MECHANISM OF 2.0NA ENGINE
Contents
1. 9 Dismantle engine oil pump assembly 10 Dismantle the frame assembly under cylinder block and remove the crankshaft and thrust washer 48 MECHANISM OF 2 0NALC ENGINE Lo amz CHERY A21 SERVICE MANUAL MECHANISM OF 2 0NALC ENGINE 7 3 Inspection A i 1 E 1 radial clearance of crankshaft A WA f pr e Ss Clearance Gauge m S i a F vi le aw r ES J S a s un Te K a Clean the journal and bearing bushing i 1 L Fm Fin u b Install crankshaft c Make the length of plastic clearance gauge equal to the width of bearing Then put it on the journal paralleling the axis 49 Zoe aliz CHERY A21 SERVICE MANUAL d Mount the main bearing cap carefully and screw down the bolt with specified torque e Dismantle the main bearing cap carefully f Measure the width at the most bread part of pressed plastic line with ruler on plastic clearance gauge package then get clearance value Standard Value 0 0035 0 034 Replace the new bearing bushing 1f the measured clearance value exceeds the limit value Note Replace the whole group when replacing bearing bushing Selecting method of main bearing bushing By observing the sign on cylinder see the picture we could see 5 As which correspond to bearing bushings respectively There two kinds of signs on this vehicle A and B corresponding to two kinds bushing red one and blue one the color can be recognized on the n2. 4 Replace front oil seal of crankshaft 4 1 Needed tools and auxiliary materials Ratchet wheel and ratchet rod 13 15 17 22 sleeve 13 open end wrench allen wrench engine transmission oil and guide sleeve of crankshaft oil seal 4 2 Process of Replacement 4 2 1 Process of Removal 1 Dismantle the timing belt See replacing the timing belt for details 44 MECHANISM OF 2 0NALC ENGINE Lo SIS CHERY A21 SERVICE MANUAL MECHANISM OF 2 0NALC ENGINE 2 Engage the gear to 5th then press the brake with toes Dismantle the connecting bolt of timing belt pulley and crankshaft with torque wrench Remove the timing belt Torque 130 10 then screw 65 5 3 Pry out the old oil seal with right angled screwdriver carefully Note Be careful in dismantling the oil seal not to damage the oil seal seat ring 4 2 2 Installation 1 Clean the oil seal seat ring and spread transmission oil on the seat ring 2 Spread transmission oil at the seal lip 3 Enclose the guide sleeve of crankshaft oil seal special tool with that oil seal Guide Sleeve of Crankshaft Oil Seal 4 Press the oil seal into oil seal seat ring and knock it to right position with hammer 5 Replacement of oil pump 5 1 Needed tools and auxiliary materials A set of big sleeves a set of small sleeves and a set of open end wrench 45 Zo 5m2 CHERY A21 SERVICE MANUAL MECHANISM OF 2 0NALC ENGINE 5 2 Process of Replacement
3. replace oil pan for details 2 Remove the connecting bolt between engine oil strainer and frame with 10 sleeve wrench total 8 bars 3 Draw out the engine oil strainer carefully 2 2 2 Installation 1 Spin the nozzle of engine oil strainer into the frame carefully 2 Mount the 8 bolts for the strainer and fasten them Note the bolts should be mounted with Le Tai 243 glue Torque 8 3Nm 3 Install oil pan See installation of oil pan for details 33 MECHANISM OF 2 0NALC ENGINE Lo amz CHERY A21 SERVICE MANUAL 3 Replace the piston piston ring piston pin and connecting rod bearing 3 1 Needed tools and auxiliary materials 10 open end wrench 10 15 17 sleeve ratchet wheel and ratchet rod Le Tai 5901 Glue engine oil torque wrench Special tools for installing piston feeler gauge clearance gauge micrometer caliper 3 2 Process of replacement 3 2 1 Process of removal 1 Dismantle the see dismantle the timing belt in the section of replacement of engine timing belt for details timing belt 2 Remove the oil pan see REPLACE OIL PAN for details 3 Remove the cylinder head see removal of cylinder head for details 4 Dismantle the engine oil strainer see the replacement of engine oil strainer for details 5 Loosen the big bolt on connecting rod 6 Remove the connecting rod bearing lower cover Connecting Rod Bearing Lower
4. Hexagonal Flange Bolt 4 Throttle Valve Body Assembly 5 Gasket Throttle Valve Body Assembly 6 Oil injector Assembly 7 Fuel Distribution Pipe Assembly 8 Bracket 15 Lo amz CHERY A21 SERVICE MANUAL ji ON AN JS LA I 1 Intake Valve 2 Valve Oil Seal 3 Valve Spring Seat 4 Valve Spring 5 Valve Spring Retainer 6 Keeper 7 Exhaust Valve 8 Intake Camshaft Assembly 9 Bearing Cap Assembly 10 Control Valve Camshaft Phaser Assembly 11 First Bearing Cap Assembly 12 13 14 15 16 17 18 19 20 21 MECHANISM OF 2 0NALC ENGINE Front Camshaft Oil Seal Exhaust Camshaft Assembly Rocker Arm Assembly Hydraulic Tappet Assembly Stud Bolt 9 Bars Cylinder Head Gasket Temperature Sensor Engine Hanger Cylinder Head Bolt Cylinder Head Assembly Lo aliz CHERY A21 SERVICE MANUAL MECHANISM OF 2 0NALC ENGINE II MAINTENANCE 2 1 Replace intake manifold delivery pipe and oil injector 2 1 1 Needed tools and auxiliary materials Ratchet wheel ratchet rod 10 sleeve and crosshead screwdriver 2 1 2 Process of removal 1 Put the ignition key at the OFF position 2 Loosen the plug of oil injector 3 Remove the connecting bolt between engine oil dipstick and intake manifold 4 Remove the clamp between intake hose and throttle valve body 5 Remove the connecting bolt of throttle valve body and take out throttle valve body Note Because this t
5. to tension the belt and make the finger of tensioner point to the middle of U slot opening Fasten the bolt of tension pulley the fastening bolts of air intake and exhaust camshaft tension pulleys and camshaft Torque 120 5Nm 10 Remove the special timing tool and mount the valve cover the high voltage ignition cable and the timing belt cover CHAPTER 2 ENGINE BODY SECTION 1 WHEEL TRAIN I STRUCTURAL DIAGRAM pf ParName Torque value Nm Bolt Lower Part Of Timing m Front Cover Bolt Upper Part Of Timing Front ae Cover Bolt Upper Part Of Timing Front Ge Cover 8 Washer Crankshaft TimingGear 9 Crankshaft Timing Ger 10 TimingBee u WaterPump 12 Bolt Timing Gear Rear Cover sus 13 TimingGearRearCover N 14 CamshatTimingGer 15 Bolt Camshaft Timing Gear 1208 16 Bolt Timing Tensioner 2727 17 Timing Tensioner a 18 Bolt Timing idlerwheel sos 19 Timingidlerwheel 20 Contactiderwhel PG 10 Lo SIS CHERY A21 SERVICE MANUAL MECHANISM OF 2 0NALC ENGINE II MAINTENANCE 1 Replace upper and lower covers of timing belt 1 1 Needed tools and auxiliary materials Allen wrench 10 13 sleeve ratchet wheel and ratchet rod 1 2 Removal 1 Loosen the five bolts on the upper cover with Allen wrench 2 Remove the upper cover of timing belt 3 Clip the flywheel with flywheel tool Flywheel Tool 4 Remove the crankshaft p
6. 5 2 1 Process of Removal 1 Dismantle the timing belt See removal of timing belt for details 2 Engage the gear to Sth then press the brake with toes and remove the timing belt pulley 3 Dismantle the fastening bolt of oil pump with 10 sleeve and take out the oil pump Torque 8 3NM 4 Pry out the oil seal 5 Clean the seat ring of oil pump 5 2 2 Installation 1 Spread oil on the gasket of oil pump 2 Mount the oil pump in its seat ring Note The bulge of oil pump should be put downwards because the wrong position can not make the bolt be screwed in 3 Mount the oil seal 4 Mount the other parts 6 Replacement of crankshaft rear oil seal 6 1 Needed tools and auxiliary materials A set of big sleeves a right angled screwdriver a small hoist and engine oil 6 2 Process of Removal 1 Suspend the engine assembly from vehicle See suspending of engine vr assembly for details e E 2 Remove the clutch pressure plate 3 For removing the flywheel lock the flywheel with special tool and then screw off the fastening bolt with sleeve wrench 4 Pry the old oil seal with the right angled screwdriver Note Do not damage the oil seal seat ring 46 6 2 Installation 1 Clean the oil seal seat ring Clean the oil seal seat ring with clean oiled gauze 2 Spread the oil at the lip of crankshaft front oil seal Enclose the guide sleeve of crankshaft oil seal speci
7. Cap 34 MECHANISM OF 2 0NALC ENGINE Lo ari iZ CHERY A21 SERVICE MANUAL MECHANISM OF 2 0NALC ENGINE 7 Uplift the connecting rod and the piston with a wooden stem and then remove the connecting rod and piston assembly 8 Remove the piston ring 9 Remove the retainer ring of piston pin and draw out the piston pin Note With large tension the retainer ring may hurt people in the process of removal 3 2 2 Inspection I Check piston 1 Examine the diameter of piston Measure the diameter along the vertical direction to piston pin and at the place 11mm under piston skirt with micrometer caliper Cylinder No Standard Size 33 460 009 3 4620 009 53 4620 009 53 4620 009 Replace with the new one if the part cannot be worn and torn any longer 35 Zoe amz CHERY A21 SERVICE MANUAL 2 Examine the clearance between piston ring and ring groove Clean up the accumulated carbon in the ring groove with piston ring Examine the clearance between piston ring and ring groove with feeler gauge mn Reference Value mm 0 04 0 08 0 01 0 025 Replace with the new one if the examined clearance cannot be worn and torn any longer 3 Inspect the end clearance of piston ring a Put the piston ring at the position 45mm below the top surface of cylinder aperture and push the piston ring into cylinder with piston b Measure the opening with feeler gauge Replace with the new piston i
8. F 2 0NALC ENGINE TECHNOLOGY DATA INSTRUCTION Item Standard Value Cam Height 0 040 Camshaft Camshaft Diameter ry Axial clearance of Camshaft Plane Degree of Lower Surface Cylinder Whole Height Ges Surface Grind Limit Total Grinding Quantity of Cylinder Block and Head Intake Valve Exhaust Valve Intake Valve 5 98 0 008 Valve Stem Diameter Exhaust Valve 5 96 0 008 Intake Valve Fringe Thickness on Top of Valve Seal Bandwidth Exhaust Valve Tilt Angle Intake Valve 107 998 Height Exhaust Valve 106 318 Working Tension in Advance Working Height Kg mm 620N 32mm Valve Valve Guide Length 3840 95 i SEN Valve Gap Between Valve Stem And Guide Zoe erie CHERY A21 SERVICE MANUAL MECHANISM OF 2 0NALC ENGINE 0 051 ES Pressure Height 16 0 3 Protruding Part of Valve Stem Piston St Diameter 83 46 0 009 0 04 0 08 Side Clearance 2 Ring 0 01 0 025 re pm 02 04 0 4 0 6 iston aes Ring I Ring 1 2 0 03 0 04 0 03 Oil one GE 0 01 Ring Height Depth 0 005 Dar 41 NIE EE nae Piston Pin Leen Ge ET 0 005 Cylindricity gt Connecting Rod Journal Diameter Roundness o Whole Height 218 0 05 Cylinder Cylinder Hole Roundness Straightness Accuracy Upper Surface Planeness Connecti ES Flywheel Tool Guide Sleeve of Crankshaft Oil Seal Guide Sleeve of Camshaft Oil Seal Hydraulic Hoist Lo
9. Replace the camshaft if the value of axial clearance exceeds the normal value Standard Value Intake camshaft 0 015 0 02 Exhaust camshaft 0 015 0 02 25 MECHANISM OF 2 0NALC ENGINE Top of Valve Stem i Protruding High of Valve Stem Seat of Valve Spring Lo aliz CHERY A21 SERVICE MANUAL MECHANISM OF 2 0NALC ENGINE 6 Examine the planeness of cylinder a Clear the lower surface of cylinder head b With the help of ruler and feeler gauge check whether the lower surface of cylinder head is warped Measure it in the sequence of A C D E F G in the picture Standard Value Cylinder head planeness 26 Lo aris CHERY A21 SERVICE MANUAL MECHANISM OF 2 0NALC ENGINE C Revise it if the planeness exceeds and replace when it exceeds the limit value The permitted maximum abrading thickness between cylinder block and cylinder head 1s 2 2 3 Installation The installing steps are reverse to those for removal Note 1 Dismantle valve springs into groups The Ist and 4th cylinders are in one group and the 2nd and 3rd ones are in the other group Then put the piston to the upper point of Ist and 4th cylinders in order to dismantle the valve spring of Ist and 4th cylinders replace their valve oil seal and mount the spring immediately And put the piston to the upper point of 2nd and 3rd cylinders in order to replace the other valve oil seal Those steps prevent from that the valve
10. Zoe 5 2 CHERY A21 SERVICE MANUAL MECHANISM OF 2 0NALC ENGINE MECHANISM OF 2 0NA ENGINE CONTENT CHAPTER I ENGINE PARAMETER AND SPECIAL MAINTENANCE TOOLS 2 SECTION I TECHNOLOGY DATAINSIRUCTION 2 SECTION EN EE E ENK E see een ee 6 SECTION 3 ENGINE NUMBER POSITION 0 0 eeeneceeeeceeeeeeeeceeeeeeeceeeeeeeeees 7 SECTION 4 COLLATING METHOD OF ENOGINETIMINO 8 CHAPIFR2 ENGINE BOD E 10 SECTION 1 WHEEL TRAIN nennen 10 FONN C ENDER TEAD a E 15 EOIN RL Ae Le EE 29 Zoe aria CHERY A21 SERVICE MANUAL MECHANISM OF 2 0NALC ENGINE CHAPTER 1 ENGINE PARAMETER AND SPECIAL MAINTENANCE TOOLS SECTION 1 TECHNOLOGY DATA INSTRUCTION EN Engine Model SQR481H 4 Cylinder Water Cooled In line Double Engine Type Overhead Camshaft 16 Valve 2 Controllable Burning Rate Variable Valve is ER Cylinder Diameter mm T Rev at Rated Power r min 5500 r mim RAC Kw Cylinder Pressure Bar Fuel Pressure Bar Low Idle Speed GINE CHA 800 50r min High Speed Engine Oil High Idle Speed Pressure Bar 2000r min 4000r min Zoe 5M2 CHERY A21 SERVICE MANUAL MECHANISM OF 2 0NALC ENGINE Pressure Relief Valve Release Pressure to 88414 5 E ion Tank xpansion Tan Outside Cap kpa Vacuum Valve Lead Air 10 2 into Tank Thermostat Start Working 87 Working Temperature Full Worki Temperature Lo aria CHERY A21 SERVICE MANUAL MECHANISM O
11. al tool with that oil seal Then press it into oil seal seat ring 3 Mount the flywheel and the clutch pressure plate and then mount the engine on the vehicle Torque 25 5N M then screw 30 5 7 Replace crankshaft and thrust washer 7 1 Needed tools and auxiliary materials A set of open end wrenches a set of sleeve tools a small hoist Le Tai glue Engine oil feeler gauge feeler gauge micrometer gauge 7 2 Process of Removal 1 Suspend the engine assembly from vehicle See suspending of engine assembly for details 2 Drain out the engine oil 3 Remove the timing belt see replace timing belt for details Guide Sleeve of Crankshaft Oil Seal 47 MECHANISM OF 2 0NALC ENGINE Zoe SIS CHERY A21 SERVICE MANUAL 4 Dismantle the accessories such as dynamo A C compressor power steering pump and bracket See the replacement of engine accessory for details 5 Dismantle the engine cylinder head assembly See the replacement of cylinder head for details 6 Dismantle the engine clutch pressure plate the flywheel and the timing belt pulley 7 Remove the oil pan and engine oil strainer See the replacement of oil pan and strainer for details 8 Remove the piston connecting rod assemblies for 4 cylinders and Put them in order Note You d better stick the number on each piston connecting rod assembly to prevent from wrong mounting
12. aliz CHERY A21 SERVICE MANUAL MECHANISM OF 2 0NALC ENGINE Fuel Pressure Gauge Cylinder Pressure Gauge when measure the cylinder pressure firstly remove the spark plug screw the pipe end of instrument instead of it and operate the engine by starter then take the maximum value in cylinder pressure gauge as cylinder pressure SECTION 3 ENGINE NUMBER POSITION Zo 5m2 CHERY A21 SERVICE MANUAL MECHANISM OF 2 0NALC ENGINE SECTION 4 COLLATING METHOD OF ENGINE TIMING 1 Remove the upper cover of engine timing belt 2 Remove the lower cover of engine timing belt 3 Loosen the central bolt of timing belt tension pulley and remove the timing belt 4 Draw out the high voltage ignition cable Lo amz CHERY A21 SERVICE MANUAL 5 Loosen the bolt of valve cover and remove the valve cover 6 Rotate the camshaft in order to clip the camshaft tool into the slot at the end of camshaft 7 Loosen the bolts of air intake and exhaust camshaft tension pulleys with torque wrench Note It is not to remove but loosen 8 Revolving the crankshaft you may rotate in the crankshaft tool so as to it cannot move in both direction Note Do it with patience and carefulness lest the crankshaft should be broken Crankshaft Tool MECHANISM OF 2 0NALC ENGINE Camshaft Tool Lo amz CHERY A21 SERVICE MANUAL MECHANISM OF 2 0NALC ENGINE 9 Mount the timing belt and rotate tension pulley with Allen wrench in order
13. d expander are staggered The angle of expander connector points to the top of piston and the 1st ring and 2nd ring form 120 with the upper expander 42 MECHANISM OF 2 0NALC ENGINE 12 mme Center Bottom The Openings Of Rings Form 1720 With Each Other Lo aliz CHERY A21 SERVICE MANUAL MECHANISM OF 2 0NALC ENGINE 3 Mount the upper bearing of connecting rod and the connecting rod together Note the gap on bushing should be orderly with that of connecting rod 4 Spread the engine transmission oil in the engine cylinder clasp the piston ring with special tool tap the piston head with wooden handle and encase the piston connecting rod assembly Note the end of connecting rod with a point should face the cylinder and consists with the arrowhead on the top side of piston 43 Lo a HiZ CHERY A21 SERVICE MANUAL 5 Mount the lower bearing of connecting rod and the connecting rod cap together Then spread engine transmission oil Note the gap on bushing should be orderly with that of connecting rod 6 Close the connecting rod cap and screw down the bolt Torque 25 3Nem then screw 90 5 7 Examine the axial clearance of connecting rod Examine the axial clearance with micrometer guage or feeler gauge Standard Value mm 0 15 0 50 8 Mount the engine oil strainer 9 Mount the oil pan 10 Mount the cylinder head 11 Mount the timing belt during timing adjusting
14. end wrench allen wrench coolant 8 2 Removal 1 Remove the engine timing belt see engine timing calibration for details 2 Loosen the engine water exhaust pipe and exhaust coolant 3 Removal the coolant pump 8 3 Installation The installing steps are reverse to those for removal Infuse enough coolant after installation Note Do not splash the coolant on the timing belt and skin 52 MECHANISM OF 2 0NALC ENGINE
15. ew bushing but it is possible unrecognized the color on the old one corresponds to red bushing and B corresponds to blue bushing 50 MECHANISM OF 2 0NALC ENGINE CAE Lo SEZECHERY A21 SERVICE MANUAL 2 Inspect the crankshaft axial clearance Mount the crankshaft and measure its radical clearance with micrometer guage P Standard Value 0 076 0 265 Replace the new thrust washer 1f the measured value exceeds the limit value Standard thickness of thrust washer 7 4 Installation 1 Clean the engine and spread the engine transmission oil on the crankshaft journal 2 Mount the crankshaft correctly and then mount the thrust washer 3 Mount the cylinder frame and screw down the crankshaft fastening bolt See the picture for the screwing sequence Screwing way and Torque A Pre fasten the bolt according to the sequence in the picture B Screw the bolt as the sequence on the picture to 45 5 N m C Screw 180 5 4 Mount and screw down the bolt of frame periphery Torque 23N m 5 Mount the engine oil strainer oil pan crankshaft front and rear oil seal and oil pump 6 Mount the engine accessories suspend the engine assembly from vehicle and 51 MECHANISM OF 2 0NALC ENGINE Zo Siz CHERY A21 SERVICE MANUAL mount the water pipe and insert electric connector 8 Replace coolant pump 8 1 Needed tools and auxiliary materials A box sleeve wrench a set of open
16. f the examined clearance exceeds the limit 36 MECHANISM OF 2 0NALC ENGINE Zoe amz CHERY A21 SERVICE MANUAL 4 Inspect the diameter of piston pin and piston pin hole As the following picture measure the around with caliper And take the value as the diameter of piston pin position micrometer maximum piston pin Measure the diameter of piston pin hole around with micrometer guage for inside diameter as the following picture and take the minimum value as the diameter of pin hole Standard Size 0 Diameter of piston pin Diameter of piston pin hole Replace with the new piston and pin if the examined clearance exceeds the limit 37 MECHANISM OF 2 0NALC ENGINE Zoe amz CHERY A21 SERVICE MANUAL 5 Inspect the connecting rod journal and connecting rod bearing a Examine the diameter of connecting rod journal Measure the axle diameter of connecting rod with micrometer caliper Rotate the crankshaft 90 and measure it again Work out the Roundness and cylindricity through twice measuring Roundness Max diameter Min diameter 2 as the picture take the vertical diameters on the same plane subtract the half of Minimum from the Maximum to get roundness cylindricity Maximum bore Minimum bore 2 As the picture measure the bores of 3 planes along both A direction and B direction respectively Get the maximum and the minimum from 6 values and then subtract the ha
17. falls into cylinder and the unanticipated trouble occurs 2 Wipe the engine transmission oil on the opening of oil seal when mounting the valve oil seal 3 Fasten the cylinder bolt as the following process A Smear some oil on the top and root of ola m Ueol Leet A Cellet bol SE DPS wt en er O t ch Wl Su Let Te F ji Wr a Fasten to 40 5NM in sequence Fasten 90 5 degree clockwise I em REN S i Fasten 90 5 degree clockwise oy ZC P t k FJ AS ie Sie FEL GO EG HO 2 3 Replace thermostat 2 3 1 Structural diagram 27 lt A Si 46 24 CHERY A21 SERVICE MANUAL MECHANISM OF 2 0NALC ENGINE 1 Pad Thermostat Seat 2 Thermostat Seat 3 Hexagonal Flange Bolt 4 Thermostat Assembly 5 Hexagonal Flange Bolt 6 Cover Thermostat Seat 2 3 2 Needed tools and auxiliary materials Hatch clamp 10 sleeve ratchet wheel and wrench 2 3 3 Removal 1 Loosen the clamp of thermostat water exhaust pipe with hatch clamp to release the coolant Note Do it after the temperature decreased to prevent scald 2 Remove the 4 bolts of thermostat cover with 10 sleeve wrench 3 Take out the thermostat 2 3 4 Inspection Put the thermostat in the boiling water and use it with thermometer Then observe the temperatures when the thermostat 1s turning on and fully opened Temperature value Regular unlocking temperature fully opened temperature 104 Replace the new thermostat if the measured value i
18. hrottle valve body is electronic do not force the middle vanes turning manually or with other objects 6 Loosen the joint of oil intake pipe 17 Lo aim 2 CHERY A21 SERVICE MANUAL MECHANISM OF 2 0NALC ENGINE 7 Remove the fastening nut of intake manifold and take out the intake manifold Lo aliz CHERY A21 SERVICE MANUAL MECHANISM OF 2 0NALC ENGINE 2 1 3 Installation steps The installing steps are reverse to those for removal 2 2 Replace camshaft bearing bushings valve and valve oil seal 2 2 1 Needed tools and auxiliary materials Special tools for valve oil seal engine transmission oil a set of sleeve tools an adjustable spanner special tools for timing and a set of Allen wrenches 2 22 Removal 1 Remove the dynamo belt see removal of dynamo belt for details 2 Remove the timing belt see replacement of engine timing belt and timing calibration for details 3 Remove the cover of engine valve chamber 4 Clamp the timing special tool into camshaft slot and fasten the bolt Lom amz CHERY A21 SERVICE MANUAL 5 Dismantle the belt pulley of air intake and exhaust camshafts with torque wrench 6 Remove the back cover of timing belt 7 Dismantle the bearing caps of air intake and exhaust camshaft respectively and put them down in the sequence Note The second third fourth and fifth camshaft bearing caps are marked with I1 I2 D I4 El E2 E3 E4 which sta
19. icture Standard Value an value warping 0 04 amount l C Revise it if the warping amount is excessive Replace with the new cylinder if it exceeds the limit The maximum for the sum of permitted abrading thickness of cylinder block and cylinder head is 40 MECHANISM OF 2 0NALC ENGINE Lo arm 2 CHERY A21 SERVICE MANUAL MECHANISM OF 2 0NALC ENGINE 41 Lo SF CHERY A21 SERVICE MANUAL 7 Inspect cylinder a Inspect if the cylinder wall is scratched or scored If there are cylinder scoring and scratching you need to hone cylinder wall replace cylinder liner or replace cylinder block diameter and cylindricity of cylinder with cylinder gauge Standard value b Examine the inner cylindricity 0 008 cylindricity Maximum bore Minimum bore 2 As the picture measure the bores of 3 planes along both A direction and B direction respectively Get the maximum and the minimum from 6 values and then subtract the half of Minimum from the Maximum to get cylindricity 3 2 3 Installation 1 Spread oil on the piston pin and in the piston pin hole connect the piston and connecting rod with piston pin and mount the piston pin circlip 2 Mount the piston ring Mount the rings on the piston in the sequence of oil ring expander upper and lower segments 2nd air ring and Ist air ring Pay attention to the direction of piston ring the side with TOP should be upward The two segments an
20. ing bolt of oil pan with 10 open end wrench and 10 sleeve 18 bars of M725 3 bars of M7 x40 4 bars of M7x95 3 Remove the connecting bolt 2 bars black between oil pan and transmission housing with 17 sleeve wrench 31 MECHANISM OF 2 0NALC ENGINE CHAT ALTO ET 4 Remove the connecting bolt between the oil return pipe of PVC valve and the oil pan with 15 sleeve wrench 5 Tap the edge of oil pan with rubber pestle and then remove the oil pan Note Pay attention to safety because the oil pan might fall down when being tapped 6 Clean the engine frame with right angled tool to get rid of old Le Tai glue Note Do not lacerate the frame surface 1 2 2 Installation 1 Spread Le Tai 5910 glue on the connection surfaces of frame and oil pan close the oil pan and fasten the fastening bolt of oil pan Note Spread glue to the inner of hole for installing bolt on the oil pan 2 Screw the bolt Screw to combine enough at first then to get specified Torque See the diagram for screwing sequence Torque 1543NM 3 Infuse engine oil to specified capacity 32 MECHANISM OF 2 0NALC ENGINE Lom SEZECHERY A21 SERVICE MANUAL 2 Replace the engine oil strainer 2 1 Needed tools and auxiliary materials 10 open end wrench 10 15 174 sleeve ratchet wheel and ratchet rod Le Tai 5901 Glue engine oil 2 2 Process of replacement 2 2 1 Process of removal 1 Remove the oil pan See
21. lf of Minimum from the Maximum to get cylindricity Standard Value 0 me the connecting rod bearing b Inspect radial clearance of Inspect the radial clearance of connecting rod bearing with clearance gauge Clean up the connecting rod journal and connecting rod bearing And put clearance gauge on the journal fasten bearing bushing and fasten the bolt according to set torque 38 MECHANISM OF 2 0NALC ENGINE Lo SIS CHERY A21 SERVICE MANUAL MECHANISM OF 2 0NALC ENGINE Note Do not rotate the crankshaft during the process 39 Zoe amz CHERY A21 SERVICE MANUAL Loosen the connecting rod bolt remove the cap and measure the maximum width of pressed clearance gauge with the ruler on its package to get the clearance value Standard Abrasion Value Limit Clearance 0 016 0 051 Replace with the new connecting rod bearing if the examined clearance exceeds the limit Note Use the same brand consistent with assorting sign when you replace the bearing bushing Selection of connecting rod bearing You may select the connecting rod bearing by observing the sign on the first balance weight at the front end of crankshaft sec picture unavailable 6 Inspect the planeness of cylinder block surface a Clean the upper surface of cylinder block b Check with ruler and feeler gauge whether the surface of cylinder block is warped Measure it in the sequence of A C D E F G in the p
22. nds for the corresponding bearing cap of 1 2 3 4 cylinder respectively I refers to intake camshaft E refers to exhaust camshaft Torque 20 MECHANISM OF 2 0NALC ENGINE Lo amz CHERY A21 SERVICE MANUAL MECHANISM OF 2 0NALC ENGINE See the following picture for removal sequence of intake and exhaust camshaft bearing caps e E RR r l or ir en eg ae ye ed Pei E d J Rap CN x I Mit hj g TI AF Sf T TE sin iS Be 5 m I I 8 Take out the camshaft and the hydraulic tappet 9 Remove the valve spring with special tools Picture is unavailable 10 Remove the used valve oil seal with special tools Picture is unavailable 2 2 3 Inspection 1 Check the valve spring Measure the free length the verticality and the length under special pressure with caliper Standard Value mm Free length Length of Replace with the new valve spring if the measured value exceeds the limit value 21 Zoe amz CHERY A21 SERVICE MANUAL 2 Check camshaft Measure the camshaft diameter with micrometer caliper Standard Value a Limit Value mm mm Replace with the new camshaft if the measured value exceeds the limit value 3 Examine camshaft Measure the high of cam with micrometer caliper Standard Value limit value Replace with the new camshaft if the measured value exceeds the limit value 4 Examine diameter of valve stem a Measure the diamete
23. r of valve stem with micrometer caliper See the picture for measuring points they are 26 52 and 78 mm from measure positions to bottom of valve External Diameter Internal Diameter OP keen Of Valve Guide 22 MECHANISM OF 2 0NALC ENGINE Measuring Point Zoe amz CHERY A21 SERVICE MANUAL b Use internal micrometer guage to measure the internal diameter of valve guide and the measuring point is a quartering point of guide c Calculate the difference of measured value and the clearance Replace the valve or the guide if the value exceeds the limit value d Examine the contact bandwidth of valve e Check the valve seat insert 23 MECHANISM OF 2 0NALC ENGINE Measuring Point Contact Position Should be Edge the Center of Slope Thickness Lo 5 2 CHERY A21 SERVICE MANUAL MECHANISM OF 2 0NALC ENGINE Standard Value Outer Diameter 5 98 0 008 of Valve stem mm 5 96 0 008 Inner Diameter 5 4 0 1 of Valve guide mm EX 5 4 0 1 Clearance mm Thickness of 0 3 0 15 Valve Top EX 0 3 0 15 mm i 1 158 EX 1 306 24 Zoe arin 2 CHERY A21 SERVICE MANUAL f Examine the protruding capacity of valve stem And Examine the protruding high of valve stem with vernier caliper See picture Standard Value mm Protruding Capacity Of Intake Valve stem Protruding Capacity Of Exhaust Valve stem 5 Examine the axial clearance of camshaft
24. r out and requires continuing infusion 2 If the belt is spotted with much oil stains and the rubber may be damaged due to expansion you should replace the belt Lom SF CHERY A21 SERVICE MANUAL 2 4 Installation The installing steps are reverse to those for removal Note Do engine timing 3 Replace idler wheel tensioner and contact belt pulley 3 1 Needed tools and auxiliary materials Allen wrench 10 13 and 15 sleeve ratchet wheel and ratchet rod 3 2 Removal 1 Remove the timing belt see replace timing belt for details 2 Remove idler wheel tension pulley and contact belt pulley 3 3 Inspection 1 Check from appearance Check idler wheel tension pulley and contact belt pulley carefully for any damages such as sunken trace and sliding damage etc 2 Check performance Revolve tension pulley idler wheel and contact belt pulley respectively to insure that they can run freely without stagnancy Replace it with the spare part if any above problem is found 3 4 Installation 1 The installing steps of tension pulley idler wheel and contact belt pulley are reverse to those for removal 2 Mount the timing belt and collate engine timing 3 Mount other parts MECHANISM OF 2 0NALC ENGINE CHAT AUTO ET Zoe Ee CHERY A21 SERVICE MANUAL MECHANISM OF 2 0NALC ENGINE SECTION 2 CYLINDER HEAD I STRUCTURAL DIAGRAM 1 Gasket Intake Manifold 2 Intake Manifold Assembly 3
25. s abnormal 2 3 5 Installation The installing steps are reverse to those for removal Note Fill in the engine coolant with fixed quantity after installation 28 MECHANISM OF 2 0NALC ENGINE Zoe SECTION III SHORT ENGINE I STRUCTURE DIAGRAM Piston Connecting Rod Upper Bearing Timing Hole Plug Connecting Rod Lower Bearing Pad Bolt Oil Filter Oil Cooler Oil Filter Seat 10 Connecting Rod Bolt 11 Connecting Rod Bearing Cap Go A Ch P L H EE 29 8 SG sf i H EI dee Ei GO d e PoF i E i A EI i i A Ee A pie e i a jie a F e dafa 12 13 14 15 16 17 18 19 20 2 Oil Pump Bolt Gasket Crankshaft Timing belt pulley Gasket Bolt Crankshaft Pulley Bolt Bolt Coolant pump 22 Coolant Pump Gasket Lo aliz CHERY A21 SERVICE MANUAL MECHANISM OF 2 0NALC ENGINE 23 Crankshaft Main Bearing Bolt 26 O Type Ring 24 Frame Bolt 27 Crankshaft 25 Frame 28 Cylinder Block 30 II MAINTENANCE 1 Replace oil pan 1 1 Needed tools and auxiliary materials 10 open end wrench 10 15 and 17 sleeve ratchet wheel and ratchet rod Le Tai 5901 Glue engine oil 1 2 Process of Replacement 1 2 1 Process of removal 1 Loosen the oil discharge bolt of oil pan to discharge the engine oil Note Engine oil should be stored in special container And Pay attention to environment protection 2 Remove the fasten
26. ulley with 13 sleeve Lo amz CHERY A21 SERVICE MANUAL 5 Remove the 5 bolts on the lower cover of timing belt with 10 sleeve ratchet wheel and ratchet rod 6 Remove the lower cover 1 3 Inspection Observe the timing cover and the timing belt Replace the timing belt cover or adjust the position of timing belt if any trail from crack or friction is found 1 4 Installation The installing steps are reverse to those for removal Note Install the lower cover first and then install the upper one 2 Replace timing belt 2 1 Needed tools and auxiliary materials Allen wrench 10 13 sleeve ratchet wheel and ratchet rod 2 2 Removal 1 Remove the upper and lower covers of timing belt see replace covers of MECHANISM OF 2 0NALC ENGINE Lo amz CHERY A21 SERVICE MANUAL MECHANISM OF 2 0NALC ENGINE timing belt for details 2 Loosen the central bolt of tension pulley and remove the timing belt 2 3 Inspection Check the timing belt carefully replace the parts if any following situation occurs 1 Chap of back side rubber 2 Chap of dedendum chap of separated cord fabric 3 Wearing gear missing and incomplete gear of cord fabric Chap Wearing 4 Abnormal wearing of belt flank Gear Missing Abnormal Wearing Belt Core Desquamation Replace the belt as any following situation occurs even though abrasion cannot be found directly 1 The water pump leaks wate
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