the water inlet pipe of the motor-driven water pump.

6.1.20 Remove the timing chain See P8 for details. 6.1.21 Remove the oil pump chain and the tensioning plate 6.1.21.1 Remove the oil pump hood; 6.1.18 Remove the oil sump 6.1.18.1 Unscrew twenty oil sump bolts; 6.1.18.2 Gently tap the oil sump downward with a rubber mallet to separate the contact surface of the oil sump and the cylinder block, and then remove the oil sump.

6.1.21.2 As shown in the right figure, carefully tighten the tensioning plate spring of the oil pump chain to separate it from the stud, then unscrew the tensioning plate stud A and slowly loosen the spring to make the chain loose; 6.1.21.3 Unscrew the tensioning plate pin roll B of the oil pump chain, and then remove the chain tensioning plate and the tensioning plate spring;

6.1.19 Remove the timing cover 6.1.19.1 As shown in the right figure, unscrew the mounting bolts and nuts of the timing cover; 6.1.19.2 Slightly tap the timing cover with a rubber mallet to loosen it, and then carefully pry the timing cover out from the contact surface of the cylinder block, cylinder head, camshaft housing and timing cover with a slot type screwdriver.

6.1.21.4 Position the oil pump sprocket with a special tool and carefully unscrew the oil pump sprocket bolt;

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6.1.21.5 Remove the oil pump sprocket, crankshaft sprocket and oil pump chain. 6.1.22 Remove the high-pressure fuel pump

BYD Suri Maintenance & Repair Manual

6.1.24 Remove the camshaft housing and the camshaft

6.1.22.1 Unscrew two fixing bolts of the high-pressure fuel pump;

6.1.24.1 Unscrew the camshaft housing bolts evenly in the order as shown in the figure 15-1;

6.1.22.2 Remove the high-pressure fuel pump and the roller tappet.

6.1.24.2 Remove the camshaft housing.

Note: Please do not damage the O-ring

Roller Tappet

Check that the axial clearance of the camshaft is 0.5 mm or less.

6.1.23 Remove the dual pipe component 6.1.23.1 Pinch off the clamp between the oil cooler water outlet hose and the oil cooler water pipe assembly, and the clamp between the dual pipe component and the supercharger water inlet hose; 6.1.23.2 Screw off the fixing bolts of the dual pipe component and remove the dual pipe component.

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6.1.25 Remove the thermolator components and the inlet pipe of water pump 6.1.25.1 Unscrew 4 mounting bolts of the thermolator components; 6.1.25.2 Slowly pull out the inlet pipe of water pump from the cylinder block. Do not damage the O-rings. Then remove the thermolator components and the inlet pipe of water pump.

6.1.27.2 Remove the cylinder head and cylinder head gaskets. 6.1.28 Remove the valve 6.1.28.1 Remove the valve collet, valve spring upper seat and valve spring with the special tools; 6.1.26 Remove the roller rocker arm and the hydraulic tappet 6.1.26.1 Carefully take out the hydraulic tappet and roller rocker arm.

Note: Place the removed valve collet, valve spring upper seat and valve spring in the cylinder order as well as intake and exhaust sequence.

Note: Place them in a clean and sealed condition in the cylinder order as well as intake and exhaust sequence

6.1.27 Remove the cylinder head 6.1.27.1 Slowly and uniformly loosen and screw off the cylinder head bolts in the order as shown in the figure 1-8, and then remove the bolts and gaskets;

Special Tool

6.1.28.2 Remove the valves

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Note: Place the removed valves in the cylinder order as well as intake and exhaust sequence. 6.1.28.3 Remove the valve oil seal with needle nose pliers. 6.1.29 Remove the motor-driven water pump 6.1.29.1 Unscrew two fixing bolts of the motor-driven water pump support; 6.1.29.2 Remove the motor-driven water pump support, motor-driven water pump, three-way valves and related hoses.

6.1.31 Remove the oil cooler 6.1.31.1 Unscrew the fixing bolts of the oil cooler water pipe assembly; 6.1.31.2 Unscrew five mounting bolts of the oil cooler; 6.1.31.3 Remove the oil cooler, water pipe assembly and gaskets.

6.1.30 Remove the tension pulley support 6.1.30.1 Unscrew three mounting bolts of the tension pulley support; 6.1.30.2 Remove the tension pulley support.

6.1.32 Remove the labyrinth gland Unscrew six bolts and remove the labyrinth gland. 6.1.33 Remove the flywheel 6.1.33.1 Position the flywheel with a special tool, and uniformly unscrew six flywheel

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bolts; 6.1.33.2 Remove the flywheel and the clutch baffle.

6.1.35.2 Carefully clean the connecting rod bearing shell and journal;

6.1 34 Remove the crankshaft rear oil seal component See P6 for details.

6.1.35.3 Put a plastigauge on the connecting rod journal; 6.1.35.4 Apply oil on the threads of the connecting rod bolt and bearing shoulder, and then install the connecting rod cap. Screw in the bolts with a tightening torque of 30 Nm.

6.1.35 Inspect the connecting rod big end oil film clearance

Plastigauge

6.1.35.1 Unscrew two connecting rod bolts, and then remove the connecting rod cap and bearing shell;

6.1.35.5 Unscrew two connecting rod bolts, and then remove the connecting rod cap and lower bearing shell;

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6.1.35.6 Measure the oil film clearance at the widest part of the plastigauge;

turns.

Standard oil film clearance: 0.02-0.06 mm Maximum oil film clearance: 0.09 mm Note: Do not turn the crankshaft when measuring the oil film clearance; The plastigauge must be completely removed after measurement.

Assemble the removed connecting rod and bearing shell;

Replace the connecting rod bearing shell if the measured value is greater than the maximum oil film clearance; Replace the crankshaft if the measured value is still greater than the maximum oil film clearance after the bearing shell is replaced. 6.1.35.7 Use the same method to measure the oil film of other three connecting rods. 6.1.36 Remove the connecting rod Note: The connecting rod must be replaced as a unit; 6.1.36.1 Screw off the connecting rod bolts, and remove the connecting rod caps;

Place the assembled piston connecting rod assemblies in order depending on the cylinders; 6.1.37 Measure the crankshaft end clearance Pry the crankshaft back and forth with a screwdriver, and then measure the crankshaft end clearance with a feeler gauge. Standard clearance: 0.07-0.18 mm, Wear limit: 0.38 mm; Replace the thrust plate if the measured value is greater than the maximum clearance; Replace the crankshaft if the measured value is still greater than the maximum clearance after the thrust plate is replaced.

6.1.36.2 Push the piston connecting rod assembly and the upper connecting rod bearing shell through the cylinder bore, and then take them off from the top surface of the cylinder block; Note: Do not damage the surface of the upper connecting rod bearing shell 6.1.36.3 Remove the piston connecting rod assembly from the other three cylinders in

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back and forth along the axis to loosen and remove it.

6.1.38 Measure the oil film clearance of main journal

6.1.38.2 Clean the internal surface of main bearing shell, the main bearing cap, the main journal and the crankshaft;

Note: Do not turn the crankshaft during measurement 6.1.38.1 Unscrew the main bearing cap bolts, and then remove five main bearing caps;

6.1.38.3 Put a plastigauge on the crankshaft main journal;

Plastigauge Note: Loosen the main bearing cap bolts in 2 - 3 steps in the order as shown; Remove and arrange the main bearing caps and main bearing cap bolts in the original order. If it is difficult to remove the main bearing cap, lightly tap it back and forth with a rubber mallet to loosen it; Hold the bolt with both hands as shown in the figure, and shake the main bearing cap

6.1.38.4 Install the main bearing caps and screw in the bolts. Tighten the bolts in 2 – 3 steps in the order from 1 to 10 as shown to a tightening torque of 50 Nm.

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Replace the crankshaft if the measured value is still greater than the maximum clearance after the main bearing shell is replaced. 6.1.39 Remove the oil cooling nozzles Unscrew the oil cooling nozzle bolts, and remove the oil cooling nozzles in turns.

6.1.38.5 Unscrew the main bearing cap bolts of 1st gear, and remove the main bearing caps and the main bearing shells; 6.1.38.6 Measure the oil film clearance at the widest part of the plastigauge; New oil film clearance: 0.03-0.18 mm 6.1.40 Remove the fixing and supporting plate assembly

Wear limit: 0.20 mm Note: The plastigauge must be completely removed from the bearing journal after the measurement

Replace the main bearing shell in the same set if the measured value is greater than the maximum clearance; Main Bearing Hole (Set No.) A

Main Bearing Shell (Set No.) A

B

B

Clearance 0.024~ 0.059 mm 0.024~ 0.059 mm

Unscrew the fixing bolts, and remove the fixing and supporting plate assembly.

Fixing and Supporting Plate Assembly

6.1.41 Remove the piston ring Remove the first air ring, second air ring and the steel strip combination oil ring with the piston ring expander.

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6.1.42 Remove the piston pin 6.1.42.1 Remove the wire ring for holes on one side from the notch with spring pliers; 6.1.42.2 Push the piston pin out of the other side carefully.

Note: Do not scratch the sealing surfaces when removing the sealant. 6.2.3 Inspect the timing chain and oil pump chain Inspect whether the timing chain and oil pump chain are excessively worn or cracked. If any, change the chain, and detect the corresponding sprocket.

Note: Place the removed piston, piston ring, piston pin, connecting rod and connecting rod bearing shell in the cylinder order

6.2 Inspection of Engine 6.2.1 Remove the residual sealant on the sealing surfaces of the oil sump and cylinder block with a scraper; 6.2.2 Remove the residual sealant on the sealing surfaces of the camshaft housing and cylinder head with a scraper;

6.2.4 Inspect the VVT components and exhaust camshaft sprocket Inspect whether the sprocket is worn or damaged. If any, replace the camshaft sprocket.

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0.5 mm

6.2.7 Inspect the camshaft housing 6.2.5 Inspect the crankshaft sprocket Carefully clean the intake and exhaust camshaft holes of first, second and third gears

Inspect whether the crankshaft is worn or damaged. If any, replace the crankshaft sprocket.

6.2.8 Inspect the camshaft 6.2 8.1 Inspect the axial clearance of the camshaft: 6.2.6 Inspect the chain guide plate and chain tensioning plate Inspect the wear degree of the chain guide plate and chain tensioning plate, and replace the plates if the wear is greater than 0.5 mm.

a

Install the camshaft on the camshaft housing;

b

Slightly move the camshaft back and forth, and measure the axial clearance with a dial gauge. New axial clearance: 0.1-0.3 mm; Wear limit: 0.5 mm. Replace the camshaft housing if the measured axial clearance exceeds the wear limit;

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Replace the camshaft if the camshaft thrust surface is worn.

6.2.11 Repair the valve seat ring 6.2.11.1 Repair the valve seat ring again with a 45°reamer to make the width of the sealing surface of the seat ring meet the requirements; 6.2 9 Clean the valve Clean the carbon deposit on the valve with a brush. Note: Wear the protective glasses during operation.

6.2.10 Inspect the valve spring 6.2.10.1 Inspect the verticality of the valve spring with the square and feeler gauge as shown in the figure; Maximum clearance: 1.5 mm; Replace the valve spring if the measured value is greater than the maximum clearance.

Note: Confirm the central position of the valve seat ring before repairing. Gradually reduce the reamer force during repairing to avoid damage to the surface quality of the seat ring sealing surface.

6.2.11.2 Inspect the assembly position of each valve, and repair the sealing surfaces of the valve seat ring with a 45°reamer to center the valve sealing surface on the seat ring sealing surface; Width of the sealing tape: 1.5-1.8 mm 6.2.11.3 Repair the 45°sealing surface with the 30°and 60°reamer. Make sure the valve and the seat ring are completely sealed and the width of sealing surface meets the requirements;

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6.2.11.4 Uniformly coat the lapping compound on the surface of valve and valve seat by hand. 6.2.14 Clean the piston 6.2.14.1 Clean the carbon deposit on the piston with a used piston ring or equivalent; Note: Wear the protective glasses during operation. Do not scratch the piston surface 6.2.12 Clean the cylinder block

6.2.14.2 Remove the carbon deposit from the piston with special solvent.

Clean the contact surfaces between the cylinder block and the timing cover, cylinder head, oil sump as well as oil return hole cover plate with an adhesive stick or equivalent. Note: Wear the protective glasses during operation. Do not scratch the surface of cylinder block, and do not allow any impurity to drop into the water jacket of the cylinder block. 6.2.13 Inspect the flatness of cylinder block surface Inspect the flatness of the cylinder block upper surface with the straight edge and feeler gauge in the direction as shown in the figure; Maximum flatness: 0.05 mm Repair limit: 0.10 mm Replace the cylinder block if the measured value is larger than the limit value.

6.2.15 Inspect the piston Measure the outside diameter of the piston at the position which is perpendicular to the piston pin hole and 10 mm above the piston bottom as shown in the figure; Standard size: 76.44 mm Minimum size: maximum derivation 0.04 mm Replace the piston if the measured value is lower than the minimum size.

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6.2.16 Inspect the piston ring groove clearance Insert a new piston ring into the piston ring groove, and inspect the clearance in the piston ring groove with a feeler gauge; Standard Clearance (mm) First Air Ring

0.065 ~ 0.095

Second Air 0.03 ~ 0.07 Ring Wear limit: 0.15 mm Replace the piston if the measured clearance is greater than the maximum value.

6.2.17.2 Measure the end gap of piston ring with a feeler gauge;

First Air Ring Second Air Ring

Standard End Gap 0.15-0.40 mm 0.40-0.60 mm

Wear limit: 1.0 mm Replace the piston ring if the measured value exceeds the maximum clearance; Replace the cylinder block if the measured value is still greater than the maximum clearance after the piston ring is replaced.

6.2.17 Measure the end gap of piston ring

6.2.18 Inspect the crankshaft

6.2.17.1 Push a piston ring into the cylinder by 45 mm with the piston, and then remove the piston;

6.2.18.1 Measure the diameter of each main journal with a micrometer at the position as shown in the right figure; Size range: 53.963-53.978 mm; If the measured value is not within the range, inspect the oil film clearance of the crankshaft.

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6.3 Installation of Engine 6.3.1 Install the piston ring 6.3.1.1 Install the oil ring first; 6.3.1.2 Install the second and first air rings;

6.2.18.2 Measure the diameter of each connecting rod journal with a micrometer at the position as shown in the figure below.

Note: Distinguish the cross section of the first air ring from that of the second air ring; the mark of the air ring should face the top of the piston;

Standard size: 47.763-47.778 mm; If the measured value is not within the range, inspect the oil film clearance of the connecting rod.

6.3.1.3 Adjust the opening direction of the piston ring as shown in the figure

6.2.19 Inspect the crankshaft thrust plate Measure the thickness of the crankshaft thrust plate with a micrometer; Standard thickness: 2.475-2.500 mm; If the measured value is not within the range, replace the crankshaft thrust plate.

6.3.2 Install the oil return hole cover plate 6.3.2.1 Clean the sealing surfaces of the oil return hole cover plate and the cylinder block;

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6.3.2.2 Apply the sealant with the diameter of Φ2.5-Φ3.5 mm on the position as shown in the figure without breaking point;

then tighten it;

Note: After the sealant is coated, the part must be installed within five minutes. If not, remove the residual and apply the sealant again.

Tightening torque: 20 Nm Oil Limiting Plug

6.3.3.3 Apply the pipe thread sealant on the threaded plug I of the cylinder block and install it on the cylinder block; Tightening torque: 35 Nm 6.3.2.3 Tighten six bolts alternatively, and install the oil return hole cover plate.

Threaded plug I of cylinder block

Tightening torque: 10 Nm 6.3.3 Install the oil cooling nozzle, oil limiting plug and plug 6.3.3.1 Carefully clean the mounting surface of the oil cooling nozzle, and tighten the bolts with a tightening torque of 25 Nm.

6.3.4 Install the main bearing shell 6.3.4.1 Install the lower main bearing shell on the main bearing cap; Note: Clean the mounting surface of the bearing shell with a piece of silk cloth before installation; Align the positioning lip on the shell with the locked gap of the main bearing cap; 6.3.3.2 Apply the pipe thread sealant on the threaded plug II of the cylinder block and

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6.3.5.2 Apply oil on the inner surface of the upper main bearing shell, and then install the crankshaft;

Locked Gap

Do not apply oil on the back of the bearing shell and the mounting surface of the main bearing cap. 6.3.4.2 Install the upper main bearing shell on the main bearing support; Note: Clean the mounting surface of the bearing shell with a piece of silk cloth before installation; Align the positioning lip on the shell with the locked gap of the main bearing support, and align the oil hole on the shell with the oil hole of the main bearing support;

Oil Groove

6.3.5.3 Apply oil on the lower main bearing shell, point the arrow on the main bearing cap to the front of the engine, and install the main bearing cap in the order of numerical markers from 1st to 5th gear.

6.3.5.4 Apply a little oil on the main bearing cap bolts, and tighten the bolts in 3 steps in the order from 10 to 1 as shown in the figure. Do not apply oil on the back of the bearing shell and the mounting surface of the main bearing support. The main bearing shell should be selected and matched in groups.

Step 1: 20 Nm Step 2: 50 Nm Step 3: 90 ºrotating angle (1/4 circle)

6.3.5 Install the crankshaft 6.3.5.1 Slide two thrust plates into the main bearing support of third gear with the oil groove on the thrust plate faces outward;

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6.3.5.5 Rotate the crankshaft after the installation. The crankshaft should be rotated freely without being stuck and the torque is 6 Nm or less. The axial play must be within 0.04-0.19 mm after the crankshaft is assembled.

BYD Suri Maintenance & Repair Manual

6.3.6.2 The connecting rod bearing shell on the connecting rod cap; Note: Clean the mounting surface of the bearing shell with a piece of silk cloth before installation; do not apply oil on the back of the bearing shell or the mounting surface of the connecting rod cap;

6.3.7 The connecting rod

6.3.6 The connecting rod bearing shell 6.3.6.1 The connecting rod bearing shell on the connecting rod body;

6.3.7.1 Ensure the piston ring is installed correctly. top compression ring scraper ring

Note: Clean the mounting surface of the bearing shell with a piece of silk cloth before installation; Do not apply oil on the back of the bearing shell or the mounting surface of the connecting rod body; Align the oil hole on the bearing shell with the oil hole on the connecting rod body.

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6.3.7. 4 On the lower connecting rod bearing shell, make the 'BYD' mark face the front end of the engine, and install the connecting rod cap. Note: Check that the threads of the connecting rod bolts are not damaged;

6.3.7.2 l The friction surfaces shown in the figure, and the other surfaces should be clean and free of any impurity;

6.3.7.3 Install the piston connecting rod assembly in the cylinder block with the piston ring compressor. Note the arrow at the exhaust side on the top of piston points to the front end of the engine (the end of the crankshaft pulley);

Make sure 4 connecting rods are of the same quality; Make sure the connecting rod body and the connecting rod cap contact closely.

6.3.7.5 As shown in the figure, apply a small amount of oil on the threads of connecting rod bolts and the bolt bases. Make sure the hold-down surfaces of the bolts are clean and free of any impurity; 6.3.7.6 Alternatively tighten the connecting rod bolts in 2 - 3 steps; The tightening torque is 30 Nm

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6.3.7.7 Mark on the connecting rod bolts with a marker pen along the front end of the engine; Front end of the engine Mark 6.3.9.2 Apply oil on the rod part of 26 mm from the valve end;

6.3.7.8 Rotate the connecting rod bolts 90º clockwise, and retighten the connecting rod bolts; 6.3.7.9 The crankshaft should be rotated freely after installation, and the torque should not exceed 10 Nm. 6.3.8 Install the crankshaft rear oil seal component

6.3.9.3 Install the valve, valve spring and valve spring upper seat; Note: The valve spring can be installed at any direction as it has equal pitch.

See P6 for details The special tool 6.3.9 Install the valve 6.3.9.1 Install the valve oil seal on the valve guide with the special tool; Note: MP lithium grease should be applied on 16 new valve oil seals before the installation.

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6.3.9.4 Compress the valve spring with the special tool, install the valve collet at the valve end and then loosen the valve spring carefully.

6.3.10 Install the cylinder head gaskets 6.3.10.1 Vertically tap two positioning sleeves into the seat holes with a copper mallet; 6.3.10.2 Install the cylinder head gaskets on the top of the cylinder block. The positioning holes on the gaskets should be aligned with the positioning sleeves, and the wider end should face the front end of the engine (crankshaft pulley end). At this time, the oil holes and water holes of cylinder block are aligned with the oil holes and the water holes on the cylinder head gaskets. Note: The surface of cylinder head gasket and the mating surface of cylinder block and cylinder head should be clean and free of grease and other foreign materials.

Special Tool 6.3.9.5 Gently tap the end of the valve stem with a pin punch to fix the valve and the valve collet securely.

6.3.11 Install the cylinder head 6.3.11.1 Align the positioning sleeve holes and

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then slowly lower the cylinder head on the cylinder block; Note: The cylinder head should be lowered gently to avoid damage to the cylinder block gasket. 6.3.11.2 Install the cylinder head bolt gaskets to the cylinder head bolts, and apply a proper amount of oil on the cylinder head bolts as shown in the figure; 6.3.12 Install the roller rocker arm component 6.3.12.1 Apply a proper amount of oil in the positions as shown in the figure; The contact surfaces of hydraulic tappet, roller and valve end

6.3.11.3 Tighten the cylinder head bolts in two steps in the order as shown in the figure; Step 1: 20 Nm Step 2: 70 Nm

6.3.11.4 Mark the cylinder head bolts with a marker pen along the front end of the engine; 6.3.11.5 Rotate the cylinder head bolts 90º clockwise and tighten the bolts.

6.3.12.2 Slowly install the roller rocker component into the plunger hole. Avoid damage to the surface of the tappet. Note: The roller rocker arm must be correctly positioned at the end of the valve stem.

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6.3.12.3 Install the sparkplug hole seal rings and the OCV filter screen on the cylinder head.

BYD Suri Maintenance & Repair Manual

6.3.13.3 Rotate the intake and exhaust camshafts for 1 or 2 circles. They must be rotated freely without being stuck; 6.3.13.4 Make sure the camshaft is positioned at the compression top dead center of a cylinder with the special tool, and prevent the camshaft from dropping. See P9 for details 6.3.14 Install the camshaft housing 6.3.14.1 Uniformly apply a thin layer of sealant in the areas as shown in the figure.

6.3.13 Install the camshaft 6.3.13.1 Apply a proper amount of oil in each bearing support of the camshaft housing;

6.3.13.2 Insert the camshaft into the camshaft housing from rear to front. Note the journal and cam should not be knocked and the intake and exhaust camshafts should not be inversely installed.

Note: The sealant should not be applied thickly, or the excessive sealant may enter the oil hole, causing blockage of the oil circuit.

6.3.14.2 Screw two studs into the cylinder head. Carefully and vertically lower the camshaft housing with two studs passing through, and align the positioning pins.

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Tightening torque: 24 Nm Note: The oil pump should rotate freely without being stuck before it is installed.

6.3.14.3 Tighten the mounting bolts in two steps in the order as shown in the figure; Step 1: 10 Nm Step 2: 90ºrotating angle 6.3.14.4 Install the camshaft phase sensor into the corresponding seat hole, and tighten the bolts with the specified torque;

6.3.15.2 Install the oil collector on the oil pump, and uniformly tighten the bolts in several times. Tightening torque: 10 Nm Note: Add a small amount of oil through the oil suction port of oil pump. Check if the O-ring of oil collector is in good condition.

6.3.14.5 Install the front and rear lifting hooks of the engine, and then tighten the bolts with the specified torque; 6.3.16 Install the oil pump chain 6.3.14.6 Install the OCV solenoid valve into the corresponding seat hole, and tighten the bolts with the specified torque;

6.3.16.1 Hang the oil pump chain on the oil pump sprocket and crankshaft sprocket;

6.3.15 Install the oil pump and the oil collector 6.3.15.1 Align the positioning pin hole, install the oil pump on the bottom surface of the cylinder block and tighten the bolts;

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rotated freely after installation. Apply oil on the contact area between the tensioning plate and the chain.

6.3.16.2 Install the oil pump sprocket and the crankshaft sprocket in place on the crankshaft and the camshaft sprocket. The notch of oil pump sprocket should be aligned with that of the oil pump sprocket shaft, and the notch of crankshaft sprocket should be aligned with that of the crankshaft;

6.3.16.5 Place the tensioning plate spring in the correct position, tighten the retaining bolts after tensioning the spring and then loosen the spring carefully; 6.3.16.6 Install the oil pump hood.

6.3.16.3 Position the oil pump sprocket with the special tool, and then screw up and tighten the bolts; Tightening torque: 30 Nm

6.3.17 Install the timing chain See P8 for details 6.3.18 Install the timing cover 6.3.16.4 Pass the tensioning plate pin roll through the oil pump chain tensioning plate after the oil is applied on its outer, and then tighten the tensioning plate pin roll;

6.3.18.1 Press the crankshaft front oil seal into the position shown in the right figure with the special tool.

Note: The tensioning plate should be

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Special Tool

6.3.18.2 Install two oil-retaining seal rings of the timing cover and the oil gas separator in place, and then uniformly and alternatively tighten the bolts in two to three times;

Connecting Sleeve

6.3.18.4 Install the timing cover in place with the positioning pins, and uniformly and alternatively tighten the bolts in two to three times; Note: Protect the oil seal lip with the special tool before installing the front oil seal into the connecting sleeve. 6.3.19 Install the oil sump 6.3.19.1 Remove the sealant from the bottom of the cylinder block and the mounting surface of the oil sump. Make sure the surfaces are clean and free of any impurity; 6.3.19.2 Apply the flange sealant with the diameter of Φ2.5-Φ3.5 mm on the inner side of the oil sump joint surface without breaking point;

6.3.18.3 Install the timing cover gasket with two positioning pins. First install the O-ring into the connecting sleeve and then install the connecting sleeve on the crankshaft; Note: The sealing surface should be clean and free of grease. Apply the sealant before installation.

6.3.19.3 Make sure the rear end surface of oil sump is aligned with the rear end surface of cylinder block with the special tool. Install the oil sump in place. Uniformly and alternatively tighten the bolts in several times;

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6.3.19.4 Tighten the oil drain plug. Tightening torque: 25 Nm Note: Check the rubber seal gasket of the oil drain plug before installation and make sure the gasket is complete and smooth.

BYD Suri Maintenance & Repair Manual

6.3.21 Install the clutch 6.3.21.1 Install the clutch driven plate assembly; Insert the centering plug into the crankshaft rear end bearing hole after passing through the clutch driven plate assembly; Note: The flat surface faces inwards and the convex surface faces outwards.

6.3.20 Install the flywheel 6.3.20.1 Attach the flywheel to the mounting surface of the crankshaft, carefully rotate it to the correct position, and screw up the flywheel bolt by hand for two to three threads; Note: The flywheel surface should be clean and free of the oil stain. 6.3.20.2 Alternatively and uniformly tighten the flywheel bolts in several times. Tightening torque: 60 Nm+90ºrotating angle

6.3.21.2 Install the clutch cover assembly Align three positioning pins and install the clutch pressure plate to the rear end of the flywheel; Tighten six bolts in the order as shown in the figure to fix the clutch pressure plate on the flywheel. Tightening torque: 25 Nm Note: Check if the driven plate assembly is centered after installation. Gently shake the centering plug and remove it after completing the above operation.

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tighten the bolts in several times; Tightening torque: 24 Nm 6.3.22.3 Install the fuel inlet fittings on the high-pressure fuel rails. Note: Clean the sealant on the threads before installation and apply the pipe thread sealant again. Tightening torque: 80 Nm 6.3.22 Install the high-pressure fuel rail 6.3.22.1 Fully press four fuel injectors into the cylinder head;

6.3.23 Install the high-pressure oil pump 6.3.23.1 Clean the surface of the roller tappet and apply a proper amount of oil. Then push it into the camshaft housing; Note: Do not apply oil or grease on the packing ring as shown in the figure below. The seal ring, elastic part and packing ring shown in the figure below can only be used once. Seal Ring

Note: During the assembly, insert the locating block indicated by the arrow in the figure into the corresponding groove.

Elastic Part Packing Ring

6.3.22.2 Place the high-pressure fuel rail gasket on the mounting surface with the positioning pin. Align the high-pressure fuel rails with four fuel injectors, and press the seal rings of the fuel injectors into the high-pressure fuel rails. Then uniformly

6.3.23.2 Install the high-pressure oil pump in place, and tighten the bolts;

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Note: Perform installation in the direction as shown in the figure, and do not reverse the installation direction.

BYD Suri Maintenance & Repair Manual

O-ring

6.3.23.3 Install the oil inlet tube component in place. First screw in the union nuts for two to three threads, and then screw in the support plate bolts for two to three threads. Tighten the union nuts, and then the support plate bolts. Buckle

Tightening torque: Union nut 17 Nm 6.3.25 Install the sparkplug

6.3.25.1 Install the sparkplug in the cylinder head and tighten it; See P10 for details 6.3.25.2 Install the ignition coil on the camshaft housing, and tighten the bolts; Tightening torque: 10 Nm

6.3.24 Install the thermolator 6.3.24.1 Confirm the O-rings at both ends of the oil inlet tube of the water pump are complete without damage. Install the water inlet tube of the water pump in the thermolator component through the positioning groove; 6.3.24.2 Install the other end of the water inlet tube of the water pump into the cylinder block, and then tighten the mounting bolts of thermolator component.

6.3.25.3 Apply sealant on the threads of the oil pressure switch, screw it into the mounting base hole and tighten it; Tightening torque: 15 Nm 6.3.25.4 Install the knock sensor in the corresponding position at the intake side of cylinder block with the plug part facing the lower rear part of the engine with an angle of 45º, and then tighten it; Tightening torque: 20 Nm

6.3.24.3 Lock the water inlet tube of the water pump with a buckle.

6.3.26 Install the motor-driven water pump

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6.3.26.1 Install the motor-driven water pump on the motor-driven water pump support, and tighten the bolts;

BYD Suri Maintenance & Repair Manual

assembly and the water outlet hose of the oil cooler in place, and then tighten the hoops.

6.3.26.2 Install the motor-driven water pump support on the cylinder block, and tighten the bolts; Note: The mounting surface of the motor-driven water pump should face the front end of the engine, and do not reverse the installation direction; 6.3.26.3 Install the dual pipe component and the water inlet tube of motor-driven water pump, and tighten the bolts; 6.3.26.4 Assemble the components shown in the figure, and then tighten the hoops.

6.3.27.3 Screw the oil filter screwed tube into the seat hole of timing cover, screw the oil filter into the screwed tube, and tighten them to the specified torque. Note: Before installation, check that the seal ring is complete and smooth without wear. The seal ring is higher than the flange end surface and a proper amount of oil is applied on its surface.

6.3.27 Install the oil cooler 6.3.27.1 Install the oil cooler on the cylinder block and tighten the bolts in several times; Tightening torque: 24 Nm Note: Make sure the sealing surface is free of grease and other impurities before installation; Check that the gasket surface is complete without damage before installation; 6.3.27.2 Install the water tube assembly of oil cooler. Check that the O-ring at the oil cooler end is complete without damage. Tighten two bolts to install the water tube

6.3.28 Install the intake manifold 6.3.28.1 Install the intake manifold in place, and tighten the bolts alternatively in several times; Note: Check if four washers are complete before installation.

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6.3.28.2 Align the positioning pins to install the throttle valve and throttle valve clamping seat, and tighten the bolts; 6.3.28.3 Install the sealing strips, supporting strip I and II of the intercooler in the corresponding positions. Then install the intercooler (Do not reverse the installation direction) and tighten the screws. 6.3.28.4 Install the intake temperature pressure sensor into the corresponding seat hole of the intake manifold, and tighten the screws. Note: The wire harness plug should face the front end of the engine

6.3.29.4 Install the intake fitting component (Do not reverse the installation direction) and then tighten the bolts; 6.3.29.5 Install the supercharge pressure solenoid valve as shown in the figure (Do not reverse the installation direction) and tighten the bolts. Then install the connection hose I, II and III in place. 6.3.29.6 Check that the O-rings on the intake manifold and the turbocharger are complete and smooth without damage. Assemble the intake manifold and the semi-circular clamping block, and tighten the screws.

6.3.29 Install the turbocharger

Note: Two gaskets must be installed for each hollow bolt.

6.3.29.1 Install the exhaust manifold, exhaust manifold gasket, fixed plate I and II in place, and then tighten the screw cap;

Note: It is necessary to fill oil into the oil inlet during installation if the turbocharger has been left for a long time.

6.3.29.2 Respectively install the turbocharger oil return pipe and the turbocharger. Then install the turbocharger on the exhaust manifold and tighten the turbocharger nuts; 6.3.29.3 Install the supporting plate assembly, turbocharger water inlet tube, turbocharger water return tube and turbocharger oil inlet pipe, and then tighten the hollow bolts; Note: It is necessary to fill the oil of more than 5 ml into the turbocharger oil inlet before installing the turbocharger oil inlet pipe.

6.3.30 Install the crankshaft housing ventilator and the fuel evaporative emission control system 6.3.30.1 Install the PCV four-way components, and tighten the bolts; Note: Check if the O-rings of PCV four-way components are complete and smooth without damage. 6.3.30.2 Install the PCV breather tube I, II and the intake fitting rubber sleeve;

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Note: Check if the O-ring of the PCV breather tube I is complete and smooth without damage. 6.3.30.3 Install the charcoal canister control valve, connection hose and vacuum pipe component; 6.3.30.4 Install the camshaft housing connection hose and one-way valve. Note: Do not install the one-way valve reversely.

Check Valve

Camshaft housing connection house

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Part 2 Lubrication System Section 1 Schematic Diagram of Engine Lubrication Circuit

1st Gear Main Journal

Cylinder 1 Oil Cooling Nozzle 2nd, 3rd, 4th, 5th Gear Main Journal

Cylinder 2, 3, 4 Oil Cooling Nozzle

1st Gear Camshaft Journal Exhaust Side 2nd, 3rd Gear Camshaft Journal 1st Gear Camshaft Journal Intake Side Oil Collector

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Section 2 Inspection of Oil Pressure Warning: The oil temperature in the hot engine is very high, which can cause burns. Perform operation after the engine is stopped and cooled down. 2.1 Remove the oil pressure switch;

Engine Speed

Oil Pressure

2000 r/min

Above 200 kPa

Note: The oil pressure may vary depending on the oil viscosity and temperature; If the pressure is not within the specified range, find out the cause and perform the repair or replacement as necessary. 2.4 Install the oil pressure switch 2.4.1 Stop the engine and cool it down; 2.4.2 Remove the oil pressure gauge and converter; 2.4.3 As shown in the figure, uniformly apply anaerobic pipe thread sealant on the threads of oil pressure switch; 2.4.4 Install the oil pressure switch;

2.2 Connect the oil pressure gauge to the oil pressure switch mounting holes with a special adapter;

Tightening torque: 15 Nm Note: Do not start the engine within one hour after the oil pressure switch is installed; 1.0 ~ 2.0 mm

Sealant Application Area

4.0 ~ 6.0 mm

2.3 Start the engine and keep it running until the normal working temperature is reached (≥80°C);

2.4.5 Connect the wire harness connector of oil pressure alarm; 2.4.6 Start the engine and check for oil leakage.

Increase the engine speed until the specified speed is reached, and check the reading on the oil pressure gauge; Oil pressure: 200-340 kPa (2000 r/min)

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Section 3 Engine Oil 3.1 Engine Oil Inspection 3.1.1 Park the vehicle on a level ground, and stop the engine after it is started and the normal working temperature is reached; 3.1.2 After five minutes, pull out the oil dipstick and observe the oil level and condition. Check if the oil level is between A and B; Add or replace the oil if necessary

and then drain the oil into a suitable container; 3.2.3 Clean the drain plug. Check if the drain plug gasket is complete and smooth, and replace it if damaged. Tighten the drain plug; Tightening torque: 25 Nm 3.2.4 Install a new oil filter; Check and clean the mounting surface of the oil filter, gently screw the oil filter into the filter base and turn it with the special tool. See P for details. The removal is in the reverse order of installation. 3.2.5 Fill oil in the engine; Oil filling quantity:

3.1.3 Insert the oil dipstick again.

Item

3.2 Engine Oil Replacement

The oil filter is replaced The oil filter is not replaced

Warning: Avoid burns as the oil temperature in the hot engine is very high; Waste oil may cause cancer, therefore wash the skin with soap and clean water after replacement; For environment protection, the waste oil and oil filter must be treated in the specified area. 3.2.1 Lift the vehicle horizontally with a lifter, or drive the vehicle onto a ditch;

Filling Quantity (L) 4.0 3.8

3.2.6 Tighten the oil filler cap; 3.2.7 Start the engine and check for any oil leakage; 3.2.8 Check the oil level, and add oil if necessary. Engine oil grade: Special oil specified and approved by BYD Auto Co., Ltd.

3.2.2 Remove the oil filler cap and drain plug,

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Section 4 Oil Sump 4.1 Removal of oil sump 4.1.1 Disconnect the negative battery terminal;

4.3.3 Slightly tap the oil sump with a rubber mallet to loosen it, and remove the oil sump with a remover if necessary.

4.1.2 Drain the engine oil; 4.4 Notes on installation of oil sump 4.1.3 Unscrew the oil sump mounting bolts. 4.2 Installation of oil sump 4.2.1 Perform installation in the reverse order of removal; 4.2.2 Start the engine and check for any oil leakage.

4.4.1 Clean the bottom surface of cylinder block and the mounting surface of oil sump, and make sure no grease exists; 4.4.2 Apply sealant around the inside of the oil sump peripheral holes; Diameter of sealant: Φ2.5-Φ3.5 mm Note: The oil sump should be installed within five minutes after the flange sealant is applied. Otherwise it is necessary to clean the residual and recoat new sealant. The sealant must be dried for about thirty minutes after the oil sump is assembled. Then fill the engine oil;

4.3 Notes on removal of oil sump

4.4.3 Uniformly tighten the mounting bolts in several times: Twenty M6 bolts for connecting the cylinder block, timing cover and rear oil seal component, and two M10 bolts for connecting the transmission

4.3.1 Remove the oil sump bolts; Tightening torque for drain plug: 25 Nm 4.3.2 Remove the sealant on the threads and sealing surface;

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Section 5 Oil Pump 5.1 Removal of Oil Pump 5.1.1 Make sure the oil sump has been removed before the removal of oil pump; 5.1.2 Fix the oil pump sprocket with the special tool, and loosen the fixing bolts; Note: Do not remove the oil pump sprocket bolts.

5.1.4 Loosen the oil pump mounting bolts and remove the oil pump.

5.2 Installation of Oil Pump The installation is in the reverse order of removal; 5.2.1 Install the oil pump in place and tighten the bolts; Tightening torque: 24 Nm 5.2.2 Press the oil pump chain tensioning plate in the direction indicated by the arrow as shown in the figure with a screwdriver or equivalent. Put the sprocket in the chain and then on the oil pump shaft;

5.1.3 Press the oil pump chain tensioning plate in the direction indicated by the arrow as shown in the figure with a screwdriver or equivalent. Unscrew the oil pump sprocket bolts, and remove the sprocket from the oil pump and the chain;

Note: Check if the sprocket is installed in place on the oil pump shaft. 5.2.3 Screw in the oil pump sprocket bolts, position the oil pump sprocket with the special tool, and tighten the bolts; Tightening torque: 30 Nm 5.2.4 Install the oil sump.

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Part 3 Cooling System Section 1 Schematic Diagram of Engine Cooling System Water Pump

Thermolator ll

Motordriven Water Pump

Intercooler

Turbocharger

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Section 2 Thermolator 2.1 Removal of Thermolator 2.1.1 Disconnect the negative battery cable; 2.1.2 Drain the coolant; 2.1.3 Remove the thermolator cap. Unscrew the thermolator cap bolts, and remove two thermolators. Thermolator I

Thermolator II

2.2.2 Check the opening temperature and full-open temperature of the thermolator. Thermolat or I

2.2 Inspection of Thermolator 2.2.1 Visually inspect whether the thermolator meets the requirements; The mark on the thermolator indicates the opening temperature. If the mark on the thermolator does not match with the engine, replace the thermolator.

Opening Temperature (°C) Full-open Temperature (°C) Full-open Travel (mm) Maximum Travel (mm)

Thermolator II 83 (+2/-1)

95 (+2/-1) 98 110 7~10 12

7~10 12

Replace the thermolator if not as specified.

Thermolator I: 83°C Thermolator II: 95°C

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Section 3 Water Pump 3.1 Removal of Water Pump 3.1.1 Drain the coolant; and see section 2 for details. 3.1.2 Remove the driving belt; Refer to the removal of driving belt for details Rotate the tension pulley counterclockwise (to the left) to the limit position with the front end bolt so as to loosen the belt and remove the driving belt.

3.2 Installation of Water Pump The installation is in the reverse order of removal; 3.2.1 Install the water pump 3.1.3 Remove the water pump pulley; See P5

3.2.1.1 Inspection before the installation

Unscrew three fixing bolts and remove the water pump pulley. 3.1.4 Remove the water pump;

Rotate the water pump by hand and check if the water pump emits abnormal noise. If any, replace the water pump assembly;

3.1.4.1 Screw off five mounting bolts of the water pump;

Check if the water pump gaskets are damaged. If any, replace the water pump gasket;

3.1.4.2 Remove the water pump and the water pump gaskets.

Carefully clean the sealing surfaces of the water pump and cylinder block and water pump gasket;

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3.2.1.2 Install the water pump and water pump gaskets to the cylinder block, and then tighten five bolts; Tightening torque: 24 Nm

3.2.1.3 Install the water pump pulley, and tighten three bolts; Tightening torque: 24 Nm 3.2.1.4 Install the driving belt.

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Part 4 Clutch Section 1 Clutch Device 1.1 Removal of Clutch 1.1.1 Remove the starter;

1.1.3.1 Insert the centering plug into the crankshaft rear end bearing hole after passing through the clutch driven plate assembly; Note: The flat surface faces inwards and the convex surface faces outwards.

1.1.3.2 Screw off six fixing bolts as shown in the figure, and remove the clutch. 1.1.2 Remove the transmission Remove the bolts for connecting the transmission to the cylinder block and oil sump.

1.2 Inspection of Clutch 1.2.1 Inspect the clutch driven plate assembly 1.2.1.1 Measure the depth of rivet head on the friction disc with a vernier caliper; Minimum depth: 0.3 mm.

Connect the oil sump

Replace the clutch driven plate assembly if necessary.

1.1.3 Remove the clutch

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1.2.1.2 Measure the circular run-out of the friction disc with a magnetic stand dial gauge and a deflection instrument; The allowed maximum circular run-out is 0.8 mm.

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1.2.3 Inspect the clutch cover assembly As shown in the figure below, check the wear of the presure plate leaf spring with the vernier caliper; Allowed maximum depth: 0.6 mm Allowed maximum width: 0.5 mm Replace the clutch cover assembly if the measured value exceeds the allowed maximum value. Note: Do not allow the oil and other impurities to drop on the surfaces of the driven plate assembly and the flywheel.

Replace the clutch driven plate assembly if necessary. 1.2.2 Inspect the flywheel 1.2.2.1 Measure the circular run-out of the rear end surface of the flywheel with the magnetic stand dial gauge; The allowed maximum circular run-out is 0.1 mm. Replace the flywheel if necessary.

1.3 Installation of Clutch 1.3.1 Install the clutch driven plate assembly; Insert the centering plug into the crankshaft rear end bearing hole after passing through the clutch driven plate assembly; Note: The flat surface faces inwards and the convex surface faces outwards.

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Note: Check if the driven plate assembly is centered after the installation; Slightly shake the centering plug to remove it after completing the above operation; Make sure no oil stain is on the contact surface of the flywheel and friction disc before installation.

1.3.2 Install the clutch cover assembly 1.3.2.1 Align three positioning pins, and install the clutch pressure plate to the rear end of the flywheel; 1.3.2.2 Screw in and tighten six bolts in the order as shown in the figure, and fix the clutch pressure plate on the flywheel. Tightening torque: 25 Nm

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Section 2 Flywheel 2.1 Removal of Flywheel 2.1.1 Fix the flywheel with the special tool; 2.1.2 Uniformly and alternatively unscrew the flywheel bolts in several times, and then remove the flywheel.

Tightening torque: 60 Nm+90ºrotating angle

2.3 Inspection of Flywheel Measure the axial circular run-out of the flywheel with a magnetic stand dial gauge; The allowed maximum axial circular run-out: 0.1 mm. Replace the flywheel if necessary.

2.2 Installation of Flywheel 2.2.1 Attach the flywheel to the crankshaft mounting surface, and rotate it to the correct position; 2.2.2 Screw in the flywheel bolts. 2.2.3 Position the flywheel with the special tool, and then uniformly and alternatively tighten the flywheel bolts in several times;

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Chapter 3 Transmission Contents Section 1 Structural parameters............................................................................................ 133 1.1 Structural parameters of transmission................................................................... 133 Section 2 Service Guidelines ................................................................................................ 134 2.1 Service Materials ................................................................................................... 134 2.2 Auxiliary Materials Table ........................................................................................ 134 2.3 Service Regulations............................................................................................... 135 Section 3 Service of transmission ......................................................................................... 136 3.1 Disassembly of Transmission ................................................................................ 136 3.2 Inspection of reverse gear shaft fork clearance .................................................... 141 3.3 Inspection of shift lever clearance ......................................................................... 142 3.4 Disassembly and reassembly of manual gear shift assembly .............................. 143 3.5 Disassembly and reassembly of manual gear shift assembly (Note: Applicable for transmissions with neutral switch assembly) ........................................................ 144 3.6 Inspection of gear shifting fork clearance.............................................................. 145 3.7 Disassembly and reassembly of gear shifting fork ................................................ 146 3.8 Inspection of main shaft assembly clearance ....................................................... 147 3.9 Disassembly of main shaft .................................................................................... 148 3.11 Reassembly of main shaft ..................................................................................... 150 3.12 Inspection of counter shaft assembly clearance ................................................... 151 3.13 Disassembly of counter shaft ................................................................................ 152 3.14 Inspection of counter shaft .................................................................................... 153 3.15 Reassembly of counter shaft ................................................................................. 154 3.16 Inspection of synchronizer gear sleeve and gear hub .......................................... 157 3.17 Inspection of synchronizer ring and gear .............................................................. 158 3.18 Replacement of main shaft bearing and oil seal ................................................... 159 3.19 Replacement of counter shaft bearing .................................................................. 160 3.20 Adjustment of main shaft meshing clearance ....................................................... 160 3.21 Reassembly of transmission ................................................................................. 161 Section 4 Differential ............................................................................................................. 165 4.1 Disassembly of differential .................................................................................... 165 4.2 Inspection of backlash ........................................................................................... 166 4.3 Removal and Installation of final drive driven gear ............................................... 166 4.4 Replacement of differential housing/vehicle speed sensor driving gear............... 166 4.5 Replacement of differential oil seal ....................................................................... 167 4.6 Replacement of differential adjusting shim ........................................................... 168

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Section 1 Structural parameters 1.1 Structural parameters of transmission Transmission model Applicable Engine Model Type Axial Distance (mm) Overall Length (mm) Dimensions (length × width × height) (mm) Gear Ratio of Differential 1st gear 2nd gear 3rd gear Transmission efficiency 4th gear 5th gear Reverse 1st gear 2nd gear Synchronizer ring 3rd gear dimensions (mm) 4th gear Synchronizer ring type 5th gear Reverse Shift lever ratio Gear shifting control mechanism Select lever ratio Gear ratio Speed sensor Type SAE viscosity classification Gear Oil API classification Oil volume (L) Net weight (without clutch) (kg) Transmission model Gears Gear ratio Drive ratio Final drive gear ratio Final drive ratio Total drive ratio Transmission model Gears

I 43/13 3.308

13.782 I

Gear ratio

43/13

Drive ratio Final drive gear ratio Final drive ratio Total drive ratio

3.308

14.787

BYD5T-14/BYD5T-14-1/BYD5T-14-4 /BYD5T-14-1A/BYD5T-14-4A/BYD5T-14-5A BYD473QE/BYD473QB Manual 5-gear 69-118 363 363×515×382 16:10 0.98 0.98 0.98 0.98 0.98 0.97 Φ74.9 Φ74.9 Φ68.8 Φ68.8 Φ62.8 Φ62.8 45.55/24.5 57.4/34.6 19/23 Electronic 80W-90 (Summer in northern China), 75W-90 (Winter in northern China) 80W-90 or 85W-140 (All year round in southern China) GL-4 1.6 L 33

BYD5T-14-1A/BYD5T-14-4A/BYD5T-14-5A II III IV V R 42/23 35/29 31/33 27/37 31/13×42/31 1.826 1.207 0.939 0.73 3.231 75/18 4.167 7.609 5.029 3.914 3.041 13.462 BYD5T-14/BYD5T-14-1/BYD5T-14-4 II III IV V R 31/13 42/23 35/29 31/33 27/37 X42/31 1.826 1.207 0.939 0.73 3.231 76/17 4.471 8.164 5.396 4.2 3.262 14.443

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Section 2 Service Guidelines 2.1 Service Materials The materials listed in the following table are essential for maintaining the transmission. Therefore, the materials should be prepared for use at any time. In addition, the washing liquid and lubricant of specified type should be used.

2.2 Auxiliary Materials Table No.

Materials and type

Materials and type currently in use

Position

2 # sodium base grease

Release fork Release bearing Front oil seal of input shaft Vehicle speed sensor assembly Gear selecting block Differential oil seal

1 2 3 4

Lubricant

5 6

7

Gear Oil

8 9

Sealant

10

11

12

Gear Oil

Sealant

Gear Oil

13

API grade GL-4 and above 75W-90 Winter in northern China 80W-90 Summer in northern China 80W-90 or 85W-140 (All year round in southern China) Loctite 587 API grade GL-4 and above 75W-90 Winter in northern China 80W-90 Summer in northern China 80W-90 or 80W-140 (All year round in southern China) TONSAN TS1567F API grade GL-4 and above 75W-90 Winter in northern China 80W-90 Summer in northern China 80W-90 or 80W-140 (All year round in southern China) TONSAN TS1567F

Sealant 14

TONSAN Kesaixin 1262

Transmission assembly

Sealing plug Input shaft needle bearing Output shaft needle bearing Contact surface of the transmission box Gear shifting fork and shift lever assembly Mounting surface of manual gear shift assembly Reverse shaft fork assembly bolts Reverse gear lock cam assembly

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2.3 Service Regulations Prepare the parts kit and parts rack in advance to store the removed and disassembled components. Put them in order and make markers if necessary to avoid confusion and misplacement. Be careful when serving the aluminum alloy parts to avoid damage to the machined surface. Prepare sufficient auxiliary materials for use in the process of servicing. For the bolts and other fastening parts with standard tightening torque requirements, tighten them with special tools in accordance with the required values.

After servicing, disposable supplies should be scrapped and replaced with new ones. Use correct removal tools for disassembly and assembly. Refer to this service manual as much as possible during work. If you encounter any difficult technical problems during servicing, it is recommended to consult our aftersales technical service department.

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Section 3 Service of transmission 3.1 Disassembly of Transmission Disassembly diagram of front casing

(1) Differential assembly (2) Reverse gear lock cam assembly (3) Mounting bolts (15 Nm) (4) Gear shifting fork assembly (5) Counter shaft assembly (6) Main shaft assembly (7) Magnet assembly (8) Slide bush (9) Cylindrical roller bearing (10) Oil guide plate 2 (11) 58 mm deep groove ball bearing (12) Main shaft oil seal

(13) Reverse gear shaft (14) Idler gear assembly (15) Mounting bolts (15 Nm) (16) Reverse shaft fork assembly (17) Positioning pin (18) Dust cover (19) Release arm (20) Release arm screw (30 Nm) (21) Release arm spring (22) Release bearing (23) Differential right oil seal

(24) Pull cable support (25) Hexagon flange bolt M8×45 (25 Nm) (26) Hexagon flange bolt M6×22 (10 Nm) (27) Vehicle speed sensor assembly (28) O-ring (29) Vehicle speed sensor driven gear (30) Spring (31) 8 mm washer (32) Clamp spring (33) 8 mm spring washer (34) Fork shaft screw (25 Nm)

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(35) Transmission front casing Note: The matching condition of the vehicle speed sensor, neutral switch, front casing and rear casing is listed below. Transmission model BYD5T-14 BYD5T-14-1 BYD5T-14-4 BYD5T-14-1A BYD5T-14-4A BYD5T-14-5A

Vehicle speed sensor Available Available Unavailable Available Unavailable Available

Neutral switch Unavailable Available Available Available Available Unavailable

Front casing

Rear casing

5T14-1701411 5T14-1701411 5T14-4-1701411 5T14-1701411 5T14-4-1701411 5T14-1701411

5T14-1701412 5T14-1-1701412 5T14-1-1701412 5T14-1-1701412 5T14-1-1701412 5T14-1701412

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Disassembly diagram of rear casing

(1) (2) (3) (4) (5) (6) (7) (8)

Check bolt (22 Nm) Check spring Steel ball 12 mm flat washer Drain plug (39 Nm) 14 mm flat washer Sealing plug (25 Nm) Hexagon flange bolt M8×40 (25 Nm) (9) Bolt M8 × 45 (25 Nm) (10) Mounting support for high pressure steel pipe of clutch (11) Mounting support for oil tube of separation pump (12) Hexagon flange bolt M6×8 (10 Nm) (13) Oil deflector 1

(14) 72 mm washer (15) Drainage trough plate (16) 80 mm washer (17) Reversing light switch gasket (18) Reversing light switch assembly (30 Nm) (19) Hexagon flange bolt M6×20 (10 Nm) (20) Manual gear shift assembly (21) Cylindrical pin (22) 20 mm flat washer (23) Oil filler plug (45 Nm) (24) Differential left oil seal (25) Neutral switch assembly (35 Nm) (Note: Applicable for transmissions with neutral switch assembly)

Note: BYD5T-14-5A transmission has all the above components except the neutral switch assembly Note: Prop up the transmission front casing with two wood blocks thick enough to prevent the main shaft from hitting the service stand.

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3.1.1 Remove the neutral switch assembly (A) (Note: Applicable for transmissions with neutral switch assembly)

3.1.2 Remove the check bolt (A), 12 mm flat washer, check spring, steel ball and reversing light switch assembly (B).

3.1.5 Remove the hexagon flange bolts M8 × 40 (A), mounting support for the high pressure steel pipe of clutch (B) and hexagon flange bolts M8 × 45 (C) alternatively.

3.1.3 Remove the manual gear shift assembly (A) and the cylindrical pin (B).

3.1.4 Remove the drain plug, 14 mm flat washer (A), oil filler plug, 20 mm flat washer (B) and vehicle speed sensor (C). Check if the O-ring (D) is broken, and replace it when necessary.

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3.1.5.1 Remove the sealing plug (A).

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3.1.5.5 Remove the reverse shifting fork assembly.

3.1.5.2 Open the counter shaft circlip (B) with the circlip pliers, and then remove it from the groove.

3.1.5.6 Remove the reverse gear lock cam assembly. 3.1.5.3 Remove the transmission rear casing (C) and positioning pin (D).

3.1.5.4 Remove the idler gear assembly (A) and reverse gear shaft (B).

3.1.5.7 Wrap the main shaft spline with the tape, and then remove the main shaft assembly (A), counter shaft assembly (B) and gear shifting fork assembly (C) from the front casing.

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3.2 Inspection of reverse gear shaft fork clearance

3.1.5.8 Remove the fork shaft screw (E) and 8 mm spring washer (F). 3.1.5.9 Remove the differential assembly (A) and magnet (B).

3.2.1 Measure the clearance between the reverse gear shaft fork assembly (B) and the idler gear assembly (A) with the feeler gauge (C). If the clearance exceeds the repair limit, go to step 2. Standard: 1.50-1.90 mm Repair limit: 2.10 mm

3.2.2 Measure the clearance of the reverse gear shaft fork. 3.1.5.10 Remove the drainage trough plate (A), oil deflector 1 (M) and 72 mm washer (B).

3.2.3 If the clearance does not meet the standard, replace with a new reverse gear shaft fork assembly. 3.2.4 If the clearance meets the standard, replace with a new idler gear assembly.

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3.3.2 Measure the shift lever assembly groove. 3.3.2.1 If the clearance does not meet the standard, replace with a new shift lever assembly. 3.3.2.2 If the clearance meets the standard, replace with a new select lever assembly. Standard: 13.00-13.15 mm

Standard: 13.5-13.8 mm

3.3 Inspection of shift lever clearance 3.3.1 Measure the clearance between the shift lever assembly (A) and the select lever assembly (B) with a feeler gauge (C). If the clearance exceeds the repair limit, go to step 2. Standard: 0.05-0.30 mm Repair limit: 0.50 mm

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3.4 Disassembly and reassembly of manual gear shift assembly Before the reassembly, wash all the parts with solvent, and then apply lithium grease for all the contact surfaces (A, B, C and D) after they are dry.

10 Nm

Vent pipe assembly

Gear shifting arm cover

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3.5 Disassembly and reassembly of manual gear shift assembly (Note: Applicable for transmissions with neutral switch assembly) Before the reassembly, wash all the parts with solvent, and then apply lithium grease for all the contact surfaces (A, B, C and D) after they are dry.

Hexagon flange bolt 10 Nm Dust cover Gear shifting shaft seal

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3.6 Inspection of gear shifting fork clearance Note: Replace the synchronizer hub if the synchronizer gear sleeve is to be replaced. 3.6.1 Measure the clearance between the gear shifting fork (A) and its synchronizer gear sleeves (B). If the clearance exceeds the repair limit, go to step 2. Standard: 0.40-0.7 mm Repair limit: 1.0 mm

3.6.3 Measure the clearance between gear shifting fork (A) and the shift lever fork head (B). If the clearance exceeds the repair limit, go to step 2. Standard: 0.2-0.5 mm Repair limit: 0.62 mm

3.6.4 Measure the width of the shift lever fork head. 3.6.2 Measure the thickness of the gear shifting fork head. 3.6.2.1 If the thickness does not meet the standard, replace with a new gear shifting fork. 3.6.2.2 If the thickness meets the standard, replace with a new synchronizer gear sleeve.

3.6.4.1 If the width does not meet the standard, replace with a new shift lever fork. 3.6.4.2 If the width meets the standard, replace with a new gear shifting fork. Standard: 12.9-13.0 mm

Standard: 1/2/3/4 gear shifting fork: 7.4-7.6 mm 5 gear shifting fork: 6.7-6.9 mm

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3.7 Disassembly and reassembly of gear shifting fork Before the reassembly, wash all the parts with solvents, and then apply lithium grease on all the contact surfaces after they are dry.

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3.8 Inspection of main shaft assembly clearance Note: Replace the synchronizer hub if the synchronizer gear sleeve is to be replaced. 3.8.1 Prop up the bearing inner race with a proper tube seat (A), and then push it down to the main shaft (B).

3.8.4 Measure the clearance between the 4th gear (A) and the distance ring (B) with a dial gage (C). If the clearance exceeds the repair limit, go to step 5. Standard: 0.10-0.25 mm Repair limit: 0.40 mm

3.8.2 Measure the clearance between the 2nd gear and the 3rd gear with a feeler gauge (E). 3.8.2.1 If the clearance exceeds the repair limit, go to step 3.

3.8.5 Measure the distance  on the distance ring.

3.8.2.2 If the clearance meets the repair limit, go to step 4. Standard: 0.10-0.25 mm Repair Limit: 0.40 mm

3.8.5.1 If the distance  does not meet the standard, replace with a new distance ring.

3.8.3 Measure the thickness of 3rd gear

3.8.5.2 If distance  meets the standard, go to step 6. Standard: 24.03-24.08 mm

3.8.3.1 If the thickness of 3rd gear is less than the repair limit, replace with a new 3rd gear. 3.8.3.2 If the thickness of 3rd gear meets the repair limit, replace with a new 3rd / 4th gear synchronizer hub. Standard: 27.85-27.90 mm Repair limit: 27.78 mm

3.8.6 Measure the thickness of 4th gear. 3.8.6.1 If the thickness is less than the repair limit, replace with a new 4th gear. 3.8.6.2 If the thickness meets the repair limit, then replace with a new 3rd / 4th gear synchronizer hub.

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Standard: 26.88-26.93 mm Repair limit: 26.81 mm

3.8.9 Measure the thickness of 5th gear.

3.8.7 Measure the distance between the distance ring (A) and the 5th gear (B) with a dial gage (C). If the distance exceeds the repair limit, go to step 8. Standard: 0.10-0.25 mm Repair limit: 0.40 mm

3.8.9.1 If the thickness is less than the repair limit, replace with a new 5th gear. 3.8.9.2 If the thickness meets the repair limit, replace with a new 5th gear synchronizer hub. Standard: 28.88-28.93 mm Repair limit: 28.81 mm

3.8.10 Measure the thickness of distance ring. If the thickness does not meet the standard, replace with a new distance ring. Standard: 12-12.05 mm 3.8.8 Measure the distance  on the distance ring. 3.8.8.1 If the distance  does not meet the standard, replace with a new distance ring. 3.8.8.2 If the distance  meets the standard, go to step 9. Standard: 24.03-24.08 mm

3.9 Disassembly of main shaft 3.9.1 Remove the deep groove ball bearing, conical ring, main shaft distance ring, reverse gear synchronizer ring and 5th gear synchronizer gear sleeve. 3.9.2 Prop up the 5th gear (A) on a steel block, and then press out the main shaft from the 5th gear synchronizer hub (B) as a puller may damage the gear tooth.

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A (Mounting surface of deep groove ball bearing): 26.002-26.015 mm B (Mounting surface of the 3rd/4th gear distance ring): 29.008-29.021 mm C (Mounting surface of needle bearing): 34.975-34.991 mm D (Mounting surface of deep groove ball bearing): 26.002-26.015 mm E (Guiding shaft): 14.81-14.85 mm 3.9.3 Prop up the 3rd gear (A) on a steel block, and then press out the main shaft from the 3rd/4th gear synchronizer hub (B) as a puller may damage the gear tooth.

Repair limit: A: 25.95 mm B: 28.95 mm C: 34.92 mm D: 25.95 mm

3.10.2 Prop up both ends of the main shaft to inspect its circular run-out data. Rotate the main shaft 2 turns during measurement. If the data exceeds the repair limit, replace with a new main shaft. Standard: Max. 0.02 mm Repair limit: 0.05 mm

3.10

Inspection of main shaft

3.10.1 Inspect the gear surface and the bearing surface for any wear or damage, and then measure the main shaft at points A, B,C, D and E. If any part of the main shaft is less than the repair limit (except point (E)), replace with a new main shaft. Standard:

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3.11 Reassembly of main shaft Disassembly diagram

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3.12 Inspection of counter shaft assembly clearance 3.12.1 Measure the clearance between the 1st gear (A) and the counter shaft (B) with a feeler gauge (C). If the clearance exceeds the repair limit, go to step 2. Standard: 0.20-0.34 mm Repair limit: 0.46 mm 2.12.3 Measure the thickness of distance ring. 2.12.3.1 If the thickness is less than the repair limit, replace with a new distance ring. 2.12.3.2 If the thickness meets the repair limit, go to step 5.

3.12.2 Measure the thickness of 1st gear.

Standard: 27.5-27.56 mm Repair limit: 27.45 mm

3.12.2.1 If the thickness of 1st gear is less than the repair limit, replace with a new 1st gear. 3.12.2.2 If the thickness of 1st gear meets the repair limit, replace with a new 1st/2nd synchronizer hub. Standard: 26.84-26.9 mm Repair limit: 26.79 mm

3.12.4 Measure the thickness of 2nd gear. 3.12.4.1 If the thickness of 2nd gear is less than the repair limit, replace with a new 2nd gear. 3.12.4.2 If the thickness of 2nd gear exceeds the repair limit, replace with a new 1st/2nd synchronizer hub.

3.12.2.3 Measure the clearance between the 2nd gear (A) and the 3rd gear (B) with a feeler gauge (C). If the clearance exceeds the repair limit, go to step 4.

Standard: 27.21-27.3 mm Repair limit: 27.18 mm

Standard: 0.20-0.35 mm Repair limit: 0.47 mm

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3.13 Disassembly of counter shaft 3.13.1 Clamp the counter shaft assembly to the vise firmly with a wood block.

3.13.5 Prop up the 4th gear (A) on a steel block (B), then press out the counter shaft (E) from the 4th gear using the press (C) and accessory (D).

3.13.2 Use the chisel (A) to pry the lock nut lug (B) from the counter shaft groove. 3.13.3 Remove the lock nut (left-handed thread) (A) and the spring washer (B).

3.13.6 Prop up the 3rd gear (A) on a steel block (B), and then press out the counter shaft (E) from the 3rd gear using the press (C) and accessory (D).

3.13.4 Prop up the 5th gear (A) on a steel block (B), and then press out the counter shaft (E) from the ball bearing (F) using the press (C) and accessory (D).

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3.14 Inspection of counter shaft 3.14.1 Inspect the gear surface and the bearing surface for wear or damage, and then measure the counter shaft at points A, B and C. If any part of the counter shaft is less than the repair limit, replace with a new counter shaft. Standard: A (Ball bearing surface): 24.992-25 mm B (Needle bearing surface): 37.989-38 mm C (Needle bearing surface): 33.995-34.011 mm

3.14.2 Prop up both ends of the counter shaft to inspect its run-outs. Rotate the counter shaft for 2 turns during measurement. If the run-out exceeds the repair limit, replace with a new counter shaft. Standard: Max. 0.02 mm Repair limit: 0.05 mm

Repair limit: A: 24.942 mm B: 37.939 mm C: 33.945 mm

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3.15 Reassembly of counter shaft Disassembly diagram Counter shaft distance ring

1st/2nd gear synchronizer hub

1 st gear

Needle bearing

Needle bearing

Note: Refer to the disassembly diagram if necessary when performing the following steps.

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3.15.1 Before the reassembly, wash all the parts with solvents, and apply lithium grease on all contact surfaces after they are dry. 3.15.2 Install the needle bearing (A), 1st gear of counter shaft (B) and 1st gear shock absorber of counter shaft (C) onto the counter shaft. 3.15.3 Install the 1st gear synchronizer ring (D) and the 1st/2nd gear synchronizer spring (E) onto the counter shaft. 3.15.6 Align the needle (C) on the 2nd gear shock absorber of counter shaft with the groove (D) on the 1st/2nd gear synchronizer hub, and then install the distance ring (A) and the 2nd gear shock absorber of counter shaft (B).

3.15.4 Align the needle (A) on the 1st gear shock absorber of counter shaft with the groove (B) on the 1st/2nd gear synchronizer hub, and then install the 1st/2nd gear synchronizer hub onto the counter shaft. 3.15.7 Install the needle bearing (A) and 2nd gear (B).

3.15.5 Install the 1st/2nd gear synchronizer gear sleeve (A), 2nd gear synchronizer spring (B) and 2nd gear synchronizer ring (C) onto the counter shaft.

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3.15.8 Install the 3rd gear (A) with special tools and the press (B).

3.15.11 Install 5225 cylindrical roller bearing (A) with special tools and the press (B).

3.15.9 Install the 4th gear (A) with special tools and the press (B).

3.15.10 Install the 5th gear (A) with special tools and the press (B).

3.15.12 Install the deep groove ball bearing (A) with special tools and the press (B).

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3.16.1 Check the gear teeth on all the synchronizer hubs and gear sleeves for any round corner, which is a sign of wear. 3.16.2 Install the synchronizer hub (A) into the synchronizer gear sleeve (B), and check if it can move freely. Make sure 3 sets of long teeth (C) (with an interval angle of 120º) on the synchronizer gear sleeve fit well with the groove (D) on the synchronizer hub. Do not install the long teeth into the slot (E) on the synchronizer hub when installing the synchronizer gear sleeve, as the spring coil may be damaged.

3.15.13 Install 22 mm spring washer (A) and lock nut (B) (left-handed thread).

Note: Replace the synchronizer hub if the synchronizer gear sleeve is to be replaced.

3.15.14 Clamp the counter shaft assembly to the vise firmly with a wood block. 3.15.15 Tighten the new lock nut to 110 Nm, loosen it and then tighten it again to the same torque. Put the lug of lock nut into the groove.

3.16 Inspection of synchronizer gear sleeve and gear hub

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3.17 Inspection of synchronizer ring and gear 3.17.1 Inspect the inside of each synchronizer ring (A) for any wear.

3.17.4 Inspect the stress surface (D) of each gear hub for any wear. 3.17.5 Inspect the conical surface (E) of each gear hub for any wear or roughness. 3.17.6 Inspect the gear teeth on all the gears (F) for any wear, scratch or crack. 3.17.7 Apply oil on the conical surface of each gear (E), and install its synchronizer ring. Rotate the synchronizer ring, and make sure it does not slip. 3.17.8 Measure the clearance between each gear (A) and its synchronizer ring (B) one by one. Push the synchronizer ring against the gear, and then measure the clearance. If the measured value is less than the repair limit, replace the synchronizer ring and the gear. Clearance between the synchronizer ring and gear Standard: 0.85-1.10 mm Repair limit: 0.4 mm

Illustration of synchronizer ring gear teeth

Good

Worn

Illustration of synchronizer gear sleeve and gear teeth

Good

Worn

3.17.2 Inspect the teeth (B) of each synchronizer ring for any wear (round corner). 3.17.3 Inspect the teeth (C) of each synchronizer gear sleeve and the mating teeth on each gear for any wear (round corner).

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3.18 Replacement of main shaft bearing and oil seal 3.18.1 Remove the differential assembly. 3.18.2 Remove the deep groove ball bearing (A) from the front casing (B) with special tools.

3.18.5 Tap the new bearing into the transmission casing from the side with special tools.

3.18.3 Remove the oil seal (A). Be careful not to damage the casing while removing the oil seal.

3.18.4 Tap the new oil seal into the transmission casing from the side with special tools.

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3.19 Replacement of counter shaft bearing 3.19.1 Remove the cylindrical roller (A) and then remove the engine oil deflector 2 (C) with special tools.

3.20.2 Select a proper 72 mm adjusting shim from the following table. Use the measurement results in step 1 (See the following examples).

3.20 Adjustment of main shaft meshing clearance 3.20.1 Measure the height (A) from the contact surface of front casing to 72 mm deep groove ball bearing on the main shaft, and then measure the depth (B) from the contact surface of rear casing to the mounting hole of 72 mm deep groove ball bearing on the main shaft. Make sure the proper clearance is left.

Marker A B C D E F G H I J K L M

Thickness 0.60 mm 0.65 mm 0.70 mm 0.75 mm 0.80 mm 0.85 mm 0.90 mm 0.95 mm 1.00 mm 1.05 mm 1.10 mm 1.15 mm 1.20 mm

Marker N O P Q R S T U V W X Y -

Thickness 1.25 mm 1.30 mm 1.35 mm 1.40 mm 1.45 mm 1.50 mm 1.55 mm 1.60 mm 1.65 mm 1.70 mm 1.75 mm 1.80 mm -

Basic formula: B-A-(0.10-0.18) = Gasket thickness 3.20.3 Install the selected 72 mm adjusting shim (A) and oil deflector 1 onto the rear casing (B).

Standard: 0.10-0.18 mm

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3.21 Reassembly of transmission Note: Before the reassembly, wash all the parts with solvents, and apply lithium grease on all contact surfaces after they are dry.

BYD Suri Maintenance & Repair Manual

3.21.4 Install the reverse gear lock cam assembly, and then apply sealant on the threads of the mounting bolts. 15 Nm

3.21.1 Install the magnet (A) and differential assembly (B).

3.21.5 Install the reverse gear shaft fork assembly, and then apply sealant on the threads of the mounting bolts. 15 Nm

3.21.2 Install 8 mm spring washer (A) and fork shaft screw (B).

3.21.6 Install the idler gear assembly (A) and reverse gear shaft (B).

3.21.3 Wrap the main shaft spline (C) with the adhesive tape, and then install the main shaft and counter shaft (E) onto the gear shifting fork assembly as an assembly.

3.21.7 Select the proper 72 mm washer (A) according to the measured value in the section "Adjustment of main shaft meshing

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clearance". Install the drainage trough plate (B), engine oil deflector 1 (M) and 72 mm washer onto the transmission rear casing.

3.21.10 Open the counter shaft circlip (B) with circlip pliers, clamp it in the groove of the counter shaft bearing and verify the condition.

3.21.8 Remove the oil strain on the contact surface of the transmission box. Apply sealant on the contact surface, and make sure the perimeter of the bolt hole has been sealed to avoid oil leakage. Note: If the parts are not installed within 5 minutes after the sealant was applied, the sealant must be applied again. Fill the oil in the transmission only when the sealant is dried for at least 20 minutes after the parts are assembled.

3.21.11 Install the positioning pin (A).

Sealant

3.21.9 Apply sealant on the threads of the sealing plug (25 Nm) (A), and then install it onto the transmission rear casing.

3.21.12 Install the hexagon flange bolt (A) M8 × 40 (25 Nm), high pressure steel pipe mounting bracket of clutch (B) and hexagon flange bolt (C) M8 × 45 (25 Nm).

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3.21.13 Install the cylindrical pin (A) and manual gear shift assembly (B).

10 Nm

C

3.21.13 Tighten the lock bolts alternatively. 3.21.14 Install the check bolt (A) (22 Nm), 12 mm flat washer, check spring, steel ball and reversing light switch assembly (B) (30 Nm).

3.21-14 Remove the oil strain on the contact surface of the gear shifting arm cover, and then apply sealant. (The width of the sealant should be 2.5 mm±0.5 mm)

3.21.15 Install the neutral switch assembly (A) (35 Nm). (Note: Applicable for transmissions with neutral switch assembly)

Sealant

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3.21.16 Install the drain plug, 14 mm flat washer (A), oil filler plug, 20 mm flat washer (B) and vehicle speed sensor (C). Check if the O-ring (D) is broken, and replace it when necessary.

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Section 4 Differential 4.1 Disassembly of differential Disassembly diagram of differential

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4.2 Inspection of backlash 4.2.1 Put the differential assembly on a V-block, with half shaft installed on both ends.

4.4 Replacement of differential housing/vehicle speed sensor driving gear 4.4 1 Check if the differential bearing is worn abnormally and if it can rotate freely. The bearing is in good condition if it can rotate freely and there is no abnormal wear. 4.4.2 Remove the left and right bearings of the differential from the differential housing with the puller and bearing extractor.

4.2.2 Measure the backlash with a dial gage while putting the gauge outfit on the tooth surface of the planetary gear. Replace the fault parts if the backlash does not meet the following standard. Standard: 0.05 mm - 0.25 mm.

4.3 Removal and Installation of final drive driven gear 4.3.1 Remove the differential bolts alternatively in several steps, and then remove final drive driven gear from the differential housing. 4.4.3 Remove and install the driving gear of the vehicle speed sensor.

4.3.2 Install the final drive driven gear with the bore upper chamfer facing the differential housing, and tighten the bolts alternatively in several steps. Tightening torque for the differential bolts: 100 Nm.

Note: Using the special tools, install the left and right bearings of the differential with the bearing dust cover facing outwards.

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4.5 Replacement of differential oil seal 4.5.1 Remove the differential assembly.

4.5.4 Install the new oil seal to the transmission casing with special tools.

4.5.2 Remove the left oil seal of differential from the transmission rear casing;

4.5.3 Remove the right oil seal of differential from the transmission front casing.

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4.6 Replacement of differential adjusting shim If the differential housing, transmission front casing or transmission rear casing is replaced when servicing, a new 80 mm adjusting shim should be selected. 4.6.1 Install the differential assembly into the front casing.

4.6.4 Measure the clearance between the end face of the differential left bearing and the rear casing with a feeler gauge, then select an 80 mm adjusting shim with the proper thickness based on the measurement result. Make sure to leave a proper clearance between the adjusting shim and outer ring of the differential left bearing.

4.6.2 Close the transmission rear casing, and tighten the assembly bolts around the differential alternatively in several steps.

Select a proper gasket from the following table. Standard clearance: 0 mm - 0.10 mm

Tightening torque: 25 Nm

4.6.3 Tap the differential assembly gently with the special tool, and make sure the differential assembly is properly installed in the front casing.

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Adjust the gasket thickness:

K

1.20 mm

L

1.25 mm

M

1.30 mm

N

1.35 mm

O

1.40 mm

P

1.45 mm

Q

1.50 mm

-

-

Marker

Thickness

Marker

Thickness

A

0.70 mm

B

0.75 mm

C

0.80 mm

D

0.85 mm

E

0.90 mm

F

0.95 mm

G

1.00 mm

H

1.05 mm

I

1.10 mm

J

1.15 mm

4.6.5 Remove and install the bolts and transmission rear casing. 4.6.6 Reinstall the transmission.

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Chapter 4 6T25 Manual Transmission Contents

Section 1 Introduction of Transmission ................................................................................. 171 1.1 Structural Parameters ............................................................................................ 171 1.2 Service Guidelines................................................................................................. 172 1.3 General Requirements .......................................................................................... 172 Section 2 Transmission Operating Mechanism .................................................................... 175 2.1 Introduction of Manual Gear Shift Assembly ......................................................... 175 2.2 Service of Manual Gear Shift Assembly ................................................................ 175 2.3 Installation of Manual Gear shift Assembly ........................................................... 176 2.4 Introduction of Gear Shifting Fork Shaft Assembly ............................................... 178 2.5 Gear Shifting Fork Shaft Assemblies for Each Gear ............................................. 178 Section 3 Transmission mechanism ..................................................................................... 179 3.1 Transmission Sketch ............................................................................................. 179 3.2 Disassembly and Assembly of Main Shaft Components....................................... 179 3.3 Disassembly and Assembly of Counter Shaft 1 Components .............................. 180 3.4 Disassembly, Inspection and Assembly of Counter Shaft 2 Components ............ 185 3.5 Disassembly and Assembly of Differential Components....................................... 190 Section 4 Transmission Assembly ........................................................................................ 193 4.1 Construction of Transmission Assembly ............................................................... 193 4.2 Disassembly of Transmission Assembly ............................................................... 194 4.3 Service of Transmission Assembly ........................................................................ 196 4.4 Assembly of Transmission Assembly .................................................................... 200

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Section 1 Introduction of Transmission 1.1 Structural Parameters Transmission model Applicable Engine Model Type Overall Length (mm) Overall dimensions (length×width×height) (mm) Maximum input torque ( Nm) Classification

Gear Oil

Volume (L) Weight (excluding clutch) (kg) Transmission model

BYD6T25/BYD6T25-1A BYD488QA/BYD476ZQA 6-gear MT 375 375×510×490 250 80W-90 (For summer in northern China), 75W-90 (For winter in northern China) 3.0 52 BYD6T25-1A

Gear

1st gear

Gear ratio Drive ratio Final drive gear ratio Final drive ratio Total drive ratio

49/13 3.769

2nd gear 48/23 2.087

3rd gear 45/34 1.324

4th gear 42/43 0.977

5th gear

6th gear

Reverse gear

39/40 0.975

35/43 0.814

36/13×23/14 4.549

72/17 15.962

72/22

4.235 8.838 5.607

Transmission model

4.138

3.191

3.273 2.664

14.89

BYD6T25

Gear

1st gear

Gear ratio Drive ratio Final drive gear ratio Final drive ratio Total drive ratio

47/13 3.615

2nd gear 48/22 2.182

3rd gear 47/32 1.469

4th gear 46/40 1.150

5th gear

6th gear

Reverse gear

43/36 1.194

39/40 0.975

34/13×23/14 4.297

71/18 14.258

3.944 8.606 5.794

71/23 4.536

3.686

3.087 3.01

13.265

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1.2 Service Guidelines

Clean the joint surface of the box thoroughly and apply sealant.

1.2.1 Prepare the parts kit and parts rack in advance to store the removed and disassembled components. Put them in order and make markers if necessary to avoid confusion and misplacement. 1.2.2 Be careful when positioning the aluminum alloy parts to avoid damage to the machined surface. 1.2.3 Prepare sufficient auxiliary materials for use in the process of servicing. 1.2.4 For the bolts and other fastening parts with standard tightening torque requirements, tighten them with special tools in accordance with the required values. 1.2.5 After servicing, disposable supplies should be scrapped and replaced with new ones. 1.2.6 Use correct removal tools for disassembly and assembly. 1.2.7 Refer to this service manual as much as possible during work. 1.2.8 Refer to the structural sketch of the transmission when necessary. 1.2.9 If you encounter any difficult technical problems during servicing, it is recommended to consult our aftersales technical service department.

1.3 General Requirements 1.3.1 Oil seal and seal ring The oil seal is a disposable product which should be replaced after removal. Before installation, thoroughly clean the mounting surface of the oil seal. Before installing the oil seal, check each part for crack, scratch and notch. If so, the oil seal cannot be used. The new oil seal lip contains grease which should not be coated again. Before removing and installing the part with a seal ring, check if the seal ring still functions. If not, replace it. 1.3.2 Sealant

The flange sealant should be applied uniformly and continuously so that it can fully fill the sealing strip. It is recommended that the sealant diameter is between 2 mm~3 mm. There should be no sealant in the threaded hole, ventilation hole or on the positioning pin. 1.3.3 Circlip The circlip is a disposable product which should be replaced after removal. Select the thickest circlip that can be fitted into the circlip groove. 1.3.4 Nut and bolt 1.3.4.1 Loosen or tighten the bolts or nuts on the transmission diagonally. 1.3.4.2 Tighten the bolts or nuts in accordance with the specified tightening torque. 1.3.4.3 For all the threaded holes with sealant, remove the residues from the holes with a thread tap before using them again. 1.3.5 Bearing 1.3.5 There is no need to lubricate the new bearings if they are supplied as a complete set. 1.3.5.2 The bearings on the same shaft must be replaced together and the bearings from the same supplier should be used. 1.3.5.3 The inner ring and outer ring of conical bearing must be used in sets and cannot be exchanged. 1.3.6 Adjusting shim 1.3.6.1 Measure the adjusting shim at several positions with a micrometer and take the average as the thickness of the adjusting shim. 1.3.6.2 Check for any burr or damage. 1.3.6.3 Only install the adjusting shims without defects. 1.3.7 Synchronizer ring 1.3.7.1 The removed synchronizer ring

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components should be placed in sets and installed in the original positions on the synchromesh gear when reused.

oil.

1.3.7.2 Check if the conical surface of the synchronizer ring is worn and replace it when necessary. 1.3.7.3 The coating of the synchronizer ring should not be damaged.

1.3.8 Gear 1.3.8.1 Before installation, clean the gears to check for any sign of collision or defect. 1.3.8.2 After assembly, check the gear clearance and if the gear can rotate freely. 1.3.9 Auxiliary materials

1.3.7.4 Before installation, lubricate the conical surface of the synchronizer ring with gear

The materials should be prepared for use at any time.

Auxiliary Material Table 1: Fitting Position

Front box assembly

Rear box assembly

Manual gear shift assembly

Grease application area

Model or specification

Inner lip and outer ring of main shaft oil seal Inner lip and outer ring of differential oil seal Inner and outer rings of gear shifting shaft sleeve Counter shaft 1 front bearing outer ring Counter shaft 2 front bearing outer ring Differential bearing outer ring Inner lip and outer ring of differential oil seal Inner and outer rings of gear shifting shaft sleeve Counter shaft rear bearing outer ring Differential bearing outer ring Inner and outer rings of shift lever oil seal Shift lever shaft sleeve Select lever bearing Mating surface of gear shifting bracket assembly and gear selecting fork head

No.2 lithium grease (GB/T 7324-1984 General lithium grease) or verified equivalent

Auxiliary Material Table 2:

Part name Gear shifting arm cover Front box Gear shifting steel ball assembly Drain plug assembly Neutral switch

Sealant application area Inside of the sealing surface edge Inside of the sealing surface edge Bolt threads Drain plug threads Neutral switch threads

Name, brand or specification of the sealant Flange sealant (Loctite 587 or verified equivalent) Thread sealant (Loctite 567 or verified equivalent)

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1.3.10 The transmission fasteners should be tightened to the specified tightening torque as follows. Tightening torque table:

Part Hexagon flange bolt Drain plug assembly Reversing light switch assembly Gear shifting steel ball assembly Release bearing assembly mounting bolts Neutral switch Hex nut Assembly bolt Stud bolt Hexagon flange bolt Hexagonal head bolt and spring washer assembly Hexagonal head bolt and spring washer assembly

Bolt size

Part No./International Standard No.

Quantity per unit

Tightening torque (Nm)

M8×25

Q1840825T1F6

2

20

M18×1.5

BYD6T25-1701680

2

30

M12×1.5

BYD6T25-4113010

1

35

M27×1.5

BYD6T25-1701620

1

45

M7×1

BYD6T25-1601111

3

15

M18×1.5 M8 M8×1.5 M12×1.25

BYD5T19-1-3781100 GB/T 41 BYD6T25-1701601 BYD6T25-1701604

1 1 20 3

35 23 40 35

M6×20

Q1840620T1F3

1

15

M8×20

Q1420820T1F6

1

20

M8×25

Q1420825T1F6

1

20

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Section 2 Transmission Operating Mechanism 2.1 Introduction of Manual Gear Shift Assembly 2.1.1 Shift lever assembly 2.1.2 Gear shifting arm cover The select lever shaft sleeve on the gear shifting arm cover should not be removed. It must be replaced together with the gear shifting arm cover. 2.1.3 Split washer It is a disposable product which should be replaced with new parts after removal. 2.1.4 Gear selecting bracket assembly 2.1.5 Gear selecting fork head 2.1.6 Hex nut Tightening torque: 18 Nm 2.1.7 Spring washer 2.1.8 Flat washer 2.1.9 Gear shifting bracket assembly 2.1.10 Vent pipe cap 2.1.11 Vent pipe The vent pipe assembly should not be blocked. During installation, align the flat key opening. Note: The parts in the dotted box as shown in the right figure should not be further disassembled.

2.2 Service of Manual Gear Shift Assembly 2.2.1 Check if the gear shifting shaft (a) on the shift lever assembly 1 is worn. 2.2.2 Check the gear shifting oil seal press-fitted in the gear shifting arm cover 2 for oil leakage or abnormal wear. Replace it if there is any abnormity. Note: The shift lever assembly 1 and the gear shifting arm cover 2 cannot be separated. They must be replaced as a whole when necessary.

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2.2.3 Check if the gear shifting fork head 5 can slide freely when fitted with the gear selecting bracket assembly 4 and gear shifting assembly 9. The No.2 lithium grease (GB/T 7324-1994 General lithium grease) or verified equivalent should be applied on the gear selecting fork head 5 to ensure it can slide freely. Replace the gear shifting fork head 5 if aging, breakage or plastic deformation occurs.

BYD Suri Maintenance & Repair Manual

2.3 Installation of Manual Gear shift Assembly 2.3.1 Install the vent pipe and vent pipe cap Tap the vent pipe 3 gently into the gear shifting arm cover 2 with a tool and install the vent pipe cap 4. Note: The shift lever assembly 1 and the gear shifting arm cover 2 cannot be separated. They must be replaced as a whole when necessary.

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2.3.2 Install the gear selecting bracket assembly 4 and gear selecting fork head 5. Note: The No.2 lithium grease (GB/T 7324-1994 General lithium grease) or verified equivalent should be applied on the gear selecting fork head 5. The split washer 3 is a disposable product which should be replaced with a new part after removal.

BYD Suri Maintenance & Repair Manual

2.3.3 Install the gear shifting bracket assembly, flat washer, spring washer and hex nut in turns to finish installation of the manual gear shift assembly. Note: The tightening torque for the hex nut is 18 Nm.

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2.4 Introduction of Gear Shifting Fork Shaft Assembly The gear shifting fork shaft assemblies for each gear are installed on the shaft as shown in the right figure: 1 2 3 4 5 6 7 8 9 10 11 12

Counter shaft 1 assembly 1st/2nd gear shifting fork shaft assembly 3rd/4th gear shifting fork shaft assembly Counter shaft 2 assembly 5th/6th gear shifting fork shaft assembly Reverse gear shafting fork assembly Main shaft assembly Reverse shaft assembly End bearing stopper plate T-tube assembly Front box Differential assembly

2.5 Gear Shifting Fork Shaft Assemblies for Each Gear A B C D 1 2

3rd/4th gear shifting fork shaft assembly 5th/6th gear shifting fork shaft assembly 1st/2nd gear shifting fork shaft assembly Reverse gear shafting fork assembly Vibration damper Linear bearing Note: The gear shifting fork shaft assemblies for each gear should not be further disassembled.

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Section 3 Transmission mechanism 3.1 Transmission Sketch 1 2 3 4 5 6 7 8 9 10 11 12 13

Reverse idler gear shaft assembly Counter shaft 2 assembly Main shaft assembly Counter shaft 1 assembly Differential assembly Final drive driven gear Counter shaft 2nd gear assembly Counter shaft 1st gear assembly Counter shaft 4th gear assembly Counter shaft 3rd gear assembly Counter shaft 5th gear assembly Counter shaft 6th gear assembly Reverse idler gear 3.2.2 Disassembly of Main Shaft Components 3.2.2.1 Pull out the main shaft rear bearing Remove the main shaft rear bearing circlip. Place the press block and pressure piece on the output shaft before installing the puller. Place the diffuser in the groove of main shaft rear bearing circlip.

3.2 Disassembly and Assembly of Main Shaft Components 3.2.1 Assembly Overview 1 2 3 4 5 6 7 8

Main shaft rear bearing outer circlip Rear box Rear bearing circlip Main shaft rear bearing Main shaft 5th gear Main shaft Main shaft front bearing Front box

3.2.2.2 Press out the main shaft 5th gear to finish the disassembly of main shaft components.

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3.2.2.3 Install the main shaft rear bearing outer circlip Select the proper main shaft rear bearing circlip A. After installation, use a feeler gauge C to measure the clearance between A and B and make sure it is less than 0.05 mm.

3.2.2 Assembly of Main Shaft Components 3.2.2.1 Press out the main shaft 5th gear. The groove in the gear must face upward (indicated by the arrow in the right figure) .

3.3 Disassembly and Assembly of Counter Shaft 1 Components 3.3.1 Assembly Overview of Counter Shaft 1 Components

3.2.2.2 Press in the main shaft rear bearing. The circlip groove should face upward (indicated by A in the right figure). The bearing shoulder should face the main shaft 5th gear (indicated by B in the right figure). Apply the grease before reassembly.

1 2 3 4 5 6. 7. 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Front box Oil deflector Oil guide sleeve Counter shaft 1 front bearing outer ring Counter shaft 1 front bearing Counter shaft 1 1st, 2nd and 4th gear needle bearing Counter shaft 2nd gear assembly 1st and 2nd gear synchronizer inner rings 1st and 2nd gear synchronizer middle steel rings 1st and 2nd gear synchronizer outer rings 1st and 2nd gear synchronizer assembly 1st and 2nd gear synchronizer hub circlips 1st and 2nd gear synchronizer outer rings 1st and 2nd gear synchronizer middle steel rings 1st and 2nd gear synchronizer inner rings 1st, 2nd and 4th gear needle bearings Counter shaft 1st gear assembly Counter shaft 1st gear snap-gauge Counter shaft 1st gear snap-gauge outer ring 1st, 2nd and 4th gear needle bearings Counter shaft 4th gear assembly 4th gear synchronizer ring 3rd and 4th gear synchronizer assembly 3rd/4th gear synchronizer hub circlips

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26 27 28 29 30 31 32 33 34 35

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3rd gear synchronizer outer ring 3rd gear synchronizer middle steel ring 3rd gear synchronizer inner ring 3rd gear needle bearing Counter shaft 3rd gear assembly Counter shaft rear bearing Rear bearing circlip Counter shaft rear bearing outer ring Counter shaft adjusting shim Rear box

3.3.2.4 Remove the 3rd/4th gear synchronizer hub circlip. 3.3.2.5 Use a tool to remove the 3rd/4th synchronizer assembly, counter shaft 4th gear assembly, 4th gear synchronizer ring and 4th gear needle bearing.

3.3.2 Disassembly of Counter Shaft 1 Components 3.3.2.1 Remove the oil guide sleeve.

3.2.6 Remove the counter shaft 1st gear snap-gauge outer ring and counter shaft 1st gear snap-gauge.

3.3.2.2 Remove the bearing circlip at the rear end of the counter shaft.

3.3.2.7 Remove the counter shaft 1st gear assembly.

3.3.2.3 Use a tool to remove the counter shaft rear bearing and remove the counter shaft 3rd gear assembly, 3rd gear needle bearing, 3rd gear synchronizer outer ring, 3rd gear synchronizer middle ring and 3rd gear synchronizer inner ring in turns.

3.3.2.8 Remove 1st/2nd gear synchronizer outer ring C, 1st/2nd gear synchronizer middle steel ring B and 1st/2nd gear synchronizer inner ring A in turns.

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Press the synchronizer ring assembly for each gear onto the corresponding gear cone and measure the clearance a with a feeler gauge. 3.3.2.9 Press out the counter shaft 2nd gear assembly and 1st/2nd gear synchronizer assembly.

Clearance a 1st/2nd gear synchronizer ring assembly 3rd/4th gear synchronizer ring assembly 4th gear synchronizer ring

Standard size

Repair limit

0.75~1.25 mm

0.5 mm

0.75~1.25 mm

0.5 mm

1.0~1.7 mm

0.5 mm

3.3.3.5 Disassemble each gear synchronizer assembly if necessary and check each component for any abnormal wear. 1 Synchronizer spring 2 Slide block 3 Synchronizer gear sleeve 4 Synchronizer hub 3.3.3 Service of Counter Shaft 1 Components 3.3.3.1 Check each component for abnormal wear and damage. 3.3.3.2 Turn each gear and bearing to check for seizure or abnormal noise. 3.3.3.3 Check if each gear synchronizer can be shifted to the corresponding gear position easily. 3.3.3.4 Check the synchronizer ring for wear.

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3.3.3.6 Install the synchronizer assembly. Install the synchronizer gear sleeve to the synchronizer gear hub. Align the gear sleeve with the missing teeth of the gear hub to make sure the slide block can be installed properly. The gear hub and gear sleeve should be installed in the correct direction. Insert the slide block and install the spring at an angle of 120°with the angled end placed into the hollow slide block. The boss in the 1st/2nd gear synchronizer hub should face downward (2nd gear direction). The end with an identification groove in the 1st/2nd synchronizer gear sleeve should face upward (1st gear direction). The boss in the 3rd/4th gear synchronizer hub should face upward (3rd gear direction). The end with an identification groove in the 3rd/4th synchronizer gear sleeve should face upward (4th gear direction).

3.3.4.2 Use a tool to press the 1st/2nd synchronizer assembly into the corresponding position. 3.3.4.3 Install the 1st/2nd gear synchronizer hub circlip of proper thickness. 3.3.4.4 Install the counter shaft 1st gear snap-gauge and snap-gauge outer ring.

3.3.4 Assembly ofCounter Shaft 1 Components 3.3.4.1 Place the counter shaft 2nd gear needle bearing, counter shaft 2nd gear assembly and 1st/2nd gear synchronizer ring assembly in the counter shaft.

3.3.4.5 Install the counter shaft 4th gear needle bearing and counter shaft 4th gear assembly. 3.3.4.6 Install the 4th gear synchronizer ring. 3.3.4.7 Press in the 3rd/4th gear synchronizer assembly. 3.3.4.8 Install the 3rd/4th gear synchronizer hub circlip of proper thickness.

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distance a from the counter shaft 1 rear bearing outer ring to the box joint surface; 3.3.5.2 Use a depth gage to measure the distance a' from the installation position of rear box counter shaft 1 rear bearing outer ring to the box joint surface; 3.3.5.3 The thickness h of rear bearing adjusting shim is calculated as follows:

h  a'a  (0.05～0.1)mm

3.3.4.10 Press in the counter shaft rear bearing.

Select the proper axial pre-tensioning thickness (0.05~0.1 mm), and correct the value h to the nearest shim thickness. For example: If a is 197.10 mm; If a' is 198.40 mm;

3.3.4.11 Select a proper counter shaft rear bearing circlip to finish the assembly of counter shaft 1 components.

0 mm;

3.3.4.9 Install the 3rd gear synchronizer ring assembly.

h  a'a  (0.05～0.1)mm =1.30+0.1=1.4 Therefore, the selected thickness of the counter shaft 2 rear bearing adjusting shim is 1.40 mm.

3.3.5 Selection of Counter Shaft 1 Rear Bearing Adjusting Shim The counter shaft 1 components must be adjusted again if any of the following components are replaced. a b c d e

Front box Rear box Counter shaft 1 rear bearing Counter shaft 1 front bearing Counter shaft 1 The counter shaft 1 assembly adjusting shim is selected as follows:

3.3.5.1 Use a height gauge to measure the

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3.4 Disassembly, Inspection and Assembly of Counter Shaft 2 Components 3.4.1 Assembly Overview of Counter Shaft 2 Components 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

Front box Counter shaft 2 front bearing outer ring Counter shaft 2 front bearing Counter shaft 2 Reverse gear synchronizer hub Reverse gear synchronizer gear sleeve (with reverse gear synchronizer ring) Reverse gear needle bearing Reverse gear assembly Distance ring Distance ring circlip 6th gear needle bearing Counter shaft 6th gear assembly 5th/6th gear synchronizer ring 5th/6th gear synchronizer assembly 5th/6th gear synchronizer hub circlip 5th gear needle bearing 5th/6th gear synchronizer ring Counter shaft 5th gear assembly Counter shaft rear bearing Rear bearing circlip Counter shaft rear bearing outer ring Counter shaft adjusting shim Rear box 5th/6th gear synchronizer spring 5th/6th gear synchronizer gear sleeve 5th/6th gear synchronizer gear hub Synchronizer slide block

3.4.2 Disassembly of Counter Shaft 2 Components 3.4.2.1 Remove the rear bearing circlip. 3.4.2.2 Pull out the counter shaft 2 rear bearing with the combination tools. 3.4.2.3 Remove the counter shaft 5th gear assembly, 5th gear needle bearing and 5th/6th gear synchronizer ring in turns. 3.4.2.4 Remove the 5th/6th gear synchronizer hub circlip.

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3.4.2.5 Clamp the snap-gauge at the bottom of counter shaft 6th gear assembly, and press out the shaft with a pressure lever. Remove the 5th/6th gear synchronizer assembly, 5th/6th gear synchronizer ring and counter shaft 6th gear assembly in turns.

BYD Suri Maintenance & Repair Manual

3.4.2.11 Press out the reverse gear synchronizer hub with the combination tools.

3.4.2.6 Remove the distance ring circlip and distance ring.

3.1.2.12 Pull out the counter shaft 2 front bearing with the tools.

3.4.2.7 Clamp the snap-gauge at the bottom of reverse gear assembly, and press out the shaft with a pressure lever. 3.4.2.8 Remove the reverse gear assembly and reverse gear needle bearing in turns. 3.4.2.9 Remove the reverse gear synchronizer hub circlip. 3.4.2.10 Remove the reverse gear synchronizer gear sleeve.

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3.4.3 Service of Counter Shaft 2 Components 3.4.3.1 Check each component for abnormal wear and damage. 3.4.3.2 Turn each gear and bearing to check for seizure or abnormal noise. 3.4.3.3 Check if each gear synchronizer can be shifted to the corresponding gear position easily. 3.4.3.4 Check the wear condition of 5th/6th gear synchronizer ring. Position the synchronizer ring on the corresponding gear cone horizontally, and rotate it for 2 or 3 turns to make sure the synchronizer ring contact with the gear cone. Using a feeler gauge, measure the clearance a between the synchronizer ring and gear at several positions around the circumference and record the values. Clearance a 5th gear synchronizer ring 6th gear synchronizer ring

Standard size

Repair limit

1.0~1.7 mm

0.5 mm

1.0~1.7 mm

0.5 mm

3.4.3.6 Install the synchronizer assembly. Install the synchronizer gear sleeve on the synchronizer gear hub, and align the synchronizer gear sleeve with the missing teeth of the synchronizer gear hub to make sure the slide block can be installed properly. The synchronizer gear hub and synchronizer gear sleeve should be installed in the correct direction. Insert the slide block and install the spring at an angle of 120°with the angled end placed in the hollow slide block.

3.4.3.5 If necessary, disassemble each gear synchronizer assembly and check each component for any abnormal wear. 1 2 3 4

Synchronizer spring Slide block Synchronizer gear sleeve Synchronizer hub

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3.4.4 Installation of Counter Shaft 2 Components 3.4.4.1 Press in the counter shaft 2 front bearing. 3.4.4.2 Press in the reverse gear synchronizer hub. 3.4.4.3 Install the reverse gear synchronizer gear sleeve, and select and fix the reverse gear synchronizer hub circlip with proper thickness in the circlip groove. 3.4.4.4 Install the reverse gear synchronizer gear sleeve with reverse gear synchronizer ring. 3.4.4.5 Install the reverse gear needle bearing and reverse gear assembly.

3.4.4.10 Press in the 5th/6th gear synchronizer assembly. 3.4.4.11 Select a 5th/6th gear synchronizer hub circlip with proper thickness and fix it in the circlip groove. 3.4.4.12 Install the 5th/6th gear synchronizer ring, 5th/6th gear needle bearing and counter shaft 5th gear assembly in turns.

3.4.4.6 Press in the distance ring. 3.4.4.7 Select a distance ring circlip with proper thickness and fix it in the circlip groove. 3.4.4.8 Install the 6th gear needle bearing and counter shaft 6th gear assembly.

3.4.4.13 Press in the counter shaft rear bearing.

3.4.4.9 Install the 5th/6th gear synchronizer ring.

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3.4.5.2 Using a depth gauge, measure the distance a' from the installation position of rear box counter shaft 2 rear bearing outer ring to the joint surface of the box; 3.4.5.3 The thickness h of the rear bearing adjusting shim is calculated as follows:

h  a'a  (0.05～0.1)mm Select the proper axial pre-tensioning thickness (0.05~0.1 mm), and correct the value h to the nearest shim thickness. 3.4.4.14 Select a rear bearing circlip with proper thickness and fix it in the circlip groove.

For example: If a is 215.50 mm; If a' is 216.98 mm;

h  a'a  (0.05～0.1)mm =1.48+0.05≈1. 55 mm; The selected thickness of the counter shaft 2 rear bearing adjusting shim should be 1.55 mm.

3.4.5 Selection of Counter Shaft 2 Rear Bearing Adjusting Shim The counter shaft 2 components must be adjusted again if any of the following components are replaced.     

Front box Rear box Counter shaft 2 rear bearing Counter shaft 2 front bearing Counter shaft 2 The counter shaft 2 assembly adjusting shim is selected as follows:

3.4.5.1 Using a height gauge, measure the distance a from the counter shaft 2 rear bearing outer ring to the joint surface of the box;

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3.5 Disassembly and Assembly of Differential Components 3.5.1 Assembly Overview of Differential Components

1 2 3 4 5 6 7

Rear box Differential adjusting shim Differential bearing outer ring Differential bearing Final drive driven gear (with differential housing) Differential bearing Differential bearing outer ring

8 9 10 11 12 13 14 15

Differential bearing stopper plate Front box Differential oil seal Differential side gear Differential planetary gear shaft 5X35 carbon steel spring pin Differential planetary gear Differential spherical washer

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3.5.2 Disassembly of Differential Components 3.5.2.1 Remove the differential bearing with the tools.

3.5.2.2 Remove the carbon steel spring pin. Tap it out from the other side with a tool.

BYD Suri Maintenance & Repair Manual

3.5.3.4 Install the differential planetary gear shaft, and make sure to align it with the carbon steel spring pin hole.

3.5.3.5 Using a tool, tap the carbon steel spring pin in place and deform the port to prevent the carbon steel spring pin from dropping out.

3.5.2.3 Take out the differential planetary gear shaft. 3.5.2.4 Rotate 2 differential planetary gears for 180º, and then take out the differential planetary gear and differential side gear in turns. 3.5.2.5 Take out the differential spherical washer. 3.5.3.6 Press the differential bearing in place with a tool to finish the installation of differential components.

3.5.3 Installation of Differential Components 3.5.3.1 Install the differential spherical washer A. Make sure to align the holes of the planetary gear and the side gear. 3.5.3.2 Install 2 differential side gears. 3.5.3.3 Rotate and install 2 differential planetary gears with an angle of 180º.

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3.5.4 Selection of Differential Bearing Adjusting Shim The differential must be adjusted again if any of the following components are replaced. a b c d

Front box Rear box Differential housing Differential bearing The differential adjusting shim must be selected as follows:

3.5.4.1 Using a height gauge, measure the distance a from the differential bearing outer ring to the joint surface of the box; 3.5.4.2 Using a depth gauge, measure the distance a' from the installation position of rear box differential bearing outer ring to the joint surface of the box; 3.5.4.3 The thickness h of the differential bearing adjusting shim is calculated as follows:

h  a'a  (0.05～0.1)mm Select the proper differential assembly pre-tensioning thickness (0.05~0.1 mm), and correct the value h to the nearest shim thickness. For example: If a is 57.74 mm; If a' is 58.80 mm;

h  a'a  (0.05～0.1)mm =1.06+0.7≈1.1 5 mm; The thickness of the differential adjusting shim should be 1.15 mm.

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Section 4 Transmission Assembly 4.1 Construction of Transmission Assembly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Counter shaft 1 assembly 1st/2nd gear shifting fork shaft assembly 3rd/4th gear shifting fork shaft assembly Counter shaft 2 assembly 5th/6th gear shifting fork shaft assembly Reverse shaft fork assembly Main shaft assembly Reverse idler gear shaft assembly End bearing stopper plate T-tube assembly Front box Main shaft oil seal Release bearing unit seal ring Release bearing unit Release bearing assembly mounting bolt Differential assembly

1 2 3 4 5 6 7 8 9 10

Hexagon flange bolt (M6 X 20) Manual gear shift assembly Rear box Assembly bolt Oil plug Main shaft sealing cap Main shaft rear bearing outer circlip Sealing cap Neutral switch Gear selecting steel ball assembly

11 12 13 14

T-tube assembly Front box Release bearing unit Release bearing assembly mounting bolt

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4.2 Disassembly of Transmission Assembly 4.2.1 Remove the sealing cap. The sealing cap is a disposable product and must be replaced before the reassembly. 4.2.2 Remove the neutral switch with a wrench. 4.2.3 Use M22 sleeve to remove the gear selecting steel ball assembly.

4.2.7 Remove the main shaft rear bearing outer circlip with circlip pliers. 4.2.8 Pry out the circlip at the connection of the T-tube assembly and release bearing unit, and then remove the T-tube assembly. 4.2.9 Remove the release bearing assembly mounting bolts and release bearing assembly.

4.2.4 Remove the hexagon flange bolt (M6×20). 4.2.5 Pull out the manual gear shift assembly in direction indicated by the arrow. Note: Make sure each gear shift fork is in the neutral position before pulling out the manual gear shift assembly.

4.2.10 Remove the assembly bolts (20 in total).

4.2.6 Remove the main shaft sealing cap. The main shaft sealing cap is a disposable product and must be replaced before the reassembly.

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Note: The neutral switch assembly A and 1st/2nd lock pin assembly B (unlock) do not interfere with the removal and installation of the manual gear shift assembly and transmission assembly. 4.2.13 Remove the main shaft, counter shaft 1 assembly, counter shaft 2 assembly and reverse shaft assembly. Note: Three persons are needed for quicker removal. The first person presses down the front box with left hand while lifting the main shaft assembly with right hand, and assists the other 2 persons to lift the main shaft assembly in the direction of arrow. The second person holds the counter shaft 1 assembly, 1st/2nd gear shifting fork shaft assembly and 3rd/4th gear shifting fork shaft assembly with both hands, and lifts the counter shaft 1 assembly in the direction of arrow B.

4.2.11 Remove the rear box A in the direction indicated by the arrow. Note: The joint surface of the box is coated with the flange sealant; therefore there may be cohesive force on it during removal. The rear box must be placed upside down and do not damage the joint surface of the box.

The third person holds the reverse shaft assembly and reverse shaft fork assembly with the left hand, holds the counter shaft 2 assembly and 5th/6th gear shifting fork shaft assembly with the right hand, and lifts the counter shaft 2 assembly in the direction of arrow C. 4.2.14 Take out the differential assembly and finish the disassembly of transmission assembly.

4.2.12 Using a tool, remove the neutral switch assembly A and 1st/2nd lock pin assembly B from the rear box.

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4.3 Service of Transmission Assembly 4.3.1 Service of Front Box Accessories

after removal.

4.3.1.1 Service the main shaft front bearing. Grip the main shaft front bearing circlip with pliers, and pull it out together with the main shaft front bearing (with main shaft front bearing circlip) using a pull rod.

Using the pressure lever A, press the new gear shifting shaft sleeve into the front box.

Coat the bearing outer ring with grease before installation. Clamp the main shaft front bearing circlip in the circlip groove before installation. Grip the main shaft front bearing circlip with pliers and slowly press it into the front box with a pressure lever, until the main shaft front bearing circlip opens automatically. 4.3.1.3 Service the end bearing. Pull it out with the combination of pull rods.

4.3.1.2 Service the gear shifting shaft sleeve. Pull it out with the combination of pull rods. The gear shifting shaft sleeve is a disposable product and must be replaced

Press it into the front box with the pressure lever.

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4.3.1.5 Service the differential oil seal and main shaft oil seal. Note: Check the oil seals for oil leakage and abnormal oil seal lip wear. Check if the oil seals are installed in place. The oil seal is a disposable product and must be replaced after removal.

4.3.1.4 Service the counter shaft 1 front bearing outer ring, counter shaft 2 front bearing outer ring and differential bearing outer ring in the front box. Pull them out with the pull rod and check for obvious wear. Note: The shim must be reselected after replacement of the bearing outer ring. Do not mix the counter shaft 1 front bearing outer ring with the counter shaft 2 front bearing outer ring as they have the same appearance. Make markers on them and use them with the corresponding bearing.

4.3.2 Service of Rear Box Accessories 4.3.2.1 Service the 1st/2nd gear lock pin assembly. Remove the angle lever from the 1st/2nd gear lock pin, and pry out the lock pin with a screwdriver. The 1st/2nd gear lock pin assembly is a disposable product and must be replaced before reinstallation.

Press the bearing outer ring into the front box.

Press it into the rear box with a special pressure lever.

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4.3.2.3 Service the gear shifting steel ball assembly. Tap out the gear shifting steel ball assembly with a mandrel.

4.3.2.2 Service the gear shifting shaft sleeve. Pull out the gear shifting shaft sleeve with the pull rod and pressure plate. Press the gear shifting steel ball assembly into the rear box with the special pressure lever. Note: The gear shifting steel ball assembly is a disposable product and must be replaced before reinstallation.

Press the gear shifting shaft sleeve into the rear box with the special tool.

4.3.2.4 Service the shift lever shaft sleeve. Pull out the shift lever shaft sleeve with an inner puller. Coat grease on the out ring of shift lever shaft sleeve before reuse.

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Press in the shift lever shaft sleeve with the special tool. Note: The shift lever shaft sleeve is a disposable product and must be replaced before reinstallation.

BYD Suri Maintenance & Repair Manual

4.3.3 Service of Other Components in Transmission 4.3.3.1 Check the magnet. Take out the magnet and check for any obvious and large particles of iron scurf. The amount and size of the particles on the magnet are the primary basis to judge whether the transmission is damaged. The magnet must be wiped clean before reuse. 4.3.3.2 Replace the components in the main shaft assembly. (For details, refer to section 3.2 ―Disassembly and Assembly of Main Shaft Components‖) 4.3.3.3 Replace the components in the counter shaft 1 assembly. (For details, refer to section 3.3 ―Disassembly and Assembly of Counter Shaft 1 Components‖) 4.3.3.4 Replace the components in the counter shaft 2 assembly. (For details, refer to section 3.4 ―Disassembly and Assembly of Counter Shaft 2 Components‖) 4.3.3.5 Replace the components in the differential assembly. (For details, refer to section 3.5 ―Disassembly and Assembly of Differential Components‖)

4.3.2.5 Service the differential oil seal. Note: Check the oil seals for oil leakage and abnormal oil seal lip wear. Check if the oil seals are installed in place. The oil seal is a disposable product and must be replaced after removal.

4.3.3.6 Do not disassemble the reverse idler gear shaft assembly. Replace it as a unit if necessary. 4.3.3.7 Check each gear shift lever fork assembly for any abnormal wear.

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4.4 Assembly of Transmission Assembly 4.4.1 Prepare the serviced front box assembly with accessories. Note: Press the differential bearing outer ring, counter shaft 1 and 2 front bearing outer rings into the front box. Do not mix the counter shaft 1 front bearing outer ring with the counter shaft 2 front bearing outer ring.

4.4.6 Install the counter shaft 2 assembly, 5th/6th gear shifting fork shaft assembly and reverse gear shifting fork assembly. Note: Assemble the 5th/6th gear shifting fork shaft assembly, reverse shaft fork assembly and counter shaft 2 assembly and put them in the corresponding position. 4.4.2 Before assembly, remove the sealant and oil from the joint surface of the box for the application of new sealant. 4.4.3 Inspect the differential oil seal and main shaft oil seal. The oil seals should be installed in place without any abnormal wear. 4.4.4 Place the clean magnet and positioning pin in the corresponding positions. Carefully clean the iron chips and oil on the magnet before placing. 4.4.5 Install the differential assembly. Note: The differential assembly should be rotated freely to ensure it can be installed in place.

4.4.7 Install the reverse shaft assembly. Note: Quicker installation can be achieved by 2 persons working together. One lifts up the counter shaft 2 assembly together with the 5th/6th gear shifting fork shaft assembly and reverse shaft fork assembly to a certain height with both hands, and the other one installs the reverse shaft assembly. When the reverse shaft assembly is engaged with the counter shaft 2 assembly, they should be placed into the front box by 2 persons.

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fork assembly and reverse shaft assembly to a certain height with both hands. The second person assists the first person by lifting up the main shaft assembly to a certain height.

4.4.8 Install the main shaft assembly.

The third person installs the counter shaft 1 assembly together with the 1st/2nd gear shifting fork shaft assembly and 3rd/4th gear shifting fork shaft assembly. When the counter shaft 1 assembly is engaged with the main shaft assembly, all the shafts and gear shifting fork shaft assembly should be placed into the front box by 3 persons together.

Note: Quicker installation can be achieved by 2 persons working together. One lifts up the counter shaft 2 assembly together with the 5th/6th gear shifting fork shaft assembly, reverse shaft fork assembly and reverse shaft assembly to a certain height with both hands, and the other one installs the main shaft assembly. When the main shaft assembly is engaged with the counter shaft 2 assembly, they should be placed into the front box by 2 persons.

4.4.10 Apply sealant on the joint surface of the box as specified. Note: The sealant should be applied uniformly without breakpoint. For the threaded hole and positioning pin, the sealant should be applied to the position close to the inside of the box. 4.4.9 Install the counter shaft 1 assembly, 1st/2nd gear shifting fork shaft assembly and 3rd/4th gear shifting fork shaft assembly. Note: Quicker installation can be achieved by 3 persons working together. The first person lifts up the counter shaft 2 assembly together with the 5th/6th gear shifting fork shaft assembly, reverse shaft

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4.4.11 Prepare the serviced rear box assembly with accessories. Note: Press the differential bearing outer ring and its adjusting shim, counter shaft 1 rear bearing outer ring and its adjusting shim as well as counter shaft 2 rear bearing outer ring and its adjusting shim into the rear box together. 4.4.11.1 For the selection of counter shaft 1 rear bearing adjusting shim, refer to section 3.3.5 ―Selection of Counter Shaft 1 Rear Bearing Adjusting Shim‖ 4.4.11.2 For the selection of counter shaft 2 rear bearing adjusting shim, refer to section 3.4.5 ―Selection of Counter Shaft 2 Rear Bearing Adjusting Shim‖

BYD Suri Maintenance & Repair Manual

4.4.14 Install the assembly bolts. Note: There are 20 assembly bolts in total, and their tightening torque is 25 Nm. 4.4.15 Install the main shaft rear bearing outer circlip and main shaft sealing cap. 4.4.16 Install the mounting bolts of release bearing unit and release bearing assembly. Note: There are 3 mounting bolts for the release bearing assembly, and their tightening torque is 18 Nm. 4.4.17 Install the T-tube assembly.

4.4.11.3 For the selection of differential bearing adjusting shim, refer to section 3.5.4 ―Selection of Differential Bearing Adjusting Shim‖ 4.4.12 Check the installation position and wear condition of the differential oil seal. 4.4.13 Complete the assembly of the front and rear boxes. Note: Make sure to align the positioning pins of the front and rear boxes during assembly. 4.4.18 Install the manual gear shift assembly and hexagon flange bolts. Note: Put all the gear shift fork assembly in the neutral position before installation of the manual gear shift assembly. There are 2 hexagon flange bolts (M6×20) in total, and their tightening torque is 15 Nm. 4.4.19 Install the gear selecting steel ball assembly and neutral switch assembly (The tightening torque is 35 Nm). 4.4.20 Install the sealing cap. Note: The sealing cap is a disposable product and must be replaced before reinstallation.

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4.4.21 Tighten the oil drain plug assembly to finish the assembly of transmission assembly.

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Chapter 5 BYD6DT25 Dual Clutch Transmission Contents Section 1 Introduction of Transmission ................................................................................. 205 1.1 Structural Parameters ............................................................................................ 205 1.2 Servicing Description ............................................................................................. 205 Section 2 Dual Clutch............................................................................................................ 207 2.1 Disassembly of Dual Clutch .................................................................................. 207 2.2 Repair Clutch Engaging Device ............................................................................ 208 2.3 Adjustment of Engaging Bearing 1 and 2 ............................................................. 210 2.4 Assembly of Dual Clutch ....................................................................................... 213 Section 3 Operating Mechanism and Housing ..................................................................... 216 3.1 Replacement of Transmission Oil ......................................................................... 216 3.2 Removal of Electric Hydraulic Control Module...................................................... 218 3.3 Installation of Electric Hydraulic Control Module................................................... 220 3.4 Disassembly and Assembly of Transmission ........................................................ 221 Section 4 Gear and Drive Shaft ............................................................................................ 229

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Section 1 Introduction of Transmission 1.1 Structural Parameters Transmission model Type

Gear ratio

Synchronizer ring size (mm) Synchronizer ring type

Dual clutch transmission gear oil Total weight (kg)

1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear Reverse gear 1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear Reverse gear Model Oil volume (L)

BYD6DT25 DCT 3.765 2.273 1.531 1.122 1.176 0.951 4.170 3-cone 3-cone 3-cone 2-cone 1-cone 1-cone 1-cone Castrol MTF 95+EP+FM 1.7 72 kg

1.2 Servicing Description 1.2.1 Servicing Guidelines

ones.

1.2.1.1 Prepare the parts kit and parts rack in advance to store the removed and disassembled components. Put them in order and make markers if necessary to avoid confusion and misplacement.

1.2.1.6 Use correct removal tools for disassembly and assembly.

1.2.1.2 Be careful when servicing the aluminum alloy parts to avoid damage to the machined surface.

1.2.1.8 If you encounter any difficult technical problems during servicing, it is recommended to consult our aftersales technical service department.

1.2.1.3 Prepare sufficient auxiliary materials for use in the process of servicing. 1.2.1.4 For the bolts and other fastening parts with standard tightening torque requirements, tighten them with special tools in accordance with the required values.

1.2.1.7 Refer to this service manual as much as possible during work.

1.2.2 Materials for Servicing The materials listed in the following table are essential for servicing the transmission of this model. Therefore, they should be prepared for use at any time. In addition, the washing liquid and lubricant of specified models should be used.

1.2.1.5 After servicing, disposable supplies should be scrapped and replaced with new Auxiliary Material Table:

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No.

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Materials and type

Materials and type currently in use

Position Differential oil seal Ball bearing Main shaft oil seal Taper bearing outer ring 6th gear shift lever bushing Differential oil seal Transmission assembly Main shaft needle bearing Counter shaft needle bearing Ball bearing

1

Grease

2

Gear oil

API grade: GL-4 SAE viscosity:75W

3

Anti-rust oil

Mobilarma 524 or Shell Ensis N Oil

Main shaft spline

4

Assembly sealant

Loctite 587

Joint surface of transmission front and rear boxes

3# Lithium grease

1.2.3 Precautions 1.2.3.1 Do not allow the contaminants to enter the transmission when the transmission is disassembled. 1.2.3.2 Put removed parts on a clean work stand and cover them with a piece of clean and fibreless cloth to protect them from contamination.

1.2.3.3 Install the clean parts only and take out the original parts from their package only when they are to be installed. 1.2.3.4 The transmission has two fuel supply systems with one for gears and shafts and the other one for the electric hydraulic control module. Do not add any additives into oil. 1.2.3.5 The engine oil drained should not be used for refilling. Dispose the waste oil properly.

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BYD Suri Maintenance & Repair Manual

Section 2 Dual Clutch 2.1 Disassembly of Dual Clutch Special tools and servicing equipment needed 2.1.1 Mounting bracket-T10012.1.2 Removal bracket-T1002 2.1.3 Cushion block-T10032.1.4 Circlip pliers 2.1.5 Depth gauge 2.1.6 Vernier caliper

2.1.6.2 Fix the transmission with the dual clutch facing upward. 2.1.6.3 Remove the circlip indicated by the arrow from the damping disc.

a

Tips The clutch has self-regulating function. Vibration will influence the self-regulating device. Therefore do not drop the clutch into the transmission when installing the clutch. Even when the electric hydraulic control module has been removed, taking out the screwdriver underneath the engaging level could also have a negative effect on the self-regulating device.

2.1.6.4 Remove the damping disc with the circlip pliers and screwdriver.

2.1.6.1 Use the proper plugs to seal two air outlets indicated by the arrows avoid oil leakage.

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2.1.6.5 Remove the main shaft 2 front circlip.

b

Tips

2.1.6.5.1 The circlip may be fixed very securely. In this case, the clutch and the circlip contact with each other closely, so the circlip is "stuck". 2.1.6.5.2 The clutch can be pressed down slightly only when the circlip cannot be removed from the circlip groove. Do not tap the clutch or shaft using a hammer! 2.1.6.5.3 Replace the circlip each time it is removed. 2.1.7 Fully turn the threaded rod of the mounting bracket -T1001- in the direction of arrow, and install the mounting bracket -T1001- in the opposite direction to the dual clutch.

BYD Suri Maintenance & Repair Manual

2.1.8 Turn the threaded rod of the mounting bracket - T1001- in the direction of arrow and pull out the dual clutch.

2.1.9 Remove the clutch along with the removal bracket.

2.2 Repair Clutch Engaging Device 1 Connecting arm support 2 Engaging bearing 2 sleeve thrust ring 3 Engaging bearing 2 sleeve 4 Engaging bearing 1 sleeve pressure plate 5 Engaging bearing 1 sleeve 6 Connecting arm 2 7 Hexagon flange bolt a b c

2 Replace them after removal 10 Nm

8 Connecting arm 1 9 Engaging bearing 1

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10 Engaging bearing 1 gasket 11 Engaging bearing 2 gasket 12 Engaging bearing 2

BYD Suri Maintenance & Repair Manual

2.2.3 Turn the lugs of the thrust ring indicated by the arrows for 90°with respect to the connecting arm 2. 2.2.4 Pull out the sleeves of engaging bearing 1 and 2 together.

Removal of connecting arm 2, sleeves of engaging bearing 1 and 2, engaging bearing 1 pressure plate 2.2.1 Remove the bolts indicated by the arrows 2.2.2 Remove the connecting arm 2 and sleeves of engaging bearing 1 and 2.

Disassembly and assembly of connecting arm 1 and engaging bearing 1 Disassembly 2.2.5 Pull the engaging bearing 1 in the direction of arrow A while pulling the engging bearing 1 out of the connecting arm 1 locating slot in the direction of arrow B.

Disassembly of connecting arm 2, sleeves of engaging bearing 1 and 2

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Assembly 2.2.6 Press the engaging bearing 1 downward in the arrow direction until the sound of engaging bearing 1 fixing clips entering the connecting arm 1 locating slot is heard.

The position of engaging bearing must be adjusted after the following operations are performed  Replace the electric hydraulic control module of dual clutch transmission.  Replace the connecting arm.  Replace the engaging bearing.  Replace the connecting arm holder. If the following conditions are met, there is no need to perform any adjustment after removing and reinstalling all the above parts.

2.3 Adjustment of Engaging Bearing 1 and 2 Special tools and servicing equipment needed a

Gauge block-T1004-

b

H plate-T1005

 The tools used are in good condition.  The mating surface of the transmission and the engine should be kept smooth so as to better support the H plate.  The electric hydraulic control module has been installed. Brief Description Refer to the clutch clearance of transmission for the position of engaging bearing. In the BYD6DT25 dual clutch transmission, both the transmission engaging system and the transmission itself have tolerance. The dual clutch also has tolerance. Observe each tolerance

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separately when performing adjustment. The following contents will describe how to determine all necessary dimensions on the transmission side so that a proper adjusting shim can be selected. Then the clutch tolerance can be determined by means of experience and the tolerance will be used as a coefficient in the calculation later. The thickness of adjusting shim is determined by the tolerance of the transmission side and the clutch. 2.3.1 Selection of Engaging Bearing 1 Adjusting Shim: After assembling the engaging bearing 1, measure the depth H from the circlip upper surface to the joint surface of the engine and transmission. Measure the depth Hd from the tool -T1004- upper surface to the joint surface of engine and then calculate the thickness td of engaging bearing 1 adjusting shim based on the above measurement results: td= (Hd+48-H) 50.08 2.3.1.1 Install the clutch parts of engaging bearing 1 2.3.1.2 Do not install the engaging bearing 1 and the adjusting shim. 2.3.1.3 Install the main shaft 2 front circlip indicated by the arrow

BYD Suri Maintenance & Repair Manual

2.1.3.5 The H plate -T1005 - should be kept in this position in the following measurement. 2.1.3.6 The depth gauge is placed on the main shaft. 2.1.3.7 Reset the depth gauge to zero 2.1.3.8 Measure the distance H

b

Tips

2.1.3.9 Do not perform the measurement at the connection of circlip, or the circlip may be disconnected, causing the incorrect measurement. 2.1.3.10 Place the block gauge-T1004- on the engaging bearing 1. 2.1.3.11 Press the block gauge-T1004- and turn it at the same time. The rotation condition of engaging bearing can be observed so that the block gauge -T1004- can be correctly installed on the engaging bearing 1. 2.1.3.12 Place the depth gauge above the main shaft. 2.1.3.13 Reset the depth gauge to zero. 2.1.3.14 Measure the distance Hd.

2.3.1.3.4 Place the H plate -T1005- on the joint surface of the transmission and the engine. a

Tips

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BYD Suri Maintenance & Repair Manual

2.1.3.15 Determine which shim to be inserted by referring to the following table. Unit: mm 2.1.3.16 Measure the provided shims using a vernier caliper, select the desired shim and then install it.

Marker

Thickness (Range for actual Marker Thickness (Range for actual shim shim measurement) measurement) 100 1.0 (0.51~1.05) 160 1.6 (1.51~1.65) 115 1.15 (1.06~1.20) 175 1.75 (1.66~1.80) 130 1.3 (1.21~1.35) 190 1.9 (1.81~2.35) 145 1.45 (1.36~1.50) Only 1 shim can be inserted during installation, 2.3.2.2 Check if the engaging bearing 2 is instead of 2. correctly installed and if the groove position is correct by turning. 2.3.2 Selection of Engaging Bearing 2 Adjusting Shim:

Similarly, assemble the engaging bearing 2 first, and then measure the depth Hx from the tool -T1004- upper surface to the joint surface of the engine and the transmission. The thickness tx of engaging bearing 2 adjusting shim can be calculated by using the depth value H of circlip upper surface measured in the previous step: tx=34.35- (Hx+36-H) 2.3.2.1 Install the engaging bearing 2. Do not install the adjusting shim! a The engaging bearing 2 can only be installed in one position due to 4 grooves.

2.3.2.3 Install the gauge block -T1004- on the engaging bearing 2. 2.3.2.4 Place the depth gauge above the main shaft. 2.3.2.5 Reset the depth gauge to zero. 2.3.2.6 Measure the distance Hx.

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Determine which shim to be inserted by referring to the following table. Unit: mm Marker

50 65 80

Thickness (Range for actual shim measurement) 0.5 (0.21~0.55) 0.65 (0.56~0.7) 0.8 (0.71~0.85)

Marker

95 110

Thickness (Range for actual shim measurement) 0.95 (0.86~1.0) 1.1 (1.01~1.15)

2.4.1 Insert the connecting arm 2 and its sleeve. 2.4.2 Make sure the connecting arm is installed in the correct position. 2.4.3 Fix the sleeve using 2 new bolts. Tightening torque: 10 Nm

2.3.2.6 Measure the provided shims using a vernier caliper, select the desired shim and then install it. b c

Only 1 shim can be inserted during installation, instead of 2. Tips

2.3.2.7 For more accurate measurement, place the depth gauge in the opposite position twice and adopt the average value. In this case, the measured value is more accurate as the shake caused by the engaging bearing can be minimized to avoid inaccurate measurement.

2.4 Assembly of Dual Clutch Insert the plastic holder of the connecting arm.

Note that the sleeve of connecting arm and all the mechanisms of engaging bearing must be kept dry and free of the oil or grease. a

Tips Before installation, the position of engaging bearing 1 and 2 must be adjusted if the following operations have been performed. 2.4.3.1 Replace the electric hydraulic control module. 2.4.3.2 Replace the connecting arm.

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BYD Suri Maintenance & Repair Manual

2.4.3.3 Replace the engaging bearing. 2.4.3.4 Replace the connecting arm holder. 2.4.3.5 The dual clutch can be installed only after the engaging bearing is properly adjusted! 2.4.4 If the above operations have not been performed, insert the connecting arm 1 directly. 2.4.5 Check if the mounting positions of two connecting arms are correct. c The adjusting shim indicated by the arrow must be installed on the two connecting arm bearing.

b The engaging bearing 2 can only be installed in one position due to 4 grooves on the engaging bearing 2.

2.4.7 Insert the clutch into the transmission shaft. The clutch can be put in the transmission with the help the removal bracket. d

Tips

2.4.7.1 The clutch is self-regulating. The vibration will influence the self-regulating device. 2.4.6 Check if the engaging bearing is installed correctly and if the mounting positions of the grooves are correct by turning the engaging bearing.

Therefore do not allow the clutch to drop into the transmission even when installing the clutch. 2.4.8 Install the mounting bracket -T1001- on the transmission.

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e

BYD Suri Maintenance & Repair Manual

Tips 2.4.8.1 Put a hand on the clutch while the clutch is pressed. When slight vibration is felt, it means the clutch is pressed to the required position. In addition, the condition when the clutch is pressed to the limit position can also be felt.

2.4.9 Install the clutch circlip indicated by the arrow If the circlip cannot be installed, it means the clutch is not pressed to the mounting position. Reinstall the clutch.

2.4.10 Install the damping disc and damping disc circlip.

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BYD Suri Maintenance & Repair Manual

Section 3 Operating Mechanism and Housing 3.1 Replacement of Transmission Oil 3.1.1 Replacement of Gear Oil If the gear oil leaks from transmission, check for leaking area.

3.1.1.3.2 Mark the mounting position of operating lever and remove it from the gear shifting shaft.

3.1.1.1. Drain the remaining gear oil and dispose it properly.

3.1.1.3.3 Remove the P gear cover plate.

3.1.1.2. Repair the leaking area.

3.1.1.3.4 Fill 1.7L gear oil through the opening.

3.1.1.3. Reinstall the drain plug. Tightening torque: 30 Nm

3.1.1.3.1 Press the operating lever by hand along the direction of pull cable seat indicated by the arrow until the limit position is reached.

a

Tips

3.1.2 Make sure the gear oil does not splash out and fill the transmission with the exact 1.7L gear oil. 3.1.3 The gear oil should be added properly, or the malfunction may be caused! 3.1.3.1 Install the P gear cover plate. 3.1.3.2 Install the gear shift operating lever based on the position marked before. Torque of P gear cover plate bolt 9 Nm Tightening torque of gear shift operating lever bolt15 Nm

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BYD Suri Maintenance & Repair Manual

Tips Replace the bolts on the gear shift operating lever each time.

opening. Tips Make sure the hydraulic oil does not splash out. Fill the mechano-electronic unit with the exact 1 L hydraulic oil and do not fill too much or too little. Or the malfunction may be caused! b

Install a new oil filling port bolt.

3.1.2 Replacement of Hydraulic System Oil 3.1.2.1 Discharging The hydraulic oil is a long-life hydraulic oil with no need for replacement. It is not necessary to check the oil level in the transmission. Therefore, there is no oil level inspection equipment. If the hydraulic system oil leaks, check for leaking area. 3.1.2.1.1 Remove the drain plug indicated by the arrow. 3.1.2.1.2 Drain the remaining hydraulic oil and dispose it properly. 3.1.2.1.3 Repair the leaking area. 3.1.2.1.4 Install a new drain plug in the position shown by the arrow. 3.1.2.2 Filling 3.1.2.2.1 Remove the oil filling port bolt of the electric hydraulic control module indicated by the arrow. 3.1.2.2.2 Fill 1 L hydraulic oil through the

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3.2 Removal of Electric Hydraulic Control Module a

Tips 3 2.1The clutch is self-regulating. Vibration will influence the self-regulating device. Even if the electric hydraulic control module has been removed, pulling out the screwdriver from the underneath of the connecting arm suddenly may also have a negative effect on the self-regulating device.

3.2.1.1 Drain the gear oil and reinstall the drain plug. 3.2.1.2 Pull out the exhaust hose and seal it

Instructions of detaching the clutch connecting arm from the electric hydraulic control module:

with an appropriate plug to avoid oil leakage. 3.2.1.3 Remove the bolt -1- and remove the cover plate -2- from the transmission.

To take out the electric hydraulic control module, two connecting arms must be "pressed out" from the clutch push rod of electric hydraulic control module. Or the connecting arms will press on the clutch push rod of electric hydraulic control module and it is impossible to take out the electric hydraulic control module. b

Tips 3.2.2 It is not allowed to connect the screwdriver with the electric hydraulic control module.

3.2.1.4 Detach the transmission input shaft speed sensor from the housing carefully along the arrow direction using a screwdriver.

3.2.3 Careful press the two connecting arms out of the push rod.

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3.2.9.1 Take out the electric hydraulic control module. 3.2.3.1 Insert the screwdriver along the arrow direction as shown in the figure. 3.2.3.2 Press the connecting arms out of the push rod using the screwdriver and fix the connecting arms in the position. Do not take out the screwdriver and keep it between the connecting arms and the transmission housing during the whole process. c

Tips

3.2.4 Do not take out the screwdriver. Keep it inserted during installation of the electric hydraulic control module.

If the electric hydraulic control module cannot be removed: In this case, the gear position adjuster is hooked on the upper left of the transmission housing. 3.2.9.2 Put the electric hydraulic control module in the transmission housing first and then fix it using a bolt. 3.2.9.3 Put the electric hydraulic control module in its original position. 3.2.9.4 Take out the electric hydraulic control module.

3.2.5 Do not damage the rubber seal cartridge of clutch push rod. 3.2.6 Do not allow the connecting arms to hit the housing! 3.2.7 Loosen the bolts alternatively (4 long bolts and 3 short bolts) d

Tips

3.2.8 Do not remove all the bolts! 3.2.9 Do not remove the electric hydraulic control module cover plate bolt.

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BYD Suri Maintenance & Repair Manual

3.3 Installation of Electric Hydraulic Control Module

and check if the gear shifting fork is stuck. If so, reinstall it after the cause has been found out. If not, engage the gear shifting fork to "neutral position".

3.3.1 Tips Make sure all gear shifting forks are in N "Neutral". N-Neutral position of transmission R-Reverse gear 1- 1st gear 2- 2nd gear 3- 3rd gear 4- 4th gear 5- 5th gear 6- 6th gear

3.3.2 Tips 3.3.2.1 Adjust the position of gear shift adjuster and keep it in "neutral position" or the transmission cannot be shifted normally! Please be aware that the 4 gear shift adjusters protrude 25 mm -a-. 3.3.2.2 Do not damage the sensor when prying the gear shift adjuster from the electric hydraulic control module. 3.3.2.2.1 Use an appropriate plug to seal the vent hole on the electric hydraulic control module to avoid oil leakage.

3.3.2.2.2. Be aware of the gear selecting piston rod. 3.3.2.2.3 Install the electric hydraulic control module. 3.3.2.2.4 Tighten the bolts by hand. -

-

Check 4 gear shifting forks one by one.

3.3.3 Tips

Each gear shifting fork has 3 positions: "Engage a gear- Neutral - Engage a gear".

3.3.3.1 Replace with new bolts after removal.

Engage each gear shifting fork to each position once in order. Disengage all gears

3.3.3.2 The tightening torque of the bolt is 10 Nm.

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3.3.3.3 Slowly take out the screwdriver for holding the clutch engaging levers, and install two clutch engaging levers on the push rod. 3.3.4 Tips 3.3.4.1 Do not release the clutch suddenly. If the clutch engaging lever hit the electric hydraulic control module, the self-regulating function of the clutch may be damaged. 3.3.4.2 Install the transmission input shaft speed sensor on the transmission housing. 3.3.4.3 The sensor and its clamp plate must be pressed tightly against the transmission housing. If the sensor is loose, replace the electric hydraulic control module.

BYD Suri Maintenance & Repair Manual

3.4 Disassembly and Assembly of Transmission Special tools and equipment needed  Assembly bracket-T1006 Disassembly bracket-T1007 Guide sleeve-T1008 Cover plate -T1009 Guide pillar-T1010 Screwdriver  Circlip pliers  Copper bar

3.3.5 Tips 3.3.5.1 Do not remove the seal cover from the air outlet of electric hydraulic control module if the transmission is not to be installed immediately.

3.4.1 Disassembly of Transmission

3.4.1.2 Remove the main shaft rear circlip using circlip pliers.

3.4.1.1 Remove the sealing cap using a screwdriver.

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BYD Suri Maintenance & Repair Manual

3.4.1.3 Remove the bolts (20 in total) for connecting the front and rear box assembly.

3.4.1.3 Install the tools in place, turn the bolt clockwise using an open-end wrench and then remove the rear box. b

Tips

3.4.1.3.1 Turn the bolt with even force and do not use too much strength to avoid damage to the rear box.

a

Tips The sealing cap may influence the disassembly. Align the screwdriver with the center of sealing cap and tap it into the cap. Do not tap too deeply to avoid damaging the main shaft. Never use the removed sealing cap.

3.4.1.2.1 Do not hit the main shaft rear bearing when removing the main shaft rear circlip using the circlip pliers. 3.4.1.2.2 Before disassembly, make sure the clutch and the electric hydraulic control module have been removed. 3.4.1.2.3 Make sure all the assembly connecting bolts have been removed. 3.4.1.4 Remove the differential -5-. c

Tips

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3.4.1.4.1 When removing the differential, lift one side of the differential and pull it out. Use even strength, and do not use "too much strength". Make sure the gear will not hurt your finger.

3.4.2 Selection of Front Box Adjusting Shim 3.4.2.1 Selection of Counter Shaft 1 Front Bearing Adjusting Shim:

3.4.1.5 Pull out the shift fork and counter shaft 1 -4- together. 3.4.1.6 Pull out the shift fork as well as the

counter shaft 2 -7- and reverse shaft -6together. d

When the gear sleeve is in 2nd and 3rd gear, measure the height h2 and h3 from the upper surface of the gear sleeve to the joint surfaces of the box. Based on the height, the thickness t1 of counter shaft 1 front bearing adjusting shim can be determined: t1= {(48.2-h2) + (131.3-h3)}/2

Tips

3.4.1.6.1 Shake the shaft slightly to make the drive system loose when pulling out the shaft. This can help pull out the shaft and shift fork. 3.4.1.6.2 Take out the main shaft 1 -1-. 3.4.1.6.2.1 When removing the main shaft 1, pull it upward along the centerline of counter shaft 2. This can avoid damaging the main shaft 2 oil seal. 3.4.1.6.3 Remove the main shaft 2 bearing pressure plate bolt -33.4.1.6.4 Remove the main shaft 2 -2-

3.4.1.6.4.1 Tap the front end of main shaft 2 slightly using a rubber hammer when removing the main shaft 2. Refer to the following table for shim selection Marker

Thickness

Marker

Thickness

Marker

Thickness

0.7 0.75

0.7 0.75

0.95 1.0

0.95 1.0

1.20 1.25

1.20 1.25

0.8

0.8

1.05

1.05

1.30

1.30

0.85

0.85

1.10

1.10

1.35

1.35

0.9

0.9

1.15

1.15

Counter shaft 1 front bearing adjusting shim

Unit: mm

3.4.2.2 Selection of Counter Shaft 2 Front Bearing Adjusting Shim: When the synchronizer gear sleeve is in the counter shaft 2 gear ring, measure the height h7 from the upper surface of 5th gear synchronizer gear sleeve to the joint surfaces of the box. Based on the height, the thickness t2 of counter shaft 2 front bearing adjusting shim can be determined: t2=127.45-h7

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Refer to the following table for shim selection Unit: mm Marker 0.7 0.75 0.8 0.85 0.9

Thickness 0.7 0.75 0.80 0.85 0.90

Marker 0.95 1.0 1.05 1.10 1.15

Thickness 0.95 1.0 1.05 1.10 1.15

Marker 1.20 1.25 1.30 1.35 1.40

Marker 0.7 0.75 0.8 0.85 0.9

Thickness 0.7 0.75 0.8 0.85 0.9

Marker 0.95 1.0 1.05 1.10 1.15

Thickness 0.95 1.0 1.05 1.10 1.15

Marker 1.20 1.25 1.30 1.35

Thickness 1.20 1.25 1.30 1.35 1.40

Unit: mm

3.4.2.3 Selection of Reverse Shaft Front Bearing Adjusting Shim: When the synchronizer gear sleeve is in reverse gear, measure the height hd from the upper surface of synchronizer gear sleeve to the joint surface of the box. Based on the height, the thickness t3 of reverse shaft front bearing adjusting shim can be determined: t3=62.25-hd

Refer to the following table for shim selection

Thickness 1.20 1.25 1.30 1.35

3.4.2.3.1 Install the special tools for of all the bearing outer rings in place in the front box before adjusting the front box shim, or the shim adjustment accuracy will be affected.

3.4.3 Selection of Rear Box Adjusting Shim The adjusting shims for the rear box counter shaft, reverse shaft and differential rear bearing are selected as follows: First, install the adjusted front box adjusting shim in the corresponding position and install the shafts and differential components to the front box. Then measure the heights hf1 (for counter shaft 1) , hf2 (for counter shaft 2), hd (for reverse shaft) and hc (for differential) from the shafts and the differential left bearing outer ring end face to the joint surface of the box. Then measure the depths Hf1 (for counter shaft 1) , Hf2 (for counter shaft 2) , Hd (for reverse shaft) and Hc (for

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differential) from the rear box counter shaft, reverse shaft and the machined surface of differential mounting hole to the joint surface of the box. Finally, the thickness of each bearing adjusting shim of the rear box can be calculated as follows: tf1=Hf1-hf1+ (0.05~0.1); tf2=Hf2-hf2+ (0.05~0.1); td=Hd-hd+ (0.05~0.1); tc=Hc-hc+ (0.05~0.1).

Refer to the table below for selection of tf1, tf2 and td shims; Unit: mm Unit: mm Marker 0.7 0.75 0.8 0.85 0.9

Thickness 0.7 0.75 0.80 0.85 0.90

Marker 0.95 1.0 1.05 1.10 1.15

Thickness 0.95 1.0 1.05 1.10 1.15

Marker 1.20 1.25 1.30 1.35 1.40

Thickness 1.20 1.25 1.30 1.35 1.40

Refer to the attached table A.3 for selection of tc adjusting shim. Unit: mm Marker 0.8 0.85 0.9 0.95 1.0

Thickness 0.8 0.85 0.9 0.95 1.0

Marker 1.05 1.1 1.15 1.20 1.25

3.4.3.1 Tips Adjust the shim again in any of the following situations: 3.4.3.1.1 After replacing the rear box, adjust the shims of the rear box. 3.4.3.1.2 After replacing the front box, adjust the shims of the front box.

Thickness 1.05 1.1 1.15 1.20 1.25

Marker 1.30 1.35 1.40 1.45 1.50

Thickness 1.30 1.35 1.40 1.45 1.50

3.4.3.1.3 After replacing the shaft and the differential bearing, adjust the corresponding shims. 3.4.3.1.4 After the shaft has been disassembled, adjust the corresponding shims of the front and rear box. After adjusting the shim, assemble the rear box and rotate the shafts and differential. When you feel the pre-tensioning force, it

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means that the shim is adjusted appropriately. If not, adjust again. 3.4.4 Installation of Transmission

BYD Suri Maintenance & Repair Manual

2.4.9.2 During installation, pull the differential in the direction of arrow 3 to lift one end of the differential. In this way, the shaft and the fork can be installed easily. 2.4.9.3 After installation, lift the main shaft 1 upward so that the gear can be engaged in place. During rotation, there is no clamping stagnation. 2.4.9.4 Lower the main shaft 1 slowly along the axis of main shaft 2 to avoid damaging the oil seal of the main shaft 2.

2.4.1 Install the assembly positioning pin and the magnet. 2.4.2 Install the main shaft 2 in place. 2.4.3 Main shaft 2 bearing pressure plate bolts (3) torque: 10 Nm. 2.4.4 Install the main shaft 1 in place. 2.4.5 Install the differential in place. 2.4.6 Install the shift fork and the counter shaft 1 to the front box - arrow 3-. 2.4.7 Install the shift fork, counter shaft 2 and reverse gear shaft to the front box - arrow 1-. 2.4.8 Apply sealant on the joint surfaces of the front and rear box. 2.4.9 Rotate the differential and the entire drive system has no clamping stagnation. a

Tips

2.4.9.1 During installation, place the fork rod into the corresponding fork hole, and then place the shaft in the corresponding hole.

3.4.9.4.1 Place the cushion block indicated by the arrow 1 under the main shaft. b

Tips

2.4.9.5 Insert the front end of main shaft 1 into the groove on the cushion block as shown by the arrow 2. In this way, the rear box can be installed in place. 2.4.9.6 Make the joint surface of the transmission and the engine face downward and place the transmission on the "flat" bench, so as to make sure the rear box can be installed in place.

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c

Tips

3.4.9.8 Rotate the bolt with even force to prevent the rear box from being damaged. 3.4.9.8.1 Install the circlip indicated by the arrow 1 in place using circlip pliers. d

Tips

3.4.9.9 If the circlip is not installed in place, it means that the rear box is not installed in place. Press the rear box downward until the circlip is clamped in the groove.

3.4.9.6.1 Install the assembly bracket in place. 3.4.9.7 After rotating the bolt counterclockwise, press the rear box downward in place so that the main shaft 1 rear bearing circlip groove indicated by the arrow 2 should be exposed.

3.4.9.9.1 Install the new sealing cap assembly.

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3.4.9.9.2 Install the assembly connecting bolts. 3.4.9.10 Front box assembly connecting bolts M8X35 (14), torque: 25 Nm. 3.4.9.11 Rear box assembly connecting bolts M8X50 (6), torque: 25 Nm.

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BYD Suri Maintenance & Repair Manual

Section 4 Gear and Drive Shaft Counter shaft 2 and reverse shaft cushion block- T1011 -. Counter shaft 1 cushion block - T1012 -. Main shaft 2 oil seal tool - T1013 -. Pressing block - T1014 Synchronizer installation tool - T1015 5th gear distance ring installation tool T1016 Counter shaft conical bearing installation tool - T1017 4th/6th gear distance ring installation tool T1018  1st gear distance ring installation tool T1019  Counter shaft 1 conical bearing installation tool - T1020  Snap-gauge - T1021  Guide sleeve installation tool - T1022  3rd gear distance ring installation tool – T1023 -

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4.1 Main Shaft 1

1

Gear oil guide sleeve;

2

Main shaft 1;

3

Main shaft 5th gear;

4

Main shaft 1 signal disc;

5

Main shaft 3th gear;

6

Main shaft distance ring;

7

Main shaft middle circlip;

8

Main shaft 1 rear needle bearing;

9

Main shaft 1 front needle bearing

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Disassembly

BYD Suri Maintenance & Repair Manual

4.1.2.3.1 Install the front and rear needle bearings of the main shaft 1.

4.1.1 Remove the front and rear needle bearings of the main shaft 1.

4.1.2.3.2 Install the main shaft distance ring and the main shaft middle circlip.

4.1.2 Remove the main shaft middle circlip and the main shaft distance ring. -

Remove the gear oil guide sleeve.

4.1.2.3.3 Use the guide sleeve mounting tool T1022 - to install the gear oil guide sleeve.

Service 4.1.2.1 Check if the needle bearing has any abnormity. 4.1.2.2 Check each gear for any sign of collision and obvious tooth face damage. 4.1.2.3 Replace the damaged parts in time. Assembly

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4.2 Main Shaft 2

1

Main shaft 4th/6th gear roller bearing;

2

Main shaft 2;

3

Main shaft 2 bearing pressure plate;

4

Main shaft 2 bearing;

5

Main shaft 2 middle circlip;

6

Main shaft 2 oil seal assembly.

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Disassembly

Assembly

4.2.1 Remove the 4th/6th gear roller bearing and the main shaft 2 oil seal.

4.2.3.3.1 Install the main shaft 2 bearing pressure plate and the main shaft 2 bearing. Pay attention to the direction of pressure plate indicated by the arrow.

4.2.2 Use the circlip pliers to remove the main shaft 2 middle circlip. 4.2.3 Use the snap-gauge - T1021 - to remove the main shaft 2 bearing pressure plate and the main shaft 2 bearing.

4.2.3.3.2 Install the main shaft 2 middle circlip. 4.2.3.3.3 Use the tool - T1013 - to install the main shaft 2 oil seal.

Service 4.2.3.1 Check if the needle bearing has any abnormity. 4.2.3.2 Check each gear for any sign of collision and obvious tooth face damage.

4.2.3.3.4 Install the 4th/6th gear roller bearing.

4.2.3.3 Replace the damaged parts in time.

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4.3 Counter Shaft 1

1 2. 3. 4. 5 6. 7 8 9 10 11 12 13 14 15 16 17 18

Counter shaft 1 front bearing Counter shaft 1; 4th/6th gear needle bearing; Counter shaft 2nd gear assembly; 2nd gear synchronizer inner ring; 2th/4th gear synchronizer middle steel ring; 2nd gear synchronizer outer ring; 2nd/4th gear synchronizer circlip; 2nd/4th gear synchronizer hub; 2nd/4th gear synchronizer gear sleeve; Synchronizer slide block; 4th gear synchronizer inner ring; 4th/6th gear distance ring; Counter shaft 4th gear assembly; 3rd/4th gear distance ring retainer; 3rd gear distance ring; 3rd gear needle bearing; Counter shaft 3rd gear assembly;

19 20 21 22 23 24. 25 26 27 28 29 30

1st/3rd gear synchronizer inner ring; 1st/3rd gear middle steel ring; 1st/3rd gear synchronizer outer ring; 1st/3rd/reverse gear synchronizer circlip; 1st/3rd gear synchronizer gear sleeve; 1st/3rd gear synchronizer hub; 1st gear needle bearing; 1st gear distance ring; Counter shaft 1st gear assembly; Counter shaft 1st gear pressure plate; Counter shaft conical bearing; Counter shaft tightening screw.

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shown and use a press to press the tool so as to remove the 3rd distance ring, retainer, 4th gear and needle bearing.

4.3.1 Loosen and remove the counter shaft tightening screw. 4.3.2 Clip the 1st gear of counter shaft 1 assembly onto the snap-gauge - T1021 as shown. Use a press to press the tool so as to remove the counter shaft conical bearing and pressure plate as well as the 1st gear needle bearing. 4.3.2.1 Place the removed parts in good order.

4.3.4 Clip the 2nd gear of the counter shaft 1 assembly onto the snap-gauge - T1021 as shown and use a press to press the tool so as to remove the synchronizer ring, synchronizer and 2nd gear needle bearing.

4.3.3 Clip the 3rd gear of the counter shaft 1 assembly onto the snap-gauge - T1021 as shown and use a press to press the tool so as to remove the 1st/3rd gear synchronizer and synchronizer ring as well as the distance ring.

Service 4.3.4.1 Check if the 1st, 2nd and 3rd gear inner rings are damaged. 4.3.1 Clip the 4th gear of the counter shaft 1 assembly onto the snap-gauge - T1021 as

4.3.4.2 Check if the convex on the inner ring is burnt.

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4.3.4.3 Press the inner ring on the cone of the shift gear and measure the clearance a with a feeler gauge. If a