MR479Q MR479QA MR481QA JL481Q ENGINE SERVICE WORKSHOP REPAIR SHOP MANUAL

Chapter 1 Engine Overview ......................................................................................................01
Section 1 Basic Structure and Working Principle of Engine. ......................................................................01
Section 2 Structural Characteristic of Engine ................................................................................. ............04
Section 3 Engine Technical Performance and Parameters ......................................................................12
Section 4 Engine Servicing Datasheet .......................................................................................................18
Section 5 Maintenance of Engine ............................................................................................... ................23
Chapter 2 Cylinder Block Assembly ....................................................................................26
Section 1 Structural Characteristic of Cylinder Block ................................................................................26
Section 2 Detach, Assembly and Servicing of Cylinder Block ..................................................................27
Chapter 3 Cylinder Head Assembly ...................................................................................45
Section 1 Structural Characteristic of Cylinder Head ................................................................................45
Section 2 Detach, Assembly and Repair of Cylinder Head ......................................................................45
Chapter 4 Piston & Connecting Rod Mechanism ....................................................69
Section 1 Construction of Piston & Connecting Rod Mechanism ............................................................69
Section 2 Dismantling and Inspection of the Connecting-rod and its Bearing ......................................72
Section 3 Common Faults and Troubleshooting of the Piston Connecting-rod Mechanism ................73
Chapter 5 Crank Mechanism ..................................................................................................76
Section 1 Structural Characteristics of Crank Mechanism ....................................................................... .76
Section 2 Disassembly & Maintenance of Crank Mechanism ..................................................................78
Section 3 Common Faults and Troubleshooting of Crank Mechanism ...................................................83
Chapter 6 Valve Train ..................................................................................................................
Section 1 Make-up of Valve Train & its Design Features ........................................................................ ....84
Section 2 Valve Timing ........................................................................................................ ..........................85
Section 3 Make-up of Valve train Assembly and its Features ...................................................................86
Section 4 Service of Valve Train ...................................................................................................................89
Section 5 Common Faults and Troubleshooting of Valve train ................................................................93
Chapter 7 Fuel Supply System .................................................................................................94
Section 1 Makeup and Features of Fuel Supply System for Electronic Fuel Injection Engine ................94
Section 2 Matters Needing Attention in Use and Maintenance of Electronic Fuel Injection System....99
Section 3 Troubleshooting the Electronic Fuel Injection System .............................................................102
Section 4 Evaporative Emission & Positive Crankcase Ventilation Control System ..............................124
Chapter 8 Ignition System .........................................................................................................127
Section 1 Introduction to Ignition System ..................................................................................... .............127
Section 2 Troubleshooting of Ignition System ...........................................................................................128
Chapter 9 Lubrication System ...............................................................................................132
Section 1 Makeup and Features of Lubrication System ..........................................................................132
Section 2 Examination & Maintenance of Lubrication System ..............................................................136
Section 3 Common Faults and Troubleshooting of Lubrication System ................................................141
Chapter 10 Cooling System .....................................................................................................143
Section 1 Composition & Features of Cooling System ............................................................................143
Section 2 Inspection and Maintenance of Cooling System ...................................................................147
Section 3 Common Faults and Troubleshooting of Cooling System ......................................................149
Chapter 11 Clutch ..........................................................................................................................150
Section 1 Structure of Clutch and Its Operating Mechanism .................................................................150
Section 2 Clutch Troubleshooting ..............................................................................................................152
Section 3 Assembly and Adjustment of Clutch and its Operating Mechanism ...................................155
Section 4 Common Faults and Troubleshooting of Clutch .....................................................................158
Chapter 12 Common Faults and Troubleshooting of Engine ........................160
Section 1 Overview .....................................................................................................................................160
Section 2 Determination and Elimination of Common Faults in Engine ................................................160
Section 3 Determination and Elimination of Abnormal Noises in the Engine ........................................171
Chapter 13 Power source .........................................................................................................173
Section 1 Structure of Clutch and Its Operating Mechanism .................................................................173
Section 2 Battery ..........................................................................................................................................175
Section 3 Normal Malfunction of Charging System and Troubleshooting ............................................176
Chapter 14 Starter ..........................................................................................................................177
Section 1 Structure of Starter ......................................................................................................................177
Section 2 Working Principle of Starter ........................................................................................................178
Section 3 Attentions in Use of Starter ........................................................................................ .................178
Section 4 Troubleshooting of Starter ..........................................................................................................179
Chapter 15 Engine Management System ....................................................................180
Section 1 System Profile ...................................................................................................... ........................180
Section 2 System Composition and Working Principle ............................................................................181
Chapter 16 Engine Electronic Control System ..........................................................184
Section 1 General Structure of Engine Electronic Control System .........................................................184
Section 2 Structural Principle of the Components of the Engine Electronic Control System ..............184