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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
[5] Timing belt removal, installation and adjustment………………………………………………. ... 43
[6] Tension pulley, crankshaft gear and camshaft gear removal, check and installation…………...45
[7] Camshaft oil seal removal and installation………………………………………………………. ... 47
[8] Valve mechanism and cylinder head removal, check and installation……………………………48
[9] Piston and connecting rod assembly removal and installation……………………………………57
[10] Flywheel assembly and rear oil seal bracket assembly removal and installation ……………...61
[11] Crankshaft, crankshaft thrust washer, bearing bushing and main bearing cap removal and
installation ……………………………………………………………………………………….…63
[12] Oil baffle assembly removal and installation……………………………………………….….…67
[13] Engine oiling system……………………………………………………………….……………. .... 68
[14] Engine cooling system……………………………………………………………………………...75
[15] Engine air intake and exhaust system…………………………………………………………….80
[16] Engine crankcase ventilation system………………………………………………………………84
[17] Engine fuel supply system………………………………………………………………………….86
Carburetor engine malfunction, cause and correction………………………………………………..93
CAC480MEngine single-point electric control injection system……………………………………..101
[1] Summarize……………………………………………………………………………………………101
[2] Operation principle ………………………………………………………………………………. ... 102
[3] Wiring diagram……………………………………………………………………………………. ... 121
[4] System service………………………………………………………………………...………………123
[5] Malfunction, cause and correction………………………………………………………………. .... 127
