Chery S18D Service Manual X1 Engine SQR 473F
After Sales Service Department of Chery Automobile Automobile Co.,Ltd.
CONTENTS Chapter One Introduction of Characteristics ....................................
4
I. Overview .................... ............................... ..................... .................... ..................... ..................... ..................... ..................... .................... ..................... ..................... ............ ..
4
II. Number Position Number Position of the Engine .................... .............................. .................... ..................... ..................... ..................... ..................... ................... .........
4
III. Connotation of Engine Number ..................... ............................... ..................... ..................... .................... ..................... ..................... ................ ......
4
Chapter Two Two Specification ...............................................................
6
I. Engine Type and a!or Parameters... Parameters............. ..................... ..................... .................... ..................... ..................... ..................... ..................... ..........
6
II. a!or aintenance Parameters of Engine .................... ............................... ..................... ..................... ..................... ..................... .............
"
III. Primary #it C$earance ..................... ............................... ..................... ..................... .................... ..................... ..................... ..................... ..................... ..........
%
I&. Engine Primary Tightening Tor'ue Tab$e .................... .............................. ..................... ..................... .................... ..................... ...........
()
&. The Parts where *ubrication are +e'uired during ,ssemb$y of Engine. Engine..... ........ ........ ........ ........ ........ ....... ...
(-
&I. The Parts where +ubber Coating are +e'uired during ,ssemb$y of Engine ...... ......... ...... ...... ...... .....
(
Chapter Three Specia$ Too$s ..........................................................
(6
I. Connotation of Specia$ Too$ Number ........... Number ..................... ..................... ..................... .................... ..................... ..................... .................. ........
(6
II. Specia$ Too$s Chart .................... ............................... ..................... ..................... ..................... .................... ..................... ..................... ..................... .............. ...
("
Chapter #our easurement of Cy$inder Pressure..........................
/)
I. 0etection of Cy$inder Pressure....... Pressure................. ..................... ..................... .................... ..................... ..................... ..................... ..................... ............
/)
(. easuring process process .................... .............................. ..................... ..................... .................... ..................... ..................... ..................... ................... ........
/)
/. 1udgment of cy$inder pressu cy$inder pressure re va$ue............. va$ue....................... ..................... ..................... ..................... ..................... ................... .........
/(
Chapter #ive 0isassemb$y of Power2assisted Steering System......
//
I. 0isassemb$y Procedure.......................................................................................................// II. Overhau$............................................................................................................................/III. Insta$$ation of the Steering Pump................ Pump.......................... ..................... ..................... .................... ..................... ..................... ................. .......
Chapter Si3 0isassemb$y of ,C Compressor ................................ II. Overhau$ of Compressor .................... ............................... ..................... .................... ..................... ..................... ..................... ..................... ................ ......
/-
/4 /
III. Insta$$ation procedure........... procedure..................... ..................... ..................... .................... ..................... ..................... ..................... ..................... .................../ ........./
Chapter Seven 0isassemb$y of 5enerator ......................................
/
I. 0isassemb$y Procedure......................................................................................................./ II. Overhau$ of 5enerator..... 5enerator............... .................... ..................... ..................... ..................... ..................... .................... ..................... ..................... ............... .....
/6
III. Insta$$ation Procedure .................... ............................... ..................... .................... ..................... ..................... ..................... ..................... ................... .........
/6
Chapter Eight +ep$acement of Engine Timing e$t.......................
/"
I. 0isassemb$y Procedure......................................................................................................./" II. Insta$$ation of Timing e$t .................... .............................. ..................... ..................... ..................... ..................... .................... ..................... .............. ...
/%
III. ,d!ustment of Timing 7genera$ overhau$8 ..................... ................................ ..................... .................... ..................... .................... ......... I&. ,d!ustment of Timing 7minor overhau$8 ..................... ............................... .................... ..................... ..................... ..................... .............
-) -)
Chapter Nine Chapter Nine 0isassemb$y of Engine ,ssemb$y ............................
-(
I. 0isassemb$y Procedure.......................................................................................................-( II. Insta$$ation Procedure........................................................................................................-%
Chapter Ten Ten 0isassemb$y of Inta9e anifo$d ................................ I. 0isassemb$y Procedure.......................................................................................................-%
-%
Chapter Two Two Specification ...............................................................
6
I. Engine Type and a!or Parameters... Parameters............. ..................... ..................... .................... ..................... ..................... ..................... ..................... ..........
6
II. a!or aintenance Parameters of Engine .................... ............................... ..................... ..................... ..................... ..................... .............
"
III. Primary #it C$earance ..................... ............................... ..................... ..................... .................... ..................... ..................... ..................... ..................... ..........
%
I&. Engine Primary Tightening Tor'ue Tab$e .................... .............................. ..................... ..................... .................... ..................... ...........
()
&. The Parts where *ubrication are +e'uired during ,ssemb$y of Engine. Engine..... ........ ........ ........ ........ ........ ....... ...
(-
&I. The Parts where +ubber Coating are +e'uired during ,ssemb$y of Engine ...... ......... ...... ...... ...... .....
(
Chapter Three Specia$ Too$s ..........................................................
(6
I. Connotation of Specia$ Too$ Number ........... Number ..................... ..................... ..................... .................... ..................... ..................... .................. ........
(6
II. Specia$ Too$s Chart .................... ............................... ..................... ..................... ..................... .................... ..................... ..................... ..................... .............. ...
("
Chapter #our easurement of Cy$inder Pressure..........................
/)
I. 0etection of Cy$inder Pressure....... Pressure................. ..................... ..................... .................... ..................... ..................... ..................... ..................... ............
/)
(. easuring process process .................... .............................. ..................... ..................... .................... ..................... ..................... ..................... ................... ........
/)
/. 1udgment of cy$inder pressu cy$inder pressure re va$ue............. va$ue....................... ..................... ..................... ..................... ..................... ................... .........
/(
Chapter #ive 0isassemb$y of Power2assisted Steering System......
//
I. 0isassemb$y Procedure.......................................................................................................// II. Overhau$............................................................................................................................/III. Insta$$ation of the Steering Pump................ Pump.......................... ..................... ..................... .................... ..................... ..................... ................. .......
Chapter Si3 0isassemb$y of ,C Compressor ................................ II. Overhau$ of Compressor .................... ............................... ..................... .................... ..................... ..................... ..................... ..................... ................ ......
/-
/4 /
III. Insta$$ation procedure........... procedure..................... ..................... ..................... .................... ..................... ..................... ..................... ..................... .................../ ........./
Chapter Seven 0isassemb$y of 5enerator ......................................
/
I. 0isassemb$y Procedure......................................................................................................./ II. Overhau$ of 5enerator..... 5enerator............... .................... ..................... ..................... ..................... ..................... .................... ..................... ..................... ............... .....
/6
III. Insta$$ation Procedure .................... ............................... ..................... .................... ..................... ..................... ..................... ..................... ................... .........
/6
Chapter Eight +ep$acement of Engine Timing e$t.......................
/"
I. 0isassemb$y Procedure......................................................................................................./" II. Insta$$ation of Timing e$t .................... .............................. ..................... ..................... ..................... ..................... .................... ..................... .............. ...
/%
III. ,d!ustment of Timing 7genera$ overhau$8 ..................... ................................ ..................... .................... ..................... .................... ......... I&. ,d!ustment of Timing 7minor overhau$8 ..................... ............................... .................... ..................... ..................... ..................... .............
-) -)
Chapter Nine Chapter Nine 0isassemb$y of Engine ,ssemb$y ............................
-(
I. 0isassemb$y Procedure.......................................................................................................-( II. Insta$$ation Procedure........................................................................................................-%
Chapter Ten Ten 0isassemb$y of Inta9e anifo$d ................................ I. 0isassemb$y Procedure.......................................................................................................-%
-%
Chapter E$even 0isassemb$y of Cy$inder :ead.............................
4)
I. 0isassemb$y Procedure.......................................................................................................4) II. Overhau$ of Cy$inder :ead System............ System....................... ..................... .................... ..................... ..................... ..................... ................... ........
4-
III. ,ssemb$y of Cy$inder :ead ,ssemb$y .................... .............................. ..................... ..................... ..................... ..................... .............. ....
4
Chapter Twe$ve 0isassemb$y and Insta$$ation of Oi$ Pump and *ubrication System ........................................................................
4;
I. 0isassemb$y Procedure.......................................................................................................4; II. Overhau$ of Oi$ Pump ..................... ................................ ..................... .................... ..................... ..................... ..................... ..................... ................... .........
)
III. Insta$$ation Procedure .................... ............................... ..................... .................... ..................... ..................... ..................... ..................... ................... .........
)
Chapter
Thirteen
0isassem ssemb b$y
of
Cran ran92Connecting
echanism....................................................................................
+od (
I. 0isassemb$y Procedure.......................................................................................................( II. Overhau$ of Cran92Connecting +od System............... System.......................... ..................... ..................... ..................... .................... ............ ..
/
III. Insta$$ation of Cran92Connecting +od System ........ ............ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ....
6
Chapter One Introduction of Characteristics I. Overview S<+4"-# engine is one of the ,CTECO series engines that are !oint$y designed and deve$oped by Chery company and ,&*2a wor$d famous engine design company. This engine adopts such advanced techno$ogies as overhead doub$e camshaft structure= 4 air va$ves= e$ectronic thrott$e body and e$ectronic acce$erator peda$ etc. In terms of such mandatory standard inde3es as emission and noise= this engine is outdoes nationa$ standard and has reached overseas advanced stage.
II. Number Position of the Engine Number Number of the engine $ocates at right side of oi$ fi$ter where bearing bearing she$$ cover and cy$inder b$oc cy$inder b$oc9 9 !oin !oin..
III. Connotation of Engine Number Each engine has a uni'ue number= from which you can 9now some characteristics and information of the engine. Engine mode$ shou$d conform to re'uirements in 5"/ and is consisted of enterprise code= number of cy$inders of the engine= bore= characteristic code and specification code. , comp$ete engine mode$ is as fo$$ows> ???
@
@@
?
? Specification code Characteristic code Cy$inder bore Cy$inder bore Number Number of cy$inders Enterprise code
,mong which= @ indicates an ,rabic numera$ whi$e ? indicates a $etter. The enterprise code is stipu$ated as S<+A Number Number of cy$inders of engine is a (2/ digit integerA The bore refers to diameter of cy$inder s$eeve= which is specified by a /2- digit integer with the decima$ part rounded and mi$$imeter as unit. Characteristic code> indicates the most basic characteristics of an engine and is specified by ( digit upper case Eng$ish $etter. Specification code> specified by ( digit upper case Eng$ish $etter= which is used as an additiona$ distinguish code when distinguish is re'uired in case structure= principa$ principa$ parameter parameter or oi$ supp$y mode etc. has changed 7for e3amp$e= the stro9e of engine has changed or the engine is a dua$ fue$ engine8 with number of cy$inders= bore and characteristic code of the engine unchanged. #or changes of periph of periphera$ era$ parts of the engine 7such as inta9e and e3haust manifo$ds8= the engine mode$ wi$$ 9eep unchanged= and engine assemb$y number wi$$ be changed for distinguish. ,mong the engines of the same series= the specification code wi$$ be used with B as the first 7among which= do not use such $etters as BI= BO= B<= BD and B8. The defau$t specification code for the first fundamenta$ structure is B,= which is omitted. The specification a$so can 'uote the characteristic code to e3press specific characteristics. Position of engine mode$ The engine mode$ shou$d be printed at an obvious part on engine cy$inder b$oc9 cy$inder b$oc9 and p$ease see provision provisionss in Assembly and Regulation for the specific position position.. and Regulation Instruction of Engine of Engine for the *eaving factory number of engine is composed of characteristic code of engine= E#I manufacturer code= character code of the year of production= production= character code of the month of production= production= se'uence number of this engine among the engines of this mode$ manufactured in that month and start stop sign BF. Comp$ete form of $eaving factory number of a engine is as fo$$ows> F?
?
@@@@ F SN among the vo$ume productio production n of the current month Character code of the month
of
Character code of the year E#I system manufacturer code Characteristic code ,mong which= @ indicates an ,rabic numera$= ? indicates a $etter and
indicates an ,rabic
numera$ or a $etter. The characteristic code of engine shou$d conform to above provision. E#I system manufacturers> C2otoro$aA 02are$$iA E20e$phiA #2G,ESA 52SiemensA :2TroitecA
Cran9 ,ng$e with 2osch Inta9e &a$ve
4))
Opening as (mm
-6%
78 Cran9 ,ng$e at Item (mm before Inta9e No. ("
6()
6%
S<+4"-
&a$ve C$osing 78
S<+4"-:
S<+4"-#
Cran9 ,ng$e with Type E3haust &a$ve
&ertica$ type= 4 cy$inder= water coo$ing= 4
&ertica$ type= 4 cy$inder= water
stro9e= in2$ine doub$e overhead camshaft= /)) contro$$ed burn rate= variab$e va$ve timing
coo$ing= 4 stro9e= in2$ine doub$e (4) overhead camshaft
S<+4"-:
S<+4"-#
Opening as (mm (
asic Parameters
78 ode$
Cran9 ,ng$e at #ue$ Supp$y ode u$ti point e$ectric contro$ gaso$ine in!ection (mm before Cy$inder 0iameter -%) -) - E3haust &a$ve "-.) 7mm8 C$osing 78 4 Piston Stro9e 7mm8 "". Ignition ,dvance Hor9ing vo$ume (; (/L (/L ,ng$e 7C,8 (./%" 7*8 Na 0imension and to$erance #it c$earance Cy$inder 6 Compression +atio ().) Compression (% ( (.))～(.- Type of 4"- engine cy$inder ho$e K"-.))L).)) Pressure 7Pa8 " +idge type Combustion 7/))M-))rmin8 ).)4 Chamber Overa$$ 0imension Piston s9irt of 4"- engine K"/.%6L).))% /) /; 6(-)""-4 Ignition Se'uence (2-242/ 7$engthwidthheight8 #ue$ 0esignation % E$ectronic fue$ %- $ead2free gaso$ine ain bearing sadd$e width of cy$inder /( G,ES (%.)2).) 7not $ess than8 in!ection system Thic9ness of thrust p$ate /.4).)) ).)"M)./6 &o$ume of Engine () -. 7new engine oi$ fi$ter8 ).)( Cran9shaft main !ourna$ Oi$ 7*8 /4. 2).)-) /
((
Engine Oi$ 0esignation
S,E()H24) 7grade S1 or above8
Cran9shaft (/
+otationa$
C$oc9wise 7see from engine be$t8
0irection (-
Starting ode
E$ectric starting
(4
Coo$ing ode
andatory circu$ating antifreeJe coo$ing
(
*ubricating ode
(6
Net ass 79g8
Combined type 7pressure and sp$ash $ubrication8 ()
Chapter Two Specification I. Engine Type and a!or Parameters
())
II. a!or aintenance Parameters of Engine
No.
Name 0imension and to$erance #it c$earance No. Name 0imension and to$erance Thic9ness of connecting rod big end //)2).( +).)/( 0iameter of cy$inder head third bearing ho$e /4 H ).(M).4 ") //).-)).( Hidth of cran9shaft connecting rod !ourna$
4
0iameter of cy$inder head fourth bearing ho$e2).)) Top compression ring height (./ 6
(.).)4).)/
(% Second compression ring height
(.2).))2).)-)
).)4)
).)-M).); +).)/(
).46L).)/
%
).)4)
−
).)/
-).6 H ).)/M).(; "()
).)(4 ).)()
).4
) )./
(-
E3haust va$ve stem diameter
K.%6L).));
0iameter of cy$inder head e3haust va$ve guide orifice
K6).)(
#it C$earance K(/2).)(( ).)"～)./6mm Q/;f"
(6 0iameter of cy$inder head second bearing ho$e
＋).)-)
～).);mm ).)/2).)//～ )2).)-) ).)-～ ).)"mm 2).))
).)-/～
).)6-
−
(" guide
0iameter of camshaft third !ourna$
).))～ ).)%)
).)4)
/4e6( ).)- ) −
−
).)/(
).)4)
/4e6( ).)- ) −
−
)M).)6
).)46
K"4 ～).)4-mm ～ ).)(/ ).)(/ K"42).)2).); ).)4-
−
+
).)-
＋
).)) -/e6( ).)66 )
/4 H "()
).))6～
).)-) ).( ～).4mm
0iameter of cy$inder head first bearing ho$e 0iameter of camshaft second !ourna$
～)./)mm ).( ＋).)-) K/;
(4
(
2).4)
)
++
,3ia$ C$earanceore of Camshaft +).)4diameter cran9shaft timing gear 0iameter of cy$inder b$oc9 sca$e tubeof orifice (6.")
0iameter of camshaft first !ourna$
).)/
).)/4 (/G"( ).))6 )
(/
2).))～
++
+
,3ia$ c$earance of connecting rod of cran9shaft timing gear Rey groove dimension 0iameter of cy$inder head va$ve guide orifice K6).)( Rey groove width of cran9shaft gear /4 #it c$earance of connecting rod bearing Outside diameter of va$ve guide K((36 Semicircu$ar 9ey width #itcy$inder c$earance of va$ve main bearing 0iameter of head guide bottom orifice K((:" / ore diameter of cran9shaft pu$$ey #it c$earance between inta9e va$ve stem and va$ve Outside diameter of inta9e va$ve stem K.%;L).)); /6 Outside diameter of timing gear 0iameter of cy$inder head inta9e va$ve guide orifice K6).)(
) ).(～)./)
+
) H "()
+−
).)4)～ ).)"4
+
((
/4 H "()).)/( )
0iameter of cran9shaft front oi$ sea$ Q-6)2).( 0iameter of cy$inder head !ib ho$e // 0iameter of cran9shaft rear oi$ sea$ Q")2).( Outside diameter of hydrau$ic !ib ) Outside ,3ia$ diameter c$earance of engine of cran9shaft oi$ dipstic9 tube (6."−).( 0iameter of cran9shaft timing gear segment /-
()
)
6( ).)- ) /4e).)/M).)"
racing spring height of stee$ strip composite type oi$ (.L).)ringOutside diameter of camshaft oi$ sea$ /( Cran9shaft 9ey0iameter groove width of cy$inder head oi$ sea$ ho$e
).)4)～ ).)"4
−
$ade height oi$groove ring width /) of stee$ strip composite Camshafttype thrust
;
/4 H "()
0iameter cy$inder head fifth bearing ho$e piston oi$ ring grooveof height /.).)-).)( "
).)"4
−
−
2).)-
Second piston ring0iameter groove height of camshaft fifth !ourna$
)
/4e6( ).)- )
0iameter of camshaft fourth !ourna$ (./).)).)#irst piston ring groove height (;
(
#it c$earance
).)4)～ ).)"4
)
).)4)～
).)%6M).(/6
guide ).)-/～).)6-mm
#it c$earance between e3haust va$ve stem and va$ve guide
).))6～).)-mm
#it c$earance between hydrau$ic !ib and cy$inder head ho$e
III. Primary #it C$earance Number
u$tip$e steps tightening 7tor'ue Tightening
of bo$ts No.
Connection part
o$t
Part name
7thread specification8
ang$e8
tor'ue
gas9ets
Nm 7primary
7piece8
tightening8
#irst step tightening
Second step Third step ang$e 78
ang$e 78
tor'ue 7Nm8 Cy$inder b$oc9 main oi$ passage :e3agona$ soc9et head (
I&. Engine Primary Tightening (;(. Tor'ue Tab$e / screw p$ug (
p$ug
Cy$inder b$oc9 main oi$ passage :e3agona$ soc9et head
/)
()(.
(
/)L-
:e3agon bo$t
(((.
4
4L
(;)L()
ain bearing cap
:e3agon bo$t
(((.D%/.
6
4L
(;)L()
#ramewor92cy$inder b$oc9
:e3agon bo$t
;(./
()
/)-
6
Rnoc9 sensor2cy$inder b$oc9
:e3agona$ f$ange bo$t
;(./-
(
/)).
/
screw p$ug /
p$ug
-
ain bearing cap
4
Connecting rod cap2connecting "
rod body
:e3agon bo$t
;(
;
/L-
%)L
:e3agon bo$t
6-
4
;-
6(/
%
;-
Oi$ pump assemb$y2cy$inder ;
b$oc9 Engine oi$ co$$ector brac9et=
%
separator2framewor9
:e3agona$ f$ange bo$t
()
$eeding p$ug2oi$ pan
:e3agon bo$t
(6(.
(
/L-
((
Oi$ pan2framewor9
:e3agona$ f$ange bo$t
"/)
(;
(-
(/
Oi$ pan2framewor9
:e3agona$ f$ange bo$t
"-
-
(-
(-
Oi$ pan2framewor9
:e3agona$ f$ange bo$t
"%)
4
(-
(4
Hater pump2cy$inder b$oc9
:e3agon bo$t
6/
;-
(4(.
/
(-
6(-)
(;
%.L(.
6(3-)
/
%.L(.
Cy$inder head oi$ passage (
thrott$e bo$t Camshaft bearing cap2cy$inder
(6
head
*ocating bo$t
Camshaft bearing cap2cy$inder ("
head
:e3agon thrott$e bo$t
:e3agona$ f$ange bo$t
No.
4/ (; (% 4/) 44 /( 4 // 46 /-
4" /4
4; /
4% /6 /" ) /% -) ( -( / -/ -4 -4 6 - " ; -6 -" % -; 6) -% 6(
No. ConnectionConnection part part
Number Number u$tip$e steps u$tip$e tightening steps tightening 7tor'ue 7tor'ue Tightening Tightening of bo$ts of bo$ts ang$e8 ang$e8 tor'ue tor'ue o$t o$t Part name Part name gas9ets gas9ets #irst step #irst step 7thread specification8 Nm 7primary Nm 7primary Second step 7thread specification8 Second Third step step Third step 7piece8 7piece8 tightening tightening tightening8 tightening8 ang$e 78 ang$e ang$e78 78 ang$e 78 tor'ue 7Nm8 tor'ue 7Nm8
64 $ower E3haust manifo$d2cy$inder head Stud bo$t ;(46 #ront cover of timing Phaser contro$ va$ve2first 6/4 :e3agona$ f$ange bo$t bo$t 6(( Inner he3agona$ / gear2engine 6 camshaft E3haust cap manifo$d2cy$inder head :e3agon nut ; E3haust pipe upper cover of timing C#ront y$inder head2cy$inder b$oc9therma$ Inner he3agona$ bo$t ()(. 6-) 66 :e3agon Inner he3agona$ bo$t bo$t shie$d2e3haust pipe0amping unit2va$ve gear2engine &a$ve cover assemb$y2cy$inder 6(-) Oi$head return of pipe brac9et2cy$inder cover #ront upper cover timing 6(6 6" :e3agon bo$t :e3agon bo$t b$oc9 gear2engine Camshaft position sensor2va$ve 6(( Inner he3agona$ bo$t 6; Oi$ return pipe ho$$ow screw ,ir compressor cover ;/ :e3agona$ f$ange bo$t brac9et2cy$inder b$oc9 6% rac9et2oi$2gas separator Inner he3agona$ bo$t;(4 :anger2cy$inder head :e3agona$ f$ange bo$t ") rac9et2oi$2gas Inner he3agona$ bo$t ,ir compressor brac9et2cy$inder +ear housing of timing separator ;6 :e3agona$ f$ange bo$t ( Cross head screw b$oc9 head gear2cy$inder Power Phaser2camshaft steering pump2steering Inner TO+D ho$$ow bo$t :e3agona$ f$ange bo$t pump brac9et Timing gear2camshaft o$t ; Other Power steering pump2steering In$et cam phaser cap2in$et cam :e3agona$ f$ange bo$t :e3agon bo$t pump brac9et phaser
% ;%
(/ /)
() ;(/ (
-;-
)L /)
(/
;-
;/) 4
(;-
/)
;). ( ()/ /)
( 6/
/ -)/
; /.L).
6
(4(.
( (4 / 6(4
Thrott$e body assemb$y2air #$ywhee$2cran9shaft inta9e pipe Signa$ whee$2f$ywhee$ rac9et2air inta9e pipe Timing be$t2tensioner rac9et2air inta9e pipe assemb$y2cy$inder b$oc9
6/ 4)
Engine oi$ dipstic9 tube2air Timing be$t2id$er compressor brac9et assemb$y2cy$inder head
64(
Engine oi$ dipstic9 u$9head2cran9shaft $ocating tube2framewor9 pin ho$e
:e3agona$ f$ange bo$t :e3agona$ f$ange bo$t
:e3agona$ f$ange :e3agon bo$t bo$t :e3agon bo$t :e3agon bo$t
(/(./ ;(/
/ (
(/)L /)
L(.
(/(./
6
/
(/)L
;L
;/
"
( (
/) -)
(L /)L
( (
/) -)
4)L
( (
/L＋ /)
;;)
,C compressor assemb$y2air Oi$ fi$ter assemb$y2oi$ fi$ter seat :e3agona$ Screw f$ange s$eeve bo$t /)(. ;()) compressor brac9et No. Oi$ fi$ter !oint *ubrication /)(. ,ir compressor assemb$y2air ;-) Oi$ fi$ter seat2cy$inder b$oc9 :e3agona$ Inner he3agona$ bo$t bo$t ;/ ( Piston pinf$ange and pin (ho$e compressor brac9et (4(./(/ Oi$ pressure switch2oi$ fi$ter 5enerator assemb$y2generator (-(-） / Piston ring groove （ ()%) :e3agona$ f$ange bo$t brac9et Thermostat assemb$y2cy$inder 66) :e3agon bo$t 5enerator $ower head ()4 :e3agona$ f$ange bo$t brac9et2cy$inder b$oc9 Thermostat cover2thermostat 6() 6/) f$ange Ignition coi$ assemb$y2brac9et :e3agona$ :e3agon bo$t bo$t case Spar9 p$ug2cy$inder head :e3agon bo$t (4(./ Coo$ant senser2thermostat she$$ (/(. Inta9e manifo$d2cy$inder head Stud bo$t 6(/ Cran9shaft timing (-(. f$ange Inta9e manifo$d2cy$inder head :e3agona$ :e3agon nut bo$t 6 gear2cran9shaft 0e$ivery pipe assemb$y2air Cran9shaft pu$$ey2cran9shaft inta9e pipe timing gear
4
;
Power steering pump2steering E3haust cam phaser cap2e3haust :e3agona$ f$ange bo$t Inner TO+D bo$t pump brac9et cam phaser
/
()
Type ( of $ubricant /L(
/) S1()H24)
/)
( (
S1()H24) -)＋
/
;4)＋
4
;-
4 ( %
-)/) -/
( %
;-
(-)L()
6L
6/) ;((
/ 6
;
/L
-)L
;(./ 6()
; 4
;-
(L
-)L
;(./ ;-)
6 /
;L/ /)
(/L/
:e3agona$ f$ange bo$t
; ;4)
( /
/"L/)
Inner he3agona$ bo$t :e3agona$ f$ange bo$t
6(6 ()6)
( (
;4)
:e3agon bo$t :e3agona$ f$ange bo$t
6(6 (6(.
( (
;/L-
-
Connecting rod bearing she$$ and connecting rod !ourna$
4 No.
Cy$inder s $eeve ho$e Parts where rubber coating are re'uired ain bearing $ining and cran9shaft main
!ourna$ Cy$inder b$oc9 bow$ p$ug Cran9shaft thrust sheet 7at oi$ groove side8 Cy$inder b$oc9 main thrust surface oi$ passage p$ug and
( 6 "
/
-
b$oc9 :ead and root of main bearing cap bo$t Outer r ing of cran9shaft rear oi$ sea$ +ear oi$ sea$ edge and cran9shaft oi$ sea$
; 4 %
1unction cy$inder :ead and p$ane threadof of framewor9 connecting and rod bo$t
#ramewor9 !ourna$a nd oi$ pan
S1()H24) S1()H24) Type of sea$ant S1()H24) *octite 64; S1()H24) *octite /4S1()H24) *octite ( S1()H24) *octite /4S1()H24) *octite %()
S1()H24) *octite /4S1()H24) *octite /4S1()H24)
&. Th e Part s wher e *ubr icatio n are +e'uir d duri g ,ss mb$y f
*octite /4S1()H24)
Engine
() 6
:ead and root of cy$inder head bo$t Cy$inder h ead bow$ p$ug
S1()H24) *octite 64;
(( " Number
&a$ve guide orifice ain oi$ passage screw p$ug Position
S1()H24) *octite /4-
(/ (; / (-%
&a$ve stem Chassis ase p$ane of first bearing cap Engine &a$ve oi$ sea$ $ip Hater temperature sensor Transmission
,ccessory&a$ve seat inserte Oi$ pressure switch odification n ody &a$ve 9eeper ring groove #irst modification e #$ywhee$ bo$t o Second modification Cam and !ourna$ of camshaft Third modification Oi$ pan main oi$ passage p$ug Camshaft bearing ho$e #ourth modification
(4 4 () ( , (( (6 C (/ 0(" ( (;
Engine oi$ co$$ector separator bo$t E3terna$ surface and base p$ane of hydrau$ic !ib
s
S1()H24) *octite "4 S1()H24) *octite /4-
*octite /4S1()H24)
&I. The Part where +ubbe
(%
:ydrau$ic !ib ho$e and va$ve roc9er arm head
S1()H24)
e'
/)
Outer ring of oi$ pump
S1()H24)
uired during
,
/(
Edge or !ourna$ of camshaft oi$ sea$
S1()H24)
ssemb$y
r
// /-
Inta9e and e3haust phaser contro$ va$ve gas9ets 1ourna$ of inta9e and e3haust phaser
Coating are +
S1()H24) S1()H24)
Chapter Three Specia$ Too$s P$ease use the specia$ too$s that we designated to perform maintenance= otherwise it wi$$ cause accident or damage the machine.
of Engine
I. Connotation of Specia$ Too$ Number In order to 9now or find the too$ c$ear$y according to parts number and improve maintenance efficiency= specia$ too$s numbering is stipu$ated as fo$$ows> ?????
@
? aintemance times coresponding to too$s
SN coresponding to too$s System code coresponding to too$s Too$s name
? indicates a $etter @ indicates an ,rabic numera$ Nomenc$ature of the too$> for a standard part= p$ease use the brand and mode$ recommended by Chery company as reference. #or e3amp$e= C: indicates a non standard part= which means it is a
specia$ too$ for repair of this part verified by ,fter Sa$es Service 0epartment of Chery ,utomobi$e Sa$es Co.= *td. :,ET indicates a standard too$ produced by this company.
C:2/)))/
Insta$$ation too$ for camshaft oi$ sea$>
used to insta$$ camshaft oi$ sea$.
C:2/)))-
Engine e
timing
too$>
used
to
Same as ,
tim Same as ,
cran9shaft.
C:2/)))4
,daptor> used to insta$$ and removeSame as , va$ve spring 7match with Eastar specia$
#or e3a
too$ *+20%%;""/,8.
mp$e> C:2 ())/, means i
C:2/)))
Insta$$ation too$ for cran9shaft rear oi$ Same as ,
t is th
sea$> used to insta$$ cran9shaft rear oi$
e / sp
sea$.
ecia$ to o$ for r
Connotation of system code corresponding to the too$>
epair o f chassi
C:2/)))6
Insta$$ation hand$e for cran9shaft rear Same as ,
s syste
oi$ sea$> used to insta$$ cran9shaft rear
m that
oi$ sea$.
has bee n
Corresponding series number of too$s> from ))( to %%%. C:2/)))" of the too$> Insta$$ation s$eeve for cran9shaft front Same as , Times of modifications oi$ sea$> used to insta$$ cran9shaft front oi$ sea$.
Note: In a$phabetica$ order. igger SN means more modification times. verified by ,fter Sa$es Service 0epartment of Chery ,utomobi$e Sa$es Co.= *td.= who commits production of this too$ to other manufacturer. This too$ is of the first modification.
:,ET26/%)2(CT means it is a standard too$ produced by :,ET company with its mode$
C:2/)));
C:2/))(" Insta$$ation s$eeve for cran9shaft Insta$$ation front too$Same for as va$ve , 9eep Same as ,
er> used
oi$ sea$
to insta$$ va$ve 9eeper.
C:2/)))%
C:2/))(;2, *ocating
too$
for f$ywhee$> &a$ve used spring Same remover> as , used to remove Same as ,
$ocate f$ywhee$.
+ecommended too$s
C:2/))()
Camshaft
timing
va$ve spring. *oop whee$ machine> used to raise engine.
too$>
used to timeSame as ,
camshaft.
C:2/))((
Insta$$ation too$ for camshaft used to insta$$ camshaft oi$ sea$.
C:2/))(/
#ue$ pressure gauge> used to measure oi$ pressure
&a$ve oi$ sea$ remover> used to remove Same as , va$ve oi$ sea$.
C:2/))(
e$t
pu$$ey bo$t
wor9bench fo
Same as ,
engine.
C:2/))(-
2(CT.
II. S Engine maintenance wor9bench> peciathe oi$ sea$> Same asassemb$y , disassemb$y and of engine. $ Too $s Ch art
&a$ve oi$ sea$ guide s$eeve> used insta$$ va$ve oi$ sea$.
as 6/%)
remover>
used
Same as ,
remove be$t pu$$ey c$ip.
Pressure gauge for cy$inder> used to measure cy$inder pressure. Hhen measuring= remove spar9 p$ug first=
screw instrument pipe orifice into the position of spar9 p$ug= use starter to drag the engine to rotate= and then fetch the ma3imum reading of the pressure gauge for cy$inder as cy$inder pressure of this cy$inder.
Chapter #our easurement of Cy$inder Pressure I. 0etection of Cy$inder Pressure easurement of cy$inder pressure is the ma!or inde3 for !udgment of engine wor9ing condition= through which= we can definite$y !udge if a certain system of engine wor9s we$$. Therefore= during maintenance of engine= measurement of cy$inder pressure is indispensab$e.
(. easuring process P$ease
se$ect
a
cy$inder pressure
gauge with accurate reading and $et its pointer return to JeroA otherwise= it may affect accuracy of reading.
(.( Turn off ignition switch= pu$$ out a$$ ignition cab$es from
spar9 p$ug
side=
and
then pu$$
out
harness
connector of in!ection noJJ$e.
(./ Gse a spar9 p$ug s$eeve to $oosen the spar9 p$ug whose cy$inder wi$$ be measured. Explanation: do not remove the spar9 p$ug whose cy$inder wi$$ not be measured. (.- Screw the cy$inder pressure gauge !oint s$ow$y and vertica$$y into the spar9 p$ug ho$e. 0o not screw too tight$y for fear that it may be difficu$t to disassemb$e. (.4 Step down c$utch peda$= start the engine and $et it run for about 26s= then fetch the numerica$ va$ue.
/. 1udgment of cy$inder pressure va$ue /.( Correct cy$inder pressure The
standard
cy$inder pressure
va$ue
shou$d be
()2(-.bar. Hith use of engine= this va$ue wi$$ fa$$= but it
shou$d
not be be$ow
%bar with
the pressure
difference among cy$inders not e3ceeding -bar. /./ In case cy$inder pressure of engine is be$ow the standard
va$ue=
it indicates
deficiency
of cy$inder
pressure= the main cause of which may be untight piston ring sea$ or va$ve. P$ease further ana$yJe and chec9. Hhen ensure
starting
ade'uate
the 'uantity
engine= of
e$ectricity. Correct cy$inder pressure can on$y be measured out with revo$ution of engine as /))2-))rmin.
Chapter #ive 0isassemb$y of Power2assisted Steering System I. 0isassemb$y Procedure (. Gse a
snap
ring p$iers
to $oosen the c$amp
connecting hose of steering f$uid reservoir and steering pump. Gse a c$ean container to rec$aim the steering f$uid.
/. Gse a /( s$eeve to remove the fi3ing bo$t of steering pump oi$ pipe. Tor'ue> /)Nm.
-. Gse a () s$eeve to $oosen the 7upper8 fi3ing bo$t of
on
steering pump ad!usting brac9et. Tor'ue> /)Nm.
4. Gse a () s$eeve to $oosen the 7$ower8 fi3ing bo$t of steering pump ad!usting brac9et. Tor'ue> /)Nm. . Gse a () open end wrench to $oosen the ad!usting bo$t of steering pump brac9et= and then pu$$ the steering pump upwards to $oosen and ta9e off the be$t.
6. Gse a () s$eeve to $oosen the connecting bo$t of steering pump and compressor brac9et= pu$$ out harness connector=
and
then
dismount
the
steering
pump
assemb$y.
Note: when dismounting the
steering pump= p$ease b$oc9 the oi$ pipe !oint with c$ean cotton c$oth.
II. Overhau$ Steering pump can not be repair= if such fai$ure as abnorma$ noise or oi$ $ea9 e3ists= rep$ace the assemb$y.
III. Insta$$ation of the Steering Pump (. #o$$ow the order adverse to that of disassemb$y to insta$$. /. ,fter insta$$ation of steering oi$ pump= du$y ad!ust tightness of be$t through ad!usting bo$t.
-. ,fter power steering pump is proper$y insta$$ed= refi$$ with specia$ steering pump oi$= and then b$eed air for the power steering pump after the engine starts. 4. ,ir b$eeding method> 4.( :oist the vehic$e to $et its front whee$s $eave ground. 4./ Turn the steering whee$ $eft and right to the ends 7duration for each time shou$d not e3ceed s= otherwise= the power steering pump is $i9e$y to be burnt out8 unti$ the oi$ pump does not ma9e sound. Note that oi$ storage 9ett$e shou$d not be $ac9 of steering pump oi$.
Chapter Si3 0isassemb$y of ,C Compressor I. 0isassemb$y Procedure efore disassemb$ing the compressor= disassemb$e the steering oi$ pump first. (. Gse a (/ s$eeve and a universa$ !oint connecting rod to $oosen the connecting bo$t of ,C high and $ow pressure pipe$ines. 7Note: if there is +(-4a in the condenser= use a specia$ e'uipment to rec$aim first.8 ,fter
the
pipe$ine
is
$oosened= immediate$y b$oc9 high and $ow pressure ho$es of the compressor with c$ean cotton c$oth to avoid entry of foreign materia$ into the compressor
/. :oist the vehic$e and then use a (- s$eeve to $oosen the fi3ing bo$t of the compressor from underside. Tor'ue> /)Nm.
-. *ower the vehic$e and then use a (- s$eeve to $oosen the fi3ing bo$t of the compressor from upside. Gse a (- s$eeve
to
$oosen
the
fi3ing bo$t
at
midd$e
of the
compressor= and then dismount the compressor assemb$y. Tor'ue> /)Nm.
II. Overhau$ of Compressor Inside of the compressor are assemb$ed with high$y machined fine parts= in case abnorma$ noise or
interna$ fai$ure is found= rep$ace the assemb$y.
III. Insta$$ation procedure #or the insta$$ation order= p$ease refer to the disassemb$y order= and then fo$$ow the order adverse to that for disassemb$y to insta$$. It shou$d be noted that= when insta$$ing the ,C pipe$ine !oint on the compressor= be sure to rep$ace with a new gas9et and tight the !oint at specified tor'ue to avoid $ea9.
Chapter Seven 0isassemb$y of 5enerator I. 0isassemb$y Procedure efore disassemb$ing the generator= remove the connecting $ine of battery first.
(. Gse a () s$eeve to remove the connecting $ine of battery.
/. Gse a () s$eeve to $oosen the fi3ing bo$t of generator ad!usting brac9et= and then ta9e off the ad!usting brac9et. Tor'ue> -)Nm. -. Gse a (- s$eeve to remove $ower fi3ing bo$t of the generator. Tor'ue> 4)Nm.
4. Gse a () s$eeve to remove the fi3ing bo$t of generator anode harness= pu$$ out the harness connector= remove the be$t and then ta9e out the generator.
II. Overhau$ of 5enerator In case the generator ma9es abnorma$ noise or its yie$d is too high or too $ow= rep$ace the assemb$y.
III. Insta$$ation Procedure The insta$$ation order of the generator is adverse to that for its disassemb$y. ,fter the generator is insta$$ed= ad!ust def$ection of the be$t.
Chapter Eight +ep$acement of Engine Timing e$t I. 0isassemb$y Procedure In order to ensure norma$ and high$y
effective
engine= rep$acing the
wor9ing
of the
timing be$t at
)=)))9m mi$eage is recommended.
(. 0isassemb$y of engine timing be$t> (.( #o$$ow the disassemb$y methods for power2assisted steering pump= compressor and generator to disassemb$e the generator and compressor be$t. (./ Gse a mm he3agon wrench to remove the five fi3ing bo$ts on timing upper cover.
(.- The positions of the five fi3ing bo$ts on timing upper cover are shown by the red circ$es in the figure.
(.4 Gse a (- s$eeve to $oosen the cran9shaft timing ad!usting ho$e bo$t. 7The ad!usting bo$t is at upside of the
(. Insert the specia$ too$ C:2/)))- into the timing ho$e and tighten= use a wrench to turn the big nut in
(.() Gs
he cran9shaft pu$$ey to ma9e the cran9shaft rotate= at the same
time=
s$ow$y
screw
in
C:2/)))-
unti$
he cran9shaft can not rotate bac9 and forth any $onger.
(.6 Gse a (- s$eeve to remove the si3 fi3ing bo$ts cran9shaft pu$$ey and ta9e out the cran9shaft pu$$ey. Tor'ue> Nm.
(. (." Gse a () s$eeve to remove the si3 fi3ing bo$ts timing $ower cover.
(.; The positions of the si3 fi3ing bo$ts on timing $ower cover are shown by the red circ$es in the figure.
(.% It shou$d be specia$$y e3p$ained that= the position of the fi3ing bo$t at $eft upside on the $ower cover is very occu$t= for remova$ of which= use of universa$ !oin t connecting rod is re'uired. ,$ternative$y= use a (-mm s$eeve to remove the three bo$ts of suspension brac9et to ta9e off the suspension brac9et.
*oosen the fi3ing bo$t of tension pu$$ey and turn the tension pu$$ey to minimum tension position. /. Insta$$ the be$t. -.
Gse a mm he3agon wrench to turn the tension pu$$ey= when it turns to a position that the he3agon wrench and the fi3ing bo$t are rough$y on the same horiJonta$ $ine= stop and tighten the fi3ing bo$t.
4.
Insta$$ timing $ower cover.
.
Insta$$ cran9shaft pu$$ey.
6.
Insta$$ re$evant accessories and chec9 def$ection of the be$t.
".
Insta$$ timing upper cover.
;.
The insta$$ed timing be$t is as shown in the figure. Note> 0uring the disassemb$y process= be
sure
not
otherwise=
to
turn
cran9shaftcamshaftA
ignition timing
wi$$
need
re2chec9.
III. ,d!ustment of Timing 7genera$ overhau$8 (. Turn the cran9shaft to ma9e the four pistons a$ign on a horiJonta$ $ine in the cy$inders= screw the specia$ too$ into the cran9shaft timing ad!usting ho$e at $eft rear of the cy$inder 7$ast segment of the cran9shaft8= and then ma9e the cran9shaft unab$e to turn $eft and right 7the bo$t of the specia$ too$ must enter into the screw ho$e p$ane of the cy$inder8. /. ,fter inta9e and e3haust camshaft is insta$$ed proper$y= insta$$ the camshaft timing gear= turn the groove at tai$ of inta9e and e3haust camshaft to horiJonta$ direction= and then insert the specia$ too$ into the groove and fi3. -. ,fter cran9shaft and camshaft have been fi3ed according to re'uirements= insta$$ timing be$t. In order to faci$itate insta$$ation of timing be$t= temporari$y do not tighten the bo$t fi3ing the timing gear onto camshaft and $et it rotate free$y= then fi3 the timing gear bo$t after the tensioner pu$$ey has fastened the timing be$t to the specified va$ue. ,fter that= insta$$ other parts.
I&. ,d!ustment of Timing 7minor overhau$8 +ep$ace va$ve spring= grind va$ve and rep$ace camshaft 7do not raise the engine8. (. +emove the va$ve cover. /. +emove the timing gear cover. Turn the timing gear. -.
*et the groove at tai$ of inta9e and e3haust camshaft on a horiJonta$ $ine= then insert the pro!ecting portion of the specia$ too$ into the groove and fi3.
4. Turn the cran9shaft= screw the specia$ too$ into the cran9shaft timing ad!usting ho$e at $eft rear
of the cy$inder 7$ast segment of the cran9shaft8= and then ma9e the cran9shaft unab$e to turn $eft and right 7if the cy$inder head is removed= it can be found that the pistons of the four cy$inders now a$ign at a horiJonta$ position8. . Insta$$ timing be$t and ma9e tightness of the be$t conform to re'uirements. 6. #asten the fi3ing bo$t of timing gear. ". Insta$$ other accessories= such as timing cover and be$t pu$$ey etc.
Specia$ too$ for camshaft timing chec9 7C:2/))()8
Specia$ too$ for cran9shaft timing chec9 7C:2/)))-8
Chapter Nine 0isassemb$y of Engine ,ssemb$y I. 0isassemb$y Procedure Note> P$ease use regu$ar e'uipment= especia$$y for such e'uipment as crane etc.= so as to avoid occurrence of accident. efore any disassemb$y !ob= disassemb$e cathode of battery first= so as to protect safety of e$ectricity consumption e'uipment. Hhen disassemb$ing engine
suspension= pay attention to
disassemb$y order= so as to avoid occurrence of accident.
(. 0isassemb$y of engine wire harness (.( Pu$$ out the connecting p$ug of engine wire harness.
(./ Gse a () s$eeve to $oosen the fi3ing bo$t of engine ground.
/. Gse a () s$eeve to remove the fi3ing bo$t and bearer of battery. -. Gse a (- s$eeve to remove the bo$t of battery support fi3ed mount.
4. 0isassemb$y of coo$ing system. 4.( :oist the vehic$e= p$ace away a coo$ant co$$ector= unscrew b$eeder bo$t of the water tan9 to discharge the coo$ant.
4./ Gse the snap ring p$iers to $oosen the c$amp on connecting pipe of water tan9.
4.- Gse the snap ring p$iers to $oosen the connecting water pipe of ,C heating water tan9. 4.4 Gse the snap ring p$iers to $oosen other connecting water pipes.
. 0isassemb$y and insta$$ation of water pump assemb$y> .( +emove upper and $ower covers of timing gear 7refer to disassemb$y and insta$$ation of gear and be$t of timing
gear8. ./ Gse a ca$iper to ta9e off the c$amps on the three discharging tubes and then pu$$ out the rubber hoses. .- Gse a ()mm s$eeve to remove the fi3ing bo$t of discharging tube of water pump and then pu$$ out the discharging tube. Note: in case the O2ring on discharging tube of water
pump is $oose= bro9en or aging= be sure to rep$ace.
.4 Gse a ()mm s$eeve to remove the fi3ing bo$t of water pump and then ta9e out the water pump assemb$yA when removing= be carefu$ not to damage cushion of the water pump= if damaged= rep$ace with a new one. The water pump can not be decomposed to maintain. . Chec9 water sea$ of the water pump for water $ea9A if water pump bearing is $oose= rep$ace the assemb$y. #o$$ow the order adverse to that for disassemb$y of the water pump to insta$$ it. .6 0isassemb$y and insta$$ation of thermostat ." Gse a ca$iper to ta9e off the c$amps on the two discharging tubes and then pu$$ out the rubber hoses.
.; Gse a ()mm s$eeve to remove the fi3ing bo$t of thermostat cover and then ta9e out the thermostat.
.% Gse a ()mm soc9et wrench to remove the thermostat seat. e carefu$ not to damage the thin sheet gas9et. 6. Inspection of thermostat> 7(8 Gnder norma$ temperature= inspect seating status of the va$ve and it shou$d tight$y seat. 7/8 Inspect opening temperature and ma3imum stro9e of the va$ve. Opening temperature of the va$ve is ;"L/℃
a3imum stro9e of the va$ve is ;mm #u$$ opening temperature of the va$ve is ()4℃ 7-8 Then chec9 if the va$ve c$oses at the temperature ℃ $ower than the opening temperature. If not comp$iant= rep$acement with a new thermostat is re'uired.
#o$$ow
the
order adverse
to
that
for
disassemb$y of the thermostat to insta$$ it. Hhen insta$$ing= chec9 if the gas9et of the thermostat is damaged= if thermostat seat and thermostat cover casing p$ane are satisfactory.
Chec9 the sea$ing
gas9et for damage= if damaged= rep$ace with new sea$ing e$ement. ". 0isassemb$y of ,C pipe$ine See Disassembly of A/C Compressor for disassemb$y of ,C pipe$ine. ;. 0isassemb$y of power2assisted steering pipe$ine. See Disassembly of Power-assisted Steering Oil Pump for disassemb$y of power2assisted steering pipe$ine. %. 0isassemb$y of inta9e and e3haust manifo$d. %.( Gse a () s$eeve to remove the fi3ing bo$t of air inta9e pipe.
%./ Gse a cross2head screwdriver to $oosen the c$amp connecting inta9e hose and e$ectronic thrott$e body. %.- Gse a (- s$eeve to remove the connecting bo$t of three2way cata$ytic converter and e3haust intermediate pipe. Tor'ue> 6)L Nm.
%.4 Gse a () s$eeve to remove heat insu$ating mattress of e3haust pipe.
%. Gse a (- s$eeve to remove the connecting bo$t of e3haust manifo$d and three2way cata$ytic converter. Tor'ue> 6)L Nm.
%.6 Gse a (- s$eeve to remove the fi3ing bo$t of e3haust manifo$d.
(). 0isassemb$y of connecting portion of transmission case. ().( Gse p$iers to remove the fi3ing stee$ wire c$ip of gearshift contro$ cab$e. ()./ Gse p$iers to remove the fi3ing c$ip of gearshift contro$ cab$e outer case and then ta9e off the gearshift contro$ cab$e.
().- Gse a (- s$eeve to $oosen the ad!usting screw of c$utch contro$ cab$e and then ta9e off the c$utch contro$ cab$e.
().4 Gse a (- s$eeve to $oosen the fi3ing bo$t of c$utch contro$ cab$e on the transmission case.
(). Gse a (" wrench to $oosen the b$eeding bo$t of transmission case to discharge the gear oi$. ().6 See Servie !anual for C"assis for disassemb$y of suspension trave$ portion. ()." Gse a crow to pry out the ha$f shaft. ((. 0isassemb$y of suspension portion ((.( Gse a (- s$eeve to remove the fi3ing bo$t for rear engine mount brac9et of transmission case. Tor'ue> 6)LNm. ((./ Gse a (; s$eeve to $oosen the fi3ing bo$t for front engine mount brac9et. Tor'ue> ;)L Nm.
((.- Gse a crane to hoist the engine unti$ the iron chain !ust bears tensi$e force.
((.4 Gse a ( s$eeve to $oosen the fi3ing bo$t for right engine mount brac9et. 7at rear of transmission8 Tor'ue> ())L Nm.
((. Gse a (- s$eeve to $oosen the three connecting bo$ts for right engine mount brac9et. Tor'ue> 6LNm.
((.6 Gse a (- s$eeve to $oosen the three connecting bo$ts for $eft engine mount brac9et. ((." Pu$$ out oi$ pipe connector and !unctions of re$evant pipe$ines. a9e sure that re$evant !unction parts have a$$ detached. ((.; :oist the engine up. (/. Separation of transmission case assemb$y and engine (/.( Gse a () s$eeve to remove the gearshift contro$ cab$e brac9et on the transmission case.
(/./ Gse a (- s$eeve to $oosen the four fi3ing bo$ts for front engine mount brac9et. Tor'ue> 6LNm.
(/.- Gse a (- s$eeve to remove the connecting bo$t of transmission case and engine= and then ma9e the engine and the transmission separate. Tor'ue> ())L() Nm.
II. Insta$$ation Procedure (. P$ease fo$$ow the order adverse to that for disassemb$y to insta$$= but care shou$d be ta9en for the fo$$owing matters. 7(8 Hhen hoisting= do not insta$$ e3haust manifo$d first= because the $ongitudina$ separation of engine compartment is not big enoughA otherwise= it may affect the assemb$y. 7/8 ,fter insta$$ation= p$ease ad!ust the stro9e of c$utch peda$. Hhen ad!usting= ad!ust it to a proper position according to the corresponding re'uirements= in case of a too big free stro9e of c$utch= it may ma9e sound when shifting gear or fai$ to re$easeA whi$e in case of a too sma$$ stro9e= wear of friction p$ate may be acce$erated and trave$ wea9ness may occur= if severe$y= the friction p$ate may be burnt out.
Chapter Ten 0isassemb$y of Inta9e anifo$d I. 0isassemb$y Procedure (. Gse an ; s$eeve to remove the four fi3ing bo$ts of ignition
coi$
and
then
remove
such
connections
as
ignition cab$ein!ection noJJ$e harness etc.
/ Gse a () s$eeve to remove the bo$t of inta9e manifo$d fi3ing brac9et. -. Gse a () s$eeve to remove the fi3ing bo$t of compressor brac9et. Tor'ue> -)L- Nm.
4 Gse a () s$eeve to remove the fi3ing bo$t of inta9e manifo$d and then ta9e off the inta9e manifo$d assemb$y. Tor'ue> ;-Nm.
Chapter E$even 0isassemb$y of Cy$inder :ead I. 0isassemb$y Procedure
( Gse a () s$eeve to remove the fi3ing bo$t of va$ve cover. Tor'ue> ;L- Nm.
/. 5et the specia$ too$ C:2/))() stuc9 into the groove on camshaft. -. Gse a (; s$eeve to $oosen the fi3ing bo$t of camshaft timing gear. Tor'ue> (/)LNm. Note> There
is
no
difference
between
inta9e
camshaft and e3haust camshaft= they can be interchanged.
4. Gse a cross2head screwdriver to $oosen the fi3ing bo$t on inner fender of timing gear and then ta9e out the inner fender of timing gear.
. Gse a () s$eeve to remove the fi3ing bo$t of camshaft bearing= ta9e out the camshaft assemb$y and then the hydrau$ic tappet system. Tor'ue> %.L(. Nm. Note> The positions of both camshaft bearing and bo$ts=
inc$uding
the
order of camshaft
bearing=
are
unchangeab$e= and shou$d be conformity with the mar9s during assemb$ydisassemb$y.
6. Gse an he3agon tor'ue wrench to $oosen the fi3ing bo$t of cy$inder head and then ta9e off the cy$inder head assemb$y.
Tor'ue> )L Nm. Note> #o$$ow the order as shown in the figure to $oosen the fi3ing bo$ts of cy$inder head.
". 0isassemb$y of va$ve ".( Gse a specia$ too$ to press down the va$ve spring= ta9e out the $oc9ing p$ate= and then ta9e off va$ve spring= va$ve and va$ve seat insert.
"./ Gse a specia$ too$ to pu$$ out the va$ve oi$ sea$.
II. Overhau$ of Cy$inder :ead System (. 0etection of camshaft (.( easurement of height of cam. Gse an outside micrometer to measure whee$ height of the cam. Hhee$ height of the inta9e camshaft> -".((mm. Hhee$ height of the e3haust camshaft> -".)%mm.
(./ Inspection of camshaft !ourna$. Gse an outside micrometer to measure each !ourna$ of the camshaft= p$ease see Speifiation #able for specific data.
/. 0etection of va$ve /.( 0etection of va$ve spring. Two items of data of va$ve spring shou$d be measured. *ength of the spring> 4%mm S'uareness of the spring> (./mm 7$imit8
/./. 0etection of va$ve.
/./.( easurement of diameter of va$ve stem /././ easurement of va$ve guide inside diameter Gse
an
inside
micrometer
to
easurement point easurement point
measure
inside
diameter of the guide. Note> If abnorma$
noise
is
generated
due
to
serious wear of va$ve guide= do not rep$ace the va$ve guide= because the assemb$y techni'ue re'uirements to va$ve guide is very strictA p$ease rep$ace the cy$inder head assemb$y.
#it c$earance between inta9e va$ve stem and va$ve guide> ).)(/M).)4-mm #it c$earance between e3haust va$ve stem and va$ve guide> ).)-/M).)6-mm /.- oring and grinding va$ve seat insert /.-.( Inspection of fitting surface of va$ve. ,pp$y a circ$e of red $ead on the va$ve sea$ing strip and then gent$y p$ace the strip onto the va$ve seat insert= soft$y and forcib$y press it down= but do not turn it. Ta9e out the va$ve= observe if there is bro9en part on the red $ead= if any= boring and grinding the va$ve seat insert is re'uired.
/.-./ Se$ect an appropriate reamer= use 4 conica$ surface as cooperate standard va$ue to chec9 va$ve cooperation position> the optima$ position is the center of the va$ve= if not so= be sure to revise. Cut on the conica$ surface ") inward and -) outward at the center of the cooperation position.
/.-.- Perform seat grinding for the va$ve sea$ing strip with po$ishing compound /.-.4 0etection of p$aneness of cy$inder head #o$$ow the
method as
shown
in
the
figure
to
measure p$aneness of the cy$inder head with a fee$er gaugeA the p$aneness of the cy$inder shou$d not e3ceed
).)2).()mm=
if
e3ceeding
rep$ace the cy$inder head assemb$y.
this
va$ve=
III. ,ssemb$y of Cy$inder :ead ,ssemb$y (. P$ease
fo$$ow the
order adverse
to that
for
disassemb$y of cy$inder head to insta$$= but care shou$d be ta9en for the fo$$owing matters during insta$$ation. /. Gse the specia$ too$ C:2/))(/ to insta$$ new va$ve oi$ sea$ onto the guide first.
-. Insert big end of the guide onto the va$ve guide.
4. Enve$ope the specia$ too$ onto C:2/))(/= and then soft$y and forcib$y compact. . Gse a hammer to 9noc9 the va$ve oi$ sea$ insta$$ation too$= when a meta$ crash sound is heard= ta9e out C:2/))(/.
6. The methods for insta$$ation and assemb$y of va$ve spring are the same. Then insta$$ va$ve= spring= 9eeper= top barre$ and roc9er arm. 7when insta$$ing the top barre$= add a $itt$e engine oi$ into the ho$e8.
". Insta$$ camshaft and camshaft bearing she$$ cover assemb$y.
Note> Hhen insta$$ing= remember to differentiate inta9e camshaft from e3haust cam. The inta9e camshaft has a gear at tai$= and pay attention to the diacritica$ mar9s on camshaft bearing she$$ covers.
;. Insta$$ation of camshaft and oi$ sea$ ;.( ,fter adding engine oi$ on the camshaft bearing she$$= p$ace inta9e and e3haust camshafts= cover bearing she$$ covers proper$y= insta$$ the fi3ing bo$ts for the bearing she$$ covers= and then use a ()mm s$eeve to ho$d down the bearing she$$ covers step by step 7the two bo$ts on the one and the same bearing she$$ cover shou$d be tightened at the same time8. Tor'ue> ;.L(. Nm. %. +emember to app$y sea$ant to the position as shown in the figure when insta$$ing the first bearing she$$. (). Tightening order of camshaft bearing she$$ cover. Tighten the camshaft bearing she$$ cover as shown in the figure. Insta$$ation of camshaft oi$ sea$> ,pp$y a $itt$e engine oi$ on the camshaft oi$ sea$= enve$op the oi$ sea$ onto the camshaft= and then insta$$ use the specia$ too$.
((. +emember to chec9 e$asticity of va$ve cover gas9et for aging and brea9down= if any= rep$ace with new
one. Hhen insta$$ing=
pay
attention to
insta$$ation position. (/. Tighten the va$ve cover bo$t.
Chapter Twe$ve 0isassemb$y and Insta$$ation of Oi$ Pump and *ubrication System
I. 0isassemb$y Procedure (. +o$$ over the engine and use a () s$eeve to remove the fi3ing bo$t of oi$ pan. Tor'ue> (- Nm
/. Gse a screwdriver to pry out the oi$ pan at the given position for prying out on the oi$ pan. Note> ecause the oi$ pan and cy$inder b$oc9 are sea$ed with g$ue= so= do not 9noc9 with such hard artic$es as hammer etc. when disassemb$ing= use a rubber hammer to s$ow$y stri9e at $eft and right instead.
-. Gse a () s$eeve to remove the fi3ing bo$t of engine oi$ strainer. 4. Gse an ; s$eeve to remove the fi3ing bo$t of engine oi$ guard board.
. Gse an ; s$eeve to remove the four fi3ing bo$ts of oi$ pump. Tor'ue> ;-Nm
6. Ta9e off the oi$ pump assemb$y and then the oi$ pump shim. Note>
0o not sp$it the oi$ pump shim forcib$y when disassemb$ing for fear to cause $ea9.
".
Gse
an
he3agon
wrench
to
remove
the
two
connecting bo$ts of oi$ pump.
;. Gse a screwdriver to pry the cran9shaft front oi$ sea$ and then ta9e out the oi$ sea$.
II. Overhau$ of Oi$ Pump if it is suspected that engine oi$ pressure may has prob$em= disassemb$e the oi$ pump and chec9 e$astic force of re$ief va$ve spring and if the va$ve is $oc9ed. Note> The oi$ pump is of inner rotor type= which can not be maintained under norma$ conditions= because its finish siJe and materia$ ensure its re$iabi$ity.
III. Insta$$ation Procedure The insta$$ation order is adverse to that for disassemb$y= but care shou$d be ta9en for the fo$$owing matters. (. The insta$$ation direction of oi$ pump re$ief va$ve is as shown in the figure.
/. Comp$ete$y and soft$y shove$ off the g$ue on the surface of oi$ pan with a f$at shove$ and then app$y new sea$ant uniform$y 7see the tab$e above for type of the sea$ant8. Note> ,s soon as new sea$ant is app$ied proper$y= assemb$e at onceA otherwise= the sea$ant
may freeJe=
which may affect the sea$ing effect.
Chapter Thirteen 0isassemb$y of Cran92Connecting +od echanism I. 0isassemb$y Procedure ( Gse a (- s$eeve to remove the fi3ing bo$t of c$utch cover. Tor'ue> /-L/ Nm
/. Gse the specia$ too$ C:2/)))% to $oc9 the cran9shaft and then use a (- s$eeve to remove the connecting bo$t of f$ywhee$ and cran9shaft.
-. Gse a (- s$eeve to $oosen the fi3ing bo$t of connecting rod bearing cy$inder by cy$inder and then ta9e off the piston and connecting rod assemb$y. Note> ,fter the pistons are ta9en out of the cy$inders= reset and connect the bearing caps of connecting rod big end and bo$ts proper$y and then put them by order.
4. Gse a () s$eeve to remove the fi3ing bo$t of cran9shaft $ower bearing cap and cy$inder b$oc9.
. Gse a (% s$eeve to remove the fi3ing bo$t of cran9shaft main bearing cap. Note> The surface between cy$inder b$oc9 and bearing cap is ensured by high precision machining p$ane= so= do not use any hard artic$e to scuff this surface.
6. Ta9e off cran9shaft rear oi$ sea$ assemb$y= remove bearing
she$$
cover=
and
then
ta9e
off cran9shaft
assemb$y.
II. Overhau$ of Cran92Connecting +od System (. 0etection of cran9shaft. (.( 0etection of cran9shaft main !ourna$> use an outside micrometer to measure main !ourna$ of cran9shaft
and
the
norma$
va$ue
shou$d
be
46.)(mm. (./ 0etection of connecting rod !ourna$> use an outside micrometer to measure connecting rod !ourna$ of cran9shaft and the norma$ va$ue shou$d be 44.4;244.4%mm.
(.- easurement of main !ourna$ c$earance> p$ace a p$astic fee$er gauge on the cran9shaft main !ourna$= tighten the main bearing she$$ cover to specified
tor'ue
and
then
$oosen
it=
use
the
thic9ness chec9 $ist on the p$astic fee$er gauge to read
the
va$ue.
The
norma$
va$ue shou$d be>
).)/2).)6mm. Gse the same method to measure connecting rod !ourna$ c$earance. (.4 easurement of cran9shaft a3ia$ c$earance> tighten the main bearing she$$ cover to specified tor'ue and then use a dia$ gauge to measure the cran9shaft a3ia$ c$earance. Hhen measuring= push the cran9shaft off the dia$ gauge first and 9eep the dia$ gauge has certain amount of compression= set
the pointer to Jero= and then push the cran9shaft to the adverse
direction and the numerica$
va$ue
fetched from the dia$ gauge wi$$ be the cran9shaft a3ia$
c$earance.
The
norma$
va$ue
shou$d be
).)/2).-)mm. If e3ceeding this scope= rep$ace the cran9shaft thrust sheet or the cran9shaft. /. 0etection of piston /.( 0etection of piston diameter> use an outside micrometer to measure the piston diameter. Hhen Contents
#irst ring
End p$ay
)./
Second ring Third ring ).4
measuring= remember to measure at the p$ace about
((mm up from $ower end of the piston. The norma $
Side c$earance
).)-
).)-
Thic9ness
(./
(.6
va$ue shou$d be K"/.%6L).))%. /./ The piston pin is of semi2
f$oating type= which can
not be
disassemb$ed
during
maintenance=
because it can not be assemb$ed using common machining
techni'ue
after disassemb$ed.
If
abnorma$ noise occurs due to improper piston pin c$earance= rep$ace the piston assemb$y. /.- easurement of piston ring. /.-.( easurement of piston ring end p$ay> first= p$ace the piston ring into cy$inder.
/.-./ Push the piston head vertica$$y against the piston ring in the cy$inder and $et the piston ring be on a p$ane. /.-.- Gse a fee$er gauge to measure the gap between piston ring ends and the norma$ va$ue shou$d be> )./mm.
/.-.4 easurement of piston ring side c$earance> p$ace the removed piston ring into the ring groove
7$ean to one side as possib$e8 and then p$ace a fee$er gauge into the other side to measure the c$earanceA certain resistance fee$ing after the fee$er gauge is p$aced in indicates that the measurement with fee$er gauge wi$$ be correct. The norma$ va$ue shou$d be ).)-mm. Gnit> mm
-. easurement of roundness and cy$indricity of cy$inder -.( Se$ect appropriate cy$inder gauge and outside micrometer.
-./
Gse
a
vernier ca$iper to
measure
rough
diameter of the cy$inder ho$e. -.- ,d!ust the outside micrometer to the data measured out by the vernier ca$iper= se$ect the sp$icing po$e suitab$e to the range of the cy$inder gauge= and then set the outside micrometer to Jero according to this data.
-.4 P$ace the cy$inder gauge into the cy$inder to measureA when measuring= the yawing ang$e of cy$inder gauge shou$d not e3ceed (U. #etch the ma3imum numerica$ va$ue.
-. The measuring position of the cy$inder gauge in cy$inder is as shown in the figure. Ca$cu$ation method for roundness> ,2 or a2b
Ca$cu$ation method for c y$indricity> the difference of ma3imum
diameter
Gpper stop position of piston
subtracting minimum diameter among ,= a= = and b. The norma$ va$ue shou$d be> if roundness or
*ower stop position of piston
cy$indricity e3ceeds the range= rep$ace with new cy$inder b$oc9 or insta$$ new cy$inder s$eeve. -.6 easurement of p$aneness of cy$inder b$oc9> use
stee$
ru$e
and
fee$er
gauge
to
measure
p$aneness of the cy$inder b$oc9. If the p$aneness e3ceeds the range= rep$ace the cy$inder b$oc9.
III. Insta$$ation of Cran92Connecting +od System The
insta$$ation
disassemb$y= but
order care
is
adverse
shou$d be
to
ta9en
that
for
for the
fo$$owing matters. (. Insta$$ation of cran9shaft thrust sheet. Hhen insta$$ing the cran9shaft thrust sheet= $eave the side with oi$ groove outwards.
/. Insta$$ation of cran9shaft front oi$ sea$ /.( C$ear smudge on oi$ sea$ seat ring= and then app$y a $ayer of $ubricant on the seat ring. /./ ,pp$y a $ayer of engine $ubricant on the oi$ sea$ $ip.
/.- Enc$ose the new oi$ sea$ with $ubricant app$ied into the specia$ too$. Press the specia$ too$ against the oi$ sea$ seat ring and soft$y stri9e to compact.
-. Insta$$ation of cran9shaft rear oi$ sea$ -.( C$ean the oi$ sea$ seat ring. 0ip engine oi$ with a piece of gauJe and then use it to c$ear the impurities inside the oi$ sea$ seat ring. -./
,pp$y a
$ayer of engine
oi$
uniform$y on
cran9shaft rear oi$ sea$ $ip and a $itt$e engine oi$ uniform$y on outer ring of oi$ sea$. Enve$ope the oi$ sea$ onto the specia$ too$ and then press it into the oi$ sea$ seat ring. 4. Hhen insta$$ing cy$inder cushion= insta$$ it with the side with word up. Note> The cy$inder cushion has been app$ied with sea$ant= so= providing that the cy$inder head or cy$inder b$oc9 has been disassemb$ed= be sure to rep$ace the cy$inder cushion.
. Hhen insta$$ing piston ring= remember to $eave the side of the second ring with word up.
6. The opening position of the piston ring during insta$$ation is as shown in the figure.
#irst ring Second ring Oi$ ring
*ower b$ade #irst ring #ront
*iner ring
Gpper b$ade ". The $abe$ on piston head prompts direction and position of insta$$ation. ;. Gse a specia$ too$ to insta$$ the piston ring.
%. Hhen insta$$ing connecting rod bearing she$$= pay attention to insta$$ation mar9. (). ethod for she$$ matching. Note>
The machining techni'ue for connecting rod and connecting rod she$$ cap adopts Instant$y Swe$$ and rea9 machining method= so= each
Second ring +ear
machined surface maintains the shape of origina$ materia$. Hhen insta$$ing= 9eep any sundries out of this machined surface. In addition= on$y the two machined surface of the same connecting rod can comp$ete$y engage. The tightening tor'ue for insta$$ing the fi3ing bo$t of connecting rod bearing is /L-Nm 7then turn %)L c$oc9wise8. ((. Gse the piston insta$$ation specia$ too$ to insta$$ the piston.
