ENGINE SERVICE MANUAL
Contents
1. CSR TERR el ee Se PELE EL Leen Teel ect Be TT eT T3 10 199 7101 TRESE S nde gross power net power Fig 10 Full load performance curve of the DA465Q gasoline engine 11 DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual VANTAGE VEHICLE INTERNATIONAL INC Meo Ner 80 70 HHHH HHEH LLI TUE ERO 4E RRR ERR Eee BU tet TON BN PEPE Lr BB SERRE Rb UR XR Se ee NEVER See BNL GR ER ER EE Pee he SRR LANN ILL HN tt sq LIS L m E 33 Li a LLA LLL Na ed DB PR D E L HHH REECE EEE eee BS LALELLEELLIEEELLELELELELLLELTELLEELIET LEENS a HH N A HHHH HHH HHHH HHHH LLILLITIIMM T HAS gross power net power Fig 11 Full load performance curve of the DA465Q 1A gasoline engine 12 DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual VANTAGE VEHICLE INTERNATIONAL INC Chapter 2 Operation of the petrol engine Section 1 Brief introduction The EMS of the electric fuel injection engine DELPHI adopts closed loop control The system has the feature of grouping fire sequential injection and has the function of emission control idle control and evaporation emission control The core of the system is an Electronic Control Module ECM and calculates th2. 2090 10W40 10 30 5W30 WD 3 20 10 0 10 20 30 4 DAD 80 90 1010 Co 0 0 9 pn 2 3 24 kk Replace oil after 2500km run in of a new engine and every 5000km normal running of an 2 Measurement of oil level of the engine The oil level in oil pan is measured by oil stick To measure the oil level withdraw the oil stick Fig20 about 5 minutes after the engine stops wipe off the oil with clean cloth and insert it into oil pan for measuring The oil level shall be between the upper and lower marks on the stick see Fig 21 if the oil level is close to or lower than the lower mark fill the oil up to upper mark Check the oil level before your setting off with x your car and every 300 to 500 km of driving Fig 20 the oil stick FULL LOW Fig 21 oil level 3 Renewing oil Driving on asphalted road oil shall be renewed every 5000km while driving on sandy soil road check shall be often performed to oil and renew oil in time depending on the oil quality but anyhow oil shall be renewed every 5000km DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual Vantage Vehicle International Inc L a To renew oil preheat the engine for about 10minutes then stop the engine open filler cap see Fig 22 and unscrew the drain plug on oil pan of the engine see Fig 23 while oil is still warm and drain off the oil renew and tighten the drain plug Fill
3. Remove the spark plug referring to flywheel graduations through the sight hole on the bell housing rotate the flywheel in the working direction so that the key way on the front end of the crankshaft is in line with the arrow on inner cover of the timing belt then check to see if the piston of the first cylinder of the engine at the radiator side is at top dead point of its compression stroke that is there is clearance between the inlet valve and the rocker arm and between the exhaust valve and the rocker arm If not rotate the crankshaft for further 360 the circular pit mark on the driven timing gear edge opposite to the keyway should be aligned with the arrow on the inner cover of the timing belt If big deviation is found adjustment should be done Also check the timing belt tension 28 following the requirements of fig 37 Rotate the crankshaft for 360 so that the first cylinder is at top dead point of its exhaust stroke and the fourth cylinder is at top dead point of compression stroke so one of the two marks on the driven timing gear edge which is opposite to the key way should be in line with the triangular mark V on the timing belt cover see fig 34 Driven timing gear Fig 34 Maintenance of valve mechanism DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual Vantage Vehicle International Inc 2 Timing belt serious cases timing belt should be Check the timi
4. 441 40 45 742 DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual Vantage Vehicle International Inc 118 147 L2 1 5 nipple for oil filter 19 6 24 5 2 0 2 5 set screws for rear suspension bracket 17 7 22 6 1 8 2 3 18 set screws for engine bracket left and 17 7 22 6 1 8 2 3 right mounting bolts for damping cushion 24 5 29 4 2 5 3 0 20 screws threaded bush for 14 7 22 6 1 5 2 3 tensioning wheel support 15 20 1 5 2 0 Oxygen sensor 23 set screws for throttle body 24 set screws for crankshaft position 8 10 sensor 25 set screws for inlet manifold air 8 10 pressure sensor 26 spring seat for safety valve of oil 14 7 19 6 pump Section 3 Tightening torque of the main bolts for gearbox No Description tightening torque 1 connecting screws for gearbox 14 7 19 6 1 5 2 0 housing 2 oil filling and drain plugs 29 4 49 0 3 0 5 0 5 connecting screws for extension 14 7 19 6 1 5 2 0 housing 8mm po screws for gear shift shaft housing 6mm locking screws for gear shifter shaft 14 7 19 6 1 5 2 0 connecting bolts for gearbox and 19 6 24 5 2 0 2 5 DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual Vantage Vehicle International Inc jcoylinderblock 12 Section 4 Tightening torque of the main bolts for clutch No Description tightening torque N m kgf m screw
5. ECM damaged d 1 cylinder gasket cracked force of damaged replace ade reduced worn Section 2 Idle speed too high 1 damage of throttle position sensor Self learning after power off 2 throttle gate unable to completely return home Check and adjust position 3 leakage of intake system Check and repair 4 idle speed regulator step motor damaged Section 3 Power insufficient during running 1 improper adjustment of accelerator pedal and Adjust throttle body wire 2 reduction of cylinder compression force 1 check leakage of valve sparkplug and cylinder gasket 2 grind the cylinder bore 3 ignition timing not accurate Adjust 4 fuel pressure regulator is damaged so gasoline Adjust or replace supply is insufficient Check air intake system 6 exhaust system stocked Check exhaust system and remove carbon deposit Clean or replace DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual Vantage Vehicle International Inc 11 electric fuel pump with insufficient pressure Repair or replace Section 4 Knock inside the engine bush camshaft cam and rocker arm worn 2 crankshaft crank pin and piston pin seriously Replace or repair worn 3 piston ring damaged 4 improper gap of valve 5 excessive thrust clearance of camshaft and Adjust crankshaft Section 5 Engine overheating 1 improper ignition timing adjust 2 improper spark plug gap or carbon adjust or clea
6. with heating system shall be available or water inside the radiator and engine shall be drained out in time after parking to prevent from damage to radiator or engine resulting from freezing For the engine of which cylinder block has no water drain plug water cannot be used as coolant in winter As water is frozen its volume will be expanded this will damage the sealed radiator water pump cylinder head and cylinder block 2 Filling the coolant Proceed to fill the coolant as follows 1 Unscrew the radiator cover and fill up the radiator with coolant Fig 26 and the coolant tank shall be filled up to FULL mark Fig 27 Caution shall be exercised so as not to surpass the FULL mark 24 Fig 27 water level mark of water tank 2 Putthe radiator cover in place and tighten it 3 Start the engine run it at idle speed for2 3 minutes then unscrew the radiator cover When some air in water piping goes out the coolant level will decrease at this time replenish coolant to the level mark FULL 4 Replace the radiator cover and tighten it then the engine can operate normally In hot condition of the engine it is not allowed to open the radiator cover to avoid personnel being burned 3 Coolant replenishing DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual Vantage Vehicle International Inc After long time of operation when coolan
7. 7 Maintenance of the Ignition 8 30 Section 8 Maintenance of Spark 30 Section 9 Maintenance of Positive Crankcase Ventilation valve DC ju Ned Pesos RARE e eio tut 30 Chapter 4 Regular check of the gasoline engine 3l Section 1 The maintenance period and 1 31 Section 2 Tightening torque of main bolts for engine 32 Section 3 Tightening torque of the main bolts for gearbox 33 Section 4 Tightening torque of the main bolts for clutch 34 Chapter 5 Malfunction and troubleshooting 34 Section 1 Difficult to SUM ria OR tab OR IM pai eoo ax us 34 Section 2 Idle speed too aude ettet eo pec Pee eH A IHRE 35 Section 3 Power insufficient during running seesssse 35 Section 4 Knock inside engine ao eoe tete t tetendit 36 Section 5 Engine overDeatInp uuu ecce ener eren t ren eei ker 36 Section 6 Excessive oil consumption sssseeeeeeeereee 36 Section 7 Difficulty in shifting gears 37 Section 8 Noise inside the clutch 37 DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual VANTAGE VEHICLE INTERNATIONAL INC Sect
8. DELPHI EMS series gasoline t nd Maintenance Instruction Manual VANTAGE VEHICLE INTERNATIONAL INC ENGINE SERVICE MANUAL VANTAGE VEHICLE INT L INC V DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual VANTAGE VEHICLE INTERNATIONAL INC Contents Chapter 1 Performance and structural parameters of the petrol Jil M P ES 9 Section 1 Performance and structural parameters of the petrol engine spn ic ads ee 9 Section 2 Full load performance curve of the gasoline engine 11 Chapter 2 Operation of the petrol engine 13 Section 1 Brief introduction rece veste t e aia eer I 13 Section 2 Notice on operation of the engine 15 Section 3 Run in of the new gasoline 19 Chapter 3 Maintenance of the gasoline engine 21 Section 1 Maintenance of the lubrication system 21 Section 2 Maintenance of the cooling 23 Section 3 Maintenance of the fan rubber belt 25 Section 4 Maintenance of the air cleaner 26 Section 5 Maintenance of the Gasoline Filter and Fuel Pipelines 27 Section 6 Maintenance of the Valve Train and Timing Belt 21 Section
9. Filler plug of gearbox DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual Vantage Vehicle International Inc Fig 25 Drain plug of gearbox 6 Washing of lubrication system If a large quantity of impurities is accumulated in oil pan washing with light spindle oil shall be carried out to the lubrication system Washing with gasoline kerosene is absolutely prohibited To wash the interior of the engine fill in 3 light spindle oil through filler port start the engine with starter to idle speed for 2 or 3 times lasting 1 minute each time then rapidly drain off the light spindle oil for washing and fill in lubrication oil according specifications If washing is performance whenever the oil is renewed the engine service life will be greatly increased Each time after renewing oil run the engine for 3 5 minutes without load to ensure the lubrication system and all lubricating points are supplied with enough oil 7 Replacement of oil filter 208 Replace the oil filter every 10 000 km running after running in for 2500 km The tightening torque when mounting the filler is 9 81 14 7N m C 1 0 1 5kg n m 8 Check of oil pressure indication system In normal condition when power supply switch is turned to ON position the oil pressure indicator lamp lights up that indicates there is no oil pressure Then continue to turn the switch to Start pos
10. INC Chapter 1 Performance and structural parameters of the petrol engine Section 1 Performance and structural parameters of the petrol engine Table 1 Technical characteristics and structural parameters of the petrol engine LJ465QE1 LJ465Q 1AE1 Electronically controlled MPI gasoline engine with 4 cylinder 4 stroke forced water cooling in line cylinder and overhead camshaft Ratio 3000 3500r min consumption 5000r min 5200r min 850 50r min 850 50r min At idle speed CO lt 0 5 HC lt 100PPm DB11 044 1999 Emission At es COS0 3 HCx100PPm DB11 044 1999 D In NEDC cycle COS2 2 g km HC NO lt 0 5g km 96 Counter clockwise viewed from backside 1 3 4 2 0 294 0 539MPa 3 0 5 5kgf em 23000 Lead free gasoline RON90 GB19730 1999 Jor higher Selected according to the temperature of the region where the engine is operated 11121 1995 Glycol water solution or soft water Single leaf spring diaphragm spring Overall dimension Clutch housing 217X 63mm 2 8 kg gear ratio Gear 1 3 505 Gear 1 3 652 Gear 2 2 043 Gear 2 1 948 9 DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual VANTAGE VEHICLE INTERNATIONAL INC Gear 3 1 383 Gear 3 1 424 Gear 4 1 000 Gear 4 1 000 Gear 5 0 806 Gear 5 0 795 Reverse gear Reverse gear 3 505 3 466 Gear meshing type all with synchronizer Type 1 reverse 5 Sforwardgears Sf
11. about 3 liter of new oil before putting the filler cap in place Fig 23 oil drain plug Five minutes after start up of the engine check oil leakage then stop the engine and wait for another 5 minutes to check the oil level Replenish oil top upper mark of the oil stick if it is not enough Caution shall be exercised so as not to be burnt by hot oil when unscrewing the oil drain plug 4 Oil for gearbox 85W 90 GL 4 gear oil or GL 5 gear oil GB13895 92 Or No 18 hypoid gear oil 2295 Use of suitable oil for engine and gearbox is an essential factor to ensure their normal operation and service life Special attention shall be given when making choice of oil not to mix up oils of different origins brands and standards in order to prevent from chemical reaction thus adversely affecting the normal operation of engine 5 Renewing oil in gearbox Gear oil in gearbox shall be renewed every 40000 km except for run in stage To change gear oil for gearbox preheat the engine for about 10minutes then stop the engine then unscrew the filler plug on middle casing of gearbox see Fig 24 and the drain plug on bottom of middle casing of gearbox see Fig 25 drain off the oil in gearbox and renew the drain plug Fill the gear oil through filler port up to oil overflow from the filler port Filling oil through the mounting hole for reversing light switch is strictly forbidden Fig 24
12. agnosis by removing the spark plug wire while the engine is running 4 Don t force the engine to operate when the engine is flameout resulted from ignition system failure Otherwise it will result in the damage to the TWC 5 Don t force the engine to start or operate when the engine does not operate very stably at idle speed or the engine can not start through long time 6 If the car performance becomes worse to great extent or the engine does not operate normally such as malfunction of fuel supply or ignition system you shall stop your car immediately and try to eliminate the fault If it is not allowed to stop immediately you shall reduce the speed and drive for a short distance to find a service station 14 Throttle body The adjustment screw on throttle valve body shall not be adjusted by the customer it has been set for air leakage in the factory before it is delivered The idle speed and emission may adversely affected if you adjust the Screw 15 Electric fuel pump When the car is filled with fuel at the first time or the fuel is used up the filling amount not less than 5 liters is recommended shall ensure the fuel level of fuel tank exceed the fuel inlet height of fuel storage barrel making the suction port of the fuel pump in the fuel storage barrel is completely immersed in the fuel and the car start up successfully Due to special structure design of the 19 fuel storage barrel when the fuel level i
13. d outlet fuel pipes of the fuel rail are removed Otherwise fire may take place due to gasoline flowing out 12 Fuelinjector According to the operation of the imported car equipped with fuel injection system in China and the actual condition of the fuel in our country when the car is to be parked for long time it is required that the engine shall run for 3 to 5 minutes every 2 3 months to avoid that the fuel injector is blocked due to gumming in petrol ensuring the car in good condition 13 Three Way Catalyst TWC The TWC is mounted on exhaust system of EMS for post treatment of exhaust It can effectively reduce the harmful gas in the exhaust A set of quality EMS shall not only ensure the normal operation of the engine but also ensure the efficient conversion operation and provide the overheat protection function to prolong its service life of TWC The TWC is subject to overheat during operation of gasoline engine and is easily damaged due to overheat In order to protect the TWC the driver shall pay attention to the following conditions during driving 1 only quality lead free gasoline 90 or above can be used 2 Do not start the engine by forced pulling forward or dragging the car When the battery is low please use auxiliary battery to start the engine DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual Vantage Vehicle International Inc 3 Don t make ignition di
14. e amount of air aspirated in each cycle according to the signal from inlet manifold air pressure sensor speed sensor and inlet air temperature sensor and determined the amount of fuel to be injected in each cycle and corrects the fuel injection according to the signals from coolant temperature sensor and other sensors Under the case of closed loop fuel control ECM corrects the fuel injection according to the signals from oxygen sensor to keep a theory A F ratio And it can make the three way catalyst purify the emission maximumly reduce the CO HC NOx in the emission This is equal air fuel ratio closed loop control emission control l Principle of closed loop control to idle speed The idle speed of the engine under normal temperature is closed loop controlled EMS closes the throttle completely when under idle speed and controls the amount of the intake air with idle controller on the throttle body And according to the speed of the engine adjusts the spark advance angle to control the actual idle speed and let the engine working at stated idle speed area 2 Principle of electronic control to ignition timing ECU determines a preset value of ignition advance angle according to load and speed and corrects this value based on coolant temperature acceleration etc and then fixes a reasonable ignition advance angle Thus ignition timing is determined Because of the EMS equipped with LIUJI injection engine has well star
15. f the fan is used for driving the electric motor water pump and fan Check and maintenance should be often carried out to fan rubber DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual Vantage Vehicle International Inc belt IF the fan belt is not properly tensioned or is worn out it will cause engine overheating and electrical energy generation reduced 1 Adjustment Stop the engine loosen the two fixation screws in the lower part and the set screws in the upper part of the electric generator see fig30 pull outward the electric generator so that the fan belt reaches the tension required in item 2 of the section Fig 30 fixation screws for electric generator 2 Measurement of tension Apply a force of about 98N 10kg on the belt in the middle position between the electric generator and the fan as shown in fig 31 For new belt deviation should be about 7 10mm while for used belt it is about 10 15mm 26 Fig 31 check of tension 3 Appearance The fan belt should have a perfect appearance Replace it if there are any defects affecting its normal use Section 4 Maintenance of the air cleaner The cleaner is used for filtering the air entering the cylinder A poor cleaning of air will speed up wearing of the engine and shorten the service life And air cleaner plugging affects adversely air entering the engine causing insufficient air flowing into the engi
16. he fuel filter shall have sufficient cleaning performance otherwise the block of injector and even the malfunction of engine will be resulted Normally the gasoline filter shall be replaced after every 10000 km In case the fuel is very dirty the filter shall be replaced in time to prevent the injector from blocking Gasoline filter for carburetor conventional engine shall not be used for EFI gasoline engine Section 6 Maintenance of the Valve Train and Timing Belt Frequently check and maintain the valve train and timing belt In case of timing belt broken or slipped collision of valve with piston will occur resulting in the damage of components including valve piston rocker arm and camshaft etc Therefore except during DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual Vantage Vehicle International Inc breaking in period check it after every 20000km and properly adjust or replace it if necessary It is strongly recommended that this check or maintenance work be performed by the car manufacturer our service station or our authorized service center whether you are the expert or not 1 Check of Timing Gear and Adjustment Valve Clearance Open the timing belt cover check the assembling mark position of the driving and driven timing gears for correctness if the mark positions are not correct or timing is doubtful following check is necessary
17. icle shall be filled with acceptable quality lead free gasoline otherwise EMS Three way Catalyst and oxygen sensor will be fatally damaged and the performance of environment protection reduced 5 Start up of gasoline engine Since engine is equipped with electronic controlled fuel injection system this system will automatically provide gas mixture at suitable ratio under operating condition Therefore before and as starting the engine the accelerator pedal shall not be used when the engine is in any condition When the engine cannot be started up after several trials the spark plug is probably short circuit resulting from more fuel in cylinder At this time the accelerator pedal shall be stepped down to the end then starting the engine again after 5 6 seconds high speed gas flow will blow the overflowed fuel off Then the pedal shall be released and the engine can be started up again DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual Vantage Vehicle International Inc Starter shall not operate for over 5 seconds each time When the engine can not be started it shall be started 10 seconds later otherwise the starter may be damaged If the engine can not be started after several attempts please check the fuel injection system and electrical system or come to motor plant and our company s service station for repair 6 Idlespeed After start up of the engi
18. ion 9 The fault indicator on instrument panel keeps Section 10 Emission not acceptable Chapter 6 Preservation and unseal of the engine Section 1 Preservation and storage of the engine Section 2 Unseal of the USER S Figures DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual VANTAGE VEHICLE INTERNATIONAL INC Figure 2 Engine picture front view DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual VANTAGE VEHICLE INTERNATIONAL INC Figure 3 Engine picture right view on Ne a E TN il Figure 4 cutaway view of the gasoline engine lengthways DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual VANTAGE VEHICLE INTERNATIONAL INC Figure 6 outline of the gasoline engine without casing of timing belt DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual VANTAGE VEHICLE INTERNATIONAL INC Figure8 Front view of valve mechanism transmission DELPHI EMS series gaso line engine Operation and Maintenance Instruction Manual VANTAGE VEHICLE INTERNATIONAL INC 4 9 top view of the intake system of the engine DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual VANTAGE VEHICLE INTERNATIONAL
19. ition the engine is started and enters idle speed condition at this time oil pressure indicator lamp goes out automatically that indicates oil pressure is normal If the oil pressure indicator lamp does not go out that means oil pressure in the engine lubrication system is abnormal the check is needed to see if there is sufficient oil in the engine When the oil pressure indicator lamp does not light up after turning the power switch to I position while there is still electric current in circuit and there is no current at idle speed that indicates oil pressure sensor is in good condition At this time check should be performed to indicator lamp and to relevant circuits for defect Section 2 Maintenance of the cooling system The cooling system is one of those conditions indispensable for normal DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual Vantage Vehicle International Inc operation of the engine therefore sufficient quantity of coolant must be assured inside the engine and checks must be carried out before driving and replenish coolant if necessary 1 Coolant Distilled water or suitably treated soft water as well as anti freezing fluid can be used as coolant for the electric fuel injection engine The ice point of the anti freezing fluid shall be 5 C lower than the minimum temperature in the region where the engine is used When water is used as coolant in winter garage
20. ixing inlet and exhaust manifolds and of the bolts for the cylinder heads 5 joilfiter TR R R R R R R R R After running in for 2500km be renewed every 5000km of driving fuel rubber pipe connections check for aging of rubber pipe and cracking or damage of connections rubber pipe and connections for engine cooling system check for water leakage and damage ual degradation and damage 10 sparkplug S 11 air cleaner m asphalted road to be cleaned every 10000km of running On soil road to be cleaned every 2500km of running ERR R RR R DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual Vantage Vehicle International Inc 16 gear oil for gearbox check for oil leakage in horizontal R I I I I I I condition Note Meaning of symbols used in the table check or adjust lubricate replace check and adjust or replace if necessary check with special torque wrench DNE Whether you are a expert or not we recommend the items marked with an asterisk 4 to be entrusted to technical service stations or special maintenance centers of car manufacturer or our company Section 2 Tightening torque of main bolts for engine 6 screws for driving timing gear 49 0 58 8 5 6 8 screws for crankshaft bearing cover 42 2 471 43 48 9 flywheelscrew 392
21. l Put the engine into packing box Section 2 Unseal of the engine 38 Clean off the grease from external surface of the engine Unscrew spark plugs run the engine without load drain off as far as possible the anti rust oil inside the cylinders cleaning inside of the cylinder with small amount of gasoline can be effected if necessary Fill the engine with oil DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual Vantage Vehicle International Inc 4 Fillthe engine with coolant 5 Unseal all plugged places USER S COMMENTS To improve ceaselessly the engine performances and quality and to better serve the vast users please send us at any time in the midst of your pressing affairs any problems found in operating your engine purchased from our company and your improving comments to following address and give detailed description of the problems found and your comments Sales department User comments 39 DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual Vantage Vehicle International Inc manufacture unsealing date Total operation EM time or mileage User name comments and suggestions in detail 40
22. l injection amount and closed loop control of A F ratio Fig 16 Oxygen sensor 4 Electronic control module ECM Fig 17 lt was equipped on the vehicle body After analysis and treatment to the signal input from sensors ECM gives instruction to actuator DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual Vantage Vehicle International Inc Fig 17 Electronic control Module 5 Actuator 1 Electric fuel pump mounted inside fuel tank controlled by relay through ECM In case of engine shutdown the electric fuel pump automatically stops 2 Fuel injector mounted on fuel rail assembly to inject fuel towards air port under control of ECU 3 Ignition coil Fig 18 The ECM of the engine adopt advanced no distributor direct ignition technology The mount support of the ignition coil must be reliably grounded Fig 18 Ignition coil 4 Idle speed regulator mounted on the throttle body its movement is controled by ECM to change the cross section area of bypass passage thus changing the bypassing amount of air at idle speed for control of idle speed 5 Purge solenoid Fig 19 it mounted under the inlet air manifold Its duty cycle is controlled by ECM thus the cleaning air flow from 15 carbon canister to inlet air manifold Fig 19 Purge solenoid Section 2 Notice on operation of the engine 1 Operation and maintenance manual Please read this manual ca
23. n deposit 3 intake manifold loosened exhaust tighten or purge manifold blocked 4 fan belt insufficiently tensioned 5 coolant flow insufficient or water pipe blocked 6 water pump clearance insufficient or defective 7 lack of oil replenish 8 oil passage blocked or oil pump unblock or replace defective 9 cylinder gasket damaged 10 clutch slippery 11 radiator blocked by scales adjust replenish or purge repair or adjust replace repair or replace clean up or replace Section 6 Excessive oil consumption 1 oil seal of the valve guide worn or replace defective 36 DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual Vantage Vehicle International Inc 2 oil ring worn or damaged 3 piston ring gap not staggered as required 4 defective cylinder gasket 5 valves and guides worn 6 engine overheating internal pressure increasing partial oil going out through the vent Section 7 Difficulty in shifting gears replace adjust replace replace check components troubleshoot concerned and 1 synchronized internal gear wore 2 synchronized external gear wore 3 positioning ball damaged 4 shifter fork distorted or worn Section 8 Noise inside the clutch throw out bearing worn or damaged 2 bearing of front output shaft worn 3 clutch hub loosened 4 clutch housing cracked 5 cone springs loosened 6 clutch plate stained with oil 7 clutch damping rubber or spring
24. n fuel tank is low the fuel level in storage barrel can be kept higher that that of the tank thus it is ensured that the engine will not be flameout during downhill or uphill driving resulting from no fuel from fuel pump 16 Fault indication Indicators optional are mounted on the instrument panel whenever the system has fault the indicator will light at this time please come to the professional personnel for fault diagnosis by means of fault diagnosis instrument When some of parts EMS are broken you can continue to drive your car but the driving performance will worsen to remind you that you shall send your car for service Section 3 Run in of the new gasoline engine The service life of a gasoline engine is largely related to the initial operation condition Run in of a new engine shall be carried out for about 2500 km on the car or for 30 hours on the test bench according to the run in regulations The procedures for run in of engine on the car are as follows 1 Check Check to see if the oil coolant DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual Vantage Vehicle International Inc fuel and electrolyte in battery etc are sufficient replenish or correct if quantity is not sufficient or leakage must be replenished 2 Road surface The car shall run on cement or asphalted road and shall try not to drive on other roads especially on sandy soil road 3 S
25. ne let it run for several minutes at idle speed for warm up Normally the idle speed water temperature over 60 C is 850 50r min or 850 50r min At cold state the engine controlled by ECM runs at 1000 r min for warm up With the water temperature increasing this idle speed of engine will be gradually recovered to normal idle speed If the air conditioner is turned on while the engine operates at idle speed the ECU will increase the idle speed up to 1100r min or so 7 Running The coolant temperature shall be kept between 80 C 90 C normal running of the vehicle At intermediate speed attention shall be given that the oil pressure not be lower than 0 294Mpa 3kg em Due to use of EMS the car has the 17 function of fuel cut off in deceleration which can realize the purpose for satisfactory fuel saving While the engine keeps operating at idle speed when the car slides at neutral speed it still consumes fuel 8 Engine shutdown During operation of the engine especially under high speed and high load condition the engine shall not be suddenly shut down and shall be shut down after 3 5 minutes of running at lower speed The car shall not stop near flammable material because the TWC with high temperature will probably cause fire 9 In raining condition or across water area When running in raining on water road or across water area in normal times the tightness of air cleaner must be
26. ne and reduces horsepower The filtering element of the air cleaner should be often dismounted or cleaned On asphalted road every 10000km of running the element should be cleaned while on soil road every 2500km of running the element should be cleaned Cleaning is to be conducted according to following procedures 1 cleaner dismounting Open the clamp on the air cleaner body remove the cleaner cap to DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual Vantage Vehicle International Inc withdraw filtering element see fig 32 The gasoline engine is not allowed to operate without air cleaner Air cleaner going along with the engine should be used Check the seal strip at both ends of the cleaner to assure perfect tightness while mounting A poor tightness would make the cleaner unable to play its role and speeds up wearing of the engine Fig 32 Air cleaner 2 Cleaning Blow off dust on filter element with compressed air see fig 33 Paper element can be washed with gasoline and then blown dry with compressed air Damaged element should be replaced in time 27 Fig 33 cleaning of the air cleaner 3 Remounting Remount the filter element and the cleaner cap in reverse order Section 5 Maintenance of the Gasoline Filter and Fuel Pipelines The high fuel supply pressure up to 0 3MPa of EFI system and small diameter of injector orifice require that t
27. ng belt in changed to a new one In normal accordance with the requirements of conditions timing belt should table 4 and if there are cases similar to replaced every 10000 km of driving those listed in the table locate the causes and eliminate them in time For Table4 Check of timing Description of failures 1 Hardening of the belt surface The back of the belt is bright has no longer resilience and 15 hardened No trace left when pressing the belt with the nail The belt back cracked The belt cracked or the fiber cloth stripped Teeth wore at first stage The fiber cloth on the edge of load wore lateral face also wore 5 Teeth wore final stage The fiber cloth on the edge of load wore out The rubber exposed tooth thickness reduced S 22 Lateral face of tho beltwore 79 Lateral face of thebelt cracked 99 DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual Vantage Vehicle International Inc Section 7 Maintenance of the Ignition System Ignition angle was controlled bye ECU need not to adjust Section 8 Maintenance of Spark Plug Replace the spark plug after every 10000 km Replace it any time if the damage is found Pay attention to make sure the type of spark plug 6 4 7 thread M14 X 1 25 The contact surface between insulator of spark center electrode and external electrode shall be clean f
28. orwardgears gears 5 forward gears Overall dimension EA WAI LXWXH 477 5 X 270 X 287 4mm 535 5X 390 4 276 3mm Gear oil to be selected according to the temperature of the region where the engine is operated GL 4 or GL 5 gear GB13895 92 or No 18 hypoid gear oil Lubrication oil A The Rated power Max Torque and Min fuel consumption index of the petrol engine is gross power net power A A The emission standard for petrol engine is a mandatory national regulation that is subject to continuous modification The MPI series engine made by Liuji Company will be improved continuously to meet the up to date national regulation 10 DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual VANTAGE VEHICLE INTERNATIONAL INC Section 2 Full load performance curve of the gasoline engine 80 70 60 ge g KW h 290 270 250 E e iui pod E dul 170 3 4 3 1 4 iti dsl LI 19513 L1 1 12 E e a a a a elsi TT dcl EEE EC Tis acer er PEEL tel gabe 1 MID Irae Serene pope rr DEES 48 BUR SRR RESO
29. pecifications for run in The run in of the gasoline engine on the car must be performed in accordance with the specifications listed in table 2 below The speeds at different gears in the table must not be exceeded If there is any deviation between run in specifications of the car and the run in specifications herein the latter shall prevail 4 Load During run in operation for the first 1000 km the load shall not exceed 50 of the rated load and for the remaining 1500km the load shall not exceed 75 of the rated load 5 Maintenance After run in for 2500km the engine shall be maintained in compliance with the requirements listed in Table 3 Table 2 specifications for run in of a new engine on car speed position of gearbox 20km h 35km h 55km h 65km h Table 3 maintenance to be performed to a new engine after run in 3 Valve Check and adjust if necessary 3 Valvegap for inlet and exhaust manifold 8 Spark plug gap 220 Check and adjust to rated value DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual Vantage Vehicle International Inc Chapter 3 Maintenance of the gasoline engine Section 1 Maintenance of the lubrication system 1 Oil for gasoline engine Select applicable API oil SE SD or SF based on the operation temperature of the oil and according to the temperature in the area where the engine is used
30. perfect to avoid infiltration of water into the engine cylinder thus to damage connecting rods etc Water is incompressible fluid With water entered the cylinder it produces several decades of pressure rise on the connecting rods causing the rods to be bended or broken 10 Warming up of the gasoline DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual Vantage Vehicle International Inc engine in winter winter the temperature 15 relatively low the oil viscosity 15 increased and the lubrication is not as efficient as in summer So the car shall not immediately run after engine start up and moreover the engine shall not operate under high speed and high load condition The car shall run only when the engine is warmed up for about 10 minutes to let the oil and coolant temperature increase and let the engine lubricate sufficiently In winter if the engine operates when the lubrication is insufficient this will result in excessive wear or even blocking of valve train components such as camshaft 11 Gasoline piping Due to high inlet fuel pressure 0 3Mpa 3 bar the fuel inlet pipe must be explosion proof rubber pipe the pipe must be fixed by fastener and fuel leakage at pipe connection shall be checked frequently As checking the fuel pipes it is strictly prohibited to check the electrical fuel pump by starting the engine after the inlet an
31. ree of carbon deposit Remove with fine sand paper if there is carbon deposit Spark plug gap shall be 1 0 1 2mm shown in Fig 35 evenly and equally distributed through the surface of center electrode j des Snid x1eds Fig 35 Spark Plug Gap 30 Section 9 Maintenance of Positive Crankcase Ventilation valve PCV valve PCV valve is composed of valve body valve gate valve cap and spring and is not dismountable Its main purpose is to direct the air in the crankcase through the PCV valve into the inlet manifold and a small amount of air goes into inlet manifold through PCV valve directly from the air cleaner so that some problems such as icing in the throttle body insufficient combustion and bad emission avoided Dismount it every 5000 km of driving clean it with gasoline and blow it dry and then push the flap with a steel wire to make sure its free movement If the flap is blocked the valve should be replaced DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual Vantage Vehicle International Inc Chapter 4 Regular check of the gasoline engine Section 1 The maintenance period and items The service periodicity X 25 10 20 30 50 is calculated on basis of ERR M ll odometer or months whichever comes first mom 2 6 Paiva ETAT and wearing a Rn and wearing inlet and outlet valve gap tightening torque of the EIL and screws for f
32. refully and operate and maintain your engine in accordance with the instructions recommended therein 2 Coolant Check the coolant of engine and if necessary replenish the coolant in accordance with the method described in section 2 of Chapter3 kk During operation of the engine there must be sufficient quantity of coolant to ensure the normal operation of engine otherwise phenomenon will engine functions in overheating condition its service life will be adversely affected and moreover serious problems boiling occur and if the DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual Vantage Vehicle International Inc could occur such as scuffing of cylinder bore 3 Oil Check the oil level and replenish oil in time if necessary according to the method in section 1 of Chapter 3 kk Insufficient oil will result in excessively low oil pressure and improper lubrication worsening of the engine wear and poor cooling thus bringing failure affecting adversely service life of engine 4 Fuel Use of 87 Octane or above quality lead free gasoline for motor is mandatory Use of lower RON or poor quality gasoline containing excessive lead phosphor and sulfur etc will damage the catalyst and oxygen sensor Our company will not take any responsibility for any damage to catalyst converter and oxygen due to use of improper fuel 2346 The veh
33. s broken replace replace repair replace repair or replace clean up or replace replace Section 9 The fault indicator on instrument panel keeps 1 fault with EMS 2 fault with wire harness 237 Diagnosis instrument Check secure connection cut off or short circuit with diagnosing DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual Vantage Vehicle International Inc Section 10 Emission not acceptable 1 oxygen sensor and catalytic damaged due to Replace the usage of petrol with lead 2 oxygen sensor and catalytic damaged due to Replace the fault of ignition system miss fire and improper ignition timing 3 leakage of exhaust system and ECU received Repair wrong oxygen sensor thicker fuel injected Chapter 6 Preservation and unseal of the engine Section 1 Preservation and storage of the engine 5 Drain off coolant from the radiator and the cylinder block Wipe the external surface of the engine with washing gasoline While the engine is still in hot condition and the pistons are between top and bottom dead points unscrew the spark plugs fill every cylinder with 10 15g of 2172 anti rust oil and rotate the engine 3 5 revolutions then retighten the spark plugs with specified tightening torque and plug the exhaust pipe Wrap the connections of the throttle body the water inlets and outlets of the engine the bush of the tachometer or plug them wel
34. s for clutch housing 17 7 27 5 1 82 8 Chapter 5 Malfunction and troubleshooting Section 1 Difficult to start Symptoms and causes Remedy a Starter 1 loose connection at battery pole or low Retighten or recharge does not battery rotate 2 with disconnection on circuit Check and correct 3 starter damage Repair or replace b Ignition 1 improper grounding Repair system 2 ignition coil damaged Replace fault 3 improper spark plug gap or presence Readjust clean of carbon deposit replace 4 cut off or short circuit with harness Repair or replace 5 disconnection of crankshaft position Check and repair sensor 6 damage of crankshaft position sensor Replace 7 main relay or oil pump relay damaged Replace 8 Electronically Controlled Module Replace ECM damaged c trouble in 1 fuel pressure from electrical pump Repair or replace fuel supply not sufficient system 2 fuel injector damaged or blocked Replace or clean 3 fuel pipe or filter blocked Readjust or replace 4 vacuum tube of oil pressure regulator Mount or replace fallen off or damaged 5 crankshaft position sensor damage or Replace or Readjust wire broken 34 DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual Vantage Vehicle International Inc 6 main relay or oil pump relay damaged 7 cut off or short circuit with harness Check and repair 8 Electronically Controlled Module Repair or replace
35. t performance drivability acceleration performance economy performance and excellent environmental protection 3 Sensors 1 Throttle the vehicle electric fuel valve position sensor Fig 12A mounted outside the throttle body with throttle valve on same axle to offer load acceleration and deceleration information Fig 12 Throttle valve position sensor 2 Inlet manifold air pressure MAP 1 DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual Vantage Vehicle International Inc sensor Fig 13 mounted on inlet manifold stabilizer chamber or the fourth inlet manifold to provide engine load information Fig 13 MAP sensor 3 Crankshaft position sensor Fig 14 mounted at gearbox provide speed and crankshaft phasic signal the later will provide reference point for injection timing and ignition timing Fig 14 Crankshaft position sensor 4 Inlet air temperature sensor Fig 14 integrated into inlet air manifold pressure sensor to offer air temperature for correcting fuel injection amount and ignition timing 5 Coolant temperature sensor Fig 15 mounted at water outlet of inlet air manifold to offer coolant 14 temperature data for correcting fuel injection timing amount and ignition Fig 15 Coolant temperature sensor 6 Oxygen sensor mounted between engine and Three way catalyst Fig 16 to offer exhaust gas concentration data for correcting fue
36. t level in the tank is below the level mark LOW see Fig 30 coolant replenishing shall be performed in accordance with the procedures for coolant filling If in short time the coolant is reduced considerably there is possibly leakage in cooling system Careful check shall be made 4 Coolant renewing After long term of operation because of deterioration of coolant or repair etc renewing coolant becomes necessary Proceed as follows 1 Unscrew the radiator cover open the drain valve at the bottom of the radiator Fig 28 to drain out the coolant Fig 28 Drain valve of radiator 2 Dismount the coolant tank empty it of coolant 3 Unscrew the water jacket drain plug on the lower part of the fourth cylinder to drain out coolant 4 Reassemble the water tank radiator drain valve water drain plug on cylinder block and fill in coolant according to coolant filling procedures 95 Fig 29 Water drain plug for cylinder body When renewing coolant the car shall park level ground 5 Not placing the thermostat is prohibited If the thermostat 15 not replaced after being dismounted the warming up time of engine after startup will be prolonged and if the engine operates under low temperature for long time the mechanical parts wear will be worsened and service life of engine be adversely affected Section 3 Maintenance of the fan rubber belt The rubber belt o
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