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Engine Zna Rich
Engine Zna Rich
SERVICE MANUAL
RCHRM2A21
QUICK REFERENCE INDEX
GENERAL INFORMATION GI
MAINTENANCE MA
ENGINE MECHANICAL EM
ENGINE LUBRICATION &
COOLING SYSTEM LC
CLUTCH CL
Y40F
MANUAL TRANSMISSION MT
TRANSFER TF
Engine for ZG24
PROPELLER SHAFT &
DIFFERENTIAL CARRIER PD
FRONT AXLE &
FRONT SUSPENSION FA
BRAKE SYSTEM BR
STEERING SYSTEM ST
RESTRAINT SYSTEM RS
ELECTRICAL SYSTEM EL
ZG24
Engine machnical
SECTION EM
Contents
1.ZG24Engine Outline
EM-1
ZG24
1. ZG24Engine Outline
EM-2
ZG24
EM-3
ZG24
EM-4
ZG24
EM-5
ZG24
EM-6
ZG24
2. ZG24 Engine characteristics curve
Effective torque
ti
Correction effective
Fuel consumption
Fuel consumption
Rt
Fuel consumption
Engine Speed(r/min)
EM-7
ZG24
3. Technical parameters of ZG24-type gasoline engine
Cylinder
diameter×stroke 95×86
( mm)
Total displacement
2.438
(L)
Idling speed(r/min) 750±50
Total power/rotation
102/4600~5000
speed(kW/ r/min)
Maximum
(Nm/ r/min)
SG-class 10W-30 or
Engine oil brand
15W-40
External dimensions
760×552×670
( mm)
EM-8
ZG24
4. Advanced performance overview of ZG24-type gasoline engine
gasoline engine is the system with Delphi MT20U2 engine control module
(ECM) at the core. Viewing from its functions, it has been able to meet
Diagnostic (EOBD).
(217N.m). Torque characteristic curve is smooth and the engine has well
of this engine meets requirements of Euro Ⅲ Regulation in one go. (It has
etc).
EM-9
ZG24
In overall arrangement: ZG24-type gasoline engine adopts
connecting rod (hole distance 135), water channel and oil duct with
aspect of accessories: oil pump and water pump attaching on sprocket room,
make accessories system have light weight and small volume; on aspect of
material selecting: aluminous cylinder cap and sprocket room, etc are
adopted, which further reduces weight of the complete machine (total mass
silicone oil clutch fan and other structures are adopted to improve
mechanical efficiency.
direction, in this way the spark plug can be put near the center of
EM-10
ZG24
combustion chamber, which is in favor of cyclic flame spreading and
in valve chamber; for engine block and cylinder cap design, its external
belt pulley and silicone oil clutch fan with rubber vibration isolator make
this engine have small vibration and low noise. Camshaft directly running in
ignition and electric control system is high and clear; overhaul of all parts is
EM-11
ZG24
Modern vehicle has a higher and higher performance requirement on
4-valve mechanism receives more and more attention, its advantages are:
(1) Air inlet flow area increases, flow resistance reduces, therefore,
coefficient of charge increases, pump gas loss reduces and torque per liter
is near hemispheric, spark plug can be put in position near the center, which
and realize fast burning. It can properly improve compression ratio and
(3) Moving parts of valve train have small mass, small inertia force and
overhead camshaft
EM-12
ZG24
Major advantages: (1)Valve mechanism is directly driven by double
reduces inertia mass, i.e. reduces inertia force of valve mechanism and
valve mechanism.
(2) It can reduce valve clearance and reduce noise to the maximum
extend.
engine speed.
(4) Small inertia mass of the structure enables valve to open and close
gear
thermal
EM-13
ZG24
expansion clocking, enough clearance must be left between two driving
ZG24 adopts the structure of gapless gear drive: the structure consists
of master gear and pinion. There is a torsion spring clamped between master
gear and pinion. Two ends of the torsion spring prop up two pins
respectively fixed on master gear and pinion. The torsion spring make tooth
flanks of master gear and pinion form a small angle. The form look like
scissors.
bigger, at this point, under the elastic force of torsion spring, the two tooth
flanks of master gear and pinion of gapless gear form a small angle to fill up
the clearance between driving gear and driven gear. Vice versa.
noise.
main parts
6.1 Assembly of
cylinder cap
EM-14
ZG24
components of engine. It mainly integrates main components and parts
(camshaft, valve and tappet, etc.) of valve mechanism and some components
and parts (e.g. spark plug, etc.) of ignition system, by which normal air inlet,
chamber; its spark plug lies in the center of combustion chamber; inlet and
injector is installed on
deadening.
dead center.
EM-15
ZG24
make timing mark of the pulley align at the mark of “0” on cap of sprocket
Dismantle high voltage line, spark plug, cylinder cap, ignition coil,
inlet manifold support strip, oil pipe and uncoupling cooling water bypass
hose, etc.
Dismantle bolt of
sprocket of admission cam shaft, camshaft bearing cap and camshaft from
EM-16
ZG24
Firstly screw off the 2 bolts in front of cylinder cap, as shown in
drawing.
Inspect worn condition of valve seat and whether there is damage and
if necessary, should reseat valve seat. At this point, should firstly inspect
worn condition of valve guide, if it has been worn excessively, should firstly
replace valve guide; then thin the valve seat with valve seat reamer or valve
seat grinder. Valve seat should be machined into the shape shown in the
drawing; the width of contact segment of valve seat and valve-face is 1.0
mm~1.4 mm.
Finally, grind valve and valve seat with valve grinding compound to
make it joint closely without air leakage. After grinding, completely clean
of valve guide.
replaced.
parts.
EM-17
ZG24
Assembly key points of cylinder cap parts
Valve and valve seat should be sealed reliably. After assembling spark
plug, fill the combustion chamber with coal oil and observe that there is no
When assembling valve oil seal, should not damage or scuff the lip;
when assembling the locker, should not scuff valve stem. When assembling
Assemble cylinder cap on engine block and fix it with pin bush. Apply
assemble cylinder
drawing).
bolts and screw down the 10 bolts as per sequence shown in the drawing.
EM-18
ZG24
Screw down force of the first time is 39N.m ± 4 N.m, screw down of the
2) Assembly of camshaft
When assembling camshaft, should firstly clean joint line and apply
appropriate amount of engine oil to shaft neck surface of camshaft; then, put
camshaft and camshaft bearing cap. Back and forth direction of camshaft
and sequence number and forward mark of camshaft bearing cap must be
correct and knock on camshaft bearing cap slightly with rubber ha mmer to
the designated position. Then apply a small amount of engine oil to screw
thread of camshaft bearing cap bolts, screw down with fixed torque wrench
Notice:
position upward; when assembling exhaust cam shaft, should align timing
mark on driving gear of admission cam shaft with that on gear of exhaust
cam shaft.
3) Assembly of timing
shaft
EM-19
ZG24
Lift sprocket and chains with hand. Meanwhile, rotate the crankshaft
until piston of the first and the fourth cylinders being put on the position of
top dead center. Rotate crankshaft to align timing mark on gear of admission
cam shaft with that on gear of exhaust cam shaft and make them on the same
upward); align the sprocket with the angle positioning pin on admission cam
shaft and assemble it, then assemble bolt and screw down.
4) Assembly of tightener
Loosen the pawl, completely press the gear rack in and cover the pin
hook on fixed pin to make the gear rack can not spring out; assemble
washer and tightener to the designated position together and screw down
with 2 nuts. Rotate the crankshaft to make pin hook of tightener come away
from fixed pin of gear rack, the gear rack will spring out and make the
EM-20
ZG24
5) Inspection and adjusting of valve clearance
Inspection of valve
clearance
Rotate crankshaft
compression. Inspect
Rotate crankshaft pulley for a circle and align the groove of pulley with
timing mark “0”, Inspect whether valve clearance shown in bottom part of
(cold state)
EM-21
ZG24
Press valve tappet down with valve clearance adjusting clamp and keep
clearance.
sequence: fan belt, silicone oil clutch (fan), water pump pulley, AC
generator, crankshaft pulley, oil pan, oil filter, sprocket room, cam shaft
timing sprocket,
shoe subassembly,
subassembly, crankshaft
timing sprocket.
EM-22
ZG24
Straighten the chain, and choose 3 to 4 positions to measure the total
Inspection of
sprocket is conducted as
minimum value of
mm.
Inspection of
subassembly.
Assemble cam shaft timing chain and admission cam shaft timing
sprocket.
EM-23
ZG24
When crankshaft timing sprocket is installed to crankshaft timing
sprocket, align black chain-timing mark of chain with timing rut mark of
Make sure that subassembly of crawler shoe and vibration damper plate
generator, water pump pulley, silicone oil clutch (fan), fan belt and cylinder
cap in sequence.
Cylinder body,
components of engine
assembled, is an
EM-24
ZG24
The indispensable working surroundings of engine are composed of cylinder
and cap. Engine can apply work outwards due to combustion chamber
composed of cylinder body and cap. And water jacket ensures engine
overwhelms wet liner. Cylinder body adopts fully supporting type, making
EM-25
ZG24
connecting-rod in right order. Don’t change the order when assembling.
When dismantling main bearing cap, main bearing bush, crankshaft and
Inspection of components
of cylinder body
clearance mm
clearance washer
EM-26
ZG24
94.995 mm~95.005 mm - If exceeding
cylinder or
replace cylinder
94.925 mm~94.935 mm -
94.945 mm~94.955 mm -
mm
Ring groove clearance Replace piston
No.2: 0.030 mm ~ 0.70 -
mm
EM-27
ZG24
piston pins and holes
head pore of
connecting rod
of connecting rod mm
axis of crankshaft
EM-28
ZG24
rear main axis hole of downward plane of cylinder body, and install them in
Notice: put bearing bush with oil holes into cylinder, and apply a little
As in the drawing, put thrust washer in the both sides of No. 3 main
EM-29
ZG24
As in the drawing, put lower thrust washer at the both sides of No. 3
main bearing cap of cylinder with oil groove outwards, and put main bearing
shown in drawing.
Before assembling main bearing cap bolt, should lay a little engine oil on
screwthread parts, and screw tightly main bearing cap bolt alternately from
Tightening moment is 39
N.m.
EM-30
ZG24
flexible tube, and apply a small amount of engine oil on the cylinder wall
EM-31
ZG24
and journal of crankshaft connecting-rod.
depression mark of piston align at the frontage of cylinder, and slightly push
direction of onward mark of connecting rod cap, and connecting rod cap and
29N.m. Mark at the foreside of nut end, and then rotate 90° to further tighten
each nut.
requirements.
EM-32
ZG24
6.4 Cooling system
drawing.
Keep adequate coolant in the water tank. If using antifreeze, please mix
for the first time, add or replace coolant fully. Add more after generator
necessary.
EM-33
ZG24
Examine and adjust tightness of fan belt. Press in the middle of belt
Ensure that groove of fan belt and belt wheel is in good joint. As shown
in the drawing.
Examine thermostat.
88℃ ~ 76℃
Temperature of starting
valve: 88℃~76℃
Lifting height of
88℃
Examine status of water pump and timing sprocket room about crack or
EM-34
ZG24
hurt of joint line, and examine whether water pump bearing rotates flexibly
(there is oil line to cylinder body) are lubricated; sprocket, chains and
tightening mechanism are lubricated by oil injector in main oil duct; valve
tappet, valve, bore hole, piston pin and pinholes and so on are lubricated by
splashing.
EM-35
ZG24
Internal rotator of oil pump stirs external rotator to make it move eccentric
space. Oil will be extracted from oil pan to working room of oil pump by
negative pressure produced, while positive pressure will push oil to main oil
duct. If there is fault in oil pump: 1. if foreign matters exist and oil pump is
ja mmed, camshaft and distributor block tooth will be damaged; 2. when oil
pressure is not rather little, it will cause each motive part of engine makes
even damage of accessories. Oil filter is a device of filtering oil, which can
oil duct. When oil pump is working, in oil duct, there should be lubricating
with certain
pressure ensuring
every component of
engine in normal
lubricating
condition, and
EM-36
ZG24
pressure of lubricating oil in duct will rise to push the slice in alarm.
Meanwhile, cut off, and if the driver sees that the indicator lamp is off, he
normal condition.
sealant is about 3.5 mm, and the sealant should be even and
continuous.
crankcase ventilation and waste air of EGR evenly to each cylinder, and
waste air discharged from each cylinder of engine to lead it into exhaust
main.
aluminum alloy and long independent air duct of each cylinder; exhaust pipe
is steel pipe and has the properties of excellent thermal stability and liability,
EM-37
ZG24
EM-38