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Section 6    Difficult Gearshift of the Transmission 

 

No. 

Trouble Phenomenon and Cause 

Troubleshooting 

1 

Worn synchronous gear 

Replace 

No. 

Trouble Phenomenon and Cause 

Troubleshooting 

2 

Worn synchronous gear 

Replace 

3 

Damaged fixed ball 

Replace 

4 

Deformed shift fork or uneven wear 

Repair or replace 

 

 

 

Содержание LJ465Q-1ANE1

Страница 1: ...Model LJ465Q 1ANE1 Petrol Engine Instruction Book ...

Страница 2: ... LJ465Q 1ANE1 electronic fuel injection type DELPHI system front drive petrol engine produced by our plant Model LJ465Q 1ANE1 petrol engine including petrol engine clutch and transmission a new type petrol engine which meets the requirements of environmental protection is jointly developed by our plant and DELPHI ...

Страница 3: ...e This instruction book briefly demonstrates main technical performance technical data and service maintenance of Model LJ465Q 1ANE1 petrol engine Please read this manual carefully and observe the regulations strictly before you use the petrol engine so that your vehicle is often kept under an optimum condition to play greater efficiency and achieve better economic benefits When you read this inst...

Страница 4: ...y our plant kindly let us know by correspondence even if you are engaged we will thank you very much Model LJ465Q 1ANE1 petrol engine is an ideal engine of mini buses purchasing Model LJ465Q 1ANE1 petrol engine as minibus engine is your optimum choice Guangxi Liuzhou Wuling Motors Co Ltd Liuzhou Machine Plant ...

Страница 5: ...tes driver and passenger s personnel safety please pay special attention to and follow it as required Indicates the safety and maintenance of the engine please follow it as required Indicates simplifying and facilitating maintenance ...

Страница 6: ...on of the Petrol Engine Section 3 Running in of the Petrol Engine Chapter 3 Maintenance of the Petrol Engine Section 1 Maintenance of the Lubrication System Section 2 Maintenance of the Cooling System Section 3 Maintenance of the Generator Belt Section 4 Maintenance of the Petrol Filter Section 5 Maintenance of the Distribution Mechanism and Synchronous Chain Section 6 Maintenance of the Spark Plu...

Страница 7: ...bles and Troubleshooting of the Petrol Engine Section 1 Difficult Starting of the Petrol Engine Section 2 Sufficient Power in Running Section 3 Knocking Sound inside the Petrol Engine Section 4 Overheating of the Petrol Engine Section 5 Excessive Engine Oil Consumption Section 6 Difficult Gearshift of the Transmission Section 7 Noise inside the Clutch Chapter 6 Sealing up and Unsealing of the Petr...

Страница 8: ...der diameter 65 5 mm Piston stroke 78 mm Compression ratio 8 8 1 Displacement 1 1 L Rated power 38 5 kW Maximum torque 83 N m 3000 rpm 3500 rpm Minimum fuel consumption 275g kW h Rated revolution 5200 rpm Idle speed 900 30 rpm Idle discharge GB14761 99 Co 3 5 Rotation Clockwise viewed from the front side of the engine Work order 1 3 4 2 Engine oil pressure 0 924Mpa 0 490Mpa 3000rpm Overall dimensi...

Страница 9: ...t 2 7L newly fitted engine oil filter 2 5 L old engine oil filter Coolant Ethanediol water solution or soft water Clutch Type Single membrane spring Overall dimensions Pressure plate housing Φ271 33 6 mm Weight 2 7 kgs Transmission Every gear ratio Four gear transmission Five gear transmission 1st gear 3 818 3 818 2nd gear 2 210 2 210 3rd gear 1 423 1 423 4th gear 0 906 1 033 5th gear 0 844 Transm...

Страница 10: ...23 kgs 25 kgs Lubrication 85W 90 GL 4 or GL 5 gear oil GB 13895 92 or fix the brand in special areas according to the application environment and temperature Amount of lubrication 2 1 L Note The idle discharge standard of the petrol engine is national mandatory regulations and will be continuously amended Model LJ465Q 1ANE1 petrol engine will continuously meet the requirements of the latest nation...

Страница 11: ... The idle discharge index of the engine produced by the plant at ex factory is strictly controlled within the requirements of the national standard idle speed of model LJ465Q 1ANE1 petrol engine is 900 30 r min The idle mechanism of the petrol engine is reset at ex factory customers should change it arbitrarily Keep the engine at hot state while checking discharge that is above 80 of water tempera...

Страница 12: ...osition circuit open or shorted to battery P0120 Too low throttle valve position circuit shorted to earth P0130 No signal from the oxygen sensor P0170 Excessive rich period of the oxygen sensor Trouble Code Descriptions P0170 Excessive thin period of the oxygen sensor P0201 Circuit malfunction of injector A cylinder 1 P0202 Circuit malfunction of injector B cylinder 3 P0203 Circuit malfunction of ...

Страница 13: ...earth P0480 Fan 1 circuit shorted to battery P0480 Fan 1 circuit open or shorted to earth Trouble Code Trouble Descriptions P0481 Fan 2 circuit open or shorted to battery P0481 Fan 2 circuit open or shorted to earth P0500 No signal from the speed sensor P0505 Idle control malfunction P0560 Excessive battery voltage P0650 Failure indicator circuit shorted to battery P0650 Failure indicator circuit ...

Страница 14: ...w temperature of the rear evaporimeter Trouble Code Trouble Descriptions P2100 Rear circulation cut off valve of air conditioner circuit shorted to battery P2100 Rear circulation cut off valve of air conditioner circuit open or shorted to earth Section 3 Running in of the Petrol Engine The service life of the petrol engine is mainly dependent on the earlier use New petrol engine should be run in i...

Страница 15: ...ad surface Vehicles should run on the cement or asphalt road surface do not attempt to run on other road surfaces especially on sand mud roads 3 Running in standard The petrol engine should be run in on the vehicle follow the running in standard of the petrol engine shown the following table it is not allowed to be higher than every gear speed shown in the following table If there exists between t...

Страница 16: ...ear Vehicle Speed 1st gear 10 km h 2nd gear 20 km h 3rd gear 35 km h 4th gear 55 km h 5th gear 65 km h 4 Load During running in the vehicle load is not allowed to exceed 50 of rated load in the first 1000 kilometers and 75 of rated load in the next 1500 kilometers 5 Maintenance ...

Страница 17: ...r Running in New Petrol Engine No Items Maintenance contents 1 Generator belt Check wear and adjust tension 2 Synchronous chain tensioner Check flexibility and adjust tension 3 Throttle valve clearance Check adjusting if necessary Cold 0 13mm 0 18mm Warm 0 23mm 0 28mm 4 Cylinder head bolt and fixed nuts of intake exhaust manifold Tighten according to the specified torque ...

Страница 18: ...6 Engine oil of the petrol engine Replace 7 Transmission gear oil Replace 8 Spark plug clearance Check and adjust to the specified value 9 Idle speed and discharge Check idle and discharge value and adjust according to regulations ...

Страница 19: ...15W40 gasoline engine oil is used When ambient temperature is lower than 20 SF5W 30 gasoline engine oil GB11121 1995 or API SG SAE5W30 gasoline engine oil is used Replace engine oil after running in new petrol engine for 2500 kilometers and run smoothly every 5000 kilometers 2 Engine oil level of the petrol engine Engine oil amount inside the engine oil tray is measured with a dipstick on the righ...

Страница 20: ...etrol engine on the asphalt road surface once every 5000 kilometers often check it on the severe sand and mud change in time according to the oil quality but it s not allowed to exceed once every 5000 kilometer When changing engine oil of the petrol engine warm up the petrol engine for 10 minutes open the oil cap after stopping the vehicle and tighten the discharge plug of the engine oil tray of t...

Страница 21: ...tion oil of the petrol engine and the transmission is an important factor to ensure good work and service life customers should pay special attention to the oil choice do not mix engine oil with the different production areas brand and standard so as to prevent the different oil variety to cause chemical change and affect proper work of the petrol engine It s not allowed to use engine oil brand wh...

Страница 22: ...n the extension power brake behind the transmission after stopping the vehicle empty out engine oil inside the transmission screw in the oil discharge plug replenish gear oil from the oil plug hole till the oil is overflowed Never replenish gear oil from the mounting hole of the back up light switch 6 Cleaning of lubrication system If there are excessive foreign matters deposited in the engine oil...

Страница 23: ...sh the petrol engine with engine oil as required again After changing new engine oil every time run the petrol engine at the no load condition for 3 5 minutes so as to ensure sufficient engine oil is available in the lubrication system and its oil supply parts 7 Replacement of engine oil filter Replace one engine oil filter once every 10000 kilometers The fixed torque is 12 16 N m 1 2 1 6kgf m 8 C...

Страница 24: ... to ON the engine oil pressure indicator goes off but the engine oil pressure switch is connected to the bonding iron of the body at idle the engine oil pressure switch cuts off the bonding iron of the body showing the engine oil pressure switch works normally At that time check the indicator and related circuit have malfunction Section 2 Maintenance of the Cooling System The cooling system is one...

Страница 25: ...rain out the cooling water of the radiator and the petrol engine in time after stopping the vehicle to avoid frost crack of the radiator and the petrol engine For the petrol engine without a discharge plug in the cylinder do not use water as coolant in winter Water volume can be expanded after frozen which seals the radiator water pump cylinder head the cylinder body will be burst open 2 Replenish...

Страница 26: ... use when coolant level in the storage water barrel is lower than LOW graduation replenish the coolant according to the following steps If the coolant is reduced greatly in a short time the cooling system could be leaked it should be checked carefully 4 Replace coolant After long time use when replacement of the coolant is needed because the coolant is deteriorated or do some repair the following ...

Страница 27: ...e coolant according to the filling steps When replace coolant the vehicle should be kept on a level place 5 Never remove and not fit the thermostat assembly Not fitting the thermostat assembly will prolong the warm up time after starting the petrol engine the petrol engine working at low temperature for a long time will result in rapid wear of the machine parts and affect the service life ...

Страница 28: ...maged generator belt could result in excessive heat of the petrol engine and reducing generated energy 1 Adjustment When the petrol engine is stopped release two fixed screws in the lower part of the generator and adjusting screws in the upper part of the generator push the generator outwards till the generator belt reaches the required tension shown in Section 2 of this chapter 2 Tension measurem...

Страница 29: ...s 10 15 mm 3 Appearance Appearance of the generator should be in good order replace in time if it s poor to affect service Section 4 Maintenance of the Petrol Filter Replace gasoline filter in time so as not to affect oil supply or result in injector clogging For the petrol engine with the electric injection system do not use gasoline filter of the petrol engine with a common carburetor ...

Страница 30: ...lt in damage of the throttle valve piston rocker and camshaft Therefore besides running in period of the vehicle check once every 20000 kilometers and adjust or replace properly if necessary Even if you are expert we recommend that you should send the maintenance items to the auto plant or technical service station or our technical service center 1 Check and Adjustment of Timing Sprocket Open the ...

Страница 31: ...the transmission to ensure the key on the front end of the crankshaft align with the arrow inside the belt cover Check the piston of the number one cylinder near the radiator at the up dead line of compression situation i e has gap at the intake exhaust valve and adjust screw of the rocker arm If it is not correct turn the crankshaft 360 again the mark on the driven synchronization gear align with...

Страница 32: ...ression situation one of the two marks on the synchronization belt must align with mark on the belt cover fig 7 Check the synchronization belt according to situation mentioned on table remove it if any was found replace it in case of serious situation Normally it should be replaced every 100000KM Drive synchronization gear Table 4 checking of the belt 序号 Fault situation 1 Adhesive belt cirrhosis o...

Страница 33: ...orn at the whole side circle 9 Side cracked Section 6 Maintenance of the Spark Plug Replace the spark plug after the vehicle runs every 10000 kilometers always check and replace if damaged when replacing pay attention to model F6RTC and screw M14 1 25 The insulator surface of the center electrode of the spark plug and exterior electrode should be kept clean carbon deposit is not allowed remove wit...

Страница 34: ...del LJ465Q 1ANE1 petrol engine is dual coil ignition system The electronic ignition system can greatly improve control accuracy of ignition time work reliability ignition energy and ignition voltage 1 Composition The system is composed of power source ignition electronic controller ignition coil high pressure damping coil and spark plug etc 2 Wiring Ignition coil Ignition fuse 3 ...

Страница 35: ...Spark plug Dual coil ignition system ...

Страница 36: ...fold through PCV valve and be burnt finally so as to avoid environmental pollution of waste gas in the crankcase remove it once every 10000 kilometers wash and clean oil as well as dry it then push its valve with steel wire and to see if it is flexible Replace with new valve if the valve is seized up or not ventilated Chapter 4 Periodic Inspection the Petrol Engine Section 1 Service Intervals and ...

Страница 37: ...0 36 42 48 1 Generator belt check for elasticity and wear A I R I R 2 Synchronous chain check for damage and wear I I I I 3 Intake exhaust throttle valve clearance A A A A A 4 Torque of cylinder head bolt and nuts and screws of fixed intake exhaust manifold T T T T T The service period should be judged according to the kilometers 1000 2 5 10 20 30 40 50 60 70 80 ...

Страница 38: ...kilometers 7 Fuel rubber pipe and connector aging pipe cracked or damaged connector I I I I I I I I I 8 Rubber pipe and connector of cooling system of the petrol engine water leakage and damage etc I I I 9 High pressure damping coil deteriorated and damaged I I I 10 Spark plug R R R R R R R R The service period shouldkilometers 1000 2 5 10 20 30 40 50 60 70 80 ...

Страница 39: ... for asphalt road Clean once every 2500 kilometers for dust road 13 Accelerator control pull wire and throttle valve shaft I L I L I L I L I L I L I L I L 14 Idle and idle discharge A A A A A A A A A 15 PCV valve I I I I I I I I 17 Clutch clearance I I I I I I I I 18 Transmission gear oil check for oil leakage under a level condition R I I I R I I I R Notes the meaning of the symbols in the table ...

Страница 40: ...ace if necessary T Check with special torque spanner Even if you are expert we recommend that you should send the maintenance items marked with to the auto plant or technical service station and special repair center of our plant Section 2 Torque of Main Bolts of the Petrol Engine ...

Страница 41: ...S 18 23 3 Spark plug 20 28 4 Mounting bolt of camshaft timing sprocket 55 60 5 Adjusting nut of throttle valve 18 20 6 Mounting bolt of crankshaft timing sprocket 55 60 7 Connecting rod bearing cap nut 28 32 8 Crankshaft head bolt 43 48 9 Flywheel bolt 40 45 10 Engine oil tray bolt 4 5 ...

Страница 42: ...pressure sensor 12 15 15 Engine oil filter pipe nipple 20 25 16 Fixed bolt of rear suspension bracket 18 23 17 Safety valve spring base of engine oil pump 15 20 18 Fixed bolt of the petrol engine suspension left right 18 23 19 Bolt nut of suspension cushion 35 40 20 Tensioner mounting bolt 18 23 ...

Страница 43: ...ssion housing 15 20 2 Oil filling and oil discharge plug 32 38 3 Connecting bolt of extension power brake housing 15 20 4 Shift shaft housing screw 8 mm 9 12 5 Shift shaft housing screw 6 mm 6 10 6 Thrust screw of shift fork shaft 15 20 7 Connecting bolt between transmission and cylinder body 32 38 ...

Страница 44: ...Section 4 Torque of Main Bolts of the Clutch No Name Torque N m 1 Clutch pressure plate screw 25 29 ...

Страница 45: ...ause Troubleshooting a The engine is not rotated 1 Loose connection of battery electrode or insufficient power Tighten or charge 2 Open circuit Check and repair 3 Damaged engine Repair or replace b The spark plug is not lighted 1 Poor earthing Repair 2 Damaged ignition coil Replace 3 Improper spark plug clearance or burnt Adjust or replace ...

Страница 46: ...r or replace 2 Gasoline hose and gasoline filter plug Clean d Reduced cylinder compressed pressure 1 Broken cylinder gasket Replace 2 Improper adjustment of throttle valve clearance or damaged Adjust repair or replace 3 Worn piston piston ring and cylinder Repair or replace ...

Страница 47: ...Adjust 2 Reduced cylinder compressed pressure 1 Check throttle valve spark plug cylinder gasket for leakage 2 Grind cylinder 3 Insufficient gasoline supply Adjust or repair 4 Insufficient intake air Check intake system 5 Air exhaust clogging Check exhaust system and remove carbon deposit 6 Improper spark plug clearance or damaged Adjust or replace ...

Страница 48: ...and Cause Troubleshooting 1 Worn bush camshaft cam and rocker Replace 2 Severe wear of camshaft connecting rod neck and piston pin Replace or repair 3 Damaged piston ring Replace 4 Improper throttle valve clearance Adjust 5 Excessive thrust clearance of the camshaft Adjust ...

Страница 49: ...ghten or clean 3 Insufficient tension of generator belt Adjust 4 Insufficient coolant or clogged water pipe Replenish or clean 5 Improper clearance of water pump or damaged Repair or replace 6 Insufficient engine oil Replenish 7 Oil line clogging or damaged engine oil pump Clean or replace 8 Damaged cylinder gasket Replace 9 Slipped clutch Repair or replace 10 Radiator clogged by scale Clean or re...

Страница 50: ...Replace 2 Worn or damaged oil ring Replace 3 Piston ring is not staggered as required Adjust 4 Damaged cylinder gasket Replace 5 Worn throttle valve and throttle valve conduit Replace 6 Excessive heat of the petrol engine inner pressure increase some lubrication oil exhausted along with ventilating hole Check related parts and remove ...

Страница 51: ...ion No Trouble Phenomenon and Cause Troubleshooting 1 Worn synchronous gear Replace No Trouble Phenomenon and Cause Troubleshooting 2 Worn synchronous gear Replace 3 Damaged fixed ball Replace 4 Deformed shift fork or uneven wear Repair or replace ...

Страница 52: ...d release bearing Replace 2 Worn front output shaft bearing Replace 3 Loose clutch hub Repair 4 Cracked clutch pressure plate Replace 5 Loose pressure plate and diaphragm spring Repair or replace 6 Oil immersed in clutch friction lining Clean or replace 7 Broken damping spring of the clutch Replace ...

Страница 53: ...engine is warm the piston is between the upper and lower limit screw out the spark plug of every cylinder fill about 10 15g of No 217 antirust oil into the cylinder and run for 3 5 circles then screw in the spark plug and cover the exhaust pipe as specified torque 4 Pack or seal the throttle valve intake intake outlet of the petrol engine and tachometer bushing with paraffin paper 5 Place the petr...

Страница 54: ...Engine 1 Remove exterior grease of the petrol engine 2 Screw out the spark plug race the petrol engine empty out the antirust inside the cylinder as much as possible 3 Replenish engine oil 4 Replenish coolant 5 Unseal every sealing hole ...

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