chery manual de motor.docx

8/18/2019 Chery manual de motor.docx

1/49

Chery S18D Service ManualX1

Engine SQR 473F

After

Sales

Service

Department

of

Chery Automobile

Co.,Ltd.

CONTENTS

Chapter

One

Introduction

of

Characteristics

....................................

4

I. Overview .............................................................................................................................. 4

II. Number Position of the Engine ........................................................................................... 4

III. Connotation of Engine Number ......................................................................................... 4


2/49

Chapter Two Specification ............................................................... 6

I. Engine Type and a!or 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............................ (-

&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 ................................................................................. (6

II. Specia$ Too$s Chart ........................................................................................................... ("

Chapter

#our

easurement

of

Cy$inder

Pressure..........................

/)

I. 0etection of Cy$inder Pressure........................................................................................... /)

(.

easuring

process

..................................................................................................... /)/. 1udgment of cy$inder pressure va$ue.......................................................................... /(

Chapter #ive 0isassemb$y of Power2assisted Steering System...... //

I. 0isassemb$y Procedure.......................................................................................................//

II. Overhau$............................................................................................................................/-

III. Insta$$ation of the Steering Pump..................................................................................... /-

Chapter

Si3

0isassemb$y

of

,C

Compressor

................................

/4

II. Overhau$ of Compressor ................................................................................................... /

III. Insta$$ation procedure......................................................................................................./

Chapter

Seven

0isassemb$y

of

5enerator

......................................

/

I. 0isassemb$y Procedure......................................................................................................./

II. Overhau$ of 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

0isassemb$y

of

Engine

,ssemb$y

............................

-(

I. 0isassemb$y Procedure.......................................................................................................-(

II. Insta$$ation Procedure........................................................................................................-%

Chapter

Ten

0isassemb$y

of

Inta9e

anifo$d

................................

-%

I. 0isassemb$y Procedure.......................................................................................................-%


3/49

Chapter E$even 0isassemb$y of Cy$inder :ead............................. 4)

I. 0isassemb$y Procedure.......................................................................................................4)

II. Overhau$ of Cy$inder :ead 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 0isassemb$y of Cran92Connecting +od

echanism....................................................................................

(

I.

0isassemb$y

Procedure.......................................................................................................(II. Overhau$ of Cran92Connecting +od System..................................................................... /

III. Insta$$ation of Cran92Connecting +od System ................................................................ 6

Chapter One Introduction of Characteristics

I. Overview

S


4/49

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

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 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$ 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

periphera$

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

F ? ? @@@@ F

SN among the vo$ume of

production of the current month

Character code of the month


5/49

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


6/49

2osch

Chapter

Two

Specification

I.

Engine

Type

and

a!or

Parameters

No.

Itemasic Parameters

S


7/49

II.

a!or

aintenance

Parameters

of

Engine


8/49

No. Name 0imension and to$erance #it c$earance

4

Thic9ness of connecting rod big end //)2).(

).(M).4

Hidth of cran9shaft connecting rod !ourna$ //).-)).(

#irst

piston

ring

groove

height (./).)).)-).)-M).);

Top compression ring height 2).))(./ 2).)-

6Second piston ring groove height (.).)4).)/

).)/M).)"Second compression ring height (.2).))2).)-)

"

piston oi$ ring groove height /.).)-).)(

).)/M).(;$ade height of stee$ strip composite type oi$ ring ).46L).)/

racing spring height of stee$ strip composite type oi$

ring(.L).)-

; Cran9shaft 9ey groove width).)(4

+−).)()

% 0iameter of cran9shaft front oi$ sea$ Q-6)2).(

() 0iameter of cran9shaft rear oi$ sea$ Q")2).(

((

Outside diameter of engine oi$ dipstic9 tube)

(6."−).(

0iameter of cy$inder b$oc9 sca$e tube orifice+).)4-

(6.")

(/

0iameter of cy$inder head va$ve guide orifice K6).)(

Outside

diameter

of

va$ve

guide K((36 2).)//～

2).))0iameter of cy$inder head va$ve guide bottom orifice K((:"

(-Outside diameter of inta9e va$ve stem K.%;L).)); ).)(/～

).)4-0iameter of cy$inder head inta9e va$ve guide orifice K6).)(

(4E3haust va$ve stem diameter K.%6L).)); ).)-/～

).)6-0iameter of cy$inder head e3haust va$ve guide orifice K6).)(

(

0iameter of camshaft first !ourna$−).))

-/e6(−).)66 ) ).))～).)%)0iameter

of

cy$inder

head

first

bearing

ho$e

(6

0iameter of camshaft second !ourna$−).)4)

/4e6(−).)- ) ).)4)～).)"4

0iameter of cy$inder head second bearing ho$e+).)/(

/4 H

"()

)

(" 0iameter of camshaft third !ourna$−).)4)

/4e6(−).)- ) ).)4)～guide

#it C$earance

,3ia$ c$earance of cran9shaft ).)"～)./6mm

,3ia$ C$earance of Camshaft ).(～)./)mm

,3ia$ c$earance of connecting rod ).(～).4mm

#it

c$earance

of

connecting

rod

bearing ).)/-～).);mm

#it c$earance of main bearing ).)-～).)"mm

#it c$earance between inta9e va$ve stem and va$ve ).)(/～).)4-mm

No. Name 0imension and to$erance #it c$

0iameter of cy$inder head third bearing ho$e+).)/(

/4 H

"()

) )

(;

0iameter of camshaft fourth !ourna$−).)4)

/4e6

(−).)-

) ).))0iameter of cy$inder head fourth bearing ho$e

+).)/(

/4 H

"()

)

(%

0iameter of camshaft fifth !ourna$−).)4)

/4e6(−).)- ) ).))

0iameter of cy$inder head fifth bearing ho$e+).)/(

/4 H

"()

)

/) Camshaft thrust groove width+).)/

-).6 H

"()

) ).(～

/(

Outside diameter of camshaft oi$ sea$).4

)++)./ 2).)

2)0iameter of cy$inder head oi$ sea$ ho$e

+).)/

) H

"() )

//0iameter of cy$inder head !ib ho$e

).)/4 (/G"(++).))6 ) ).))

Outside diameter of hydrau$ic !ib K(/2).)((

/- 0iameter of cran9shaft timing gear segment Q/;f"

ore diameter of cran9shaft timing gear K/;＋).)-)

/4

Rey groove dimension of cran9shaft timing gear ＋).)-)

)MRey

groove

width

of

cran9shaft

gear

＋).)-)

Semicircu$ar 9ey width )2).)-)

/ ore diameter of cran9shaft pu$$ey ).)46K"4).)%6

/6 Outside diameter of timing gear K"42).)2).);


9/49

III.

Primary

#it

C$earance

I&. Engine Primary Tightening Tor'ue Tab$e

guide

#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

).))6～).)-mm

No. Connection part Part nameo$t

7thread specification8

Number

of bo$ts

gas9ets

7piece8

Tightening

tor'ue

Nm 7primary

tightening8

u$tip$e steps tightening 7tor'ue

ang$e8

#irst step

tightening

tor'ue 7Nm8

Second step

ang$e 78

Third step

ang$e 78

(Cy$inder b$oc9 main oi$ passage

screw p$ug (

:e3agona$ soc9et head

p$ug(;(. / /)

/

Cy$inder b$oc9 main oi$ passage

screw

p$ug

/

:e3agona$ soc9et head

p$ug()(.

( /)L-

- ain bearing cap :e3agon bo$t (((. 4 4L (;)L()

4 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 ;(./- ( /)).

"Connecting rod cap2connecting

rod body:e3agon bo$t ;( ; /L- %)L

;Oi$ pump assemb$y2cy$inder

b$oc9 :e3agon bo$t 6- 4 ;-

%Engine oi$ co$$ector brac9et=

separator2framewor9 :e3agona$

f$ange

bo$t 6(/ % ;-

() $eeding p$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/ ;-

(Cy$inder head oi$ passage

thrott$e bo$t:e3agon thrott$e bo$t (4(. / (-

(6Camshaft

bearing

cap2cy$inder

head*ocating bo$t 6(-) (; %.L(.

("Camshaft

bearing

cap2cy$inder

head:e3agona$ f$ange bo$t 6(3-) / %.L(.


10/49



Number

of

bo$ts

gas9ets

7piece8

Tightening

tor'ue

Nm 7primary

tightening8

u$tip$e steps tightening 7tor'ue

ang$e8

#irst step

tightening

tor'ue

7Nm8

Second step

ang$e 78

Third step

ang$e 78

(;Phaser

contro$

va$ve2first

camshaft

capInner he3agona$ bo$t 6(( / ;-

(% C y$inder head2cy$inder b$oc9 Inner he3agona$ bo$t ()(. () )L

/)&a$ve cover assemb$y2cy$inder

head

0amping unit2va$ve

cover 6(-) (/ ;-

/(Camshaft

position

sensor2va$ve

cover Inner he3agona$ bo$t 6(( / ;).

// :ange r2cy$inder head :e3agona$ f$ange bo$t ;(4 / /)

/-+ear housing of timing

gear2cy$inder headCross head screw ( 6 /

/4Phaser2camshaft Inner

TO+D

ho$$ow

bo$t (/(./ / (/)L

Timing gear2camshaft o$t (/(./ / (/)L

/In$et cam phaser cap2in$et cam

phaser :e3agon bo$t ( -)

/6E3haust cam phaser cap2e3haust

cam phaser Inner TO+D bo$t ( -)

/" Oi$ fi$ter assemb$y2oi$ fi$ter seat Screw s$eeve /)(. ( /L-

/% Oi$

fi$ter

!oint /)(. ( /L-

-) Oi$ fi$ter seat2cy$inder b$oc9 Inner he3agona$ bo$t ;/ - /)

-( Oi$

pressure

switch2oi$

fi$ter

(4(./(/

（(-(-） ( (/L/

-/Thermostat assemb$y2cy$inder

head:e3agon bo$t 66) - ;-

--Thermostat cover2thermostat

case:e3agona$ f$ange bo$t 6/) 4 ;-

-4 Coo$ant senser2thermostat she$$ (/(. ( /)

-Cran9shaft timing

gear2cran9shaft:e3agona$ f$ange bo$t (-(. ( (-)L() 6L

-6Cran9shaft pu$$ey2cran9shaft

timing gear :e3agona$ f$ange bo$t ;(( 6 /L -)L

-" #$ywhee$2cran9shaft :e3agona$

f$ange

bo$t ;(./ ; (L -)L

-; Signa$ whee$2 f$ ywhee$ :e3agon bo$t ;(./ 6 ;L/

-%Timing be$t2tensioner

assemb$y2cy$inder b$oc9 :e3agona$ f$ange bo$t ; ( /"L-

4)Timing be$t2id$er

assemb$y2cy$inder head:e3agona$ f$ange bo$t ()6) ( 4)

4(u$9head2cran9shaft $ocating

pin ho$e:e3agona$ f$ange bo$t (6(. ( /L-



Number

of bo$ts

gas9ets

7piece8

Tightening

tor'ue

Nm 7primary

tightening8

u$tip$e

steps

tightening

7tor'ue

ang$e8

#irst step

tightening

tor'ue 7Nm8

Second step

ang$e 78

Third step

ang$e 78

4/#ront

$ower

cover

of

timing

gear2engine:e3agona$ f$ange bo$t 6/4 ;-

4-#ront upper cover of timing

gear2engineInner he3agona$ bo$t 6-) ( ;-

44#ront upper cover of timing

gear2engine:e3agon

bo$t 6(6 4 ;-

4,ir compressor

brac9et2cy$inder b$oc9 :e3agona$

f$ange

bo$t ;/ ( ()-

46,ir compressor brac9et2cy$inder

b$oc9 :e3agona$ f$ange bo$t ;6 - -)-

4"Power

steering

pump2steering

pump brac9et:e3agona$ f$ange bo$t ;(/ ( /)

4;Power steering pump2steering

pump brac9et:e3agona$

f$ange

bo$t ;/ ( /)

4%Power steering pump2steering

pump brac9et:e3agona$

f$ange

bo$t ;;) ( /)

),C compressor assemb$y2air

compressor brac9et:e3agona$ f$ange bo$t ;()) ( /)＋

(,ir

compressor

assemb$y2air

compressor brac9et:e3agona$ f$ange bo$t ( ;-) ( /)

/ 5enerator

assemb$y2generator brac9et

:e3agona$ f$ange bo$t ()%) ( -)＋

-5enerator $ower

brac9et2cy$inder

b$oc9 :e3agona$ f$ange bo$t ()4 / 4)＋

4 I gnition coi$ assemb$y2brac9et :e3agon bo$t 6() 4 ;-

Spar9 p$ug2cy$inder head :e3agon bo$t (4(./ 4 -)-

6 Inta9e manifo$d2cy$inder head Stud bo$t 6(/ % -/

" Inta9e

manifo$d2cy$inder

head :e3agon

nut 6 % ;-

;0e$ivery pipe assemb$y2air

inta9e pipe:e3agona$ f$ange bo$t 6/) / ;-

%Thrott$e

body

assemb$y2air

inta9e pipe:e3agon

bo$t 6() 4 ;-

6) rac9et2air

inta9e

pipe :e3agon

bo$t ;-) / /)

6( rac9et2air inta9e pipe :e3agona$ f$ange bo$t ;4) / /)

6/Engine oi$ dipstic9 tube2air

compressor brac9etInner

he3agona$

bo$t 6(6 ( ;-

6-Engine oi$ dipstic9

tube2framewor9 :e3agon

bo$t 6(6 ( ;-

No. *ubrication Type of $ubricant

( Piston pin and pin ho$e S1()H24)

/ Piston

ring

groove S1()H24)



Number

of bo$ts

gas9ets

7piece8

Tightening

tor'ue

Nm 7primary

tightening8

u$tip$e

steps

tightening

7tor'ue

ang$e8

#irst step

tightening

tor'ue 7Nm8

Second step

ang$e 78

Third ste

ang$e 7

64 E3haust

manifo$d2cy$inder

head Stud

bo$t ;(46 % (/-

6 E3haust

manifo$d2cy$inder

head :e3agon

nut ; % /)

66E3haust

pipe

therma$

shie$d2e3haust pipe:e3agon bo$t ;(/ - /)

6"Oi$

return

pipe

brac9et2cy$inder

b$oc9 :e3agon bo$t ;/) ( /)

6; Oi$ return pipe ho$$ow screw (4(. ( (-

6% rac9et2oi$2gas separator Inner he3agona$ bo$t (4 / 6/

") rac9et2oi$2gas separator Inner he3agona$ bo$t 6(4 / ;-

; Other

4 /.L).

L(.

6 ;L-

" (L-

; /)L

() 4)L


11/49

&. The Parts wher e

*ubr ication

are +e'uir

e d

durin g

,sse mb$y o f

Engine

&I.

The

Parts where +ubbe

r Coating are +

e' uired

during

, ssemb$y

of Engine

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.

- Connecting rod bearing she$$ and connecting

rod !ourna$S1()H24)

4 Cy$inder s$eeve ho$e S1()H24)

ain bearing $ining and cran9shaft main

!ourna$

S1()H24)

6 Cran9shaft thrust sheet 7at oi$ groove side8

and thrust surfaceS1()H24)

" :ead and thread of connecting rod bo$t S1()H24)

; :ead and root of main bearing cap bo$t S1()H24)

% +ear oi$ sea$ edge and cran9shaft oi$ sea$

!ourna$S1()H24)

() :ead and root of cy$inder head bo$t S1()H24)

(( &a$ve guide orifice S1()H24)

(/ &a$ve stem S1()H24)

(- &a$ve oi$ sea$ $ip S1()H24)

(4 &a$ve seat insert S1()H24)

( &a$ve 9eeper ring groove S1()H24)

(6 Cam and !ourna$ of camshaft S1()H24)

(" Camshaft bearing ho$e S1()H24)

(; E3terna$

surface

and

base

p$ane

of

hydrau$ic !ib

S1()H24)

(% :ydrau$ic !ib ho$e and va$ve roc9er arm head S1()H24)

/) Outer ring of oi$ pump S1()H24)

/( Edge or !ourna$ of camshaft oi$ sea$ S1()H24)

// Inta9e and e3haust phaser contro$ va$ve

gas9etsS1()H24)

/- 1ourna$ of inta9e and e3haust phaser S1()H24)

No. Parts where rubber coating are re'uiredType of sea$ant

( Cy$inder

b$oc9

bow$

p$ug *octite

64;

/ Cy$inder b$oc9 main oi$ passage p$ug *octite /4-

- 1unction p$ane of framewor9 and cy$inder

b$oc9 *octite (

4 Outer ring of cran9shaft rear oi$ sea$ *octite /4-

#ramewor9 and oi$ pan *octite %()

6 Cy$inder head bow$ p$ug *octite 64;

" ain

oi$

passage

screw

p$ug *octite

/4-

; ase p$ane of first bearing cap *octite "4

% Hater temperature sensor *octite /4-

() Oi$ pressure switch *octite /4-

(( #$ywhee$ bo$t *octite /4-

(/ Oi$ pan main oi$ passage p$ug *octite /4-

(- Engine oi$ co$$ector separator bo$t *octite /4-

odification

, #irst modification

Second modification

C Third modification

0 #ourth modification

Number Position

( Chassis

/ Engine

- Transmission

4 ,ccessory

ody


12/49

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


13/49

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


14/49

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.

#or e3a

mp$e>

C:2

())/,

means i

t is th

e / sp

ecia$ to

o$ for r

epair o

f chassi

s syste

m that

has bee

n

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$

Connotation of system code corresponding to the too$>

Corresponding series number of too$s> from ))( to %%%.

Times of modifications of the too$>

Note: In a$phabetica$ order. igger SN means more modification times.

C:2/)))/ Insta$$ation too$ for camshaft oi$ sea$>

used

to

insta$$

camshaft

oi$

sea$. Same

as

,

C:2/)))- Engine timing too$> used to tim

e

cran9shaft.

Same as ,

C:2/)))4 ,daptor>

used

to

insta$$

and

remove

va$ve spring 7match with Eastar specia$

too$ *+20%%;""/,8.

Same as ,

C:2/))) Insta$$ation

too$ for cran9shaft rear oi$

sea$> used to insta$$ cran9shaft rear oi$

sea$.

Same as ,

C:2/)))6 Insta$$ation hand$e for cran9shaft rear

oi$ sea$> used to insta$$ cran9shaft rear

oi$ sea$.

Same as ,

C:2/)))" Insta$$ation s$eeve for cran9shaft front

oi$ sea$> used to insta$$ cran9shaft front

oi$

sea$.

Same as ,


15/49

as 6/%)

2(CT.

II.

S pecia$ Too$s

Chart

Pressure gauge for cy$inder> used to measure cy$inder

pressure. Hhen measuring= remove spar9 p$ug first=

C:2/))); Insta$$ation s$eeve for cran9shaft front

oi$ sea$

Same as ,

C:2/)))% *ocating

too$

for

f$ywhee$>

used

$ocate f$ywhee$.

Same as ,

C:2/))() Camshaft timing too$> used to time

camshaft.

Same as ,

C:2/))(( Insta$$ation too$ for camshaft oi$ sea$>

used to insta$$ camshaft oi$ sea$.

Same as ,

C:2/))(/ &a$ve oi$ sea$ guide s$eeve> used

insta$$ va$ve oi$ sea$.

Same as ,

C:2/))(- &a$ve oi$ sea$ remover> used to remove

va$ve oi$ sea$.

Same as ,

C:2/))( e$t

pu$$ey

bo$t

remover>

used

remove be$t pu$$ey c$ip.Same

as

,

+ecommended too$s

C:2/))(" Insta$$ation too$ for va$ve 9eep

er> used

to insta$$ va$ve 9eeper.

Same as ,

C:2/))(;2, &a$ve

spring remover> used

to

remove

va$ve spring.

Sam

*oop whee$ machine> used to raise engine.

Engine maintenance wor9bench> the wor9

disassemb$y and assemb$y of engine.

#ue$

pressure

gauge>

used

to

measure

oi$

pengine.


16/49

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=

duringmaintenance 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$esfrom

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.


17/49

/. 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 starting the engine=

ensure ade'uate 'uantity of

e$ectricity.

Correct

cy$inder

pressure

canon$y be measured out with revo$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

onconnecting 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


18/49

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.


19/49

-. ,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


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


20/49

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

adverseto 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


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.


21/49

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

isinsta$$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

wor9ing

of

the

engine= rep$acing 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.


22/49

(.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


23/49

(.() Gs

(.

(. Insert the specia$ too$ C:2/)))- into the timing ho$e

and tighten= use a wrench to turn the big nut in

he

cran9shaft pu$$ey to ma9e the cran9shaft rotate= at the

same time= s$ow$y screw in C:2/)))- unti$

hecran9shaft 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

veryoccu$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.


24/49

*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=

besure not to

turn

cran9shaftcamshaftA

otherwise= 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

thespecia$ 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


25/49

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 Specia$ too$ for cran9shaft timing chec9

7C:2/))()8 7C:2/)))-8

Chapter

Nine

0isassemb$y

of

Engine

,ssemb$y


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

batteryfirst= 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.


26/49

/. 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


27/49

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/℃


28/49

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.


29/49

%. 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.


30/49

(). 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.


31/49

((.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.


32/49

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


33/49

( 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.


34/49

Tor'ue> )L Nm.

Note>

#o$$ow the order as shown in the figure to

$oosen the fi3ing bo$ts of cy$inder head.


35/49


36/49

". 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.


37/49

/./.( easurement of diameter of va$ve stem easurement point

/././ easurement of va$ve guide inside diameter

Gse an inside micrometer to 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

easurement point

/.-.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 this va$ve=

rep$ace the cy$inder head assemb$y.


38/49

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.


39/49

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


40/49


(. +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>


41/49

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.


42/49

/. 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


( 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.


43/49

. 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


44/49

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

measuring= remember to measure at the p$ace about

((mm up from $ower end of the piston. The norma

$

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

Contents #irst

ring Second

ring Third

ring

End p$ay )./ ).4

Side

c$earance ).)- ).)-

Thic9ness (./ (.6


45/49

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


46/49

subtracting minimum

diameter among ,= a= = and b.

The norma$ va$ue shou$d be> if roundness or

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.

Gpper stop position of piston

*ower stop position of piston

III.

Insta$$ation

of

Cran92Connecting

+od

System

The

insta$$ation

order

is

adverse

to

that

for disassemb$y=

but

care

shou$d

be

ta9en

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


47/49

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

*ower b$ade

#irst ring

Oi$ ring

Second ring

#ront

*iner ring +ear

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


48/49

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.


49/49

(/. Tighten the fi3ing bo$t of connecting

rod bearing cap.

Tightening tor'ue>

#irst time> /L-Nm. Second time> turn

%)L .

(-. Insta$$ the main bearing cap and then

fo$$ow the order as shown in the figure to

tighten the bo$t.

Tightening tor'ue>

#irst time> 4LNm.

Second time> turn (;)L().

(4. Tighten the fi3ing bo$t of main

bearing cap and cy$inder b$oc9.

Tor'ue> /)- Nm.

chery manual de motor.docx

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