Joyner JNSZ1600DL Owner's Manual
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Joyner JNSZ1600DL Owner's Manual

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Owner's manual
JNSZ1600DL
Parts manual
READTHISMANUALCAREFULLY
IT CONTAINS IMPORTANT SAFETY INFORMATION.
MINIMUM
RECOMMENDED
OPERATOR AG
FOR OFF-ROAD USE ONLY
This vehicle is designed and manufactured for off-road use only.
USA only;
It does not confirm to federal motor vehicle safety standards, and operation on public streets, roads, or
highways is illegal
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  • Page 1: Is Your Vehicle Ready To Drive

    Owner’s manual JNSZ1600DL Parts manual READTHISMANUALCAREFULLY IT CONTAINS IMPORTANT SAFETY INFORMATION. MINIMUM RECOMMENDED OPERATOR AG FOR OFF-ROAD USE ONLY This vehicle is designed and manufactured for off-road use only. USA only; It does not confirm to federal motor vehicle safety standards, and operation on public streets, roads, or...
  • Page 2 This warranty does not apply to any part, which in opinion of sold was defective because of improper maintenance, improper assembly, alterations, abuse, negligence or accident. Should warranty service be required on your JNSZ1600DL during the 90 days warranty period, please contact your nearest authorized dealer for repairs.

  • Page 3: Table Of Contents

    CONTENTS OWNER’S MANUAL Page 1. FOREWORD -----------------------------------------------------------------------------------------------3 2. A FEW WORDS ABOUT SAFETY -------------------------------------------------------------------- 4 3. IMPORTANT SAFETY INFORMATION ----------------------------------------------------------- 5 4. SAFETY LABELS ----------------------------------------------------------------------------------------- 7 5. ARE YOU READY TO DRIVE? ----------------------------------------------------------------------- 8 6. IS YOUR VEHICLE READY TO DRIVE? --------------------------------------------------------- 10 7.

  • Page 4: Specifications

    SPECIFICATIONS DIMENSIONS Overall Length---------------------------------------------------------------------------------------128.5in. (3265mm) Overall Width ---------------------------------------------------------------------------------------88.5 in. (2250mm) Overall Height ----------------------------------------------------------------------------------------71.7 in. (1822mm) Wheelbase ---------------------------------------------------------------------------------------------89.8 in. (2280mm) Front Track ------------------------------------------------------------------------------------------- 68.8 in. (1748mm) Rear Track --------------------------------------------------------------------------------------------72.4in. (1840mm) Ground Clearance ------------------------------------------------------------------------------------ 14.2in. (360mm) ENGINE Type ---------------------------------------------------------------------------------4-Bore,4-Stroke, Liquid-cooled Bore x Stroke --------------------------------------------------------------------------------------------79.94mm×79.52mm Displacement ------------------------------------------------------------------------------------------------------1596 cc Compression ratio ------------------------------------------------------------------------------------------------- 9 .75:1 Carburetor ---------------------------------------------------------------------------------------------Electric Fuel Injection...

  • Page 5: Operations

    OPERATION A. Operation controls WARNING-Do not attempt to start or operate the engine until completely familiar with the location and use of each control necessary to operate this vehicle. The operator must know how to stop this machine before starting and driving it. a.
  • Page 6 OPERATION d. Start engine 1. Press the clutch pedal down, put the shift lever in neutral 2、Insert the key into the ignition-switch Fig. 2 If the engine is cold; 1. Press down the clutch pedal 2. Turn the key clockwise to the “on” position. Release the key and the clutch pedal when the engine starts.
  • Page 7 Before you start the engine, check that the parking brake is engaged, and the gear shift lever is in neutral. Trying to start the engine in gear may damage the starter motor, clutch or gearbox. Release the key at once if the engine starts. Holding the key in start position when the engine is running will cause damage to the starter motor.
  • Page 8 OPERATION 11. Check Brake Light. Check for proper operation. 12. Check Wheels. Check for tightness of wheel nuts and axle nuts; check that axle nuts are secured by cotter pins. 13. Check Steering. Check for free operation and for any unusual looseness in any area. Always follow rules for safe operation and wear a helmet.
  • Page 9 OPERATION E. Parking Adjustment(See Fig. 4 ) Pull the park brake lever up so that the unit can engage park brake. To release the unit, press button on front end of parking lever then push the parking lever to the bottom.
  • Page 10 Fig. 7 G. Break-in The first month is most important in the life of your vehicle. Proper operation during this break-in period will help assure maximum life and performance from your new vehicle. The following guidelines explain proper break-in procedures. 1.

  • Page 11: Service Instructions

    • SERVICE INSTRUCTIONS A．Service Air Filter Service air filter every 80 hours NOTE: Service more often under dusty conditions. Fig.8 Remove filter cover(See Fig. 8) b. Check the filter cover and the air filter, if the filter cover and the air filter is dusty, please clear the filter cover and replace with a new air filter.
  • Page 12 SERVICE INSTRUCTIONS Fig. 11 Fig. 12 a. With the engine warm, put the vehicle on the level ground. b. Shut down the engine, put a collecting oil plate under the engine oil outlet. Loosen the oil outlet plug in the warm engine. Let the engine oil out fully (see Fig. 9). c.
  • Page 13 SERVICE INSTRUCTIONS C. Transmission lubrication You must change the oil in the transmission after the first 5 hours of operating of your new engine and after 10 hours of use thereafter. That will insure proper lubrication of internal parts and prevent costly repairs due to excessive wear.
  • Page 14 SERVICE INSTRUCTIONS a. Put the vehicle on the level ground. b. Shut down the engine, put a collecting oil plate under the transmission oil outlet. Loosen the oil outlet plug in the warm engine. Let the transmission oil out fully (see Fig. 14、15). c.
  • Page 15 SERVICE INSTRUCTIONS 4. Increase the engine rev’s a few times 5. Repeat 2,3,4 till the coolant is at neck and no bubbles come up. 6. Refit the coolant cap, turn it clockwise and tighten it 7. Turn the reserve coolant case cap counterclockwise and open the cap (see Fig. 17). 8.
  • Page 16 SERVICE INSTRUCTIONS Fig.20 Cleaning Instructions Keep your kart clean. With a clean rag, wipe off any dirt and oil from around controls. Wipe off any spilled fuel and oil. Keep the engine clean of foreign object and be sure to check that air intake fan is free of debris for proper cooling.

  • Page 17: Repair

    REPAIR Front Wheel Alignment 1. Put the vehicle on level ground. 2. The “toe-in” of the front wheels should be 0.63 inches. To check for alignment, measure distance A and B between the centerline (CL) of the wheels. The proper toe-in dimension A should be 0.63 inches greater than dimension B.

  • Page 18: About Engine

    About engine A. precaution a. strictly observe all requirements and specifications in this manual. Check the earth polarity of accumulator. this gasoline engine adopts negative earth. c. Grinding in must be conducted when using a new gasoline engine. d. When gasoline engine is running, your head, hand, cloth, tool and other things should be strictly forbidden to approach the running fan and pump belt.

  • Page 19: Periodical Check And Service

    PERIODICAL CHECK AND SERVICES The maintenance intervals in the following table are based upon average driving conditions. Driving in unusually dusty areas, require more frequent servicing. Time of service Initial Monthly Quarterly Yearly Item service Engine 1. Tighten bolts on engine. 2.

  • Page 20: Engine Maintenance And Service

    ENGINE MAINTENANCE AND SERVICE Introduction…………………………………………………………………………………………...….30 Engine configuration view and sectional view……………………… ………………………………..31 Main engine technical indexes and operation parameters……………………………….……….……32 Engine structural features……………………………………………………………………………..35 Engine maintenance..……………………………………………………………………….....…….36 Engine removal and assembly procedure……………………………………………………………..39 [1] Positioning no.1 cylinder top dead center (compression) …………………………………………39 [2] Upper and lower timing gear cover assemblies removal and installation………………………..40 [3] Crankshaft pulley removal and installation………………………………………………………..41 [4] Valve cover and seal gasket removal and installation……………………………………………..42...

  • Page 21: Introduction

    Introduction CAC480 series vehicle gasoline engines, which are the products introduced from Ford (Britain) corporation CVH production line, are made by Anhui Chery 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 22: Engine Configuration View And Sectional View

    ENGINE CONFIGURATION VIEW AND SECTIONAL VIEW Fig.22 Fig.23...
  • Page 23 Fig.24 1.Temperature regulator seat assembly 11. Camshaft thrust plate 2.Temperature regulator seat 12. Camshaft timing gear 3. Distributor 13. Timing belt...

  • Page 24: Main Engine Technical Indexes And Operation Parameters

    4. Camshaft assembly 14. Upper\ lower timing gear cap assembly 5. Fuel pump assembly 15. Water pump assembly 6. Air intake manifold assembly 16. Camshaft timing gear 7. Fuel pressure switch 17. Tensioner pulley assembly 8. Oil filter assembly 18. Oil pump assembly 9.
  • Page 25 Overall dimensions (Length * width * highness) 620×610×650 (mm) Ignition angle at idle (Crankshaft angle 10°±1° ，Before top dead center) Valve timing(Crankshaft angle) Intake valve opened Before top dead center18° Intake valve closed After bottom dead center57° Exhaust valve opened before bottom dead center 60°...

  • Page 26: Engine Structural Features

    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. Intake and exhaust valve seats and valve guides strutting.6 camshaft supports.
  • Page 27 quenched，With conical surface angle 45°. With large nest seat in the valve head for hemispherical combustion chamber. Exhaust valve：4Cr9Si2-21-4N. With conical surface angle 45°. With smaller end quenched. 17. Gear：Made from iron base powder metallurgy. 18. Timing belt：Made from cyaniding butadiene-acrylonitrile rubber. 19.

  • Page 28: Engine Maintenance

    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 ——Clean air filter，check air intake tube for cracking —— Check PCV valve ——Check spark plugs ——Check accessories drive belt Per16000km ——Check timing belt and tension pulley...
  • Page 29 480Contents and intervals for Constant maintenance ×1000km ☆ ☆ ☆ ☆ ☆ ☆ Replace engine oil ☆ ☆ ☆ ☆ ☆ ☆ Replace oil filter ☆ ☆ ☆ ☆ ☆ ☆ Clean air filter core ☆ ☆ ☆ ☆ ☆ ☆...

  • Page 30: Engine Removal And Assembly Procedure

    Engine removal and assembly procedure 【1】. Positioning no.1 cylinder top dead center (compression) Fig.26 ——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. Note：Before rotation，spark plugs may be removed to reduce effort.

  • Page 31: Upper And Lower Timing Gear Cover Assemblies Removal And Installation

    Rotate crankshaft, aligning the TDC mark on the crankshaft gear shaft with the TDC mark on the oil pump case. Check whether the TDC mark on camshaft gear aligns with the TDC mark on the front end of cylinder head. if not aligned, rotate crankshaft one turn，aligning the TDC mark on camshaft gear with the TDC mark on the front end of cylinder head.

  • Page 32: Crankshaft Pulley Removal And Installation

    ——Install lower timing gear cover and seal gasket on crankshaft，finger screw in 2 bolts and tighten to 9.0—11Nm. ——Clean upper timing gear cover. ——Mount new seal gasket with shot nail or glue on lower timing gear cover. ——Install upper timing gear cover seal gasket with 2 bolts on cylinder block，tightening torque is 9—11Nm.

  • Page 33: Valve Cover And Seal Gasket Removal And Installation

    ——Install pulley on crankshaft journal, aligning keyway with semicircular key. ——Slip cushion block onto bolts and finger screw in. ——Block flywheel ring gear with screwdriver, preventing crankshaft from turning. ——Tighten bolts to 100—115Nm. Fig.32 【4】. Valve cover and seal gasket removal and installation Fig.33 Removal：——...

  • Page 34: Timing Belt Removal, Installation And Adjustment

    Fig.34 Fig.35 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. ——Install 9 hexagon head bolts of long column end with butterfly gasket， finger screw them into cylinder head.
  • Page 35 Fig.38 Fig.39 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. Installation and adjustment：——Crankshaft should be positioned at no.1 cylinder TDC，if necessary, crankshaft may only be turned slightly for adjustment and blocked at flywheel ring gear.

  • Page 36: Tension Pulley, Crankshaft Gear And Camshaft Gear Removal, Check And Installation

    【6】. Tension pulley, crankshaft gear and camshaft gear removal, check and installation 1. Tension pulley Removal： ——Rotate crankshaft to no.1 cylinder compression TDC. ——Remove belt. ——Loosen 2 tension pulley mounting bolts，push tension pulley aside to release belt tension with a large screwdriver. ——Remove 2 mounting bolts and take out tension pulley.
  • Page 37 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 newbolt though cushion block，new bolt should bepre-pasted and tightened to 52—60Nm. ——Check whether crankshaft is positioned at compression TDC. Crankshaft gear Removal：——Block crankshaft and remove belt.

  • Page 38: Camshaft Oil Seal Removal And Installation

    【7】. Camshaft oil seal removal and installation Fig.42 Fig.43 Removal：——Remove camshaft gear. ——Note the direction of oil seal installation, pry out oil seal from the oil seal hole in cylinder head， be sure not damage the oil seal hole. Installation： ——Clean the oil seal hole in cylinder head ,apply clean engine oil on oil seal edge and camshaft oil seal journal，...

  • Page 39: Valve Mechanism And Cylinder Head Removal, Check And Installation

    【8】. Valve mechanism and cylinder head removal, check and installation 1.Valve mechanism for 480 engine： Fig.44 2.Cylinder cover bolts removal and cylinder head assembly installation Fig.45 Fig.46...
  • Page 40 Fig.47 Fig.48(A dowel B cyclinder head gasket) 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. Cylinder head assembly reinstallation：...
  • Page 41 Fig.51 ——Install new cylinder head bolts and washers into bolt holes, screw in by hand. ——Tighten cylinder head bolts in four steps in the order as diagram specified. Step 1：Tighten to 20—40Nm Step 2：Tighten to 40—60Nm Step 3：Rotate 90°Step 4：Rotate 90° During rotating, torque-angle torque wrench or line plotting methods may be applied.
  • Page 42 Fig.54 Fig.55 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. ——Install rocker arm, rocker arm support，then finger screw in new nut，tighten to 25—29Nm.
  • Page 43 Hydraulic lifting rod installation：——Hydraulic lifting rod size： Unit ： Cylinder head Lifting rod Grade lifting rod hole clearance outside diameter diameter Φ22.25±0.015 Φ22.200—Φ22.212 Standard 0.023—0.065 Φ22.50±0.015 Φ22.454—Φ22.466 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 44 Fig.60 Fig.61 Fig.62 ——Camshaft journal and cylinder head cam bearing hole size： (1) Standard size mm Cylinder head Camshaft journal Camshaft journal bearing hole 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 45.74—45.76 45.783—45.808 (2). Over size (0.38) mm Cylinder head Camshaft journal Camshaft journal...
  • Page 45 Fig.63 Fig.64 Fig.65 Fig.66 6. 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 46 Fig.67 Fig.68 Fig.69 Fig.70 ——Measure valve spring free length and spring force: Compression Spring free Spring load (N) (mm) length L1=37.084 L0=47.2 L2=27.7 892.7 L3=27.0 ——Grinding the valve and the valve seat with the valve conical angle (Intake valve and exhaust valve): 44°30′—45°30′Valve seat sealing width: 1.75 —...
  • Page 47 lock piece groove with a special compression tool. Then put the lock pieces into it and release the compression tool slowly and remove the tool. ——Put the cylinder head on a wood lump after all lock pieces are assembled. And tap the small head of the valve stem with a plastic or copper hammer to fit for the valve mechanism.

  • Page 48: Piston And Connecting Rod Assembly Removal And Installation

    The size of valve guide and valve guide hole The valve The diameter Press fit Level guide of ylinder clearance hole head tube hole 13.555 0 Standard 13.481-13.519 -0.01 14.305 0 Oversize 14.231-14.269 0.026-0.07 -0.01 14.505 0 Oversize 14.481-14.519 -0.01 【9】.
  • Page 49 ——Measure the diameter of cylinder bore. Unit: mm 480 cylinder bore 79.94—79.95 79.95—79.96 Factory group 79.96—79.97 79.97—79.98 80.23—80.24 Factory 80.24—80.25 repair 80.25—80.26 Standard 79.965—77.975 mainte Oversize 80.245—80.255 nance 0.29 Oversize 80.466—80.475 Fig.75 Fig.76 ——Grind the cylinder bore with the service gauge and the figured twins angle is 50°—60°.
  • Page 50 * 480M piston should be applied on 480E engine ——Measure the diameter. of the hole of piston pin Unit：mm diameter of the piston pin hole White 20.630—20.633 20.633—20.636 Blue 20.636—20.639 ——Measure the diameter of piston pin Unit：mm diameter of the piston pin hole White 20.622—20.625...
  • Page 51 Fig.78 Fig.79 Fig80 ——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. Before assembling, check the piston head mark and make sure that it is in accord with cylinder No.4.

  • Page 52: Flywheel Assembly And Rear Oil Seal Bracket Assembly Removal And Installation

    outside cut section should be put down and remember not to the contrary. Firstly the oil controlling ring, then the second compression ring, and finally the first compression ring. As assembling the ring, its maximum tension should be inferior to the diameter of the cylinder(+1. 65mm), or the ring would be deformed and broken.
  • Page 53 Fig.82 Fig.83 Fig.84 Fig.85 Fig.86 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 ——Use chisel or screwdriver to pry the real oil seal from the carrier of the real seal oil.

  • Page 54: Crankshaft, Crankshaft Thrust Washer, Bearing Bushing And Main Bearing Cap Removal And Installation

    seal carrier with vise.. The magnitude of interference for real oil seal and carrier hole is 0.26—0.50mm. ——Install new sealing gasket of real oil seal carrier. ——Install real oil seal carrier assembly. Before assembling, wrap a piece of plastic piece on the crankshaft to avoid damaging oil seal.
  • Page 55 Fig.87 Fig.88 Fig.89 Remove main bearing bolt. Take out the main bearing cap Fig.90 Fig.91 Fig.92 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 56 The thickness of The diameter of connecting connecting rod Level rod journalφ bushing Standard 47.89—47.91 1.480—1.487 ndersize 0.025 47.89—47.91 1.492—1.499 Undersize 0.25 47.64—47.66 1.605—1.612 Undersize 0.5 47.39—47.41 1.730—1.737 Undersize 0.75 47.14—47.16 1.855—1.862 Undersize 1.0 46.89—46.91 1.980—1.987 ——The size of main journal and main bearing hal Unit：mm The thickness The diameter.
  • Page 57 Fig.93 —the size of crankshaft thrust, thrust washer and cylinder block thrust：Unit：mm The size of The size of The thickness of cylinder body Level crankshaft thrust thrust washer thrust Standard 24±0.03 28.825—28.875 2.326±0.025 Oversize 24±0.03 2.516±0.025 29.205—29.255 0.38 Installation：——Before installation, use the second screw tap taps the threaded hole in cylinder body, especially the threaded hole of cylinder head bolt and main bearing bolt.

  • Page 58: Oil Baffle Assembly Removal And Installation

    groove is 0.00—0.051mm 。After the semicircular key is installed, check the protrusion height. It should be 1.392—1.739mm. ——Crankshaft thrust washers are two pieces. They are only installed on the front and back thrust surface of cylinder block. Before installation, apply the engine oil on the surface with oil groove of thrust washer. Position the surface with oil groove towards the cylinder body and the surface with oil groove towards crankshaft.

  • Page 59: Engine Oiling System

    【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. The pressure oil comes into the full flow type oil filter through the assistant oil passage (4) on the left of cylinder body (viewed from the front).
  • Page 60 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.98 Fig.99...
  • Page 61 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 Installation：...
  • Page 62 Fig.103 Fig.104 Fig105 Fig.106 Fig.107 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 ——Pry out the front oil seal of crankshaft by screwdriver or chisel. Note: Don’t damage the front oil seal bore.
  • Page 63 Fig.108 Fig.109 Fig.110 Fig.111 ——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. ——Check the radial clearance between inner rotor and outer rotor of oil pump. The radial clearance between inner rotor and outer rotor of oil pump should be 0.05—0.18mm.
  • Page 64 Fig.112 Fig.113 Fig.114 Fig.115 ——If relief valve spring is not to specification, it must be replaced. Installation： ——Install the outer and inner rotor into the oil pump house ensuring the installation mark of outer and inner rotor upward. ——Install oil pump cover on oil pump. Tighten seven chamfer head screws. Tightening torque is 7-10Nm.
  • Page 65 ——Wrap a plastic tape on the oil seal journal of crankshaft avoiding to damage the edge of front crankshaft oil seal. ——Apply engine oil on the edge of front crankshaft oil seal. Press the oil seal in place using appropriate socket or sleeve and crankshaft pulley and pulley bolt and washers.

  • Page 66: Engine Cooling System

    Fig.118 【14】. Engine cooling system 1) Description for cooling system The cooling system is of pressure system. It includes water pump driven by timing belt, crosscurrent radiator, expansion tank, pressure cap, thermostat and electric fan, fan shroud. When engine coolant temperature is low, water pump draws the coolant in the left water room of radiator and pump it to the cylinder block, cylinder head and intake manifold after pressurizing, going from the local circulation pipe of the thermostat seat to the warm air heat exchanger, and then from heat exchanger back to water pump inlet.
  • Page 67 —cooling system parameters： Total system capacity (L)8 electric fan water pump Engine capacity (L) 3.3 diameter. 280mm diameter of impeller 72mm radiator capacity (L) 2.1 blade quantity 6 speed ratio 1.053∶1 expansion tank capacity(L)0.4 operating voltage 9－16V pressure cap GradeⅠ1500r/min operating pressure 160kPa Grade Ⅱ2800r/min...
  • Page 68 a. Drain coolant b. Remove outlet hose of radiator. Insert the water supply hose into the inlet of radiator until the water drained is clean. c. Connect the hose connected to water supply to the water outlet of thermostat seat to wash the engine until the water drained from the water pump inlet is clean.
  • Page 69 2) The removal and installation of water pump assembly ——The structure of water pump assembly —water pump case —water pump impeller —water pump gear —water pump bearing —water pump seal (ceramics—black lead) Removal：——Loosen and remove four bolts from the front end of cylinder block ——Remove water pump assembly ——Remove sealing gasket of water pump Installation：...
  • Page 70 ——Loosen three M6×40 bolts and remove them ——Remove thermostat seat with thermostat assembly ——Pry out spring clip by chisel or screwdriver ——Take out the thermostat ——Take out sealing gasket ——Remove sealing gasket of thermostat seat Measure the opening temperature of thermostat in hot water. Fig.125...

  • Page 71: Engine Air Intake And Exhaust System

    ——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. ——Install the sealing gasket of the new thermostat seat on the thermostat assembly with a bolt. ——Install the thermostat together with thermostat assembly into the rear end hole of cylinder head.
  • Page 72 The exhaust system of the carburetor engine 480 includes Exhaust Manifold, Heat Insulation Cover, Exhaust Hose, Front Muffler, Rear Muffler. 2. Description for the Exhaust System of Engine 2.480M: Fig.127 intake and exhaust system schematic drawing of engine 480M The Intake System of Engine 480M includes: air filter, Intake Hose, Guide Cover, Throttle Valve, Intake Manifold, Intake air preheating hose of Positive Crankcase Ventilation （...
  • Page 73 Removal and assembly of the Intake Manifold Assembly and Front lifting Lug: 1. The Intake Manifold Assembly of the Carburetor Engine. Fig.128 composing of intake manifold assembly of carburetor engine Fig.129 composing of intake manifold assemble of electric injection engine The intake manifold ‘s air may be preheated by the electrical heater as well as by coolant.
  • Page 74 ——Loose and remove the remaining four M8 lock nuts. ——Remove the intake manifold. ——Remove the intake manifold sealing gasket. ——Remove six studs with equal length using two M8 nuts. Assembly: ——Apply lotite sealant 201 on the cylinder head bolt threads and screw six studs into the cylinder head.

  • Page 75: Engine Crankcase Ventilation System

    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 . －Loose and remove 8 M8 lock nuts and washers.
  • Page 76 2. Description for PCV system of 480M engine Fig.132 Fig.133 2.1 Description of PCV system. The PCV system is a closed system. The leaking air of piston goes to the rear cylinder head cover from the Crankcase through the PCV hose. PCV valve is connected to the intake manifold. Meantime, a Ф 15 hose in the front of the valve chamber cover assembly is connected to the guide cover and PCV valve by the 3-way connector through a hose.

  • Page 77: Engine Fuel Supply System

    【17】. Fuel supply system of the carburetor engine 1. Fuel supply system of the carburetor engine. Fig.134 Fig.135 1.1 Description of the fuel supply system. The fuel in the tank flows into oil filter pumped by the fuel pump and goes into carburetor after being filtered through fuel pump. A amount of fuel returns to the tank through return pipe.
  • Page 78 1.2 Removal and assembly of the fuel pump: ——Remove two M8 lock nuts. ——Take out the fuel pump. ——Remove the fuel pump sealing gasket. ——pull out the push rod. Fig.137 Fig.138 ——Remove the studs of same length. Assembly: ——Submerge the push rod into the engine oil or pour engine oil into the rod’s hole of the cylinder head and install the push rod into the hole.
  • Page 79 Installation: Use studs, nuts, and washers to connect the transition flange with intake manifold. Screw the studs into intake manifold and tighten them with nuts. Tightening torque is 8-10Nm. Adjustment: The carburetor adjustment mentioned in this introduction only specifies the idle speed adjustment and CO adjustment.
  • Page 80 system, idle speed should be raised if the A/C is on during idling. By adjusting idle adjustment screw of the idle up actuator valve, idle speed may be adjusted to the specified valve under load. 2.1 Description for fuel system. The fuel pump in the fuel tank supplies fuel, though fuel filter, to the fuel injector in the throttle valve body.
  • Page 81 Fig.143 Fig.144 Fig.145 The JFZ1913—4 alternator for independent assembly. Fig.146 Fig.147 The JFZ18D13 ZB alternator for independent assembly...
  • Page 82 Fig148 Fig.149 The alternator bracket for independent assembly 2. Starter Rated output: 0.95kW Speed range: 1000-1800r/min Voltage: Type: QDY1258 SD6RA78 ——The flywheel gear ring for vehicle and the one for independent engine assembly is different and also the starter gear modulus is different, so different starters need to be applied. ——The figure indicates SD6RA78.
  • Page 83 ——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 84: Carburetor Engine Malfunction, Cause And Correction

    6. High tension ignition wire assembly: The high tension ignition wire assembly is mounted on the cylinder wire bracket which is installed on the valve cover, also cylinder wire and coil wire clips exist between the distributor Fig.156 Fig.157 Fig.158 Carburetor engine faults, causes and corrections 1.
  • Page 85 (7). No engine ground wire or ground wire is disconnected Connect or replace the ground wire 2. Engine runs but no spark exists during starting: Cause Correction (1). No fuel in fuel tank Fuel the tank (2). No fuel in the carburetor float chamber Keep trying to start engine (3).
  • Page 86 (3). Hydraulic valve lifting rod is damaged Replace the lifting rod 5. The starter noise or rough engagement. Cause Correction (1). Flywheel gear ring or starter’s pinion loose or broken Replace flywheel gear ring or starter (2). Starter retaining bolt loose or missing Tighten retaining bolt or replace bolt (3).
  • Page 87 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 Check and clean (3). Choke not open or out of work Check choke system (4).
  • Page 88 (3). Fuel pump damaged. Or low fuel outlet pressure Replace fuel pump (4). Carburetor acceleration pump clogged or Clean or replace accelerator pump diaphragm damaged (5). Part-load fuel way clogged Clean and service (6). Spark plug corroded, damaged or Spark plug gap abnormal Replace spark plug 11.Engine speed is not as specified Cause...
  • Page 89 (3). Carburetor fuel level too low or Check and adjust float chamber needle valve mixture too lean (4). Carburetor measuring orifice blocked or Clean float chamber watery (5). Spark plug overheated or too much carbon deposits Adjust and service (6). Intake valve sealing not well Check and service (7).
  • Page 90 (2). Whistle noise: Cause Correction a. Intake manifold sealing gasket leaks Replace sealing gasket or tighten bolts b. Exhaust manifold sealing gasket leaks or Replace sealing gasket or tighten bolts exhaust pipe sealing gasket leaks c. Vacuum hose leaks Replace d.
  • Page 91 18. Engine is too cold Cause Correction (1). themostat damaged replace thermostat (2). Water temperature sensor damaged replace water temperature sensor 19. Too much fuel consumption Cause Correction (1). Air filter blocked replace air filter core (2). Too high idle speed adjust idle speed (3).

  • Page 92: Cac480Mengine Single-Point Electric Control Injection System

    CAC480M Engine’s single port injection system ［1］. Summarize The system, referred as “λSpeed Density”type (running speed, air density, mixture control), is designed to perform the control for injection and distributorless ignition. According to the following figure (figure 159) of Single Port Injection System, three basic parts are included as the following: 1.

  • Page 93: Operation Principle

    ［2］. Operation principle: Single Port Injection System is applied on the vehicle equipped with 3 way catalyst converter .the system insures air/fuel mixture ratio in the vicinity of the ideal air/fuel ratio. The ideal air/fuel ratio is important for catalyst converter to work normally. The aim having the catalyst converter installed is to reduce harmful exhaust emission.
  • Page 94 may operate ECU microprocessor to check whether the following accessories are running well or not: fuel pump, fuel injector, and fuel vapor recirculation solenoid. After service, you may erase trouble code stored. To check stepper motor, technician needs to start the engine before checking. ECU memory stores a series of emergency parameters for resuming operation.
  • Page 95 ——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). The regulator is designed to keep the specified fuel pressure at 1bar(0.9-1bar), and redundant fuel will recirculate flowing into fuel tank. Fuel will clean and cool injector during recirculation.
  • Page 96 ——Working procedure of Fuel pressure regulator. Spring (2) applies pressure on the diaphragm (7) connected to sealing valve (6) keeping cavum closed between fuel delivery pipe and fuel return pipe (4). When fuel pressure in pipe (3) exceeds 1 bar, pressure on diaphragm (7) will overcome spring (2) resistance, then diaphragm goes up raising sealing valve up to allow redundant fuel to flow back and returns to proper work pressure.
  • Page 97 Fig.164 When fuel injector is not operating, it is sealed and doesn’t allow fuel drain. Fuel needed by engine, is controlled by ECU (supplied electricity by relay (87)) directly. And ECU decides the open time of each intake order and fuel injection duration. Fuel injection time is controlled by the following measures: -Synchronous (for normal operation).
  • Page 98 Fig.165 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. ·throttle valve position sensor · stepper motor · hot water loop near the throttle valve and idle air by-pass · absolute pressure signal port in the lower throttle valve (necessary to be connected with pressure sensor) ·PCV recirculation pipe ——Throttle valve position sensor “PF2C”.
  • Page 99 · with absolute pressure sensor out of work, the position sensor will function when working condition comes back. ·ECU supplies 5V voltage to the variable resistance terminal of throttle valve potentiometer . And potentiometer output voltage varies with throttle valve position. ·sensor needs not adjustment(through assembling hole), for ECU program may self adjust to minimum impedance (2°to 14°).
  • Page 100 Fig.167 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 101 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 102 Fig.171 Speed/ TDC sensor Check if the sensor is located in the twentieth tooth after the breach in the flywheel signal panel 1— Speed/ TDC sensor (crankshaft position sensor) 2— Pulley 3— TDC reference point on the pulley 4— TDC reference point on the timing gear cover 5—...
  • Page 103 Fig.172 3-way connector (figure. 173) a. Supply 5V voltage b. Negative pole signal c. Positive pole signal When engine is shut down, the sensitive membrane will bent according to the value of atmospheric pressure (mmHg). After the ignition switch is switched on, the actual atmospheric pressure may be obtained by this method.
  • Page 104 5. Ignition advance calculation and high voltage distribution The system uses two high tension ignition coils and assigns ignition voltages directly to spark plugs by static electricity (distributorless ignition) directly. Connector and controlling triode are comprised in the ECU injection system and connected to ECU connector 1 and connector 19 . (figure. 175). When ECU microprocessor identifies the signals of two tooth-missed signals, it will begin to count tooth.
  • Page 105 —— During acceleration and deceleration shut —— When shutten off —— During over speeding during idling, the engine rpm is 900±50r/min，and ignition advance is 10°±1°(Engine is already warmed and with no electrical load). 6 . Zirconiumλsensor 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.
  • Page 106 The outside of the ceramic body (b) is exposed to the exhaust emission and the inside (a) is exposed to ambient atmosphere. The working principle of sensor is as following: When the temperature is over 300 ℃，the ceramic material will be the conductor of ferric oxide. Under this condition, if the percentage content of the oxygen in the two sides of sensor (a, b) are not the same, the voltage difference will occur in the two sides.
  • Page 107 Exhaust emission is controlled by λsensor and the above relative systems and three-way catalytic converter. Catalytic converter may damp the three contaminations in the exhaust: unburned hydrocarbon (HC), carbon monoxide (CO) and nitrogen oxide (NOX). 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 108 Fig.178 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. ——When the fuel tank is full, the multi-function valve 4 is closed. The fuel cannot flow into charcoal canister 6, therefore it doesn’t damage charcoal canister.
  • Page 109 ·Under the starting condition , the solenoid keeps close preventing the fuel vapor from richening the mixture until the specified engine coolant temperature is reached. ·during engine’s running, ECU sends a square wave signal to the solenoid. The signal is used to control the fuel vapor recirculation valve by energizing or deenergizing it.
  • Page 110 Fig.180 1. Battery 8. 5A 2. ECU fuse 3.1# ignition coil (cylinder 1 、4) 9. Dual relays (A—ECU，B—fuel pump) 10.λsensor 11. Fuel pump 4. Fuel injector 12. Fuel vapor recirculation solenoid 5. 2# ignition coil (cylinder 2 、3) 13. ECU 6.
  • Page 111 Fig.181...

  • Page 112: Wiring Diagram

    ［3］．Wiring diagram 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.
  • Page 113 ECU I/0 function 1. Primary signal for ignition coil 16.water temperature/air/pressure sensor 2.B phrase idling actuator signal and ground wire of throttle valve 3.D phrase idling actuator signal position sensor 4.Protect relay signal 17. Main ground wire of engine 5.Without connection line 18.Fuel injector signal 6.

  • Page 114: System Service

    ［4］. System service Fig.183 (*) A/C input and signal (if euipped) Note：1) All connector are viewed from the intake side of the cable 2) Cable color and number indicates the 35-pin ECU connector connection of injection system...
  • Page 115 Fig.184 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 8.Idling speed actuator 17.5A ECU fuse 9.Water temperature sensor 18.
  • Page 116 Fig.185 Fig.186 ——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 If a sensor failure (except the speed sensor/ TDC sensor) is indicated, ECU will substitute the preset value for the input data from the faulted sensor to keep engine operating.
  • Page 117 ——Remove quick release fuel Outlet pipe and fuel return pipe Remove and reinstall filter ——Loosen and remove the filter mounting bolt from the bracket ——Remove the sealing clip of fuel pipe from the filter ——During operating, use an appropriate container to collect the fuel drained The fuel filter must be replaced every 30,000km.

  • Page 118: Malfunction, Cause And Correction

    ［5］.malfaction, cause and correction Malfuction Cause Correction Fuel pump. fuel injector Check for operation by CHECK—UP1 IVM523 Vehicle cannot Tachometer Check wring, sensor resistance and installation of the start senser. sensor. Dual relays Check for function, connector connection and blown fuse. 35——pin Check for the wiring connection to ECU.

  • Page 119: Transmission Maintenance And Service

    TRANSMISSION MAINTENANCE AND SERVICE Page 1、Outline Drawing of AQ015D Transmission……………………………………………………..….129 2、Specifications ………………………………………………………………………………………...130 3、Structural Type and Applicability…………………………………………………………………..131 4、Service and Operation……………………………………………………………………………….131 5、Drive System Schematic Drawing…………………………………………………………………..131 6、Transmission Assembly Schematic Drawing………… ……………………………………………132 7、Dismantlement and Installation Transmission ……………………………………………………133 8、Maintenance of Transmission ………………………………………………………………………141 9、Common Failure and Trouble-Shooting……………………………………………………………149 10、Wearing Part list………………………………………………………………………………….
  • Page 120 Specifications Transmission AQ015AD Type Ratio: Z2 : Z1 Master Gearing 62:15=4.5 1st Speed 38:11=3.455 2nd Speed 37:18=2.056 3rd Speed 37:27=1.560 4th Speed 32:31=1.207 Reverse Speed 38:12=3.167 Rated Power 65KW Rated Torque 133Nm Rated Speed 6300r/min Lubricating Oil Capacity 2.0L Lubricating Oil Type API 80(75) W-90 GL-3 Gear Oil 24 Teeth, Involute Spline;...
  • Page 121 Structural Type and Applicability 5T15AA is a kind of transverse mechanical transmission for middle and high grade cars, which is introduced and absorbed by our company. It has five forward speeds and a reverse speed. The forward speeds adopt the synchronizer shift, and the reverse speed uses the sliding gear meshing shift.
  • Page 122 Transmission Assembly schematic Drawing Fig.191 1．Clutch Housing 2. Input Shaft 3. Output Shaft 4. 1st Speed Reverse Speed 6. 2nd Speed 7. 3rd Speed 8. 4th Speed 9. Transmission Case 10. Rear Case 11.Main reducing gear...
  • Page 123 Dismantle and Installation of Transmission Dismantlement The transmission is put up. The drain plug on clutch side is screwed off. And at same time, the drain plug on the rear case is screwed off. The oil is drained away. Fig.192 The release lever of clutch is drawn out.
  • Page 124 Fig.195 Transmission Assembly structural Resolution The plug cover of shift shaft is screwed off with special tool. The spreader spring and shift shaft assembly are taken out. Fig.196 The locking screw of reverse speed shaft is removed. Fig.197 5th speed driven gear clamping ring is removed. And 5th speed driven gear is removed with the special tool.
  • Page 125 Fig.198 The retainer screw of output shaft rear bearing is screwed off. Fig.199 Before the transmission is removed,The fork shaft assembly and its up and down spring are taken out. And then 5th speed fork guiding plate and 5th speed fork sleeve component, the reverse speed fork guiding plate, 3rd and 4th speed fork and 1st and 2nd speed fork are removed.
  • Page 126 The output shaft assembly is removed. When removed, it is noticed that the reverse speed gear is not in mesh. Fig.202 3rd speed driven gear clamping ring is removed from the output shaft. And then 3rd speed driven gear, 2nd speed driven gear, needle bearing and synchronizer ring are removed. If necessary, the special tool may be used.
  • Page 127 Fig.205 ⑾The tightening screw of output shaft mid-bearing seat is screwed off. The output shaft mid-bearing seat and the output shaft are taken out. The differential assembly is taken out. The reverse speed fork assembly and the support are removed. Fig.206 Installation The process of transmission installation is basically reversal process of its dismantlement.
  • Page 128 Fig.208 5. The reserve speed idler and the idler shaft are installed on the clutch housing. The idler shaft tap hole is toward outside. The vertical distance from the center distance of tap hole to the faying face of clutch housing is 82.5-83mm.
  • Page 129 Fig.211 8. When the fork shaft is installed, the balancing spring of fork shaft is first set in the fork shaft hole of clutch housing. Fig.212 9. The fork assembly is installed in the right postion. 1－ 1st and 2nd speed fork 2－...
  • Page 130 Fig.214 11. The retainer screw is screwed in the tap hole. The fork shaft is held. The transmission case is tapped with the plastic hammer. The bearing will be stretched out and to the right position. The retainer screw is screwed down with 15Nm of force moment. The idler shaft locking screw is screwed down with 20Nm of force moment.
  • Page 131 Maintenance of Transmission For ensuring the maintenance quality of transmission, the maintenance operation should be careful and to keep the transmission clean in this time. The suitable maintenance tool should be chosen. The common and basic safety regulations are also suitable to maintenance of AQ015 transmission. For avoiding the tedious writings, the following explanations are common in a series of maintenance process.
  • Page 132 lubrication oil is filled. 3. When the oil level is inspected on the removed transmission, the transmission should be laid on the horizontal position. The drain plug is screwed off. The oil level should be even with the drain plug hole. 4.
  • Page 133 The rear cover is removed with the special tool. It is noticed that the contact surface is not damaged. The locking clamper of release finger is removed. The release shaft assembly of clutch is drawn out. The release finger and the release spring are taken out. The release shaft oil seal assembly is dismantled with the special tool.
  • Page 134 Fig.220 Maintenance of Shift Shaft Bearing When the shift shaft bearing is changed, the shift shaft assembly has to be taken out. And then the oil seal is removed. Dismantlement: To use the special tool is inserted into the transmission case. As the figure shown, the bearing is tapped, till the bearing is stretched out.
  • Page 135 Fig.224 Fig.225 Breakdown: The small spreader spring seat is inward pressed. With the aid of the way, the spring in the seat is compressed. And the position is kept. In this condition, the clamping ring is removed. Installation: The process of installation is reversal process of above mentioned process. Notice: The fork system is ensured in the neutral speed position.
  • Page 136 Fig.226 As the figure shown, the front bearing is installed with the special tool. The bearing is ensured in position. Fig.227 Dismantlement and Installation of Input Shaft Oil Seal Dismantlement: When the oil seal is removed, the transmission assembly is not broken down. The oil seal is removed with the special tool in the direction of the arrow.
  • Page 137 Installation: The oil seal lip is fully coated with the lubricating grease. The oil seal is pressed in position with the special tool. Fig.229 Dismount and Installation of Conical Roller Bearing: The front bearing, the mid-bearing on the output shaft and the differential bearings on the clutch housing and the transmission case are the conical roller bearing.
  • Page 138 The bearing is lubricated with the gear oil. And then it is inserted into the output shaft assembly. The fastening screw is screwed down with the 40Nm of force moment. Adjustment of Power Output Assembly 1mm thickness of adjusting shim is put in the relative position in the clutch housing. Fig.232 Fig.233 The bearing outer ring of power assembly is fully pressed in with the special tool.

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