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Vantage Engine Service Manual
Vantage Engine Service Manual
Vantage Engine Service Manual
ENGINE SERVICE
MANUAL
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DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
VANTAGE VEHICLE INTERNATIONAL, INC.
Contents
Chapter 1 Performance and structural parameters of the petrol
engine ....................................................................................................- 9 Section 1 Performance and structural parameters of the petrol engine
.......................................................................................................- 9 Section 2 Full load performance curve of the gasoline engine. ..- 11 Chapter 2 Operation of the petrol engine .......................................- 13 Section 1 Brief introduction ............................................................ 13
Section 2 Notice on operation of the engine ................................... 15
Section 3 Run-in of the new gasoline engine .................................. 19
Chapter 3 Maintenance of the gasoline engine ................................... 21
Section 1 Maintenance of the lubrication system............................ 21
Section 2 Maintenance of the cooling system ................................. 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 ........... 27
Section 7 Maintenance of the Ignition System................................ 30
Section 8 Maintenance of Spark Plug ............................................. 30
Section 9 Maintenance of Positive Crankcase Ventilation valve
(PCV valve) ..................................................................................... 30
Chapter 4. Regular check of the gasoline engine................................ 31
Section 1 The maintenance period and items .................................. 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 start ............................................................... 34
Section 2 Idle speed too high........................................................... 35
Section 3 Power insufficient during running................................... 35
Section 4 Knock inside the engine .................................................. 36
Section 5 Engine overheating.......................................................... 36
Section 6 Excessive oil consumption .............................................. 36
Section 7 Difficulty in shifting gears............................................... 37
Section 8 Noise inside the clutch .................................................... 37
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DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
VANTAGE VEHICLE INTERNATIONAL, INC.
Figures
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DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
VANTAGE VEHICLE INTERNATIONAL, INC.
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DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
VANTAGE VEHICLE INTERNATIONAL, INC.
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DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
VANTAGE VEHICLE INTERNATIONAL, INC.
DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
VANTAGE VEHICLE INTERNATIONAL, INC.
DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
VANTAGE VEHICLE INTERNATIONAL, INC.
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DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
VANTAGE VEHICLE INTERNATIONAL, INC.
65.5mm
72mm
8. 8 : 1
65.5mm
78mm
9. 0: 1
995cc
35.5/31kW
74/68N=m
30003500r/min
275/300g/kW=h
1051cc
38.5/34kW
83/76N=m30003500r/min
275/300g/kW=h
5000r/min
5200r/min
85050r/min
85050r/min
At idle speed
CO0.5% HC100PPm DB11/044-1999
At high idle
CO0.3% HC100PPm DB11/044-1999
Emission
speed
In NEDC cycle
CO2.2 g/km HC+NOX 0.5g/km ECE96
Sense of rotation
Counter clockwise (viewed from backside)
1342
Ignition sequence
Oil pressure
Fuel
Oil
Gear
box
Clutch
Coolant
0.2940.539MPa3.05.5kgf/cm2 3000r/min
Lead free gasoline RON90 (GB19730-1999 )or higher
Selected according to the temperature of the region where
the engine is operated GB11121-1995
Glycol water solution or soft water
Model
Overall dimension
Weight
gear ratio
Gear 21.948
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DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
VANTAGE VEHICLE INTERNATIONAL, INC.
Type
Overall dimension
Weight
Lubrication oil
Gear 31.383
Gear 31.424
Gear 41.000
Gear 50.806
Gear 41.000
Gear 5: 0.795
Reverse gear
Reverse gear
3. 505
3. 466
Gear meshing type, all with synchronizer ,
1 reverse gear.
5 forward gears
5 forward gears
LWH
LWH
477.5270287.4mm
535. 5390.4276.3mm
16kg
28kg
The Rated power, Max Torque and Min. fuel consumption index of the petrol
engine is gross power/net power.
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.
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DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
VANTAGE VEHICLE INTERNATIONAL, INC.
gross power
net power
Fig.10 Full load performance curve of the DA465Q gasoline engine.
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DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
VANTAGE VEHICLE INTERNATIONAL, INC.
gross power
net power
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DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
VANTAGE VEHICLE INTERNATIONAL, INC.
DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
Vantage Vehicle International, Inc.
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DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
Vantage Vehicle International, Inc.
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and
maintenance
Operation
manual
Coolant
DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
Vantage Vehicle International, Inc.
Oil
Fuel
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DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
Vantage Vehicle International, Inc.
Idle speed
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In raining condition or
across water area
Water is an 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
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DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
Vantage Vehicle International, Inc.
engine in winter
In winter the temperature is
relatively low, the oil viscosity is
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.
Gasoline piping
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Fuel injector
DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
Vantage Vehicle International, Inc.
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Fault indication
DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
Vantage Vehicle International, Inc.
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.
speed position of
gearbox
Gear 1
Gear 2
Gear 3
Gear 4
Gear 5
Car speed
10kmh
20kmh
35kmh
55kmh
65kmh
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DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
Vantage Vehicle International, Inc.
lubrication system
1
10W
-30
5W
-30
5W
-20
0
-30
-20
10 20 30 40 50 60 70 80 90 100 110
-10
10
20
30
40
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DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
Vantage Vehicle International, Inc.
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DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
Vantage Vehicle International, Inc.
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DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
Vantage Vehicle International, Inc.
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DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
Vantage Vehicle International, Inc.
Coolant renewing
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DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
Vantage Vehicle International, Inc.
belt.
Appearance
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DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
Vantage Vehicle International, Inc.
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.
2
Gasoline
filter
for
conventional
carburetor
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 the
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DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
Vantage Vehicle International, Inc.
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.
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
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Camshaft
timing belt
crankshaft
Fig. 34.
Maintenance of valve
mechanism
DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
Vantage Vehicle International, Inc.
Timing belt
Check the timing belt in
accordance with the requirements of
table 4, and if there are cases similar to
those listed in the table, locate the
causes and eliminate them in time. For
No.
1
2
3
4
6
7
8
9
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Description of failures
Hardening of the belt surface
The back of the belt is bright, has no longer resilience and is
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.
Teeth wore (final stage)
The fiber cloth on the edge of load wore out
The rubber exposed (tooth thickness reduced)
Teeth roots cracked
Teeth detached
Lateral face of the belt wore
Lateral face of the belt cracked
DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
Vantage Vehicle International, Inc.
S p a r k p lu g g a p
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DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
Vantage Vehicle International, Inc.
Chapter 4.
2.5 10
20 30
40 50
60 70 80
12 18
24 30
36 42 48
A
T
A
T
A
T
A
T
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DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
Vantage Vehicle International, Inc.
Note:
Whether you are a expert or not, we recommend the items marked with an
asterisk * 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
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
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Description
cylinder head screws
nuts for air inlet and outlet manifold
spark plug
screws for driven timing gear
nuts for adjusting valve gap
screws for driving timing gear
nuts for connecting rod bearing cover
screws for crankshaft bearing cover
flywheel screws
screws for oil pan
oil drain plug
screws for valve cover
screws for cover of timing belt
fixing screws for oil pump
tightening torque
Nm
kgfm
53.9~58.8 5.5~6
17.7~22.6 1.8~2.3
19.6~29.4 2~3
49.0~58.8 5~6
14.7~19.6 1.5~2
49.0~58.8 5~6
27.5~31.4 2.8~3.2
42.2~47.1 4.3~4.8
39.2~44.1 4.0~4.5
3.92~4.90 0.4~0.5
19.6~24.6 2.0~2.5
3.92~4.90 0.4~0.5
2.94~3.92 0.3~0.4
7.85~9.81 0.8~1.0
DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
Vantage Vehicle International, Inc.
15
16
17
18
19
20
21
22
23
24
25
26
1
2
3
4
5
6
7
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1.2~1.5
2.0~2.5
1.8~2.3
1.8~2.3
24.5~29.4
14.7~22.6
2.5~3.0
1.5~2.3
15~20
38~46
8~10
1.5~2.0
3.9~4.7
0.8~1.1
Section 3
No.
11.8~14.7
19.6~24.5
17.7~22.6
17.7~22.6
0.8~1.1
0.8~1.1
1.5~2.0
Description
tightening torque
N.m
kgf.m
gearbox 14.7~19.6 1.5~2.0
29.4~49.0
14.7~19.6
3.0~5.0
1.5~2.0
8.83~11.8
0.9~1.2
5.88~9.81
0.6~1.0
14.7~19.6
19.6~24.5
1.5~2.0
2.0~2.5
DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
Vantage Vehicle International, Inc.
cylinder block
Section 4
No.
1
Description
screws for clutch housing
tightening torque
N.m
kgf.m
17.7~27.5 1.8~2.8
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Remedy
Retighten or recharge
Check and correct
Repair or replace
Repair
Replace
Readjust, clean
replace
Repair or replace
Check and repair
Replace
Replace
Replace
Repair or replace
Replace or clean
Readjust or replace
Mount or replace
Replace or Readjust
or
DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
Vantage Vehicle International, Inc.
Replace
Check and repair
Repair or replace
Replace
Readjust, repair
replace
Repair or replace
or
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
Replace
Section 3 Power insufficient during running
1 improper adjustment of accelerator pedal and Adjust
throttle body wire.
2 reduction of cylinder compression force
check leakage of
valve, sparkplug and
cylinder gasket
grind the cylinder
bore
3 ignition timing not accurate
Adjust
4 fuel pressure regulator is damaged, so gasoline Adjust or replace
supply is insufficient
5 insufficient intake air
Check air intake system
6 exhaust system stocked
Check exhaust system
and remove carbon
deposit
7 improper gap or defective spark plug
Adjust, clean or replace
8 injector blocked or damaged
Clean or replace
9 fuel filter blocked
Replace
10 throttle position sensor damaged
Replace
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DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
Vantage Vehicle International, Inc.
Repair or replace
Replace
Replace or repair
Replace
Adjust
Adjust
adjust
adjust or clean
tighten or purge
adjust
replenish or purge
repair or adjust
replenish
unblock or replace
replace
repair or replace
clean up or replace
DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
Vantage Vehicle International, Inc.
replace
adjust
replace
replace
check
components
troubleshoot
concerned
and
replace
replace
replace
repair or replace
replace
replace
repair
replace
repair or replace
clean up or replace
replace
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DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
Vantage Vehicle International, Inc.
Chapter 6.
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 217# anti-rust oil and rotate the
engine 3 ~5 revolutions, then retighten the spark plugs with
specified tightening torque and plug the exhaust pipe.
4. Wrap the connections of the throttle body, the water inlets and
outlets of the engine, the bush of the tachometer or plug them
well.
5. Put the engine into packing box.
1.
2.
3.
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DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
Vantage Vehicle International, Inc.
Sales department
User comments
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DELPHI EMS series gasoline engine Operation and Maintenance Instruction Manual
Vantage Vehicle International, Inc.
No. of the
engine
unsealing date
Date
of
manufacture
Total operation
time or mileage
User name
comments and suggestions (in detail):
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