LJ276M/LJ276MT-2 GASOLING ENGING SERVICE MANUAL
Contents
1. 1 Connecting rod bearing matching group number connecting rod big end matching group number connecting rod neck matching group number 2 Upper and lower connecting rod should be fitted with the same group bearing B When installing two gas ring and the combined oil ring into grooves of piston Stagger their opening fig 3 9 The marked surface of the first and second rings should face piston head C Main points for installing piston and connecting rod assembly There are fitting marks on piston head and connecting rod shank Sure that the mark s are in the same direction refer to fig 3 10 Be careful to avoid mistakes D When installing piston and connecting rod assembly into cylinders The marked surfaces of the connecting rod and piston must face the front of engine fig 3 10 The concave surface facing the front The front of engine eO The opening of 7 first ring The opening of second ring The opening of NS The opening of scraper ring caraper ring The opening of compound ring Fig 3 8 Relative position of piston rings Fig 3 9 The direction of piston and connecting rod in cylinder 3 5 DISTRIBUTOR ASSEMBLY Distributor is driven by a special bevel gear on crankshaft The shaft end drives oil pump Obviously the installation angle of distributor decides ignition timing The steps for distributor installation is as follows A Rotate crankshaft to TDC position Then use a screwdriver to tur2. 25 Ignition timing too early Fuel supply blocked Adjust Clean 10 Generator problems 11 Clutch problem 12 Transmissi on problem Stator coil or rotor coil breakaway Replace or repair C Abnormal noise Clutch slip Bearing over loosed distribute noise Rotor knock with stator Rectifier short circuit stator coil short circuit Clutch lining oily Clutch lining worn serious A short circuit or bonding Generator Rectifier tube burned out Replace or repair does not breakaway or short circuit work Pole isolator damaged wire Replace or repair breakaway Rectifier damaged Replace B Lack of Brush contact not good sliding ring oily Clear oily power Replace or fill grease adjust Replace Replace Replace Remove clean Replace Clutch vibration and noise Shift easy to slipping Bhaft change difficulty Release bearing moving inefficient or worn No 1 shaft bearing moving inefficient or worn Clutch pin hub loosen Pressure plate and spring loosen Clutch pressure plate crack Clutch pressure plate crack Pressure on locating spring too weak Locating ball damaged Synchronism sleeve and engage gear worn Synchronizer ring worn Synchronizer hub worn Clean fill grease or replace Replace Repair Replace or repair Replace Replace Replace Replace Replace Replace Replace Abnormal no
3. chamber is too low or wrong problems adjustment Mixture too rich or too poor Adjust chock valve and fuel valve Cylinder gasket damaged Replace d Cylinder Wrong valve clearance Readjust Compressi Leakage through valve and valve seat Repair on pressure leakage through intake manifold Repair insufficient Piston ring or cylinder over worn Replace Cylinder compression pressure Done as item 1 d insufficient Fuel supply insufficient Done as item I c 2 Lack of power Spark plug firing weakness Done as item 1 b Wrong adjustment of fuel valve and Readjust carburetor Exhaust blocked Check exhaust system and clear carbon deposit Fn belt loosen or water pump Adjust belt or replace water pump d d 3 Over heat ER Insufficient of cooling Liquid or Replenish cooling Liquid or 24 water pipeline blocked Thermostat does not open Too much carbon deposit in combustion chamber Oil too much insufficient or poor Ignition timing too late or too early Clutch slipping clean water pipeline Replace Clean carbon deposit Adjust oil level Readjust Repair or replace 4 Carburetor firing back Ignition timing too late Over heat Mixture gas too poor A Carburetor jet blocked B Insufficient of fuel supply Valve leakage High voltage cable damage Adjust Done as item 3 Clean Done as item l c Adjust clearance or lap the valve Replace 5 Knocking noi
4. colored at Piston pin external diameter 1 Bae internal hole Red gt 0 009 lt 0 006 Yellow gt 0 006 lt 0 003 Blue gt 0 003 lt 0 Requirement of connecting rod small end matching group is in the table below Connecting rod small end matching group 0 020 Group and mark Connecting rod small end diameter 18 04 A gt 0 047 lt 0 038 gt 0 038 lt 0 029 Requirement of connecting rod bearing matching group is in the table below Piston pin matching relation Matching group number Connecting rod small end Piston pin Piston pin boss hole A B C Requirement of connecting rod big end matching group is in the table below Group and mark Connecting rod big end dimension 43 20 lt 0 008 gt 0 008 lt 0 016 gt 0 016 lt 0 024 Requirement of connecting rod bearing matching group is in the table below Connecting rod bearing matching group Group and mark Identifying color Center thickness C 1 503 1 Yellow 0 014 lt 0 010 gt 0 010 lt 0 006 gt 0 006 lt 0 002 gt 0 002 lt 0 002 gt 0 002 lt 0 006 Connecting rod matching relation is in the table below Connecting rod matching relation connecting rod Connecting rod neck group number matching group Connecting rod big end group number Note
5. o d Keep water temperature within 75 95 C At medium speeds normal oil pressure should not be less than 245Kpa 2 5kgf cm e Use RQ 700rRON 90 or above petrol as fuel When detonation happens adjust distributor so that ignition timing is retarded properly It is not allowed to run engine under detonation f If abnormal phenomenons happen during running turn off engine and check it without delay g When draining water from cooling system to avoid being scalded don t open drain plug before water temperature drops 2 2 RUNNING IN OF NEW ENGINE The service life of engines depends greatly on their initial operating states When anew engine is installed in a vehicle The vehicle must be drive for 2500 km in accordance with running in specification The proposed running in specification is as follows Mileage km Load Speed 0 250 No load Engine Speed Not Over 1600r min 250 1000 50 of Rated Load Engine Speed Not Over 2200r min 1000 1500 75 of Rated Load Engine Speed Not Over 2800r min 1500 2500 Rated Load Increase Speed Gradually To Maximum Speed In The Operating Gears 2 3 STARTING RUNNING AND TURNING OFF ENGINE 2 3 1 PERPARATIONS BEFORE STARTING Do the following before starting engine a Check water level in radiator and reservoir tank tightening of water pipe connections and tensioning if fan belt b Check level of Lubricating oil in oil pan c Check fuel quantity in fuel tank and soundness of fuel supp
6. off should be complete and clutching on should be smooth It should be smooth to shift gears of transmission H Replace lubricating oil of transmission 4 1 4 MAINTENANCE ECERY 5000 KM A Carry out the maintenance in point 4 1 3 refill lubricating oil instead of replacing lubricating oil B Clean fuel tank fuel line and carburetor barrel C Check battery for cracks or leakages of electricity D Check functioning of regulator 4 1 5 MAINTENANCE EVERY 10000 KM A Carry out the maintenance in point 4 1 4 B Replace air filter element C Replace oil filter and change engine oil D Remove cylinder head and clean carbon deposit on the surface of combustion chamber and on piston head Clean the dirt inside intake and exhaust system E Remove and clean alternator and starting motor Replace the grease in their bearings F Check the functioning of throttle operating wire and carburetor shaft G Check the contamination of lubrication oil in transmission Replace if necessary H Replace the antifreeze coolant in the cooling system 4 2 PONINTS OF ATTENTION FOR ENGINE MAINTENANCE 4 2 1 LUBRICATION SYSTEM MAINTENANCE A Measurement of oil level The quantity of oil in oil pan is measured by a dipstick on the right side of engine To check the oil level turn off engine and wait until oil surface is quiet about after 5 minutes take out the dipstick and remove oil trace with a clean cloth then insert the dipstick and take out again The
7. replenish clean soft water every time before going out with a vehicle It is prohibited to use hard alkaline water with many minerals In winter antifreeze must be used Generally speaking the freezing point of the selected antifreeze must be 5 C lower than the lowest temperature of the area where engine is used If antifreeze is not used drain cooling water from radiator and cylinder block after turn off of engine without delay COOLING SYSTEM MAINTENANCE alternator Fig 4 2 Adjustment of tensioning of fan belt B It is necessary to check tensioning of fan belt regularly Adjust tensioning if necessary refer to fig4 2 The appearance of fan must be good The excessively worn belt must be replaced without delay 4 2 3 FUEL SYSTEM MAINTENANCE A The air filter element must be replaced regularly in accordance with maintenance instruction B and road conditions The carburetor has been adjusted pre delivery and adjustments are not necessary It is prohibited to turn the screw which marked with paint Turning this screw arbitrarily will make the transient performances economy and exhaust at idle speed deteriorate The idle speed of LJ276M engine is 900 50r min When adjusting idle speed The water temperature of engine must be 75 95 C Check if ignition advance angle is an follows Turn the idle adjusting screw and speed adjusting screw refer to fig4 3 alternatively to make engine run at a
8. speed a speed adjustment screw bit higher than idle speed Then turning idle adjusting screw until the engine speed is lower than idle speed and turn back for 1 4 turns chock spring C The fuel level in the float chamber must be within the 3 circle in the centre of fuel mirror When the f fuel level is too high or too low it can be be regulated by changing the thickness of the spaces of float needle valve Fig 4 4 Adjustment seat gt of choke spring D The position of choke valve spring in order to facilitate starting when ambient temperature is below 15 C the mixture must be richer For this purpose The hook up position of the choke valve spring on the rocker must be changed from steplto step2 fig 4 4 4 2 4 IGNITION SYSTEM MAINTENANCE 4 2 4 1 The ignition timing has been adjusted prp delivery and is happens during operation due to change of ignition timing and readjustment is necessary carry out adjustments as follows A Turn crankshaft to set the piston of No 1 cylinder at TDC position of compression stroke B Open distributor cover and observe the position of rotor head make the end with notch of contact set face forward fig 4 5 C Turn crankshaft again and check the cross firing moment across breaker contact points When cross firing happens the angle on the timing chain cover facing the boss mark of crankshaft is ignition timing D If ignition timing is not within 642 C loosen the lockn
9. 02 40 03 Main points for installing balance chain A Rotate crankshaft to BDC position B Mark direction of counter weight on balancing shaft to be the same as that of counterweight on crankshaft fig 3 6 balancing shaft t E y balancing shaft Naw l counter 4 weight crank counter weight i shaft v hS i t er oe ee ee ee ee Fig 3 6 The position of counter weights and balancing shaft C Align the marks white and bright chain elements on two balancing shaft sprockets grooves respectively fig 3 7 Then install crankshaft sprocket and two balancing shaft sprocket with balance chain on crankshaft and balancing shaft single whirt double white and buight and bright crankshft chain element chain element sprocket sprocket Alignment of balancing chain marks Fig 3 7 3 3 CRANKSHAFT AND MAIN SHAFT BEARING 3 3 1 Crankshaft Crankshaft is made of ductile iron On No 1 and No 4 crank each mark with connecting group number refer to fig 3 8 At the front end of the crankshaft fitted with balancing shaft drive pulley timing chain and belt pulley each used for drive balancing shaft camshaft water pump alternator the fly wheel with toothed ring fitted at the end of the crankshaft No lcylinder connecting rod jz neck matching group nuaber No 2 cylinder connecting rod neck matching group nuaber No 3 main shaft neck matching group nuaber No 2 main shaft n
10. LJ276M LJ276MT 2 GASOLING ENGING SERVICE MANUAL Shanghai Goka Sports Motor Co Ltd CONTENTS DRAWING Chapter one Engine technical data and specification ccccsccescccsccscccsscesccsccees 2 1 1 Engine technical data and specification ccecece eee ence eee eee eee eeeeeeeaeeaenaees 2 1 2 Petrol Engine External Character Curve ccccc cece nee e eee e nent ena e ene ene en ae ene ennenes 5 Chapter two Engine operation cccccccccsccscccscccccccccscccscceccesccessccsccsscesscsssces 6 2 1 Points for attention in engine OperatiONn c cece cece ence eee cee eeeenenae een eee 6 2 2 Running in of NEW CNAINE cece eee eee eee tenet tee teeete essers een 2 3 Staring Running and turning off engine cece cece e cree eee eee e en eeenes 6 Chapter Three Structural characteristics and assembly requirements of engine 8 3 1 Cylinder head assembly 022 0 lt sneer cee nee cies av anienn E ate RERE EEEE aes 8 3 2 Cylinder block assembly and balance chain 0 cc cece cece cence ence eee eee ene enaeens 9 3 3 Crankshaft and main shaft bearing ccc cece cece eee e ene ee cene eee e ae enee ene eennnee 11 3 4 Piston and connecting rod assembly cc cece cc ences cece ence eee neene nee enae eae enn een ed 12 3 5 Distributor assembly noniis et eect E a E UPNdex caves Poe Cee SrA ieee 15 3 6 Carburetor assembly 0 cece cece cece
11. Surface The Area With A Width Of 10mm on each side of Top Surfaces Of semicircle Front naval Rear Oil Seals And The Area With A Width Semi circle Oil Seals Of Cylinder head Of 10mm Jointing Cylinder head Top Surfaced The Curved Surfaces Of Semi Circle Oil Seal 29
12. a 3000r min Mode Of Cooling Forced Water Cooling Cooling Water Capacity 1 4L Type Of Water Pump Centrifugal Thermostat Wax Type Type Of Fan Belt AV 10840 75 95 C Water Temperature Type Of Air Filter Type of Fuel Pump Celectromotion ModelQK1706 00 Paper Element JB12D II 12V Model CSH101E Double Venturi tube Single Chamber CARBUREROR Type Balancing Float Chamber Flat Absorb Type Of Choke Valve Manual Firing By battery Ignition Timing 10 2 BTDC 900r min Firing Order 1 2 Ignition Coil Model DQ130 12V Distributor Model FDW261 p Magnetic pulse igniter without contact Ignition Type piece system Ignition f Centrifugal Vacuum Advance SPARK Model F6T E6TC M14x1 25 Diameter Electrode 0 740 1mm Gap ALTERNATOR Model and Type JF132 JF138A Silicon Rectified Alternator Power Output 14V 30A Used With Voltage Regulator STARTING MOTOR Model QD112A QD115 Power Output 12V O0 8KW Battery POWER TRAIN SYSTEM Clutch Type Model 6 QA 36S Single Disc Diaphragm Spring Dry Operating Mode Forced Dimension Of Frictional Dise Outer Dia xThickness Dia Inner 160x110x7 8 TRANSMISSION T Normally engaged helical gears as synchronous at full speed Mode of operation Floor shift Crankshaft to Transmission m
13. ain shaft Normally 1 6 Engaged drive ratio First Gear 2 413 30 14 Second 1 318 29 22 Gear Transmission Third P 0 862 25 29 main shaft to Gear Lay shaft Fourth Gear R A leis 99 195 Gear LJ276M LJ276MT 2 First Gear 3 429 4 S d To 2 109 2 8 Gear Speed ratio Third 1 379 1 8 Gear Fourth 1 000 1 0257 Gear Reverse 3 600 3 363 Gear Mileage Counter 14 3 13 3 Lubricant GL 4 Lubricant Capacity 0 7L 1 5L Normal modulus Mm Tooth Number Z Normal Tooth Pressure Spline Data Of The Output Shaft angle Normal Tooth Stand off Measure Normal Line w k Measure Span M 1 2 Petrol Engine External Characteristic Curve The Petrol Engine External Characteristic Curve refer to fig 1 1 Contec ting 24 offective f tongue Conecting 43 MeO M effective outpart PAE W a5 20 36 16 30 y T i4 rin E l2 LL 10 a 4 speafie fael commu pce 3 gele k Wh 330 300 230 1500 2000 2500 3000 3500 4000 4500 5000 5500r rmn Fig 1 1 CHAPTER TWO ENGINE OPERATION 2 1 POINTS FOR ATTENTION IN ENGINE OPERATION a Make adjustments and carry out maintenance in accordance with the maintenance methods and rules in this book b Check bonding of earth of battery Negative terminal of battery is connected to the earth for model LJ276M engine c When operating new engines carry out running in accordance with the specification below Don t accelerate or overload suddenly
14. ces for leakage of oil and water C Check high tension cables for looseness D Check electrolyte level in battery Refill distilled water if the level is not high enough E Carefully listen to the sound of engine running at idling speed after starting Observe the functioning of different instruments 4 1 2 MAINTENANCE AFTER FIRST 1000KM A Carry out the maintenance mentioned in daily maintenance B Check the tightening of bolts between engines and bracket and exhaust manifold between engine and air filter C Check the tightening of cylinder head bolts If there is looseness retighten in accordance with the order in the instruction D check valve clearances Adjust if necessary E Check the tensioning of fan belt Adjust if necessary F Check idling speed and ignition timing G Check gravity of electrolyte in battery or voltage of battery H Check connections of alternator regulator Ignition coils and spark plug for looseness I Check and adjust the free travel of clutch pedal 4 1 3 MAINTENANCE AFTER RORST 2500 KM A Carry out the maintenance mentioned in daily maintenance B Check the wear and tensioning of fan belt Replace or adjust if necessary C Clean the electrodes of spark plug Adjust electrode gap if necessary D Replace the paper element of air filter E Change oil of engine and replace oil filter F Start engine and check for any abnormal noises from power train under no load G Operate clutch Clutching
15. cover The screw fitting oil filter and main oil gallery are distributed in timing chain cover The chain is lubricated by spraying of oil from nozzle Forced and splash lubrication system is used for engine Oil filter is convenient in use and easy in replacement with a one assembly structure Oil pressure is indicated by an oil pressure switch When oil pressure is under specified value the indicator is on 3 8 COOLING SYSTEM Engine is cooled by pressurized circulating water A centrifugal water pump and a nylon fan with blades of different lengths are adopted Results of food radiation small power loss and small noise for fan are achieved The opening temperature of the paraffin thermostat is at 75 C 3 9 ELECTRICAL SYSTEM A Alternator silicon rectified high speed alternator its negative terminal is connected to the Earth B Starting motor electromagnetic drive unidirectional clutch C Distributor contact type with rechargeable indicator D Regulator contact type with rechargeable indicator The electrical diagram of engine is shown in fig 3 13 Alternator is driven by crankshaft pulley through fan belt It is necessary to adjust tensioning of fan belt in accordance with specification refer to chapter 4 cooling system maintenance GEE spark piug AN SRE lgnitiopn coil ignition ammeter Fig 3 12 The electrical diagram of engine 3 10 CLURCH ASSEMBLY AND TRANSMISSION ASSEMBLY Clutch disc is of si
16. eck matching group nuaber No 1 main shaft neck matching group number Fig 3 8 Connecting rod neck main shaft neck matching group number 11 Connecting rot neck and main shaft neck matching group number is in the table below Connecting rod neck matching group Main shaft neck matching group Group and Connecting rod neck ark dimension 40 924 gt 0 024 lt 0 016 Group and Main shaft neck dimension mark D43 0 024 gt 0 024 lt 0 016 gt 0 016 lt 0 008 2 gt 0 016 lt 0 008 3 3 2 Main shaft bearing Main shaft bearing grouping according to the dimension of centre thickness see the table below Main shaft bearing matching group Centre thickness 2 ors on E ow When fitting in order to ensure the bearing clearance it needed to matching on group the matching relation is in the table blow Main bearing matching relation Main shaft neck matching group number 2 Main bearing matching group number Main bearing hole matching group number Note 1 Main bearing matching group number main bearing hole matching group number main shaft neck matching group number 2 Upper and lower bearing should be fitted with the same group bearing set 3 4 PISTON AND CONNECTING ROD ASSEMBLY Piston is made of special aluminum alloy There are two gas rings and one oil ring on each piston The surfaces of the first gas ring and oil ring are chromium plated T
17. eee enn EEE EEE EE EEE EEE EEE EE EEE EEE EEE Ea 16 3 7 Lubrication System oeras eee a pea gia Sek eens Bae eA eee el bine aes 16 3 8 Cooling systema ecc cscseeceg severe ee cee aia Cee ban vende Foe ca cose odes duc K r ae aa iaeia cond E Eai 16 3 9 Electrical Systems 2 22 ssasi2 dete nd dicta ots Bed ays iaa BEEN bed Gs Gdeaghns Uiedied sei ws ee aioe 16 3 10 Clutch assembly and transmission assembly ccecee eee ee cence eee eesenseeeeeeeaeens 17 3 11 Engine leakage prevention ccc cece cence eee eee eee nee een eee ene ent nen ee Etat es 18 Chapter Four Engine maintemance cceccccccscccsccscccsccesccscccsccesccscescsessseess 19 4 1 Engine maintenance Cycle cece ccc cence eee nee ee ee cete ne ences ene nets nett ete ees 19 4 2 Point of attention for engine maintenance c cece cece cece eee eee ee eeeeeeeeaees 20 Chapter Five Engine main troubles and remedies ccsccscescccsccccscscccsccescoees 24 Appendix A Fit Clearances of Main Component cceccecececereneeeeeeeeeeeeeneeaeeas 27 Appendix B Tightening Torque c cece ccc ence eee eee nnn eee ene enn e ne ene ene tenet ened 28 Appendix C Sealing Surfaces and Sealant ccc cece ccc cee n eee e eee e nee ene eens eeneenaees 29 CHAPTER ONE ENGINE TECHNICAL DATA AND SPECIFICATION 1 1 ENGINE TECHNICAL DATA AND SPECIFCATION Model LJ276M LJ276MT 2 Two C
18. he second gas ring is slightly conical and serves to proof gas and form lubricating oil zone when piston is going upwards and scrape oil when piston is going downwards The combined oil ring consists of an upper scrape ring a lower scrape ring and a compound ring in the middle The oil ring has radial and axial sealing function and can prevent lubricating oil enter combustion chamber Piston pin is pressed into the hole of connecting rod with interference In order to prevent knocking the hole of piston pin deviates Imm from supporting and compressing direction Main points for installing piston assembly A Piston and connecting rod assembly matching group Requirement of matching group of the piston skirt diameter is in the table below Piston skirt diameter matching group Group and mark Skirt dimension 76 93 gt 0 030 lt 0 020 gt 0 020 0 010 gt 0 010 0 Requirement of piston matching relation is in the table below Piston matching relation Matching group Engine block 1 2 piston 1 2 3 Requirement of piston pin boss hole matching group is in the table below Piston pin boss hole matching group Group and mark hole dimension 18 Oto gt 0 001 lt 0 002 gt 0 002 lt 0 005 gt 0 005 lt 0 008 4 Requirement of piston pin external diameter matching group is in the table below Piston pin external diameter matching group mark
19. ise Needle bearing or ball bearing damage Gear worn serious or damage 26 Replace Replace APPENDIX A FIT CLEARANCES OF MAIN COMPONENTS cae Clearance No Description Type of fit Remarks mm Connecting rod neck and l f Matching clearance 0 026 0 066 connecting rod bearing hole Connecting rod big end side Shaft direction 2 0 08 0 24 clearance Clearance 3 First piston ring and cylinder Gap 0 25 0 45 4 Second piston ring and cylinder Gap 0 2 0 4 5 Piston scraper ring and cylinder Gap 0 3 0 5 Crankshaft thrust bearing and Shaft direction 6 0 05 0 166 main shaft neck gap Clearance 7 Balance shaft and bearing hole Clearance 0 06 0 106 Cam shaft neck and bearing 8 Clearance 0 050 0 091 hole 9 Cam shaft direction clearance Shaft direction clearance 0 09 0 24 Exhaust valve seat and cylinder 10 Interference 0 112 0 153 head Intake valve seat and cylinder l1 Interference 0 112 0 153 head 12 Exhaust valve and guide Clearance 0 04 0 07 13 Intake valve and valve guide Clearance 0 025 0 035 Rocker arm shaft and rocker Bi Clearance 0 016 0 054 arm hole Oil pump external rotor and 13 Clearance 0 05 0 12 inner rotor Oil pump rotor and oil pum 16 7 aad Clearance 0 02 0 065 housing end surface 17 Oil pump external rotor and Clearance 0 08 0 158 Piston pin and connecting rod 18 Matching clearance 0 029 0 041 small end 19 Piston pin and piston
20. ly line and connections Eliminate any leakage d Check level of electrolyte in battery e Check tightening of connections for battery alternator fuel pump distributor spark plug regulator ignition coils and other electric components 2 3 2 PROCEDURE FOR STARTING ENGINE A Set gearshift level to idling position B Move carburetor choke valve near to close position Then slightly open throttle vale with starting lever so that rich mixture is obtained C Step down clutch pedal D Turn ignition switch to start position Starting time should not be over 5 seconds The interval between two adjacent starts should not be less than 20 seconds E After starting engine release ignition switch immediately so that it goes back to ignition position automatically At the same time open choke valve partially With the increase of engine temperature open choke valve gradually until its fully open position 2 3 3 STARTING ENGINE AT THE ATMOSPHERIC TEMPERATURE OF LOWER THAN 5 C When starting engine at low temperature in addition to above mentioned checks SE10W 30 OE engine oil for winter use and antifreeze coolant should be used And engine should be warmed up Steps for Engine Warming Up A If Antifreeze coolant is not used Feed hot water of above 90 C into engine B Feed oil of 80 C 90 C into engine The oil should be that which has been drained from engine previously Draining of oil should be done immediately after engine turn off so
21. mpact in structure and low noise Rocker arm is made of high strength aluminum alloy with inlaid alloy resists very high temperature A sealing unit is used for value stem so that engine oil can not enter combustion chamber phase angle between the No 1 cylinder and the No 2 cylinder is 360 degrees crank angle Camshaft dowel pin hole A Point for installing timing chain Rotate crankshaft to TDC position before installing timing chain Camshaft sprocket Then align marks on timing sprocket of crankshaft and camshaft sprocket with the white and bright chain Timing element respectively Now the chain ee bright chain locating pin in camshaft should be element right at the top position refer to fig 3 1 Tellsion plate B Locating TDC wane Bless Rotate crankshaft to make 5 s White and pistons in two cylinders go to their brishte chain bak r l t TDC positions in turn Now the SAG center mark on boss of crankshaft Hark Crankshaft pulley should align with the boss of timing sprocket timing chain cover Remove cylinder l a Fig 3 1 Alignment of timing head cover if the locating pin in chain marks camshaft sprocket is at the position shown in fig 3 2 The piston in No 1 cylinder is at the position of compression stroke If locating pin is at opposite position the piston in No 2 cylinder is at TDC position of compression stroke timing mark at TDC Fig 3 2 Fig 3 3 C Tightening and removing cyli
22. n the groove in shaft end of oil pump refer to fig 3 11 Align the mark on distributor shaft with that on the housing refer to fig 3 12 C Align the flat tongue face on distributor shaft with the groove on shaft end of oil pump Slowly install the distributor into timing chain cover until its shaft inserts into the groove on oil pump D Tighten locknuts on the distributor housing and check ignition timing refer to chapter 4 ignition system maintenance parallel line to crankshaft Fig 3 10 The position of groove in Fig 3 11 The direction of piston and oil pump shaft connecting rod in cylinder 3 6 CARBURETOR ASSEMBLY In order to achieve good power performance and economy with low exhaust gas pollution Engine is equipped with a meticulously designed and adjusted carburetor It has a sliding valve which serves to prevent mixture to be too rich during decelerating and reduce CO and HC content in exhaust gas The air equilibrating chamber which is connected to float chamber serves to avoid fuel vapor overflow and to avoid negative effects caused by clogged air filter In addition the P32Q 1 carburetor also has a start high speed idling speed mechanism which serves to have a good cooperation between choke value and throttle value under starting and idling speed operating conditions to make engine run at higher idling speed to reduce warming up time 3 7 LUBRICATION SYSTEM Oil pump is installed in oil pan under timing chain
23. nder head bolts The tightening order for cylinder head bolts is shown in fig 3 3 tighten bolts uniformly in three steps Unfasten are remove bolts in reverse order IGHTENING TORQUE requirement NO 1 NO 6 Bolts NO 7Bolt 68 6 73 3N m Cold 7 7 5kgfm 4 9 6 86N m Tightening torque 75 8 83 4N m Hot 8 8 5kgf m 0 5 0 7kgfm 3 2 CYLINDERBLOCK ASSEMBLY AND BALANCE CHAIN Cylinder block is made of alloy cast iron which has high strength and is wear resistant In order to make operation of engine stable and to reduce vibration Advanced balancing mechanism is adopted The balancing mechanism consists of counter weights and balancing Shaft which are ocated on two sides of crankshaft respectively balancing shaft is driven by a chain On top surface of the cylinder block marked with cylinder matching group number at bottom marked with main bearing hole matching group number refer to fig 3 4 3 5 Be asin bearing hele satching group susber cylinder matching group number Bo 2 main bearing hole aatching group nuaber j Ho 3 asain bearing hole ast ching croup suaber Fig 3 4 Fig 3 5 Requirement of matching group is in the table below Cylinder matching group Main bearing hole matching group Group number Cylinder Group number Cylinder and mark diameter76 y and mark diameter47 ar ia lt 0 008 gt 0 008 lt 0 016 oa gt 0 lt 0 01 4 gt 0 016 lt 0 024 i F 2 0 01 lt 40 02 3s 0
24. ngle dry frictional disc Diaphragm spring plate is of normally pressurized drive type Transmission with synchronizer has four forward gears and one reverse gear All fears of the forward speeds are normally engaged helical fears Which have the advantage of stable in transmission Low noise and transmitted torque The structure diagram of transmission is shown in fig 3 13 fourth thirt second first fear gear gear gear reverse gear drive output shaft counter shaft reverse gear Es train reverse gear drive Fig 3 13 Structure diagram of fransmission 3 11 ENGINE LEAKAGE PREVENTION In order to overcome leakage of oil gas sealing ee point water The jointing surfaces and the surfaces for oil seals have been properly designed and sealants are applied to main jointing surfaces Place which must be applied with sealants are shown in fig 3 15 3 16 3 17 Fig 3 15 The jointing surface between oil pan and cylinder block No 609 sealant 10 10 10 10 No 609 sealant Fig 3 16 The front and rear sear sealing surfaces of cylinder head cover Fig 3 17 The jointing surface between cylinder block and timing chain cover CHAPTER FOUR ENGIN MAINTENANCE 4 1 ENGINE MAINTENANCE CYCLE 4 1 1 DAILY MAINTENANCE A Check the levels of fuel Cooling water and oil Replenish if necessary B Check jointing surfa
25. oil level must be between the upper and lower lines refer to fig 4 1 B Changing oil Proper selection and change of oil in accordance with the maintenance cycle are very important to ensure good operation Fi g 4 1 and service life of engine Users should select oils in accordance D ip sti ck with instruction strictly Don t mix and use oils of different brands Before replacing oil drain oil from oil pan when engine is hot If there are large amount of impurities inside oil pan the engine lubrication system must be cleaned with light spindle oil Kerosene or petrol are prohibited to be used for cleaning Filling 3 liters of light spindle oil through oil filler port Start engine oil with starting motor to idling speed for 2 3 times for one minute upper a time drain spindle oil quickly and fill oil into engine in level accordance with specification oil Every time after change of oil run engine at idle upper speed for 3 5 minutes to ensure that lubrication system obtains level enough oil Replace transmission lubricating oil when lubricating oil is still warm Open drain plug on the hole of hexagon headed bolt on the right side of the housing until oil goes up to lower edge of the hole 20 C For lubricating distributor cam and breaker contacts drip 1 2 drops of oil on felt periodically 4 2 2 A To ensure normal operation of engine There must be enough coolant Therefore it is necessary to check coolant and
26. se from inside Ignition timing too early Too much carbon deposit in combustion chamber Main bearing connecting rod hearing over worn Cylinder piston piston pin over worn Piston ring and ring edge over worn Valve clearance too big Balance chain was long drawn Adjust Clean Replace or repair Replace or repair Replace Adjust Replace 6 Oil consumption excessive 7 Oil pressure too low Valve seal worn or damage The spring of the piston scraper ring reduce or piston ring openings do not stagger Cylinder worn Over heat or crankshaft breathing blocked Too much or too less oil case Oil temperature too high Oil too poor Oil pipe leakage Oil filter blocked Oil pressure meter problem Replace Replace or adjust Repair Reduce heating or clean the orifices Replenish or drain out the oil Check cooling system Replace Repair or replace Clean or replace Replace 8 Echaust manifold firing back 9 Without idle speed Fuel level too high in the carburetor float chamber Exhaust valve leakage Firing too late Carburetor valve open too big Carburetor idle speed jet out of function Inlet pipe leakage Spark plug carbon deposit or wrong gap Drain out the unnecessary fuel and adjust fuel level in the float chamber Lap the valve Adjust ignition angle Adjust Adjust or replace Tighten or replace Clean or adjust
27. smooth Matching clearance 0 005 0 011 pin hole 20 Piston skirt and cylinder Matching clearance 0 02 0 04 21 Crankshaft neck and shaft Matching clearance 0 020 0 044 bearing 27 APPENDIX B TIGHTENING TORQUE Description Torque N m kg m Remarks 68 6 73 5 7 7 5 Cold Cylinder head Bolt 78 5 83 4 8 8 5 Hot Camshaft Bearing Cap 24 5 29 4 2 5 3 Camshaft Sprocket 58 8 78 5 6 8 Main Bearing Cap 58 8 68 6 6 7 Timing Chain Cover Including water pump 14 7 19 6 1 5 2 Sprocket Tensioner 49 0 58 8 5 6 Crankshaft pulley 49 0 58 8 5 6 Flywheel 40 0 45 0 4 1 4 6 Counterweight 24 5 29 4 2 5 3 Balancing sprocket 17 7 21 6 1 8 2 2 Con Rod Cover 34 3 39 2 3 5 4 Oil Pan plug 34 3 44 1 3 5 4 5 Oil filter Spark Plug 20 25 2 1 2 6 10 8 12 7 1 1 1 3 Transmission Assembly M12 26 4 39 2 2 7 4 0 Transmission level plug 39 2 49 4 5 Transmission Drain Plug 39 2 49 4 5 cooling fan Spark plug 4 9 7 8 0 5 0 8 19 6 29 4 2 3 Other bolts 3 9 5 9 0 4 0 6 9 8 7 8 0 8 1 0 14 7 21 6 1 5 2 2 28 APPENDIX C SEALING SURFACES AND SEALANT Description Position of painting Sealant Oil Pan Gasket The surfaces jointing cylinder block 609 sealant The Surfaces Jointing t The Circumference of Cylinder block Top Cylinder head Gasket Surface And Timing Chain Cover Top
28. ted metal surfaces and surfaces without paint D Loosen fan belt E Seal the water ports carburetor inlet and tachometer bushing with paraffin paper or plugs UNSEALING A Clear the water ports carburetor inlet and tachometer bushing with paraffin paper or plugs B Remove spark plug and race engine Drain as completely as possible sealing oil from cylinders C Adjust and retighten fan belt in accordance with specification D Refill oil E Refill coolant F Unseal all sealed ports 23 CHAPTER FIVE ENGINE MAIN TROUBLES AND REMEDIES TROUBLES CAUSE REMEDY Battery pole connecting loosen or Tighten or charge a Starter electric insufficient does not Electric circuit breakaway Repair work Starter damaged Check or Repair Ignition coil damaged Replace Spark plug burned out or isolator Replace damaged b Spark Spark plug carbon deposit or wrong Clean Carbon deposit or adjust gap plug does gap not firing High voltage cable damaged or wrong Replace cable or tighten connecter or Firing gap Weakness Low voltage circuit damaged or poor Replace or tighten 1 Engine connecting starting Capacitor damaged Replace difficulty Distributor cover or firing head Replace damaged Wrong ignition Adjust Fuel pump does not work Repair or replace c Fuel Fuel pipeline blocked or damaged Repair or replace supply Carburetor blocked fuel pressure in the Clean or readjust system float
29. that oil is not contaminated Rotate crankshaft of warmed up engine by hand several turns so that cylinders suck in small amount of fuel Start engine and run it at idling speed for 2 3minutes Then run engine from Low load until normal working load Don t warm up engine at high speed 2 3 4 RUNNING ENGINE A Running in of an engine in a vehicle must be carried out in accordance with running in specification Don t start or accelerate engine suddenly at high speed Avoid overloading engine after running in B It is prohibited to run engine when there is no oil pressure Oil pressure if too low abnormal noises take place engine is overheated and abnormal vibration happens 2 3 5 TURNNING OFF ENGINE It is prohibited to turn off engine at high speed and high load Before running off engine Load must be removed Then run engine at low speed for 3 5 minutes and turn off ignition switch In icy season if antifreeze coolant and cylinder block immediately after turning off engine CHAPTER TEREE STRUCTURAL CHARCAITERISTICS AND ADDEMBLY REQUIREMENTS OF ENGINE 3 1 CYLINDERHEAD ASSEMBLY Cylinder head is made of high strength aluminum alloy The shape of combustion chamber is hemispherical Intake and exhaust runners are distributed on two sides The overhead camshaft of value train has very good suitability by three bearing in the cylinder head and driven by timing chain There are the advantages of being stable in transmission co
30. uts for distributor housing and adjust it by swinging the housing swinging anticlockwise increases ignition advance angle while swinging clockwise reduces it fig 4 6 4 2 4 2 The type of spark plug is F6T The surfaces of insulator and electrode must be clean and free from carbon deposit The electrode gap is 0 740 1mm Within the end face of enter electrode the gap valve must be more or less the same It is possible to adjust the electrode gap by moving ground electrode When installing and removing spark plug care must be taken to prevent the screw hole in cylinder head from damage Replace spark plug if it is faulty 22 gt the front of engine parallel line to crankshaft increase advance angle Fig 4 6 Adjustment of ignition Fig 4 5 The position of rotor head advance angle when the piston in No 1 dylinder is at TDC compression stroke 4 2 5 SEALIING AND UNSEALING ENGINE When engine will not be used for a long time it must be sealed After having been stored for a long time engine must be unsealed before starting SEALING A Before sealing drain all cooling water from cylinder block and wipe the outer surfaces of engine with petrol B Rotate crankshaft to BDC Position and remove spark plug Fill 15 gram of SE10W 30 or SE15W 40 car oil into each cylinder Rotate crankshaft for 5 8 turns and install spark plug C Apply HDJ special antirust grease to the surfaces of electrical contacts connects unpla
31. ylinders Four Stroke Water cooled Type In line Inclined hemispherical combustion chamber Overhead Camshaft valve gear es Chain Transmission BorexStroke 76x71mm Total Displacement 644ml Compression Ratio 9 0 1 Maximum Power Speed 20 6 KW at 4500rpm Rated Power Speed 18KW at 4500 rpm Maximum Torque Speed 49 N m at 2700 3300 rpm Minimum Specific Fuel Consumption At Full Load 280g KW h Idling Speed Direction of rotation 900 50r min Counter Clockwise Look from power output Overall Dimension LJ276M LJ276MT 2 lengthwidthxheight 795x540x435mm_ 670x550x525mm Net Weigh Of Engine LJ276M LJ276MT 2 86 kg lke 0 09 0 2 mm cold Inlet Valve Gap 0 15 0 2 mm hot 0 1840 2 mm cold Exhaust Valve Gap 0 25 0 2 mm hot Intake Valve Opens 23 BTDC Intake Valve Closes 53 ABDC VALVE TIMING Exhaust Valve Opens 53 BBDC Exhaust Valve Closes 23 ATDC Starting Mode Crankcase Ventilation Electromagnetic drive Unidirectional clutch Closed LUBRICATION SYSTOM COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM Use SEI5W 40 petrol engine oil if Ambient Temperature is Above 0 C a Use SE15W 40 pewel engine oil if Ambient Temperature is Below 0 Lubricating Mode Pressurized And Splash Type Of Oil Pump Cycloid Rotor Pump Type Of Oil Filter Screwed joint JO706 Oil Capacity with filter 2 9L Oil Pressure 0 245Mpa 0 440Mp
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