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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.

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

Fig.71

Diameter of
intake valve
seat

Diameter of
the cylinder
head valve
seat hole

Press fit
clearance

Standard 43.877+0.01 44.763+0.025
480

-0.01

Oversize
0.5

44.377+0.01
-0.01

44.263+0.025
0

Oversize 44.877+0.01 44.763+0.025

0.079—0.124

1.0

-0.01

The size of exhaust valve seat and cylinder head valve seat hole

Diameter of
intake valve
seat

Diameter of
the cylinder
head valve
seat hole

—Press fit
clearance

Standard 38.377+0.01 38.263+0.025
480

-0.01

Oversize
0.5

38.877+0.01
-0.01

38.763+0.025
0

Oversize 39.377+0.01 39.263+0.025

0.079—0.124

1.0

-0.01

Содержание JNSZ1600QL

Страница 1: ...IMPORTANT SAFETYINFORMATION 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...

Страница 2: ...600QL during the 90 days warranty period please contact your nearest authorized dealer for repairs What is not covered under this warranty This warranty does not cover any sold vehicle that has been s...

Страница 3: ...READY TO DRIVE 8 6 IS YOUR VEHICLE READY TO DRIVE 10 7 SAFE DRIVING PRECAUTIONS 12 8 SPECIFICATIONS 13 9 OPERATIONS 14 10 SERVICE INSTRUCTIONS 20 11 REPAIR 26 12 ABOUT ENGINE 27 13 PERIODICAL CHECK A...

Страница 4: ...sure to follow the recommended maintenance schedule and service your kart accordingly Preventative maintenance is extremely important to the longevity of your ATV JOYNER believes in conservation and p...

Страница 5: ...ing a ATV You must use your own good judgment You will find important safety information in a variety of forms including Safety Labels On the ATV Safety Messages Preceded by a safety alert symbol and...

Страница 6: ...TV take time to become familiar with how this ATV works and handles Practice in a safe area until you build your skills and get accustomed to this ATV s size and weight Because many accidents involve...

Страница 7: ...V Failure to adhere to this warning will cause physical harm to your body Skidding or Sliding The terrain surface can be a major factor affecting turns Skidding a turn is more likely to occur on slipp...

Страница 8: ...information and recommendations to help you drive your ATV safely please take a few moments to read these pages The labels are considered permanent parts of the ATV If a label comes off or becomes ha...

Страница 9: ...cle helmet eye protection boots gloves long pants and long sleeved shirt or jacket whenever you drive Although complete protection is not possible wearing proper gear can reduce the chance of injury w...

Страница 10: ...th your hands to the ground when the ATV turning over could lead to serious injury or death Never support with your hands to ground when the ATV will turn over Age Recommendation It is strongly recomm...

Страница 11: ...ap is securely fastened Check for leaks Tires Use a gauge to check the air pressure Adjust if needed Also look for signs of damages or excessive wear Nuts Bolts Check the wheels to see that the axle n...

Страница 12: ...and regulations Obtain permission to drive on private property Avoid posted areas and obey no trespassing signs You should never drive your ATV on public streets roads or highways even if they are no...

Страница 13: ...ATV overturning or going out of control Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV Never drive past the...

Страница 14: ...k Plug K7RTC Torque Of Spark Plug 17 0 30 0Nm Fuel type RQ90 unleaded Lubricate oil SAE 10W 40 CAPACITIES Maximum load 400kg Fuel tank 58 0L Engine oil 3860ml Coolant 6000ml Starting 5s Climbing 20 25...

Страница 15: ...pushed all the way forward the assembly is working smoothly and returns to idle when released Do not operate if pedal or engine throttle linkage fail to return to idle If unable to correct the problem...

Страница 16: ...Press the throttle slightly and turn the key clockwise to the on position release the key and the throttle when the engine starts Each time prior to starting the engine check the throttle assembly to...

Страница 17: ...il Level Check for transmission Oil Level Check for leaks add oil if required 2 Check the coolant Check for leaks add the coolant if required 3 Check for Fuel Level Add fuel as necessary and do not ov...

Страница 18: ...t The seat must always be securely fastened in the position which best allows the operator control of the foot pedals steering wheel and the remote stop key Fig 4 a Pull seat adjustment handle upward...

Страница 19: ...then push the parking lever to the bottom b Adjust the parking cable if necessary Park brake OFF Fig 5 Park brake On Fig 6 F Gear Shift Adjustment 1 Loosen the bolts 2 Press down the clutch pedal full...

Страница 20: ...st 1000 km 1st Gear 25km h 2nd Gear 45km h 3rd Gear 70 km h Max speed in each gear 4th Gear 100km h H Starting And Operating Instructions a Before starting the engine be sure that the driver is seated...

Страница 21: ...if the filter cover and the air filter is dusty please clear the filter cover and replace with a new air filter B Engine Lubrication Engine oil replacement You must change the oil in the crankcase af...

Страница 22: ...the engine oil out fully see Fig 9 c Tighten the engine oil outlet plug d Remove the oil filler cap see Fig 10 fill oil SAE 10W 30 50 about 3 86 liters to the engine e Pull out the engine oil dip sti...

Страница 23: ...nge 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 re...

Страница 24: ...Remove the plug see Fig 13 fill oil API 80 75 W 90 GL 3 Gear Oil about 2 0 liters Check transmission oil If the color of transmission oil changes you need to replace oil Replace transmission oil as ab...

Страница 25: ...re injury Never open the radiator cap while the engine is hot New and used coolant can be hazardous Children and pets may be harmed by new or used coolant Continuous or brief contact with coolant may...

Страница 26: ...t to be operated for periods in excess of 30 days or at the end of each driving season prepare for storage as follows a Drain fuel tank by allowing engine to run out of fuel or use a fuel stabilizer b...

Страница 27: ...of the wheels The proper toe in dimension A should be 0 63 inches greater than dimension B 3 To adjust the alignments loose the lock nuts on both sides of Front Tie Rods To make Dimension B smaller t...

Страница 28: ...ctrolyte of accumulator should be sufficient Don t operate it at high speed at once after starting the engine You should preheat it step by step You d better drive it on cement pavement or asphaltum p...

Страница 29: ...gnition I 9 Air cleaner C I 10 Throttle cable I A L I R A 11 Fuel tank cover Breathe hose and joint I I R 12 Idle I 13 Breathe hose I 14 Fuel hose and joints I I I R Control system 15 Wire and plugs I...

Страница 30: ...mshaft 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...

Страница 31: ...control fuel injection system and multipoint electric control fuel injection system of the above engines are developed though the joint effort with Italy M M Corp With advanced product performance re...

Страница 32: ...31 ENGINE CONFIGURATION VIEW AND SECTIONAL VIEW Fig 22...

Страница 33: ...32 Fig 23 Fig 24 Fig 25 1 Temperature regulator seat assembly 11 Camshaft thrust plate 2 Temperature regulator seat 12 Camshaft timing gear...

Страница 34: ...meters CAC480M Type Line 4 cyl four strokes water cooling Cylinder bore diameter mm 79 94 Stroke mm 79 52 Total displacement L 1 596 Compression ratio 9 75 1 Nominal power RPM 62 5500 kW r min Total p...

Страница 35: ...5 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 min 2000r min 80 280kPa min Engine...

Страница 36: ...n Steel strip combination oil ring With scape blade excircle chroming 5 Piston pin Low carbon steel Surface carbonizing and quenching Semi floating structure Interference fit with small end of connect...

Страница 37: ...nitrile rubber 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 iro...

Страница 38: ...on contact distributor Driven by the rear end of camshaft Type is FDW451 JFD459 Only applied for carburetor engine 32 Ignition controller Type are ZJ5701 HG KH 3A Only applied for carburetor engine 33...

Страница 39: ...tube for cracking Check PCV valve Check spark plugs Per16000km Check accessories drive belt Check timing belt and tension pulley Check radiator and hoses for leaking Per30000km Replace fuel filter Pe...

Страница 40: ...r filter core and clean case Check accessory driving belts Check radiator and hoses for leaking Replace spark plugs Replace timing belt Replace fuel filter Check high tension wires Check lambda sensor...

Страница 41: ...shaft pulley aligns with the TDC mark 0 on timing gear cover Note Before rotation spark plugs may be removed to reduce effort Fig 27 Check whether the TDC mark on the camshaft gear aligns with the mar...

Страница 42: ...e 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 2 Upper and lower timi...

Страница 43: ...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...

Страница 44: ...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 turnin...

Страница 45: ...acting 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 Inst...

Страница 46: ...row indicated in diagram push tension pulley aside with a large screwdriver To release belt tension tighten 2 tension pulley mounting bolts with tension pulley in this position To reuse belt mark the...

Страница 47: ...2 turns until no 1 cylinder reaches its TDC of compression Grab the midway of the right side belt between crankshaft gear and camshaft gear with thumb and forefinger If belt tension is as specified b...

Страница 48: ...mshaft gear Camshaft gears are not permitted to be exchanged between 480 engine during replacement the mark on the original gear should be referred Fig 40 Installation Check gear tooth for wear pittin...

Страница 49: ...ey Installation Check gear tooth for wear pitting or scratch Install semicircular key protrusion should be 1 392 1 739mm Install shim with curved face side forward Install crankshaft gear with boss si...

Страница 50: ...lean the oil seal hole in cylinder head apply clean engine oil on oil seal edge and camshaft oil seal journal install oil seal on oil seal journal carefully push oil seal in perpendicularly into place...

Страница 51: ...50 1 Valve mechanism for 480 engine Fig 44 2 Cylinder cover bolts removal and cylinder head assembly installation Fig 45 Fig 46...

Страница 52: ...ld not be deposits in tapped hole or fluid pressure resulting from bolts screwing may possibly results in cylinder block cracking Rotate crankshaft until no 1 cylinder piston is 20mm or so under the d...

Страница 53: ...ate 90 During rotating torque angle torque wrench or line plotting methods may be applied 3 Rocker arm mechanism and hydraulic lifting rod removal and installation Rocker arm mechanism removal Loosen...

Страница 54: ...53 Fig 52 Fig 53...

Страница 55: ...r arm rocker arm support then finger screw in new nut tighten to 25 29Nm Note Before installing each rocker arm and tightening nut appropriate hydraulic lifting rod should be at thelowest position Hyd...

Страница 56: ...tallation removal Measure camshaft end play clearance should be 0 049 0 129mm Loosen thrust washer bolt remove thrust washer bolt as shown in diagram Remove thrust washer Pull camshaft assembly out fr...

Страница 57: ...t journal diameter Cylinder head bearing hole diameter 1 45 12 45 14 45 163 45 188 2 45 37 45 39 45 413 45 438 3 45 62 45 64 45 663 45 688 4 45 87 45 89 45 913 45 938 5 46 12 46 14 45 163 45 188 Insta...

Страница 58: ...ut an appropriate pipe on spring seat so the valve locking piece will not be impacted Put a wooden block on valve head with cylinder head combustion chamber facing workbench and then strike pipe end w...

Страница 59: ...iameter Valve guide hole diameter Clearance Valve stem diameter Valve guide hole diameter Clearance Standard 8 043 0 0 018 8 063 8 094 0 02 0 069 8 017 0 0 018 8 063 8 094 Oversize0 4 8 443 0 0 018 8...

Страница 60: ...der head valve or valve guide Lubricate the valve stem and guide with clean engine oil Install the valve Notice that the intake and exhaust valve for 480 are not interchangeable Refer to the previous...

Страница 61: ...of intake valve seat and cylinder head valve seat hole Fig 71 Diameter of intake valve seat Diameter of the cylinder head valve seat hole Press fit clearance Standard 43 877 0 01 44 763 0 025 480 0 0...

Страница 62: ...fore removal Remove the connecting rod bolts and remove the rod cap Take the connecting rod bushing out and stick on cylinder marks and labels on the upper or lower halves Push the connecting rod and...

Страница 63: ...t should be taken at the position 10mm to the bottom skirt For 480E piston measurement should be taken at the position 19mm to the bottom skirt Unit mm 478 dia of piston skirt mm 488 dia of piston ski...

Страница 64: ...63 Oversize 0 5 77 71 77 735 80 43 80 455 80 465 80 475...

Страница 65: ...cotter intermission of piston ring First compression ring 0 30 0 50mm Second compression ring 0 30 0 50mm Steel combination oil ring 0 40 1 40mm Measure the piston ring end play in the piston groove U...

Страница 66: ...iston head means the front arrow The outer end of piston pin means the front lug which should has a same direction with F near the large end of the connecting rod with 480 mark on some blanks and the...

Страница 67: ...ssembly by hammer into the cylinder bore Apply engine oil on the connecting rod bushing Mount connecting rod cap Retain connecting rod body and cap with two elastic retaining pins Tighten connecting r...

Страница 68: ...he 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 o...

Страница 69: ...ator to and then use post to push the crankshaft toward such as possible Check dial indicator The reading is end play The end play of the crankshaft should be 0 092 0 303mm If dial indicator is not av...

Страница 70: ...ed in the cover of plastic clearance gauge Check the bearing clearance from the third main bearing and extending to the two sides The clearance of main bearing is 0 011 0 058m m Check clearance of con...

Страница 71: ...e diameter of main bearing bore of cylinder body The thickness of main bearing half shell Standard 57 98 58 00 62 2935 0 0065 2 131 2 138 Oversize 0 4 57 98 58 00 62 6935 0 0065 2 331 2 338 Undersize...

Страница 72: ...4 0 03 28 825 28 875 2 326 0 025 Oversize 0 38 24 0 03 29 205 29 255 2 516 0 025 Installation Before installation use the second screw tap taps the threaded hole in cylinder body especially the thread...

Страница 73: ...ress fit between rabbet and cylinder body The press fit clearance is 0 025 0 145mm After installation the surface of the first and the fifth main bearing caps should be even or lower than the front an...

Страница 74: ...gh oil passage in the crankshaft There is a small oil port in the connecting rod bearing bore near the exhaust side in the connecting rod body The oil sprays out from this small oil port to lubricate...

Страница 75: ...sealant on the joint place between flange surface of oil pan of cylinder body and oil pump case and carrier of real oil seal Put the new rubber seal gasket on the cylinder body and have the two sides...

Страница 76: ...75 Replace the sealing gasket of drain plug Screw in the drain plug by hand and tighten to 21 25Nm...

Страница 77: ...ng washers Installation Install a new sealing gasket of oil collector on the flange face of oil pump and then install oil collector assembly Screw two bolts with gasket by hand Fig 101 Fig 102 Screw t...

Страница 78: ...l 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...

Страница 79: ...tor of oil pump The radial clearance between inner rotor and outer rotor of oil pump should be 0 05 0 18mm Check the end play of rotor The end play of rotor should be 0 014 0 100mm Remove horizontal h...

Страница 80: ...nto the oil pump bore Screw 3 8 plug screw into the oil pump house Keep it in place Tightening torque is 20 25Nm Stick the new oil pump sealing gasket on the front end of cylinder block Install the oi...

Страница 81: ...r Removal Remove the oil filter Rotate oil filter counterclockwise during removal Remove the oil pressure sensor Installation Apply engine oil on the sealing gasket of oil filter and screw into the co...

Страница 82: ...temperature reaches the point for thermostat to open the coolant for cooling cylinder block going through the opened thermostat combusting chamber and behind the valve seat will go into the right wate...

Страница 83: ...ting temperature Grade 95 thermostat Grade 102 3 opening temperature 85 89 cut off temperature Grade 84 wide opening temperature 89 102 Grade 91 resistance temperature 70 159 21 3 90 86 7 11 110 52 3...

Страница 84: ...oming out from the water pump inlet is clean Add coolant 1 Before adding coolant check if the drain plug of radiator is closed and if the pipeline is connected and tight 2 Remove the pressure cap and...

Страница 85: ...er 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 asse...

Страница 86: ...ining bolt by hand then tighten to 7 0 10 0Nm Note The water pump assembly may not be serviced When water seal or bearing is damaged the water pump assembly should be replaced 3 The removal and instal...

Страница 87: ...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...

Страница 88: ...Fig 126 intake and exhaust system arrangement of carburetor engine The air filter is equipped with an intake air temperature controller When the temperature is low the hot air intake valve controlled...

Страница 89: ...ve 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 fa...

Страница 90: ...preheating switch is installed in the M22 bolt hole in the thermostat seat with the hole plugged by plug screw for carburetor engine The intake preheating switch s operation parameters Switching off t...

Страница 91: ...M8 nuts Assembly Apply lotite sealant 201 on the cylinder head bolt threads and screw six studs into the cylinder head Assemble the new sealing gasket onto the studs Install the intake manifold assemb...

Страница 92: ...14 19Nm install the rear lug and tighten allen screw with hands tightening torque is 50 60Nm 5 For oxygen sensor and 3 way catalyst Converter See CAC480M Engine s single port injection system 16 Posi...

Страница 93: ...fle assembly PCV pipe cylinder block PCV hose PCV valve 3 way connector valve chamber cover connecting hose and ventilation hose 2 2 PCV valve s function Under the low speed condition the vacuum of in...

Страница 94: ...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 thro...

Страница 95: ...e oil into the rod s hole of the cylinder head and install the push rod into the hole The gap between push rod and hole is 0 035 0 055mm Screw in the studs into the threaded hole and tighten with the...

Страница 96: ...ld 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 adjustm...

Страница 97: ...r from the fuel tank goes into the charcoal canister by fuel vapor pipe and is sucked into air intake pipe though the fuel vapor recirculation solenoid valve which is controlled by ECU For more detail...

Страница 98: ...not beyond 40V During servicing the alternator apply enough No 2 lithium base grease into the alternator sealing bearing for the operation period before the next service The electronic regulator needs...

Страница 99: ...ndependent assembly 2 Starter Rated output 0 95kW Speed range 1000 1800r min Voltage 12V Type QDY1258 SD6RA78 The flywheel gear ring for vehicle and the one for independent engine assembly is differen...

Страница 100: ...brush spring is pressed on the brush correctly Pay more attention to keep the wire bayonet clip clean Make sure there s no oil fouling and water Or the voltage drop is too high and the engine doesn t...

Страница 101: ...er TDC mark on the distributor flange Install the distributor inserting the lug into the camshaft groove Rotate distributor to align the mark on distributor flange with the mark on cylinder head Tight...

Страница 102: ...lywheel gear ring or starter 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 f...

Страница 103: ...rature 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 Hydraulic valve...

Страница 104: ...ct Check fast idling spring for fallout readjustment 7 Low or unstable Cylinder compression pressure Check and service 8 Timing belt tightening incorrectly Adjust timing belt tension 9 Idle mixture to...

Страница 105: ...rvice 10 Engine accelerates hesitate 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 ou...

Страница 106: ...ne ignited too late Check or adjust distributor 2 Incorrect Timing belt assembling or Adjust teeth belt tension and tension pulley inadequate belt tension 3 Carburetor fuel level too low or Check and...

Страница 107: ...utor b Incorrect fuel grade Use fuel of correct grade c Intake manifold or connecting hose vacuum leakage Check and service d Too much carbon deposits in Spark plug or combus tion chamber carbon sever...

Страница 108: ...abnormal 5 Expansion tank pressure cap damaged Replace 6 Water pump leaks or damaged Service or replace 7 Ignition timing too late Adjust ignition timing 8 Air exists in cooling system Bleeding the a...

Страница 109: ...108 7 cylinder compression pressure decreases check engine 8 Incorrect ignition timing adjust ignition timing 9 Too low tire pressure inflate the tire...

Страница 110: ...hrottle valve body 3 Two BAE 800 AK Ignition coil The whole system includes fuel pump fuel filter RPM sensor absolute pressure sensor sensor and so on Fig 159 1 Fuel tank 2 Fuel pump 3 Fuel filter 4 C...

Страница 111: ...ting device to integrate idle speed spray ignition s control Moreover HCMOS microprocessor with wonderful static prevention and high speed calculation ability and low power consumption may fulfill the...

Страница 112: ...pped and ignition switch is on ECU may perform active diagnostic function which may operate ECU microprocessor to check whether the following accessories are running well or not fuel pump fuel injecto...

Страница 113: ...hrottle valve Throttle valve features small accessories compact structure and a bran new inner geometry structure to better the fuel atomization from fuel injector and get the most proper mixture for...

Страница 114: ...0 9 1bar and redundant fuel will recirculate flowing into fuel tank Fuel will clean and cool injector during recirculation Working procedure of Fuel pressure regulator Spring 2 applies pressure on the...

Страница 115: ...g corrosive material is applied figure 164 shows fuel injector structure and some technical parameters Technical parameters winding resistance R 1 8 10 20 power supply voltage V 6 16V spraying shape a...

Страница 116: ...ngine warming up As accelerator pedal is released fuel will be cut off ti 0mS Running condition and readjusting condition may be changed according to water intake air temperature or A C condition inta...

Страница 117: ...ction 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...

Страница 118: ...m idle air intake is set by valve returning position i e about 200 steps 8mm travel The operation steps are the function of engine conditions preheating cycle electrical load A C working condition eng...

Страница 119: ...61 from the sensor When engine is warmed enough for fan to reach the operation range the enrichment is zero 4 2 speed top dead center and s s s synchro pickup CVM01 see figure 170 Fig 170 Sensor is mo...

Страница 120: ...ched see figure 171 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...

Страница 121: ...mospheric pressure mmHg After the ignition switch is switched on the actual atmospheric pressure may be obtained by this method When engine is running the vacuum will produce a mechanical effect on th...

Страница 122: ...figure 175 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...

Страница 123: ...l 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...

Страница 124: ...h a heating unit 4 to reach the operation temperature as soon as possible When the current flows over the heating unit it shortens the time for ceramic becoming the conductor of iron and may have the...

Страница 125: ...verter capability for the chemical reaction should not occur within 80 thousand kilometers or five years Besides lead the unburned fuel in the converter is another factor for the catalytic converter f...

Страница 126: ...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 The operation when engine is run...

Страница 127: ...the neighboring magnet attraction Under the specified accelerating load the steel ball is released from the magnetism stillness and begins to move up the cone seat with the travel of the movement dep...

Страница 128: ...l cylinder 1 4 9 Dual relays A ECU B fuel pump 10 sensor 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 o...

Страница 129: ...128 Fig 181...

Страница 130: ...unter 27 Throttle valve position sensor 8 Ignition coil 1 cylinder 1 4 28 Main ground wire of engine 9 Ignition coil 2 cylinder 2 3 29 Absolute pressure sensor 10 Fuel vapor recirculation solenoid 30...

Страница 131: ...nection line 23 Fuel pump relay speed counter signal 11 Tacho sensor negative input 24 A C relay signal see note 12 sensor negative input 25 Without connection line 13 Water temperature sensor negativ...

Страница 132: ...tem 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 injectio...

Страница 133: ...ter temperature sensor 18 Fuel vapor recirculation solenoid 10 Absolute pressure sensor 19 sensor connector 11 Intake air temperature sensor Self diagnosis system The information is stored permanently...

Страница 134: ...r the corresponding signal channel fails the above program is also applied When a failure is detected and the corresponding substitute value is applied the warning light on the instrument panel will t...

Страница 135: ...e sensor Remove sensor from the case During reassembling grease should be applied on threads Antiseize boron nitrogen grease is recommended Tightening torque 0 5 0 6Nm At ambient temperature The resis...

Страница 136: ...sensor or intake air temperature sensor The temperature indicated should be in the vicinity of the ambient temperature Idle intermittent wave 1 Throttle valve body 30MM4 1 check the throttle valve cab...

Страница 137: ...dy check fuel filter and fuel pipes TRANSMISSION MAINTENANCE AND SERVICE Page 1 Outline Drawing of AQ015D Transmission 129 2 Specifications 130 3 Structural Type and Applicability 131 4 Service and Op...

Страница 138: ...137 Outline Drawing of 5T15 Transmission...

Страница 139: ...138 Fig 189 Specifications...

Страница 140: ...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 Input Shaft Spline 24 Teeth Involut...

Страница 141: ...oth driving low noise and long service life etc The transmission is mainly matched with CAC480 series of engines single point injection and multi point injection Service and Operation 1 When shifting...

Страница 142: ...141 Fig 191 1 Clutch Housing 2 Input Shaft 3 Output Shaft 4 1st Speed 5 Reverse Speed 6 2nd Speed 7 3rd Speed 8 4th Speed 9 Transmission Case 10 Rear Case 11 Main reducing gear...

Страница 143: ...screwed off The oil is drained away Fig 192 The release lever of clutch is drawn out Fig 193 The bolts connecting the rear case and the transmission are screwed off The rear case assembly is removed A...

Страница 144: ...ift 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...

Страница 145: ...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 for...

Страница 146: ...ar needle bearing and synchronizer ring are removed If necessary the special tool may be used Fig 203 The idler shaft is tapped upward with the reverse speed idler Until the idler and idler shaft are...

Страница 147: ...When the differential assembly is installed on the clutch housing the output flange will be not installed temporarily 2 The output assembly is installed And the output shaft mid bearing seat is set T...

Страница 148: ...gear are installed When the 3rd speed driven gear is installed the shoulder side is toward the 2nd speed driven gear Fig 210 7 After the 3rd speed driven gear is installed the axial size should be adj...

Страница 149: ...212 9 The fork assembly is installed in the right postion 1 1st and 2nd speed fork 2 3rd and 4th speed fork 3 5th speed fork guiding plate and sleeve 4 reverse speed fork guiding plate Fig 213 10 The...

Страница 150: ...h 25Nm of force moment The input shaft rear bearing retainer is screwed down with 15Nm force moment Notice The fork shaft is not drawn from 5th speed sleeve Otherwise the fork shaft in the case and th...

Страница 151: ...ng force moment is suitable to the oil free bolt and nut Bearing When the needle bearing is installed the thick and big wall side is toward the installation tool When installed the bearings are lubric...

Страница 152: ...al Conical roller Bearing Not Adjusted Adjusted Output Shaft Adjusted Not Adjusted Output Shaft Mid bearing Seat Adjusted Not Adjusted Differential Case Not Adjusted Adjusted Output Shaft Mid Bearing...

Страница 153: ...is installed to the position that is shown in the figure And then the release shaft the spring and the clamper are installed When the spring in installed its position is show in the figure The new re...

Страница 154: ...use the special tool is inserted into the transmission case As the figure shown the bearing is tapped till the bearing is stretched out Fig 221 Installation Fig 222 As the figure shown the special to...

Страница 155: ...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...

Страница 156: ...al 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 oi...

Страница 157: ...changed the installation position of relative shaft must be readjusted Adjustment of Output Shaft and Differential Assembly Adjustment of Output Shaft The distance B1 from the big plane of output sha...

Страница 158: ...ace of the assembly bearing outer ring to the contact surface of clutch housing is measured The bearing hole depth A2 of output power assembly on the transmission case is also measured To Calculate th...

Страница 159: ...eal washer and recoated Bruised joint face and not refaced in time To inspect and reface the joint face Leaking Oil Damaged differential bearing To change the bearing Improper adjusted clutch not thor...

Страница 160: ...onizer ring 1 14 015 311 295 AA 4th and 5th speed synchronizer ring 2 15 015 301 189 AA Oil seal assembly output flange 2 16 015 311 113 AA Oil seal assembly output shaft 1 17 015 301 227AA Oil seal a...

Страница 161: ...160 WIRING DIAGRAM...

Страница 162: ...ut Shaft Assembly 171 4 Output Shaft Assembly 172 5 Rear Cover assembly 174 6 Output assmebly 175 BODY 1 Frame assembly 176 2 Engine bracket and muffler assembly 177 3 Gear shift mechanism 180 4 Steer...

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