Great Wall GW491QE User manual
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Based on the model GW491Q (4Y) carburetor petrol engine, the GW491QE petrol
engine produced by our company is of one petrol engine able to electrically inject fuel
at multiple points, and is developed from electrical control components made by Delphi
company, USA, and Shanghai United Electronic Company. This model shows a
predominant improvement in aspects of power and economical efficiency, and is in
compliance with GB18352.2-2001 “Limits and measurement methods for exhausts
of pollutants from light vehicles (II) ”(equivalent to European Class-II standard), and
conforms to stipulations at phase III for GB18352.3-2005 “Limits and measurement
methods for exhausts of pollutants from light vehicles (at phase III &IV in China)”
(equivalent to European Class-III standard).
To meet the needs from numerous maintenance /technical / management
personnel, we prepare this “GW491QE Petrol Engine Service Manual” based on the
latest technical materials.
Allcontents,specifications,anddatastatedinthismanualarethelatestinformation
before printing and this service manual will be subject to a supplemental, revision, and
completion from time to time.
This manual may be used for the reference by mechanics, drivers, and technical /
management personnel as the manual is complete in contents, definite in requirements,
and simple in maintenance.
Constrained by the level of the writer, it’s unavoidable to have some defects in
this manual, and your comments and suggestions are highly appreciated.
Preface
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Model GW491QE petrol engine
Service Manual
Engine service &maintenance data......................................................................................
United Electronic engine management system..................................................................
Delphi engine management system......................................................................................
Engine body..............................................................................................................................
Cylinder head............................................................................................................................
Valve mechanism......................................................................................................................
Cooling system.........................................................................................................................
Lubrication system..................................................................................................................
Ignition system.........................................................................................................................
Starting system........................................................................................................................
Charge device..........................................................................................................................
Clutch.........................................................................................................................................
G1
EF.1
EF.2
EM.1
EM.2
EM.3
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Engine service /Maintenance data
Key technical parameters for model GW491QE petrol engine.......................
Specification &adjustment parameters for key components ...........................
Technical data for maintenance......................................................................
Tighteningtorqueforfastening elements.........................................................
Troubleshooting............................................................................................
Engine service /maintenance data..................................................................
Page
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Key technical parameters for Model GW491QE petrol engine
S.N. Item Specification and parameters
1 Model Model GW491QE
2 Pattern Four-cylinder, inline, water-cooled, overhead valve，4-stroke
petrol engine
3 Fuel supply pattern Electronic controlled jet injection by group at multiple points
4 Measurement method for air intake
amount Velocity &density type
5 Pattern of combustion chamber Wedge typed
6 Diameter of cylinder bore 91mm
7 Piston stroke 86mm
8 Displacement 2.237L
9 Compression ratio 8.8:1(European class-II)9.1：1European class-III
10 Rated power 78kw/4600 r/min(European class-II)
78kw/4600 r/min(European class-III)
11 Max. torque 190·m/2400~2800 r/min
12 Min. fuel consumption rate ≤265g/kw·h(European class-II)≤250g/kw·h(European
class-III)
13 Fuel specRONNot lower than 93#GB17930-1999
14 Stable idle-speed 750±50r/min
15 Idle-speed control pattern Electronically closed-loop control
16 Piston average velocity 13.18m/s
17 Average valid pressure 874kpa
18 Compression pressure of cylinder
when at 250r/min1128kpa(European class-II); 1350kpaEuropean class-III
19 Ignition sequence 1-3-4-2
20 Ignition control pattern Without ignition distributor, and direct ignition under an
electronic control
21 Spark plug clearance 1.0~1.2mm
22 Model of spark plug F6RTC
23 Valve clearance 0mmhydraulic tappet
24
Valve timing:
Inlet-valve open lead angle;
Inlet-valve close lag angle;
Exhaust-valve open lead angle;
Exhaust-valve close lag angle;
12°before the top dead center,
48°before the bottom dead center;
54°before the bottom dead center;
10°before the top dead center;
25 Pattern of lubrication A combined pattern of pressure and splash.
26 Oil spec SG grade machine oil API10W-40GB11121-1995for petrol
engine
27
Main passage oil pressure
When at idle-speed 750±50r/min
or 3000r/min
49 kpa
(245-490) kpa
28 Oil capacity 4.2L
29 Oil temperature (85~90)℃
Engine service /maintenance data-Key technical parameters for Model GW491QE petrol engine
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GI-3S.N.ItemSpecificationandparameters30Max.oiltemperature11031Consumptionrateofoil2g/kw·h32Fuelconsumptionratioofmachineoil33CoolingmethodUseforcedwatercirculationforcoolingpurpose.34Completemass150kg35PatternofstartupElectrical36Exteriordimensionlength×width×height(754.5×518×651)mm(electronicfan)37Dualidle-speedemissionGB18285-200538EmissioncontrollevelwhenunderoperatingconditionWithathree-waycatalyticconverter,andaclosedloopcontrolforair/fuelratio,andthewithlight-dutyvehiclesatisfiesrequirementsfromGB18352.2-2001andGB18352.3-2005standards.39Differencebetweencylinders98kpa40Vacuuminsideairintakepipewhenatidle-speed53.3kpa41Temperatureofoutletcoolingwater(80~90)42TensiondegreeoffanbeltPressure98NBeltdeviation:7~8mmEngineservice/maintenancedata-keytechnicalparametersforModelGW491QEpetrolengine
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GI-4Engineservice/maintenancedata-specification/adjustmentparameters/maintenancetechnicaldatadataforkeycomponeatsSpecification/adjustmentparametersforkeycomponentsS.N.ItemSpecificationandparameters1SparkplugF6RTC2StartermotorDeceleratingtypewhenunderanelectromagneticcontrolU=12VP=1KW3GeneratorandvoltageregulatorU=14VI=65A/90A4PetrolpumpBlade-typeelectricalpump5OilpumpRotortyped6CoolingwaterpumpCentrifugaltype7ThermostatWaxtype8PetrolfilterSteelcover,withsuperhighmolecularweight,andfiltrationcore9OilfilterFull-flow&integraltype,screwinstalledfiltrationpapercores10IgnitioncoilU=12V11ClutchDiaphragmspringtypeMaintenancetechnicaldata1.EnginemechanismUnitmmNameTestitemsStandardvalueUselimitCylinderheadPlanenessonthecontactsurfaceofbody;Planenessonthecontactsurfaceofmanifoldpipe;SlopeangleofvalveseatAirintakeAirexhaustContactangleContactwidth0.050.0530,45,6030,45,60451.2~1.60.150.10ValveguideInnerdiameterExteriordiameterIncreasedsize0.05Temperaturewhenchangingonthesideofcylinderhead81313.088~13.100Heatto80~100ValveWholelengthofvalveAirintakeAirexhaustAngleofvalveworkingsurfaceAirintakeandexhaustDiameterofvalverodAirintake108.20.10108.50.1044.58107.7108.0ValveAirexhaustGapofvalverodAirintakeAirexhaustEdgethicknessofvalveplateAirintakeAirexhaust80.025~0.0600.030~0.0650.100.120.50.8ValvespringFreelengthInstallationheightInstallationtensionNonperpendicularity470.540.6(282~345)N2822.0+0.030+0.010+0.050+0.038-0.015-0.030-0.020-0.035
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GI-5Engineservice/maintenancedata-specification/adjustmentparameters/maintenancetechnicaldataforkeycomponentsNameTestitemsStandardvalueUselimitRockerandaxisforvalveInnerdiameterofrockerholeDiameterofrockershaftGapbetweenrockerandrockershaft18.518.50.018~0.0460.08IntakemanifoldpipePlaneness0.050.4Timinggear/chaingearWhenthesaggingofchainis98N,Diameterofrearchainwheel(withchain)CrankshaftCamshaftLengthofchainwarpafteruseThicknessofchaintensionerThicknessofshockabsorber13.558.2113.23291.412.55CamshaftandbearingMax.circumferentialradialbeateccentricityHeightofcamMin.convexvalueAirintakeAirexhaustAxialdiameterofcamshaftNo.1No.2No.3No.4No.5ClearanceofaxialdiameterAxialclearance0.0538.679138.686946.546.254645.7545.50.025~0.0810.07~0.220.100.30CylinderblockPlanenessDiameterofboreholeincreasedsize0.50increasedsize0.75increasedsize1.00910.0591.2491.7491.9992.24PistonandpistonringPistondiameterincreasedsize0.50increasedsize0.75increasedsize1.00ClearanceofpistonSideplayofannulargrooveOpeninggapofpistonringFirstgasringSecondgasringOilring90.938~90.96891.425~91.45591.675~91.70591.925~91.9550.042~0.0620.03~0.0750.20~0.400.35~0.550.20~0.800.065~0.0851.111.071.10PistonpinandconnectionrodAxialclearanceofmainbodyforconnectionrodonbigheadendAxialclearanceofconnection-rodcoverBendofconnectionrodevery100mmDistortofconnectionrodevery100mmInnerdiameterofconnectionrodonsmallheadExteriordiameterofpistonpinGapofinnerholeonsmallheadsideofpistonpinandconnectionrod0.16~0.310.021~0.0510.030.0322.010~22.01622.003~22.0060.004~0.0130.18~0.320.050.15+0.0130-0.018-0.0330-0.20-0.23-0.025-0.041-0.025-0.041-0.025-0.041-0.025-0.041-0.025-0.041+0.0300
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GI-6Engineservice/maintenancedata-maintenancetechnicaldataUni
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NameTestitemsStandardvalueUselimitCrankshaftandbearingAxialclearanceThicknessofthrustwasherIncreasedby0.125Increasedby0.250MainjournaldiameterClearanceofmainjournaldiameterjournaldiameterofconnectionrodjournalclearanceofconnectionrodCircumferentialplayofmainaxialdiameterRoundness/diameterofcolumn,formainaxialdiameterandconnectionroddiameter0.02~0.222.450~2.4902.575~2.6152.700~2.740580.021~0.053480.021~0.0530.030.010.300.100.100.060.022.CoolingsystemNameTestitemsStandardvalueUselimitCapacityofcoolingfluidinengine7.9LRadiatorPressurewhenthepressurereliefvalveofcoverisopened.(73.6~103)kpaMin.valuenotlessthan58.9kpaThermostatTemperaturewhenvalveisopened.Liftdistanceofvalve95(8084)8mm<76<8mmTransmissionbeltBendingdeflectionoftransmissionbeltwhena98Nforceisapplied.NewbeltUsedbelt(5~7)mm(7~8)mm3.LubricationsystemNameTestitemsStandardvalueUselimitCapacityofoilTotalcapacityofoildryinjectionRe-injectionaftertheremovalWithoutoilfilterWithoilfilter4.2L3.0L3.5LOilpumpClearancebetweenrotorandpumpClearancebetweenmasteryrotorandslaveryrotorEndclearanceofrotor(0.10~0.15)mm(0.07~0.12)mm(0.03~0.07)mm>0.20mm0.20mm0.15mmPressureofoil(75050)r/minatidle-speed(200050)r/min(300050)r/minMax.temperatureofoil49kpa170kpa(245.2~490.3)kpa110<245.2kpa0-0.0150-0.015
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GI-7Engineservice/maintenancedata-tighteningtorqueforfasteningelements4.IgnitionsystemNameTestitemsStandardvalueUselimitSparkplugModelClearanceF6RTC1.0~1.2mmHigh-tensionwiringResistance16k/m5.StartingsystemNameTestitemsStandardvalueUselimitStarterRatedvoltageOutputpowerZero-loadcharacteristicssizeofcurrentspecifiedwhenit’s11.5VRectifierExteriordiameterDepthofTchannelCircumferentialradialplayLengthofelectricbrushWorkloadofspring12V1kw90A30mm(0.50~0.80)mm0.05mm13mm(17.5~23.7)N>90A<29mm<0.20mm>0.05mm<8.5mm<17.56N6.ChargedeviceNameTestitemsStandardvalueUselimitBatteryDensityofelectrolyteforbatteryWhenfullchargeofbatteryat201.25~1.27ACgeneratorResistanceofrotorcoilsDiameterofslipringExposedlengthofelectricbrush4.0(32.3~32.5)mm12.5mm<32.1mm5.5mmRegulatorAdjustmentvoltageat20(13.95~14.4)VDrivingbeltA98Nbending-deflectionforceisappliedtodrivingbeltbetweenACgeneratorandwaterpump.NewbeltUsedbelt(5~7)mm(7~8)mmTighteningtorqueforfasteningelements1.TighteningtorqueforspecialcomponentsFrequentlytightenedsparepartsNmValverockerarmshaftcylinderheadM8Cylinderheadbolt10-M121.253-M8Airintake/exhaustmanifoldpipecylinderheadSparkplugcylinderheadCamshafttimingchaingearcamshaftCamshaftflangecylinderbodyWaterpumpboxoftimingchainchamber2490205018901818
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GI-8Engineservice/maintenancedata-TighteningtorqueforfasteningelementsFrequentlytightenedsparepartsNmWaterpumpcylinderbodyBoxoftimingchainchambercylinderblockBoltNutBearingcoverofconnectionrodconnectionrodBearingcoverofcrankshaftcylinderblockCrankshaftbeltpulleycrankshaftFlywheelcrankshaftOilbottomoilpancylinderblockGeneratoradjustmentsupportcylinderblockRearoil-sealseatcylinderblockDrainplugofoilpan40181850801608513401220~252.StandardbolttighteningtorqueTighteningtorqueGradediametermmscrewpitchmmhexagonal-headedboltNmhexagonalflangeboltNm4T681012141611.251.251.251.51.5512.52647741156142953845T681012141611.251.251.251.51.56.515.53259911407.517.536651006T681012141611.251.251.251.51.5819397111017092144801257T681012141611.251.251.251.51.510.52552951452301228581051658T810121.251.251.25296111033681209T810121.251.251.2534701253778140
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GI-9Engineservice/maintenancedata-Troubleshooting
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GradediametermmscrewpitchmmHexagonal-headedboltNmHexagonalflangeboltNm10T810121.251.251.253878140428815511T810121.251.251.2542871554797175Commonfailuresandtroubleshooting1.EnginenotstartorstartwithdifficultyCauseoffailureMethodsofelimination1.Failureinstartingsystem1Batteryhasinsufficientvoltage2Batterynotconnectedwell3Fusebroken4Failureinstarter5Failureinignitionswitch2.Failureinignitionsystem1High-tensiondampingwiringdamagedornotconnectedwell.2Ignitioncoildamaged3Inappropriateclearancebetweenbothelectrodesofsparkplug.4Sparkplugisdampedortheelectrodehascarbondeposit.5Insulatoronsparkplugisruptured.3.Failureinthefuelsupplysystem1Petrolpipelineisblockedorwithairresistance.4.Engineunderabadcondition1Valveisleakingairordamagedbyburning.2Padofcylinderisdamaged.3Piston,pistonring,andcylinderaremuchabraded.4Intakemanifoldisleakingair,orvacuumplugislost.5Pipelinefromtheventvalveofcrankshaftboxtothethermalbaffleofsolenoidvalveisleakingair.1.(1)Chargewithpower.(2)Cleanwiringterminalsandtightenbatteryline.(3)Changethefuse(4)Repairorchangestarter(5)Repairorchangeignitionswitch2.1Changethehigh-tensionresistanceline2Changetheignitioncoil3Adjusttheclearancebetweenbothelectrodes.4Haveitbakedorclearawaythecarbondeposit.5Changethesparkplug3.1Washthepetrol-oilpipelineorclearawaytheairresistance.4.1Repairorchangevalve2Changeit.3Repairorchangeit.4Checktheintakemanifoldpipeandgasket,tightenthenut,andblockwellthevacuumtube.5Fixtheconnectionpipetightly.2.Enginecannotbeacceleratedorisslackaccelerated.CauseoffailureMethodsofelimination1.Failureintheignitionsystem1Sparkplugnotworkingwell2Thehigh-tensiondampingwiringisdamaged.3Theignitioncoilsaredamaged.2.Failureinengine1Valveisleakingairordamagedbyburning.2Cylinderisunderabadcompressioncondition.3Padofcylinderisleakingair.4Intakemanifoldpipeisleakingair.1.1Checkorchangethesparkplug2Changethehigh-tensiondampingwiring(3)Changetheignitioncoil2.1Repairorchangevalve2Repairorchangerelevantspareparts3Changethecylinderpad4Checktheintakemanifoldpipeandgasket,andtightenthenut.
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isslack.CauseoffailureMethodsofelimination1Engineisunderabadcompressioncondition.1Valveisleakingair.2Hydraulicretainingcolumnnotworkingwell.3Valvespringiswithaninsufficientforceorevenbroken.4Padofcylinderisleakingair.5Pistonringisstuckorbroken.6Pistonorcylinderismuchabraded.2FailureinignitionsystemSparkplugnotworkingwell.3Petrolsupplyisblocked.1Petroltankhascontaminantdeposits.2Petrolpipeisblocked.3Petrolfilterisblocked.4Petrolpumpnotworkingwell.5Airexistsinthefuelsystem.4Petrolnotconformingtothespecification.5Intakemanifoldpipeisleakingair.6Airenteringtheairpipeisinsufficient.1Airfilterisblocked.2Chokevalvehasnotbeenopenedcompletely.7.Enginetoohot.11Abradethevalve.2Checkorchangeorwashthehydraulictappet.3Changethevalvespring.4Changethecylinderpad.5Changethepistonring.6Repairorchangerelevantspareparts.2Clean,adjustorchangethesparkplug.31Cleanorchangetheoiltank.2Cleantheoilpipeormakeitthrough.3Changethepetrolfilter.4Repairorchangepetrolpump5Checkandtighteneachjoint.4Makeitsubjecttotechnicalspecifications.5Checktheintakemanifoldpipeandgasket.61Washthecover,andcleanthefiltrationcorebypurging.2Repairandadjustitscontrolmechanism.7Refertothe“methodsofelimination”incaseoffailure“enginetoohot”.4.Engineisbackfiredordeflagrated.CauseoffailureMethodsofelimination1Failureinignitionsystem1Jointontheignitionlineisloose.2Sparkplugnotworkingwell.3Theheatcharacteristicsofsparkplugareinappropriate.2Inappropriatecontentofmixedgas1Petrolsupplyisblocked.3Failureinthevalvemechanism1Valveisstuckorleakingair.2Thevalvehydraulicretainingcolumnnotworkingwell.3Valvespringiswithinsufficientstrength.4Thecoverofcylinderunderabadcondition1Combustionchamberhascarbondeposit.2Thecoverofcylinderisoverhotorthecoolingisinsufficient.3Thecoverofcylinderisdamaged.5.Thehigh-tensionresistancelineismisconnectedordamaged.11Checkandtighteneachjoint.2Wash,adjustorchangethesparkplug.3Replacewithsparkplughavingappropriateheatcharacteristics.21Refertoarticle3inthe“engineslack”.31Abradeorchangethevalve.2Changeorwashthehydraulicretainingcolumn.3Changethevalvespring.41Clearawaythecarbondeposit.2Clearairawayfromthecoolingwatersleeve.3Changethecylinderhead5Correctorchangeit.Engineservice/maintenancedata-Troubleshooting
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GI-11Engineservice/maintenancedata-Troubleshooting5.Unstableidle-speedforengineCauseoffailureMethodsofelimination1Withairleakage1Theintakemanifoldpipeisleakingair.2Failureinignitionsystem3Failureinvalvemechanism1Badsealingofvalve;2Hydraulictappetisnotworkingwell;3Clearancebetweenthevalverodandthevalveguidingrodismuchbig.4Thepadofcylinderisleakingair.5Thesupplyofpetrolisnotsmooth.11Checktheintakemanifoldpipeandgasket.2Article2of“enginenotstartorstartwithdifficulty”.31Abradethevalve.2Changethehydraulicretainingcolumn.3Changethevalveortheguidingrodofvalve4Changethecylinderpad5Refertoarticle3of“engineslack”.6.AbnormalsoundoccurredinengineCauseoffailureMethodsofelimination1Clearanceproducedduetothefailureinhydraulicretainingcolumn2Pistonpintoomuchloose.3Piston,pistonring,andcylinderabradedtoomuch.4Thebushingofconnectionrodabradedtoomuch.5Mainbushingabradedtoomuch.6Thrustpieceofcrankshaftabradedtoomuch.7Muchclearancebetweencamshaftandthethrustplateofcamshaft.8Timingchainandtimingchainwheelabradedtoomuch.9Chaintensionernullandvoid.10Toomuchcarbondepositinthecombustionchamberofcylinder.11Petrolisnotconsistenttothespecification.1Checkandchangethehydraulicretainingcolumn.2Changethepistonpinorpiston.3Check,repair,andchangetherank.4Changeit.5Changeit.6Changeit.7Changethethrustplateofcamshaft.8Changeit.9Changeit.10.Clearawaythecarbondeposit.11Followthetechnicalspecifications.7.LargeconsumptionofpetrolCauseoffailureMethodsofelimination1Pipelinehasleakageofpetroloil.2Airfilterisblocked.3Failureinignitionsystem1Errortimingofignition.2Failureinsparkplug.4Badcompressionofengine.5Slipperyofclutch.1Tightenconnectorsandclampsateachpoint.2Checkandcleantheairfilter.31Adjustthetiming.2Checkorchangethesparkplug4Refertoarticle1of“engineslack“5Checkandadjusttheclutch.
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GI-12Engineservice/maintenancedata-TroubleshootingEng
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CauseoffailureMethodsofelimination1Leakageofmachineoil1Theoil-dischargeboltonbottomoilpanisloose.2Thefixingboltonbottomoilpanisloose.3Gasketofbottomoilpanisdamaged.4Fixingboltforthecoverofchainwheelchamberisloose.5Sealingringofshieldcoverforvalvechamberisdamaged.6Front/backoilsealforcrankshaftisdamaged.7Fixingboltforoilpumpisloose,orgasketisdamaged.8Fixingboltforoilfilterisloose,orgasketisdamaged.2Combinedpistonoilringsareabradedtoomuchorevendamaged.3Pistonandcylinderareabradedtoomuch.4Oilsealonvalverodisdamaged.5Valverodandguidingrodareabradedtoomuch.6Theventilationsystemofcrankshaftboxisblocked.7Engineisrunningwithsmallloadathighspeedforalong-termperiod.11Tightentheoil-dischargebolt.2Tightenthefixingbolt.3Changethegasket.4Tightenthefixingboltorchangethegasket.5Changethesealingring6Changetheoilseal7Tightenthefixingboltorchangethegasket.8Tightenthefixingboltorchangethegasket.2Changethecombinedpistonoilrings.3Sentitonservice.4Changethevalveoilseal5Changethevalveandguidingrod.6Check,cleanandmakeitthrough.7Avoidtheenginerunningwithsmallloadandathighspeedwhenpossible.9.Enginenotflameouraftertheignitionswitchisclosed.CauseoffailureMethodsofelimination1Enginetoohot.2Sparkplugtoohot.3Toomuchcarbondepositincombustionchamber.1Haveenginerunningatidlespeed,decreasethewatertemperaturebelow80,andclosetheignitionswitch.2Selectthespecifiedmodelofsparkplug.3Clearawaythecarbondeposit.10.EnginetoohotCauseoffailureMethodsofelimination1.Insufficientamountofcoolingfluid2.Fanbeltlooseordamaged3.Failureinwaterpump4.Failureinthermostat5.Radiator,cylinderblock,cover/pipeline/passageofcylinderblockedorleaked6.Failureinsilicon-oilclutch7.Machineoilinsufficientorthedensityislow;8.Toomuchcarbondepositincylinderheadorcombustionchamber;9.Exhaustsystemnotthrough1.Addcoolingfluid2.Adjustthetensiondegreeofbeltorchangethebelt.3.Repairorchangethewaterpump.4.Changethethermostat.5.Clean,repairorchangerelevantspareparts.6.Checkorchange.7.Addorchangethemachineoil.8.Clearcarbondepositaway.9.Cleanorchangesparepartsfortheexhaustsystem.
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GI-13Engineservice/maintenancedata-engineservice/maintenancedata11.PressureofmachineoilistoolowCauseoffailureMethodsofelimination1Theleakageofmachineoil2Muchinsufficientmachineoilorthedensityistoolow;3Thetemperatureofmachineoilisbeyondthelimit.4Failurecausedbythepressurereliefvalveonoilpump.5Failurecausedbyoilpump6Oilfilterisblocked,orconnectionpipeisleakingoil.7Oilfilterisblocked.8Failurecausedbytheoilpressuresensor9Mainbushing,thebushingorcamshaftforconnectionrodabradedtoomuch.10Failureofoilmanometer.11Toomuchoilleakageatrockershaftorwherechainistensioned.1Refertoarticle1in“Toomuchmachineoilconsumption”;2Addmachineoil,orchangethemachineoil;3Checkthecoolingsystemwhentheenginecoolsdown.4Sendthepressurereliefvalveonservice.5Repairorchangetheoilpump.6Wash,clean,andtightentheconnector.7Changetheoilfilter8Changetheoilpressuresensor9Changethebushingorbearing.10Changethemachineoilmanometer11Check,repair,andfixit.Engineservice/maintenancedata1.SSTspecialmaintenancetoolsNotesortA=usedintheroutinerepairduringtheinspectionofvehicles,orusedasgeneraltools;B=usedintheoverhaulingastodismantlecomponents;C=usedintherareandspecialworkswhicharenotsimilartoAandB.ChapterOutlineddiagramPartNo.PartnameSortIVVVIVIIVIIIIXXXIXIIRemark09032-00100ToolsusedtocutoilsealonbottomoilpanA09043-880108mmhexagonalnutspannerA09201-41020ToolsusedtochangetheoilsealonvalverodB09201-60011ToolsusedtodismantleandrepairguidingrodonvalveA09202-43013SpringpresserforvalveA09213-31021RemoverforbeltpulleyoncrankshaftA09213-70010ToolsusedtofixthebeltpulleyontocrankshaftA09215-00100ToolsusedtodismantleandrepairthecamshaftbearingC09216-00020Belttension-gaugeA09216-00030Belttensioncable
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GI-14Engineservice/maintenancedata-engineservice/maintenancedataToolsusedtodismantleandchangethepistonpinsMainbodySpringsleeveAguidingrodAguidingrodBToolsusedtochangetheoilsealbeforethecrankshaftToolsusedtochangetheoilsealaftertheco-axis.SpannerforoilfilterToolsusedtorepairradiatorSpannerusedtoadjustidle-speedscrewsRockersupporttoolsValvepushrodtoolsCone-shapedtoolsusedforthecrankshaftbearingoninjectionpumpToolsusedtodismantlethesplinedshaftfrominjectionpumpOil-sealremoverToolsusedtofixflangesinpairsUniversalremoverBeltpulleyforcrankshaft
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GI-15Engineservice/maintenancedata-engineservice/maintenancedataClutchguidingtoolsToolsusedtodismantleguidebearingfromcrankshaftToolsusedtodismantleguidebearingfromcrankshaftToolsusedtoalignwithclutchfilmspring2.SSMspecialrepairdataNameofmaterialProductNo.Usage,etc.1282Bsealant1282BThreebondorsimilarproducts08823-00100Cooling-waterbypassflangeRear-endcoverplateforcylinder1324bond1324Threebondorsimilarproducts08833-00070ThermostatformanifoldpipeBoltsforflywheelordrivingplateFixingscrewsforinductioncoil1324bond1324Threebond242Letaiorsimilarproducts08833-00080Cooling-fluiddischargevalveforengineOilpressureswitch
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EF.1-1
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Description of system.................................................................................................
Precautions to the maintenance of electric-injection system..........................................
Analysisofthe function /principal/failure for systemparts&components .....................
General troubleshooting and steps to engine ...............................................................
Criteriontoflashingcode /mountingtorqueof componentswithinM1.5.4system........
Description of the diagnosis function on M7.9.7 system failure....................................
M7.9.7 system service &diagnosis flow process based on fault code..........................
United Electronic engine management system
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EF.1-2
Model GW491QE petrol engine adopts BOSCH Motronic1.5.4 and Motronic7.9.7 engine management system
for electric-injection: As for the exhaust, the former is in compliance with European Class-II standard, and the
latter is in compliance with European Class-III standard.
BOSCH Motronic1.5.4 engine management system for electric-injection
As one set of advanced engine management system, M1.5.4 system has one engine electronic control unit
abbreviated to ECU used as the control center, and is able to measure various working parameters of
engine using appropriate sensors installed at different position of engine, to precisely control the oil injection
amount and the ignition lead-angle as per control programs set in engine electronic control unit, and to have
engine working with best performance under various conditions, ie. optimum dynamic output, most cost-
effective oil consumption, and best tail gas exhaust.
M1.5.4 system is subject to a multi-point oil injection control as per some sequence, and its control strategy
covers: starting control, closed-loop control of idle-speed, closed-loop control of air /fuel ratio, carbon-canister
control, transition working condition control, ignition angle control, knock control, air-conditioner control, slide
oil cut control, over-speed oil cut control, heating &protection control by three-way catalytic converter, and
system self-diagnosis, etc. The system has provided ABS, automatic gear box, air bag, etc, with applicable
communication interfaces, and is with theft-prevention function. The system is composed of three parts: sensor
air inlet pressure /temperature sensor, throttle position sensor, cooling-fluid temperature sensor, knock sensor,
oxygen sensor LSH25, rotating speed sensor, phase sensor , actuator idle-speed adjustor EWD3, oil injector
EV6, electrical fuel pump, fuel pressure adjustor DR, carbon-canister control valve TEV, and ignition coil
ZSK , and ECU electronic controller.
BOSCH Motronic7.9.7 engine management system for electric-injection
The key feature of M7.9.7 engine electronic control management system is the application of a control
strategy based on torque aimed at linking a number of various controlled objects together. And this is the only
fixed method to have various functions integrated on ECU flexibly in accordance with the model of engine and
vehicle.
Basic components within the M7.9.7 engine electronic control system include: electronic controller ,
air inlet pressure /temperature sensor, air mass flowmeter, cooling-fluid temperature sensor, throttle position
sensor, phase sensor, rotating speed sensor, knock sensor, oxygen sensor, idle-speed adjustor, oil injector,
electronic fuel pump, fuel pressure adjustor, oil pump support, fuel distributing pipe, carbon-canister control
valve, and ignition coil.
M7.9.7 engine management system, namely a petrol engine electronic control system, is available with many
control characteristics fit for operator, vehicle, and device, and is the combination of open-looped control and
closed loop control feedback to provide various control signals while engine is running. Key function of
system includes:
1. An application physical model of basic engine management function
(a) System structure based on torque
(b) The cylinder loading capacity to be determined by the air inlet pressure sensor /air-flow sensor
(c) Improve the function as to control the gas mixture under a static or dynamic status;
(d) typed closed-loop control
(e) Fuel injection by cylinder as per some sequence
(f) Ignition timing, inclusive of knock control by cylinder
Description of system
UASE Electronic Control Engine Management System -System Introduction
ProCarManuals.com
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