GoKa Sports LJ276M, Service Manual

Page 1: ...LJ276M LJ276MT 2 GASOLING ENGING SERVICE MANUAL Shanghai Goka Sports Motor Co Ltd ...

Page 2: ...2 Cylinder block assembly and balance chain 9 3 3 Crankshaft and main shaft bearing 11 3 4 Piston and connecting rod assembly 12 3 5 Distributor assembly 15 3 6 Carburetor assembly 16 3 7 Lubrication system 16 3 8 Cooling system 16 3 9 Electrical system 16 3 10 Clutch assembly and transmission assembly 17 3 11 Engine leakage prevention 18 Chapter Four Engine maintenance 19 4 1 Engine maintenance c...

Page 3: ... Power Speed 18KW at 4500 rpm Maximum Torque Speed 49 N m at 2700 3300 rpm Minimum Specific Fuel Consumption At Full Load 280g KW h Idling Speed 900 50r min Direction of rotation Counter Clockwise Look from power output LJ276M LJ276MT 2 Overall Dimension length width height 795 540 435mm 670 550 525mm LJ276M LJ276MT 2 Net Weigh Of Engine 86 kg 91kg Inlet Valve Gap 0 09 0 2 mm cold 0 15 0 2 mm hot ...

Page 4: ... Capacity 1 4L Type Of Water Pump Centrifugal Thermostat Wax Type Type Of Fan Belt AV10 840 Water Temperature 75 95 COOLING SYSTEM Type Of Air Filter ModelQK1706 00 Paper Element Type of Fuel Pump electromotion JB12D II 12V Model CSH101E Type Double Venturi tube Single Chamber Balancing Float Chamber FlatAbsorb FUEL SYSTEM CARBUREROR Type Of Choke Valve Manual Firing By battery Ignition Timing 10 ...

Page 5: ...Normally engaged helical gears synchronous at full speed Mode of operation Floor shift Crankshaft to Transmission main shaft Normally Engaged drive ratio 1 6 First Gear 2 413 30 14 Second Gear 1 318 29 22 Third Gear 0 862 25 29 Fourth Gear Transmission main shaft to Lay shaft Reverse Gear 2 25 27 12 LJ276M LJ276MT 2 First Gear 3 429 4 Second Gear 2 109 2 8 Third Gear 1 379 1 8 Fourth Gear 1 000 1 ...

Page 6: ...put Shaft Normal modulus Mm Tooth Number Z Normal Tooth Pressure angle Normal Tooth Stand off Measure Normal Line w k Measure Span M 20 874 1 2 Petrol Engine External Characteristic Curve The Petrol Engine External Characteristic Curve refer to fig 1 1 Fig 1 1 ...

Page 7: ...lug before water temperature drops 2 2 RUNNING IN OF NEW ENGINE The service life of engines depends greatly on their initial operating states When anew engine is installed in a vehicle The vehicle must be drive for 2500 km in accordance with running in specification The proposed running in specification is as follows Mileage km Load Speed 0 250 250 1000 1000 1500 1500 2500 No load 50 of Rated Load...

Page 8: ...freeze coolant is not used Feed hot water of above 90 into engine B Feed oil of 80 90 into engine The oil should be that which has been drained from engine previously Draining of oil should be done immediately after engine turn off so that oil is not contaminated Rotate crankshaft of warmed up engine by hand several turns so that cylinders suck in small amount of fuel Start engine and run it at id...

Page 9: ...hase angle between the No 1 cylinder and the No 2 cylinder is 360 degrees crank angle A Point for installing timing chain Rotate crankshaft to TDC position before installing timing chain Then align marks on timing sprocket of crankshaft and camshaft sprocket with the white and bright chain element respectively Now the locating pin in camshaft should be right at the top position refer to fig 3 1 B ...

Page 10: ...DERBLOCK ASSEMBLY AND BALANCE CHAIN Cylinder block is made of alloy cast iron which has high strength and is wear resistant In order to make operation of engine stable and to reduce vibration Advanced balancing mechanism is adopted The balancing mechanism consists of counter weights and balancing Shaft which are ocated on two sides of crankshaft respectively balancing shaft is driven by a chain On...

Page 11: ...Main points for installing balance chain A Rotate crankshaft to BDC position B Mark direction of counter weight on balancing shaft to be the same as that of counterweight on crankshaft fig 3 6 Fig 3 6 The position of counter weights and balancing shaft C Align the marks white and bright chain elements on two balancing shaft sprockets grooves respectively fig 3 7 Then install crankshaft sprocket an...

Page 12: ...each mark with connecting group number refer to fig 3 8 At the front end of the crankshaft fitted with balancing shaft drive pulley timing chain and belt pulley each used for drive balancing shaft camshaft water pump alternator the fly wheel with toothed ring fitted at the end of the crankshaft Fig 3 8 Connecting rod neck main shaft neck matching group number ...

Page 13: ...aring matching group number 1 2 3 4 3 2 1 5 4 3 2 Main bearing hole matching group number 6 5 4 3 Note 1 Main bearing matching group number main bearing hole matching group number main shaft neck matching group number 2 Upper and lower bearing should be fitted with the same group bearing set 3 4 PISTON AND CONNECTING ROD ASSEMBLY Piston is made of special aluminum alloy There are two gas rings and...

Page 14: ...pin boss hole matching group is in the table below Piston pin boss hole matching group Group and mark hole dimension Ф18 0 008 0 001 A 0 001 0 002 B 0 002 0 005 C 0 005 0 008 Requirement of piston pin external diameter matching group is in the table below Piston pin external diameter matching group group mark colored at internal hole Piston pin external diameter Ф180 0 009 A Red 0 009 0 006 B Yell...

Page 15: ...02 0 006 Connecting rod matching relation is in the table below Connecting rod matching relation Connecting rod neck group number connecting rod matching group 1 2 3 4 3 2 1 5 4 3 2 Connecting rod big end group number 6 5 4 3 Note 1 Connecting rod bearing matching group number connecting rod big end matching group number connecting rod neck matching group number 2 Upper and lower connecting rod sh...

Page 16: ...tor installation is as follows A Rotate crankshaft to TDC position Then use a screwdriver to turn the groove in shaft end of oil pump refer to fig 3 11 B Align the mark on distributor shaft with that on the housing refer to fig 3 12 C Align the flat tongue face on distributor shaft with the groove on shaft end of oil pump Slowly install the distributor into timing chain cover until its shaft inser...

Page 17: ... chain is lubricated by spraying of oil from nozzle Forced and splash lubrication system is used for engine Oil filter is convenient in use and easy in replacement with a one assembly structure Oil pressure is indicated by an oil pressure switch When oil pressure is under specified value the indicator is on 3 8 COOLING SYSTEM Engine is cooled by pressurized circulating water A centrifugal water pu...

Page 18: ...phragm spring plate is of normally pressurized drive type Transmission with synchronizer has four forward gears and one reverse gear All fears of the forward speeds are normally engaged helical fears Which have the advantage of stable in transmission Low noise and transmitted torque The structure diagram of transmission is shown in fig 3 13 ...

Page 19: ...ly designed and sealants are applied to main jointing surfaces Place which must be applied with sealants are shown in fig 3 15 3 16 3 17 Fig 3 15 The jointing surface between oil pan and cylinder block Fig 3 16 The front and rear sear sealing Fig 3 17 The jointing surface between surfaces of cylinder head cover cylinder block and timing chain cover ...

Page 20: ... Adjust if necessary F Check idling speed and ignition timing G Check gravity of electrolyte in battery or voltage of battery H Check connections of alternator regulator Ignition coils and spark plug for looseness I Check and adjust the free travel of clutch pedal 4 1 3 MAINTENANCE AFTER RORST 2500 KM A Carry out the maintenance mentioned in daily maintenance B Check the wear and tensioning of fan...

Page 21: ... then insert the dipstick and take out again The oil level must be between the upper and lower lines refer to fig 4 1 B Changing oil Proper selection and change of oil in accordance with the maintenance cycle are very important to ensure good operation and service life of engine Users should select oils in accordance with instruction strictly Don t mix and use oils of different brands Before repla...

Page 22: ...It is necessary to check tensioning of fan belt regularly Adjust tensioning if necessary refer to fig4 2 The appearance of fan must be good The excessively worn belt must be replaced without delay 4 2 3 FUEL SYSTEM MAINTENANCE A The air filter element must be replaced regularly in accordance with maintenance instruction and road conditions B The carburetor has been adjusted pre delivery and adjust...

Page 23: ...t the piston of No 1 cylinder at TDC position of compression stroke B Open distributor cover and observe the position of rotor head make the end with notch of contact set face forward fig 4 5 C Turn crankshaft again and check the cross firing moment across breaker contact points When cross firing happens the angle on the timing chain cover facing the boss mark of crankshaft is ignition timing D If...

Page 24: ...er Rotate crankshaft for 5 8 turns and install spark plug C Apply HDJ 2 special antirust grease to the surfaces of electrical contacts connects unplated metal surfaces and surfaces without paint D Loosen fan belt E Seal the water ports carburetor inlet and tachometer bushing with paraffin paper or plugs UNSEALING A Clear the water ports carburetor inlet and tachometer bushing with paraffin paper o...

Page 25: ... not work Fuel pipeline blocked or damaged Carburetor blocked fuel pressure in the float chamber is too low or wrong adjustment Mixture too rich ortoo poor Repair or replace Repair or replace Clean or readjust Adjust chock valve and fuel valve 1 Engine starting difficulty d Cylinder Compressi on pressure insufficient Cylinder gasket damaged Wrong valve clearance Leakage through valve and valve sea...

Page 26: ...ean Replace or repair Replace or repair Replace Adjust Replace 6 Oil consumption excessive Valve seal worn or damage The spring of the piston scraper ring reduce or piston ring openings do not stagger Cylinder worn Over heat or crankshaft case breathing blocked Replace Replace or adjust Repair Reduce heating or clean the orifices 7 Oil pressure too low Too much or too less oil Oil temperature too ...

Page 27: ...Replace Replace Clutch slip Clutch lining oily Clutch lining worn serious Remove clean Replace 11 Clutch problem Clutch vibration and noise Release bearing moving inefficient or worn No 1 shaft bearing moving inefficient or worn Clutch pin hub loosen Pressure plate and spring loosen Clutch pressure plate crack Clutch pressure plate crack Clean fill grease or replace Replace Repair Replace or repai...

Page 28: ...t direction clearance Shaft direction clearance 0 09 0 24 10 Exhaust valve seat and cylinder head Interference 0 112 0 153 11 Intake valve seat and cylinder head Interference 0 112 0 153 12 Exhaust valve and guide Clearance 0 04 0 07 13 Intake valve and valve guide Clearance 0 025 0 035 14 Rocker arm shaft and rocker arm hole Clearance 0 016 0 054 15 Oil pump external rotor and inner rotor Clearan...

Page 29: ...oner 49 0 58 8 5 6 Crankshaft pulley 49 0 58 8 5 6 Flywheel 40 0 45 0 4 1 4 6 Counterweight 24 5 29 4 2 5 3 Balancing sprocket 17 7 21 6 1 8 2 2 Con Rod Cover 34 3 39 2 3 5 4 Oil Pan plug 34 3 44 1 3 5 4 5 Oil filter 20 25 2 1 2 6 Spark Plug 10 8 12 7 1 1 1 3 Transmission Assembly M12 26 4 39 2 2 7 4 0 Transmission level plug 39 2 49 4 5 Transmission Drain Plug 39 2 49 4 5 cooling fan 4 9 7 8 0 5 ...

Page 30: ...e Surfaces Jointing t The Circumference of Cylinder block Top Surface And Timing Chain Cover Top Surface Ditto The Area With A Width Of 10mm on each side of Top Surfaces Of semicircle Oil Seals And The Area With A Width Of 10mm Jointing Cylinder head Top Surfaced Ditto Front and Rear Semi circle Oil Seals Of Cylinder head The Curved Surfaces Of Semi Circle Oil Seal Ditto ...