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Anhui Chery Automobile CAC478 Instruction Book On Using And Maintenance

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CAC Gasoline Engine Maintenance And Servicing Manual
ANHUI CHERY AUTOMOBILE CO., LTD
CAC478/480 GASOLINE ENGINE
Instruction Book on Using and Maintenance
3
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  • Page 1 CAC Gasoline Engine Maintenance And Servicing Manual ANHUI CHERY AUTOMOBILE CO., LTD CAC478/480 GASOLINE ENGINE Instruction Book on Using and Maintenance PDF 文件使用 "pdfFactory Pro" 试用版本创建 www.fineprint.com.cn...

  • Page 2: Table Of Contents

    https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual Catalogue Int ro duct io n…… …………………………… ……………… ……………………………1 Engine configuration view and sectional view……………………………………………3 Main engine technical indexes and operation parameters………………………………11 Engine structural features………………………………………………………………13 Engine service……………………………………………………………………………15 Engine removal and assembly procedure………………………………………………17 [1]、Positioning no.1 cylinder top dead center (compression) …………………………17 [2]、Upper and lower timing gear cover assemblies removal and installation………18...
  • Page 3 CAC Gasoline Engine Maintenance And Servicing Manual Foreword CAC478、 CAC480 series vehicle gasoline engines , which are the products introduced from Ford ( Britain) corporation CVH production line, are made by Anhwei chelly automobile Corp. Products are made up of carburetor type, single-point electric control fuel injection type and electric control fuel injection type , which may meet the requirements for different performance and emission.
  • Page 4 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual PDF 文件使用 "pdfFactory Pro" 试用版本创建 www.fineprint.com.cn...
  • Page 5 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual PDF 文件使用 "pdfFactory Pro" 试用版本创建 www.fineprint.com.cn...
  • Page 6 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual PDF 文件使用 "pdfFactory Pro" 试用版本创建 www.fineprint.com.cn...
  • Page 7 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual PDF 文件使用 "pdfFactory Pro" 试用版本创建 www.fineprint.com.cn...
  • Page 8 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual PDF 文件使用 "pdfFactory Pro" 试用版本创建 www.fineprint.com.cn...
  • Page 9 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual PDF 文件使用 "pdfFactory Pro" 试用版本创建 www.fineprint.com.cn...
  • Page 10 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual Carburetor engine exploded view PDF 文件使用 "pdfFactory Pro" 试用版本创建 www.fineprint.com.cn...
  • Page 11 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual 1、 temperature regulator seat assembly 11、camshaft thrust plate temperature regulator seat 12、camshaft timing gear 2、 distribulator 13、timing belt 3、 camshaft assembly 14、upper\ lower timing gear cap assembly 4、 fuel pump assembly 15、water pump assembly 5、...

  • Page 12: Main Engine Technical Indexes And Operation Parameters

    https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual Main engine technical indexes and operation parameters CAC478C CAC480C CAC480M ← ← Type Line,4-cyl, four strokes, water-cooling ← Cylinder bore diameter(mm) 77.24 79.94 ← Stroke(mm) 74.30 79.52 ← Total displacement(L) 1.392 1.596 Compression ratio 9.5∶1 9.75∶1...
  • Page 13 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual Application parameters： Lubricant(With temperature at - 10℃ or more) SAE10W/30—50( grade SF) Gasoline 93#(SH0041) Common unleaded Gasoline Engine oil pressure Idling 100kPa 2000r/min(80℃) 280kPa Engine oil capacity (L) 3.86(New oil filter) Oil pump pressure regulator starts to open(pressure) kPa 440±20 Engine oil filter by-pass valve starts to open (pressure) kPa 78—118...

  • Page 14: Engine Structural Features

    https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual Engine structural features 1.Cylinder block：Made from gray cast iron. Without bibcock. Without cylinder liner.5 main bearing seats. Main Intermediate bearing anti-thrust. Main bearing caps are retained by spigot. Main bearing bolts of 12.9 grade. 2.Cylinder head：Made from aluminum alloy.
  • Page 15 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual 19.Intake manifold：Made from Aluminum alloy. With mixture warm upped by water jacket. Electric heated intake manifold is optional. 20.Exhaust manifold：Made from ductalloy or black cast iron. 21.Oil pan：Stamping ，Low carbon steel. Oil pool is in the front of cylinder block. 22.Oil pump：Rotor type.

  • Page 16: Engine Maintenance

    https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual Engine maintenance： —— Check lubricant level Daily maintenance —— Check coolant level —— Check bolt for loosing —— Check for leaking (oil, water, air) —— Replace engine oil and oil filter Per8000km ——...
  • Page 17 CAC Gasoline Engine Maintenance And Servicing Manual CAC478、480Contents and intervals for Constant maintenance ×1000km ☆ ☆ ☆ ☆ ☆ ☆ Replace engine oil ☆ ☆ ☆ ☆ ☆ ☆ Replace oil filter ☆ ☆ ☆ ☆ ☆ ☆ Clean air filter core ☆...

  • Page 18: Engine Removal And Assembly Procedure

    https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual Engine removal and assembly procedure 【1】、Positioning no.1 cylinder top dead center (compression) ——Remove two M6×55 flange-shaped bolts, remove upper timing gear cover. ——Install a wrench on crankshaft pulley bolt, rotate crankshaft Clockwise (viewed from the direction of pulley) until the TDC notch on crankshaft pulley aligns with the TDC mark (0) on timing gear cover.

  • Page 19: Upper And Lower Timing Gear Cover Assemblies Removal And Installation

    https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual 【2】、Upper and lower timing gear cover assemblies removal and installation upper timing gear cover assembly Removal： ——Loosen and remove 2 bolts for upper timing gear cover assembly. ——Remove upper timing gear cover and seal assembly.

  • Page 20: Valve Cover And Seal Gasket Removal And Installation

    https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual Installation： ——Clean pulley and crankshaft journal， remove the oil in pulley groove . ——Install pulley on crankshaft journal, aligning keyway with semicircular key. ——Slip cushion block onto bolts and finger screw ——Block flywheel ring gear with screwdriver, preventing crankshaft from turning.

  • Page 21: Timing Belt Removal, Installation And Adjustment

    https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual Installation： ——Clean cylinder head and valve cover contacting surface. ——Push the wedge of valve cover seal gasket into appropriate valve cover groove, integrating valve cover with seal gasket. ——Install valve cover and seal gasket assembly on cylinder head.
  • Page 22 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual Note：With belt removed， don't turn gear excessively，or piston head and valve may be damaged for contacting. ——If belt need to be reused ，check for improper wear ,delaminate crack (particularly at the foot of teeth) or dirt. If lightly suspected, replace it.
  • Page 23 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual 【6】、Tension pulley, crankshaft gear and camshaft gear removal, check and installation 1. Tension pulley Timing gear Removal： ——Rotate crankshaft to no.1 cylinder compression TDC. ——Remove belt. cushion ——Loosen 2 tension pulley mounting bolts， push tension pulley aside to release belt tension with a large screwdriver.

  • Page 24: Camshaft Oil Seal Removal And Installation

    https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual Installation： ——Check gear tooth for wear, pitting or scratch. ——Install camshaft semicircular key，protrusion should be 1.64—2.11mm. ——Install camshaft gear on camshaft with new bolt though cushion block，new bolt should be pre-pasted and tightened to 52—60Nm.——Check whether crankshaft is positioned at compression TDC.
  • Page 25 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual 【8】、Valve mechanism and cylinder head removal, check and installation 1.Valve mechanism for 478 and 480 engine： Rocker arm-8 Rock arm nut-8 .tightening torque 25-29n.m Rocker arm seat-8 Rocker arm seat washer-8 Valve locking piece-16 hydraulic lifting rod-8 clearance with...
  • Page 26 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual 2.Cylinder cover bolts removal and cylinder head assembly installation Cylinder head bolts removal： ——Rotate camshaft until keyway is rightly upside. ——Loosen cylinder cover bolts in order as specified in diagram. ——Note：Cylinder cover bolts must be replaced after removed and are not permitted to reuse.
  • Page 27 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual ——Install new cylinder head bolts and washers into bolt holes, screw in by hand. ——Tighten cylinder head bolts in four steps in the order Fig.24 as diagram specified. Step 1：Tighten to 20—40Nm Step 2：Tighten to 40—60Nm Step 3：Rotate 90°...
  • Page 28 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual Installation： ——Check rocker arm contact surface for abnormal wear， replace rocker arm if necessary. ——Pull rocker arm support washers onto rocker arm double end studs. ——Lubricate rocker arms and rocker arm supports with engine oil.
  • Page 29 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual Hydraulic lifting rod installation： ——Hydraulic lifting rod size： Cylinder head Lifting rod Grade lifting rod hole clearance outside diameter diameter Φ22.200—Φ22.212 Φ22.25±0.015 Standard 0.023—0.065 Fig.31 Φ22.454—Φ22.466 Φ22.50±0.015 0.023—0.065 ——Apply hyperbolical gear lubricant or engine oil on lifting rod, lifting rod outside diameter and lifting rod ends, install lifting rods in original order into the holes in the cylinder head.
  • Page 30 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual ——Camshaft journal and cylinder head cam bearing hole size： (1) Standard size Cylinder head Camshaft Camshaft journal bearing hole journal number diameter diameter 44.74—44.76 44.783—44.808 44.99—45.01 45.033—45.058 45.24—45.26 45.283—45.308 45.49—45.51 45.533—45.558 Fig.35 45.74—45.76 45.783—45.808 (2).
  • Page 31 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual 5.Valve, valve spring, valve oil seal, spring seat assembly removal and installation： Removal： Using special tools for valve compression, take out valve locking pieces, don't compress spring excessively, compress spring enough to slip locking pieces out of its stroke, or valve stem may be bent.
  • Page 32 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual ——Measure valve spring free length and spring force: Compression (mm) Spring load (N) Spring free length =37.084 =27.7 892.7 =47.2 =27.0 Fig.42 Fig.42 ——Grinding the valve and the valve seat with the valve conical angle(Intake valve and exhaust valve): 44°30′—...
  • Page 33 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual 6.the sizes for intake valve, intake valve seat, exhaust valve seat and valve guide ―the size of intake valve seat and cylinder head valve seat hole ― Diameter of the Diameter. of intake press fit cylinder head Fig.46...
  • Page 34 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual 【9】: Removal and installation of the piston and rod assembly. Removal: ——Remove the crankshaft to the bottom dead center of the cylinder. Check and make sure that there is a cylinder mark on the connecting rod and its cap.
  • Page 35 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual position 19mm to the bottom skirt. unit：mm 488 dia. of 478 dia. of piston 480E *dia. of piston skirt skirt(mm) piston skirt (mm) (mm) 77.19—77.20 79.91—79.92 79.915—79.925 77.20—77.21 79.92—79.93 79.925—89.935 factory group 77.21—77.22 79.93—79.94 79.935—79.945...
  • Page 36 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual ——Measure the crosshead end bore of the connecting rodФ20.589 +0.02 PDF 文件使用 "pdfFactory Pro" 试用版本创建 www.fineprint.com.cn...
  • Page 37 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual ——Check and make sure that the oil injection hole of the connecting rod large end is not blocked. The outside diameter is φ1mm. Installation: ——Need not to divide into groups for the piston weight, piston pin holes and the accessory piston skirt.
  • Page 38 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual Installation of the piston and rod assembly： Apply engine oil on piston, piston ring and cylinder bore. Stagger 120°among the first compression ring, the second ring and oil ring cotter, then install piston rod into cylinder bore. push the piston an rod assembly by hammer into the cylinder bore.
  • Page 39 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual 2). The removal and installation of carrier assembly of the real oil seal: Removal： ——Remove 4 bolts (as arrow indicates). ——Take out carrier assembly of the real oil seal ——Remove carrier sealing gasket of the real oil seal Fig.58 ——Use chisel or screwdriver to pry the real oil seal from the carrier of the real seal oil.
  • Page 40 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual ——Tighten four M6 bolts to 8.0 —11.0Nm。 ——Remove the plastic piece. Sealing plate M6 bolt×20（4） Tighten torque 8~11Nm Fig.62 【11】. Removal and installation crankshaft, crankshaft thrust washer, halves and main bearing cap Removal：...
  • Page 41 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual carefully. Arrange them according to the sequence. Read the bearing clearance according to the proportion stated in the cover of plastic clearance gauge. Check the bearing clearance from the third main bearing and extending to the two sides.
  • Page 42 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual —the size of crankshaft thrust, thrust washer and cylinder block thrust： unit：mm The size of size The thickness of level cylinder body crankshaft thrust thrust washer thrust standard 24±0.03 28.825—28.875 2.326±0.025 oversize 24±0.03 29.205—29.255 2.516±0.025...
  • Page 43 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual ——Nine main bearing bolts are hex head flange side bolts, and one is stud. For horizontal engine, the stud is mounted in the left threaded hole of the second main bearing cap (see from the front) which is for installing the carrier of oil collector.

  • Page 44: Engine Oiling System

    https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual 【13】. Engine oiling system: 1). The description of the oiling system: Through oil collector (2), the rotary oil pump(1) which is installed in the front end of crankshaft draws oil from oil pan (3) and pressurizes.
  • Page 45 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual 2) The removal and installation of oil pan： removal： ——Loosen drain plug and drain oil ——Loosen eighteen M6×20 bolts ——Take out the sealing gasket of oil pan ——Check if the left and right reinforced plates are still clipped on the back face of oil pan flange face Fig.
  • Page 46 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual The removal and installation of oil collector assembly removal： ——Loosen locknut of oil collector assembly and take out the nut and flat washer ——Loosen carrier bolts and take out the bolts。 ——Loosen flange face bolt of oil collector (two ) and take out the two bolts with spring washers Fig.
  • Page 47 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual 4. The removal and installation of oil pump with oil seal assembly removal： ——Loosen six M6×30 hexagonal flange surface bolts. Remove the bolts (as the figure indicates ) ——Remove oil pump with oil seal assembly Fig.
  • Page 48 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual ——Check the clearance between outer rotor of oil pump and case bore of oil pump. The clearance between outer rotor of oil pump and case bore of oil pump should be 0.06—0.19mm. Fig.
  • Page 49 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual ——If relief valve spring is not to specification, it must be replaced. Installation： ——Install the outer and inner rotor into the oil pump house Fig. 87 ensuring the installation mark of outer and inner rotor upward. ——Install oil pump cover on oil pump.
  • Page 50 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual ——Remove the thin plastic protective tape Fig. 91 tightening torque 18.0-25.0Nm removal and installation of oil filter and oil pressure sensor. Removal： ——Remove the oil filter. rotate oil filter counterclockwise during removal. ——Remove the oil pressure sensor Installation：...
  • Page 51 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual 【14】 Engine cooling system 1) Description for cooling system warm wind heat The cooling system is of pressure system. It expansion pressure exchanger tank includes water pump driven by timing belt, hose hose crosscurrent radiator, expansion tank, pressure hose...
  • Page 52 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual Grade Ⅱ≤91℃ wide opening temperature 89°－102° Operating voltage 12V PDF 文件使用 "pdfFactory Pro" 试用版本创建 www.fineprint.com.cn...
  • Page 53 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual ——Coolant draining ： (1) remove pressure cap of expansion water tank (2) connect a container under the radiator. Remove the outlet hose of radiator or open the drain plug of radiator. ——Cleaning cooling system： (1) drain the coolant and then close the drain plug of radiator or install the outlet hose of radiator (2) add clean water into the max water level of expansion tank and install the pressure cap (3) start engine and keep idling., warm engine to normal working temperature and stop engine cooling...
  • Page 54 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual 2) The removal and installation of water pump assembly ——The structure of water pump assembly 1—water pump case 2—water pump impeller 3—water pump gear 4—water pump bearing 5—water pump seal (ceramics—black lead) Fig.
  • Page 55 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual 3) The removal and installation of thermostat seat with thermostat assembly ——Loosen three M6×40 bolts and remove them ——Remove thermostat seat with thermostat assembly ——Pry out spring clip by chisel or screwdriver Fig.96 ——Take out the thermostat Fig.
  • Page 56 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual thermostat Spring clip Sealing gasket Sealing gasket Overflow pipe Drainage pipe Sealing gasket Small recircula- ting pipe Temperature seat assembly Plug screw Tighten torque Fig.100 Assembly: ——Clip the thermostat seat, and put the rubber seal ring into the thermostat hole. ——Install the thermostat(with spring outward) ——Install spring clip, ensure that the clip is clipped in the thermostat seat groove.
  • Page 57 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual guide cover Intake hose carburetor Air filter exhaust manifold Intake preheat hose intake manifold engine front sound absorber back sound absorber Exhaust hose Fig. 101 intake and exhaust system arrangement of carburetor engine ——The air filter is equipped with a intake air temperature controller.
  • Page 58 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual ——The air filter is equipped with a intake air temperature controller. When the temperature is low, the hot air intake valve controlled by the temperature controller will open and the hot air, flowing by the exhaust manifold, will be directed into the air filter from the intake preheating hose to supply more hot air and facilitate the fuel atomization during cold winter.
  • Page 59 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual The intake manifold ‘s air may be preheated by the electrical heater as well as by coolant. As the coolant’s temperature is lower than 60°, the electronic heater will be energized to facilitate the cold starting. The electrical heater’s energizing or deenergizing is controlled by the intake preheating switch and relay.
  • Page 60 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual 4. The removal and assembly for the exhaust manifold, heat insulation cover and rear lifting lug: Removal: －Loose and remove the M12×25 allen screw, and remove the rear lug . －Loose and remove two M8×12 screw and remove the heat insulation cover .
  • Page 61 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual 【16】 Positive Crankcase Ventilation（PCV）system of engine. 1. Description for PCV system of the Carburetor engine: PCV system is a closed system. The leaking air of piston from the Crankcase goes to the Connection cylinder head cover through the PCV hose.
  • Page 62 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual 2.2 PCV valve’s function: under the low speed condition, the vacuum of intake manifold is very high, which keep the valve closed, and only a small opening exists to allow the gas pass through. Therefore it won’t change the mixture rate.
  • Page 63 Push rod 2-M8 stud Fig.113 1.3 Carburetor. Idle and overdrive cut-off valve basic parameters: Thermo time Pierburg 2E3 carburetor: control valve CAC478 CAC480 Larger throat pipe diameter 20/24 22/26 Mixing chamber size 28/30 28/30 Pierburg 2E3 carburetor Installation:...
  • Page 64 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual ——Adjustment of Peirburg 2E3 carburetor: CO adjustment Idle overdrive Idle speed adjustment: screw cut-off valve Rotating the screw inward will increase idle speed. Rotating the screw outward will decrease idle speed. CO adjustment: Cone valve Rotating the CO screw inward will enrich the mixture .
  • Page 65 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual 【18】 Engine electrical system. The electrical system includes battery, alternator, starter, breakerless distributor, ignition controller, spark plug, high-power ignition coil, high pressure assembly, water temperature sensor, oil pressure switch, electric fan, thermo switch, and idle speed solenoid valve of carburetor. 1.
  • Page 66 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual The JFZ1913—4 alternator for independent assembly. Fig. 121 The JFZ18D13 ZB alternator for independent assembly. Fig. 122 alternator bracket for independent assembly. Fig. 123 Starter. Rated output: 0.95kW Speed range: 1000-1800r/min Voltage: Type: QDY1258 SD6RA78...
  • Page 67 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual ——The left chart is QDY1258 ——When checking starter, you should clean carbon brush. Its surface should not have dust and calibrator, and the brush can move freely in the carbon brush carrier. Change them if the brush and carrier are damaged severely.
  • Page 68 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual PDF 文件使用 "pdfFactory Pro" 试用版本创建 www.fineprint.com.cn...
  • Page 69 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual ——Loosen and remove two M6× 20 bolts. ——Remove the distributor. ——remove the distributor’s “O “seal. Assembly: Fig. 129 distributor assembly ——Insure that the engine is set correctly with No.1 Cylinder at TDC. TDC mark tongue ——install new “O”...
  • Page 70 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual 7. Ignition coil assembly. type Ignition coil assembly Fig. 132 Connector wiring harness assembly. ng assembly PDF 文件使用 "pdfFactory Pro" 试用版本创建 www.fineprint.com.cn...
  • Page 71 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual Carburetor engine faults ,causes and corrections 1.engine does not run during starting: Cause correction (1). Battery wires are loose or corroded reconnect or replace the wires . (2). Battery is discharged or damaged recharge or replace the battery .
  • Page 72 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual 4. difficult to start for engine when temperature is high: Cause correction (1). Air filter is dirty or blocked clean air filter core or replace case (2). low cylinder compression pressure sent to service spot for check and service (3).
  • Page 73 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual (8). Timing belt tightening incorrectly adjust timing belt tension (9). Idle mixture too rich or lean adjust carburetor idle mixture adjustment screw 8. engine Stalls during idling: Cause Correction (1). Low idle speed adjust idle speed (2).fuel outlet port or transition port for Idle speed blocked...
  • Page 74 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual 10. Engine accelerates hesitately Cause Correction (1). Intake manifold or connecting hose vacuum leaking service and check (2). Fuel filter clogged replace fuel filter (3). Fuel pump damaged. Or low fuel outlet pressure replace fuel pump (4).
  • Page 75 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual 13. Carburetor backfire. Cause Correction (1). Engine ignited too late check adjust distributor adjust ‘teeth’ belt tension and (2). Incorrect Timing belt assembling or inadequate belt tension tension pulley (3). Carburetor fuel level too low or check and adjust float chamber mixture too lean needle valve...
  • Page 76 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual 16. Engine noise. (1). Preigniton or knocking occursduring accelerating or under heavy load Cause Correction check ‘teeth’ belt tension, tension a. Incorrect ignition timing pulley or distributor b. Incorrect fuel grade fuel correct grade c.
  • Page 77 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual (8). Air exists in cooling system bleeding the air (9). Too lean mixture adjust carburetor 18. Engine is too cold Cause Correction (1). themostat damaged replace thermostat (2). Water temperature sensor damaged replace water temperature sensor 19.
  • Page 78 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual Fig. 134 single port injection system 1. fuel tank 2. fuel pump fuel filter 4. check valve 5. fuel pressure regulator fuel injector 7. air filter 8. fuel vapor connecting pipe 9.engine idle speed actuator...

  • Page 79: Genera

    https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual advance is calculated by a basic chart(pressure, revolution) and trimmed by engine load, water temperature, and air temperature. In addition, it may perform dynamic ignition advance to stabilize idle speed. Engine idle speed actuator adjusts the by-pass pipe opening to keep idle value constant .
  • Page 80 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual Fuel vapor recirculate solenoid Engine idle actuator Fuel pump Oil injector High pressure ignition coil Absolute pressure sensor TDC/RPM sensor Throttle valve position sensor PDF 文件使用 "pdfFactory Pro" 试用版本创建 www.fineprint.com.cn...
  • Page 81 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual Water temperature sensor Intake temperature sensor A/C signal λ sensor Fig. 135 The control-illustration for single Port Injection System According toλsensor signal, ECU will automatically revise C0 parameter(close loop). When λsensor fails, ECU may work under open loop. 2.
  • Page 82 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual The following accessories and engine air filter are installed on the upper body of throttle valve. ·fuel system pipe and fuel return pipe ·fuel pressure regulator ·bottom-supplying fuel injector IWM ·intake air temperature sensor. ——Fuel pressure regulator As engine is running, fuel pump supplies fuel (fuel supply volume of pump is about 80L/h) through filter and pipe to fuel pressure regulator(chart 137).
  • Page 83 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual IWM523 fuel injector applied in the system is of the shortened type of the first generation. It is entirely made of stainless steel and superior in the function. The advantage may be embodied when the commercial fuel containing corrosive material is applied.
  • Page 84 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual Connecting chart water Fig.139 temperature sensor and principle 2.2 Lower body(air system)—description and function of accessories Excepted that connecting throttle valve to accelerator pedal by a lever, the following parts should be installed on the lower body.
  • Page 85 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual holes in the bracket for installing the potentiometer on throttle valve. · there is spline on the shaft. the spine provides data about throttle position. The data is used to confirm idle operation condition(accelerator pedal released), full load(accelerator pedal depressed) and accelerating or decelerating conditions.
  • Page 86 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual feature by-pass channel idle actuator parameter throttle spiral resistance valve operation temperature throttle valve leak by-pass valve air control. Fig. 141 Idle step motor and air by-pass valve If stepper motor needs to be replaced, remove the positive connector first and replace actuator. Then turn ignition key to position 1(accessory position), ECU will readjust actuator position(to limit switch) and adjust for steps according to engine water temperature so as to adjust idle speed with valve linear (axial direction)movements(forward or backward).
  • Page 87 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual 3.2 fuel filter Fuel filter (see drawing 143) is connected between fuel pump and the fuel intake port of the throttle valve body. It comprises an aluminum case and a bracket with a stainless steel in it. for the high sensitivity of fuel injector and the the existence of external impurities being in the fuel system, it is necessary to use the high-efficiency paper filter core.
  • Page 88 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual timing： Rotate the engine pulley(2) to keep cylinder 1 and cylinder 4 at TDC, i.e. the mark on the pulley (2) and the mark (3 and 4) on the timing wheel cover of engine must be matched (see figure. 145). see from the front end, rotation direction top dead center position crankshaft...
  • Page 89 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual 3-way connector ( figure. 147) a. supply 5V voltage b. negative pole signal c. positive pole signal Fig. 147 absolute pressure sensor When engine is shut down, the sensitive membrane will bent according to the value of atmospheric pressure (mmHg).
  • Page 90 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual When ECU microprocessor identifies the signals of two tooth-missed signals , it will begin to count tooth. cylinder 1 or cylinder 4 TDC comes after 20 teeth are counted .cylinder 2 or cylinder 3 TDC comes after 50 teeth are counted (determine by pair).
  • Page 91 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual 6 zirconiumλ sensor is designed to detect the oxygen in exhaust emission In endothermal engine, the combustion is produced by the reaction of hydrogen and oxygen and then emits heat. Fuel is composed of hydrocarbons. It includes carbon atom and hydrogen atom which are combined together by different modes (paraffin, olefine, aromatics).
  • Page 92 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual to check all sensors and actuators, injection system ECU has a complete high-efficiency self-diagnosis system. When failure occurs, the warning light will turn on. Warning：Before checking exhaust emission orλsensor, check： 1. The warning light should go out, or use CHECK—UP1 diagnosis instrument to determine the failure and adjust it for correct operation.
  • Page 93 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual Catalytic converter may damp the three contaminations in the exhaust: unburned hydrocarbon (HC), carbon monoxide(CO) and nitrogen oxide (NO two kinds of complicated chemical reactions exist in the catalytic converter: the oxidation of carbon monoxide and hydrocarbon changing into carbon dioxide and water;...
  • Page 94 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual Ignition switch Fig. 154 principle drawing of anti-fuel vaporization system 1. fuel tank 2. Two-way check valve 3. fuel Injection pressure system 4.multi-function valve 6. charcoal canister 7. fuel vapor recirculation solenoid 8.throttle valve body After long time since engine stopped, the temperature in the fuel tank will rise (Since the vehicle doesn’t move, the dynamic ventilation is not enough.) and the pressure in the fuel tank will rise.
  • Page 95 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual If the pressure in the fuel tank (1) rises beyond the specified value, two-way check valve (2) will open reducing the pressure in the fuel tank. If necessary, the valve may open reversely to vent inward when the fuel tank is vacuumed. —When the fuel level is at middle or low , when it exceeds a specified pressure, the multi-function valve (4) will permit the fuel vapor to reach the charcoal canister (6) and be absorbed by the activated carbon granule.
  • Page 96 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual Fig.156 1.fuel tank 2.fuel pump (submerged in fuel tank) 3. Filter screen prefilter (installed in the inlet of fuel pump) 4.fuel filter 5.fuel delivery pipe 6.fuel injector(installed in the throttle valve) 7.pressure regulator 8.fuel return pipe 9.fuel recirculation check valve (stop backflowing ) 10.fuel cut-off switch...
  • Page 97 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual Relay of system power supply Fig.157 1. battery 8.5A ECU fuse 3.1# ignition coil (cylinder 1、4) 9.dual relays (A—ECU，B—fuel pump) 3.λsensor 11.fuel pump 4.fuel injector 12. fuel vapor recirculation solenoid 5.2# ignition coil (cylinder 2、3) 13.ECU 6.ignition switch 14.main ground wire of engine...
  • Page 98 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual Fig. 158 PDF 文件使用 "pdfFactory Pro" 试用版本创建 www.fineprint.com.cn...
  • Page 99 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual 1.injection/ignition system ECU 17.injection system warning light (on the instrument panel) 2.battery 20.fuel cut-off switch 3.ignition switch 21.A/C control unit 4.25A system fuse 22.A/C compressor relay 5.5A ECU fuse 23.A/C compressor 6.dual relays 26.engine idling actuator 7.revolution counter 27.throttle valve position sensor...
  • Page 100 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual 27.without connection line 28.speed sensor positive input 29.λsensor positive input 30.throttle valve potentiometer signal input 31.intake air temperature sensor signal input 32.absolute pressure sensor signal input 33.without connection line 34.main ground wire of engine 35.ignition switch +12V power supply input A/C I/O may only be supplied to the vehicle equipped with A/C and the ECU of the corresponding engine, i.e.
  • Page 101 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual system fuse ECU fuse dual relays ignition coil of cylinder 2,3 ignition coil of cylinder 1, 4 fuel vapor solenoid sensor sensor fuel injector step motor throttle valve position sensor intake gas temperature sensor absolute pressure sensor water temperature sensor tacho/top dead center sensor...
  • Page 102 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual the installation position in engine single point injection/ ignition system Fig. 161 1.injection/ignition ECU2 diagnosis passage 12.λsensor 3.speed/ TDC sensor 13.fuel pressure regulator 4.engine flywheel 14.fuel injector 5.ignition coil with dual high-pressure connector 15.dual relays (for ECU and fuel pump) 7.throttle valve position sensor 16.25A injection/ ignition system fuse...
  • Page 103 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual ——engine idling speed actuator doesn’t work ——shorted fuel injector +12V circuit ——opened or shorted ignition coil circuit also, monitor the following failure： ——with engine cycling start or engine working, signal wheel is not synchronous. ——opened or shorted λsensor circuit ——opened fuel pump circuit Fig.
  • Page 104 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual Removal and reinstallation for fuel pump： Fuel pump is installed inside the fuel tank. Removal procedure is as following: —— switch off the power supply —— remove quick release fuel Outlet pipe and fuel return pipe Remove and reinstall filter ——...
  • Page 105 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual tightening torque 0.5—0.6Nm at ambient temperature, The resistance indicated by digital multimeter should be 2.5—4.5Ω. Note: Even though little lead exists in the fuel, the sensor may fail soon. the function inspection is specified every 45,000km and 90,000km.

  • Page 106: Malfunction, Cause And Correction

    https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual 5.malfaction, cause and correction Malfuction cause Correction Fuel pump. fuel check for operation by CHECK—UP1 injector IVM523 Tachometer Check wring, sensor resistance and installation of the sensor. Vehicle cannot start senser. Dual relays Check for function, connector connection and blown fuse.
  • Page 107 https://www.automotive-manuals.net/ CAC Gasoline Engine Maintenance And Servicing Manual PDF 文件使用 "pdfFactory Pro" 试用版本创建 www.fineprint.com.cn...

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