Mechanical details
Contents
1. Measure outside diameter 4 4 Routine checks 4 4 1 Cylinder cover 1 Use the straight knife sharp edge ruler to measure the levelness at various points as shown in the figure Cylinder cover 0 10mm Air inlet branching pipe surface 0 10 mm 2 Use a square ruler to measure the right angle of the valve spring Replace the spring if it fails to meet the specifications Limit 1 2mm 3 Measure the free state of spring Benchmark value 37mm 4 4 3 Throttle Routine checks on throttles 1 Check to see if there are some deformations obvious tears and wears Routine check list on valve Unit mm Standard 0 85 1 41 Wide E 1 07 1 Width of valve top E 1 0 40 2 x mo 20 Chery Automobile Co Ltd PDF SAFE pdfFactory Pro WHARE Www fineprint com cn A gt SQR7080 Service Manual 372 Engine Mechanical System Measure point Measure point 2 Checks on the clearance between the throttle guiding pipe and throttle thrusting rod 1 Use a dial gauge to measure the inner diameter of the throttle guiding pipe and use a caliper to measure the outer diameter a Work out the differences of the measured values If it is above the specified limits the throttle or the guiding pipe must be replaced Attention The measurement points are shown as the figure Work out the clearance of the final torn and worn section Valve guide inside 05 0 diameter mm Valve stem outside diameter 05 0 mm2. Standard of valve clearance 2 When it is beyond the benchmark value the adjustment washer has to be replaced and the clearance should be adjusted The valve number that goes beyond the benchmark value has to be recorded and the result of measurements should be recorded as well 1 Use a caliper to measure and adjust the thickness of the separation cushion 240 262 242 2 64 2 Select proper separation cushion on the basis of the 2 44 266 throttle thrusting rod benchmark values 2 24 2 46 2 68 2 26 2 48 2 70 IN 750 379 Selected cushion thickness removed cushion 252 274 oa measured throttle spacing 0 18mm 2 58 2 80 Aah thickness measured throttle spacing 2 54 2 76 0 25mm Reference there are 32 kinds of shim is thickness Shown as the illustration Selected cushion thickness removed cushion 17 Chery Automobile Co Ltd PDF XAFI pdfFactory Pro WHW G3 www fineprint com cn lt A gt SQR7080 Service Manual 372 Engine Mechanical System 7 Use the selected adjusting gasket to adjust the throttle clearance P Ap Attention Install the feeler with the identification mark Forword facing downwards lower 4 Cylinder head 4 1 Configuration diagram Do the following operations in the procedures for the dismounting and installation of the camshaft Spark plug20 1Nm Cylinder head Weather seal I Cylinder head gasket Adjust shim Valve lifter Keeper Valve
3. 0 056 I i mm 0 066 2 Replacement of valve guide a Heat the cylinder cover to 80 100 degrees C with hot water b Use special tools to drive in the valve guiding pipe to the position as shown in the right figure from the side of the combustion chamber The removed guiding pipe cannot be used repeatedly The air intake and exhaust valve guiding pipes should not be mixed up in installation c Use special tools to drive in the new valve guiding pipe to the position as shown in the right figure In the process of driving in the guiding pipe into the cylinder cover the operation should be carried out slowly until the pipe gets to the proper position No excessive driving should be exerted Pay attention to the specifications in the operation 21 Chery Automobile Co Ltd PDF SCPESERS pdfFactory Pro WHEE www fineprint com cn gt SQR7080 Service Manual 372 Engine Mechanical System m C Oto O ed a GA u es oF O o a ro Ree We ie L TS Se P ae a ar i paa m Model EF Item GL ZL RL GS ZS Height mm a aU EX 12 11 0 25 Driving in depth of throttle guiding pipe Use reamer to grind the inner diameter to achieve the standard value of the clearing 3 Valve mating surface a Smear thin layer of red lead powder on the valve mating surface Do not turn the valve and gently drive it in Check the mating condition and the width of mating line Correct
4. 8 Turn the crankshaft for two circles towards the engine rotating direction so that the camshaft pulley and the crankshaft pulley matches the clockwise marks respectively 4 Use hands to press down for about 5mm The force for pressing the clockwise belt is about Reference 20 30 N Notice When the deflection of the timing belt fails to meet the specifications the key is to adjust the above mentioned stretcher fastening bolt by widening the spacing Tighten the S A fixing bolt of the stretcher with the specified torque of 25 3N m 4 Install the baffle of the crankshaft timing pulley Attention Install the baffle towards the direction outboard shown in the right figure i gt 10 Chery Automobile Co Ltd PDF XAFI pdfFactory Pro WHEE Www fineprint com cn lt A gt SQR7080 Service Manual 372 Engine Mechanical System 5 Install the timing cover cap torque 6 1N m 6 Install the torsional vibration damper use SST 1 When there is not a flying wheel 1 Fix a part of the crankshaft pulley 2 Pay attention not to make the gear belt moving tighten the bolt according to the specified torque torque98 0 10N m 10 1 kgm 2 When there is a flying wheel C Fix the flywheel to prevent the tooth ring from F turning 2 Then tighten bolt of torsional vibration damper 11 Chery Automobile Co Ltd PDF cette pdfFactory Pro whHARAS GE www fineprint com cn lt A gt
5. SQR7080 Service Manual 372 Engine Mechanical System Chapter3 Camshaft Service 3 1 Diagram Removal and installation order for timing belt 1 Valve cage cover 2 Valve cage cover gasket 3 Camshaft timing pulley 4 Camshaft cover 5 Circular plug 6 Camshaft bearing cap 7 Exhaust camshaft 8 Intake camshaft 9 Oil seal 10 Spring retainer 11 Wave washer 12 Intake camshaft sub gear 13 Snap ring d 14 Lock nut 7 Non reusable part 15 Flange 3 2 Removal Remove cylinder head cover assembly Remove the valve chamber cover cap bolt from two sides to the centre symmetrically 2 Remove valve chamber cover gasket 2 Routine check of valve valve clearance standard Valve IN 0 18 0 05 clearance 0 25 0 05 3 Dismount the camshaft clockwise gear Attention You must prevent the camshaft from rotating 12 Chery Automobile Co Ltd PDF xE pdfFactory Pro WHAREI www fineprint com cn lt A gt SQR7080 Service Manual 372 Engine Mechanical System 4 Removal of camshaft cover cap and camshaft bearing cover 1 Align the marks on the camshaft gears as shown in the right figure 2 Use bolt to position the master and slave gears on the air inlet camshaft as shown in the right figure In order to eliminate the radial force keep the camshaft in the leveled position before dismounting it to avoid possible damages caused by excessive radial forces 3 Remove the bolts in the sequence
6. coaxiality Replace the crankshaft if the measurement result exceeds t he limit Limit 0 03mm Attention The bending value should be 1 2 of the fluctuation for one circle of turning the crankshaft 2 Check the tears and wears of the crankshaft 1 Use a caliper to measure the shaft diameter and work out the circularity and cylindricity Limit 0 005mm 2 Use a caliper to measure the connecting rod diameter and work out the circularity and cylindricity Limit 0 004mm the measuring position is shown as the figure 41 Chery Automobile Co Ltd PDF XAFI pdfFactory Pro WHR www fineprint com cn SQR7080 Service Manual Frontward mark Ring open angle Down scraping No 1 ring x Gasket Up scraping From up to down No 1 ring No 2 ring Oil ring No 2 ring A 372 Engine Mechanical System 7 4 5Assmbling of the crankshaft connecting rod mechanism 1 Assembly of the piston and connecting rod 1 Use special tools to assemble the piston connecting rod and piston pin in the following specified procedures 1 Smear lubricating oil to the connecting rod pin hole and make the assembly according to the marks for the same unit and in the indicated direction 2 Make the installation shown as the right figure 8 Make adjustments and installation of the piston and the connecting rod shown as the right figure 4 After smearing lubricating oil to the piston pi
7. of crankshaft timing gear Check to see 1f there is any deformation Standard size of crankshaft timing gear Wide 28 6mm 8 Chery Automobile Co Ltd PDF XIE H pdfFactory Pro WHR Gt www fineprint com cn A gt SQR7080 Service Manual nn O O O Timing mark a ae Timing mark Timing mark Clockwise 372 Engine Mechanical System 4 Installation 4 1 Installation of crankshaft timing gear 4 2 Installation of timing belt 4 2 1 On the upper thrust point of the first cylinder compression Place the camshaft timing gear around the front end of the air exhaust camshaft so as to make the positioning groove on the gear be aligned with the positioning pin on the end surface of the camshaft Then use screws to fix the clockwise gear with the torque of 100 S5N m 4 2 2 Make sure that the punched mark on the crankshaft clockwise pulley is aligned with the mark of the oil pump 4 2 3 Install timing pulley accordingly 9 Chery Automobile Co Ltd PDF XAFI pdfFactory Pro WHR www fineprint com cn A gt SQR7080 Service Manual 372 Engine Mechanical System 4 3 Install the tensioner 4 3 1 Adjust the tension of the timing belt 1 As shown in the figure make the space between the edge of the stretching wheel and the water pump case arc to be about 8mm 2 Tighten the bolt of the stretching wheel with a torque of 25 3N m Use a screwdriver to swing the stretcher toward the right
8. rod mechanism 1 Check the connecting rod axial clearance 1 Use centimeter or feeler to measure axial spacing Benchmark 0 15 0 24mm Limit 0 30mm 2 Check the connecting rod bush vertical clearance 2 Remove the bush cover Attention Parts and components of various cylinders should be placed in good order 1 Clean the bush and axle diameter 4 Place clearance gauge on the connecting bearing diameter 5 Tighten bush cover according to regulated torque torque 40 2N m Do not turn the crankshaft 6 Remove the bush cover measure the maximum width of the spacing ruler Benchmark 0 020 0 044 mm Limit 0 07 mm 35 Chery Automobile Co Ltd PDF XAFI pdfFactory Pro WHR www fineprint com cn lt a SQR7080 Service Manual 372 Engine Mechanical System 6 Replace the bush if width is beyond the limit Attention Connecting In replacing the bushes you should use the products rod bush Connecting of same brand and from the same manufacturer which Tee ww todcovet can accord with the request of clearings a 3 Removal of connecting rod bearing cover and connecting rod bush 1 The threaded section of the connecting rod bolt is to be equipped with protective sleeve to prevent from scraping the cylinder hoe and crankshaft connecting rod axle diameter Then knock the piston connecting rod out with the handle of a hammer Attention Put the parts and components of various cylinders in
9. sealing stripes 2 Install the water pump principal body Tighten with a torque of 25 1 5N m 2 Install the new O rings 25 Chery Automobile Co Ltd PDF xE pdfFactory Pro iWFAhRAS GIS www fineprint com cn lt A gt SQR7080 Service Manual aaa ee 372 Engine Mechanical System 6 Oil pump 6 1 Configuration diagram The dismounting and installation of the lubricating oil pump should be carried out according to the following procedures Oil pan tighten bolt 842 Nm 2 Oil strainer 3 Oil collector gasket 4 Oil pump Oil pump gasket Rear oil seal bracket Non reusable part 6 2 Dismounting 1 The engine being turned upside down on the dismounting frame take off the bolts 26 Chery Automobile Co Ltd PDF xE pdfFactory Pro iWFARRAS GIS www fineprint com cn Saas SQR7080 Service Manual 372 Engine Mechanical System 2 Remove the oil pan from the cylinder body Do not make the oil pan flange section to be l deformed i 5 eo a Wi Le ji ji 3 Remove the oil collecting filter and its flange Attention The filter flange is not reusable Dismount the oil pump assembly and oil pump cushion 5 Dismounting of oil seal stand 27 Chery Automobile Co Ltd PDF xE pdfFactory Pro WHAREI www fineprint com cn lt 4 SQR7080 Service Manual 372 Engine Mechanical System 6 3 Clearing 1 For the mating surfaces of the oil bottom case oil pump and oil seal sta
10. shown in the right figure Remove the camshaft bearing cover 4 Remove the spark plug 5 Remove the camshaft slave gear Use the special tool as shown in the right figure Clip the camshaft tightly and turn the gear to keep the bite state of master and slave gear remove the fixing bolts of slave gear Attention Do not damage the surface of the camshaft 13 Chery Automobile Co Ltd PDF HEH pdfFactory Pro iQHAAMAS ANE www fineprint com cn tee SQR7080 Service Manual 372 Engine Mechanical System 6 Use tensioning apparatus to remove the bearing use elastic snap ring remove wave washer and teethed ring 3 3 Camshaft 1 Use the caliper to measure the height of the camshaft If it is below the specified limits make proper replacement Camshaft Unit mm Item Standard 2 Checks on camshaft axial clearance 1 When the axial spacing is measured with a clipper to be larger than the benchmark value the camshaft is to Poe 3 A be replaced i EEA L oe l hA HE J S The air inlet camshaft axial clearance is 0 1 0 170mm The air exhaust camshaft axial spacing is 0 1 0 173mm Limits for operation 0 18mm 3 4 Cleaning 1 Clear off the spark plug carbon accumulation with a metal brush 14 Chery Automobile Co Ltd PDF XAFI pdfFactory Pro WHEE www fineprint com cn SQR7080 Service Manual 372 Engine Mechanical System 3 5 Installation 1 Fix the two 6 holes of
11. spring seat Valve spring Intake valve Exhaust valve Valve oil seal X Non reusable part Valve seat Unit N m kg cm Valve guide 18 Chery Automobile Co Ltd PDF xE pdfFactory Pro iWFARRAS GIS www fineprint com cn A gt SQR7080 Service Manual 372 Engine Mechanical System 4 2 Dismounting 1 Removal of spark plug 2 There are 8 cylinder cover bolts In the process of removing the cylinder please follow the sequences shown as the right illustration loosen the bolts one by one evenly and gently 3 Removal of the cylinder dustproof sealing and cylinder cover base The cylinder cushion can not be used repeatedly 4 Removal of throttle adjusting separation cushion and valve thrusting rod 5 Use special tools to remove the valve spring locking block throttle spring stand valve spring IN valve and EX valve SST for valve oil seal 6 Removal of valve oil seal and valve spring washer 4 3 Clearing 1 The accumulated carbon residue covered on the valve must be cleared 2 Use scraper to clear the cylinder cover the air inlet and exhaust branching pipe surfaces and bottoms Attention Do not damage the cylinder cover surface by scraping during the process of clearing Do not drop filth into the air inlet and the water channel 19 Chery Automobile Co Ltd PDF xE pdfFactory Pro WHAREI www fineprint com cn lt A gt SQR7080 Service Manual 372 Engine Mechanical System
12. the conditions shown 1n the figure occurs 3 1Cracks on the back side rubber 3 2Cracks of teeth roots cracks clearing off the fabric lining layer 3 3Tears and wears of fabric lining layer missing rear teeth broken teeth etc Chap and 3 4 Abnormal tears and wears on belt sides Abnormal i at of belt core tears and wears 7 Chery Automobile Co Ltd PDF SCPESERS pdfFactory Pro WHEE www fineprint com cn in SORT Service Manuel aging Mechanioal Spates _ 3 5 Even if the damages on the outer appearance can not be confirmed the belt should be replaced under any of the following circumstances 3 5 1If the water in the water pump is leaked which makes it necessary to refill the water continuously 3 5 2 There are much oil stains on the belt the belt should be replaced for the rubber will be damaged when it 1s expanded 3 6 Specifications and model of the timing belt 372 1007081 3 7 Timing belt tensioner Turn the belt tensioner supporting stand bolts to see if there are any abnormal sound Check to see if there are any damages on the contacting surface of the belt Specifications and model of the timing belt tensioner ee 3 8 Check to see if there are any damages on the outer appearance Specifications and model of clockwise pulley E P Gigs Ls Gos Lcd Diameter of camshaft timing 0110 7 92 gear mm Diameter of crankshaft timing 054 65 0 13 gear mm 3 9 Baffle
13. 1 Cover auxiliary tools on the valve rod head smear Oil sealing oil on the outer circle of the auxiliary roundness and inside of new valve oil seal install it on the illustrated Spring bottom position pull out the auxiliary tools of valve oil seal plate Reference Insert the oil sealing up to the dimension as shown in the right figure 2 Installation of IN and EX Mark 3 Assembling of valve springs It is for you to distinguish the different suppliers by means of paintings on the valve spring valve spring of same engine should have the same identification paint marking 23 Chery Automobile Co Ltd PDF XAFI pdfFactory Pro WHEE Www fineprint com cn lt A gt SQR7080 Service Manual 372 Engine Mechanical System 4 Install the locking blocks for the valve spring stands Protective eye glasses must be worn in the process of this operation to protect the eyes Beware of the flying spring and other objects Upon completion of the installation of the throttle springs and throttle spring stands use special tools to install the locking blocks for the throttle spring stands Apply oil position 5 Installation of the throttle thrusting rod and throttle _ spacing by adjusting the separation cushions 6 Install the cylinder cover base make identification of the marks for the front and rear directions 7 Assembling of dustproof sealing strip and cylinder cover a Apply lubricating oil at the threads and grooves of the bo
14. DF XAFI pdfFactory Pro WHEE www fineprint com cn SQR7080 Service Manual 372 Engine Mechanical System Spring bush pulling and removing device Valve locking block removal device Auxiliary tools Flying wheel fixture Valve guiding pipe punch Installing crankshaft oil seal Dismounting and installation of valve spring locks Dismounting and installation of crankshaft Removing and installation of valve guiding pipe Shaft oil seal replacer Oil seal stand screw driver ee Outer appearance Code and Name Crankshaft belt wheel fixture Wrench Purpose Remove and install crankshaft belt wheel Remove and install camshaft slave gear wheel 2 Chery Automobile Co Ltd PDF XAFI pdfFactory Pro WHEE www fineprint com cn Replace valve spacing adjust washer SQR7080 Service Manual 372 Engine Mechanical System Water pump pulley assembly wrench water pump Assembly Measuring Clearance gauge calipers Micrometer ruler centesimal meter cylinder gauge pressure meter torque wrench Piston ring dismounting device Engine lubricating oil bond Chapter 2 Timing Belt Service 1 Configuration diagram Water pump pulley Timing belt cover Timing belt Torsion shock absorber Timing pulley damper Tensioner NNW NF WN Crankshaft timing pulley X Non reusable part Unit N m kg cm 3 Chery Automobile Co Ltd PDF XAFI pdfFactory Pro WHEE W
15. a gt SQR7080 Service Manual 372 Engine Mechanical System SQR372 Engine Service Manual Chery Automobile Co Ltd Forewords In order to help the technical servicing personnel to have correct understanding and good command of the cute Chery Model SQR7080 vehicle and to master the skills for fast repairs and rational maintenance a special edition of the Chery QQ Technical Service Manual 372 Engine Mechanics Division is compiled and published This Manual gives a detailed description on the dismounting installation checks and tests adjustments and diagnoses technical standards and specifications for adjustments and diagnoses of various parts and components as well as subsystems of Chery QQ 372 engines This Manual is published by Chery Automobile Co Ltd Any parts or sections of this Manual shall not be copied or duplicated in whatever form or by whatever approach without the written authorization of the publisher The right of interpreting the Manual belongs to the Service Department of Chery Automobile Co Ltd Editors March of 2004 3 Special tools for maintenance i Outer appearance Code and Name Purpose or l Mounting onto engine Auxiliary devices for engine j A dismounting and check dismounting and checks send Dismounting and Engine dismounting and check stand l l installing engine Camshaft clockwise lockwi It wheel h a a nen belt wheel dismounting 1 Chery Automobile Co Ltd P
16. all the parts according to the forward induction mark on the crankshaft bearing cover 4 After applying the lubricating oil tighten the bolts in the sequence shown as the right figure for 2 3 cycles with the specified torque Torque 70 3 5N m 5 Rotate the crankshaft after assembling you should rotate it with ease the torque should be less than 1Nm Attention The torque of crankshaft rotating should be less than 1Nm The torque is for installing the crankshaft only not for installing the piston connecting rod 43 Chery Automobile Co Ltd PDF SCHIE pdfFactory Pro QR AS GUE www fineprint com cn lt 4 SQR7080 Service Manual 372 Engine Mechanical System 4 Assemble the piston connecting rod Ay connecting rod bush and connecting rod bearing cover according to the following instructions 1 The openings of the air ring and oil ring should match the specified direction 2 Use nylon sleeves for the bolts of the connecting rod to prevent from scraping the cylinder hole and axial diameter 3 Apply lubricating oil to the piston I the connecting rod and the surfaces of the other related moving parts 4 Make sure the frontward indication mark on the piston Should be frontward and assemble the piston connecting rod Ay with SST The cylinder number on the piston connecting rod Ay should be identical to the cylinder number 5 Assemble the connecting rod bearing cover and bush according to the followi
17. e Mechanical System 4 Remove the bearing cover and measure the maximum width of the spacing If it goes beyond the limit replace the bush Benchmark 0 025 0 069mm Limit 0 10mm 5 Disassembling of connecting rod assembly of the piston 1 Use the piston ring pliers to remove the primary ring the secondary ring and the oil ring Attention Do not mix up the pistons and piston rings for each unit of assembly 2 Use SST to remove the piston connecting rod and piston pin 1 Remove the piston pin to take off the piston and the connecting rod by using SST 7 3 Clearing 7 3 1 Cylinder body Wear eye glasses during the clearing Operation to protect your eyes 1 Use flat chisel to clear the cylinder body the cylinder cover the oil bottom casing the oil pump and the oil seal 7 3 2 Piston Wear eye glassed in the process of cleaning to protect your eyes 1 Use the old ring to clean the accumulated carbon in the ring groove 2 Clean the accumulated carbon at various parts with detergents Do not use metal brush or some other hard substance to do the cleaning 38 Chery Automobile Co Ltd PDF SCR AHEAD pdfFactory Pro iWFAhRA GIS www fineprint com cn lt 4 SQR7080 Service Manual 372 Engine Mechanical System 7 4 Routine checks 7 4 1 Cylinder block 1 Checks on the levelness of cylinder top surface 1 Use a ruler and feeler to do the measurements of the six parts as shown in the r
18. emoved oil seals are not reusable 29 Chery Automobile Co Ltd PDF SAFE pdfFactory Pro iA FARRAH www fineprint com cn lt 4 2 SQR7080 Service Manual Pressing Inside direction Oil sealing out 5mm 372 Engine Mechanical System 6 4 3 Routine checks 1 Checks on lubricating oil pump spacing 1 Follow the mark on the interior and exterior gears of the oil pump to place it into the lubricating oil pump body on the cylinder body 2 Use a feeler to measure the clearance between the interior gear and the exterior gear Benchmark 0 05 0 18mm average of 9 points Limit 0 35 mm 1 Use a feeler to measure the clearance between the rotator and the pump body Benchmark 0 10 0 181mm Limit 0 25mm 2 Routine checks on the pressure relief valve 1 Remove the pressure relief valve there should be no visible tears wears and scrapes on the pressure relief valve 6 4 4 1 After smearing lubricating oil on the lips of the new T shaped oil seals use SST to make the assembly Attention Use new oil seal The exposed part of the outer edge of the oil seal after being pressed in should be less than 0 5mm 30 Chery Automobile Co Ltd PDF AFE pdfFactory Pro WHEE Www fineprint com cn lt 4 SQR7080 Service Manual 372 Engine Mechanical System 2 Assembling of the oil pump pressure relief valve and split pins Attention The split pins are not reusable 3 The marks of the exterior and in
19. good order 2 Use a caliper to measure the crankshaft axial clearance If the axial clearance is above the limits it is needed to replace the axial thrust washer or the crankshaft Benchmark 0 089 0 211 mm Limit 0 30mm Item value Thickness of thrust 19a face 40 11 1 9 0 03 36 Chery Automobile Co Ltd PDF xE pdfFactory Pro iWFAhRAS GIS www fineprint com cn lt 4 SQR7080 Service Manual 372 Engine Mechanical System 4 Remove the main bush of the crankshaft the crankshaft the crankshaft bush and the axial thrust plate of crankshaft Check the radial clearance of the crankshaft 1 Remove the crankshaft bearing cover use a resin hammer to knock the bearing cover off gently 2 Clean the inside of the bushes the inside of the bearing cover the cylinder walls the axle diameter etc Make thorough checks for any tears and wears as well as other damages Pl 3 Use a clearance 6 gauge to adjust the radial rar T a clearance of the crankshaft tighten the bolts of a bearing bush cover with specified torque Torque 7043 5N m Attention Tighten the bolts of the crankshaft bearing cover in three times to the regulated value in the sequence as shown in the right figure Attention Don t turn the crankshaft after tightening because of the clearance gauge 37 Chery Automobile Co Ltd PDF XAFI pdfFactory Pro WHR www fineprint com cn aSr SQR7080 Service Manual 372 Engin
20. h wrench i nh ay a ae as a E E I i A if ay align timing mark of camshaft timing gear with the ED TS Wi e f cam mark of camshaft cover cap SA Jef EP ie Al T hac Fi Attention You can rotate the engine clockwise only after installing the pulley Before removal make a arrow mark on the position of timing mark assemble according to original state 3 Make sure that the crankshaft timing pulley wheel mark is aligned with the mark of the oil pump 4 Remove the tensioner bolt and take off the tensioner 5 Chery Automobile Co Ltd PDF xE pdfFactory Pro WHISE www fineprint com cn SQR7080 Service Manual 372 Engine Mechanical System Remove the timing belt Caution It is absolutely not allowed to use screw driver or some other sharp edged tools to remove the belt Attention Pay attention to the following points while using timing belt Don t bend the belt even at a small angle otherwise it will result in rope fracture inside the belt Service life of belt is short don t pollute the belt with grease and water You have no choice but rotate the engine clockwise after installing the belt 2 7 Remove the crankshaft timing gear 6 Chery Automobile Co Ltd PDF XAFI pdfFactory Pro WHEE www fineprint com cn lt SQR7080 Service Manual 372 Engine Mechanical System 3 Make careful and detailed checks on the timing belt Replace with new parts if any of
21. ight figure Limit 0 08mm 2 The use of cylinder meter Measure the values at the parts as shown in the right figure and work out the Top dead maximum value and the minimum value Replace the center cylinder body or do the boring of the cylinder if the values exceed the limits Limit 0 03mm Reference Circularity A B or a b Poton ead Cylindricity A a or B b eons Reference Cylinder standard diameter 072 00 72 01mm 7 4 2 Piston 1 Check the clearance between the piston pinholes 1 Use a caliper to measure the positions of the piston shown in the following figure with the maximum value as the size of the piston pin diameter 2 Use the inner diameter centimeter to measure the positions of the piston hole diameter shown as the following figure take the minimum value as the size of the pinhole diameter 39 Chery Automobile Co Ltd PDF xE pdfFactory Pro iWFAhRAS GIS www fineprint com cn lt 4 SQR7080 Service Manual 372 Engine Mechanical System 3 Work out the clearance on the basis of the size difference between the hole diameter and the pin diameter Replace the piston pin or the piston if the result exceeds the benchmark value Benchmark 0 004 0 009mm Limit 0 015mm 1 Measurement of the piston diameter 1 Make the measurement at the position 11mm below the piston skirt and along the vertical direction of the piston pin Benchmark 672 0 025 2 Check the clearance between the p
22. ing oil in the plug cap hole and assembling surface of the plug use SST to press the plug lid Attention Install the plug lid shown as the right illustration Keep unbiased with cylinder head end surface after pressing 7 Smear engine oil on the oil seal installation port of cylinder head camshaft oil seal edge of blade and outside ring use M10 bolt length 50 60 mm and SST press the cylinder lower 1mm than the end surface of the cylinder4 head Under the condition of use the oil seal repeatedly press here with engine oil adhesive agent The oil seal should not be pressed inclining to one side 8 Installation of the timing gear of camshaft After smearing the fluid sealant use SST to prevent rotating tighten the timing gear bolt of camshaft according to regulated torque of 100 5N m 16 Chery Automobile Co Ltd PDF AFE pdfFactory Pro WHEE Www fineprint com cn tee SQR7080 Service Manual 372 Engine Mechanical System 9 Installation of valve chamber cover cap 1 The used base facing the cylinder cover of the timing belt cover must be cleaned thoroughly 2 Install the new base correctly into the groove of the valve cage cover cap 3 Install valve cage cover cap to cylinder head from two sides to the centre symmetrically according to the regulated torque of 641N m 1 Use feeler gauge to check the throttle clearance Attention Make sure to measure the clearance between basic circle of cam and valve adjusting gasket
23. ion of valve base stand ring Signs of breaking or cracking should not appear on the correction surface Take it out slowly after the correction is completed 1 Use a 45 degree cone as the mating benchmark value 2 Check the mating position of the throttle If it is in the center of the valve the position is the best one If not proper corrections have to be made 3 Make conic cutting at the center of the mating position with 70 degrees toward inwards and 30 degrees outwards 22 Chery Automobile Co Ltd PDF XAFI pdfFactory Pro WHEE www fineprint com cn lt 2 gt SQR7080 Service Manual 372 Engine Mechanical System 4 Use polishing agent to grind and polish the throttle sealing 4 5 Assemble of cylinder head 4 5 1 Cylinder head Pay attention to the following instructions in the _ Spark plug insulator process of assembling for the other accessories on the cylinder cover 1 Spark plug insulator 1 Put the spark plug insulator in the corresponding hole on the cylinder head with special use auxiliary tools smear fluid sealant before pressing pressing height 1s shown as the illustration Attention Pay attention that the vertical degree of its pressing depth and the cylinder head top surface The insulator should not be deformed while being pressed otherwise it is easy for the valve chamber cover cap to lea 4 6 Installation a 1 Installation of valve spring washer and valve oil sealing yaive
24. iston ring and the ring groove 1 Use a feeler to measure the rings RN imi mm 0 03 0 06 secs ring 3 Check the clearance of piston ring ends 1 Put the piston ring in the position which is 45 mm under the cylinder hole top surface in order to make the piston ring keep flattened you can press the piston ring with piston top surface then use a piston gauge to measure the open clearance mm Primary ring 0 25 0 40 ring Oil ring 0 20 0 70 40 Chery Automobile Co Ltd PDF SCHIE pdfFactory Pro QR AS GUE www fineprint com cn sae SQR7080 Service Manual 372 Engine Mechanical System 7 4 3 Check the clearance between the piston and the cylinder wall 1 The positions for measuring the inner diameter of the cylinder and the piston skirt are as shown in the right figure Replace and repair the piston or the ae Pha a cylinder body or bore the cylinder if the measured results exceed the limits Benchmark 0 018 0 03 Limit 0 10 Reference The clearance between the piston and the cylinder hole is subject to the innermost diameter of masure positi T cylinder in vertical direction minus the maximum outer diameter of the piston 2 After the replacement of the piston or the cylinder body it is needed to confirm the clearance of the replaced cylinder once again Datum 0 018 0 030 7 4 4 Crankshaft 1 Check the coaxiality of the main shaft diameter 1 Use the centimeter to measure the
25. lts b The tightening of the cylinder bolts should follow the sequence as shown in the right figure The tightening is to be carried out in 2 3 operations till the torque meets the specifications The torque for the first tightening operation is 30 2N m the torque for the second tightening operation is 50 3N m and the torque for the third tightening operation is 70 3 5 Nm Torque 70 3 5Nm Installation of the spark plug Torque 20 1 Nm Attention The tools should be placed vertically so as not to make the spark plug insulator become deformed otherwise it is easy to leak oil 24 Chery Automobile Co Ltd PDF XAFI pdfFactory Pro WHEE Www fineprint com cn lt A gt SQR7080 Service Manual 372 Engine Mechanical System 5 Water pump 5 1 Configuration diagram the dismounting and assembling of the cylinder body should be done in the following procedures 1 O ring non reusable 2 Oil pump body 3 Weather seal Non reusable part 5 2 Dismounting 1 Dismounting and removal of O shaped ring These rings are not reusable 2 Removing the three bolts and dismount the water pump principal body 3 Removal of the dustproof sealing stripe 5 3 Clearing 1 Clearing of the mating surface of the water pump 5 4 Routine checks 1 Check to see if there are any deformation or damages 2 Use a hand wrench to see if the turning is OK and if it is smoothly lubricated 5 5 Installation 1 Install the dustproof
26. n use pressurizing device to assemble the piston and the connecting rod Pay attention to the assembling direction when pressing in the piston pin U The small bit of connecting rod should be heated to 300 C while pressing the piston pin in the piston U Exert pressure in the process of pressing by assuring the alignment of the pin 2 Side face with marks should be upright install steel belt assembly oil ring gasket ring down scraper and upper scraper then install the secondary ring then install the primary ring Open degree of every ring is shown as the illustration 42 Chery Automobile Co Ltd PDF AFE pdfFactory Pro WHEE Www fineprint com cn lt 4 SQR7080 Service Manual 372 Engine Mechanical System 3 The crankshaft main bearing cover Assemble the crankshaft shaft bush shaft body and thruster according to the following instructions 1 The protruding thrust block on the bush should match the groove on the cylinder body for installation Use the bush made by the same manufacturer 2 Smear lubricating oil on this side upper side of Outward the crankshaft before installing it fps The side thrust chip with oil sink should face fy outward crankshaft handle for installation on the L ke cylinder body bearing stand f jt Attention Smear lubricating oil on the side of the oil fifa Mm sink 3 Smear lubricating oil on the friction side opposite to the contact of the bush lower parts Inst
27. nds 2 For the mating surfaces of the rear oil seal stand and oil pump scraper and chipping chisel or some other tools may be used to clear the used ones Attention Do not drop the residues into the cylinder body 6 4 Disintegration and assembling of oil pump 6 4 1 Configuration diagram Weather seal Oil pump cover plate Driven rotor Drive rotor Split pin Relief valve spring seat Relief valve spring O 40au Nn BW WN Relief valve Q SA Hi I ei X Non reusable part Crankshaft front oil sealing AO tee a H ALHAO SJ 10 Onl pump body 28 Chery Automobile Co Ltd PDF xE pdfFactory Pro iWFAhRAS GIS www fineprint com cn lt 4 SQR7080 Service Manual 372 Engine Mechanical System 6 4 2 Disintegration 1 Weather seal Attention The weather seal are not reusable 2 Remove the oil pump cover Attention The bolt is assembled with glue loosen it with screw driver according to the illustrations 3 Remove the driven and drive rotor of the oil pump 4 Take off the split pin The split pins are not reusable Attention Pay attention not to make the spring and spring seat sending forth and dropping suddenly while taking off the open pins pressure relief valve 5 Removal of the oil pump pressure relief valve spring pressure relief Spring seat stand spiral spring oil pump pressure relief valve slider valve 6 Removal of the front oil seal of the crankshaft Attention The r
28. ng instructions 1 Smear a little lubricating oil on the bolt and screw nut stand before they are mounted according to the indication mark 2 Tighten the left and right screw nuts alternately for a couple of times with the specified torque Torque 40 2N m The connecting rod and the rod bush should be bought from the same supplier 44 Chery Automobile Co Ltd PDF AFE pdfFactory Pro iWFAhRA Gt www fineprint com cn
29. ng oil collecting and filtering device oil pump collecting and filtering device Torque 6 1N m 4 Assembling of oil pan 1 Clear the mating surface with the cylinder body 2 Apply sealing silica before assembling Grease Letai 5699 Attention The liquid cushion with silica line diameter of 3 4mm without any broken section Make the assembly in 15 minutes after the application of silica 3 Tighten in the sequence shown in the right figure with the torque of 6 1N m from the centre to the two sides 33 Chery Automobile Co Ltd PDF AFE pdfFactory Pro WHEE Www fineprint com cn Sas SQR7080 Service Manual 372 Engine Mechanical System 7 Crankshaft connecting rod mechanism 7 1 Configuration diagram Dismount and assemble the oil pump in the follow sequence SS ee Ml e E 1 Connecting rod cover 2 Connecting rod bearing bush 3 Piston and connecting rod assembly 4 Main bearing cover 5 Crankshaft 6 Crankshaft bush 7 Thrust washer 8 Cylinder block 9 No 1 compression ring ll 10 No 2 compression ring 11 Oilring 12 Piston 13 Connecting rod 14 Piston pin Non reusable part 34 Chery Automobile Co Ltd PDF xE pdfFactory Pro WHAREI www fineprint com cn sate SQR7080 Service Manual 372 Engine Mechanical System 7 2 Disintegration of crankshaft connecting
30. terior gears of the lubricating oil pump should be on the visible side when being assembled into the pump body 4 The new weather seal should be put inside the oil pump cover groove 6 5 Disintegratin and assembling of oil seal 6 5 1 Configuration diagram i Non reusable part 31 Chery Automobile Co Ltd PDF xE pdfFactory Pro WHAREI www fineprint com cn lt 4 SQR7080 Service Manual 372 Engine Mechanical System 5 2 Disintegration 1 Use a flat screwdriver to remove the rear oil seal ttention The oil seals are not reusable 6 5 3 Checks Check to see if the tears and wears of the lip section of the oil seals are within the normal conditions and if there are any damages in outer appearance 6 5 4 Assembling Smear lubricating oil on the new oil seal lip section 2 Install the oil seal shown as the right figure 6 6 Assembling 1 Assembling of the oil sealing stands 1 Smear oil sealing silica on the oil sealing stands shown as the right figure Grease Letai 5699 Attention The liquid sealing silica is to be smeared to the mating section of the oil seal stands and cylinder body surface with a width of 3 4mm Torque 25 1 5N m 32 Chery Automobile Co Ltd PDF MCP ERG pdfFactory Pro WHARE Www fineprint com cn sae SQR7080 Service Manual 372 Engine Mechanical System 2 Assembling of new oil pump washer oil pump assembly Torque 20 1 5N m 3 Installation of new lubricati
31. the camshaft gear S A 2 Turn the slave gear to the right match the mark hole on the slave gear with the mark on the master gear or align the marks on the slave gear with the mark on the master gear then fix the slave gear with bolt thread M5 pitch 0 8 2 Installation of the camshaft Size of the axial clearance of the camshaft 1 Smear lubricating oil at the camshaft gear section SST and the cylinder cover axial diameter section 2 Fix the camshaft slave gear by roughly adjusting on the cylinder cover 3 It is necessary to measure the size of axial clearing of camshaft 4 Install camshaft the timing mark must be aligned shown as the right figure 5 Smear lubricating oil on the camshaft assembly the gears and the cylinder head axial diameter section 3 Tighten the camshaft bearing cap shown as right figure 4 Remove the bolt for fixing the slave gear of the camshaft assembly 15 Chery Automobile Co Ltd PDF HEH pdfFactory Pro iQAAAMAS AE www fineprint comcn a gt SQR7080 Service Manual 372 Engine Mechanical System SST cy 2 a 7 ay 3 ra rs s Le rig i A ki H aem i it gie fap m r al _ et ae ae a Y outside 5 installation of camshaft head cap Smear the fluid sealant on the camshaft head cap section with oil groove shown as the right figure Tighten the bolts according to the sequences shown as the right figure with the specified torques 6 After smear
32. ww fineprint com cn A gt SQR7080 Service Manual 372 Engine Mechanical System Remove torsional vibration damper 1 Remove water pump pulley Remove the water pump pulley according to the gt illustration Remove it with screwdriver and wrench according to the illustration Remove torsional vibration damper 1 Fix the flywheel and prevent the gear ring from rotating aa gn 1 I l 1 a wit L P if 7 oo m A z Capa ae ee ge ts cai stom a u w 2 Remove bolt of torsional vibration damper ys a pan F an e ii if fee T ia pee Rpt Ege te eae O Ea us a Tayara i it ant E wee re va a ga iara l i a ry ri 2 i i I I rin ay i I CNA Beg WEE ES Vea Woe fate pee ae I ame i i li s L wy E ne i 4 LI l aldy igh l l il 5 cS rin l i n 1 7 so 7 i Th t a a i z 4 ai 5 a lI l m u i ee SoBe I T A ae fee ae Se ees ate 4 Chery Automobile Co Ltd PDF xE pdfFactory Pro iWFAhRAS GIS www fineprint com cn lt A gt SQR7080 Service Manual 372 Engine Mechanical System Remove timing cover cap Torque 6 1N m Remove timing pulley damper A 66 22 Timing mark Do mark Remove the tensioner 1 Carry out the operation at the upper thrust point Clockwise Sa s Sas compression of the first cylinder piston ge iE N 2 After removing the timing cover cap turn the bolt a A bik zi SN and rotate the timing gear clockwise wit
Download Pdf Manuals
Related Search