Chery QQ Maintenance Manual 465 Engine Mechanical System

Chery QQ Maintenance Manual 465 Engine Mechanical System
CONTENTS
CHAPTER 1…………………………………………………2
CHAPTER 2…………………………………………………5
CHAPTER 3…………………………………………………21
CHAPTER 4…………………………………………………31
CHAPTER 5…………………………………………………34
CHAPTER 6…………………………………………………35
CHAPTER 7…………………………………………………37
CHAPTER 8…………………………………………………39
CHAPTER 9…………………………………………………41
CHAPTER 10……………………………………………… 43
CHAPTER 11……………………………………………… 45
CHAPTER 12……………………………………………… 46
CHAPTER 13……………………………………………… 49
CHAPTER 14……………………………………………… 50
CHAPTER 15………………………………………………51
CHAPTER 16………………………………………………52
-1–
Chery Automobile Co., Ltd
CHAPTER 1 Technical Parameters of Engine

1 Specification
1.1 Technical specification
Model DA465Q-1A2/D
Four cylinders.Four stroke. Water-cooling. Rectitrain.
Mode
.Breadthways. Overhead camshaft. EFI
Bore 65.5mm
Stroke 78mm
Pressure ratio 9. 0: 1
Displacement 1051m1
Nominal power 38.5kW（5200 r/min）[gross power]
MAX torque 83N5m（3000～3500r/min） [gross power]
MIX fuel consumption 275g/kw5h[gross power]
Nominal RPM 5200r/min
Idle speed 850±50r/min
Idle speed CO≤0.5% HC≤100PPm DB11/044-1999
Tail gas High idle speed CO≤0.3% HC≤100PPm DB11/044-1999
Mode CO≤2.2 g/km HC+NOX≤0.5g/km EC 96
Strays GB 14023-2000
Steering Widdershing
Spark advance angle 6°～7° [idle model]
Spark order 1－3－4－2
Oil pressure 0.294～0.539MPa（3.0～5.5kgf/cm2）3000r/min
Outline Inclusive mission 776×609×656.7mm

long×width×height× Not inclusive mission 396×609×656.7mm
Weight Not inclusive mission 98kg
Fuel 90# GB19730-99 unleaded gasoline
Oil Environmental temperature >－20℃ SF15W/40
<－20℃ SF5W/30
Coolant quantity 3.5L
Oil quantity 3.0L
Mission oil quantity 1.5L
Suction filter Turf
Spark F6RTC
Generator Silicon rectify generator
Start-mode Electricity start-up
Cooling method Pump circulation water-cooling
Lubricating method Pressure and splash compound
-2–
1.2 Oil pump

3000rpm 294 - 539kpa
1.3 Specification of fastener
Application Specification
Engine Metric(N.m)
Pulley bolt 95 + (30°- 45°)
Stretching pulley accessories bolt 26±4
Camshaft bracket cover bolt 8±2
Camshafttiming pulley bolt 45±5
Connect rod bearing cap bolt 28～32
Coolant temperature sensor Max 20
Cankshaft main bearing cap bolt 43-48
Cylinder head bolt 55-60
Engine flywheel bolt 40-45
Exhaust manifold nut 18-23
Engine mounting bracket set bolt 25±2.5
Knock sensor bolt 15-25
Intake manifold nut 18-23
Oil filter 12-16
Oil pan bolt 4-5
Oil pan drain plug 20-25
Oil pressure sensor 12-15
Oxygen sensor 40-60
Oil pump bolt 8-10
Spark plug 20-30
Left overhang of connecting front frame 50±5
side member
Engine left overhang gasket of 40±5
connecting transmission
Engine rear overhang and vehicle body 100±5
Engine rear overhang and bracket 100±5
Engine right overhang and vehicle body 50±2.5
Engine right overhang and bracket 100±5
2 Engine lubricant
Viscosity of oil is decided by outer temperature of gasoline or diesel engine,it is acceptable
for engine temperature to be much higher or lower than given temperature in a short time.It
is necessary for the user not to make the engine working at high speed for a long time and it
is necessary for the user not to make the engine overloaded, if the temperature exceeding the
limit or the user uses low-viscosity oil such as SAE 5W-30.
-3–
Regulations
C = Conventional engine oil
NT=New Technological oil
Classification of viscosity — ACEA/API grade

SAE Scope of Temperature Grade of Quality
Engine oil From To ACEA API Standard
Standard
5W—30 -20 +20 A1/B1 SH SJ/CE CF
A2/B2
10W—30 -20 +20 A1/B1 SH SJ/CD CE
A2/B2
10W—40 -20 >+40 A2/B2 SH SJ/CD CE
A3/B3
Conventional 10W—50 -20 >+40 A2/B2 SH SJ/CE CF
A3/B3
Engine oil -20 >+40 A2/B2 SH SJ/CE CF
10W—60
A3/B3
15W—40 -15 >+40 A2/B2 SH SJ/CE CF
A3/B3
15W—50 -15 >+40 A2/B2 SG/CD
20W—40 -10 >+40 A2/B2 SF SG/CD
20W—50 -10 >+40 A2/B2 SF SG/CD
10W—30 -20 >+40 A3/B3 SJ/CF
10W—40 -20 >+40 A3/B3 SJ/CF
5W—30 <-30 >+40 A3/B3 SJ/CF

NT- New
5W—40 <-30 >+40 A3/B3 SJ/CF
technique
5W—50 <-30 >+40 A3/B3 SJ/CF
0W—30 <-30 >+40 A3/B3 SJ/CF
0W—40 <-30 >+40 A3/B3 SJ/CF
Notice:
It is applicable only under the circumstance of ACEA and API standard being listed
ACEA standard can not replace API standard,on the contrary ,API standard can take the
place of ACEA standard.
Viscosity is not equal to quality.
-4–
CHAPTER 2 Diagosis of the Engine

1 Engine pressure test.
It can make sure the condition of piston ring valve and cylinder head gasket to carry out
compression pressure test for the engine cylinder.
1 The storage battery must be up to the standard of normal voltage or close to the normal
voltage if you want the operational temperature of engine to be normal.
2 Turn off the engine.
3 Stop ignition.
4 Stop fuel system.
5 Remove all spark plugs.
6 Remove anti-vacuum pipe in throttle valve body.
7 Lock the throttle valve to be open with dog.
8 Check the engine pressure according to the following steps:
You shall fix the pressure gauge in spark-plug hole,while the engine working along with the
starter, you should make the testing cylinders finish 4 compression strokes at least.You shall
examine and record the readings of every stroke pressure gauge,then throw out the pressure
gauge,as to the other cylinders,repeat above-mentioned steps to carry out the pressure test.
9 Record all pressure readings of all cylinders
Standard pressure of cylinder:1.32Mpa ( Rotational speed of engine shall be no less than
300r/min), pressure of every cylinder shall be no less than 1.10Mpa，pressure difference
between any two cylinders shall be no more than 0.098Mpa.
10 Example of possible testing results are introduced as follows:
a Pressure of all cylinders shall be steadily improved to approach the stipulated pressure
promptly, when the pressure is tested to be normal
b It is probably due to piston ring if pressure of the first stroke is too low,but it is showing
a tendency to go up in the afterwards strokes but not reaching the normal standard yet ,or
the pressure goes up obviously after three times being infected with oil.
c It is probably due to valve if pressure of the first stroke is too low and it remains low in
afterwards strokes or the pressure keep the former state after being injected with oil.
d It is probably due to cylinder head gasket if pressure of two neighboring cylinders is too
low or there is some coolant in the crankcase.
11 Remove dog from throttle valve plate
12 Install anti-vacuum pipe to throttle valve body
13 Install spark plug
2 General introduction to digonosis of engine noise

Notice: Comparing with sound of other engines,you should make sure that you are not
giving a lot of trouble to maintain the normal one,because some engines have normal special
noise out of consideration of design.
-5–
The following 4 factors shall be considered when you make diagnosis of engine noise:
● Classification of noise
● Conditions for noise to happen
● Frequency for noise to happen
● Position for noise to happen in the engine
Noise of engine is usually synchronous with engine speed or half of engine speed.You
should try to make sure frequency of the noise.
1 Main bearing noise
Noise results from main bearing damage or wear is just like the sound of knocking, it
happens once every circle that the engine rotate,the noise comes to maximum when the
engine works with heavy load,knock of interval knoking sound which is much more piercing
than the main bearing wear noise,shows that axial clearance of crankshafts is too big.
The following conditions can lead to main bearig noise:
● The pressure of oil pump is too low.
The oil is too thin or/and the oil filter is too dirty.
The clearance of main bearing is too big.
The end clearance of crankshaft is too big.
The shaft journal of crankshaft is out of round.
Belt tension is too high.
Crankshaft pulley is not tight enough.
Main bearing cover is not tight enough.
Driving belt pills.
2 Connecting rod bearing noise
Sound of knocking is generated at all speed under the condition of connecting rod bearing
being damaged or wear ,connecting rod noise and knocking sound of piston or looseness of
piston pin may be confused together easily in early stage of connecting rod bearing
damage,knocking sound of connecting rod will become louder along with engine speeding
up,this noise comes to maximum while decelerating.
The following circumstances can be the cause of noise:
Bearing clearance is too big.
Crankshaft connecting rod journal wear
The oil is too thin or/and oil filter is too dirty
Oil pressure is too low
The shaft journal of crankshaft connecting rod is out of round.
Connecting rod malposition
Connecting rod nut fixed torque is not correct
Bearing halfshell is not correct or bearing halfshell is malposition
3 Piston noise
It is hard to distinguish the noise generated by piston pin ,piston and connecting rod,loose
piston pin may result in sharp double knocking sound,usually,it can be heard when the
engine is idling or the engine speeds up suddenly then slow down;the piston pin will be
ticking slightly if the piston is installed not properly, the noise becomes more obvious if the
engine works without heavy load;too much clearance between piston and cylinder liner will
result in sound of knocking the cylinder from inside,this kind of noise is similar to metal
-6–
knocking sound,just like the piston slap the cylinder shell from inside during the process of
stroke. Engine noise slowing down after warming up is a sign for piston to slap
cylinder,there is too much clearance between piston and cylinder liner when the engine is
cold,sound of slaping is much louder.
The following circumstance can lead to piston noise:
Piston pin wear or looseness
Piston pin is installed not properly.
There are too much clearance between piston and cylinder liner.
Lubrication is not enough.
The carbon deposit at piston crown knocks cylinder head.
Piston ring groove wear or fracture
Piston fracture
Connecting rod malposition
Piston ring wear or damage
The clearance of piston ring groove is too big.
The clearance of piston ring ends is not enough.
Piston malposition is at a angle of 180 degree
The shape of piston skirt is not correct.
4 Flywheel noise
Check whether or not the flywheel is loose or fractural according to the following steps:
4.1 Drive the vehicle at the speed o f 32 km/h.
4.2 Turn off the engine
The flywheel may be loosened or damaged if you hear the kind of pinging sound,this kind of
pinging sound comes to maximum while decelerating.Bearing knocking sound can result
from looseness of bolts.It depends on stability of idling to generated how much slapping
sound when the engine is idling at high speed,the noise can be made or can not be made if
transmission drive put into gear.Check the connecting bolts between transmission and
flywheel, crankshaft and flywheel first,before make sure whether or not there is some
relationship between the knock and bearing.
5 Valve device noise
Valve device malfunction can be shown by means of slight slapping sound of any frequency
or frequency is equal to half of engine speed,the noise will go up along with acceleration of
the engine.
First,warm up the engine before judging the valve device noise,so as to make the engine
parts expand to normal state.Listen to engine noise under the circumstance of engine cover
being shut.
Remove the rocker arm head ,make sure the parts of valve device which result in noise with
stethoscope,if the noise of valve device is abnormal.The cause of noise are introduced as
follows:
Valve spring fracture, resiliency of valve spring is not enough.

Valve is blocked or curved
Rocker is curved
The cam of camshaft is damaged or poor performance.
-7–
Lubrication of valve device is not good or oil pressure is too low.

The clearance of valve stem and valve guide pipe is too big.
Valve guide pipe wear
Push rod wear
Valve rocker wear
Bolt of valve rocker fracture
Auxiliary parts of valve rocker is too loose or damaged.
3 Diagnosis of engine noise

1 Exhaust device
Symptom Cause of malfunction/ Troubleshooting
Looseness or malposition of exhaust parts,you can carry out the
following procedures:
Vibriation or quack
1 Align the joints.
noise of exhaust
2 Fasten the joints.
system
3 Check to see whether or not exhaust lifting hook , mounting
bracket and clamp are damaged.
The following conditions can result in waste gas leak or noise:
Exhaust parts joints or connection leak.
Tighten clip or connecting parts to regulated torque.
Installation of exhaust system is not correct or malposition.
Align and tighten the clip.
There are some cracks on the exhaust manifold.
Leakage between exhaust manifolds or between the
cylinder heads.
Fasten the exhaust manifold on the cylinder head according
Waste gas leak or to the regulation
noise Tighten or replace exhaust manifold washer.
Exhaust expansion connection parts damage or wear.
Replace parts if necessary.
Exhaust pipe is burned or rusty.
Replace the exhaust pipe if necessary.
Sliencer is damaged or burned.
Replace the silencer assembly.
Exhaust clip and/or bracket are damaged or loosened.
Replace the parts if necessary.
2 Valve device
-8–
Symptom Cause of malfunction/Troubleshooting

This kind of noise has nothing to do with malfunction
of tappet,it is becomes more obvious under low gear
speed of 10-15 km/h,this kind of noise sounds just
like ticktack,the following condition can result in this
kind of noise:
Valve end or Valve rocker gasket wear
Clearance of valve stem and valve guide is too
There is some noise while big.
idling,the noise becomes Radil run-out of valve seat is too remarkable.
lounder when the rotational Radil run-out of valve working surface is too
speed is much higher. remardable.
Malposition of valve spring
1 Rock the engine until the nosing valve depart from
the valve seat.
2 Rotate valve spring and valve
3 If the noise is corrected ,check the valve spring to
see whether or not it is in malposition. If the
malposition exceeds the limit,replace the valve spring.
High-speed driving noise may result from the
following condition:
Oil level is too high.If oil level is higher than FULL
(full mark),crankshaft balancer will stir the oil into
foams,when the foam is pumped into the tappet,the
Driving at high-speed ,there is
tappet will make noise.Make the oil being put in
some noise,while driving at
correct oil level.
low-speed,the noise disappear.
Oil level is too low.
If oil level is lower than ADD(add mark),the
atmosphere will be pumped in by oil pump,it will
result in tappet noise,add oil if necessary.
Oil pump filter screen is bent or too loosened.
Noise which has nothing to do Check the following circumstances:
with engine speed. Lubricating system of rocker.
Rocder ball wear.
Rocker is bent or damaged.
Valve rocker is too loosened or damaged.
3 Abnormal noise diagnosis of engine
-9–
Symtom Cause of malfunction/Troubleshooting

There is some knocking Oil viscosity is not suitable.
sound while starting ,but Use suitable oil viscosity according to estimated
only continue several temperature,see the maintenance and lubrication for
seconds. reference.
Engine cold start pinking sound usually disappears when
the specified cylinder secondary ignition circuits connect
the ground.Check the engine to see if it is under the
following circumstances:
Cold start knocking,continue Crankshaft balancer or drive pulley is loose or
2-3 minutes. broken.
Tighten or replace parts if necessary
Clearance of piston and cylinder liner is too big.
Check the parts of piston, replace if necessary
Connecting rod is bent
Check the engine to see if it is under the following
circumstances:
Driving belt wear
Check tension , replace driving belt if necessary.
The compressor of air condition system
Replace parts if necessary .
Oil viscosity is not suitable.
Knocking noise while idling
Use oil with suitable visocosity according to
heat start
estimated temperature,see maintenance and
lubrication for reference.
Piston pin clearance is too big.
Replace piston and piston pin if necessary.
Calibrate location of connecting rod
Check connecting rod,replace if necessary.
- 10 –
Clearance of piston and cylinder liner is not enough.

Bore cylinder , install new piston
Adjust looseness or torque of crankshaft balancer.
Replace damaged parts
Make sure that the direction of piston pin is right.
Install piston correctly.
Check to see if the engine is under the following
conditions:
Detonation or ignition knock
Slight pinking sound while See engine control system for reference.
heat start. Exhaust manifold leak gas.
Fasten bolt or replace gasket
Clearance of connecting rod bearing is too big.
Replace connecting rod bearing if necessary
Check to see if the engine is under the following
circumstances:
Crankshaft balance or pulley nave is broken.
Replace parts if necessary
Transmission belt of auxilary is too tight or there are
some scratching marks on it.
Severe knocking sound
Replace driving belt if necessary
while increasing the torque.
Flywheel is broken.
Replace flywheel
Clearance of crankshaft main bearing is too big.
Replace parts if necessary.
Clearance of connecting rod bearing is too big.
Replace parts if necessary
4 Diagnosis of driving belt noise

- 11 –
Step Operation Yes No

The following circumstances indicate that there is whispering noise:
There is a high pitch noise when drive belt or pulley rotate every circle.
It usually happens in cold and damp morning.
Sprinkle some water on the drive belt for confirmation,the noise should stop
immediately.
Check to see whether or not the pulley is
malposition.
1 To step2 To step3
Check to see if there are any pulleys are
malposition?
Fix position of the pulley which is malposition
2 once again,to see whether or not there is still To step3 System normal
any whispering noise?
Check to see whether or not the bracket is bent
3 or broken. To step4 To step5
Are there any bent or broken bracket?
Replace the bent or broken bracket
4 To step5 System normal
Is there any whispering noise?
Check to see whether or not the fastener is
5 loose or lost. To step6 System normal
Is there any loose or lost fasteners?
Fasten any loose fasteners.
Lost fastener should be replaced immediately.
See the specification of fastener for reference.
Is there still any whispering noise?
Check to see whether or not the pulley flange is
7 bent. To step8 To step9
Is there any bent pulley flange?
Replace belt.
Is there any whispering noise?
Check to see if there are severe hollowness
9 exceeding 1/3 depth of the belt groove. To step10 —
Is there any severe hollowness?
Replace driving belt.
10 See the “Replacement of driving belt” for — System normal
reference.
- 12 –
5 Screaming noise of driving belt

Defination: The following circumstances indicates there are some screaming noise.
Sharp noise usually happens in the multi-rib driving belt result from driving belt
slipping.
Blocking or sliding phenomenon of A/C system compressor connecting throttle
happens when driving belt is overloaded,there is some noise.
1 malposition. To step3 To step2
Is there any malposition pulley?
Check to see whether or not the length of driving
belt is correct.
2 To step4 To step5
See “Replacement of driving belt” for reference.
Is the length of driving belt is correct or not?
Repair it or replace with new parts according to
System
3 the request. —
normal
Is the maintenance completed?
Make a test to see whether or not the tensioner
4 works normally. To step3 To step5
Does the driving tensioner work normally?
5 Check to see whether or not the size of pulley is
correct.
To step6 To step3
Check to see if the size of all pulley is correct or
not.
Check to see if the bearing is blocked badly or
whether or not there are some blocked bearing.
6 Hooting noise of driving belt

Defination: Successive high pitch noise can be generated because of bearing malfunction.
Check to see whether or not there is some damage
1 of accessories bearing. To step2 System normal
Is there any noise resulting from the bearing?
Install new parts according to the request. System
2 —
Is the maintenance completed? normal
7 Rumbling noise of driving belt

- 13 –

Defination: Low and deep slapping noise may be resulted from malposition of driving belt.
This kind of noise happens while idling cold start.
One low-frequency noise can be heard when the driving belt rotate every one circle.
Check to see whether or not there is any severe hollowness.
System
1 Is there any severe hollowness exceeding 1/3 depth of the belt To step2
normal
rib?
Clean pulley of driving belt. System
2 To step3
Install new driving belt,see “replacement of driving belt” for
System
3 reference. —
normal
8 Diagnosis of driving belt vibration

Defination: Vibration has something to do with the engine speed,vibration may be sensitive
to the accessories load.
Check to see whether or not the driving belt is wear,damaged,
1 accumulated dusts or losing reinforcement. To step2 To step3
Is there any damage or wear of the driving belt?
Replace the parts accordingly,see the replacement of
2 transmission belt” for reference,do you finish the To step3 —
maintenance?
Check to see whether or not the fastener is loose or lost.
3 To step4 To step5
Is there any loose or lost fastener?
Fasten it or replace new parts according to the actual request. System
4 —
Check to see whether or not the pulley is damaged or bent.
5 To step6 To step7
Is there any damage of driving belt?
Repair it or replace with new parts. System
6 —
Check to see whether or not the tensioner works normally.
7 To step9 To step8
Does the tensioner work normally or not?
Replace it accordingly,see “Replacement of tensioner of
System
8 driving belt” for reference. —
normal
Check to see whether or not the bracket is loose,bent or
To System
9 broken.
step10 normal
Is there any loose or bent or broken bracket?
Repair it or replace bracket if necessary. System
10 —
- 14 –
9 Diagnosis of belt out of position

Defination:The following circumstances may result in driving belt out of position.
malposition or bent。
1 To step2 To step3
damage.
Replace pulley of malposition or being bent.
Is the driving belt out of position or not?
Check to see whether or not the bracket is bent
3 or broken。 To step4 To step5
Is there any bent or broken brackets?
Replace the damaged bracket.
Is the driving belt out of position or not?
Check to see whether or not the fastener is
5 loose or lost. To step6 To step7
Is there any loose or lost fasteners?
Replace lost fastener , fasten it according to the
regulations.
See “Specification of fastener” for reference.
Is the driving belt still out of position or not?
Check to see whether or not the pulley of power
streering-wheel pump is malposition。
7 To step8 To step9
Is the pulley of power steering-wheel pump is
malposition or not?
Realign or replace pulley of power
streering-wheel pump，
8 See “Replacement of pulley of power To step9 System normal
streering-wheel pump” for reference.
Is the driving belt still out of position or not?
Check to see whether or not the transmission
9 belt is damaged。 To step10 To step11
Is the driving belt damaged or not?
Replace driving belt
Is the driving belt still out of position?
Check to see whether or not the tensioner of
driving belt works normally.
11 – To step12
Is the operation of tensioner of driving belt
normal or not?
Replace the tensioner of driving belt,see
“Replacement of tensioner of driving belt” for
12 – System normal
reference.
Is the driving belt still out of position?
- 15 –
10 Diagnosis of driving belt severe damage and wear

Defination: Driving belt outside reinforcing rib wear results from installation of driving belt is
not correct.
Check to see whether or not the reinforcing
1 — To step2
driving belt accord with the guide of pulley?
Replace the driving belt.
See “Replacement of driving belt” for
2 System normal —
reference.
11 Diagnosis of engine misfire

Check Operation
The following diagnosis touches upon the common problems or possible causes.
You can fix a breakdown through adjustment and maintenance or replacement according to the
request,after carrying out the correct diagonosis.
This malfunction diagonosis schedule wll be helpful for diagonosing engine misfire resulting
from machenism problems such as camshaft malfunction,bearing wear or being damage and
connecting rod being bent.
This schedule doesn’t include the driving elements malfunction such as injectior malfunction.
Check the motive system inside diagonosis system
You should check the initial information first,then contrast the specified classification while
carrying out the basic diagonosis of engine misfire according to this schedule.
Check the following conditions with eyes:
Engine flywheel or crankshaft pulley looseness or installation is not
correct.
There are some damaged or malpositioned parts of driving system.
2 Listen to the inside of engine to see whether or not there is any abnormal
Initial check noise.
3 Check to see whether or not the oil pressure of engine is suitable
4 Check to see whethr or not the oil consumption is too much.
5 Check to see whether or not the coolant consumption of engine is too
much.
6 Do compression test for the engine.
Inlet manifold which generates vacuum leakage will cause misfire of
engine
Check the following conditions:
Vacuum hose pipe installation is not correct
Inlet manifold leak There are something wrong with the inlet manifold or gasket or
installation is not correct
There are some cracks or damage in the inlet manifold,throttle or
gasket installation is not correct.
Inlet manifold warp
- 16 –
The sealing surface of cylinder head warp or being damaged.

Coolant consumption may be but not certain result in engine over heated
Check the following circumstances:
Coolant leak
Coolant Cylinder head gasket fault
consumption Cylinder head warp
There are some cracks on the cylinder head.
Engine body is damaged.
The length of cylinder head bolt is not correct.
1 Fuel consumption may be but not certain result in engine misfire.
2 Remove spark plug and check to see whether or not there is any oil
fouling in the spark plug.
3 Carry out cylinder pressure test or cylinder leakage test.
4 Check the following conditions if the cylinder pressure test shows that
there is any damage of throttle or throttle guide:
Oil flinge wear,chip or installation is not properly.
Valve guide wear
Valve stem wear
Fuel consumption
Valve or valve seat wear or burnt.
5 Check the following conditions if the test indicating piston ring wear or
being damaged:
Piston ring fracture or installation is not correct.
End clearance of piston ring is too big.
Bore wear or taper is too big.
Cylinder is damaged.
Piston is damaged.
1 Make sure if the noise accords with the rotional speed of crandshaft or
camshaft while the engine is working.
2 The timing lamp sounds twice every flash ,that is the rotational speed of
crandshaft;the timing lamp sounds just once every flash ,that is the
rotational speed of camshaft.
3 Check the following circumstance if the noise is the same as the
frequency of camshaft rotational speed:
Valve device missing or loose.
There is some Valve rocker wear or looseness
abnormal noise Malfuction of valve spring
inside the engine. Valve being bent or being burnt
Cam of camshaft wear
Check to see if timing belt or pulley wear or being damaged.
4 Check the following conditions if the frequency of knock is the same as
the crankshaft rotional speed:
The main bearing of crankshaft or connecting rod bearing wear
Piston or cylinder wear
Piston or piston pin wear
- 17 –
Malfunction of connecting rod.

There is too much Carbon deposit on piston crown
1 Check to see if the timing belt or pulley is wear or installed not properly.
2 Remove valve rocker cover of engine side whose cylinder is misfiring.
3 Check the following conditions:
There is no
The bolt of valve rocker is too loose
abnormal noise
Push rod is bent
inside the engine.
Malfunction of valve spring
Valve wear or installation is not good.
Cam of camshaft wear
4 Fuel consumption
1 General description
Fuel consumption of engine referrs to amount of fuel used,never to confuse fuel
consumption and oil leakage of oil pan and cylinder head.
Engine fuel is used for:
1.1 Depart the contacting surface away with fuel film,prevent dry friction.
1.2 Conduct heat generated from friction
1.3 Bring the residue after burning away.
It is necessary to consume certain amount of fuel in order to achieve above-mentioned
aims,in other words,it is not realistic to find a engine without fuel consumption.Generally
speaking,amount of fuel used is small,it is ok to add a little fuel during the period of
replacing oil,even through you may not add the oil.Of course,you must add the oil if fuel
level is lower than the minimum mark of fuel consumption indicator.Meanwhile,you should
make sure that fuel level is not higher than maximum mark, otherwise oil consumption will
be more.
Generally speaking,fuel consumption becomes stable after the vehicle driving several
km,therefore,fuel consumption measurement shall be carried out after vehicle driving 7500
km.Before measurement,you should make sure that the engine doesn’t lose fuel because of
leakage.
Dipstick is used only for the purpose of inspection not for measurement.The engine must be
turned off at least 2 minutes before checking oil level,it may be the cause of manufacturing
tolerance if you add enough oil but the level is not reaching the maximum.It shows that fuel
is overused if vehicle driving 100 km consuming more than 0.075 L fuel,causes and
solutions of fuel being overused are introduced as follows:
● Fuel consumption indicator doesn’t have good function.Please make vehicle level,check
oil level and spend some time to make the oil subside.
● Oil viscosity is not suitable.Please use recommended SAE according to local temperature.
● Successive high-speed driving
● Heavy load drawing,such as towed vehicle.Please decrease oil milage .
● The performance of ventilation system of crankcase is not effecive.
● Oil leak.Please fasten bolts if necessary,replace gasket and seal gasket if necessary.
● Valve guide or oil seal wear or lost.Please install enlarge sized valve and/or new oil seal.
- 18 –
● Piston ring fracture or wear

● Piston ring or seat is installed not properly or correctly
● Installation or assembly of piston is not good.
● Cylinder head gasket and oil outlet hole is blocked.
2 Measuring method of fuel consumption

2.1Make vehicle level when checking,fuel temperature of engine is not less than 80 ℃.
2.2 Make engine idling before draining the engine fuel.
2.3 Turn off the engine immediately after drainage ,record the drainage time (3 minutes)
with chronograph,test should show that drainage should be completed within 3 minutes.
2.4 Displace fuel to state of guttate.
2.5 Cool the engine fuel of displacement to 20 ℃ for 1 to 2 hours.
2.6 Measure fuel amount after cooling with measuring cylinder.Refill enough new fuel
accordingly.You should subtract 0.25 litre fuel because the fuel filter is not replaced.
2.7These fuel is enough for the driver to drive at least 500 km/350 miles.The driver should
keep his/her own normal rount and driving style.
2.8 Repeat above-mentioned procedures from 1 to 4 afterwards,drainage time is the same.
2.9 Consumption amount of fuel in measuring tube is fuel consumption or mileage
consumption of engine.
3. Diagnosis and test of fuel pressure

The following conditions may cause low temperature of fuel or fuel without pressure.If fuel
level is too low,fill the fuel to the fuel level of the indicator.
Oil pressure switch is not correct or the performance is not good.Please replace the switch.
Fuel viscosity is not correct or fuel being diluted
- Please use new fuel with suitable viscosity according to estimated temperature.
- Please use new fuel if the old one being diluted.
- Oil pump wear or too dirty ,clean or replace the oil pump.
- Oil filter is blocked.Please replace the oil filter.
- There are some holes in the connecting rod oil dipper.Please replace the connecting
rod oil dipper.
- There are too much clearance between the bearings.Please replace the bearing.
- There are some holes in the passage or the passage being blocked.Please repair or
replace the engine block.
- Vitta hole plug lost or not properly installed.Please install or maintain it if
necessary.
- Pressure regulating valve is blocked.Please check the pressure regulating valve to
see whether or not it is blocked in the hole,check to see whether or not there are
some scores and fins in the hole.
- Valve guide wear.Repair if necessary.
3.1 Start the engine under the running temperature of more than 80 ℃.
3.2 Take off the oil pressure switch.
3.3 Oil pressure test,see the arrows in screw hole.
3.4 Measure oil pressure 0.294-0.539 Mpa (3000 r/min)
- 19 –
3.5 Take off oil manometer and adaptor.

3.6 Install oil pressure switch properly.
3.7 Fill enough fuel to maximum of fuel gauge.
Notice: Fuel temperature is decided by corresponding engine load,the temperature can be
150 ℃ under extremely heavy load.
5 Diagnosis of oil leakage

Maintain,replace the parts or seal the gasket surface after finding out the leak position before
maintenance.
1 Determine the leakage fuel whether or not are listed as follows with eyes:
● Engine fuel
● Transmission fuel
● Power steering liquor
● Brake fluid
● Other oil or liquor
Check with eyes:
1 Make vehicle temperature normal.
2 Park the vehicle on a big and clean surface,wait a minute,check to see if there are some
leaking drops.
3Identify classification of leakage and possible positions.
4 Check the suspicious position with eyes,use a mirror if necessary.
5 Check the joint or parts which are damaged to see if there is some leakage.
6 Continue according to the following procedures if you can not make sure the leakage
position.
(1) Completely clean the whole engine and its surrounding parts.
- 20 –
(2) Drive the vehicle for several miles at different speed under normal temperature.
(3) Park the vehicle on a big and clean surface.
(4) Wait a minute,check to see if there are some leaking drops.
(5) Idenitify classification of drops and possible position of leakage.
(6) Check suspicious position with eyes,use a mirror if necessary.
(7) Judge the possibility of leakage.
Adopt powder method if you can not make sure the cause of leakage yet.
2 Powder method
2.1 Completely clean the whole engine and its surrounding parts.
2.2 Smear children’s talcum powder on the suspicious position.
2.3 Driving vehicles for several miles at different speed under normal temperature.
2.4 Identify classification of fuel,make sure the possible position of leakage, in accordance
with powder changing color position.
2.5 Check the suspicious positions with eyes,check the position not easy to see ,with the help
of a mirror.
2.6 See the possibilities of leakage for reference if necessary.
3 Possibilities of leakage.
Check vehicle to see whether or not it is under the following conditions:
● Surface of liquor is higher than the recommended level.
● Pressure of liquor is higher than the recommended pressure.
● Oil filter core or pressure by-pass valve is blocked or the performance is not good.
● Ventilation system of engine is blocked or the performance is not good.
● Fastner is not good or damaged.
● Parts fracture or there are some holes in the parts..
● Installation of sealing agent or gasket is not good.
● Gasket and oil seal is damaged or wear.
● Seal surface is damaged or wear.
chapter 3 Assembly Outline Illustration

1 Front end view of engine
- 21 –
II.Cylinder head
- 22 –
1 cylinder head 2 valve guide bushing 3 restricted flow valve 4 gasket 5 cylinder head
gasket 6 locating bush 7 screw 8 cylinder head cover 9 baffle 10 gasket 11 screw 12
gasket 13 gasket 14 screw 15 filling cover 16 spark17 distributor built-up connection 18
gasket 19 locating bush 20 bolt 21 bolt 22 intake valve insert 23 exhaust valve insert 24
stay
III.Cylinder block
- 23 –
1- cylinder block 2- O-ring;3- O-ring； 17- upper baffle wall 18- furrow
4- blockage；5- blockage；6- oil pressure baffle wall；19- bolt 20- oil filter21- union
switch；7- screw；8- screw；9- screw；10- bolt 22- water jacket blockage23- gasket
facing ring；11- nut；12- locating bush； 24- knock sensor 25- screw
13- lap；14- gasket；15- screw；16- stay；
IV.Crankshaft，piston and connecting rod assembly
- 22 –
12.apron 13.timing gear

1.piston 2-1.No.1piston ring 14.woodruff key 15.crankshaft pulley
2-2. No.2 piston ring 16.fastening screw 17.crankshaft rear oil
2-3.piston ring assembly 3.piston pin seal
4.piston pin lock ring 5.connecting rod 18 rear oil seal retainer 19.gasket20.screw
6.nut 21.screw
7.connecting rod bu 22.locating sleave
8.crankshaft9.main bearing bush 23.flywheel 24 screw
10 crankshaft thrust washer 11. crankshaft 25. locating sleave
front oil seal 26.bearing
- 23 –
V.Camshaft，valve and rocker
1 camshaft 2-oil sear 3- aligner 4- screw 5- rocker shaft 6- screw 7- valve rocker 8-
spring 9adjusting screw 10- nut 11- intake valve 12- exhaust 13- valve spring 14-spring
seat 15-keeper 16- gasket 17- oil seal
- 24 –
VI.Oil pan
1.oil pan assembly 7.glue coil

2.oil pan gasket 8.screw
3. screw 9 oil dipstick guide
4. bleader screw plug 1 oil dipstick guide bracket
5. gasket 11screw
6.oil collector 12 “o”ring
13 oil dipstick assembly
- 25 –
VII.Timing belt, outside cover and inside cover assembly
1 timing belt inside cover assembly timing pulley 11 key 12 screw 13 peep
2 outer cover 3 rubber pad 4 rubber ring hole blockage 14 timing pulley 15
5 rubber ring 6 liner 7 screw 8 screw tensioner 16 screw 17 tension spring 18
9 sponge gasket 10 camshaft screw 19 gasket 20 pad
- 27 –
VIII.Engine identification
Enginer No.
- 28 –
Chapter 4 Maintenance of Intake Pipe
1 Steps of removal
1Romove the cable of negative pole from
battery。
2 Disconnect wire plug from intake
temperature sensor.
3 Remove intake hose and crankshaft
ventilation pipe from throttle valve and
intake voltage-stabilized box.
4 Pull the throttle bracing wire out of intake
pipe assembly,that is to say,take the throttle
bracing wire off the intake pipe bracket by
means of loosening the ball inserter with
clamp spring. 9 Remove power source plug of idle
5 Loosen vacuum pipe of braking servo vacuum valve and record wire path.
unit. 10 loosen and block up the oil pipe，clamp
6 Remove power source plug from injector. the petroleum pipe with spring clamp after
7 Pull out power source plug of coolant making marks.
temperation sensor. 11. Remove all kinds of hose from intake
8 Remove power source plug from power pipe assembly
source plug of idling motor and throttle 12. Remove construction bolt of intake
position sensor manifold.
13. Remove intake manifold and gasket
from cylinder for clean.
Clean intake manifold and cylinder head
gasket
- 28 –
11 Install throttle bracing wire and driving

belt of accessories
13 Connect intake hose and crankshaft vent
pipe to intake pipe
14 Connect temperation sensor connector。
15 Connect battery negative pole。
16 Exhaust the cooling system.
2 Steps of installation
1 Put new gasket between intake manifold
and cylinder head
2 Aligntion and installtion must be correct
3 Connect warm hose and vacuum hose to
intake pipe and intake manifold.
4 Reconnect fuel pipe after making mark.
5 Connect throttle position sensor plug。
6 Connect idle air valve plug。
7 Connect power source of injector.
8 Connect power source of coolant
temperation sensor.
9 Pay attention to the wire.
10 Connect braking server and intake pipe.
- 28 –
Chapter 5 Replacement of Exhaust Pipe Gasket

Steps of removal
1 Lift vehicle,remove the protective plate of engine oil pan
2 Remove exhaust pipe from exhaust manifold.
3 Loosen and remove oxygen sensor from exhaust manifold.
4 Lower the vehicle,remove protective shield of exhaust pipe.
5 Loosen nut of exhaust manifold.
6 Disconnect exhaust manifold and gasket.
2 Procedures of installation
1 Connect exhaust manifold and a new gasket to the cylinder head.
2 Screw the nut on to the bolt,you should use new nut, tighten it closely.
3Connect exhaust pipe to exhaust manifold。
4 Cover protective shield exhaust manifold 。
5 Preheat exhaust manifold。
6 Install oxygen sensor to exhaust manifold。
7 Connect power source of oxygen sensor
Chapter 6 Replacement of Camshaf Bracket Cover

- 29 –
1 Steps of removal
1 Take off venting hose between throttle body and camshaft bracket cover.
2 Loosen camshaft cover bolt in requested order.
3 Take off camshaft cover
1Reinstall camshaft bracket cover with new gasket.
2 Bolt on and tighten it in proper order accordingly.
3 Reconnect venting hose
Chapter 7 Replacement of Timing Belt

Install timing belt according to following twisted spring to the pump(in front of rear
order： cover),fasten the bolts and nuts until the
1) Connect the tension wheel assembly to tensin assembly is easy for you to move.
- 28 –
Notice: You should make sure that every

screw and nut is loosened during the 5) After installation of belt,put up one end
process of above-mentioned work,for the of torsion spring on the tension bracket,put
purpose of camshaft and pulley can rotate up the other end of torsion spring on water
freely. pump screw,the spring tune-up the belt
2) There are a dot ④ on radial line mark ① through self own tension,adjust the bolts
of camshaft timing belt pulley and another and screws to regulated value.
dot ⑤ on belt rear cover. Run belt pulley to Turn crankshaft two circles clockwise and
align dot ④ and dot ⑤. adjust the tension wheel bolts and screws
3)There is a dot⑥ on belt rear cover. Run to the regulated value.
crankshaft to align dot ③ and dot ⑥. Notice: Smear GY-340 glue on the screw
thread of the tension bolts.Fasten the
Tensioner bolt 14.71～22.56N·m adjusting bolts first,then fasten the twisted
tighten torque (1.5～2.3kg·m) bolt.
4) Two timing belt pulleys are aligned with
each other.Under this circumstances of belt
being tightened,install the timing belt
according to the illustration of ⑦
Notice: After installation of tension

pulley,turn crankshaft two circles
clockwise and check if marks ①④⑤⑥
aligned with key groove ③ to a straight
line after installing tensioner. Repeat
above-mentioned steps until you are
satisfied.
6)Press belt between camshaft and
crankshaft by hand to make sure that
tension is in the regulated scale.
(L)timing belt tension 5.5～6.5 mm
7) Adjust belt tension to the regulated
scope,then tune-up clearance of every
valve to the regulated value.
Chapter 8 Replacement of Cylinder Head
1 Steps of removal 1 Take off fuel pump relay mounted under

- 28 –
the instrument meter plate. to the rear,intake side 6237,exhaust side

Notice: Make the engine working for 5 5148.
seconds in order reduce the pressure of 3 Install camshaft.
system,collect and check up the fuel. 4 Install rocker shaft and racker。
2 Disconnect negation pole cable of battery 5 Smear mixture of sealing agent on the
3 Take off air filter and hose. placing side of crankshaft.
4 Remove cover of coolant reservoir tank 6 Istall cylinder head set bolt,tighten the
5 Remove low pressure hose of radiator and bolts accordingly.
collect the coolant 7 Install timing belt rear cover set bolt and
6 Remove all hoses and cables which fasten the bolts。
connect the cylinder head and intake 8 Install camshaft timing gear and
manifold. bolt,fixture。
7 Remove high pressure ignition coil 9 Install timing belt,see the illustration for
8 Disconnect the harness of exhaust pipe reference.
and exhaust manifold 10 Install exhaust manifold and gasket。
9 Disconnect oxygen sensor harness 11 Install oxygen sensor to exhaust
connector and take off exhaust manifold manifold ,make it connected with the wires.
10 Take off timing belt,see the illustration 12 Install exhaust pipe。
for reference. 13 Install fuel pipe to fuel oil rail。
11 Take off camshaft timing gear,see the 14 Connect high pressure coil harness to
illustration for reference. ignition module connector。
12 Remove set bolt from timing belt rear 15 Install hose that connect cylinder head
cover and intake manifold,then connect harness。
The order is to loosen 1/4 circle,then to 16 Connect low pressure hose to radiator。
loosen 1/2 circle,remove the cylinder head 17 Fill the coolant in the cooling system,see
completely,fasten the bolts relevant content of article 6.3.
13 Take off camshaft bracket 18 Install air filter and intake hose,then
14Remove rocker，rocker seat and rocker connet temperature sensor to harness。
shaft 19 Connect negative pole cable of battery.
Notice: Don’t confuse in order that you can
install it to the right position afterwards.
15 Take off the cylinder head,see the
contents of relevant chapters for reference.
Attention:
Clean cylinder head completely,remove the
old gasket,wipe the dirt and residue away.
Clean cylinder body surface and piston top
1 Install a new gasket of cylinder 。
Make sure that the upper mark of gasket is
upwards and in the front side of the engine.
2 Fasten cylinder head and cylinder body。
The fastening bolts order is: from the front
- 28 –
Chapter 9 Replacement of Sealing Washer of Valve Spring

1 Steps of removal 1.3-1.5 mm
1 Remove cylinder accordingly.
2 Remove valve lock from cylindeer head
assembly.
3 Take off spring damper.
4 Take off spring.
5 Take off sealing washer of valve stem.
6 Take off valve.
2 Cleaning
Clean the combustion chamber.It is
necessary to put a special brush in the
drilling machine for check and inspection
1 Check exhaust pipe and combustion
chamber whether or not there are some
cracks
2 Check to see whether or not there are
burning trail on the the valve top,check to
see whether or not there are some cracks in
the surface and check to see if there are
some damage of the valve rod.
3 Check the clearance between the valve rod
and guide,measure the diameter of valve rod
in upper,middle and lower position with
microscope,different value between guide
and valve rod is the distance of them.
4 If the distance is not within the scope of
0.020-0.050 mm,intake and exhaust 0.030
and 0.060 mm,you should enlarge the hole
in order that you can install the valve of
much larger size.
5 Check the concentricity of maximal ring
and minimal ring of valve seat.
standard:0.05 mm
Width of intake and exhaust valve should be
- 29 –
1 Exhaust valve seat:Use the taper rymer to

cut 3 times as shown in figure. First cut at a
angle of 15°,Then 75°and then 45°to create
satisfied touch width
2 Angle of exhaust valve seat
3 Intake valve seat:cutting sequence is the
same as the sequence of exhaust valve
seat,but cutting angle is different,shown as
the following illustration:
3 Repair of valve seat：
1 Install valve.
If the valve seat cannot touch the valve 2 Install valve stem seal.
equably or touch width is not in standard 3 Install spring.
scale, the valve and valve seat must be 4 Install valve spring damper.
repaired by grinding, cutting and polishing. 5 Install valve lock.
6 Install cylinder head as the following
illustration.
- 28 –
Chapter 10 Rplacement of Piston
1 Steps of removal making the piston lean agaist the connecting

See content of relevant chapters for rod,then stuff the piston pin properly with
reference SST,you must make sure the installation of
1. Take off cylinder head accordingly. piston pin ring is correct.
2 Wipe residue and dust of cylinder head 4 Connect connecting rod assembly to
away with rag. cylinder body with SST, arrow head of
3 Loosen the oil drainage bolt of oil pan to piston should face the front side of engine.
let oil drop out.
4 Take off oil pan
5 Take off oil pan gasket.
6 Disconnect the connecting rod bearing
cover and bearing.
Notice: Ensure bearing and bearing cover of
every connecting rod being in
correspondence with each other.
7 Take the piston connecting rod assembly
off the cylinder.
8 Put the piston on SST, take off piston pin
from assembly with remover.
9 Remove connecting rod from piston.
10 Measure the distance between piston and
cylinder
standard:0.040-0.050 mm
Notice: It is necessary to prepare enlarged
standard sized piston of 0.25 mm and 0.50
mm.
2 Procedures of installation
1 Install connecting rod to piston
2 Install piston and piston pin according to
the following steps:
Heat the connecting rod in piston pin hole at
the temperature between 280℃ and 320℃,it
is best for you to put the rod in the oil to
carry out this procedure,cool the piston pin
in dry ice, tighten the heated connecting rod
with pincer pliers
3 Install one side of piston pin by means of
- 29 –
Notice: Put oil to surface of piston ring and 4. Put the clip spring in the cylinder and use
cylinder hole,at the same time,install the piston to push it in cylinder wall at a
connecting rod. bank angle of 90 degree,in accordance with
6 Install connecting rod upper bearing corresponding measured distance between
halfshell, put oil only on the side which is piston ring ends.
facing the crank, push the connecting rod Item Standard Limit
until it is in the right position of the crank. 0.03～ 0.12
7 Install connecting rod cap on the lower Inside No.1
0.07 ㎜㎜
bearing halfshell,put oil on the side which is Ring
0.02～ 0.10
facing the crank for lubricating. gap No.2
0.06 ㎜㎜
8 Put new bolt on the connecting rod ,it is 5 Install the piston ring on the piston
not necessary to screw the bolt according to the sequence of location of
9 Rotate the crankshaft for several clearance,that is to say the split of every
circles,make alignment of the connecting ring should be staggered at a angle of 180
rod totally,then tighten the connecting rod degrees.
bolt and fix the connectingt rod bolt. 6 Measure the distance between ring and
27.46-31.38 N.m groove of ring to see whether or not the
10 Install oil pan, you shall be sure to keep following data is true:
in mind to use fixing glue for tightening the upper comperession ring 0.05mm
oil pan bolt 10N.m lower comprssion ring 0.04mm
11 Install oil drainage bolt 7 Measure the distance between piston ring
12 Install cylinder head accordingly end,put the piston in the cylinder hole,push
Notice: Use oil of SAE 10W30 for the it to the bottom of cylinder,it is necessary to
engine. replace the piston ring if the measuring
3 Replacement of piston ring value exceed the limit.
Steps of removal Procedures of installation
1 Take the connecting rod assembly of the Install the piston accordingly
piston away accordingly Standard
2 Take piston ring out. Item Limit
(mm)
3 Clean the smooth surface of piston, get rid Air
of the grease remained in pin hole and Piston ring 0.15-0.35 0.7mm
ring
fillisters with suitable knife. Open
Oil
Check and measure gap 0.30-0.90 1.8mm
ring
1 Check stem of fillisters of the piston or
skirt of the piston to see whether or not
there are some fractures.
2 Check piston ring
3 Check piston crown to see whether or not
there are some deformation,damage or rust.
- 30 –
CHAPTER 11 Replacement of Oil Pump

1 Steps of removal
1 Take off timing gear of camshaft, shown
as the illustration.
2 Take off crankshaft timing gear.
3 Take off set bolt of timing belt rear cover.
4 Take off rear cover of timing belt.
5 Take the oil drainage bolt of oil pan away
and let oil flow out.
6 Remove oil pressure indication switch.
7 Remove exhaust pipe.
8 Remove oil pan.
9 Take suction oil pipe of oil pump away.
10 Remove the oil pump by means of
loosening the bolt of oil pump.
11 Remove oil pump head.
12 Take off inside teeth gear.
13 Take off outside teeth gear.
2 Inspection of oil pump

Standard of radial clearance between inside
wheel gear and crescent caliper: 0.60～
0.80mm
Standard of radial clearance between ouside
wheel gear and crescent caliper: 0.25～
0.40mm
Outside wheel gear and pump body
clearance
limit：0.3mm
- 31 –
Side clearance
Use thickness gauge,make sure the side
clearance,in accordance with data between
thickness gauge and gear,shown as blow:
limit：0.17mm
3 Installation of oil pump

Parts of resolution should be cleaned,
you should satisfy the following requests
when installing the oil pump:
1) There is a dot mark ① on the outside
wheel gear.The dot mark should face
outwards when installing the outside wheel
gear to the pump body.Shown as blow:
2) You should use new sealing gasket when
installing the oil pump to the
crankcase.You should smear the
HZ-1213,sealing agent.The surface should
be cleaned before you smear.
Notice: You should lubricate the oil seal
mouth before installation.
1 Install oil pump and tighten bolt
2 Install oil pump suck oil pipe and make it
fastened.
3 Install oil pan and oil drainage bolt
4 Install exhaust pipe
5 Install oil pressure switch and tighten it.
6 Install timing belt rear cover
7 Install crankshaft timing gear
8 Install camshaft timing gear according to
the illustration.
Attention: Align the oil level,fill SAE 10 W
30 oil in the engine.
- 32 –
Chapter 12 Replacement of Rear Oil Seal of Engine Flywheel and

Crankshaft
1 Steps of removal
1 Disconnect the transmission assembly,see the relevant explanation of Chapter7.
2 Start ring gear, lock-up flywheel.
3 Disconnect clutch,see the relevant explanation of Chapter 7
4 Take off bolt and flywheel.
5 Remove bracket bolt of crankshaft rear oil seal.
6 Take off oil seal, install new oil seal.
7 Notice: Smear the oil on the mouth of oil seal lip when installing the new oil seal,be
careful of installation.
1 Install new rear oil seal of crankshaft.
Attention:
Smear Silicon oil on the sealing surface of new sealing washer,then fix it on the shield,in
order to prevent the sealing surface from being damaged,you should turn the sealing washer
into the shield,place the shield on the crankshaft jounal and press it to be flat,place the press
cover pipe on the shield and press the sealing washer until it is aligned with the cylinder
block side.
2 Clean the contact surface of crankshaft and flywheel
3 Install flywheel, tighten bolt
4 Install the cluth,see the relevant explanation of Chapter 7 for reference.
5 Install engine and transmission,see the relevant explanation of Chapter 7 for reference.
- 33 –
Chapter 13 Replacement of Crankshaft

1 Steps of removal
1 Remove engine and transmission
assembly from vehicle
2 Remove transmission from engine , put it
on the bracket.
3 Remove oil drainage bolt of oil pan to
drain oil and collect the oil.
4 Remove engine oil pan.
5 Remove oil pump,see the accordingly 3 Measurement
explanations. 1 Check the flatness of crankshaft according
6 Remove engine clutch. to the following methods.
7 Remove engine flywheel. 2 Lift the crankshaft with 1 and 5 bearing
8 Make mark for main bearing and with halfshell of engine block.
connecting rod bearing. 3 Install a dial gauge with touching pin on
9 Loosen connecting rod bolt and remove the place of 3 in the bearing,total reading is
connecting rod bearing cover. µm ,the maximum is 0.03 mm
10 Loosen main bearing bolt and take off Maximum taper of observing journal can
bearing cover. be:0.005 mm,Maximum roundness of
11 Take off crankshaft. observing jounal can be:0.004 mm
12 Take off upper main being halfshell. 4 Observe journal and diameter of
Attention:Don’t confuse the bearing crankshaft and check to see which is ok,if
halfshell. the value of diameter is not in the scope of
the form,you should polish the crankshaft
2 Clean and check once more or replace the crankshaft.
1 Clean the parts and dry the parts. 5 Please use plastic clearance torque,if you
2 Check to see whether or not there are want to check the distance between the
some defects such as scoring,unevenness or bearing and halfshell.
others in the journal. 6 If there is no plastic clearance gauge,take
away the crankshaft, put on the bearing
cover with halfshell and diameter of
corresponding journal .Difference between
the two values is the distance between
journal and halfshell.
- 28 –
4 Install main bearing bolt,don’t fasten it

5 Knock the two ends of crankshaft with a
plastic rod,mainly in order to adjust the rear
surface of thrust bearing, then fasten the
bolts.
5 Measurement
1 Measure axial clearance of crankshaft as
the following method.
2 Install a dial gauge with sensing pin and
the sensing pin contact crankshaft end face.
3 Move the crankshaft along its direction
with a screwdriver,pay attention to the
readings of dial gauge,the regulated
clearance is :0.13-0.28mm.
4 Install connecting rod to crank
Notice:Use lubricant only on the side facing
the crankshaft handle when install the
halfshell of connecting rod bearing,push the
connecting rod until it is in the position of
crank.
5 Lubricate the surface of lower halfshell of
crank facing the crankshaft,when installing
4 Steps of installation the connecting rod bearing cover.
1 Install upper shoe of main bearing to 6 Install connecting rod bearing cover
engine cylinder,lubricate the side which bolt,but don’t fasten it.
face the journal. 7 Turn the crankshaft for several
2 Install crankshaft to engine body circles ,make alignation.
3 Install the main bearing cover with bottom 8 Install engine flywheel and bolt,see the
shoe,lubricate the side facing the journal. relevant Chapters.
Attention:Installation of bearing cover 11 Install clutch.
should be in accordance with the mark made 12 Install the oil pump ,see the explanation.
when dismantling. 13 Install the engine oil pan,see the
explanation.
14 Tighten oil drainage bolt,see the
explanation.
15 Install the transmission to the engine,see
Chapter 7.
16 Install engine and transmission to
vehicle,see the explanation.
- 28 –
Chapter 14 Replacement of Engine Block

1 Steps of removal stone around,connect a 19mm electric drill
1 Remove engine from vehicle accordingly. to the stone,make the stone rotating inside
2 Fix the engine assembly on the bracket. the cylinder,make the stone turning up and
3 Take off the piston and connecting rod down slowly to the full unitl it can rotate
assembly of engine accordingly. freely.
4 Take off crankshaft. Put appropriate amount of kerosene in the
5 Clean the engine block thoroughly. cylinder in order to keep the hone stone and
6 Check to see whether or not there are cylinder wall clean and lubricated,continue
some cracks or wear in the engine block. to polish it and repeat the procedures until
you get requested diameter.
2 Repair cylinder Notice: Stop polishing frequently to put the
If cylinder block of engine can be still used piston in the cylinder to check whether or
while there are something wrong with the not the distance is appropriate,clean the
cylinder after inspection,so you can repair cylinder thoroughly before putting the
the cylinder by means of polishing the piston in.
inside .After performance of polishing the The engine block should be cleaned
cylinder,the cylinder shall be able to have a thoroughly after repair.
capacity of larger piston.
Polishing of cylinder 3 Steps of installation
Notice: Some of above-mentioned 1 Install the crankshaft accordingly.
procedures can be omitted ,judgement of 2 Install transmission rod of piston
necessity depends on result of inspection assembly accordingly.
before repair. 3 Install engine assembly to the vehicle
You must use fine hone stones to polish the accordingly.
cylinder after ginding,you use rough
particles stones first,then use fine particles
stones,it is not good to make the polishing
too smooth,it only needs slight smoothness
for helpful lubrication.
Put the hone stone in the cylinder and make
the hone stone close to the cylinder wall as
possible as you can,you totate the hone
- 29 –
CHAPTER 15 Replacement of Oil Cleaner
1 Steps of removal
1 Loosen oil cleaner with SST
2 Collect the oil.
3 Check oil level of engine，tune up if necessary.
1 Lubricate the sealing washer of oil cleaner with oil slightly,tighten the bolt by hand.
2 Check the oil level of engine,tune up if necessary.
3 Lubricate the sealing washer of oil cleaner with oil slightly,tighten the bolt by hand.
- 30 –
CHAPTER 16 Cooling System
1 Maintenance guide Drainage

Drainage and refilling of cooling system Hint: It is not right to drain the coolant to
Proportion of ethylene-glycol is definite,so the full,unless when you remove the water
as to ensure at least 50% of ethylene-glycol pump.You should pay attention that this
solution being used for all emission ports procedure will increase the amount of
and air holes of engine block ,during the coolant for diluting the dangerous waste
process of coolant drainage and washing. materials.
Volume of cooling system for 1.1 liter 1 Keep vehicle level.
engine is 4.8 -5.0 liter,listed volume during 2 Remove reservoir tank cap according to
the produre of refilling,including extra the following procedures after the engine is
amount of atmosphere drained and cooled.Turn the cap to hill holder
remained in cooling system after static slowly,anti-clockwise.Don’t give the
refilling.According to correct filling pressure cap more pressure while turning.It
proportion and the following procedures,it will be fizzing while draining the remaining
will ensure that density of ethylene-glycol is atmosphere,you should continue to turn the
50% in the cooling system,so as to simplify radiator cap anti-clockwise,until you open
the refilling work,see the radiator volumn of it.
static refilling for reference,at least every 5 Hint: Retrieve and store the old coolant in
years or driving 240000 km , taking the first the old reservoir tank at regular
arrival for standard, the engine cooling intervals,that procedure greatly increase the
system should be drained and refilled with
fresh coolant accordingly.
Caution: Make sure that pressure amount of coolant for diluting the
temperature of cooling system is much dangerous waste materials.
higher than solution boiling point in the 1 Put the drain tray under vichle to collect
radiator while preventing boiling at the the old coolant.
same time.To avoid the damger of being 2 Loosen the outlet hose clamp mounted on
burned,do not remove the cap while the the left side of radiator back,remove outlet
engine and radiator are still hot,because it hose of radiator
will lead the solution boiling and having 3 Loosen the hose which coolant tank to
explosive force probably,resulting in manifold inlet port, remove tank and hose.
solution rejecting to the engine wing and It is enough to remove the bottom radiator
hurting the user who remove the cap. pipe and tank hose only if you carry out
Hint: It must be sure that you should use drainage partly.
regulated coolant,if you don’t use regulated Attention: Make appropriate dispose of old
brand of coolant ,time of replacing the coolant,don’t put the old coolant into the
engine coolant should be shortened ,that is sewer.Ethylene-glycol anti-icing agent is a
driving 50000 km or 2 years. kind of extreme poisonous chemical agent.It
- 28 –
is illegal to dispose the ethylene –glycol in standard.

the sewer or groundwater for it will destroy 4 Install reservoir tank cap,make sure that
the ecological environment. the arrow on it is showing no difference
4 Refillling after draining the coolant from with the direction of coolant overflow pipe.
cooling system 5 Carry out heating and cooling the engine
Attention: Don’t use cooling system sealant for three times,then examine the anti-icing
or similar sealant unless there are some function of engine coolant with
regulated exceptions,it will prevent coolant refractometer and heat hydrometer to make
from flowing in the cooling system and sure that it has appropriate anti-icing
engine parts,coolant block will result in ability.19℃-35OF protecion.Abstract some
engine too hot or cooling system and engine mixture of coolant from the reservoir tank
parts assembly being damaged. for the use of examination.
1 Tighten collar clamp of radiator vent hose Washing
2 Reinstall after draining the waste water Washing engine cooling system:
away,clean the reservoir tank with water. Washing procedures
Attention: Various of methods and equipments can be
Add ethylene-glycol ratified for use by used to wash the cooling system.If you want
Chery Company while refilling,you should to use special equipment such as circle
use mixture of 50% ethylene-glycol and washing apparatus,please see the
50% drinking water to fill in the cooling manufacturer’s directions for referrence.
system ,if it is not necessary to wash the Cleaning of radiator
system,refilling instead. Caution:Don’t spray the water to the hot
3 Refill the cooling system slowly through radiator,hot gas generated will injure you or
coolant tank, according to the following otherr people.
procedures. Attention: Cooling fin is necessary for good
3.1 Add mixture of 50% ethylene-glycol performance of heat conduction,don’t brush
and 50% drinking water until the coolant is the fin,in case the fin will be damaged and
in the position between maximum mark and function of heat conduction is not good.
minimum mark of the coolant tank. Attention: You can clean the radiator fin
3.2 Check to see wheher or not the coolant with compression atmosphere or water,the
is in the position between maximum mark pressure shall not exceed 150kpa,it will
and minimum mark of the reservoir tank damage the radiator while the prssure
once more after two minutes,continue to exceeding 150 kpa,clean front side of
add the solution until it achieve the standard radiator once every year.Clean front side of
3.3 Start the engine for warming up ,make condenser,blow and wash the small worms
the coolant flowing from the radiator so as and tree leaves away from it with
to get rid of the atomosphere of engine compression atmosphere through the
cooling system ,check to see whether or not radiator,blow from the back side to
the coolant is in the position between frontwards,you can use water pipe to pour
maximum and minimum mark of the the water in through the radiator,you wash
reservoir tank,continue to add untill it is up with water only when the engine doesn’t
to the work and being cooled.
- 28 –
2 Replacement of top radiator pipe

Steps of removal
1 Empty cooling system parts,see the
illustration
2 Remove intake hose of thermostat
cover
3 Remove intake hose of radiator
4 Remove intake hose
Steps of installation
1 Install the intake hose to the right position
aligning the hose mark.
2 Connect intake hose and radiator
3 Connect intake hose and thermostat cover
4 Refill coolant,see the illustrations.
3 Replacement of bottom radiator pipe

Steps of removal
1 Empty the cooling system, see the
illustrations.
2 Remove vent hose from engine cooling
manifold
3 Remove vent hose of radiator
4 Remove vent hose 4 Replacement of cooling fan
Steps of installation Steps of removal
1 Install the bottom radiator pipe Caution: Electric fan of engine cover will
properly,aligning the hose mark. rotate , injure you and other people even if
2 Connect vent hose to the radiator. the engine is not working,you should be far
3 Connect vent hose and engine cooling away from the electric fan of engine cover.
manifold Caution: To avoid injuries and deaths or
4 Refill the cooling system,see the vehicle damage,you should replace the fan
illustrations. board or outer cover if they are broken or
damaged.
1 Turn off the cooling fan.
2 Remove fan cover bolt from radiator.
3 Remove engine cooling fan.
Step of installation
1 Install cooling fan
Notice: See cautions and relevant remarks
concerning fastener.
2 Install fan erection bolt
Fasten the nut to
- 29 –
nut fixture:3.5-4.5 N.m

3 Connect cooling fan power
4 Check to see whether or not fan motor
works normally.
1 Install thermostat and new gasket, tighten
the bolt if necessary.
Notice: Place the gasket properly on the
entrance.
2 Tighten the bolt
3 Connect hose to the thermostat.
4 Connect intake hose to thermostat shell.
5 Install timing belt housing rear cover.
6 Install camshaft timing pulley,see the
5 Replacement of thermostat installation illustration of camshaft timing
Steps of removal pulley for reference.
1 Remove timing belt see illustration of 7 Install timing belt,see the installation
timing belt removal for reference. illustration of timing belt for reference.
2 Remove camshaft timing pulley ,see HINT: Add drinking water and 3.3 liter
illustration of camshaft timing belt removal radiator protective liquor in the
for reference. system,drain the atmosphere of the engine
3 Remove timing belt housing bolt and rear block away.
cover of timing belt
4 Loosen and remove thermostat bolt.
5 Remove thermostat
- 30 –
6 Replacement of water pump Steps of installation

Steps of removal 1 Install new sealing washer,parts serial
1 Remove timing belt,see the removal number is 9158173,lubricate the parts with
illustration for reference. sillicon oxide grease,parts serial number is
2 Remove camshaft timing pulley,see the 9309994.
removal illustration of camshaft timing 2 Connect water pump to the engine
pulley for reference. body,don’t bolt to the regulated torque.
3 Remove time pinion from crankshaft,see 3 Connect lower hose of radiator
relevent content for reference. 4 Install rear cover of timing belt housing.
4 Loosen bolt of timing belt tension roller 5 Install time pinion on the crankshaft.
and remove timing belt tension roller 6 Install camshaft timing pulley to the
5 Remove rear cover of the timing belt. camshaft,see the installation illustration of
6 Disconnect lower hose of radiator and camshaft timing pulley for reference.
collect coolant 7 Install timing belt,see the installation and
7 Loosen water pump bolt and remove connection illustration for reference,during
water pump. this operational process,bolt the water pump
to the regulated torque and fasten it after
tune-up timing belt tension roller.
Water pump bolt: 7±3mm
Attention:Add drinking water and 3.3 liter
radiator protective liquor,parts serial
number is 9985451
Remove water lamp mounted on the top of
temperature regulation valve,drain the
atmosphere of engine body away,start the
engine to make it idle running at a speed of
900 rpm after system recovery.
7 Replacement of radiator
Steps of removal
1 Remove air filter and air passage
assembly,see the content of engine control
system for reference.
2 Loosen up and down water pipe
Removal:Drain certain proportion of
coolant (about 0.5 liter) away and collect
it,remove the condenser case (including
hose),then loosen the upper end of water
inlet pipe of the radiator,so as to pull the
baffler cover and fan motor out,see the
following illustration for reference:
- 31 –
Loosen 2 bolts:
Loosen wire harness and take out fan
assembly
Loosen 4 bolts and pull out the fan
fastener.
6 Install radiator bracket and bolt
Bolt to 6.0—8.0 Nm
7 Install cooling fan.
8 Refill the cooling system.
9 Install air filter and pipe assembly.
10 Check leakage.
8 Explanation and operation

1 Cooling system operation
cooling system
Cooling system makes engine keep
appropriate temperature under all working
conditions of engine,when the coolant
temperature is low,the fan operates slowly
to help the engine warm up.
Cooling system is composed of a
radiator,coolant reclaiming system ,cooling
fan thermostat,water pump cover and
driving belt.
Cooling system needs all components
working normally,coolant is pumped from
the radiator by water pump,it will be
recycling in inlet manifold and cylinder
head of engine body through coolant
housing, then it comes back to the
radiator,there,cooling system will make
some of the coolant lead to the heater core

from hose for being heated and
unfroze.Reservoir tank is integrated with
radiator,reservoir tank retrieve the coolant
1 Install radiator to lower bracket.
which expand outwards when the
3 Connect radiator upper hose.
temperature is high and keep suitable
4 Connect radiator lower hose.
coolant level,along with cooling and
5 Connect coolant overflow hose.
contraction of coolant,coolant is absorbed in
Pay attention to the notices relating to
- 32 –
the radiator for sake of vacuum. are not allowed to use anti-icing agent
solution exceedingt 70,because it will freeze
2 Cooling recycling system from this point,temperature will go up
Water pump is driven by belt,coolant flow rapidly,pure anti-icing agent will freeze
in water pump from left bottom side of when the temperature is -22 ℃(-8℉).You
radiator,coolant is pumped into the can comply with direction of draining and
peripheral empty cavity of cylinder liner refilling the cooling system,you are only
through coolant tubes in the shell of the allowed to use certain coolant regulated by
cylinder.Coolant flow in cylinder head Chery Company while adding or replacing
coolant tubes through cylinder head gasket the coolant,50% and 50% mixture of
hole,then flow in the sub- branch system of ethylene-glycol and drinking water will
thermostat.Tubes of inlet manifold lead provide the following protection:
coolant to the thermostat,when the ● Provide -39℃ anti-icing protection
thermostate is shut off,cold engine coolant ● Provide 131 ℃ boiling point protection
can’t return to the radiator to carry out ● Prevent rust and corrosion
recycling,preheat the engine quickly.When ● Keep appropriate engine temperature
engine is preheated to the full,the ● Make the warning light and thermostat
thermostat is open to let coolant flow into work normally
water inlet housing mounted on the upper
right position of the radiator.The recycling 5 Explanation of coolant recovery system
is performed when coolant becomes cold Reservoir tank
gradually after flowing in the water outlet Reservoir tank is the transparent tank just
housing mounted on the left side of radiator like common windscreen gasket cleaner
through level core tubes. canister,reservoir tank is integrated with
radiator through hose,it collects the
3 Cooling fan relay overflow coolant when the coolant
As to information and diagnotic condition temperature is high,otherwise these coolant
of cooling fan relay,you can see the cooling will flow out of the cooling system,level of
fan illustration for referrence coolant should be on or much higher than
the position of overflow hose in the tank.
4 Coolant temperature control system

switch
The switch control the voltage of cooling
fan relay,as to the position which relay
make the fan running at a high speed and
diagnosis,under the condition of coolant
temperature exceed 95 ℃ and 102 ℃,you
can see electric system of engine.

Notice: You can add anti-icing agent in
order to raise boiling point of the
coolant,but solidifying point will be
effected if you add excessive coolant,you
- 33 –

Chery QQ Maintenance Manual 465 Engine Mechanical System

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Chery QQ Maintenance Manual 465 Engine Mechanical System

CHAPTER 1 Technical Parameters of Engine

Outline Inclusive mission 776×609×656.7mm

1.2 Oil pump

Classification of viscosity — ACEA/API grade

20W—40 -10 >+40 A2/B2 SF SG/CD

20W—50 -10 >+40 A2/B2 SF SG/CD

10W—30 -20 >+40 A3/B3 SJ/CF

10W—40 -20 >+40 A3/B3 SJ/CF

5W—30 <-30 >+40 A3/B3 SJ/CF

0W—30 <-30 >+40 A3/B3 SJ/CF

0W—40 <-30 >+40 A3/B3 SJ/CF

CHAPTER 2 Diagosis of the Engine

2 General introduction to digonosis of engine noise

Valve spring fracture, resiliency of valve spring is not enough.

Lubrication of valve device is not good or oil pressure is too low.

3 Diagnosis of engine noise

Symptom Cause of malfunction/Troubleshooting

3 Abnormal noise diagnosis of engine

Symtom Cause of malfunction/Troubleshooting

Clearance of piston and cylinder liner is not enough.

4 Diagnosis of driving belt noise

Step Operation Yes No

5 Screaming noise of driving belt

Step Operation Yes No

6 Hooting noise of driving belt

Step Operation Yes No

7 Rumbling noise of driving belt

Step Operation Yes No

8 Diagnosis of driving belt vibration

9 Diagnosis of belt out of position

10 Diagnosis of driving belt severe damage and wear

11 Diagnosis of engine misfire

The sealing surface of cylinder head warp or being damaged.

Malfunction of connecting rod.

● Piston ring fracture or wear

2 Measuring method of fuel consumption

3. Diagnosis and test of fuel pressure

3.5 Take off oil manometer and adaptor.

5 Diagnosis of oil leakage

chapter 3 Assembly Outline Illustration

IV.Crankshaft，piston and connecting rod assembly

12.apron 13.timing gear

V.Camshaft，valve and rocker

1.oil pan assembly 7.glue coil

VII.Timing belt, outside cover and inside cover assembly

Chapter 4 Maintenance of Intake Pipe

11 Install throttle bracing wire and driving

Chapter 5 Replacement of Exhaust Pipe Gasket

Chapter 6 Replacement of Camshaf Bracket Cover

Chapter 7 Replacement of Timing Belt

Notice: You should make sure that every

Notice: After installation of tension

Chapter 8 Replacement of Cylinder Head

1 Steps of removal 1 Take off fuel pump relay mounted under

the instrument meter plate. to the rear,intake side 6237,exhaust side

Chapter 9 Replacement of Sealing Washer of Valve Spring

1 Exhaust valve seat:Use the taper rymer to

Chapter 10 Rplacement of Piston