Chapter Two Engine Section One Maintenance Data of The Engine 1. Basic Engine Specifications

Chery A15 Maintenance Manual
Chapter Two Engine

Section One Maintenance Data of the Engine
1. Basic engine specifications

In-line engine, four-cylinder, single overhead camshaft
Displacement 1.6L
Stroke 85.8 mm (3.377 in.)
Compression ratio 10.5:1
Ignition sequence 1-3-4-2
Compression pressure 1172–1551 kPa (170–225 psi)
2. Engine cylinder body
Cylinder diameter 76.9924–77.0076 mm
Max. radial run-out 0.0076 mm
Max. taper 0.051 mm
3. Piston
Piston diameter 76.956–76.974 mm
Piston upper clearance at 40.25mm: 0.018–0.52 mm
Piston weight: 219–224 g
Piston clearance at the lowest end: 0.758–0.790 mm
Piston length: 46.25 mm
Piston pin hole inner diameter: 19.008–19.015 mm
First piston ring width: 1.215–1.235 mm
Second piston ring width: 1.215–1.235 mm
Third piston ring width: 2.521–2.541 mm
4. Piston pin
Clearance between piston pin hole and piston pin: 0.008–0.015 mm
-4- Chery Automobile Co., Ltd.

Continued
Diameter: 18.995–19.000 mm
Length: 56.50–57.00 mm
5. Piston ring
First piston ring opening clearance: 0.20–0.36 mm
Max. maintenance limit: 0.8 mm
Second piston ring opening clearance: 0.25–0.46 mm
Third piston ring opening clearance: 0.20–0.58 mm
Compression ring side clearance: 0.025–0.065 mm
Maintenance maximum limit: 0.10 mm
Engine oil ring side clearance: 0.004–0.178 mm
Compression ring width: 1.17–1.19 mm
Engine oil ring width: 2.354–2.517 mm
6. Connecting rod
Bearing clearance: 0.023–0.067 mm
Maximum wear limit for maintenance: 0.075 mm
Connecting rod small head diameter: 18.96 - 18.98 mm
Connecting rod big head diameter: 47.005 - 46.991 mm
Connecting rod length: 135.6 mm
Connecting rod weight: 241.32g
Side clearance: 0.13–0.38 mm
7. Crank shaft
Connecting rod shaft collar diameter: 43.992–44.008 mm
Main shaft bearing’s shaft collar diameter: 47.922–48.008 mm
Shaft collar maximum radial run-out: 0.006 mm (Max.)
Shaft collar maximum taper: 0.008 mm (Max.)

Continued
Axial clearance: 0.09–0.24 mm
Main bearing clearance: 0.022–0.062 mm
Connecting rod bearing clearance: 0.023–0.067 mm
8. Rocker arm shaft
Rocker arm shaft diameter: 18.966–18.984 mm
9. Rocker arm/hydraulic tappet
Rocker arm shaft inner diameter: 19.00–19.02 mm
Rocker arm axial clearance: 0.016–0.054 mm
Tappet diameter: 11.979–11.966 mm
Minimum piston stroke: 2.2 mm
Lift: intake valve 3.25mm
Lift: exhaust valve 3.25mm
10. Camshaft bearing diameter
Bearing diameter: 25.359–25.380 mm
11. Camshaft
Camshaft collar diameter: 25.290–25.309 mm
Bearing clearance: 0.053–0.093 mm
Maximum maintenance limit: 0.12 mm
Axial clearance: 0.05–0.39 mm
Intake valve: 8.75mm
Exhaust valve: 8.00 mm
Exhaust valve timing: close (ATDC) 1.4; open (BBDC) 38.6: continuous angle 218.2
Intake valve timing: close (ABDC) 37.0; open (ATDC) 1.0; continuous angle 218.4
Valve overlap: 2.4
12 Cylinder gasket
Aluminum
Cylinder gasket thickness: 0.60 - 0.70 mm

Continued
13. Valve seat
Intake valve seat diameter: 31.975 -31.950 mm
Exhaust valve seat diameter: 25.20 - 25.175 mm
Max. radial run-out: 0.05mm
Intake and exhaust valve seat width: 0.75 - 1.25 mm
14. Valve conduit
Conduit inner diameter: 5.975–6.000 mm; conduit height: 13.25–13.75 mm
15. Valve
Valve angle (intake and exhaust): 45–45.5 degrees
Intake valve diameter: 30.07–30.33 mm
Exhaust valve diameter: 23.13–23.39 mm
16. Valve clearance
Intake valve clearance: 1.15–1.48 mm
Max. maintenance limit: 0.95mm
Exhaust valve clearance: 1.475–1.805 mm
Max. maintenance limit: 1.05mm
17. Valve length
Intake valve: 108.72–109.22 mm
Exhaust valve: 117.57–118.07 mm
18. Valve top height
Intake valve: 48.62 mm
Exhaust valve: 48.62 mm
19. Valve diameter
20. Valve conduit clearance

Continued
Maximum allowable 0.076mm
Maximum allowable for maintenance 0.25mm
Maximum allowable: 0.101 mm
Maximum allowable for maintenance 0.25mm
21. Valve spring
Free length: 50.0mm
Normal elasticity (valve closes): 285 - 319 N @ 43.0 mm (64 - 71.71 lbs. @ 1.6 in.)
Normal elasticity (valve opens): 774 - 846 N @ 34.25 mm (174 - 190 lbs. @ 1.28 in.)
Fixing height: 43.0 mm
22. Engine oil pump
Safety valve opening pressure: 413.69 kPa
23. Engine oil pressure
Normal temperature shall be ensured
Idle speed: 25 kPa (4 psi)
3,000 revolutions 10-550 kPa (25–80 psi)
* Do not run the engine to 3,000 rpm if the pressure is zero in the case of idle speed.
24. Screwing torque (N.M)
Camshaft position sensor: -10N·M
Crank shaft position sensor: -10N·M
Camshaft sprocket wheel bolt: -115N·M
Rocker arm/camshaft bearing cover: -25N·M
Timing chain cover: -12N·M
Timing chain guide board: -28N·M
Timing chain tensioner: -62N·M
Connecting rod bolt: -26N·M +1/ 4 angles
Crank shaft main shaft bearing cover: -30N·M
Main bearing cover bolt: -61N·M
Continued
Crank shaft shock absorber: -115N·M
Cylinder cover bolt (see Engine/Cylinder Cover-Fixing)
Cylinder cover: -12N·M
Right engine bracket
Fixture: M12 -118N·M
Fixture: M10 -68N·M
Exhaust manifold heat shield bolt: -28N·M

Exhaust manifold set bolt: -23N·M

Intake manifold bolt: -26N·M
Engine oil pressure adjusting bolt: -25N·M
Engine oil filter set bolt: -28N·M
Crankcase oil tray bolt: -31N·M
Engine oil plug: -27N·M
Engine oil pump bracket oil pipe bolt: -12N·M

Section Two Commonly-used Special Tools
Crank shaft belt pulley unfixing tool Camshaft fixing/unfixing tool
Crank shaft sprocket wheel fixing tool Crank shaft sprocket wheel aligning tool
Crank shaft shock absorber/ Puller

Sprocket wheel unfixing tool
Valve spring compressor

Spark plug conduit sealing
and fixing tool

Camshaft sprocket wheel fixing spanner Camshaft sprocket wheel fixer
Front crank shaft sealing Handle

and fixing tool
Rear crank shaft sealing conduit

Connecting rod fixing and
and fixer
guiding tool
Moving frame Engine frame

Cylinder pressure gauge Dial indicator
Engine support Dial indicator
Cylinder compression pressure adaptor Valve spring tester
Pressure sensor
Test fitting adaptor

Section Three Unfixing the Engine
One. Unfixing the crank shaft belt pulley

1. Unfixing
(1) Detach the storage battery cathode fittings;
(2) Jack up the car;
(3) Unfix the right wheel and attachment driving belt cover plate;
(4) Unfix the attachment driving belt (see Driving Belt – Unfixing)
(5) Unfix the crank shaft belt pulley bolt; use special puller and unfix the belt pulley
(Figure 1).
1-Special tool for unfixing the belt

pulley
2-Special tool for guding the belt pulley
3-Crank shaft belt pulley
2. Fixing
(1) Fix the crank shaft belt pulley with a
special tool (Figure 2). Figure 1 Unfixing the Crank Shaft Belt
(2) Screw on the bolt of the crank shaft Pulley
belt pulley with a torque of 115N.m.
(3) Fix the driving belt (see Driving Belt
– Fixing).
(4) Fix the attachment driving belt cover
plate.
(5) Lower the car.
(6) Connect the storage battery cathod
fittings.
1-Fix the special tool Figure 2 Fixing the Crank Shaft Belt
2-Crank shaft belt pulley Pulley
Two. Bracket
1. Unfixing the upper torsion bar
(1) Unscrew the bolts of the torsion bar
and the engine bracket (Figure 3).
(2) Unfix the upper torsion bar.
1,2 – Torsion bar fittings

3 – Upper torsion bar
Figure 3

2. Fixing the upper torsion bar

(1) Put the torsion bar on the bracket
(Figure 3).
(2) Screw on the bracket bolts.
3. Unfixing the rear torsion bar
(1) Jack up the car (Figure 4)
(2) Unscrew Bolt 1 and 2 of the bracket.
(3) Unfix the rear torsion bar.
4. Fix the rear torsion bar
(1) Fix the torsion bar onto the bracket.
(2) Screw on Bolt 1 and 2 of the bracket. Figure 4
(3) Lower the car.
5. Unfixing the right engine bracket.
(1) Unfix the upper torsion bar (see (3) Screw on the right engine bolts with
Engine/Engine Bracket/Torsion Bar – a torque of 118N.m.
Unfixing). (4) Fix the right frame into the hood.
(2) Unfix the fittings of the power (5) Remove the hydraulic jack.
steering pump on the right of the engine. (6) Jack up the car.
(3) Unfix the oil tank of power steering (7) Fix the bracket (see Engine/Engine
pump. Bracket/Torsion Bar – Fixing).
(4) Jack up the car. (8) Fix the driving belt guard board.
(5) Unfix the front right wheel. (9) Fix the front right wheel.
(6) Unfix the driving belt attachment (10) Lower the car.
cover plate. (11) Fix the pipes of the power steering
(7) Unfix the lower torsion bar (see pump onto the engine bracket fittings.
Engine/Engine Bracket/Torsion Bar – (12) Fix the power steering oil tank onto
Unfixing). the engine bracket fittings.
(8) Screw off the bolts of the right (13) Fix the upper torsion bar (see
engine bracket. Engine/Engine Bracket/Torsion Bar –
(9) Lower the car. Fixing).
(10) Jack up the engine with a hydraulic
jack.
(11) Unfix the right engine bracket.
(12) Screw off the bolts of the right
engine bracket.
(13) Jack up the engine.
(14) Screw off the remaining bolts of the
right engine bracket (Figure 5)
6. Fixing the right engine bracket
(1) Fix the right engine bracket,
manually screw fast the fittings with a
torque of 68N.m (50ft.lbs) for Bolt M10
and 118N.m for Bolt M12 (Figure 5).
(2) Lower the engine and screw on the
bolts of the right engine bracket.

1- Right engine bracket
7. Unfixing the left bracket

(1) Unfix the left engine bracket (see
Engine/Engine Bracket/Torsion Bar – Figure 5 Right Engine Bracket
Fixing).
(2) Mark the position of the engine
bracket with permanent inks.
(3) Unscrew the bolts of the car body
(Figure 6).
(4) Unfix the brackets of the engine and
the car body.
1-Buffer
2-Left engine bracket
3-Bolt
Figure 6 Left Engine Bracket

8. Fixing the left bracket
(1) Place the bracket onto the original
car body (Figure 6).
(2) If the mark does not fit with the
bracket, please do the following:
•Insert a new bracket into the car body.
•Align them with the hole.
•Mark accordingly where concentricity
is.
(3) Screw on the bolt with a torque of
28N.m (Figure 6)
(4) Fix the left engine bracket (see
Engine/Engine Bracket/ Enginge
Bracket – Fixing).
(5) Unfix the engine bracket.

9. Unfixing the left suspension bracket

(1) Detach the storage battery cathode
fittings.
(2) Detach the storage battery anode
fittings.
(3) Unfix the air filter assembly.
(4) Take out the storage battery tray.
(5) Jack up the car to about 30.5cm
height.
(6) Use appropriate axle shaft bracket.
(7) Unfix the front left wheel.
(8) Unfix the front guard board.
(9) Unscrew the external bolts of the car
body.
(10) Screw off the bracket bolts (Figure
7).
(11) Unfix the left suspension bracket
onto the car body fittings.
(12) Unscrew the bracket bolts (Figure
8).
(13) Unfix the bracket.
1-Left bracket
2-Bolt
3-Left suspension bracket
Figure 7 Upper Bracket Bolt
1-Bracket
2-Gearbox
Figure 8 Left bracket

10. Left bracket

(1) Fix the bracket and the attached bolts (Figure 8) with a torque of 68N.m.
(2) Fix the engine bracket onto the car body with a vertical screwing torque of 28N.m
(250in.lbs).
(3) Screw on the positioning bolts of the engine and driving axle with a torque of 118N.m
(Figure 7).
(4) Unfix the guard board.
(5) Screw on the left frame bolts.
(6) Left board, wheel guard and wheel.
(7) Lower the car.
(8) Fix the storage battery bracket.
(9) Fix the air filter assembly.
(10) Connect the storage battery anode.
(11) Connect the storage battery cathode.
Three. Unfixing the engine

(1) Unfixing steps for the fuel system.
(2) Detach the storage battery cathode fittings.
(3) Detach the storage battery anode and take out the storage battery.
(4) Take out the air filter and throttle air intake pipe.
(5) Drain the cooling fluid.
(6) Detach the water tank hose.
(7) Detach the hose connecting the water tank and the heat economizer.
(8) Detach the warm warm air water tank hose.
(9) Take out the cooling fan.
(10) Take out the drain pipe of the water tank.
(11) Detach the gear position switch and electrical wire harness of the gearbox.
(12) Detach the brake vacuum hose and the throttle hose.
(13) Detach the ground wire on the cylinder cover.
(14) Detach the following sensor plug.
Oxygen sensor
Camshaft position sensor
Ignition signal
Spray nozzle
Sensor
Knock sensor
Engine oil pressure sensor
Crank shaft position sensor
Throttle assembly
Water temperature sensor
Generator
Starter
(15) Unfix the oil pipe of the power steering pump and the fittings of the oil tank.
(16) Jack up the car.
(17) Drain the engine oil.
(18) Unfix the front wheel.

(19) Unfix the guard board of the attachmet driving belt.

(20) Take out the driving belt (see Cooling System/Attachment/Driving Belt – Unfixing).
(21) Unfix the strut and upper torsion bar.
(22) Take out the left and right driving axle (see Differential and Driving Axle –
Unfixing).
(23) Unfix the exhaust manifold.
(24) Unfix the clutch and shock absorber fittings.
(25) Unfix the power steering device.
(26) Unfix the powre steering oil pipe fittings.
(27) Detach A/C compressor solenoid clutch fittings.
(28) Unscrew the bolts of A/C compressor bracket.
(29) Lower the car.
(30) Detach the fuel suction pipe.
(31) Fix special tools under the car to jack up the car so that the engine may have
sufficient displacement.
(32) Release the engine bracket and move it to the positioning pin and lower the car until
the engine is back on the bracket. (Figure 9).
(33) Fix the cable throught the engine, tighten it and screw it fast in place (Figure 9).
Note: the cable must be able to secure the engine.
(34) Jack up the car and see if the cable is able to secure the engine assembly.
(35) Lower the car so that the weight of the engine and the transmission mechanism only
supports the engine where appropriate.
(37) Unfix the left and right engines by screwing off the bracket bolts.
(38) Keep on jacking up the car until the engine/axle shaft assembly can be clearly seen
and movable.
Figure 9 Fixing/unfixing Positions of the Engine
1-Cable 2-Special tool 3-Wooden stick

4-Special tool 5-Place the special tool into the hole

Four. Fixing – Engine Assembly

(1) Place the engine and transmission assembly under the car and then slowly lower the
car.
(2) Keep lowering the car until the engine/transmission shafts are on the place to be
installed, screw on the engine/transmission shaft bracket bolts with a torque of 118N.m
(87ft.lbs).
(3) Fix the engine upper torsion bar.
(4) Take out the cable from the engine and transmission shaft assembly and slowly jack
up the car unti it can be sufficiently moved.
(6) Fix A/C compressor set bolts and refix the A/C compressor solenoid clutch fittings.
(7) Screw on the set bolts of the power steering oil pipe.
(8) The cooling device fittings of the power steering assembly.
(9) Fix the fittings of the clutch and shock absorbers.
(10) Fix the exhaust manifold and its fittings.
(11) Fix the left and right driving shafts (see Differential and Driving Shaft/Axle Shaft –
Fixing).
(12) Fix the strut and lower torsion bar.
(13) Fix the driving belt.
(14) Fix the driving belt guard board.
(15) Fix the bolts of the front wheel.
(16) Lower the car.
(17) Connect the fuel pipeline.
(18) Connect the power steering oil tank and power steering pump oil pipe and fix the
power steering assembly onto the right engine bracket.
(19) Connect the following sensor plugs.
(20) Main oxygen sensor.
(21) Camshaft position sensor.
(22) Ignition coil and capacitor.
(23) Spray nozzle.
(24) Air intake pressure sensor
(25) Knock sensor
(26) Engine oil pressure sensor
(27) Crank shaft position sensor.
(28) Throttle body assembly
(29) Water temperature sensor
(30) Generator
(31) Starter
(32) Connect the ground wire for the cylinder cover.
(33) Connect the brake vacuum tube and the carbon canister vacuum solenoid valve.
(34) Connect the gear position switch and the solenoid valve wire harness of the gearbox.
(35) Connect the lower water tank hose.
(36) Fix the cooling fan.
(37) Connect the warm air heater onto the heat economizer’s water pipe.
(38) Connect the water pipeline between the upper water tank and the heat economizer.

(39) Connect the water pipeline between the cooling system water tank to the heat
radiator.
(40) Fix the air filter and throttle’s air suction pipe.
(41) Fix the storage battery tray ad connect its anode.
(42) Connect the cathode fittings.
(43) Fix new engine oil filter and add an appropriate amount of oil.
(44) Fill in power steering oil.
(45) Add cooling fluid (see Cooling System/Engine).
(46) Start the engine to heat it up to working temperature.

Section Four Timing Chain
One. Valve timing mark

•Timing chain
•Camshaft sprocket wheel
•Right timing chain guide board
(unfixing)
•Left timing chain guide board (fixing)
•Timing chain tensioner
1-Camshaft timing mark

2-Camshaft sprocket wheel
3-Right timing chain guide board
(moving)
4-Left timing chain guide board (fixing)
5-Sealing piston
6-Engine oil chamber
7-Timing chain tensioner
8-Crank shaft sprocket wheel
9-Timing chain
10-Crank shaft timing mark
(see Figure 10)
Figure 10 Timing Driving System

Two. Valve timing adjustment
(1) Unfix the valve chamber cover
(2) Unfix the first cylinder spark plug
(3) Turn the first cylinder to the
compression stroke upper limit with an
indicator.

(4) The camshaft sprocket wheel mark

shall be aligned with the cylinder cover
surface (Figure 11).
(5) Observe the timing mark on the
camshaft timing sprocket wheel (Figure
12).
(6) Fix the valve chamber cover.
1-Valve chamber cover sealing surface

2-Camshaft sprocket wheel mark
Figure 11 Camshaft Sprocket Wheel

Timing Mark
1-Camshaft mark
2-Engine cylinder
3-Camshaft
Figure 12 Camshaft Timing Mark

Three. Timing chain cover
1. Unfixing
fittings.
(2) Unscrew the bolts of the power
steering oil tank bracket.
(3) Drain the cooling water and unfix the
upper water tank hose
(4) Unfix the cooling fan
(6) Unfix the front right wheel
(7) Unfix the driving belt guard board.
(8) Unfix the driving belt.
(9) Unfix the crank shaft shock absorber.

(10) Unfix the driving belt tensioner.

(11) Unfix the driving belt middle wheel.
(12) Unfix the holddown bolts of the air
compressor.
(13) Unscrew the bolts of the power
steering pump/water pump bracket.
(14) Unscrew the bolts of the timing
sprocket wheel cover.
(15) Unfix the timing sprocket wheel
cover (Figure 13).
1-Front crank shaft oil seal Figure 13 Timing Chain Cover

2-Timing chain cover
2. Fixing
(1) Clean all sealing surfaces.
(2) Replace the gasket of the timing
chain cover (Figure 14).
1-Timing chain cover gasket

2-Engine oil pump
3-Pressure safety valve
Figure 14 Timing Chain Sealing Surface

(3) Apply the cylinder body with engine
sealing material (Figure 15).
1-Chain cover sealing material

2-Direct line on the cylidner body
(4) Add 4-liter engine oil before fixing

the engine oil pump.
Figure 15 Positions of the Timing Chain
Cover Seal

(5) Fix all engine oil pump attachments

onto the crank shaft. When fixing the
timing chain cover, manual screw tight
all fittings with a torque of 12N.m
(Figure 16).
(6) Fix the power steering pump/water
pump with a torque of 28N.m.
(7) Fix the compressor and screw tight
with a torque of 28N.m.
(8) Fix the driving belt attachment
middle wheel.
(9) Fix the driving belt tensioner.
(10) Fix the crank shaft belt wheel. Figure 16 Screwing Sequence of the
(11) Fix the driving belt attachements. Timing Chain Cover
(12) Fix the driving belt guard board.
(13) Fix the front right wheel.
(14) Lower the car.
(15) Fix the water tank fan.
(16) Connect the upper water tank hose.
(17) Screw on the bolts of power
steering oil tank.
(19) Add cooling water.
Four. Timing chain/guide

board/sprocket wheel
1. Unfixing
fittings.
(2) Unfix te cylinder cover.
(3) Unfix the camshaft position sensor.
(4) Unfix the timing chain cover.
(5) Turn the crank shaft until the first
cylinder reaches the compression stroke
upper limit.
(6) Fix the camshaft sprocket wheel with
a special tool and uncrew the bolts of the
sprocket wheel (Figure 17).

1-Camshaft Special Tool
Figure 17 Special Tool for the Camshaft

Sprocket Wheel
(7) Unfix the timing chain tensioner off

the cylinder body and take out the
engine oil chamber (Figure 18).
1-Screw plug with seal

Figure 18 Timing Chain Tensioner
(8) Unfix the right engine bracket (see

Engine/Engine Seat/Engine Bracket –
Unfixing).
(9) Unfix the camshaft sprocket wheel. It
is allowed to partially take out the chain.
(10) Unfix the cylinder cover plug, take
out the fittings and unfix the guide board
(Figure 19).
(11) Unfix the timing chain
1-Left timing chain guide board (moving)
2-Right timing chain guide board (fixing)
3-Fitting
4-Cylinder cover plug
Figure 19 Timing Chain Guide Board
Bracket

2. Camshaft sprocket wheel – unfixing

fittings.
(2) Unfix the valve chamber cover (see
Engine/cylinder cover/valve chamber
cover – Fixing).
(3) Unfix the crank shaft position sensor.
(5) Turn the camshaft and align the
triangle timing mark on the camshaft
sprocket wheel.
(6) Turn the camshaft to where the the
triangle mark is.
(7) Align the timing chain mark with the
canshaft timing mark (Figure 20).
1-Timing mark
2-Camshaft sprocket timing mark
Figure 20 Timing Chain Mark

(8) Fix the crank shaft sprocket wheel
with the special tool and screw off the
crank shaft sprocket wheel bolts.
the cylinder body and unfix the engine
oil chamber and timing chain tensioner.
(10) Unfix the camshaft sprocket wheel
off the crank shaft.
Five. Crank shaft sprocket wheel

1. Unfixing
(1) Unfix the timing chain
(2) Unscrew the crank shaft shock
absorber bolts and unfix the crank shaft
sprocket with special tools (Figure 21).

(3) Fix the crank shaft and unfix the

sprocket wheel.
1-Special tool
2-Special tool
3-Special tool
2. Fixing
(1) Fix the crank shaft sprocket wheel
with special tools (Figure 22) Figure 21 Unfixing the Crank Shaft
(2) Fix the crank shaft sprocket wheel Sprocket Wheel
with special tools.
(3) Fix the sprocket wheel and do not
turn the crank shaft.
1-Special tool
2-Special tool
3-Special tool
Six. Fixing the camshaft sprocket

wheel Figure 22 Fixing the Crank Shaft
(1) Align with the timing sporcket wheel Sprocket Wheel
mark and fix the timing chain onto the
camshaft sprokect wheel.
(2) Screw on the camshaft sprocket
wheel bolts with a torque of 115N.m.
(3) Reset the timing chain tensioner.
(a) Take out the engine oil chamber from
the timing chain tensioner (Figure 25).
(b) Place the timing chain onto an even
surface.
(c) Manually press the tensioner as the
figure shows (Figure 26).
(4) Fix the engine oil chamber onto the
timing chain tensioner (Figure 25).
(5) Fix the timing chain tensioner with a
torque of 62N.m (46ft.lbs).

(6) Pry off the right timing chain with a

screw driver (Figure 23).
(7) Fix the valve chamber cover (see 9-
Engine/cylinder cover/valve chamber
cover – fixing).
(8) Fix the camshaft position sensor with
a torque of 10N.m.
Figure 23 Actuate the Timing Chain

Seven. Timing sprocket wheel and Tensioner
guide board
1. Fixing
(1) Fix the left timing chain guide board
with a screwing torque of 28N.m
(250in.lbs) (Figure 19).
(2) Fix the right timing chain guide
board with a screwing torque of 28N.m
(Figure 24).
(3) Unfix the valve chamber cover to
allow the timing chain to move freely.
(4) Fix the timing chain crank shaft
sproket wheel and align it with the
timing mark (Figure 24).
1-Align the camshaft with the single
mark.
2-Camshaft sprocket wheel
3-Left timing chain guide board (moving)
4-Right timing chain guide board (fixing)
5-Piston chamber
8-Crank shaft sprocket wheel
9-Timing chain
10-Crank shaft timing mark shall be
aligned with the double metal marks Figure 24 Timing Driving System

(5) Fix the camshaft sprocket wheel.

(6) Fix the camshaft sprocket wheel, use
special tools to fix the sprocket wheel
1-Check valve
2-Tensioner plug
(7) Readjust the timing chain tensioner

as follows:
(a) Take out the engine oil chamber from
the timing chain tensioner (Figure 25). Figure 25 Timing Chain Tensioner
(b) Place the tensioner on an even
surface.
(c) Press open the check valve and
manually press the tenioner (Figure 26).
(d) Fix the engine oil chamber into the
timing chain tensioner (Figure 25).
(8) Fix the engine oil chamber of timing
chain tensioner into the tensioner.
(9) Fix the timing chain tensioner by
screwing on the plug with a torque of
62N.m (46ft.lbs.)
(10) Press down the left timing chain
guide board to allow the chain to move Figure 26 Reset the Timing Chain
freely (Figure 27). Tensioner
(11) Fix the cylinder cover plug with a

screwing torque of 18N.m.
(12) Fix the valve chamber cover (see
Engine/Cylinder Cover/Valve Chamber
Cover – Fixing). Figure 27 Actuate the Timing Chain
(13) Fix the camshaft position sensor Tensioner
with a torque of 10N.m (85in.lbs) and
connect the plug.

(14) Fix the right engine bracket (see

Engine/Engine Bracket – Fixing)
(15) Fix the timing chain (see
Engine/Valve Timing/Timing
Chain/Chain Cover – Fixing).
(16) Connect the storage battery cathode
fittings.

Section Five Cylinder Cover Components
One. Cylinder cover

1. Unfixing the cylinder cover
(1) Unfix the fuel system (see Fuel System)
(3) Detach the storage battery anode and take out the storage battery.
(4) Drain the cooling fluid (see Cooling System).
(5) Detach the air suction pipe off the throttle.
(6) Detach the ground wire on the cylinder.
(7) Detach the vacuum hose on the throttle.
(8) Detach the plugs of the following sensors.
Oxygen sensor Engine oil pressure sensor
Camshaft position sensor Crank shaft position sensor
Lighting signal Throttle assembly
Spray nozzle Water temperature sensor
Sensor Generator
Knock sensor Starter
(9) Detach the heat economizer water pipe and warm air heater’s return pipe.
(10) Detach the fittings for the warm air heater and the heat economizer.
(11) Detach the water pipe off the upper water tank.
(13) Unfix the front right wheel.
(14) Unfix the driving belt.
(15) Unfix the decorative plate of the driving belt.
(16) Unscrew the lower bolts of the right engine bracket.
(17) Unscrew the set bolts of the exhaust manifold fittings.
(18) Lower the car.

(20) Unfix the fittings from the power

steering pump to the engine bracket.
(21) Unfix the oil tank of the power
steering pump.
(22) Jack up the engine oil sump with a
hydraulic jack.
(23) Unscrew the holddown bolts of the
right engine bracket.
Engine/Cylinder Cover/Valve chamber
cover – Unfixing).
(26) Turn the crank shaft until it reaches
the upper limit of the first cylinder.
(27) Align with the camshaft timing
chain mark.
1-Align the timing chain mark with the

sprocket wheel mark.
2-Camshaft sprocket wheel timing mark.
Figure 28 Timing Chain and Cam Shaft
Mark
(28) Fix the camshaft sprocket wheel

with a special wheel (Figure 29).
1-Camshaft sprocket wheel special tool
Figure 29 Cam Shaft Sprocket Wheel

Spanners

the cylinder body (Figure 30)

1-Sealing bolt
(30) Remove the camshaft sprocket

wheel tooth off the crank shaft. Figure 30 Timing Chain Tensioner
(31) Unfix the camshaft sprocket wheel
off the camshaft and remove the timing
chain from the sprocket wheel.
(32) Unfix the cylinder cover plug, unfix
the fittings for the timing chain guide
board on the cylinder cover and take out
the timing chain guide board (Figure 31).
1-Left timing chain guide board

2-Left timing chain guide board
3-Fittings
4-Cylinder cover plug
Figure 31 Fixing the Timing Chain

Guide Board
Note: avoid damaging the ignition

plug while unscrewing the cylinder
cover bolts.
(33) Unscrew the cylinder cover bolts
(Figure 32).
(34) Unfix the cylinder cover and gasket.

1. M10 bolts of the cylinder cover

2. Cylinder gasket
3. Cylinder cover
4. M8 bolts of the cylinder cover
2. Cleaning Figure 32 Cylinder Cover and Gasket

The sealing surface must be clean to
ensure the sealing of the cylinder, which
is especially important in the case of
aluminum gasket when all foreign
matters on the cylinder cover shall be
removed and all engine oil paths shall be
cleaned.
3. Checking
(1) The required evenness is 0.1mm
(0.004in.) (Figure 33).
1. Clearance gauge
2. Ruler
Figure 33 Check the Evenness of the

Cylinder Cover
(2) Check if the camshaft bearing bush is
free of scratches.
(3) Clean the oil on the valve conduit.
(4) Measure the valve conduit with a dial
indicator (Figure 34) (see Engine –
Troubleshooting Procedure).
1-Upper
2-Middle
3-Lower
4-Valve conduit measurement position Figure 34 Check the Valve Conduit

4. Fix the cylinder cover

Note: Check the cylinder cover bolts
before fixing the cylinder cover. Replace
if any trouble is discovered (Figure 35).
1-Bolt is not elongated
2-Screw thread is uneven..
3-Screw thread is curved..
4-Bolt is elongated
Figure 35 Check the Bolts

(1) Clean the cylinder cover surface and
cylinder sealing surface.
(2) Place new gasket onto the
positioning lock.
(3) Place the cylinder cover onto the
cylinder body and make sure that the
cylinder cover is fully set into the
positioning lock.
(4) Apply engine oil onto the cylinder
cover bolts before screwing them on.
(5) Screw on the cylinder cover bolts in
sequence (Figure 36) and the screwing
torque is as follows: Figure 36 Screwing Sequence of the
Cylinder Cover Bolts
Step One
Screw on the 10 pieces of M10 bolts
with a torque of 20N.m (15ft.lbs.)
Screw on the 2 pieces of M8 bolts with a
torque of 15N.m (11ft.lbs.)
Step Two
with a torque of 41N.m (30ft.lbs.)
Step Three
again with a torque of 41N.m (30ft.lbs.)
Step Four
Turn the 10 pieces of M10 bolts by 90
degrees (do not use torque spanners).
Screw on the 2 pieces of M8 bolts with a
torque of 30N.m (22ft.lbs.).

(6) Fix the timing chain guide board

with a torque of 28N.m (250in.lbs)
(Figure 31).
(7) Resume the timing chain’s mark on
the crank shaft.
(8) Align the camshaft sprocket wheel
with the triangle timing mark.
Note: do not use pneumatic tools to
screw fast the camshaft sprocket
wheel.
(9) Fix the camshaft sprocket wheel with
special tools and screw on the camshaft
sprocket wheel bolts with a torque of
15N.m (85ft.lbs) (Figure 15).
(10) Readjust the timing chain tensioner
as follows:
(A) Unfix the timing chain tensioner’s
engine oil chamber (Figure 37).
1-Check valve
2-Plug with seal
Figure 37 Actuate the Timing Chain

Tensioner
(B) Place the timing chain onto a clean
surface.
(C) Press open the tensioner check valve
and keep pressing down manually until it
lowers to the bottom (Figure 38).
(D) Fix the engine oil chamber into the
timing chain tensioner.
(11) Fix the timing chain tensioner onto
the cylinder body.
(12) Fix the timing chain tensioner with
a torque of 62N.m (46ft.lbs).
(13) Pry in the right timing chain guide
board with a long screw driver until the
tensioner is set into the sprocket wheel
position (Figure 39). Figure 38 Reset the Chain Tensioner

(14) Fix the cylinder cover plug with a

torque of 18N.m (162in.lbs).
Engine/Engine Cover/Valve Chamber
Cover – Fixing).
(16) Fix the camshaft position sensor
with a torque of 10N.m (85in.lbs) and
connect the plug.
(17) Fix the left engine bracket (see 9-
Engine/Engine Fixing/Engine Bracket –
Fixing).
(18) Lower the car until the right engine
bracket bolts can be screwed on.
(19) Screw on the bolts of the right
engine bracket.
(20) Unfix the lower engine guard board.
(21) Fix the fittings of the power
steering oil return pipe onto the right
engine bracket. Figure 39 Actuate the Timing Chain
(22) Fix the power steering oil tank onto Tensioner
the right engine bracket.
(23) Fix the upper torsion bar.
(25) Fix the exhaust pipe fitting with a
torque of 28N.m (250in.lbs).
(26) Fix the lower torsion bar.
(27) Fix the driving belt cover.
(29) Lower the car.
(30) Connect the pipe of the upper water
tank.
(31) Fix the water pipeline from the
throttle to the water tank.
(32) Connect the water pipe and water
return pipe from the warm air heater to
the throttle.
(33) Connect the plugs of the following
sensors.

Oxygen sensor Air intake pressure sensor

Camshaft position sensor Knock sensor
Ignition coil and capacitor Throttle body assembly
Spray nozzle Water temperature sensor
(34) Connect the vacuum tube on the

throttle.
(35) Connect the ground wire on the
cylinder cover.
(36) Connect the air intake pipe of the
throttle.
(38) Add appropriate engine oil.
(39) Adjust the torsion bar.
Two. Valve chamber cover

1. Unfix the valve chamber cover
fittings.
(2) Detach the PVC vacuum tube on the
cylinder cover.
(3) Detach the ignition coil and vacuum
capacitor plug.
(4) Detach the spark plug’s power live
wire and screw off the high-voltage wire.
(5) Screw off the ignition coil bolts and Figure 40 Position of PVC Valve
take out the ignition coil.
(6) Unfix the ignition coil capacitor.
(7) Unscrew the valve chamber bolts.
(8) Unfix the valve chamber cover
(Figure 41).
2. Cleaning
Clean the cylinder cover and valve
chamber cover with proper detergents.
3. Checking
Check the evenness of the valve
chamber cover. See the Checking
Measures of the Cylinder Cover.
Figure 41 Valve Chamber Cover

4. Fixing
(1) Check the gasket and seal (Figure
42), replace spark plug conduit (see
Engine/Cylinder Cover/Spark Plug
Sealing – Unfixing) and (see
Engine/Cylinder Cover/Spark Plug
Conduit – Fixing).
1-Valve chamber gasket

2-Seal
3-Bolt
4-Spark plug conduit
Figure 42 Valve Chamber Cover Gasket

and Seal
(2) Fix the valve chamber cover and

gasket. Screw on the bolts of the valve
chamber cover bolts in sequence.
Step 1: screw with a torque of 6N.m
(60in.lbs).
Step 2: screw with a torque of 12N.m
(105in.lbs) (Figure 43).
Figure 43 Valve Chamber Cover

Screwing Sequence
(3) Fix the ignition coil capacitor
(optional).
(4) Fix the ignition coil and high-voltage
cable and ensure that the rubber ring is
placed in the ignition coil (Figure 44)
and the screwing torque is 12N.m
(105in.lbs).
1-Rubber spacer ring

2-Ignition coil
Figure 44 Ignition Coil and Rubber

Spacer Ring

(5) Connect the PVC vacuum hose

(Figure 40).
(6) Connect the ignition coil and
capacitor.
fittings.
Three. Spark plug conduit seal

1. Unfixing
Cover – Unfixing)
(2) Carefully unfix the spark plug
conduit sealing with proper tools. Do not
damage the sealing surface of the
cylinder cover.
1-Spark plug conduit sealing Figure 45 Spark Plug Conduit Sealing

2-Cylinder chamber cover
2. Fixing
(1) Clean all oil sealing surfaces.
Note: use oil seal fixing tool (Figure
46).
(2) Use special tools (Figure 46) and fix
the oil seal.
1-Special tool
2-Spark plug conduit oil seal
Figure 46 Fixing the Spark Plug Conduit

(3) Fix the valve chamber cover (see oil Seal
Cover – Fixing)
(4) Cylinder cover (see Engine/Cylinder
Cover/Valve Chamber Cover – Fixing)

Four. Spark Plug Conduit Oil Seal

1. Unfixing
(1) Unfix the cylinder cover (see
Cover – Fixing).
(2) Fix the spark plug conduit tools and
screw on the set screws with a torque of
16N.m.
(3) Unfix the valve conduit off the
cylinder cover with special tools.
1-Special tool
2-Special tool
3-Set screw
Figure 47 Unfixing the Spark Plug

Conduit Oil Seal
(4) Release the set screw, turn the
special tools and take out the conduit.
2. Fixing
(1) Clean the spark plug surrounding.
(2) Clean the bearing seat and fix special
tools.
(3) Fix the spark plug.
(4) Fix the special tools (Figure 48).
1-Special tool
Figure 48 Special Tool

(5) Carefully fix the conduit oil seal with

the special tool (Figure 49).
1-Special tool
(6) Release the special tool in the spark

plug hole and use a long bolt to unfix the Figure 49 Fixing the Spark Plug
special tool (Figure 50).
1-Special tool
2-Spark plug conduit

Engine/Cylinder Cover/Valve Chamber Figure 50 Unfixing Device
Cover – Fixing).
Five. Rocker arm shaft/rocker

arm/adjustment
1. Unfixing
fittings.
Engine/Cylinder Cover/ Valve Chamber
Cover – Fixing).
Note: please unfix the rocker arm in
sequence.
(3) Unfix the bolts of rocker
arm/camshaft bearing cover and the
central bolts.
(4) Unfix the rocker arm/rocker arm
assembly (Figure 51).

Note: please replace the hydraulic

tappet together with the rocker arm.
1-Exhaust valve rocker arm
2-Intake valve rocker arm adjusting
gasket
3- Intake valve rocker arm shaft
4- Intake valve rocker arm
5-Camshaft
6-Camshaft bearing cover
7-Exhaust valve rocker arm shaft
2. Fixing
(1) Clean and lubricate the rocker arm
with clean engine oil. Figure 51 Rocker Arm Shaft/Hydraulic
(2) Fix the rocker arm shaft/’rocker arm Tappet
shaft assembly bearing cover (Figure 34).
(3) Manually fix the rocker arm
shaft/camshaft bearing onto the cylinder
cover.
Note: please check if the camshaft is
correctly positioned when screwing
tight the rocker arm shaft/camshaft
bearing covers.
(4) Screw tight the rocker arm
shaft/camshaft bearing cover bolts in
sequence (Figure 52) with a torque of
25N.m.

Engine/Cylinder Cover/ Valve Chamber Figure 52
Cover – Fixing).
fittings.
Six. Camshaft
1. Unfixing
fittings.


Engine/Cylinder Cover/ Valve Chamber
Cover – Fixing).
(3) Detach the camshaft position sensor
plug and take out the camshaft position
sensor.
(5) Turn the camshaft until the first
cylinder reaches the compression stroke
upper limit.
(6) Secure the camshaft sprocket wheel
with a special tool and unfix the
camshaft sprocket wheel bolts (Figure
53).
1-Special tool
Figure 53 Special Tool for the Spanners

of Camshaft Sprocket Wheel
(7) Install the special tool (Figure 54) to

fix the camshaft, screw tight the tool
bracket bolts and slide the sprocket
wheel to the special tool (Figure 54).
1-Special tool
Note: please unfix the intake and Figure 54 Camshaft Sprocket Wheel
exhaust rocker arm shaft as follows: Retainer
(8) Unfix the rocker arm shaft/camshaft
bearing cover bolts and central bolts.
(9) Unfix the rocker arm shaft/rocker
arm assembly.
(10) Unfix the camshaft bearing cover
and mark accordingly (see the following
figure).

2. Checking
(1) Check if the camshaft bearing bush is
damaged or not (Figure 55). Please
check the cylinder cover and cylinder
cover oil hole if any.
(2) Check if the camshaft and bearing
surfaces suffer any abnormal wear and
damage and replace the camshaft if any.
(3) Check if the camshaft bearing cover
suffers any wear and damage.
Note: the replacement of camshaft is
determined by the abrasion of the
camshaft. It is allowed to replace the
rocker arm shaft.
(4) Measure the actual abrasion of the
cam nose (Figure 55) or replace the
camshaft.
1-Not worn out
2-Actual abrasion
3-Bearing bush
4-Cam
5-Place subject to abrasion Figure 55 Check the Abrasion of the
3. Fixing Camshaft
(1) Lubricate the camshaft bush with
clean engine oil.
(2) Fix the camshaft sprocket wheel and
lock it with a positioning pin.
(3) Fix the correct camshaft bearing
cover (Figure38).
(4) Lubricate the rocker arm with clean
engine oil.
(5) Fix the rocker arm shaft and rocker
arm assembly onto the camshaft.
(6) Manually fix the rocker arm
shaft/camshaft bearing onto the cylinder
cover.
Note: please check if the camshaft is
correctly positioned when screwing
tight the rocker arm shaft/camshaft
bearing cover.
(8) Screw tight the rocker arm
shaft/camshaft bearing cover bolts in
sequence (Figure 56) with a torque of Figure 56 Screwing Sequence of the
25N.m. Rocker Arm

(9) Install the special tool (Figure 54) to fix the camshaft and screw tight the tool bracket
bolts.
(10) Screw on the camshaft sprocket wheel bolts and use the special tool for the camshaft
to screw it tight with a torque of 115N.m (Figure 53).
(11) Screw tight the camshaft position sensor with a torque of 10N.m and plug in.
(12) Fix the valve chamber cover (see Engine/Cylinder Cover/ Valve Chamber Cover –
Fixing).
(13) Connect the storage battery cathode fittings.
Seven. Valve spring and valve oil seal

1. Unfixing sequence of the valve oil seal
(2) Fix the valve chamber cover (see Engine/Cylinder Cover/ Valve Chamber Cover –
Unfixing).
(3) Unfix the intake and exhaust rocker arm assembly (see Engine/Cylinder
Cover/Cylinder Cover Rocker Arm/Adjustment – Unfixing).
(4) Fix the special tool adaptor (Figure 57).
(5) Fix the compression special tool adaptor (Figure 57).
Figure 57 Valve Spring/Oil Seal

1-Special tool 3-Special tool adaptor
2- Special tool adaptor 4-Compressed air hose

(6) Unfix the spark plug (Figure 58).

(7) Turn the crank shaft until the
cylinder piston reaches the upper limit of
the first cylinder.
(8) Fix the spark plug adaptor and apply
90-120 psi air onto the cylinder (Figure
57).
(9) Use the special tool adaptor. (Figure
57) Compress the valve spring and fix
the lockpin.
(10) Release the valve spring tensioner
and take out the valve spring retaining
plate and valve spring. Figure 58 Special Tool Protective Cover
(11) Unfix the valve oil seal/valve spring
seat (Figure 59).
1-Valve oil seal tool

2-Valve
Figure 59 Unfixing the Valve Oil Seal

(12) Replace valve oil seal/spring seat
(Figure 61).
(13) Fix the air spring and spring seat.
(14) Use the special tool adaptor,
compress the valve spring and fix the
lockpin.
(15) Release the valve spring tensioner.
(16) Repeat the above steps to unfix
other cylinders.
(17) Uninstall the special tool.
(18) Fix the intake and exhaust rocker
arm/rocker arm shaft assembly (see
Engine/Rocker Arm/Adjustment –
Fixing).
Cover – Fixing).
2. Valve spring and valve oil seal
(unfix the cylinder cover).

Unfixing the valve spring

(1) Compress the spring with special
tools.
(2) Spring compression adaptor (Figure
60)
1-Special tool;
2-Special tool
Figure 60 Fixing/unfixing the Valve
Spring
(3) Unfix the valve lockpin (Figure 61)

(4) Release the valve compression spring
and take out the valve spring retaining
plate and valve spring.
(5) Unfix the valve oil seal/valve spring
seat (Figure 59).
(6) Replace valve oil seal/valve spring
seat.
(7) Fix the valve spring and valve spring
retaining plate.
(8) Compress the valve spring with
special tools (Figure 60).
(9) Fix the valve lockpin.
(10) Release the valve compression
spring.
(11) Repeat the above steps for the
remaining valve oil seals.
1-Lockpin
2-Valve spring seat
3-Valve spring
4-Oil seal seat/valve seat
5-Cylinder cover
6-Intake valve
7-Exhaust valve
Figure 61 Valve/Oil Seal/Spring

3. Checking
Check the spring after the valve has been
unfixed, repaired or replaced (Figure 62).
For example: the valve spring’s
compressed length is 38mm. Check with
a special tool (see Engine – Description).
1-Valve spring special tool
Figure 62 Valve Spring Test

Eight. Intake/exhaust valves and valve
seat
1. Valve and valve seat surface
treatment
It is applicable for all valve and valve
dimensions and angles.
(1) Use proper mechanical tools to adjust
the valve.
(2) Please check the remaining edges
after the valve has been adjusted (Figure
63). The intake valve edge shall not be
smaller than 0.79mm.
The exhaust valve edge shall not be
smaller than 1.19mm and replace if not
so.
1-Valve surface
2-Valve edge height
Figure 63 Intake and Exhaust Valve

(3) After the valve seat is worn out and Surface
can’t be used, its angle and width must
be repaired. Or the cylinder cover must
be replaced.
(4) Use proper mechanical tools to repair
and adjust the valve seat.
(5) The repair and adjustment values of
the valve seat must be correct.
(6) Measure the valve conduit and valve
seat with a dial indicator and the total
radial run-out shall not exceed 0.051mm.
(7) Check the sealing of valve seat.

(8) The thickness of appropriate intake

and exhaust valve seats is 0.75-1.25
(Figure 64).
1-Seat thickness
2-Valve surface angle
3-Valve seat angle
4-Valve contact area
(9) After grinding the valve seat, check

the valve tip and cylinder cover surface
dimension and measure the valve height Figure 64 Valve Surface and Oil Seal
(A) (Figure 65). Valve specifications
(see Engine – Specifications).
(10) Measure the height (B) of valve
spring (Figure 65) (see 9 Engine –
Criteria).
1-Spring
2-Valve spring seat/oil seal
3-Cylinder cover surface
A-Valve height as indicated
B-Valve spring height
Figure 65 Valve Height as

indicated/Valve Spring Height

Section Six Engine Cylinder Body Components
One. General Description

The cylinder body is made of cast iron components (Figure 66)
Figure 66 Engine Cylinder Body and Crank Shaft
1-Main bearing cover bolt 5-Crank shaft

2-Main bearing cover bolt 6-Upper crank shaft bearing shell
3-Integrated main bearing cover 7-Cylinder body
4-Lower crank shaft bearing shell

Two. Cylinder checking

1. Checking
(1) Clean all holes on the cylinder and
check for any leakage.
(2) Fix the new engine oil filter (see
Engine-Troubleshooting Steps-Engine
and Engine Oil).
(3) Check for any cracks on the cylinder
surface.
(4) Check the evenness of the cylinder Figure 67 Cylinder Model
surface. The grading shall be less than
0.1mm or the cylinder body shall be
replaced.
2. Cylinder diameter
Note: measure the cylinder diameter
and the temperature had better be 21
℃ (70 F) during measurement
Measure the radial run-out of the
cylinder surface with a dial indicator
(Figure 68) (see Engine-Description).
The cylinder’s measured values of A and
B (Figure 68) shall be 10mm for the top
and bottom (see Engine-Specifications). Figure 68 Checking the Cylinder
Three. Crank shaft bearing shell

1. General description
Note: the upper and lower bearing
shells are not interchangeable.
1-Upper crank shaft bearing shell

2-Thrust bearing
3-Lower crank shaft bearing shell
Figure 69 Crank Shaft Bearing Shell
Cover
Crank shaft
1-Crank shaft
2-Sprocket wheel
Figure 70 Crank Shaft

2. Troubleshooting steps for crank

shaft axial clearance
(1) Fix the dial indicator onto the engine
body as follows (Figure 71).
(2) Move the crank shaft
(3) Calibrate the zero value of the dial
indicator
(4) Move the crank shaft and observe the
dial indicator reading. Reading
description (see Engine-Specifications).
3. Unfixing
(1) Unfix the engine assembly off the car
(see Engine-Unfixing). Figure 71 Checking the Radial Run-out
(2) Detach the axle shaft off the engine. of the Crank Shaft
(3) Unfix the clutch and pressure plate to
take out the flywheel.
(4) Unfix the crankshaft rear oil seal (see
Engine/Engine Cylinder/Crank Shaft
Engine Oil Seal-Rear-Unfixing).
(5) Fix the engine onto an appropriate
service platform.
(6) Unfix the right engine bracket (see
Engine/Engine Support/Engine Bracket-
Unfixing).
(7) Unfix the crank shaft shock absorber
(see Engine/Engine Body/Shock
absorber-Unfixing).
(8) Unfix the timing chain (see
Engine/Valve Timing/Timing
Belt/Sprocket Wheel and Chain-
Unfixing).
(9) Unfix the intake manifold (see
Engine/Manifold/Intake Manifold –
Unfixing)
(10) Unfix the engine oil gauge and
conduit.
(11) Unfix the engine oil sump (see
Engine/Lubrication/Engine Oil Sump –
Unfixing).
(12) Unfix the engine oil pump bracket
pipe (Figure 72).

1-Fittings
2-Engine oil pump bracket
3-O ring
(13) Unfix the crank shaft position Figure 72 Engine Oil Pump Bracket Pipe
sensor
(14) Mark on the connecting rod cover
in ink.
(15) Unfix all the connecting rod bolts
and bearing covers and take care to
protect the surfaces.
Note: do not reuse the connecting rod
bolts.
(16) Unfix all main bearing covers and
crank shaft cover plates.
(17) Slightly strike the cover plate from
the cylinder body with a wooden stick to
release the pin.
(18) Take out the crank shaft bearing
shell from the pin evenly.
(19) Take the crank shaft out of the
cylinder body and make sure that the
bearing shell is not damaged.
4. Checking
The limit of the crank shaft bearing shell
is 0.025 and 0.305 in the case of
overhaul. Figure 73 Measure the Crank Shaft
Collar
5. Fixing
(1) Fix the main bearing cover and
lubricate the cylinder body (Figure 74).
(2) Clean the engine oil path.
1-Upper crank shaft bearing shell

2-Thrust bearing
3-Lower crank shaft bearing shell Figure 74 Crank Shaft Bearing Shell

(3) Fix the crank shaft bearing and crank

shaft.
(4) Apply sealant onto the cylinder body
(Figure 75).
(5) Fix the bearing shell cover onto the
engine.
(6) Screw on the main bearing cover
bolts and add engine oil for lubrication.
(7) Screw on main bearing cover bolts.
(8) Screw on upper cylinder body bolts.
Figure 75 Main Bearing Cover Oil Seal
(9) Clean three integrated bearing cover

bolts and fix them onto the cylinder
body (Bolt 11, 17, 20) (Figure 76).
Figure 76 Screwing Sequence for the

(10) Clean the remaining main bearing Main Bearing Cover
cover/integrated bearing cover bolts.
(11) Main bearing cover/integrated
bearing cover sequence (Figure 76).
•Main bearing cover bolt: 61N.m.
•Integrated bearing cover plate bolt:
30N.m
(12) After fixing the main bearing
integrated bearing cover plate, check the
crank shaft screwing torque which shall
not exceed 5.6N.m.
(13) Check the radial run-out of the
crank shaft (see Engine-Description).
(14) Screw on the connecting rod bolt.
The screwing torque is 26N.m + ¼ turn.
(15) Fix the engine oil bracket pipe.
(16) Fix the crankcase oil tray (see
Engine/Lubrication/Crankcase oil tray –
Fixing)

(17) Fix the engine oil gauge.

(18) Fix the intake manifold (see Engine/Manifold/Intake Manifold – Fixing).
(19) Fix the timing chain (see Valve Timing/Timing Belt/Chain and Sprocket Wheel –
Fixing).
(20) Fix the right engine bracket (see Engine/Engine Support/Engine Bracket).
(21) Special tool, put the engine onto the overhaul table.
(22) Fix the crank shaft rear oil seal (see Engine/Engine Cylinder Body/Crank Shaft Rear
Oil Seal – Fixing).
(23) Fix the flywheel and clutch pressure plate.
(24) Fix the engine axle shaft.
(25) Fix the engine assembly (see Engine-Fixing)
6. Unfix the front crank shaft engine oil seal
(1) Unfix the timing sprocket wheel cover (see Engine/Valve Timing/Timing Chain
Cover – Unfixing).
(2) Unfix the engine oil seal with proper tools.
Fixing
(1) Fix the front crank shaft engine oil seal onto the timing chain cover with special tools.
(2) Fix the timing chain cover (see Engine/Valve Timing/Timing Chain Cover – Fixing).
7. Unfix the rear crank shaft engine oil seal
(1) Unfix the axle shaft (see 21 Gearbox/Axle Shaft/Manually – Unfix).
(2) Unfix the clutch pressure plate.
(3) Unfix the flywheel.
1-Rear crank shaft oil seal

2-Cylinder body
3-Cylinder body
4-Rear crank shaft oil seal metal
5-Direction
6-Crank shaft
7-Screw driver
9-Screw driver
Figure 77 Metal Cover Oil Seal

8. Fixing
(1) Place the special tools onto the crank shaft (Figure 78).
(2) Fix the crank shaft oil seal.
(3) Use the special tools (Figure 78).
2-Specail tool
3-Installing the special tool
4-Driving handle of the special tool
(4) Fix the flywheel

(5) Fix the clutch and pressure plate
(6) Fix the axle shaft
(See Gearbox/Axle Shaft/Manually – Fixing) Figure 78 Fixing the Rear Crank
Shaft Oil Seal

Section Seven Piston and Connecting Rod Assembly
One. Checking the connecting rod and

bearing
(1) Meausre the connecting rod bearing
clearance with a clearance gauge (Figure
79).
Figure 79 Measure the Connecting Rod

Bearing Clearance
(2) Lubricate the new bolts with engine

oil before screwing them on.
(3) Screw on the bolts.
(4) Screw on the bolts with a torque of
26N.m +1/4 turn. Do not use pneumatic
tools.
(5) Check the connecting rod side
clearance with a gauge (Figure 80) (see
Engine-Specifications). Figure 80 Measure the Connecting Rod
Side Clearance
Two. Check the cylinder cover and
piston
1. Measuring
Clean and blow dry the piston and
cylinder. Measure the piston diameter in
90 degree position, or about 14mm (see
Figure 82 for measurement position).
Figure 81 Check the Cylinder
1-Piston diameter
2-14mm (9/16 in.)
Figure 82 Measurement Position of

Piston

2. Unfixing
(1) Please mark the crank shaft bearing
cover in ink before the piston is unfixed
(Figure 67).
(2) The piston and connecting rod must

be unfixed and turn the crank shaft to put
the connecting rod in the center. Figure 83 Mark of the Connecting Rod
(3) Unscrew the connecting rod bolts. Big End and Cylinder
(4) Install connecting rod conduit special
tools, protect the crank shaft surface
(Figure 83) and carefully press the piston
connecting rod assembly to the cylinder.
(5) Uninstall the special tool, connecting
rod conduit and screw on the bearing
cover bolts.
1-Special tool connecting rod conduit
3. Fixing Figure 84 Connectring Rod Conduit

(1) Fix the piston ring onto the piston
(see Engine/Engine Body/Piston ring –
Fixing).
(2) Turn the crank shaft and connecting
rod and lubricate the connecting rod.
(3) Fix the bearing cover onto the
connecting rod.
(4) Fix the special tool of connecting rod
guide onto the cylinder body (Figure 84).
(5) After fixing the piston and
connecting rod, make sure that the
compression clearance is correct.
(6) Pour clean engine oil into the piston
and ring.
(7) Use the special tool to compress the
piston ring.

(8) Fix the piston onto the cylinder and

mark accordingly (Figure 85).
(9) Fix the piston into the cylinder
together with the connecting rod.
(10) Unfix the conecting rod special tool.
(11) Fix the connecting rod lower
bearing cover with a torque of 26N.m
+1/4 turn.
1-Mark
2-Compression ring
3-Connecting rod conduit special tool Figure 85 Fixing the Piston/Connecting
4. Checking the piston ring clearance Rod
(Figure 86)
1. Clearance gauge
Figure 86 Piston Ring
1. Clearance gauge
Figure 87 Piston Ring Side Clearance
(1) Check the piston side clearance

(Figure 87) (see Engine-Specifications).
5. Unfixing
(1) Use an expander to unfix the upper
and middle piston rings (Figure 88).
Figure 88 Fixing/Unfixing the Piston

Ring

(2) Unfix upper/lower engine oil ring

side beam.
(3) Clear away the accumulated carbon
on the piston (Figure 89).
1-Piston ring
2-Piston ring
3-Side beam
4-Engine oil ring
5-Engine oil expander
Note: fix the piston ring
Figure 89 Fixing the Piston Ring
1-Side beam
Figure 90 Piston Ring

(4) Fix the the second and the first piston
rings (Figure 90).
(5) Fix the piston ring (Figure91).
1-Lower side beam

2-First piston ring
3-Upper side beam
4-Second piston ring
Figure 91

Section Eight Engine Lubrication System
One. Composition of Lubrication System
Figure 92 Composition of Lubrication System
Two. Engine Oil Pump

1. Sturcture
1-Timing chain cover oil seal

2-Engine oil pump
3-Pressure safety valve
Figure 93 Engine Oil Pump Structure

2. Engine oil pressure test

(1) Unfix the engine oil pressure switch
(Figure 94).
(2) Fix the engine oil pressure gauge.
(3) Heat up the engine to normal
working temperature.
(4) Monitor the pressure at 3,000rpm.
See Specifications.
1-Engine oil filter cover

3-Engine oil pressure switch
4-Oil ring
Figure 94 Engine Oil Filter

Three. Engine oil filter
1. Unfix the engine oil filter element
a) Continuously turn the engine oil filler
cover and take out the oil filter element
(Figure 95).
b) Unfix the engine oil filter (Figure 95).
c) Unfix the used O-ring.
1-Rubber seal
2-Engine oil filter element.
3-Central tube
4-Spring
5-O-ring
6-Cover
7-Relief valve
8-Central hole
9-Oil pipe
Figure 95 Engine Oil Filter

2. Fixing the engine oil filter element

(1) Fix the new O-ring (Figure 95).
(2) Fix the new engine oil filter element
(Figure 95).
(3) Fix the engine oil seal.
(4) Screw tight the engine oil filter cover
(5) Add 4L of engine oil.
(6) Start the starter and check for any oil
leakage. Figure 96 Engine Oil Filter
Four. Engine oil filter Engine oil Engine oil

1-Engine oil pressure switch filter element filter element
2-Safety valve oil outlet pipe pressure spring
3-Check valve
4-Seal
5-Relief valve Engine oil
filter
element
Relief valve
switch
Engine oil filter internal oil circuit spring
diagram
• The oil is pumped to push open the
check valve and into the filter where Safety Check
valve valve
it goes through the filter element into
the main pipeline.
• In the case of clogged filter elment,
the engine oil will push up the filter
element to actuate the relief valve,
Relief
which opens and reduces the engine valve
oil pressure. And then the engine oil
Crankcase Main Engine oil
pressure switch is actuated and the oil tray pipeline pump
engine oil flows onto the crankcase
oil tray; meanwhile, the engine oil
pushes open the safety valve to flow
directly into the main pipeline and
the crank shaft and cylinder cover
assembly can still be lubricated.
1. Unfixing
(1) Jack up the car
(2) Detach the engine oil pressure switch
fittings.
(3) Unfix the engine oil filter (see 9-
Engine/Lubrication/Engine Oil Filter –
Unfixing).

(4) Unfix the engine oil filter fittings off

the cylinder body.
(5) Take out the engine oil filter.
2. Fixing
(1) Check and clean the sealing surfaces
of engine oil filter.
(2) Replace the engine oil filter seal
(Figure 97).
(3) Fix the engine oil bracket fittings
(4) Fix the engine oil filter (see 9-
Engine/Lubrication/Engine Oil Filter –
Fixing).
(5) Connect the engine oil pressure
switch plug.
(6) Lower the car.
(7) Start the engine and check for any
leakage.
(8) Shut off engine and check engine oil
level.
1-Engine oil chamber Figure 97 Engine Oil Filter

2-Engine oil filter chamber
3-Engine oil pressure switch
4-Seal
Five. Engine crankcase oil tray

1. Unfix the crankcase oil tray
(2) Jack up the car
(3) Unfix the front right wheel.
Figure 98 Compressor Lower Bracket
(4) Unfix the guard board of the driving

belt.
(5) Drain the engine oil.
(6) Unfix the lower bracket of the
compressor (Figure 98).

(7) Unscrew the clutch subpump set

bolts (Figure 99).
(8) Unfix the crankcase oil tray fittings.
(9) Unfix the crankcase oil tray.
Figure 99 Clutch Subpump
2. Fixing the crankcase oil tray pad.

(1) Clean the crankcase oil tray and the
sealing surfaces.
(2) Replace new engine oil pad.
(3) Fix the crankcase oil tray (Figure
100).
Figure 100 Crankcase oil tray and Pad

(4) Fix the crankcase oil tray fittings
(Figure 101) with a torque of 31N.m.
(5) Screw on the clutch subpump bolts
(Figure 99).
(6) Fix the air compressor lower bracket.
(7) Fix the new driving belt guard board.
(9) Lower the car.
(10) Add 4L engine oil.
(11) Fix the storage battery cathode.
Figure 101 Screwing Sequence of the

Crankcase Oil Tray Bolts
Six. Engine oil pump strainer

1. Unfixing
Unfix the timing chain (see
Engine/Valve Timing/Valve Timing
Cover – Unfixing)
2. Fixing

Fix the engine oil chain cover (see

Engine/Valve Timing/Timing Chain
Cover – Fixing)
3. Engine oil pump – unfixing
(1) Unfix the crankcase oil tray (see
Unfixing).
(2) Unfix the engine oil pump bracket
fittings (Figure 102).
(3) Unfix the engine oil pump bracket.
1-Fittings
2-Engine oil pump bracket
3-O-ring
4. Fixing
(1) Clean the sealing surfaces.
(2) Replace the O-ring (Figure 102). Figure 102 Engine Oil Bracket
(3) Fix the oil pump bracket with a
torque of 12N.m.
(4) Fix the crankcase oil tray (see
Unfixing).
Section Nine Engine Cooling System

Traditional water-cooled forced-circulation water-cooling system is adopted for A15 car.

The power steering pump is also fixed onto the water pump and driven by the same
transimmsion shaft. In this system, the water pump pressurizes the cooling fluid and
forces it to circulate through the engine. The water pump is a centrifual pump and driven
by the driving belt.
One. Fixing/unfixing the heat radiator

1. Fixing the heat radiator
- Screw the two air deflectors onto the radiator with tapping screws using a torque of 6-
7N.m.
- Fix the radiator onto the front beam.
- Fix the tensioner onto the radiator and screw the bolts of the left and right tensioners
with a torque of 10 + 2N.m.
2. Fixing the expansion tank and expansion tank cover
- Fix the expansion tank and screw on two double-end bolts with a torque of 10 + 1Nm
- Fix the protective cover
- Screw fast the expansion tank cover
3. Fixing the water pipe
- Clamp the elastic snap hoop with a special tool and fix it onto corresponding water pipe.
- Clamp the elastic snap hoop with a special tool and fix the water pipe onto the
corresponding fitting; release the special tool and clamp the elastic snap loop where
appropriate on the water pipe.
Note:
1. The snap hoop shall be 5mm±2mm away from the water pipe outlet.
2. Do not clamp the elastic snap loop on the water pipe in an inclined manner.
Two. Fixing/unfixing the heat radiator fan

1. Unfixing
- Unfix the wire connected to the wire harness.
- Unscrew the bolts of the radiator
- Take off the radiator fan
2. Fixing

- Align the fixing holes in the fan with the fixing holes in the radiator and screw on the
bolts.
- Plug in the wire harness.
Three. Fixing/unfixing the water pump and power steering pump assembly
1) Detach the storage battery cathode.
2) Drain the cooling fluid of the cooling system.
3) Unfix the driving belt (see Fixing/Unfixing the Driving Belt)
4) Unfix the power steering pump and its attached hoses and put them aside.
5) Unfix the power steering pump bracket.
6) Release the water pump set bolts and then unfix the water pump and its O-rings.
Figure 103 Water Pump Set Bolts

Four. Adding the cooling fluid
- Add the mixed cooling fluid into the expansion tank (proportioning ratio is 50% glycol
+ 50% soft water)
- The cooling fluid level shall be between the “max” and “min” marks of the expansion
tank.
- The working temperature ofthe cooling fluid shall not be lower than -35℃, failing
which the content of glycol shall be increased as appropriate. But the glycol content shall
not exceed 60%.
Five. Draining the cooling system

1. Fill the system with water and run the engine until the radiator’s upper hose becomes
hot.
2. Drain the water in the system. For that purpose, unfix the upper water pipe’s lower end
of the radiator and refix the pipe and plug after the water is drained.

3. Take off the expansion tank cover (take the

flange and pull open the cover)
4. Add eligible cooling fluid until the fluid level
reaches the “FULL” mark and then put on the
cover.
5. Screw off the exhaust plug on the warm air
heater’s water outlet pipe that is connected to the
engine to bleed the air in the system as the figure
shows. Add eligible cooling fluid into the system
through the radiator water filler. Screw on the
exhaust plug when the cooling fluid starts to
overflow.
Figure 104 Position of the Exhaust

Plug
6. Run the engine with the expansion tank cover taken off. When the radiator’s upper
hose becomes hot, slowly add cooling fluid into the radiator until full.
7. Shut off the engine and put the expansion tank cover in place.
Note: the water pressure cover on the left of

the engine is for water pressure adjustment.
Do not take it off or add cooling fluid
through it.

Sestion Ten Air Intake and Exhaust Systems of the Engine
One. Unfixing the air intake system attachments

1. Fixing the air filter
- Fix the air filter where appropriate on the car body with the three fixing holes set onto
the car body bracket.
- Screw on the bolts with a torque of 10±2Nm.
2. Fixing the air intake hose
- Connect the air intake hose to the air filter and the throttle body.
- Screw on the two worm snap hoops (the screwing torque shall be 2.5±0.5Nm in the
case of 12mm-wide worm snap hoop and 1.5±0.2Nm in the case of 9mm-wide snap
hoop) for connection;
- Fix the crank case’s ventilating hose with the elastic snap hoop.
Two. Fiixng/unfixing the air intake manifold.

1. Unfixing
(1) Steps for releasing the fuel system pressure (see Fuel System/Fuel Conveyance –
Troubleshooting Procedure).
(3) Unfix the air intake hose of the throttle.
(4) Detach the plugs of the following sensor.
Camshaft position sensor Engine oil pressure sensor

MAP sensor (Figure 100) Crank shaft position sensor (Figure 101)
Spray nozzle sensor (Figure 99) Electronic throttle Figure 102)
Knock sensor Water temperature sensor
Generator

Figure 105 Spray Nozzle Plug Figure 106 Sensor
Figure 107 Crank Shaft Position Sensor Figure 108 Throttle Body
(1) Unfix the engine oil gauge

(2) Unfix the vacuum hose of the throttle.
(3) Unfix the fittings of the air manifold and unfix the air intake and exhaust manifolds.
2. Fixing/unfixing the air intake manifold

(1) Clean the manifold sealing surface.
(2) Check the replace air intake manifold seals.
(3) Fix the air intake manifold and fittings with a
torque of 26N.m (Figure 109).
(4) Connect the vacuum pipeline to the throttle.

(5) Fix the engine oil gauge.
(6) Connect the following sensors.
Camshaft position sensor
Figure 109 Screwing Sequence of
the Air Intake Manifold

Oil spray nozzle sensor (Figure 105)

Knock sensor
Crank shaft position sensor (Figure 107)
Electronic throttle (Figure 102)
Starter
MAP sensor (Figure 106)
(7) Fix the throttle air manifold
(8) Connect the storage battery cathode fittings.
Three. Fixing the acceleration transmission mechanism

1. Fix the accelerator pedal.
2. Screw on the limit screws of the accelerator pedal.
- Fix the pressure plate onto the limt screw of the accelerator pedal.
- Screw the accelerator pedal limit screws onto the car floor with a torque of 10±1Nm.
3. Fix the accelerator pedal cable.
- Fix the rubber jacket onto the car body front guard board.
- Lead the accelerator pedal cable through the rubber jacket and snap it in place.
- Fix the accelerator pedal cable hook into the pedal glue.
- Fix the other end of the pedal cable onto the throttle rocker arm.
- Adjust the tension of the pedal cable.
Note: while adjusting the accelerator pedal cable tension, please make sure that the
accelerator pedal is running idly to a certain extent and the limit screw assembly
works effectively at full speed (or the accelerator pedal can be stepped down to
touch the limit screw assembly).

Four. Fixing/unfixing the air exhaust manifold

1. Unfixing
(2) Detach the ignition coil’s high-voltage cables.
(3) Detach the ignition coil.
(5) Detach the exhaust pipe off the exhaust
manifold.
(6) Unscrew the bolts of the heating guard board
(Figure 110).
(7) Lower the car.
(8) Screw off the bolts of the heater board on the
exhaust manifold. Figure 110 Heating Board Bolt
(9) Screw off the exhaust manifold bolts and take
out the exhaust pipe.
2. Cleaning
Clean all the sealing surfaces of the exhaust manifold.
Figure 111 Exhaust Manifold,

Spacer Plate and Cylinder Gasket
3. Fixing
(1) Clean the cylinder gasket surface.
(2) Fix the exhaust manifold gasket and set bolts (Figure 111).
(3) Screw tight the exhaust manifold bolts with a torque of 23N.m.
(4) Fix the exhaust manifold heating plate with a torque of 28N.m.
(6) Screw on the bolts of the startup heating spacer board (Figure 110).
(7) Fix the exhaust manifold onto the exhaust manifold with a torque of 28N.m.
(8) Lower the car.
(9) Fix the ignition coil and spark plug.

(10) Connect the ignition coil and the adaptor plug.

Five. Fixing the exhaust manifold

1. Fix the front exhaust pipe assembly:
- Fixing the oxygen sensor assembly onto the front exhaust manifold assembly with a
torque of 45±4.5Nm.
- Put the exhaust pipe gasket in place and fix the front exhaust pipe assembly onto the
exhaust manifold.
- Screw on the four M8 bolts with a torque of 30±3Nm.
2. Fixing the three-way catalyst reactor

- Connect the three-way catalyst reactor assembly to the flange of the front pipe assembly
with two M8 bolts and two M8 flange nuts and fix the gasket. The screwing torque is 30
±3Nm.
3. Fixing the rear muffler
- Fix the stop buffer onto the rear muffler and hitch the pipe clamp onto the opening of
the rear muffler’s front pipe.
- Fix two hooks onto the welded bolts of the car body and screw them tight with two M8
locknuts with a torque of 30±3Nm.
- Connect the rear muffler to the car body with two lugs and two rhomboid hanging
blocks.
4. Fixing the front muffler
- Fix the front muffler between the three-way catalyst reactor and the rear muffler.
- Fix the pipe clamp assembly.
- Screw on all piple clamps and pipe clamp bolts with a torque of 30±3Nm.
Note:
a. The front muffler is about 18mm displaced from the center of the intake and exhaust
pipes. Adjust the front muffler during fixing to ensure that the clearance between the
front muffler and the passage heat-insulating plate is bigger than 10mm.
b. The pipe clamp must not be fixed onto the exhaust pipe in an inclined manner.
c. The exhaust pipe extension surface must be 1-4mm away from the pipe clamp surface.

5. Fixing the exhaust pipe bracket

- Fix the exhaust pipe bracket.
- Screw tight the four M8 locknuts with a torque of 12±1Nm.
Note: Method for checking leakage in exhaust system fittings and method for adjustment:
Check the leakage in exhaust system fittings after the engine has been warmed up for a
while. Slight leakage is allowed (except the fittings of exhaust manifold and front pipe
assembly), or the engine does not vibrate and no flopping noise is heard from the fittings.
If that is not the case, you may release the pipe clamp on the fittings a little bit, make
some turns, adjust the pipe clamp and screw it tight.

Eleven. Generator and Starter
One. Fixing/unfixing the storage battery

1. Unfixing
- Disconnect the wire to the storage battery cathode;
- Disconnect the wire to the storage battery anode;
- Screw off the set nuts of the storage battery pressure plate;
- Take off the pressure plate;
- Unfix the storage battery.
2. Fixing
Contrary to the unfixing sequence
Two. Structure of the AC generator

1. External structure
2. Internal structure
Exploded View of Generator

1-Anti-interference capacitor; 2-Terminal W; 3-Gasket; 4-
Belt pulley; 5-Generator bearing cover; 6-Generator driving
end bearing; 7-Rotor; 8-Brush end bearing; 9-Stator; 10-
Element board (diode board); 11-Generator housing; 12-
Voltage regulator

Generator Structure
1-Connecting bolt; 2-Rear end cover; 3-Element board assembly; 4-
Anti-interference capacitor; 5-Slide ring; 6, 19-Fully-closed bearing;
7-Rotor shaft; 8-Brush; 9-Magnetic field binding post; 10-Output
binding post; 11-Voltage regulator; 12-Brush braket; 13-Magnetic
pole; 14-Stator winding; 15-Stator iron core; 16-Fan; 17-V belt
pulley; 18-Nut; 20-Magnetic field winding; 21-Front end cover; 22-
Stator slot wedge; 23-Capacitor plug; 24-Rectifier diode; 25-
Excitation diode; 26-Brush bracket retainer
Three. Precautions during maintenance

In order to avoid damaging the AC generator on the car, some precautions must be taken
into consideration regarding the generator assembly.
1) For whatever reason the storage battery is unfixed, the polar connection must be
correct when it is refixed, failing which the unidirectional rectifier may be damaged.
2) When a backup storage battery is used to assist the startup, make sure that the anodes
are connected to each other and the cathode of the backup storaeg battery shall be
connected to the properly working ground terminal on the engine of the car to be started.
3) Do not use a quick charger as the backup storage battery to assist in the startup.
4) When the quick charger is used to charge the storage battery, be sure to detach the
storage battery cable.
5) Do not try to polarize the AC generator.
6) Check if the diode is electrified. Do not test with a load bigger than 12W.
7) Do not create any short circuit or ground circuit for any terminals of the AC engine.
8) Consider the matching between the polarities of the storage battery, the AC generator
and the voltage regulator before making any electric connections with the power supply
system.
9) Do not keep the AC generator circuit open. Make sure that all connections in the
circuit are clean and have a good contact.
10) Disconnect the ground wire of the storage battery during maintenance of any
electrical parts.
11) The storage battery must be disconnected during welding on the car.
Four. Installing the generator

1. Fixing the geneartor bracket:

- Fix the double-end bolts onto the cylinder cover.
- Fix the generator bracket.
- Screw tight the flange nuts on the double-end
bolts as well as the cylinder bolts with a torque of
40±4Nm.
2. Fixing the generator and tensioner assembly:
- Screw the generator onto the bracket with one
M8 inner hexagonal column bolt with a torque of
23±2Nm.
- Screw the tensioner assembly onto the generator
bracket with three M8 inner hexogonal column bolts with a torque of 23±2Nm.
- Fix the driving belt and pull out the pins of the tensioner assembly.
Note: Aligning the driving belt and the tensioner assembly.
- Turn the generator crack shaft belt pulley with a pair of spanners and turn the driving
belt for at least one turn.
- Observe the alignment of the driving belt and the tensioner. If the driving belt center
goes beyond the tensioner assembly center, unfix the tensioner assembly and adjust with
a gasket.
Five. Fixing/unfixing the starter

1. Unfixing
Disconnect the storage battery cathode cable
from the left bracket.
Note: the insulating rubber guard ring on
the cable’s ground terminal shall be placed
onto the column bolt to avoid any
accidental grounding of the storage battery
cathode cable.

Unscrew the nuts of the storage battery cable and

then disconnect the starter wires.
Unplug the connector.
Unscrew the two bolts of the starter and the
gearbox assembly.
Unfix the starter off the car.
2. Fixing
Screw on the starter connecting bolts.
Screw on the connecting bolts with a torque of
54N·m (401bf·ft).
Reconnect the starter wire and screw on the nuts with a torque of 10N·m (901bf·in).
Replug the connector.
Section Twelve Fuel System

One. Precautions for the maintenance of the fuel system

Safety is most important factor during not only the maintenance of the fuel system but
also other types of maintenance. Any maintenance or repair ignoring the safety
regulations will possibly result in severe personal injury or even death. Respect the
following rules and guidances to safely and effectively finish the maintenance and
inspection of the fuel system of the car.
1) Do remember to disconnect the storage battery cathode cable to avoid any possible
fires and personal injury unless the maintenance and test precedures require the use of
storage battery.
2) Before disconnecting any fuel system component (spray nozzle, fuel conduit and
pressure regulator, etc), pipe fitting or fuel pipe connection, be sure to relieve the
pressure of the fuel system, during which special care shall be taken to avoid exposing
skin, face and eyes to the oil. Please accept any advice available as the fuel under
pressure may penetrate skin or any other part of the body.
3) Before disconnecting pipe fittings or connections, remember to reel a handerchief or
cloth on the pipe fittings or connections to absorb the overflowing fuel. Be sure to wipe
away all overflowing fuel on the starter surface and that all cloth and hankerchieves
soaked with fuel shall be stored in appropriate waste bin.
4) Be sure to provide a dry chemical extinguisher (Class B) near the worksite.
5) No fuel or fuel vapor is allowed where there is spark or open fire.
6) Be sure to use a pair of safety spanners to release or fasten the fittings of the fuel pipe
to avoid any unnecessary pressing or twisting of the fuel pipe. Do observe the
requirements on torque.
7) Be sure to replace the aging O-ring of the fuel pipe with a new one. Do not replace any
fuel pipe with a fuel hose.
Two. Relieve the pressure of the fuel system

Caution: The fuel spraying system maintains a certain pressure even after flameout.
Therefore, the pressure must be relieved before any pipeline is unfixed, failing which a
fire or personal injury is possible.
1) Disconnect the terminal of the storage battery cathode cable where the left shock
absorber bracket is located.
2) Unfix the oil filler hole cap.

3) Unfix the oil pressure gauge hole cap on the fuel pipe.
4) Place the open end of the special equipment of the fuel pressure relief hose or similar
equipment into the approved gas container. Connect the other end of the hose to the oil
pressure gauge hole. The pressure will be relieved through the hose and the gas container.
Three. Fixing/unfixing the fuel system

1. Fixing the fuel tank assembly
- Fix the fuel tank assembly.
- Screw on the two M6 taping screws on the fuel tank inlet.
- Fix the three fuel tank fixing belts and screw on five M8 bolts.
- Screw on five M8 bolts (the screwing torque is 30±2Nm) and two M6 taping screws
(the screwing torque is 4.5±0.5Nm)
- Fix the oil filler hole cap and steel wire check ring.
- Connect the inlet and outlet pipe of the fuel tank and clamp the oil pipe snap hoop with
a special tool.
Note: the clearance between the fuel tank assembly and the rear wheel casing’s
inner plate must be bigger than 12mm.
2. Fixing the fuel filter:

- Fix the fuel filter assembly into the fuel filter
protective casing.
- Connect the inlet and outlet pipes on both sides of
the fuel filter and clamp the oil pipe snap hoop with a
special tool.
- Screw the protective casing assembly onto the car
floor with two M8 locknuts with a torque of 12±
2Nm.
Note: the clearance between the fuel tank
assembly and the rear wheel casing’s inner plate must be bigger than 12mm.
3. Fixingthe fuel pipe:
- Fix the clamp on the corresponding screw under the car body.
- Install the protective jacket and fix the fuel pipe onto the clamp in the corresponding
place.
- Put on the hose jacket and connect the corresonding oil pipe and hose.

- Clamp the oil pipe snap hoop with a special tool.

Note:
1) The clearance between the fuel pipe (bent) and the rear flange of the front bottom plate
must be bigger than 30mm.
2) Be sure to properly fix the hose jacket of the front bottom plate and the single-tube
clamp; then connect the corresponding oil pipe and hose.
3) Connect the quick tie-in and the corresponding oil pipe with a snap hoop. The bigger
quick tie-in (9.49) is connected to the outlet pipe of the oil pump and the smaller one
(7.89) is connectd to the return pipe of the oil pump.
4. Fixing the activated carbon canister assembly
- Fix the activated carbon canister assembly.
- Screw tight two M6 taping screws with a torque of 10±1Nm.
- Fix the carbon canister outlet pipe between the throttle and the carbon canister. Tightly
clamp the snap hoop on the exhaust pipe.
5. Fixing the fuel tank cover assembly.
- Fix the fuel tank cover onto the fuel tank assembly.
Chapter Thirteen Troubleshooting on Engine Mechanical Parts

One. General description

Engine troubleshooting can help to target and repair existing troubles, e.g. abnormal
noises or other operational troubles (unstable engine idle speed or flameout).
In the case of some special engine troubles, some additional troubleshooting procedures
have to be carried out other than relying on the troubleshooting flowchart.
The additional troubleshooting procedures include:
1. Testing the cylinder’s compression pressure
2. Checking for the cylinder’s combustion pressure leakage
3. Diagnosing the cylinder cover’s gasket
4. Diagnosing the noise at gear clearance
5. Checking for engine oil leakage
Two. Troubleshooting on the engine mechanical parts

1. Trouble: startup difficulty
Cause Troubleshooting method

1. Test the battery: charge or replace if necessary.
1. Insufficient battery voltage (See Circuit/Storage Battery System –
Troubleshooting)
2. Clean and screw tight the battery wires and
2. Loosened or eroded storage
apply one film of light mineral grease onto the
battery wires
fittings.
3. Test the startup system (see Circuit/Starup
3. Starter faults
System – Troubleshooting)
4. Ignition coil or controller 4. Test and replace if necessary (see relevant
module faults information on troubleshooting)
5. Adjust clearance (see Circuit/Ignition Control
5. Incorrect spark plug clearance
– Specifications)
Continued

6. Clean the system and replace fuel

6. Fuel system pollution
filter. The engine is not started.
7. Test the fuel pump and replace if
7. Defected fuel pump necessary (see relevant information on
troubloshooting)
8. Check if the timing chain suffers any
8. Engine timing errors
improper tooth engagement.
2. Trouble: engine flameout or unstable idle speed

1. (See relevant information on
1. Incorrect mixing ratio of fuel
troubleshooting)
2. Check the air intake manifold, air
2. Air intake manifold leakage
intake manifold gasket and vacuum hose
3. Test and replace if neccesary (See
3. Ignition coil trouble
relevant information on troubleshooting)
3. Trouble: insufficient engine power

1. Clean the spark plug and reset the
1. Dirty spark plug or incorrect clearance
clearance
2. Clean the system and replace fuel filter 2. Dirty fuel system
3. Test and replace if necessary (see
3. Fuel pump trouble
4. Valve timing errors 4. Check the valve timing
5. Cylinder gasket leakage 5. Replace the cylinder gakset
6. Under compression ratio 6. Test the pressure of each cylinder
7. Burned, bent or dented valve 7. Replace the valve
8. Test the exhaust capability (see
8. Clogged exhaust pipe Exhaust System – Troubleshooting and
Testing), replace a new one if necessary
9. Ignition coil troble
4. Trouble: engine flameout during acceleration


clearance
2. Clean the fuel system and replace the
2. Dirty fuel system
fuel filter
3. Burned, bent or dented valve 3. Replace the valve
5. Trouble: engine flameout at high speed

clearance
3. Dirty spray nozzle
4. Clean the fuel system and replace the
4. Dirty fuel system
fuel filter
6. Trouble: abnormal noise of valve

1. Incorrect engine oil level in 1. Check and correct engine oil quantity
the crankcase
2. Incorrect engine oil viscosity 2. Choose the engine oil of proper viscosity
3. (a) Replace the engine oil and filter
3. Low engine oil viscosity (b) Run the engine to normal working conditions
(c) Replace the engine oil and filter again
4. Engine oil under pressure 4. Check and correct the engine oil level
5. Replace the rocker arm and hydraulic tappet
5. Dirty tappet
assembly
6. Worn-out rocker arm 6. Check the oil supply circuit of the rocker arm
7. Overused tappet 7. Fix new rocker arm and hydraulic tappet assembly
8. Worn-out valve conduit 8. Replace the cylinder cover
9. Worn-out valve seat 9. Grind the valve or replace the cylinder cover
10. Failing rocker arm adjustor 10. Replace the rocker arm/hydraulic tappet assembly
7. Trouble: abnormal noise of the connecting rod


1. Insufficient engine oil 1. Check the engine oil level
2. Check the engine oil level, engine oil pump, safety
2. Engine oil under pressure
valve and spring
3. Under viscosity of engine oil 3. Add engine oil of proper viscosity
4. (A) Replace the engine oil and filter
4. Over viscosity of engine oil (B) Run the engine to normal working temperature
(C) Replace the engine oil and filter again
5. Excessive bearing clearance 5. Measure bearing clearance and repair
6. Bluntness of the connecting 6. Replace the crank shaft or grind the surface
rod shaft collar of the crank
7. Vibrating connecting rod 7. Replace the connecting rod
8. Trouble: abnormal noise of the main bearing

1. Insufficient engine oil 1. Check the engine oil level
2. Check the engine oil level, engine oil pump, safety
2. Engine oil under pressure
valve and spring
3. Under viscosity of engine oil 3. Add engine oil of proper viscosity
4. Change engine oil viscosity
(A) Replace the engine oil and filter
4. Over viscosity of engine oil
(B) Run the engine to normal working temperature
(C) Replace the engine oil and filter again
5. Excessive bearing clearance 5. Measure bearing clearance
6. Worn-out thrust bearing 6. Replace the thrust bearing
7. Bluntness of the crank shaft 7. Replace the crank shaft
8. Loosened flywheel 8. Screw tight the bolts
9. Trouble: decreased engine oil pressure


1. Insufficient engine oil level 1. Check the engine oil level
2. Engine oil pressure switch 2. Install new engine oil pressure switch
3. Under pressure of the engine 3. Check the main bearing clearance
oil
4. Clogged engine oil filter 4. Install new engine oil filter
5. Overused engine oil pump 5. Replace the engine oil pump and worn-out parts
6. Under viscosity of the engine 6. Add engine oil of proper viscosity
oil
7. Engine oil pump safety valve 7. Unfix the valve, check the clearance and replace
8. Loosened suction pipe of the 8. Unfix the crankcase oil tray and fix new pipe or
engine oil pump over clearance
9. Deformed or cracked engine 9. Fix new engine oil pump
oil pump cover
10. Excessive bearing clearance 10. Measure bearing clearance and repair
10. Trouble: engine oil leakage

1. Damaged gasket 1. Replace the gasket
2. Loosened fittings and leaked 2. Repair or replace the parts
or damaged metal parts
3. Worn-out engine oil pump 3. Replace
bolts
11. Trouble: burning engine oil or accumulated charcoal on spark plug

1. PVC system trouble 1. Check the system and repair the exhaust control
2. Worn-out or dilapidated 2. Fix new piston ring
piston ring
3. Accumulated charcoal on 3. Fix new piston ring
piston ring groove
4. Overtight piston ring in the 4. Take out the piston ring and check. Replace the
groove piston if it is overtight.
5. Worn-out valve conduit 5. Replace the cylinder cover
6. Damaged valve sealing 6. Replace the sealing parts
Three. Troubleshooting on the cylinder compression pressure

The purpose of testing the cylinder pressure is to identify the troubles of some particular
cylinder. However, the prerequisite is that the storage battery and starter must be in the
normal working mode, or the precision of cylinder pressure measurement will be affected.
(1) Check the engine oil level and add engine oil if necessary.
(2) Start up the car until the engine working temperature is reached. Run the car on an
even road and accelerate the engine for a couple of minutes.
Note: please use special tools (Figure 3) to protect the spark plug conduit when the
spark plug is being taken out.
(3) Take out all spark plugs; check if they suffer any mechanical troubles, overheating
and oil smears and record the cylinder number of the spark plug.
(4) Take out Fuse 7 and 8 off of the engine from the relay box in the front cabin.
(5) Fix the special tool for the pressure gauge fittings into the spark plug hole.
(6) Start the engine until the vacuum gauge reading is at the maximum and record the
pressure of the first cylinder.
(7) Repeat the above procedure and record the pressure values of the remaining cylinders
(8) The pressure value shall not be lower than 689KPA (100PSI) and the pressure of each
cylinder shall not differ from each other by over 25%.
(9) If one or several cylinder pressure values are improper, repeat the above pressure test.
(10) If the pressure value of any cylinder is still lower than the standard value, there must
be something wrong with the cylinder. Measuring cylinder pressure only provides a
reference to engine troubleshooting. To identify the troubles, it is still necessary to
disassemble the engine to find if the cause is under pressure of cylinder.
Four. Cylinder compression pressure leakage test

1. Basic description
The cylinder combustion pressure leakage test provides a proper way to judge the
working conditions of the engine cylinder.
What can be discovered by way of cylinder combustion pressure leakage test includes:
• Exhaust and intake valve leakage
• Water leakage into adjacent cylinder or water pipeline
• Any other troubles caused by combustion/under combustion pressure
Caution: do not take off the pressure cover on the left of the engine when the system is
heated up as hot water may cause severe scalds.
2. Checking steps
• Start the engine until it reaches the normal working temperature and then stop the
engine.
• Clean the spark plug hole with compressed air
• Take out the spark plug
• Take out engine oil filter cover
• Take out compressed air filter
• Compare the test records with the ex-works data
• The minimum and maximum compression pressure for maintenance shall be 483KPA
(70PSI) and 1,379KPA (200PSI) respectively. 522KPA (80PSI) is recommended.
• Test each cylinder as per the instructions provided by the manufacturer. When any
leakage of compressed air from the throttle, exhaust pipe and engine oil filler cap is
heard, please check relevant system problem.
The pressures shall be evenly distributed. No cylinder shall have more than 25% of air
leaked.
For example: if the cylinder is filled with a pressure of 552KPA (80PSI), then the
cylinder pressure shall maintain a minimum pressure of 414KPA (60PSI).
3. Troubleshooting – cylinder cover gasket
There will be leakage in the cylinder cover gasket between adjacent cylinders or water
pipes.
The possible problems which may be caused by the leakage between cylinders include:
Decreased engine power
Engine flameout
Higher fuel cost

The problems which may be caused by leakage of cylinders and water pipes include:
Overheated engine
Reduced cooling water
Too much steam (while smoke) in the exhaust system
Air in the cooling water
4. Sealing test of adjacent cylinders
In order to identify the leakage between adjacent cylinders, a test may be carried out as
per the cylinder combustion pressure. A pressure reduction of 50%-70% will take place
in the case of leakage between adjacent cylinders.
5. Leakage test of cylinders and water pipes
Caution: pay attention to the way of taking off the cooling water cover
When the engine is cooled, take off the cooling water cover, start the engine until the
thermostat is turned on. If there is any reduction in compression pressure, there will be
cooling water in the water pipeline.
How to test the cooling system
Caution: the pressure rises rapidly where the cooling system is measured. There will be
overpressure with the engine operation. So the pressure must be relieved. The maximum
allowable pressure is 138KPA (20PSI).
Fix cooling system checker or other equivalent tool, start the engine and observe the
measured value. If the values of a cylinder fluctuate, then there must be air leakage in that
cylinder.
Chemical test method
Use a chemical equipment to check the cooling system. Please refer to the Instructions
Manual for the testing procedure.
Five. Troubleshooting on impact noise

Similar noises may originate from different parts. So check the following items:
(1) Over or under oil level
(2) When reinstalling the cylinder cover, run the engine at low speed for about 1 hour,
failing which noise may take place.
(3) During this period, stop the engine for several minutes and restart the engine to heat
up the engine to the normal working temperature. Repeat the above steps.
(4) Under engine oil pressure

(5) Cylinder gasket leakage

(6) Air leakage into the engine oil will damage the engine oil pump vanes.
(7) Overused valve conduit
(8) Overused rocker arm shaft
(9) Loosened rocker arm shaft
(10) Tappet failure
Six. Troubleshooting on engine oil leakage

The steps are as follows:
(1) Do not clean or remove the engine oil smears at this moment as it can temporarily
stop the leakage caused by swollen rubber seals.
(2) Increase the solubility of the engine oil (recommended by the manufacturer), run the
engine for 15 minutes and check the engine oil with an oil dipstick. The engine oil must
be bright yellow under illumination. Run for another 15 minutes and check again. The
engine oil must be in a bright color.
(3) Check the quantity of candle powder in the engine with a light, especially where
leakage is suspected. If any oil leakage is discovered, repair immediately.
(4) If no candle powder is detected, drive the car at different speeds for about 15 minutes
and recheck.
(5) If the source of leaked oil can not be found, continue to check for engine oil leakage
as follows:
Remove the PVC valve off the cylinder cover and block the PVC valve. Fix a vacuum
gauge on the vacuum pipeline and adjust the engine oil dipstick.
Note: do not test with a pressure bigger than 20.6kpa (3 PSI).
Gradually increase the air pressure from 1 to 2.5 PSI. When checking the suspected
leakage with soap water, adjust the air pressure as appropriate to achieve the ideal effect
and find the tiny leakage source. Please refer to the Maintenance Manual if any leakage is
discovered. If the leakage occurs around the rear oil seal of the crank shaft, please refer to
the chapters regarding rear oil seal checking.
(6) If no leakage is found, shut off the high-pressure air supply, remove the air chamber,
plugs and covers and fix the PVC valve and new air chamber and follow the following
steps:

(7) Clean any suspected oil leakage with an appropriate solvent. Start the car for about 15
minutes and check the oil leakage with an illuminating light.
Seven. Checking rear oil seal leakage

Sometimes more complicated checking is required when it is difficult to identify the
source of engine oil leakage. The following steps may help to find tiny leakage sources.
If the leakage is located around the rear oil seal of the crank shaft:
(1) Disconnect the storage battery
(2) Jack up the car
(3) Unfix the clutch cover and check if the rear body suffers any leakage with an
illuminating light.
If any leakage is found around the rear oil seal, then unfix the gearbox and check more
carefully.
(A) Foggy engine oil keeps spraying out, which indicates damaged oil seal or crank shaft;
(B) Decrease in leaked air indicates multiple holes in the cylinder body or reduced
precision of the cylinder body surface.
(4) If no leakage is found, then seal the crank case and check for any oil leakage.
Note: the pressure shall not exceed 20.6kPa (3 psi).
(5) If no leakage is discovered, slowly rotate the crank shaft and look for any leakage.
When any leakage is discovered between the crank shaft and oil seal, the crank shaft oil
seal may have been damaged.
Note: please carefully check the crank shaft surface and sealing flange.
(6) Please disassemble the engine for overhaul and more detailed checking.
(7) After the engine leakage source has been identified, replace the damaged component
assembly if necessary.
Eight. Troubleshooting on damaged or worn-out parts

Maintenance methods for damaged or worn-out parts (excluding spark plugs and
camshaft main bearing cover)
Damage or worn-out parts may be repaired (not excluding spark plug and camshaft main
bearing cover). Fix or unfix with special tools so that the original dimension may be
achieved.
Electrical tools can be used for easy installation.

Note: Do not use the starter to start the engine or it may cause damage.
(1) Check the air filter to see if the air intake system and air intake manifold is too dirty.
(2) Disconnect the storage battery cathode.
(3) Suck out the liquid on the spark plug with cloth
(4) Take out all spark plugs and operate the crank shaft with a motor.
(5) Distinguish the liquids in the cylinder (like cooling liquid, fuel, engine oil or others).
(6) Take out all liquids from the cylinder and check for any damage of the engine
(connecting rod, piston, valve, etc).
(7) When repairing the engine or its components, avoid it if necessary.
Note: pay attention to component lubrication during reinstalling.
(8) Fix new spark plugs
(9) Drain the engine oil and unfix the engine oil filter
(10) Fix the new engine oil filter.
(11) Fill in the engine oil of the original engine manufacturer.
(13) Start the engine and check for any leakage.
Nine. Troubleshooting on engine cylinder gasket

Appropriate surface treatment is necessary to ensure the sealing effect of the cylinder
gasket, especially for the cylinder gaskets that use aluminum engine components or
multiple metal layers.
Plastic or wooden cleaning device (Figure 4)
Figure 4 Use Appropriate Surface Treatment Tools

1. Grinder 2. Steel Eraser 3. Shovel

Chapter Two Engine Section One Maintenance Data of The Engine 1. Basic Engine Specifications

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Chapter Two Engine Section One Maintenance Data of The Engine 1. Basic Engine Specifications

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Chery A15 Maintenance Manual

Chapter Two Engine

1. Basic engine specifications

-4- Chery Automobile Co., Ltd.

-5- Chery Automobile Co., Ltd.

-6- Chery Automobile Co., Ltd.

-7- Chery Automobile Co., Ltd.

-8- Chery Automobile Co., Ltd.

Exhaust manifold set bolt: -23N·M

-9- Chery Automobile Co., Ltd.

Section Two Commonly-used Special Tools

Crank shaft belt pulley unfixing tool Camshaft fixing/unfixing tool

Crank shaft shock absorber/ Puller

Valve spring compressor

-10- Chery Automobile Co., Ltd.

Camshaft sprocket wheel fixing spanner Camshaft sprocket wheel fixer

Front crank shaft sealing Handle

Rear crank shaft sealing conduit

Moving frame Engine frame

-11- Chery Automobile Co., Ltd.

Cylinder pressure gauge Dial indicator

Engine support Dial indicator

Cylinder compression pressure adaptor Valve spring tester

-12- Chery Automobile Co., Ltd.

Section Three Unfixing the Engine

One. Unfixing the crank shaft belt pulley

1-Special tool for unfixing the belt

1,2 – Torsion bar fittings

-13- Chery Automobile Co., Ltd.

2. Fixing the upper torsion bar

-14- Chery Automobile Co., Ltd.

1- Right engine bracket

7. Unfixing the left bracket

Figure 6 Left Engine Bracket

-15- Chery Automobile Co., Ltd.

9. Unfixing the left suspension bracket

Figure 7 Upper Bracket Bolt

Figure 8 Left bracket

-16- Chery Automobile Co., Ltd.

10. Left bracket

Three. Unfixing the engine

-17- Chery Automobile Co., Ltd.

(19) Unfix the guard board of the attachmet driving belt.

Figure 9 Fixing/unfixing Positions of the Engine

1-Cable 2-Special tool 3-Wooden stick

-18- Chery Automobile Co., Ltd.

Four. Fixing – Engine Assembly

-19- Chery Automobile Co., Ltd.

-20- Chery Automobile Co., Ltd.

Section Four Timing Chain

One. Valve timing mark

1-Camshaft timing mark

Figure 10 Timing Driving System

-21- Chery Automobile Co., Ltd.

(4) The camshaft sprocket wheel mark

1-Valve chamber cover sealing surface

Figure 11 Camshaft Sprocket Wheel

Figure 12 Camshaft Timing Mark

-22- Chery Automobile Co., Ltd.

(10) Unfix the driving belt tensioner.

1-Front crank shaft oil seal Figure 13 Timing Chain Cover

1-Timing chain cover gasket