Chery S18D Service Manual

X1
Engine SQR 473F

After Sales Service Department of Chery Automobile

Co.,Ltd.

CONTENTS
Chapter One Introduction of Characteristics ....................................

I. Overview ..............................................................................................................................

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

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

4
4

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

I. Engine Type and Major Parameters......................................................................................

II. Major Maintenance Parameters of Engine ..........................................................................

III. Primary Fit Clearance ........................................................................................................
IV. Engine Primary Tightening Torque Table ........................................................................
V. The Parts where Lubrication are Required during Assembly of Engine............................
VI. The Parts where Rubber Coating are Required during Assembly of Engine ...................

7
9
10
13
15

Chapter Three Special Tools ..........................................................

16

I. Connotation of Special Tool Number .................................................................................

16

II. Special Tools Chart ...........................................................................................................

17

Chapter Four Measurement of Cylinder Pressure..........................

20

I. Detection of Cylinder Pressure...........................................................................................

20

1. Measuring process .....................................................................................................

2. Judgment of cylinder pressure value..........................................................................

20
21

Chapter Five Disassembly of Power-assisted Steering System......

22

I. Disassembly Procedure.......................................................................................................22
II. Overhaul............................................................................................................................23
III. Installation of the Steering Pump.....................................................................................

Chapter Six Disassembly of A/C Compressor ................................

II. Overhaul of Compressor ...................................................................................................

23

24
25

III. Installation procedure.......................................................................................................25

Chapter Seven Disassembly of Generator ......................................

25

I. Disassembly Procedure.......................................................................................................25
II. Overhaul of Generator.......................................................................................................
III. Installation Procedure ......................................................................................................

Chapter Eight Replacement of Engine Timing Belt.......................

26
26

27

I. Disassembly Procedure.......................................................................................................27
II. Installation of Timing Belt ................................................................................................
III. Adjustment of Timing (general overhaul) ........................................................................
IV. Adjustment of Timing (minor overhaul) ..........................................................................

Chapter Nine Disassembly of Engine Assembly ............................

29
30
30

31

I. Disassembly Procedure.......................................................................................................31
II. Installation Procedure........................................................................................................39

Chapter Ten Disassembly of Intake Manifold ................................

I. Disassembly Procedure.......................................................................................................39

39

Chapter Eleven Disassembly of Cylinder Head.............................

40

I. Disassembly Procedure.......................................................................................................40
II. Overhaul of Cylinder Head System...................................................................................
III. Assembly of Cylinder Head Assembly ............................................................................

43
45

Chapter Twelve Disassembly and Installation of Oil Pump and

Lubrication System ........................................................................

48

I. Disassembly Procedure.......................................................................................................48
II. Overhaul of Oil Pump .......................................................................................................
III. Installation Procedure ......................................................................................................

Chapter

Thirteen

Disassembly

of

Crank-Connecting

50
50

Rod

Mechanism.................................................................................... 51
I. Disassembly Procedure.......................................................................................................51
II. Overhaul of Crank-Connecting Rod System.....................................................................
III. Installation of Crank-Connecting Rod System ................................................................

52
56

Chapter One Introduction of Characteristics

I. Overview
SQR473F engine is one of the ACTECO series engines that are jointly designed and developed by
Chery company and AVL-a world famous engine design company. This engine adopts such
advanced technologies as overhead double camshaft structure, 4 air valves, electronic throttle
body and electronic accelerator pedal etc. In terms of such mandatory standard indexes as
emission and noise, this engine is outdoes national standard and has reached overseas advanced
stage.

II. Number Position of the Engine

Number of the engine locates at right side of oil filter
where bearing shell cover and cylinder block join.

III. Connotation of Engine Number

Each engine has a unique number, from which you can know some characteristics and information
of the engine. Engine model should conform to requirements in GB725 and is consisted of
enterprise code, number of cylinders of the engine, bore, characteristic code and specification
code.
A complete engine model is as follows:

Specification code
Characteristic code
Cylinder bore
Number of cylinders
Enterprise code

Among which, indicates an Arabic numeral while indicates a letter.

The enterprise code is stipulated as SQR;
Number of cylinders of engine is a 1-2 digit integer;
The bore refers to diameter of cylinder sleeve, which is specified by a 2-3 digit integer with the
decimal part rounded and millimeter as unit.
Characteristic code: indicates the most basic characteristics of an engine and is specified by 1 digit
upper case English letter.
Specification code: specified by 1 digit upper case English letter, which is used as an additional
distinguish code when distinguish is required in case structure, principal parameter or oil supply
mode etc. has changed (for example, the stroke of engine has changed or the engine is a dual fuel
engine) with number of cylinders, bore and characteristic code of the engine unchanged. For
changes of peripheral parts of the engine (such as intake and exhaust manifolds), the engine model
will keep unchanged, and engine assembly number will be changed for distinguish. Among the
engines of the same series, the specification code will be used with B as the first (among which,
do not use such letters as I, O, Q, X and Z). The default specification code for the first
fundamental structure is A, which is omitted. The specification also can quote the characteristic
code to express specific characteristics.
Position of engine model
The engine model should be printed at an obvious part on engine cylinder block and please
see provisions in Assembly and Regulation Instruction of Engine for the specific position.
Leaving factory number of engine is composed of characteristic code of engine, EFI manufacturer
code, character code of the year of production, character code of the month of production,
sequence number of this engine among the engines of this model manufactured in that month and
start stop sign *. Complete form of leaving factory number of a engine is as follows:
*

*
SN
among the
volume
production of the current month
Character code of the month

of

Character code of the year

EFI system manufacturer code
Characteristic code
Among which, indicates an Arabic numeral, indicates a letter and

indicates an Arabic

numeral or a letter.
The characteristic code of engine should conform to above provision.
EFI system manufacturers: C-Motorola; D-Marelli; E-Delphi; F-UAES; G-Siemens; H-Troitec;

Crank Angle with

B-Bosch
Intake Valve
Opening as 1mm

400

369

()
Crank Angle at
Item
1mm before Intake
No.
17

569

SQR473

Valve Closing ()

SQR473H

SQR473F

Crank Angle with

Type
Exhaust Valve

Vertical type, 4 cylinder, water cooling, 4

Vertical type, 4 cylinder, water

stroke, in-line double overhead camshaft,

200
controlled burn rate, variable valve timing

cooling, 4 stroke, in-line double

140
overhead camshaft

Opening as 1mm
1

Basic Parameters
610

() Model

SQR473H
SQR473F
Crank
Angle
at
2
Fuel Supply Mode
Multi point electric control gasoline injection
1mm before
Cylinder Diameter
390
350
3 Exhaust Valve
73.0
(mm)
Closing ()
4
Piston Stroke (mm)
77.5
Ignition Advance
Working volume
18
125
125
5 Angle (CA)
1.297
(L)
Nam Dimension and tolerance Fit clearance
Cylinder
6
Compression Ratio
10.0
e
Compression
19 1
1.001.35
Type of
473 engine cylinder hole
73.0050.005
Pressure (MPa)
7
Ridge
type
Combustion
(200~300r/min)
0.04
Chamber
Overall Dimension
Piston skirt of 473 engine
72.9650.009
20 28
613507734
Ignition Sequence
1-3-4-2
(lengthwidthheight)
Fuel Designation
9 Electronic fuel
93# lead-free gasoline
Main
bearing saddle width of cylinder
21
UAES 19.50-0.05
(not less
than)
injection system
Thickness of thrust plate
2.4+0.050
3
0.07~0.265
Volume of Engine
10
3.5 (new engine oil
filter)
+0.015
Crankshaft main journal
Oil (L)
24.5
-0.030
Engine Oil
11
SAE10W-40 (grade SJ or above)
Designation
Crankshaft
12

Rotational

Clockwise (see from engine belt)

Direction
13

Starting Mode

Electric starting

14

Cooling Mode

Mandatory circulating antifreeze cooling

15

Lubricating Mode

16

Net Mass (kg)

Combined type (pressure and splash lubrication)

105

Chapter Two Specification

I. Engine Type and Major Parameters

100

II. Major Maintenance Parameters of Engine

No.
4

8
9
10

11

12

13

14

Name
Dimension and tolerance
Fit clearance
No.
Name
Dimension and tolerance
Thickness of connecting rod big end
220-0.1
0.021
Diameter of cylinder head third bearing hole
70
24H 0.15~0.4
22+0.30+0.15
Width of crankshaft connecting rod journal

24e60.053

24H 70

-0.03

0.460.02

50H 70

0.025

12G70.006

guide

+0.006
+0.035

0.030

5
0.0230.058mm
-0.022
5
0-0.030
0.0350.075mm
-0.050

0~0.06

+0.046

74
0.0120.043mm
+0.012
74-0.05-0.08
+0.043

Diameter of camshaft first journal

32e60.066

+0.050

0.050

+0.090
0.040

0.040

-0.40

0.030
50.150.4mm

+0.063

24e60.053

+0.15+0.20

0.150.20mm
280.030

6+0.015

Diameter of camshaft third journal

Fit Clearance
12-0.011
0.070.265mm
28f7

Diameter of cylinder head exhaust valve guide orifice

0.021

-0.005

0.024

+0.032

24e60.053

+0.074

0.4

500.2

Diameter of cylinder head first bearing hole

17

0.025

30.65H0.02~0.18
70

5.960.008

24H 70

0.021

Exhaust valve stem diameter

Diameter of cylinder head second bearing hole

+0.040

24H 70

25
Bore diameter of crankshaft pulley
Fit clearance
between
intakestem
valve stem and valve
Outside
diameter of
intake valve
5.980.008
26
Outside diameter of timing gear
Diameter of cylinder head intake valve guide orifice
6+0.015

16

+0.074

0.040

Diameter of crankshaft front oil seal

360-0.1
Diameter of cylinder head jib hole
22
Diameter
of crankshaft rear oil seal
750-0.1
Outside diameter of hydraulic jib
0
Outside
Axial
diameter
clearance
of engine
of crankshaft
oil dipstick tube
16.70.1

Diameter
of
crankshaft
timing
gear
segment
23
Axial ClearanceBore
of Camshaft of crankshaft timing gear
0.043
Diameter of cylinder block diameter
scale tube orifice
16.70
Axial clearance
of connecting
rod of crankshaft timing gear
Key groove
dimension
Diameter of cylinder head valve guide orifice
6+0.015
Key grooverod
width
of crankshaft gear
24 clearance of connecting
Fit
bearing
Outside diameter of valve guide
11x6
Semicircular
key
width
Fitcylinder
clearance
of valve
main bearing
Diameter of
head
guide bottom orifice
11H7

Diameter of camshaft second journal

24e6
0.053
0.025~0.07

Bracing spring height of steel strip composite type oil

1.50.03
ringOutside diameter of camshaft oil seal
21
0.014
Crankshaft keyDiameter
groove width
of cylinder head oil seal hole 50.010

15

+0.040

0.035~0.08
0.021

Second piston ringDiameter

groove height
of camshaft fifth journal 1.5+0.04+0.02
19
Second
compression ring height
1.5-0.005-0.030
Diameter
cylinder head fifth bearing hole
piston oil ring
grooveofheight
2.5+0.03+0.01
Blade height
oil groove
ring width
20 of steel strip composite
Camshafttype
thrust

+0.074

0.040

Diameter of camshaft fourth journal

1.2+0.05+0.03
First
piston
ring
groove height
18
Diameter of cylinder head fourth bearing hole-0.005
Top compression ring height
1.2

Fit clearance

+0.040

+0.074

+0.040

0.096~0.126

guide
Fit clearance between exhaust valve stem and valve
guide

0.0320.063mm

Fit clearance between hydraulic jib and cylinder

head hole

0.0060.035mm

III. Primary Fit Clearance

Number

No.

Connection part

Part name

Bolt
(thread specification)

of bolts/
gaskets
(piece)

Tightening

Multiple steps tightening (torque +

angle)

torque
Nm (primary
tightening)

First step
tightening
torque (Nm)

IV. Engine Primary Tightening M181.5

Torque Table
2

Cylinder block main oil passage Hexagonal socket head

screw plug 1

plug

Cylinder block main oil passage Hexagonal socket head

Second step Third step

angle ()

angle ()

20+5

M101.5

203

Hexagon bolt

M111.5

455

18010

Main bearing cap

Hexagon bolt

M111.5X92.5

455

18010

Framework-cylinder block

Hexagon bolt

M81.2555

10

20+3

Knock sensor-cylinder block

Hexagonal flange bolt

M81.2535

20+0.5

Hexagon bolt

M81

253

905

Hexagon bolt

M635

8+3

Hexagonal flange bolt

M612

8+3

screw plug 2

plug

Main bearing cap

Connecting rod cap-connecting

rod body
Oil pump assembly-cylinder
block
Engine oil collector bracket,
separator-framework

10

Bleeding plug-oil pan

Hexagon bolt

M161.5

253

11

Oil pan-framework

Hexagonal flange bolt

M720

18

15+3

12

Oil pan-framework

Hexagonal flange bolt

M735

15+3

13

Oil pan-framework

Hexagonal flange bolt

M790

15+3

14

Water pump-cylinder block

Hexagon bolt

M625

8+3

Hexagon throttle bolt

M141.5

15+3

Locating bolt

M6130

18

9.51.5

Hexagonal flange bolt

M61x30

9.51.5

15

16

17

Cylinder head oil passage

throttle bolt
Camshaft bearing cap-cylinder
head
Camshaft bearing cap-cylinder
head

No.

42
18
19
43
20
44
21
45
22
46
23
47
24
48
25
49
26
27
50
29
30
51
31
52
32
53
33
54
55
34
56
35
57
58
36
37
59
38
60
39
61
62
40
63
41

No. ConnectionConnection
part
part

Number Number
Multiple steps
Multiple
tightening
steps tightening
(torque + (torque +
Tightening Tightening
of bolts/ of bolts/
angle)
angle)
torque
Bolt
Bolt
torque
Part name Part name
gaskets gaskets
First step First step
(thread specification) Nm (primary
Nm (primary Second step
(thread specification)
Second
Third step
step Third step
(piece)
(piece)
tightening tightening
tightening)tightening)
angle () angle
angle()() angle ()
torque (Nm)
torque (Nm)

64 lower
Exhaust
manifold-cylinder
head
Stud bolt
M8146
Front
cover
of timing
Phaser
control
valve-first
M624
M6115
Hexagonal
flange bolt
bolt
52
Inner hexagonal
gear-engine
65 camshaft
Exhaust cap
manifold-cylinder head
Hexagon nut
M8
Exhaust
pipe
Front upper
cover
of timing
Cylinder
head-cylinder
blockthermal
Inner hexagonal bolt
M101.5
66
Hexagon
Inner hexagonal
bolt bolt M630
shield-exhaust pipeDamping unit-valve
gear-engine
Valve cover
assembly-cylinder
M6130
Oilhead
return of
pipe
bracket-cylindercover
Front upper
cover
timing
67
Hexagon bolt M616
Hexagon bolt
block
Camshaft gear-engine
position sensor-valve
M6115
Inner hexagonal bolt
68
Oil
return pipe hollow screw
Air
compressor
cover
M825
Hexagonal flange bolt
bracket-cylinder
block
69
Bracket-oil-gas
Inner hexagonal
boltM814
Hanger-cylinder
head separator
Hexagonal flange
bolt
70
Bracket-oil-gas
Inner hexagonal bolt
Air compressor
bracket-cylinder
Rear housing
of timing separator
M865
Hexagonal
flange
bolt
M515
Cross head
screw
block
gear-cylinder head

9
8+3
9

12+3

20+5

10
M812 1

38+3

505

20+5

12
M820 4

8+3

18+3

20+5

8+0.5
1
10+3
2
20+5

15+3

6+2

2
30+3
5+2

8+3

2.50.5

655

305

305

M141.5

1
M514 2
M614
M4

36

Power Phaser-camshaft
steering pump-steering Inner TORX hollow bolt
M5
51.5
M121.25
2
1205

M8125

Hexagonal flange bolt

1
20+5
pump bracket
M6
83
Timing gear-camshaft
Bolt
M121.25
2
1205

85
Other
Power steering pump-steering
M7
153
Inlet cam phaser cap-inlet cam Hexagonal flange bolt
M825

1
20+5

Hexagon bolt
1
30
pump bracket
M8
205
phaser
Power steering pump-steering
M10 1
405
Exhaust cam phaser cap-exhaust Hexagonal flange bolt
M880

20+5

Inner TORX bolt

1
30
pump bracket
cam phaser
A/C compressor assembly-air
Oil filter assembly-oil filter seat Hexagonal
Screw flange
sleeve bolt
M201.5
11
253
M8100

205
bracket
No.compressor
Lubrication
par
Type
of
lubricant
Oil filter joint
M201.5
1
253

Air compressor assembly-air

ts M830

Oil filter seat-cylinder block Hexagonal

Inner hexagonal bolt
bolt
M825
31
20+5
20+5
1
Piston pinflange
and pin 1hole
SJ10W-40
compressor
bracket
M141.2512
122

Oil pressure
switch-oil filter
1
Generator
assembly-generator
2
Piston
ring
groove
1313
M1090

305
Hexagonal flange bolt
1 SJ10W-40
bracket
Thermostat assembly-cylinder
M660

Hexagon bolt
3
8+3
Generator lower
head
M1045

405
Hexagonal flange bolt
2
bracket-cylinder block
Thermostat cover-thermostat
M620

flange
Ignition coil assembly-bracket Hexagonal
Hexagon
bolt bolt
M6150
4
8+3

case
Spark plug-cylinder head
Hexagon bolt
M141.25
4
30+3

Coolant senser-thermostat shell

M121.5
1
20+5

Intake manifold-cylinder head

Stud bolt
M6125
9
3+2

Crankshaft timing
M131.5

13010
Hexagonal
flange
bolt
1
Intake manifold-cylinder head
Hexagon nut
M6
9
8+3

gear-crankshaft
Delivery pipe assembly-air
Crankshaft pulley-crankshaft
M620

Hexagonal flange bolt

2
8+3
M8115

255
Hexagonal flange bolt
6
intake pipe
timing gear
Throttle body assembly-air
Flywheel-crankshaft
Hexagonal
flange
M81.25
84

155
M6150

Hexagon
bolt bolt
8+3
intake pipe
Signal wheel-flywheel
Hexagon bolt
M81.25
6
82

Bracket-air intake pipe

Hexagon bolt
M830
2
20+5

Timing belt-tensioner
M855
273

Bracket-air intake pipe

Hexagonal flange bolt
M840
21
20+5

assembly-cylinder block
Engine oil dipstick tube-air
Timing belt-idler
M616

Inner hexagonal bolt

1
8+3
M1060

Hexagonal flange bolt

1
40+5
compressor bracket
assembly-cylinder head
Engine oil dipstick
Bulkhead-crankshaft locating
M616

Hexagon bolt
1
8+3
M161.5
253

Hexagonal flange bolt

1
tube-framework
pin hole

Connecting rod bearing shell and connecting

rod journal

3
4
No.
5
1
6
7
8
9

2
3
4
5

10
6

s
r
eq
A

Cylinder sleeve hole

Parts where rubber coating are required
Main bearing lining and crankshaft main
journal
Cylinder
block bowl plug
Crankshaft thrust sheet (at oil groove side)
Cylinder
block
main
oil passage plug
and
thrust
surface
Junction
plane of
Head
and thread
offramework
connecting and
rod cylinder
bolt
block
Head and root of main bearing cap bolt
Outer ring of crankshaft rear oil seal
Rear oil seal edge and crankshaft oil seal
Framework
journaland oil pan
Head and root of cylinder head bolt
Cylinder head bowl plug

11
Valve guide orifice
7
Main oil passage screw plug
Number
Position
12
Valve stem
18
Chassis
Base plane of first bearing cap
2
Engine
13
Valve oil seal lip
9
Water temperature sensor
3
Transmission
14
4
AccessoryValve seat inserte
10
Oil pressure switch
Modification
n
5
Body
15
Valve
A
First modificationkeeper ring groove
e
11
Flywheel bolt
o
B16
Second modification
Cam and journal of camshaft
C 12 Third modification
Oil pan main oil passage plug
Camshaft bearing hole
D17
Fourth modification
13
Engine oil collector separator bolt
External surface and base plane of hydraulic
18
jib

SJ10W-40
SJ10W-40
Type of sealant
SJ10W-40
Loctite 648
SJ10W-40
Loctite 243
SJ10W-40
Loctite 515
SJ10W-40
Loctite 243
SJ10W-40
Loctite 5910

V. Th
e Part
s wher
e Lubr
icatio
n are
Requir
d duri
g Ass
mbly
f

SJ10W-40
Loctite 648
SJ10W-40
Loctite 243
SJ10W-40
Loctite 574
SJ10W-40
Loctite 243
SJ10W-40
Loctite 243
SJ10W-40
Loctite 243
SJ10W-40
Loctite 243
SJ10W-40
Loctite 243
SJ10W-40

19

Hydraulic jib hole and valve rocker arm head

SJ10W-40

20

Outer ring of oil pump

SJ10W-40

21

Edge or journal of camshaft oil seal

SJ10W-40

22

Intake and exhaust phaser control valve

gaskets

SJ10W-40

23

Journal of intake and exhaust phaser

SJ10W-40

Engine
VI. The Part
where Rubbe
Coating are R
uired during
ssembly

Chapter Three Special Tools

Please use the special tools that we designated to perform maintenance, otherwise it
will cause accident or damage the machine.

of Engine

I. Connotation of Special Tool Number

In order to know or find the tool clearly according to parts number and improve maintenance
efficiency, special tools numbering is stipulated as follows:

Maintemance times coresponding to tools

SN coresponding to tools
System code coresponding to tools
Tools name

indicates a letter indicates an Arabic numeral

Nomenclature of the tool: for a standard part, please use the brand and model recommended by
Chery company as reference. For example, CH indicates a non standard part, which means it is a

special tool for repair of this part verified by After Sales Service Department of Chery Automobile
Sales Co., Ltd. HAZET indicates a standard tool produced by this company.

CH-20002

Installation tool for camshaft oil seal:

Same as A5
used to install camshaft oil seal.

CH-20003

Engine timing
e
crankshaft.

CH-20004

Adaptor: used to install and removeSame as A5

valve spring (match with Eastar special
tool MLR-MD998772A).

CH-20005

tool:

used

to

tim
Same as A5

Installation tool for crankshaft rear oil Same as A5

seal: used to install crankshaft rear oil
seal.

Connotation of system code corresponding to the tool:

CH-20006

Installation handle for crankshaft rear Same as A5

oil seal: used to install crankshaft rear
oil seal.

For exa
mple:
CH1002A
means i
t is th
e 2# sp
ecial to
ol for r
epair o
f chassi
s syste
m that
has bee
n

Corresponding series number of tools: from 001 to 999.

CH-20007
Times of modifications of the tool: Installation sleeve for crankshaft front Same as A5

oil seal: used to install crankshaft front

oil seal.

Note: In alphabetical order. Bigger SN means more modification times.

verified by After Sales Service Department of Chery Automobile Sales Co., Ltd., who commits
production of this tool to other manufacturer. This tool is of the first modification.
HAZET-6290-1CT means it is a standard tool produced by HAZET company with its model

CH-20008

CH-20017
Installation sleeve for crankshaft
Installation
front
toolSame
for as
valve
A5 keep
Same as A5

oil seal

CH-20009

CH-20010

Recommended tools

er: used
to install valve keeper.

CH-20018-A
Locating

tool for flywheel: Valve

used spring
Same remover:
as A5
used to remove Same as A5
locate flywheel.
valve spring.
Loop wheel machine: used to raise engine.

Camshaft timing tool:

camshaft.

used to timeSame as A5

as 6290
-1CT.

II. S
Engine maintenance workbench:
peciathe
oil
seal:
Same
as
A5
disassembly and assembly of engine.
l Too
ls Ch
art

workbench fo

CH-20011

Installation tool for camshaft

used to install camshaft oil seal.

CH-20012

Valve oil seal guide sleeve: used Same as A5

install valve oil seal.
Fuel pressure gauge: used to measure oil pressure o
engine.

CH-20013

Valve oil seal remover: used to remove Same as A5

valve oil seal.

CH-20015

Belt pulley bolt remover:

remove belt pulley clip.

used

Same as A5

Pressure gauge for cylinder: used to measure cylinder

pressure. When measuring, remove spark plug first,

screw instrument pipe orifice into the position of spark

plug, use starter to drag the engine to rotate, and then
fetch the maximum reading of the pressure gauge for
cylinder as cylinder pressure of this cylinder.

Chapter Four Measurement of Cylinder Pressure

I. Detection of Cylinder Pressure
Measurement of cylinder pressure is the major index for judgment of engine working condition,
through which, we can definitely judge if a certain system of engine works well. Therefore, during
maintenance of engine, measurement of cylinder pressure is indispensable.

1. Measuring process
Please

select

cylinder

pressure

gauge with accurate reading and let its

pointer return to zero; otherwise, it may affect
accuracy of reading.

1.1 Turn off ignition switch, pull out all ignition cables
from spark plug side, and then pull
connector of injection nozzle.

out

harness

1.2 Use a spark plug sleeve to loosen the spark plug

whose cylinder will be measured. Explanation: do not
remove the spark plug whose cylinder will not be
measured.
1.3 Screw the cylinder pressure gauge joint slowly and
vertically into the spark plug hole. Do not screw too
tightly for fear that it may be difficult to disassemble.
1.4 Step down clutch pedal, start the engine and let it
run for about 5-6s, then fetch the numerical value.

2. Judgment of cylinder pressure value

2.1 Correct cylinder pressure
The standard cylinder pressure value should be
10-13.5bar. With use of engine, this value will fall, but
it should not be below 9bar with the pressure
difference among cylinders not exceeding 3bar.
2.2 In case cylinder pressure of engine is below the
standard value, it indicates deficiency of cylinder
pressure, the main cause of which may be untight
piston ring seal or valve. Please further analyze and
check.
When
ensure

starting

adequate

the

engine,

quantity

of

electricity. Correct cylinder pressure can

only be measured out with revolution of
engine as 200-300r/min.

Chapter Five Disassembly of Power-assisted Steering System

I. Disassembly Procedure
1. Use a snap ring pliers to loosen the clamp on
connecting hose of steering fluid reservoir and steering
pump. Use a clean container to reclaim the steering fluid.

2. Use a 21# sleeve to remove the fixing bolt of steering

pump oil pipe.
Torque: 20+5Nm.

3. Use a 10# sleeve to loosen the (upper) fixing bolt of

steering pump adjusting bracket.

Torque: 20+5Nm.

4. Use a 10# sleeve to loosen the (lower) fixing bolt of

steering pump adjusting bracket.
Torque: 20+5Nm.
5. Use a 10# open end wrench to loosen the adjusting
bolt of steering pump bracket, and then pull the steering
pump upwards to loosen and take off the belt.

6. Use a 10# sleeve to loosen the connecting bolt of

steering pump and compressor bracket, pull out harness
connector, and then dismount the steering pump
assembly.

Note: when dismounting the

steering pump, please block the oil
pipe joint with clean cotton cloth.

II. Overhaul
Steering pump can not be repair, if such failure as abnormal noise or oil leak exists, replace the
assembly.

III. Installation of the Steering Pump

1. Follow the order adverse to that of disassembly to install.
2. After installation of steering oil pump, duly adjust tightness of belt through adjusting bolt.

3. After power steering pump is properly installed, refill with special steering pump oil, and then
bleed air for the power steering pump after the engine starts.
4. Air bleeding method:
4.1 Hoist the vehicle to let its front wheels leave ground.
4.2 Turn the steering wheel left and right to the ends (duration for each time should not exceed 5s,
otherwise, the power steering pump is likely to be burnt out) until the oil pump does not make
sound. Note that oil storage kettle should not be lack of steering pump oil.

Chapter Six Disassembly of A/C Compressor

I. Disassembly Procedure
Before disassembling the compressor, disassemble the steering oil pump first.
1. Use a 12# sleeve and a universal joint connecting rod to
loosen the connecting bolt of A/C high and low pressure
pipelines. (Note: if there is R134a in the condenser, use a
special equipment to reclaim first.)
After

the

pipeline

is

loosened, immediately block high

and low pressure holes of the compressor
with clean cotton cloth to avoid entry of
foreign material into the compressor!

2. Hoist the vehicle and then use a 13# sleeve to loosen the
fixing bolt of the compressor from underside.
Torque: 20+5Nm.

3. Lower the vehicle and then use a 13# sleeve to loosen

the fixing bolt of the compressor from upside. Use a 13#
sleeve to loosen the fixing bolt at middle of the
compressor, and then dismount the compressor assembly.
Torque: 20+5Nm.

II. Overhaul of Compressor

Inside of the compressor are assembled with highly machined fine parts, in case abnormal noise or

internal failure is found, replace the assembly.

III. Installation procedure

For the installation order, please refer to the disassembly order, and then follow the order adverse
to that for disassembly to install. It should be noted that, when installing the A/C pipeline joint on
the compressor, be sure to replace with a new gasket and tight the joint at specified torque to avoid
leak.

Chapter Seven Disassembly of Generator

I. Disassembly Procedure
Before disassembling the
generator, remove the connecting
line of battery first.

1. Use a 10# sleeve to remove the connecting line of

battery.

2. Use a 10# sleeve to loosen the fixing bolt of generator

adjusting bracket, and then take off the adjusting bracket.
Torque: 30+5Nm.
3. Use a 13# sleeve to remove lower fixing bolt of the
generator.
Torque: 40+5Nm.

4. Use a 10# sleeve to remove the fixing bolt of generator

anode harness, pull out the harness connector, remove the
belt and then take out the generator.

II. Overhaul of Generator

In case the generator makes abnormal noise or its yield is too high or too low, replace the
assembly.

III. Installation Procedure

The installation order of the generator is adverse to that for its disassembly. After the generator is
installed, adjust deflection of the belt.

Chapter Eight Replacement of Engine Timing Belt

I. Disassembly Procedure
In order to ensure normal and
highly effective
engine, replacing the

working

of

the

timing belt at

50,000km mileage is recommended.

1. Disassembly of engine timing belt:

1.1 Follow the disassembly methods for power-assisted steering pump, compressor and generator
to disassemble the generator and compressor belt.
1.2 Use a 5mm hexagon wrench to remove the five
fixing bolts on timing upper cover.

1.3 The positions of the five fixing bolts on timing upper

cover are shown by the red circles in the figure.

1.4 Use a 13# sleeve to loosen the crankshaft timing

adjusting hole bolt. (The adjusting bolt is at upside of the

1.5 Insert the special tool CH-20003 into the timing hole
and tighten, use a wrench to turn the big nut in
he
crankshaft pulley to make the crankshaft rotate, at the
same time, slowly screw in CH-20003 until
he
crankshaft can not rotate back and forth any longer.

1.10 Us

1.6 Use a 13# sleeve to remove the six fixing bolts

crankshaft pulley and take out the crankshaft pulley.
Torque: 55+5 Nm.

1.
1.7 Use a 10# sleeve to remove the six fixing bolts
timing lower cover.

1.8 The positions of the six fixing bolts on timing lower

cover are shown by the red circles in the figure.

1.9 It should be specially explained that, the position of

the fixing bolt at left upside on the lower cover is very
occult, for removal of which, use of universal join
t
connecting rod is required. Alternatively, use a 13mm
sleeve to remove the three bolts of suspension bracket to
take off the suspension bracket.

Loosen the fixing bolt of tension pulley and turn the

2.
3.

4.
5.
6.
7.
8.

tension pulley to minimum tension position.

Install the belt.
Use a 5mm hexagon wrench to turn the tension
pulley, when it turns to a position that the hexagon
wrench and the fixing bolt are roughly on the same
horizontal line, stop and tighten the fixing bolt.
Install timing lower cover.
Install crankshaft pulley.
Install relevant accessories and check deflection of
the belt.
Install timing upper cover.
The installed timing belt is as shown in the figure.
Note:
During the disassembly process, be

sure not to
otherwise,

turn

crankshaft/camshaft;

ignition timing

will

need

re-check.

III. Adjustment of Timing (general overhaul)

1. Turn the crankshaft to make the four pistons align on a horizontal line in the cylinders, screw
the special tool into the crankshaft timing adjusting hole at left rear of the cylinder (last segment
of the crankshaft), and then make the crankshaft unable to turn left and right (the bolt of the
special tool must enter into the screw hole plane of the cylinder).
2. After intake and exhaust camshaft is installed properly, install the camshaft timing gear, turn the
groove at tail of intake and exhaust camshaft to horizontal direction, and then insert the special
tool into the groove and fix.
3. After crankshaft and camshaft have been fixed according to requirements, install timing belt. In
order to facilitate installation of timing belt, temporarily do not tighten the bolt fixing the timing
gear onto camshaft and let it rotate freely, then fix the timing gear bolt after the tensioner pulley
has fastened the timing belt to the specified value. After that, install other parts.

IV. Adjustment of Timing (minor overhaul)

Replace valve spring, grind valve and replace camshaft (do not raise the engine).
1. Remove the valve cover.
2. Remove the timing gear cover. Turn the timing gear.
3. Let the groove at tail of intake and exhaust camshaft on a horizontal line, then insert the
projecting portion of the special tool into the groove and fix.
4. Turn the crankshaft, screw the special tool into the crankshaft timing adjusting hole at left rear

of the cylinder (last segment of the crankshaft), and then make the crankshaft unable to turn
left and right (if the cylinder head is removed, it can be found that the pistons of the four
cylinders now align at a horizontal position).
5. Install timing belt and make tightness of the belt conform to requirements.
6. Fasten the fixing bolt of timing gear.
7. Install other accessories, such as timing cover and belt pulley etc.

Special tool for camshaft timing check

(CH-20010)

Special tool for crankshaft timing check

(CH-20003)

Chapter Nine Disassembly of Engine Assembly

I. Disassembly Procedure
Note:
Please use regular equipment, especially for such
equipment as crane etc., so as to avoid occurrence of accident.
Before any disassembly job, disassemble cathode of battery
first, so as to protect safety of electricity consumption equipment.
When disassembling engine suspension, pay attention to
disassembly order, so as to avoid occurrence of accident.

1. Disassembly of engine wire harness

1.1 Pull out the connecting plug of engine wire harness.

1.2 Use a 10# sleeve to loosen the fixing bolt of engine

ground.

2. Use a 10# sleeve to remove the fixing bolt and bearer

of battery.
3. Use a 13# sleeve to remove the bolt of battery support
fixed mount.

4. Disassembly of cooling system.

4.1 Hoist the vehicle, place away a coolant collector,
unscrew bleeder bolt of the water tank to discharge the
coolant.

4.2 Use the snap ring pliers to loosen the clamp on

connecting pipe of water tank.

4.3 Use the snap ring pliers to loosen the connecting

water pipe of A/C heating water tank.
4.4 Use the snap ring pliers to loosen other connecting
water pipes.

5. Disassembly and installation of water pump assembly:

5.1 Remove upper and lower covers of timing gear (refer
to disassembly and installation of gear and belt of timing

gear).
5.2 Use a caliper to take off the clamps on the three
discharging tubes and then pull out the rubber hoses.
5.3 Use a 10mm sleeve to remove the fixing bolt of
discharging tube of water pump and then pull out the
discharging tube.
Note: in case the O-ring on discharging tube of water
pump is loose, broken or aging, be sure to replace.

5.4 Use a 10mm sleeve to remove the fixing bolt of

water pump and then take out the water pump assembly;
when removing, be careful not to damage cushion of the
water pump, if damaged, replace with a new one. The
water pump can not be decomposed to maintain.
5.5 Check water seal of the water pump for water leak; if
water pump bearing is loose, replace the assembly.
Follow the order adverse to that for disassembly of the
water pump to install it.
5.6 Disassembly and installation of thermostat
5.7 Use a caliper to take off the clamps on the two
discharging tubes and then pull out the rubber hoses.

5.8 Use a 10mm sleeve to remove the fixing bolt of

thermostat cover and then take out the thermostat.

5.9 Use a 10mm socket wrench to remove the thermostat

seat. Be careful not to damage the thin sheet gasket.
6. Inspection of thermostat:
(1) Under normal temperature, inspect seating status of
the valve and it should tightly seat.
(2) Inspect opening temperature and maximum stroke of
the valve.
Opening temperature of the valve is 872

Maximum stroke of the valve is 8mm

Full opening temperature of the valve is 104
(3) Then check if the valve closes at the temperature
5 lower than the opening temperature. If not
compliant, replacement with a new thermostat is
required. Follow the order adverse to that for
disassembly of the thermostat to install it. When
installing, check if the gasket of the thermostat is
damaged, if thermostat seat and thermostat cover
casing plane are satisfactory. Check the sealing
gasket for damage, if damaged, replace with new
sealing element.
7. Disassembly of A/C pipeline
See Disassembly of A/C Compressor for disassembly
of A/C pipeline.
8. Disassembly of power-assisted steering pipeline.
See Disassembly of Power-assisted Steering Oil Pump
for disassembly of power-assisted steering pipeline.
9. Disassembly of intake and exhaust manifold.
9.1 Use a 10# sleeve to remove the fixing bolt of air
intake pipe.

9.2 Use a cross-head screwdriver to loosen the clamp

connecting intake hose and electronic throttle body.
9.3 Use a 13# sleeve to remove the connecting bolt of
three-way catalytic converter and exhaust intermediate
pipe.
Torque: 605 Nm.

9.4 Use a 10# sleeve to remove heat insulating mattress

of exhaust pipe.

9.5 Use a 13# sleeve to remove the connecting bolt of

exhaust manifold and three-way catalytic converter.
Torque: 605 Nm.

9.6 Use a 13# sleeve to remove the fixing bolt of exhaust

manifold.

10. Disassembly of connecting portion of transmission

case.
10.1 Use pliers to remove the fixing steel wire clip of
gearshift control cable.
10.2 Use pliers to remove the fixing clip of gearshift
control cable outer case and then take off the gearshift
control cable.

10.3 Use a 13# sleeve to loosen the adjusting screw of

clutch control cable and then take off the clutch control
cable.

10.4 Use a 13# sleeve to loosen the fixing bolt of clutch

control cable on the transmission case.

10.5 Use a 17# wrench to loosen the bleeding bolt of

transmission case to discharge the gear oil.
10.6 See Service Manual for Chassis for disassembly
of suspension travel portion.
10.7 Use a crow to pry out the half shaft.
11. Disassembly of suspension portion
11.1 Use a 13# sleeve to remove the fixing bolt for rear
engine mount bracket of transmission case.
Torque: 605Nm.
11.2 Use a 18# sleeve to loosen the fixing bolt for front
engine mount bracket.
Torque: 805 Nm.

11.3 Use a crane to hoist the engine until the iron chain
just bears tensile force.

11.4 Use a 15# sleeve to loosen the fixing bolt for right
engine mount bracket. (at rear of transmission)
Torque: 1005 Nm.

11.5 Use a 13# sleeve to loosen the three connecting

bolts for right engine mount bracket.
Torque: 655Nm.

11.6 Use a 13# sleeve to loosen the three connecting

bolts for left engine mount bracket.
11.7 Pull out oil pipe connector and junctions of relevant
pipelines. Make sure that relevant junction parts have all
detached.
11.8 Hoist the engine up.
12. Separation of transmission case assembly and engine
12.1 Use a 10# sleeve to remove the gearshift control
cable bracket on the transmission case.

12.2 Use a 13# sleeve to loosen the four fixing bolts for
front engine mount bracket.
Torque: 655Nm.

12.3 Use a 13# sleeve to remove the connecting bolt of

transmission case and engine, and then make the engine
and the transmission separate.
Torque: 10010 Nm.

II. Installation Procedure

1. Please follow the order adverse to that for disassembly to install, but care should be taken for
the following matters.
(1) When hoisting, do not install exhaust manifold first, because the longitudinal separation of
engine compartment is not big enough; otherwise, it may affect the assembly.
(2) After installation, please adjust the stroke of clutch pedal. When adjusting, adjust it to a proper
position according to the corresponding requirements, in case of a too big free stroke of clutch, it
may make sound when shifting gear or fail to release; while in case of a too small stroke, wear of
friction plate may be accelerated and travel weakness may occur, if severely, the friction plate may
be burnt out.

Chapter Ten Disassembly of Intake Manifold

I. Disassembly Procedure
1. Use an 8# sleeve to remove the four fixing bolts of
ignition coil and then remove such connections as
ignition cable/injection nozzle harness etc.

2 Use a 10# sleeve to remove the bolt of intake manifold

fixing bracket.
3. Use a 10# sleeve to remove the fixing bolt of
compressor bracket.
Torque: 303 Nm.

4 Use a 10# sleeve to remove the fixing bolt of intake

manifold and then take off the intake manifold assembly.
Torque: 8+3Nm.

Chapter Eleven Disassembly of Cylinder Head

I. Disassembly Procedure

1 Use a 10# sleeve to remove the fixing bolt of valve

cover.
Torque: 83 Nm.

2. Get the special tool CH-20010 stuck into the

groove on camshaft.
3. Use a 18# sleeve to loosen the fixing bolt of
camshaft timing gear.
Torque: 1205Nm.
Note:
There

is

no

difference

between

intake

camshaft and exhaust camshaft, they can be interchanged.

4. Use a cross-head screwdriver to loosen the fixing

bolt on inner fender of timing gear and then take out
the inner fender of timing gear.

5. Use a 10# sleeve to remove the fixing bolt of

camshaft bearing, take out the camshaft assembly
and then the hydraulic tappet system.
Torque: 9.51.5 Nm.
Note:
The positions of both camshaft bearing and
bolts,

including

the

order

of camshaft

bearing,

are

unchangeable, and should be conformity with the marks

during assembly/disassembly.

6. Use an hexagon torque wrench to loosen the

fixing bolt of cylinder head and then take off the
cylinder head assembly.

Torque: 505 Nm.

Note:
Follow the order as shown in the figure to
loosen the fixing bolts of cylinder head.

7. Disassembly of valve
7.1 Use a special tool to press down the valve
spring, take out the locking plate, and then take off
valve spring, valve and valve seat insert.

7.2 Use a special tool to pull out the valve oil seal.

II. Overhaul of Cylinder Head System

1. Detection of camshaft
1.1 Measurement of height of cam. Use an outside
micrometer to measure wheel height of the cam.
Wheel height of the intake camshaft: 37.11mm.
Wheel height of the exhaust camshaft: 37.09mm.

1.2 Inspection of camshaft journal. Use an outside

micrometer to measure each journal of the camshaft,
please see Specification Table for specific data.

2. Detection of valve
2.1 Detection of valve spring. Two items of data of
valve spring should be measured.
Length of the spring: 49mm
Squareness of the spring: 1.2mm (limit)

2.2. Detection of valve.

2.2.1 Measurement of diameter of valve stem

2.2.2 Measurement of valve guide inside diameter
Use an inside micrometer to measure inside
diameter of the guide.
Note:
If

abnormal

noise

is

generated

due

to

serious wear of valve guide, do not replace the valve

guide, because the assembly technique requirements to
valve guide is very strict; please replace the cylinder head
assembly.

Fit clearance between intake valve stem and valve

guide: 0.012~0.043mm
Fit clearance between exhaust valve stem and valve
guide: 0.032~0.063mm
2.3 Boring and grinding valve seat insert
2.3.1 Inspection of fitting surface of valve. Apply a
circle of red lead on the valve sealing strip and then
gently place the strip onto the valve seat insert,
softly and forcibly press it down, but do not turn it.
Take out the valve, observe if there is broken part on
the red lead, if any, boring and grinding the valve
seat insert is required.

2.3.2 Select an appropriate reamer, use 45 conical

surface as cooperate standard value to check valve
cooperation position: the optimal position is the
center of the valve, if not so, be sure to revise. Cut
on the conical surface 70 inward and 30 outward
at the center of the cooperation position.

2.3.3 Perform seat grinding for the valve sealing

strip with polishing compound
2.3.4 Detection of planeness of cylinder head
Follow the method as shown in the figure to
measure planeness of the cylinder head with a feeler
gauge; the planeness of the cylinder should not
exceed 0.05-0.10mm, if exceeding this valve,
replace the cylinder head assembly.

Measurement point
Measurement point

III. Assembly of Cylinder Head Assembly

1. Please follow the order adverse to that for
disassembly of cylinder head to install, but care
should be taken for the following matters during
installation.
2. Use the special tool CH-20012 to install new
valve oil seal onto the guide first.

3. Insert big end of the guide onto the valve guide.

4. Envelope the special tool onto CH-20012, and

then softly and forcibly compact.
5. Use a hammer to knock the valve oil seal
installation tool, when a metal crash sound is heard,
take out CH-20012.

6. The methods for installation and assembly of

valve spring are the same. Then install valve, spring,
keeper, top barrel and rocker arm. (when installing
the top barrel, add a little engine oil into the hole).

7. Install camshaft and camshaft bearing shell cover

assembly.

Note:
When installing, remember to differentiate intake
camshaft from exhaust cam. The intake camshaft has a
gear at tail, and pay attention to the diacritical marks on
camshaft bearing shell covers.

8. Installation of camshaft and oil seal

8.1 After adding engine oil on the camshaft bearing
shell, place intake and exhaust camshafts, cover
bearing shell covers properly, install the fixing bolts
for the bearing shell covers, and then use a 10mm
sleeve to hold down the bearing shell covers step by
step (the two bolts on the one and the same bearing
shell cover should be tightened at the same time).
Torque: 8.51.5 Nm.
9. Remember to apply sealant to the position as
shown in the figure when installing the first bearing
shell.
10. Tightening order of camshaft bearing shell cover.
Tighten the camshaft bearing shell cover as shown
in the figure.
Installation of camshaft oil seal:
Apply a little engine oil on the camshaft oil seal,
envelop the oil seal onto the camshaft, and then
install use the special tool.

11. Remember to check elasticity of valve cover

gasket for aging and breakdown, if any, replace with
new one. When installing, pay attention to
installation position.
12. Tighten the valve cover bolt.

Chapter Twelve Disassembly and Installation of Oil Pump and

Lubrication System

I. Disassembly Procedure
1. Roll over the engine and use a 10# sleeve to remove
the fixing bolt of oil pan.
Torque: 15+3 Nm

2. Use a screwdriver to pry out the oil pan at the given

position for prying out on the oil pan.
Note:
Because the oil pan and cylinder block are sealed
with glue, so, do not knock with such hard articles as
hammer etc. when disassembling, use a rubber hammer to
slowly strike at left and right instead.

3. Use a 10# sleeve to remove the fixing bolt of engine

oil strainer.
4. Use an 8# sleeve to remove the fixing bolt of engine
oil guard board.

5. Use an 8# sleeve to remove the four fixing bolts of

oil pump.
Torque: 8+3Nm

6. Take off the oil pump assembly and then the oil pump
shim.
Note:

Do not split the oil pump shim forcibly when

disassembling for fear to cause leak.

7.

Use

an

hexagon

wrench

to

remove

the

two

connecting bolts of oil pump.

8. Use a screwdriver to pry the crankshaft front oil seal

and then take out the oil seal.

II. Overhaul of Oil Pump

if it is suspected that engine oil pressure may has problem,
disassemble the oil pump and check elastic force of relief
valve spring and if the valve is locked.
Note:
The oil pump is of inner rotor type, which can not
be maintained under normal conditions, because its finish
size and material ensure its reliability.

III. Installation Procedure

The installation order is adverse to that for disassembly,
but care should be taken for the following matters.
1. The installation direction of oil pump relief valve is as
shown in the figure.

2. Completely and softly shovel off the glue on the surface

of oil pan with a flat shovel and then apply new sealant
uniformly (see the table above for type of the sealant).
Note:
As soon as new sealant is applied properly,
assemble at once; otherwise, the sealant may freeze,
which may affect the sealing effect.

Chapter Thirteen Disassembly of Crank-Connecting Rod

Mechanism
I. Disassembly Procedure
1 Use a 13# sleeve to remove the fixing bolt of clutch
cover.
Torque: 232 Nm

2. Use the special tool CH-20009 to lock the crankshaft

and then use a 13# sleeve to remove the connecting bolt
of flywheel and crankshaft.

3. Use a 13# sleeve to loosen the fixing bolt of

connecting rod bearing cylinder by cylinder and then
take off the piston and connecting rod assembly.
Note:
After the pistons are taken out of the cylinders,
reset and connect the bearing caps of connecting rod big
end and bolts properly and then put them by order.

4. Use a 10# sleeve to remove the fixing bolt of

crankshaft lower bearing cap and cylinder block.

5. Use a 19# sleeve to remove the fixing bolt of

crankshaft main bearing cap.
Note:
The surface between cylinder block and bearing cap
is ensured by high precision machining plane, so, do not
use any hard article to scuff this surface.

6. Take off crankshaft rear oil seal assembly, remove

bearing shell cover, and then take off crankshaft
assembly.

II. Overhaul of Crank-Connecting Rod System

1. Detection of crankshaft.
1.1 Detection of crankshaft main journal: use an
outside micrometer to measure main journal of
crankshaft and the normal value should be
46.01mm.
1.2 Detection of connecting rod journal: use an
outside micrometer to measure connecting rod
journal of crankshaft and the normal value should
be 44.485-44.495mm.

1.3 Measurement of main journal clearance: place

a plastic feeler gauge on the crankshaft main
journal, tighten the main bearing shell cover to
specified torque and then loosen it, use the
thickness check list on the plastic feeler gauge to
read the value. The normal value should be:
0.02-0.06mm. Use the same method to measure
connecting rod journal clearance.
1.4 Measurement of crankshaft axial clearance:
tighten the main bearing shell cover to specified
torque and then use a dial gauge to measure the
crankshaft axial clearance. When measuring, push
the crankshaft off the dial gauge first and keep the
dial gauge has certain amount of compression, set

the pointer to zero, and then push the crankshaft to

the adverse direction and the numerical value
fetched from the dial gauge will be the crankshaft
axial clearance. The normal value should be
0.02-0.30mm. If exceeding this scope, replace the
crankshaft thrust sheet or the crankshaft.
2. Detection of piston
2.1 Detection of piston diameter: use an outside
Contents

First ring

Second ring Third ring

End play

0.2

0.4

clearance

0.03

0.03

Thickness

1.2

1.6

Side

micrometer to measure the piston diameter. When

measuring, remember to measure at the place about
11mm up from lower end of the piston. The norma
l
value should be 72.9650.009.
2.2 The piston pin is of semi-

floating type, which

can not be disassembled during maintenance,
because it can not be assembled using common
machining
technique
after disassembled. If
abnormal noise occurs due to improper piston pin
clearance, replace the piston assembly.
2.3 Measurement of piston ring.
2.3.1 Measurement of piston ring end play: first,
place the piston ring into cylinder.

2.3.2 Push the piston head vertically against the

piston ring in the cylinder and let the piston ring be
on a plane.
2.3.3 Use a feeler gauge to measure the gap
between piston ring ends and the normal value
should be: 0.2mm.

2.3.4 Measurement of piston ring side clearance:

place the removed piston ring into the ring groove

(lean to one side as possible) and then place a

feeler gauge into the other side to measure the
clearance; certain resistance feeling after the feeler
gauge is placed in indicates that the measurement
with feeler gauge will be correct. The normal value
should be 0.03mm. Unit: mm

3. Measurement of roundness and cylindricity of

cylinder
3.1 Select appropriate cylinder gauge and outside
micrometer.

3.2 Use a vernier caliper to measure rough

diameter of the cylinder hole.
3.3 Adjust the outside micrometer to the data
measured out by the vernier caliper, select the
splicing pole suitable to the range of the cylinder
gauge, and then set the outside micrometer to zero
according to this data.

3.4 Place the cylinder gauge into the cylinder to

measure; when measuring, the yawing angle of
cylinder gauge should not exceed 15. Fetch the
maximum numerical value.

3.5 The measuring position of the cylinder gauge

in cylinder is as shown in the figure.
Calculation method for roundness: A-B or a-b

Calculation method for c

ylindricity: the difference
of maximum diameter

subtracting minimum
diameter among A, a, B, and b.
The normal value should be: if roundness or
cylindricity exceeds the range, replace with new
cylinder block or install new cylinder sleeve.
3.6 Measurement of planeness of cylinder block:
use steel rule and feeler gauge to measure
planeness of the cylinder block. If the planeness
exceeds the range, replace the cylinder block.

III. Installation of Crank-Connecting Rod System

The

installation

order

is

adverse

to

that

for

disassembly, but care should be taken for the

following matters. 1. Installation of crankshaft thrust
sheet.
When installing the crankshaft thrust sheet, leave
the side with oil groove outwards.

2. Installation of crankshaft front oil seal

2.1 Clear smudge on oil seal seat ring, and then
apply a layer of lubricant on the seat ring.
2.2 Apply a layer of engine lubricant on the oil seal
lip.

2.3 Enclose the new oil seal with lubricant applied

into the special tool. Press the special tool against
the oil seal seat ring and softly strike to compact.

3. Installation of crankshaft rear oil seal

3.1 Clean the oil seal seat ring. Dip engine oil with a
piece of gauze and then use it to clear the impurities
inside the oil seal seat ring.
3.2 Apply a layer of engine oil uniformly on

Upper stop position of piston

Lower stop position of piston

crankshaft rear oil seal lip and a little engine oil

uniformly on outer ring of oil seal. Envelope the oil
seal onto the special tool and then press it into the
oil seal seat ring.
4. When installing cylinder cushion, install it with
the side with word up.
Note:
The cylinder cushion has been applied with
sealant, so, providing that the cylinder head or cylinder
block has been disassembled, be sure to replace the
cylinder cushion.

5. When installing piston ring, remember to leave

the side of the second ring with word up.

6. The opening position of the piston ring during

installation is as shown in the figure.

First ring
Second ring
Oil ring

Lower blade
First ring
Front

Liner ring
Upper blade

7. The label on piston head prompts direction and

position of installation.
8. Use a special tool to install the piston ring.

9. When installing connecting rod bearing shell, pay

attention to installation mark.
10. Method for shell matching.
Note:

The machining technique for connecting

rod and connecting rod shell cap adopts Instantly
Swell and Break machining method, so, each

Second ring
Rear

machined surface maintains the shape of original

material. When installing, keep any sundries out
of this machined surface. In addition, only the
two machined surface of the same connecting rod
can completely engage.
The tightening torque for installing the fixing bolt of
connecting rod bearing is 253Nm (then turn 905
clockwise).
11. Use the piston installation special tool to install
the piston.

12. Tighten the fixing bolt of connecting

rod bearing cap.
Tightening torque:
First time: 253Nm. Second time: turn
905 .
13. Install the main bearing cap and then
follow the order as shown in the figure to
tighten the bolt.
Tightening torque:
First time: 455Nm.
Second time: turn 18010.
14. Tighten the

fixing bolt

bearing cap and cylinder block.

Torque: 20+3 Nm.

of

main