Anhui Chery Automobile CAC478 User manual

CACGasolineEngineMaintenanceAnd ServicingManual
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ANHUICHERYAUTOMOBILECO., LTD
CAC478/480 GASOLINE ENGINE
InstructionBook onUsingand Maintenance
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CACGasolineEngineMaintenanceAnd ServicingManual
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Catalogue
Introduction 1
Engineconfigurationviewandsectionalview 3
Mainenginetechnicalindexesand operationparameters 11
Enginestructuralfeatures 13
Engineservice 15
Engineremovalandassemblyprocedure 17
[1]、Positioning no.1cylindertopdeadcenter(compression) 17
[2]、Upperandlowertiming gearcoverassembliesremovalandinstallation 18
[3]、Crankshaftpulleyremovaland installation 18
[4]、Valvecoverand sealgasketremovaland installation 19
[5]、Timingbeltremoval,installationandadjustment 20
[6]、Tensionpulley,crankshaftgearand camshaftgearremoval,checkandinstallation22
[7]、Camshaftoilsealremovaland installation 23
[8]、Valvemechanismandcylinderheadremoval,checkandinstallation 24
[9]、Pistonandconnecting rodassemblyremovalandinstallation 33
[10]、Flywheelassemblyand rearoil sealbracketassemblyremovalandinstallation 36
[11]、Crankshaft,crankshaftthrustwasher,bearingbushing andmainbearingcapremovaland
installation 38
[12]、Oil baffleassemblyremovalandinstallation 41
[13]、Engineoiling system 42
[14]、Enginecoolingsystem 49
[15]、Engineairintakeandexhaustsystem 53
[16]、Enginecrankcaseventilationsystem 58
[17]、Enginefuelsupplysystem 62
Carburetorenginemalfunction,causeandcorrection 67
CAC480MEnginesingle-pointelectriccontrolinjectionsystem 74
[1]、General 74
[2]、Operationtheory 75
[3]、Wiringdiagram 95
[4]、Systemservice 97
[5]、Malfunction,causeand correction 102
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CACGasolineEngineMaintenanceAnd ServicingManual
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Foreword
CAC478、CAC480 seriesvehiclegasolineengines ,whicharetheproductsintroducedfromFord
(Britain)corporationCVH productionline, aremadebyAnhweichellyautomobileCorp.
Productsaremadeup ofcarburetortype, single-pointelectriccontrolfuelinjectiontypeand
electriccontrolfuelinjectiontype, whichmaymeettherequirementsfordifferentperformance
andemission.
Single-pointelectriccontrolfuelinjectionsystemandmultipointelectriccontrolfuelinjection
systemoftheaboveenginesaredevelopedthoughthejointeffortwithItalyM&MCorp.
Withadvancedproductperformance, reliablestructure，CAC478、CAC480 seriesautomobile
gasolineenginesmaybeappliedforbothcarandlight-dutyvehicles.
Specifications, coveringmajorparameters, structuralfeatures, assemblyandadjustment,
commonoperationrepairandmaintenance, troubleshootingforCAC478, CAC480 carburetor
andsingle-pointelectriccontrolfuelinjectionengine, maybereferredbymechanic, driver,
technologistandmanagementsection.
1
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CACGasolineEngineMaintenanceAnd ServicingManual
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Carburetor engine left view
Carburetor engine frontal
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CACGasolineEngineMaintenanceAnd ServicingManual
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Carburetor engine right viewCarburetor engine back view
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CACGasolineEngineMaintenanceAnd ServicingManual
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Carburetor engine overlook view
Carburetor flywheel rear side
jointing size illustration
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CACGasolineEngineMaintenanceAnd ServicingManual
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EI engine left view
EI engine front end
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CACGasolineEngineMaintenanceAnd ServicingManual
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EI engine right view
EI engine back view
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CACGasolineEngineMaintenanceAnd ServicingManual
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EI engine overlook view
3 locating pin holes
EI engine flywheel rear end jointing size
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CACGasolineEngineMaintenanceAnd ServicingManual
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Carburetorengineexplodedview
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1、temperatureregulatorseatassembly11、camshaftthrustplate
2、temperatureregulatorseat12、camshafttiming gear
3、distribulator13、timing belt
4、camshaftassembly14、upper\lowertiming gearcapassembly
5、fuelpumpassembly15、waterpumpassembly
6、airintakemanifoldassembly16、camshafttiming gear
7、fuelpressureswitch17、tensionerpulleyassembly
8、oil filterassembly18、oil pumpassembly
9、rearoil sealing carrierassembly19、camshaftoil sealing
10、oil collectorassembly
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Mainenginetechnicalindexesand operationparameters
CAC478CCAC480CCAC480M
TypeLine,4-cyl, fourstrokes, water-cooling ←←
Cylinderborediameter(mm)77.24 79.94 ←
Stroke(mm)74.30 79.52 ←
Totaldisplacement(L)1.392 1.596 ←
Compressionratio9.5∶19.75∶19.75∶1
Nominalpower/RPM54/5500 60/5500 62/5500
(kW/r/min)(Totalpower)
Outputmaximumtorque/RPM105/3000-3500 128/3000-3500 128/3000-2500
(Nm/r/min)(Totalpower)
Minimumfuelconsumptionof
totalpowerforexternalcharacteristic298 290 285
(g/KW·h)
FuelsupplysystemCarburetor ←Single-point
electriccontrolfuelinjection
CombustionchambershapeWedgetypeHemispheretypeHemispheretype
CylindersWorkingOrder1-3-4-2←←
DirectionofcrankshaftrotationClockwise(Viewed←←
fromthefront)
LubricationMechanicallubrication+Splashfeed←←
Idlingspeedr/min850±50 ←900±50
Emission(Idling)CO2%←1.2%
Weight(kg)105 108 108
Overall dimensions
(Length*width*highness)670×630×650 670×630×650 620×610×650
(mm)
Ignitionangleatidle
(Crankshaftangle7°±1°7°±1°10°±1°
，Beforetopdeadcenter)
Valvetiming(Crankshaftangle)
IntakevalveopenedBeforetopdeadcenter18°←←
IntakevalveclosedAfterbottomdeadcenter50 57°←
Exhaustvalveopened
beforebottomdeadcenter61°60°←
Exhaustvalveclosed Aftertopdeadcenter7°15°←
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Applicationparameters：
Lubricant(Withtemperatureat-10℃ormore)SAE10W/30—50(gradeSF)
Gasoline93#(SH0041)Commonunleaded
Gasoline
Engineoil pressureIdling100kPamin
2000r/min(80℃)280kPamin
Engineoil capacity(L)3.86(Newoil filter)
Oil pumppressureregulatorstartstoopen(pressure)kPa440±20
Engineoil filterby-pass valvestartstoopen(pressure)kPa78—118
Coolant50%Glycol+50%Softwater(Rate
byvolume)
Coolantcapacity(Total)(L)8
Thermo-sisterStartstoopen(Temperature) ℃85—89
Fullyopen(temperature)℃99—102
ExpansiontankpressurecappressurekPa160
Fandiameter(mm)280
Fanspeedr/minⅠspeed1500
Ⅱspeed2800
Airfilter1GD129607G
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Enginestructuralfeatures
1.Cylinderblock：Madefromgraycastiron. Withoutbibcock. Withoutcylinderliner.5main
bearingseats. MainIntermediatebearinganti-thrust. Mainbearingcapsareretainedby
spigot. Mainbearingboltsof12.9grade.
2.Cylinderhead：Madefromaluminumalloy. Intakeandexhaustvalveseatsandvalveguides
strutting.6camshaftsupports. Withoutcamshaftbushing.withfuelpump, Pushrodand
distributor，Thermo-sisterincylinderheadforCarburetorengine. withthermo-sisterin
cylinderheadforElectriccontrolengine. Cylindercoverboltsof10.9grade.
3.Piston：madefromeutecticaluminumsilicon. Anti-expansionsteel-struttedskirt. Ellipsehead
andskirt. Conehead. Barrelskirt.
4.Pistonring：Firstcompressionringofductilecastiron. Withexcirclesprayedmolybdenum.
Groundringwithbarrelsurface.
Secondcompressionringisoftwisttype. madefromalloycastiron.
Steelstripcombinationoil ring. Withscapebladeexcirclechroming.
5.Pistonpin：Lowcarbonsteel. Surface carbonizingandquenching. Semi-floating
structure(Interference fitwithsmall endofconnectingrod. Clearance fitwithpistonpinhole.
6.Connectingrod：Forgedsteel. Flatinsection. Withoutsmall endbushing. Connectingrodstem
andcoverareretainedby2springdowels. Pistonandcylinderblockislubricatedbyoil spray
fromconnectingrodbearingboredrill.Connectingrodboltsof12.9grade.
7.Crankshaft：4balance weight. Ductalloy. Normalizingtreatment.
8.Bearingbushing：Connectingrodbushing,Mainbearingbushingsandthrustwashersareall
madeoftin&aluminiumduplexmetal. Twopiecesofthrustwasher. Theyaremountedin
cylinderblock.
9.Flywheel：Itismadeofductalloy. Maybefittedwith190 and210 clutch. Castedwith
crankshaftspeedsignaldisk.
10.Camshaft：Itismadeofalloycastiron. Camandfuelpumpeccentriccamhighfrequency
quenchingtreatment. 5supports. Camshaftthrustspacerismadefromlowcarbonsteel.
Surface carbonitriding.
11.Rockerarm：Lowcarbonsteel、Stamping. Surface carbonitriding. Rockerarmstud of10.9
grade.
12.Hydraulicliftingrod：Thesurface contactingcamisquenched. Thecontactface withrocker
armismadeoflowcarbonsteel. Surface carbonitriding，Bothcontactface arecircular-arc.
13.Intakevalveseat：Itismadeofalloycastiron.
14.Exhaustvalveseat：Ironbasepowdermetallurgy. Quenchtreatment.
15.Valveguide：Itismadefromalloycastiron.
16.Valve：Intakevalve：Madefrom4Cr9Si2.Withsmallerendofconicalsurface
quenched，Withconicalsurface angle45°.Withlargenestseatinthevalveheadfor
hemisphericalcombustionchamber.
Exhaustvalve：4Cr9Si2-21-4N. Withconicalsurface angle45°.Withsmallerend
quenched.
17.Gear：Madefromironbasepowdermetallurgy.
18.Timingbelt：Madefromcyanidingbutadiene-acrylonitrilerubber.
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CACGasolineEngineMaintenanceAnd ServicingManual
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19.Intakemanifold：MadefromAluminumalloy. Withmixturewarmuppedbywaterjacket.
Electricheatedintakemanifoldisoptional.
20.Exhaustmanifold：Madefromductalloyorblackcastiron.
21.Oil pan：Stamping ，Lowcarbonsteel. Oil poolisinthefrontofcylinderblock.
22.Oil pump：Rotortype. Caseismadeofaluminumalloy.
Speedratio1∶1，Withpressurereliefvalveinoil pump.
23.Engineoil filter：Full flowstypespinningfilter. Withby-pass valveinit.
24.Fuelpump：Diaphragmtype. Drivenbyuppercamshafteccentriccam. Electricfuelpumpfor
electriccontrolengine. Infueltank.
25.Pushrod：Madefromlowalloysteel，Carbonization&quenchtreatment. Onlyappliedfor
carburetorengine.
26.Waterpump：Centrifugaltype，Castironimpeller，Aluminumalloycase，Drivenbytiming
beltthroughgear.
Speedratio1.053∶1.
27.Thermosister：Waxtype.
28.Thermosisterseat：Aluminumalloy，Withoverflowvalve，overflowpipeand
micro-circulationtube.
29.Carburetor：Pierbort2E3carburetor. Throttlevalvebodyfor480M30MM12 Imported
part.
30.Sparkplug：K7RTC
31.Non-contactdistributor：Drivenbytherearendofcamshaft，TypeisFDW451&JFD459.Only
appliedforcarburetorengine.
32.Ignitioncontroller：TypeareZJ5701—HG &KH—3A.Onlyappliedforcarburetorengine.
33.Generator：14V90A，TypeareJFZ1913—4orJFZ1813—2B.
34.Starter：12V0.95KWQDY1258 orSD6RA78.
35.ECU：I.A.W.6FImportedOnlyfor480Mengine.
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Engine maintenance
Dailymaintenance —— Checklubricantlevel
—— Checkcoolantlevel
—— Checkboltforloosing
—— Checkforleaking(oil, water, air)
Per8000km —— Replace engineoil andoil filter
—— Cleanairfilter，checkairintaketubeforcracking
—— CheckPCVvalve
—— Checksparkplugs
Per16000km —— Checkaccessoriesdrivebelt
—— Checktimingbeltandtensionpulley
—— Checkradiatorandhosesforleaking
Per30000km —— Replace fuelfilter
Per32000km —— Replace sparkplug
—— Checkhigh-tensionwire
Per45000km —— Checklambdasensorfunction
Per48000km—— Replace corrosionpreventivecoolantandcleancoolingsystem
—— Replace airfilter
Per64000km —— Replace timingbelt
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CACGasolineEngineMaintenanceAnd ServicingManual
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CAC478、480Contentsand intervals forConstant maintenance
×1000km 8 16 24 30 32 45 48 60 64
Replace engineoil ☆☆☆☆☆☆
Replace oil filter ☆☆☆☆☆☆
Cleanairfiltercore ☆☆☆☆☆☆
Checksparkplugs ☆☆☆☆☆☆
Replace airfiltercoreand
cleancase ☆
Checkaccessorydriving
belts ☆☆☆☆
Checkradiatorandhosesfor
leaking ☆☆☆☆
Replace sparkplugs ☆☆
Replace timingbelt ☆
Replace fuelfilter ☆☆
Checkhigh-tensionwires ☆☆
Checklambdasensor
function ☆
Checktiming beltand
tensionpulley ☆☆☆☆
CheckPCVvalve ☆☆☆☆☆☆☆
Forsevereconditionsofapplication, maintenance intervalsshouldbeshortenedaccordingto
specificconditions.
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CACGasolineEngineMaintenanceAnd ServicingManual
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Engine removal and assembly procedure
【1】、Positioningno.1cylindertopdeadcenter(compression)
——RemovetwoM6×55 flange-shapedbolts, remove
uppertiminggearcover.
——Install awrenchoncrankshaftpulleybolt, rotate
crankshaftClockwise(viewedfromthedirectionofpulley)
until theTDCnotchoncrankshaftpulleyalignswiththe
TDCmark(0)ontiminggearcover.
Note：Beforerotation，sparkplugsmayberemovedto
reduce effort.
——CheckwhethertheTDCmarkonthecamshaftgear
alignswiththemarkonthefrontendofcylinderhead. If
notaligned, rotatecrankshaftoneturn，aligningtheTDC
markonthecamshaftgearwiththeTDCmarkonthefront
endofcylinderhead，engineshouldbeatno.1cylinder
TDC.
——Withcrankshaftpulleyandlowertiminggear
removed，positionno.1cylinderatTDCasfollowing:
Rotatecrankshaft, aligningtheTDCmarkonthe
crankshaftgearshaftwiththeTDCmarkontheoil pump
case. CheckwhethertheTDCmarkoncamshaftgear
alignswiththeTDCmarkonthefrontendofcylinder
head. ifnotaligned, rotatecrankshaftoneturn，aligning
theTDCmarkoncamshaftgearwiththeTDCmarkonthe
frontendofcylinderhead.
Fig.3
Fig.2
Fig.1
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【2】、Upperandlowertiminggearcoverassembliesremovalandinstallation
Removal：
——Loosenandremove2boltsforuppertiming
gearcoverassembly.
——Removeuppertiminggearcoverandseal
assembly.
——Removesealgasketandshotnail from
uppertiminggearcover.
——Removecrankshaftpulley.
——Loosenandremove2boltsforlowertiming
gearcoverassembly.
——Removelowertiminggearcoverandseal
gasketassembly.
——Removeshotnail andsealgasketfrom
lowertiminggearcover.
Installation：
——Cleanlowertiminggearcover.
——Mountnewsealgasketwithshotnail or
glueonlowertiminggearcover.
——Install lowertiminggearcoverandseal
gasketoncrankshaft，
fingerscrewin2boltsand
tightento9.0—11Nm.
——Cleanuppertiminggearcover.
——Mountnewsealgasketwithshotnail orglue
onlowertiminggearcover.
——Install uppertiminggearcoversealgasket
with2boltsoncylinderblock，tighteningtorque
is9—11Nm.
【3】、Crankshaftpulleyremovalandinstallation
Removal：
——Ifengineisequippedwithstarter，remove
three M10×30 orM10×35 boltsandremove
starter.
——Blockflywheelringgearwithaappropriate
screwdriverorlever, preventingcrankshaftfrom
rotating.
——Loosencrankshaftpulleymountingbolts，
removeboltandcushionblock.
——Pull outpulley, ifnecessary, pullermaybe
used.
upper timing gear cover assembly
Bolt
Tightening
torque
Tightening
torque Lowertiminggearcoverassembly
Fig.4
Fig.5
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CACGasolineEngineMaintenanceAnd ServicingManual
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Installation：
——Cleanpulleyandcrankshaftjournal，removethe
oil inpulleygroove.
——Install pulleyoncrankshaftjournal, aligning
keywaywithsemicircularkey.
——Slipcushionblockontoboltsandfingerscrew
in.
——Blockflywheelringgearwithscrewdriver,
preventingcrankshaftfromturning.
——Tightenboltsto100—115Nm.
【4】、Valvecoverandsealgasketremovalandinstallation
Removal：
——Remove9boltsandbutterflygasket.
——Removevalvecoverandsealgasket
assembly.
——Removesealgasket.
Butterfly washer
pulley
Tightening torque
bolt
Valvecover
Fig. 7
Valve cover
seal gasket
Fig.6
Fig.8
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