Chery Engine SQR372

CHERY CHERY SQR7080R SERVICE MANUAL

I

ENGINE-MECHANICAL

CHERY AUTOMOBILE AUTOMO BILE CO., LTD

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CHERY SQR7080R SERVICE MANUAL

372 ENGINE-MECHANICAL

SERVICE CONTENT TYPE

SQR7080R

SQR7080R ENGINE-MECHANICAL ENGINE-MECH ANICAL

DECEMBER 2005

Please write down the changes notice after each assembly numbers, the function is to remind the users there are changes and the technical department will inform the correlated department keep them in archives for checking. ASSEMBLY

1

TECHNICAL CHANGES NOTICE

Mount the engine on the roll over stand

2 Disassembly , assembly and repair of frontal frontal drive parts of engine 3

Valve train tra in

4

Cylinder head

5

Cooling System

6

Lubrication system

7

Crankshaft connecting rod mechanism

The service man must master the technical improvement conditions of this car to provide better maintenance work.

COPY RIGHT: AUTOMOTIVE ENGINEERING & RESEARCH INSTITUTE CHERY AUTOMOBILE CO., LTD. ALL RIGHTS RESERVED




SERVICE CONTENT TYPE

SQR7080R

SQR7080R ENGINE-MECHANICAL ENGINE-MECH ANICAL

DECEMBER 2005

Please write down the changes notice after each assembly numbers, the function is to remind the users there are changes and the technical department will inform the correlated department keep them in archives for checking. ASSEMBLY

1

TECHNICAL CHANGES NOTICE

Mount the engine on the roll over stand

2 Disassembly , assembly and repair of frontal frontal drive parts of engine 3

Valve train tra in

4

Cylinder head

5

Cooling System

6

Lubrication system

7

Crankshaft connecting rod mechanism

The service man must master the technical improvement conditions of this car to provide better maintenance work.

COPY RIGHT: AUTOMOTIVE ENGINEERING & RESEARCH INSTITUTE CHERY AUTOMOBILE CO., LTD. ALL RIGHTS RESERVED




PREFACE

Dear technicians and mechanics for SQR372 engine maintenance, maintenance, You are suggested to read this manual before service and operate in accordance with the specification of manual. 1)

The manual manual supplies you you with the informat information ion of accessories, such as special tools, measures and grease. You should, by all means, prepare for this kind of accessories fully before service.

2)

Of course, we leave out the general tools, such as lifter lifter and spare parts, because because they are absolutely necessary for you.

3)

We provide provide the structural diagrams diagrams of main machines, the assembly views views of every part and their names before their service introduction. It is the reference for you on disassembly and assembly. assembly.

4)

In structural diagrams, the numbers of parts, such as , !, "#, is the sequence numbers of disassembly; the assembly steps are a re reverse to those t hose for disassembly. disassembly.

5)

The parts with a mark *! in the structural diagrams can not reused and they should be replaced in assembly.

6)

We leave out out the operations of related service tools in this manual but you you should pay attention to them during service.

7)

We leave out the operation requirements for cleaning cleaning and checking the parts in this manual. You should meet the operation requirements for cleaning and checking the parts by all means.

8)

There is no specification specification of visual inspection inspection in the manual manual but it it is a necessary element for service personnel.

Pay attention to the items above and operate please. Anyone should not new-model the manual, such as copy, edit and print without the permission of authority by the editor and we reserve the right to amend any clause at any given time.

1




TABLE OF CONTENTS DEFINITION ................................................................................................................................................3 THE MEANING MEAN ING OF MARKS AND ABBREVIATIONS ..........................................................................3 SQR372 ENGINE STRUCTURE AND PERFORMANCE PARAMETER ............................................4 ............................................4 SPECIAL MAINTENANCE TOOLS .........................................................................................................5 REMOVE THE ENGINE FORM VEHICLE ............................................................................................7 1 MOUNT THE ENGINE ON THE ROLL OVER STAND ...............................................................9 2 DISASSEMBLY , ASSEMBLY AND REPAIR OF FRONTAL DRIVE PARTSOF ENGINE .....10 2-1. STRUCTURE DIAGRAM OF FRONT TRANSMISSION TRANSMISSI ON PART ....................................10 2-2 to 2-4. DISASSEMBLY & ASSEMBLY OF ENGINE FRONT TRANSMISSION PART ...10 3. CAMSHAFT ...........................................................................................................................................17 3-1 STRUCTURAL DIAGRAM(DISASSEMBLY OF TIMING BELT AND ASSEMBLY OPERATIONS ARE CARRIED AS THE FOLLOWING VIEW.) VIEW.) ................................................17 3-2 to 3-5. DISASSEMBLY & ASSEMBLY OF CAMSHAFT ......................................................18 4. CYLINDER HEAD ............................................................................................................................25 4-1 STRUCTURAL DIAGRAM OF CYLINDER HEAD .........................................................25 4-2 to 4-6. DISASSEMBLY & ASSEMBLY OF CYLINDER HEAD ...........................................26 5. WATER PUMP...................................................................................................................................33 5-1 STRUCTURAL DIAGRAM D IAGRAM OF WATER WATER PUMP ................................................................33 5-2 to 5-5. DISASSEMBLY & ASSEMBLY OF WATER PUMP..................................................34 6. LUBRICATION SYSTEM.................................................................................................................34 6-1 STRUCTURAL DIAGRAM ..................................................................................................34 6-2 to 6-6. DISASSEMBLY & ASSEMBLY OF WATER PUMP..................................................36 7. CRANKSHAFT CONNECTING ROD MECHANISM..................................................................42 7-1 STRUCTURE DIAGRAM .....................................................................................................42 7-2 to 7-5. DISASSEMBLY & ASSEMBLY.....................................................................................43

2


CHERY SQR7080R SERVICE MANUAL 1.

2.


DEFINITION

Standard

Refers to allowed value during inspection, maintenance and adjustment.

Limit

Refers to the maximum or minimum value that should not be exceeded during inspection, maintenance and adjustment.

[Reference]

Set the standard value for simple measurement to prevent from its measuring difficulty and inconsistency to facts.

Difference

It refers to the difference between maximum value and minimum value.

Note

It carries the cases of damaging the vehicle and parts so you should pay attention to the operation description.

Warning

It records the operation descriptions of cases about person accident.

THE MEANING OF MARKS AND ABBREVIATIONS

Mark

Original words

Translated words

RH

Right Hand

!

LH

Left Hand

"!

FR

Front

#

RR

Rear

$

IN

Intake

%&

EX

Exhaust

'&

SAE

Society of Automotive Engineers

()*+,-./0

API

American Petroleum Institute

()12/0

SST

Special Service Tool

34. 56,7

T

Torque

89

Ay

Assembly

:;<=

S/A

Sub Assembly Assemb ly

<=

W/

With

><=?@ABC

M/T

Manual Transmission

DEFGH

A/T

Automatic Transmission

IEFGH

T/C

Turbo Charger

JKH

3




SQR372 ENGINE STRUCTURE AND PERFORMANCE PARAMETER

Model

SQR372

Type

VerticalL3-cylinder L4 strokeLwater coolingL in-line double overhead camshaft. Multipoint electronic control oil sequential injection

Cylinder diameter (mm)

72

Piston stroke (mm)

66.5

Displacement (ml)

812

Compression ratio

9.5:1

Rated power (kw)

38

Revolution at rated power (r/min)

6000

Aximum torque (N #m)

70

Revolution at max. torque (r/min)

3500~4000

Minimum fuel consumption rate (g/kw#h)

275

Lubricant(designation)

10W/30

Lubricant volume(L)

2.4

Fuel RON

93#

4




SPECIAL MAINTENANCE TOOLS:

Outside view

Symbol/Name

Purpose

Engine disassembly and inspection auxiliary device

Mount on the engine service stand

Engine service stand

Disassembly and assembly of engine

Clamp hole wrench for camshaft timing gears

Disassembly of camshaft timing gears

Spring bushing puller

Assembly of camshaft Oil seal

Valve keeper remove tool Assembly and disassembly of valve spring retainer lock Auxiliary tools

Flywheel clamp

Assembly and disassembly of crankshaft gear

Valve guide punch pin

Disassembly and assembly of valve guide

Axial oil seal replacing device

Oil seal seat screw driver

5



Outside view


Name or symbol

Purpose

Crankshaft pulley holding tool

Disassembly and assembly of crankshaft pulley

Wrench

Disassembly and assembly of camshaft driven gear Replace valve lash adjustment shim

Measuri ng tools

Water pump pulley locking wrench

Assembly of coolant pump

Engine landing frame

After lifting the vehicle, Take the engine under vehicle

Feeler gauge. Micrometer caliper. Ruler. Dial gauge. Cylinder gauge. Caliber. Pressure gauge. Torque wrench torque wrench

Tool

Piston ring extractor

Oil

Engine Oil. Bonding agent

6




REMOVE THE ENGINE FORM VEHICLE



Turn off the ignition switch;

!

Pull off the power supply wire and ground wire.

$

Open the cap of coolant overflow pot

"

Pull off all plugs connected to engine;

Absolute pressure sensor.stepmotor. Throttle $ position sensor. Reverse switch. Coolant temperature sensor. Oxygen sensor. Speedometer $ sensor %

Remove the connecting plug of ECU

Camshaft position sensor. Injector. Dynamo $ wire. Starter wire. Crankshaft position sensor. Transmission ground wire. Air conditioner (AC) $ connection. Steering power pressure sensor wire and so on.

Disassemble the air intake pipe and air cleaner;

Power supply

Ground

Arrange all the cables in order. Disassemble the throttle cable;

Disassemble the fuel supply pipe: air intake pipe. (oil return pipe), take the spattering fuel; Pull Off Clutch Cable On Vehicle

& Remove the transmission;

Transmission Cable

control

cable

of

$

Disassemble the clutch cable (That could be done under the vehicle after lifting vehicle.)

$

Disassemble the conjunction pipeline and the control cables.

'

Disassemble the connecting bolts for the steering booster pump and air compressor and the engine (25Nm). Do not remove the conjunction pipeline. And bend them on the radiator bracket.

Lift the vehicle

(

Disassemble the front exhaust pipe.

$

Disassemble the stabilizer bar and lever.

$

Disassemble the back plate (12Nm).

7



$

$

Disassemble the connection for the ) lower support girder of radiator and the vehicle frame and radiator; $ Remove the clutch cable


Take down the left / right inner side gear from differential. Remove the rocker outer ball section and pry out the left/right side gear;

*

Remove the drain plug and drain oil. And take oil with special container, rotate the drain plug back. (Drain oil finally and prevent from spattering oil.)

$

Disassemble the connector of coolant exhaust pipe (lowest pipe connector), drain coolant, and take coolant with special barrel for reusing (drain water finally and prevent from spattering water).

3# Right Front Engine Mounting

Let the vehicle down and place the engine landing frame on the proper position.

1# Right Rear Engine Mounting

Put down the vehicle and take the engine by wheel contacting with ground support.

4# Left Rear Engine Mounting 2# Left Front Engine Mounting

$

Remove the coolant pipe and warm blast pipe.

+

Make sure that the wheels are on the ground and the engine is supported, and then disassemble the engine mounting: the connecting bolt for 1# (75Nm).3#.4# and vehicle frame. (45Nm)

Lift the vehicle on the engine landing frame.(as the arrowhead shows)

Disassemble the transmission (60Nm). Loosen the suspension of 1#, 2#, 3# and 4# (45Nm).

8


CHERY SQR7080R SERVICE MANUAL 1


MOUNT THE ENGINE ON THE ROLL OVER STAND

Disassemble or assemble the engine with roll over stand. Disassemble or assemble the engine parts on the roll over stand.

9




2 DISASSEMBLY, ASSEMBLY AND REPAIR OF FRONT DRIVE PARTS OF ENGINE

2-1. STRUCTURE DIAGRAM OF FRONTAL DRIVE PARTS M

Water pump pulley

N

Timing Cover

O

Timing Belt

P

Torsional Damper

Q

Belt Back Plate

R

Tension Pulley

S

Crankshaft Timing Pulley

TUThe Parts Can Not Be Reused. UnitU N#M(Kg#Cm)

2-2. DISASSEMBLY

1. Disassemble The Water Pump Pulley Remove the water pump pulley as the view showing. It will be better of disassembling with special tool.

10




If without special tool, disassemble with screw driver and wrench as the view. 2. Disassembly Of Torsional damper (1) Prevent the gear ring from rotation with special tool;

Special Tool

(2) Remove the fixing bolt of torsional damper.

3. Disassembly Of Timing Cover Torque: 6$1n.M Remove the timing belt back plate.

11




4. Disassembly Of Tension Pulley Timing Mark

MakeTiming Mark !

(1) Compress the top dead center at the first cylinder piston.

Rotate Clockwise

(2) After disassembly of timing cover, pull the bolt and clockwise rotate the timing gear with wrench. And then align the timing mark of camshaft timing gear and the raised mark on camshaft cover; Note:VOnly rotate the engine clockwise after mounting the belt W V Before disassembly, an arrow should be

marked on the timing position in order to mount as original condition. (3) Confirm if the mark of crankshaft timing pulley tallies with the timing mark on oil pump.

Timing Mark

(4) Screw off the bolt of tension pulley and remove the tension pulley.

5.

Disassembly Of Timing Belt

Note: Do not use sharp tools like screwdriver during disassembly of belt. Note: Pay attention to the following items during using the timing belt: VDo not bent the belt with small angle, or t he

rigging in belt will break. VDo not pollute grease and water because the

using expectancy of belt is short. V Only clockwise rotate the engine after

mounting the belt. 6.

Disassembly Of Crankshaft timing gear

12




2-3. INSPECTION

1. Check The Timing Belt Carefully; Replace With The New Parts If Any Following Situation Occurs. (1) Chap of back-side rubber (2) Chap of dedendum, chap of separated cord fabric. (3) Wearing, gear missing and incomplete gear of cord fabric. Chap Wearing

Chap

(4) Abnormal wearing of belt flank.

Gear Missing

Abnormal Wearing Belt Core Desquamation

Note: Replace the belt as any following situation occurs, even though abrasion cannot be found directly.

(1) The water pump leaks water out, and requires continuing infusion. (2) If the belt is spotted with much oil stains, and the rubber may be damaged due to expansion, you should replace the belt.

Timing belt model and type Part number

372-1007081

Width of belt

25.3mm

13



2.


Tension Pulley Of Timing Belt

Rotate the bolt of tension pulley bracket and hear if it is noisy; check the contacting surface and look if it is damaged. Model and type of tension pulley of timing belt Part number

372-1007030

Width

27.0mm

Outer diameter

%50mm

Check if the out is damaged. Timing belt model and type Type

EF

Item

GL. ZL. GS. ZS

Camshaft timing pulley diameter (mm) Camshaft timing pulley diameter (mm)

3.

%110.7

+0.1

-0.2 +0.7 %54.65 -0.13

Timing Belt Back Plate.

Check if it is deformed. Standard size of U Width

28.6mm

2-4. ASSEMBLY

Assembly 1. Aassembly Of Crankshaft timing gear

Timing Mark

2. Assembly Of Timing Belt (1) Confirm about the position of first cylinder compression top dead center. Mount the camshaft timing gear on the front of exhaust camshaft in order to align the gear locating groove and the locating pin on camshaft. Fix the camshaft timing gear with bolts and the tightening torque of bolt is 100$5Nm.

14




(2) Make sure that the clashing mark of crankshaft timing pulley aligns with the mark of oil pump.

Timing Mark

(3) Assemble the timing belt by the mark of disassembly.

Timing Mark

Rotate Clockwise

3. Disassembly Of Tension Pulley (1) Adjust the tensile force of timing belt.

About 8mm



As the view, swing the tensioner to the right with screw driver so that the distance between the edge of tension pulley and the water pump housing cycle is about 8mmW

N

Screw down the bolt of tension pulley and the tightening torque is 25 $3Nm.

O

Rotate the crankshaft 2 cycles as the engine rotating direction. And camshaft timing gear and crankshaft timing gear both tally with the timing mark.

15



P


When pressing the mid of right 5mm, the force should be:

[Reference] 20X30 N Note: when the deflection can not reach the standard, it is necessary to adjust the fixing bolt of tension pulley mentioned above.

Screw down the bolts of tension pulley assembly with specified torque. Torque: 25$3N.m

4. Assembly Of Timing Belt Back Plate. Outside

Note:

Inside

5. Assembly Of Timing Cover Torque: 6$1N.m

6. Mount Torsional Special Tool)

Damper

(With

(1) Without flywheel



Hitch the part of crankshaft pulley with the belt of special tool.

N

Make the handle of special tool still(fixing) and do not rotate the belt. Screw down the bolt with specified torque:

Special Tool

Torque: 98.0$10N.m{10 $1kgm}

(2) With flywheel



Prevent the gear from rotating with special tool.

N

Then screw down the bolt of torsional damper.

Special tool

16




7. Assembly Of Water pump pulley Torque: 6$1N.m

It will be better to disassemble with special tool. If without special tool, disassemble with screw driver and wrench as the view.

3. CAMSHAFT 3-1 STRUCTURAL DIAGRAM (DISASSEMBLY OF TIMING BELT ASSEMBLY OPERATIONS ARE CARRIED AS THE FOLLOWING VIEW.)

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15)

AND

Cylinder head chamber cover assembly Cylinder head cover gasket Camshaft timing belt Camshaft cover Blanking cover Camshaft bearing cap Exhaust camshaft assembly Intake camshaft assembly Camshaft Oil seal Axial spring retainer ring Saddle washer Intake camshaft sub gear Transmission ring Lock nut Connecting flange Can Not Be Reused

17




3-2 DISASSEMBLY

1. 

! 2.

Disassembly of cylinder head chamber cover assembly Screw off the bolt of cylinder head cover from both sides to the middle in symmetry. Remove the cylinder head cover gasket.

Inspection Of Valve

Standard valve lash: Valve lash

IN

0.18$0.05

EX

0.25$0.05

3. Remove The Camshaft Timing Gear With Special Tool. Note: Must use the special tool to prevent the camshaft from rotating.

4. Disassembly Of camshaft Bearing Cap And Camshaft Cover

Exhaust

(1) Check if the timing mark on camshaft gear is tallied, as the picture, as can be seen from the picture.

Intake

(2) Position the main sub gear on intake camshaft with bolts, as can be seen from the right picture.

Bolt for fixing

Note: For eliminating the radical force, try to disassemble when the camshaft becomes base circle (prevent from damages as too much radical force )

(3) Screw off the bolt by the order of right picture Remove the camshaft bearing cap

(4) Remove the spark plug

18




(5) Disassemble the camshaft sub gear and the special tool will be needed, as can be seen from the picture.

Special Tool

Clamp the camshaft and plug the pins of special tool into the hole on gear; Rotate the gear to keep the meshing of driven gear and driving gear, and then remove the fixing bolt of driven gear. Note: Do not damage the surface of camshaft.

(6) Disassemble the axial elastic retainer ring with tensioner and remove the saddle spring washer, transmission ring, and so on. 3-3 INSPECTION OF CAMSHAFT 1

Measure The Camshaft With Micrometer Caliper. If It Is Below To The Specified Limit, Replace With A New One. Camshaft journal

Unit:mm Type

Item Standard value Limit

2 (1)

IN EX IN EX

EF ZL.RL GL.GS.ZS -0.02 %23.0 -0.033 -0.02 %23.0 -0.033 %22.9 %22.9

Inspection Of Camshaft Axial Clearance Replace the camshaft when the axial clearance value measured with dial gauge exceeds the standard value.

The axial clearance of intake camshaft is 0.1 X 0.170mm. The axial clearance of exhaust camshaft is 0.1 X 0.173mm. Using limitU0.18mm 3-4 CLEAN

1. Brush Away The Spark plug carbon deposits With The Metal Brush Etc.

19




3-5 ASSEMBLY Special Tool

M With special tools, fix the the 2 holes &6 of camshaft gear assembly. N Rotate the driven gear to the right with special tool and tally the mark hole of driven gear with that of camshaft driving gear, or their marking way complies with each ot her, fix the driven gear with bolts.(ThreadUM5WThread pitchU0.8) 2.

Assembly Of Camshaft

Note: the size the camshaft axial clearance

(1) Spread grease on the gear of camshaft and the axial of cylinder head. (2) Remove the fixing bolts for camshaft driven gear after mounting the camshaft. (3) It is needed to measure the size of camshaft axial clearance. (4) Mount the camshaft; align the timing mark as can be seen from the right picture. Exhaust

Intake

(5) Spread oil fully on the cam of camshaft assembly, gears and axial of cylinder head. 3. Tighten the camshaft bearing cap by the order of right picture.

20




4. Screw off the fixing bolts for driven gear of intake camshaft assembly. Bolt For Fixing

5. Assembly Of Camshaft Cover Spread sealant on the position (slot) of camshaft cover as can be seen from the right picture.

Line For Spreading Sealant

Screw down the bolts with specified torque in the order of picture.

6. After spreading oil on the blanking aperture of cylinder head and the mounting surface of blanking cover, press the blanking cover with special tool. Note: Mount the blanking cover in the direction as can be seen from the right picture. Outside

Blanking cover should align with cylinder head after pressing. 7. After spreading oil on the hole of cylinder head oil seal, the edge of camshaft oil seal and outer ring, press m10 bolt and special tool into cylinder head at the place 1 mm below cylinder head.

Special Tool

Note: #Spread the engine oil attachment when reusing and press in Oil seal without deflectionW

8. Assembly Of Camshaft Timing Gear After spreading sealant on the bolt, prevent it from rotating with special tool and screw down the bolt of camshaft timing gear in specified torque. Torque: 100$5N.m 21




9. Assembly Of Cylinder Head Cover (1) Clean away the old gasket and glue on valve mating surface by all means. (2) Put the new gasket at the right place in cylinder head cover slot. (3) Mount the cylinder head cover on cylinder head and align and tighten them from middle to both sides. Torque: 6$1N.m

Check the clearance of valve with feeler gauge. Note: Confirm the clearance between the camshaft base circle and the valve lash adjustment shim.

Standard valve lash: Valve lash

IN

0.18$0.05

EX

0.25$0.05

If the value exceeds the standard value, replace with the new adjustment shim and adjust the clearance. Note: Recode the position exceeding the standard value and measured results.

(1) Adjust the thickness of adjustment shim with micrometer caliper.

2.18

2.40

2.62

(2) Select the shim from following items in accordance with valve tappet standard value.

2.20

2.42

2.64



2.22

2.44

2.66

IN U Select shim thickness = Unload thickness +(Measured valve lash -0.18mm)

2.24

2.46

2.68

2.26

2.48

2.70

N

2.28

2.50

2.72

EX U Select shim thickness = Unload thickness +(Measured valve lash -0.25mm)

2.30

2.52

2.74

2.36

2.58

2.80

2.32

2.54

2.76

2.38

2.6

[Reference] There are 32 kinds of thickness for shim, as can be seen from the picture:

22




10. Adjust The Valve Adjustment Shim.

lash

With

Selected

Note : Mount with t he mark downward.

Downward

(1) Rotate the camshaft with the cam top upward for replacing shim; place the port of valve tappet inside.

Opening Of Valve Tappet

(2) Rotate the camshaft and press valve tappet with the cam top of camshaft downward.

(3) Place the special tool from inside of cylinder head onto valve tappet and pay attention not to press on adjustment shim, as can be seen from the picture.

Special Tool

(4) Rotate the crankshaft with cam top upward vertically. At the same time, press the valve tappet with special tool fixedly.

23




(5) Pry out the adjustment shim with screw driver; remove the shim inside with magnet.

Special Tool

(6) Rotate the crankshaft with cam top downwardL press down valve and take out special tool.

Special Tool

(7) Rotate the crankshaft 2-3 cycles and confirm the valve lash again. If it is out of standard value, adjust again according to the methods above. (8) Note U Remove the camshaft and replace shim or adjusting if necessary.

24




CYLINDER HEAD

4-1 STRUCTURAL DIAGRAM (ACCORDING TO THE OPERATING ORDERS OF ASSEMBLY AND DISASSEMBLY FOR CAMSHAFT, OPERATE AS THE FOLLOWING)

(1)

Spark Plug 20$1nm

(2) (3)

Cylinder Head Weather Strip I

(4)

Cylinder Gasket (Can Not Be Reused)

(5) (6)

Adjustment Shim Valve Tappet

(7)

Valve Spring Retainer Lock

(8)

Valve Spring Seat

(9) (10)

Valve Spring Intake Valve

(11)

Exhaust Valve

(12)

Valve Oil Seal

(13)

Valve seat

(14)

Valve Guide

TUThe Parts Can Not Be Reused. Unit: N#M(Kg#Cm)

4-2 DISASSEMBLY

1.

Disassembly Of Spark Plug

25




2. There Are 8 Bolts On Cylinder Head. During The Disassembly Of Cylinder Head, Disassemble Slowly With Torque wrench By The Sequence As Can Be Seen From The Right Picture.

3. Disassembly Of Weather Strip I And Cylinder Head Gasket. Note: cylinder gasket can not be reused.

4. Disassembly Of Valve Adjustment Shim And Valve Tappet

Special Tool

5. Disassemble The Valve Spring Retainer Lock, Spring Retainer, Spring Seat, Valve Spring, Intake Valve, And Exhaust Valve Etc With Special Tools. 6. Disassembly Of Valve Oil Seal And Spring Seat

4-3 CLEAN

1. Clean The Carbon Dust On The Valve. 2. Clean The Bottom Surface Of Cylinder Head And The Surface Of Intake And Exhaust Manifold With Scraper Knife. Note: Do Not Damage The Surface Of Cylinder Head During Cleaning.

Do Not Pollute The Intake Port And Water Passage. 4-4 INSPECTION

1.

Cylinder Head

Measure The Underside Planeness Of Cylinder Head Assembly. Cylinder Head 0.10mm The Cylinder Head Is Always 0.10 Mm On The Mounting Surface Of Intake And Exhaust Manifold.

26



2.


Valve Spring

(1) Measure the squareness of valve spring with square. Replace if it exceeds the specified value. Limit: 1.2mm

(2) Free condition Standard: 37mm

3

Valve

(1) Inspection of valve Check if it is deformed or abrased. Inspection of valve

Standard value

Limit

IN

0.85X1.41

___

EX

1.07X1.36

___

IN

1.0$0.2

0.75

EX

1.0$0.2

0.75

Item Measuring Point For Outside Width of seal Thickness of valve

Unit:mm

Measuring Point

(2) Check the clearance of valve guide and valve stem.

Thickness Of Top



Measure the inside diameter of valve guide with dial gauge, the outer diameter of valve stem with micrometer caliper.

27



! Measuring point


Figure out the difference of measured values and the clearance. If the clearance is beyond the specified value, replace valve or guide.

Note: As can be seen from the right picture, at measuring point, work out the clearance of last abrasion part. Item Valve guide inside diameter(mm) Valve guide outer diameter(mm) Clearance (mm)

IN EX

Standard value

Limit

%5.0

___

%5.0

___

0.056X 0.020mm 0.066X 0.030mm

0.07 0.08

(3) Replacement of valve guide 

Heat the cylinder head with hot water to 80-100,.

!

Take out the valve guide from one side of combustion chamber with special tool, as can be seen from the right picture.

Special Tool

Note: the removed valve guide can not be reused.

Special Tool

O

Mount the new valve guide with special tool at the place as can be seen from the right picture.

28




Note: strike the conduit slowly to the position in the cylinder head; do not strike too far and be careful for size. Type Item Height h(mm)

EF GL,ZL,RL,GS,ZS IN 13.71$0.25 EX 12.11$0.25

Rub the inside diameter with reamer to reach (1) Assorted surface of valve Spread with red lead on the assorted surface of valve. Do not rotate the valve but press lightly and check the assortment and width.

4

Repair Of Valve Seat Insert

Note: There can not be breaking trace on the repaire surface and take out with force finally.

(1)

45'wimble surface is standard mating value.

(2)

Check the valve mating position. The best position is in the center of valve. If not, correct it.

(3)

Cut wimble surface at the center of mating position with 70 ' outward and 30' inward.

29




(4) Prepare for polishing of valve seal.

4-5 ASSEMBLY OF CYLINDER HEAD ASSEMBLY

Protective Tube Of Spark Plug

Install the cylinder head assembly Pay attention to the following for installing the other auxiliary part of cylinder head: Mount protective tube of spark plug Press the protective tube of spark plug into the hole for that on cylinder head with special tool. Spread with sealant before pressing, and the pressing height is shown in the picture: Note: Pay attention to the pressing depth and the uprightness to top of cylinder head when pressing;

During pressing, the protective tube can not be deformed, or leaking will be occurred at the cylinder head cover. Auxiliary Tool 4-6 ASSEMBLY For Valve Oil 1. Assembly Of Valve spring washer And Seal

Valve Oil Seal Valve

(1) Clamp the special auxiliary tool on the top of valve stem and spread oil around Valve Oil Seal the auxiliary tool and the inner of new valve oil seal. Then mount it at the position as can be seen from the picture and pull out the mounting auxiliary tool Seat For Mounting of valve oil seal. Valve Spring [Reference] After pressing, the valve oil seal can reach the size as can be seen from the picture.

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Painting Mark


2. Assembly Of Intake Valve And Exhaust Valve 3. Assembly Of Valve Spring Note: The painting is used for recognizing the different suppliers, so the same engine should use the valve spring with same painting.

4

Assembly Of Valve keeper

Warning Operate with goggle for protecting the eyes.

Special Tool

Be care for spring jumping out. After assembly of valve spring and its seat, press the valve spring with special tool and mount the valve keeper.

Spreading Point On The Bolt Of Cylinder Head

5

Assembly Of Valve Tappet And Valve lash Adjustment Shim

6

Mount The Cylinder Head Gasket And Recognize The Direction Of Front And Back.

7

Assembly Of Dust seal And Cylinder Head Assembly

(1) Spread a little oil on the flange side of bolt and threaded part. (2) The tightening sequence of bolts on cylinder head is same to that as can be seen from the picture. Screw down 2-3 times circularly to the specified torque. Operate 3 times as the sequence that can st be seen from the picture. 1 nd rd time:30$2Nm, 2 timeU50$3NmL3 time:70$3.5Nm Torque 70$3.5N.m

31



8


Mount Spark Plug

Torque 20$1Nm Note: Tools should be vertical to prevent the protective tube of spark plug from distorting, or the oil will leak.

32




WATER PUMP

5-1 STRUCTURAL DIAGRAM (ACCORDING TO THE OPERATIONS, DISASSEMBLE AND ASSEMBLE CYLINDER)

FOLLOWING

"O! Ring, Can Not Be Reused !Water Pump Body

OWeather Strip

TUCan Not Be Reused

5-2 DISASSEMBLY

1. Disassembly Of O Ring Note: O ring can not be reused.

2. Screw Off 3 Bolts And Disassemble Water Pump Body. 3. Disassembly Of Dust Seal 5-3 CLEAN

1. Clean Of Water Pump Joint Surface 5-4 INSPECTION

1. Check If It Is Deformed. 2. Check If The Rotor Is Rotating By Hand And Check The Lubricating Condition. 5-5 ASSEMBLY

1. Mount Dust seal 2. Mount Water Pump Body Torque 25$1.5N.m 3. Mount The New O Ring

33




LUBRICATION SYSTEM

6-1 STRUCTURAL DIAGRAM (ACCORDING TO THE OPERATIONS, DISASSEMBLE AND ASSEMBLE OIL PUMP)

FOLLOWING

M Oil PanLBolt TorqueU8$2 N.M N Oil strainer O Oil Collector ShimL(Can Not Be Reused)

P Oil Pump Q Oil Pump ShimL (Can Not Be Reused)

R Rear Oil Seal Bracket

TUCan Not Be Reused T:Can not be reused

6-2 DISASSEMBLY

1. Reverse The Engine On The Disassembling Support And Screw Off The Bolts.

34




2. Remove The Oil Pan From The Cylinder With Special Tool.

Special Tool

Note: Don(t distort the flange of oil pan.

3. Remove The Engine Oil Drainer, Engine Oil Collector Shim. Note: The engine oil collector shim cannot be repeatedly used.

4. Remove The Engine Oil Pump Assembly And The Engine Oil Pump Shim.

5. Remove The Rear Oil Seal Bracket.

35




6-3 CLEANUP

1. Clean up the joint surface between the oil pan and the engine oil pump, oil seal bracket and cylinder. 2. Clean up the joint surface between the rear oil seal bracket and the cylinder. A scraper or scraper knife can be used for cleaning up the old shim. Note: Don(t let the shim fragment fall into the cylinder.

6-4 DISASSEMBLY AND ASSEMBLY OF THE ENGINE OIL PUMP DISASSEMBLY. 6-4-1

STRUCTURE DIAGRAM

M Weather Strip N Cover Plate Of Engine Oil Pump O Outer Rotor Of Engine Oil Pump P Inner Rotor Of Engine Oil Pump Q Cotter pin R Spring Seat Of Oil Drain Valve TUThe Parts Can Not Be Reused.

S Spring Of Oil Drain Valve Y Slider Z Front Crankshaft Oil Seal [ Housing Of The Engine Oil Pump

36




6-4-2 DISASSEMBLY

1. Weather Strip Note: The weather repeatedly used.

strip

cannot

be

2. Remove The Oil Pump Cover Note: The bolt is assembled with glue; tighten it with a screwdriver as shown in the figure.

3. Remove the inner rotor, outer rotor of the engine oil pump. 4. Remove The Cotter pin Note: The cotter pin cannot be repeatedly used. Note: When removing the cotter pin, be careful not to let the spring or the spring seat spring out or fall off abruptly.

Pressure Relief Valve

Slider

Spring Of Oil Pressure Relief Valve

5. Remove the spring seat of the oil pressure relief valve for the engine oil pump, the coil spring, oil pump and oil pressure relief valve etc.

Spring Seat

6. Remove the front crankshaft oil seal. Note: The removed oil seal cannot be repeatedly used.

37




6-4-3 INSPECTION

Inspect the engine oil pump for clearance. According to the marks for inner gear and outer gear in the engine oil pump, put the gears into the engine oil pump that is in the cylinder block.

1. Measure the clearance between the inner and outer gears with a feeler gauge. Standard value: 0.05-0.18mm( average for nine points measured) Limit: 0.35 mm

2. Measure The Clearance Between The Rotor And Pump Body. Standard value: 0.10-0.181mm Limit: 0.25 mm

Inspect the oil pressure relief valve No abrasion or scrape shall be found on the oil pressure relief valve.

6-4-4 ASSEMBLY

1. After the lip of the new oil seal for front crankshaft is spread with engine oil, fix it with a special tool.

Special Tool

Note: Use a new oil seal Press Direction

The oil seal should be left less than 0.5 mm at its outer edge after it is pressed down.

Inside

Appearing Part Of Oil Seal Is Below 5mm

38




2. Assembly of the oil pressure relief valve for engine oil pump and the cotter pin. Note: The cotter pin cannot be repeatedly used.

3. When The Outer Gear Or Inner Gear Is Put Into The Engine Oil Pump, Its Mark Should Be Seen.

Mark

4. The New Weather Strip Should Be Fixed In The Groove Of Oil Pump Cover.

6-5 DISASSEMBLY AND ASSEMBLY OF THE OIL SEAL 6-5-1 STRUCTURE DIAGRAM

TUCan Not Be Reused.

39




6-5-2 DISASSEMBLY

1. Remove The Rear Crankshaft Oil Seal With A Screwdriver. Note: The rear crankshaft oil seal cannot be repeatedly used.

6-5-3 INSPECTION

Edge Of Oil Seal

Inspect the oil seal for damage and the abrasion at its lip. 6-5-4 ASSEMBLY

2. Spread Engine Oil Over The Lip Of The New Oil Seal.

3. Assemble The Rear Crankshaft Oil Seal With A Special Tool As Shown In The Right Figure. Special Tool Special Tool

6-6 ASSEMBLY

Line For Spreading Sealant

1.

Assembly Of The Oil Seal Seat

Spread sealant over the oil seal seat as shown in the right figure. Grease

Le Tai glue 5699

Note: Spread the liquid sealant over the joint surface between the oil seal seat and the cylinder, with a spreading width of 3-4mm. Torque: 25$1.5N.m

40




2. Assembly Of The New Engine Oil Pump Shim And The Engine Oil Pump Assembly. Torque: 20$1.5N.m

3. Assemble The New Engine Oil Collector Shim And The Engine Oil Drainer Torque: 6$1N.m

4.

Assembly Of The Oil Pan

(1) Clean up the joint surface between the oil pan with the cylinder. (2) Spread sealant, then assemble it. Grease: Le Tai glue 5699 Note: No opening is allowed for the soft washer and the sealant line, and the diameter of the sealant line should be within 3-4 mm.

Assembly should take place fifteen minutes after glue-spreading. (3) Tighten the bolts in the middle first up to the specified torque, then the bolts beside them as shown in the right figure. Torque: 6$1N.m Front

Rear

41




CRANKSHAFT CONNECTING ROD MECHANISM

7-1 STRUCTURE DIAGRAM (THE DISASSEMBLY OR ASSEMBLY OF THE OIL PUMP IS DONE AS FOLLOWS )

(1)

Connecting Rod Cap

(2)

Connecting Rod Bushing

(3)

Piston and Assembly

(4)

Main Bearing Cover

(5) (6)

Crankshaft Crankshaft Bearing Bushing

(7)

Thrust Plate

(8) (9)

Cylinder Body Top Compression Ring

(10)

Second compression ring

(11)

Steel Strip Composite Type Oil Ring

(12) (13)

Piston Connecting Rod Piston Pin

Connecting

Rod

TUCan Not Be Reused

42




7-2 DISASSEMBLY OF THE CRANK ARM MECHANISM

1. Inspect The Connecting Rod For Its Axial Clearance. Measure the axial clearance with a dial gauge or feeler gauge. Standard value :0.15-0.24mm Limit :0.30mm 2. Inspect The Connecting Rod Bushing For Its Radial Clearance. (1)

Remove the bushing cap.

Note: Place the parts of cylinders in order.

(2)

Clean the bearing bushing and the shaft.

(3)

Place the feeler gauge on the journal of connecting rod.

(4)

Tighten the bushing specified torque.

cap

with

Torque: 40$2N.m

Note: Don(t rotate the crankshaft.

(5)

Remove the bushing cap, measure the maximum thickness of the searcher.

Standard value :0.020-0.044 mm Limit: 0.07 mm

43



(6)


Replace the bearing bushing when its wears beyond limit.

Note: The bearing bushing replaced must be of the same manufacturer and the same brand and meet the requirement for mating clearance.

Connecting Rod Bearing Connecting Rod Cap

3. Remove The Connecting Rod Bearing Cover And The Connecting Rod Bearing Bushing (1) Cover the screw of connecting rod with a protective tube, for preventing scraping the cylinder bore and the journal of the crankshaft connecting rod. Then remove the piston connecting rod with a handle of hammer

Protective Tube

Note: Place cylinders in order.

(2) Measure the axial clearance of the crankshaft with a dial gauge, if it is beyond the limit, it is necessary to replace the axial thrust plate or the crankshaft. Standard value: 0.089-0.211mm Limit: 0.30mm

Item Thickness of thrust plate

44


Standard value 1.9

-0.11 -0.03



4. Remove The Main Bearing Bushing Cap Of The Crankshaft , Crankshaft, Crankshaft bearing bushing And Crankshaft Axial Thrust Plate Inspect the crankshaft for its radial clearance. (1) Remove the crankshaft bearing cover by softly tapping with a resin hammer. (2) Clean the inner surface of bearing bushing, inner surface of bearing cover, cylinder wall and the journal of shaft etc. Inspect them for wearing and abrasion.

(3) Measure the radial clearance of the crankshaft with a feeler gauge. Feeler Gauge

Assemble the feeler gauge, then tighten the bolts for the bearing cover with specified torque. Torque: 70$3.5N.m

Note: Tighten the bolts for the crankshaft bearing cover in the order shown in the right figure. Tighten the bolts for three times, then the torque must be up to the specified value. Note: Because the feeler gauge is here, it is not allowed to rotate the crankshaft after it is tightened.

45




(4) Remove the bearing cover, measure the maximum width of the feeler gauge, if it is beyond the limit, replace the bearing bushing.

Pressed Mark

Standard value:0.025-0.069mm Limit: 0.10mm

5.

Disassembly And Assembly Of The Piston and connecting rod assembly

(1)

Remove the first ring, second ring and the oil ring with a pair of piston ring moving pliers.

Note: Don(t confuse the pistons, piston rings of various cylinders. Special Tool

(2)

Remove the piston, connecting rod and the piston pin with special tool.



Remove the piston pin with special tool, then remove the piston and the connecting rod.

Special Tool

7-3 CLEANUP 7-3-1 CYLINDER BODY Warning Wear glasses for protecting eyes when the cleanup is being done.

1. Clean Up The Cylinder Body, Cylinder Head, Oil Pan, Oil Pump And The Oil Seal With A Flat Blade. 7-3-2 piston Warning Wear glasses for protecting eyes when the cleanup is being done.

1. Use An Old Ring To Remove The Carbon In Ring Groove. 2. Remove The Carbon Of Parts With Scavenger. Note: It is not allowed to use a metal brush here or some tool made of hard material.

46




7-4 INSPECTION 7-4-1 CYLINDER BODY

1.

Inspect The Top Surface Of Cylinder Body For Its Flatness.

(1) Measure at the six points shown in the right figure with a ruler and a feeler gauge. Limit: 0.08mm

2.

Top Dead Center

Bottom Dead Center

How To Use The Cylinder Gauge Measure The Diameter Of The Cylinder bore In The Directions Shown In The Figure With A Cylinder Gauge, Work Out The Difference Between The Maximum And Minimum Values, If The Difference Is Beyond The Limit, Repair Or Replace The Cylinder.

Limit: 0.03mm [reference] roundnessUA-B or a-b

Cylindricity UA-a or B-b [reference] standard value of cylinder diameter 72.00-72.01mm 7-4-2 PISTON

1. Inspect The Piston Pin Hole For Its Clearance (1) Measure the piston pin at several positions with a micrometer caliper shown in the figure; make the maximum value as the diameter of pin.

(2) Measure the diameter of piston pin at several positions with an inner-diameter dial gauge as shown in the figure; make the minimum value as the diameter of the pin hole.

47




(3) Work out the clearance with the difference between the pin diameter and pin hole diameter, if the difference is beyond the standard value, replace the piston pin or piston. Standard value: 0.004-0.009mm Limit 0.015mm

48




2. Measure The Diameter Of The Piston Measure at about 11 mm to the bottom of the piston, along the direction vertical to the piston pin. Standard value: φ72

) 0.013 ) 0.025

3. Inspect The Clearance Between Piston Ring And Piston Ring Groove. (1) Measure around the piston with a feeler gauge and a piston ring

First ring Second ring

Standard value (mm) 0.03~0.06 0.03~0.06

Limit (mm) 0.12 0.11

4. Inspect The End Clearance Of Piston Ring (1) Place the piston ring about 45mm below the top surface of piston hole, in order that the piston ring is put horizontally, press the piston ring with the top surface of piston. Then measure the opening clearance with a feeler gauge.

First ring Second ring Oil ring segment

Standard value (mm) 0.25-0.40 0.35~0.50

Limit (mm) 0.65 0.65

0.20~0.70

1.00

7-4-3 INSPECT THE CLEARANCE BETWEEN THE PISTON AND CYLINDER WALL.

Measured points for the inside diameter of cylinder

Measured points for 1. The Measured Points For Cylinder the outer diameter of Inside diameter And Diameter Of piston Piston Bottom Are Shown In The

Figure, If The Clearance Is Beyond The Limit, Repair Or Replace The Piston Or Cylinder. Standard value: 0.018X0.030 Limit: 0.10 [Reference] The clearance between the piston and cylinder bore is controlled by the difference between the minimum inside diameter of piston hole and the

49




maximum outer diameter of piston. 2. After Replacing The Piston Or The Cylinder Body, Confirm The Clearance Again. Standard value: 0.018X0.030

50




7-4-4 CRANKSHAFT

1. Inspect The Proper Alignment Of The Main Axle Diameter. (1) Measure the proper alignment with a dial gauge, if the proper alignment is beyond the limit, replace the crankshaft. Limit: 0.03mm Note: The bending value should be equal to one-second the run-out value of crankshaft rotating one circle.

1.

Inspect The Abrasion.

Crankshaft

For

The

(1) Measure the journal with a micrometer caliper, work out the roundness and the cylindricity. Limit: 0.005mm

(2) Measure the diameter of the connecting rod with a micrometer caliper, work out the roundness and the cylindricity. Limit: 0.004mm

The measured parts are shown in the figureU

7-5 ASSEMBLY OF THE CRANKSHAFT CONNECTING ROD MECHANISM

Mark Forwards

1. Assembly Of The Piston Connecting Rod (1) Assemble the piston, connecting rod and the piston pin with special tool following the instructions below:



Spread engine oil over the pin hole of the connecting rod, assemble according to the group mark and direction mark of piston and connecting rod.

51




!

Assemble the piston and the connecting rod with special tools shown in the right figure.

O

Make adjustment as shown in the right figure, assemble the piston and connecting rod.

#

Spread engine oil over the piston pin, assemble the piston and connecting rod with a press machine.

Special Tool

Special Tool

Note: Pay attention to the assembling direction when the piston pin is pressed in.

For pressing the pin into the piston, it is necessary to heat the small end of the connecting rod up to 300 , Pressure is exerted after the pin is definitely in straight and direct position, without deflection. From Above To Below U top compression ring 2nd compression ring upper segment expander lower segment

Opening Angles Of RingsU Lower Segment to p compression ring

Front

With the side surfaces marked facing upward, first assemble the steel strip composite type oil ring (the expander, lower segment, upper segment), then assemble the second compression ring, finally the top compression ring. Opening angles of rings are shown in the figure:

2nd compression ring

Expander

(2) The first piston ring, the second piston ring and the oil ring.

Rear

Upper Segment

3. Resemble The Crankshaft Main Bearing Cover, Crankshaft, Crankshaft Bearing Bushing And The Crankshaft Axial Thrust Plate, Pay Attention To The Following: (1) When assembling the bearing bushing, its raised thrust block should fit into the locating groove in the cylinder body. Note: The bearing bushing is from the same manufacturer.

52




(2) Spread engine oil over the surface of the bearing bushing (upper piece) contacting the crankshaft, then assemble the crankshaft. Fix the crank arm in the cylinder bearing housing, with the oil duct in the thrust plate facing outwards.

Oil Duct Outwards

Note: Spread engine oil over the side with oil duct.

Fix the crankshaft bearing bushing (lower piece) in the bearing cover, the bearing bushing should fit into the thrust groove. (3) Spread engine oil over the friction surface of crankshaft bearing bushing (lower piece); assemble the bushing according to the mark forwards in the main bearing cover of the crankshaft.

Spread Engine Oil Before Assembly

(4) Spread oil over the bolts, within three or two times, tighten them with specified torque. Torque: 70$3.5N.m

(5) Rotate the crankshaft after assembly, it should rotates swiftly, the rotating torque should be less than 1Nm Note: After the crankshaft is tightened, its rotating torque should be less than 1Nm (the torque when installing crankshaft but not with connecting rod).

53




4. Assemble The Piston and connecting rod assembly, Connecting Rod Bearing Bushing And The Connecting Rod Bearing Cover, Pay Attention To The Following: (1) The opening of compression ring and the opening of oil ring should be in the specified direction. (2) The bolts of the connecting rod should be covered with nylon sleeves for fear of scraping the cylinder body and the axle. (3) The surfaces of piston and connecting rod and other surfaces where relative motion exists should be spread with engine oil. (4) Make sure that the mark on the piston faces forward; assemble the piston and connecting rod assembly with special auxiliary tool.

Nylon Stick Special Tool

Note: The cylinder number of the piston and connecting rod assembly should be in accordance with the cylinder number.

Raised Forward

(5) Assemble the connecting rod bearing cover and the connecting rod bushing, pay attention to the following:



Put the cover on the bolt as per the mark forwards, spread a little engine oil over the joint surface between the nut and its seat.

!

Tighten the right nut and the left nut alternatively for several times with specified torque.

TorqueU 40$2N.m Note: The connecting rod and the connecting rod bearing cover belong to the same component.

54


Chery Engine SQR372

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