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Chery QQ Service Manual

1. 3 2 Installation of timing at the top dead center of the first cylinder piston 3 2 1 Put the camshaft timing gear on the front end of the exhaust camshaft align the locating slot on the gear with the locating pin on the end of the camshaft and then fix the timing gear with bolts The tightening torque for the bolts is 100 5Nm Make sure that the clashing mark of crankshaft timing AR oe Taa E gt pulley aligns with the mark of oil pump E Eo oe Pe ARNE f Pa i M at a d E gt rem A l l a A A s eee a ed wie a de pe oe a a Tl l gt e a a l i hir ae ae yee ce W ae f a ss a A Ti air I F p co a a E k ee TE Mat ott Bee Se h E a a N 3 3 Install the tension pulley After adjust the tension of timing belt install the tension pulley bolt and tighten it with the torque specified Adjust the tension of the timing belt acording to the following instruction and install the tension pulley 3 3 1 As indicated in the figure make the tensioner swing to the right with a screwdriver so that the distance between the edge of the tension pulley and the circular arc of the water pump body is 8mm and then tighten the tension pulley bolts with the torque of 2543Nm 11 Chery QQ Service Manual Mechanical Part of SQR 472Engine Bet ETHE EIA 3 3 2 Rotate the crankshaft along the rotating direction of the engine for 2 rounds so that the timing mark on the timing gear of camshaft and crankshaft is ma
2. 5 1 Assembly of the piston connecting rod Chery QQ Service Manual 46 Mechanical Part of SQR 472Engine SS Measurement position of piston Cuter Diameter d Measurement position of piston Inner Diameter So Chery QQ Service Manual CHERY Bet ETHE EIA 5 1 1 Assemble the piston connecting rod and the piston pin with special tool following the instructions below 5 1 1 1 Spread engine oil over the pin hole of the connecting rod assemble according to the group mark and direction mark of piston and connecting rod 5 1 1 2 Assemble the piston and the connecting rod with special tools shown in the right figure 5 1 1 3 Adjust and assemble the piston and connecting rod as indicated in the right figure Spread the piston pin with oil and then assemble the piston and connecting rod with a oressing machine Notice When pressing in the piston pin make sure the fitting direction is correct When the piston pin is pressed into the piston the small end of the connecting rod should be heated to 300 C and the pin should be aligned properly 5 2 Install the first and second pistion ring and the oil ring according to the following instruction 5 2 1 Installation of piston ring Make the side with marks face upwards and then fix it with piston pin tools 32 2 Mount the steel tape combined oil ring bushing ring lower lower blade upper blade firstly and then mount the second gas
3. Engine Oil Pump Housing Unit N m kg cm SOOVQOHOHOHO 4 2 Disassembly 4 2 1 O ring Notice The O ring is nonreusable 4 2 2 Remove the oil pump cover Notice If the screws are tightened use a screw driver to remove them as indicated in the figure 4 2 3 Remove the inner rotor outer rotor of the engine oil pump 33 ad Chery QQ Service Manual la HER Y ERE ETHE ETA oe P 2 4 Remove the cotter pin Notice Notice When removing the cotter pin be careful not to let the spring or the spring seat spring out or fall off The cotter pin is nonreusable abruptly 4 2 5 Remove the spring seat of the oil pressure relief valve for the engine oil pump the coil spring oil pump and oil pressure relief valve etc 4 2 6 Remove the front crankshaft oil seal Notice The oil seal removed may not be reused 4 3 Routine Inspection 4 3 1 Inspect the engine oil pump for clearance 4 3 1 1 gear in the engine oil pump put the gears into the engine According to the marks for inner gear and outer oil pump that is in the cylinder block 4 3 1 2 Measure the clearance between the inner and outer gears with a feeler gauge Standard value positions Limit 0 35 mm 0 05 0 18mm average value of 9 34 Mechanical Part of SQR 472Engine Relief Valve Slide Block Relief Spring 5 j h Spring Seat I fr HEN m PT is m ROM las Cher
4. 293 4 amp 5 bearing caps Camshaft P23fg 0 033 9 Fit Clearance between Tappet Hole and Tappet Name of Component Size and Tolerance Clearance or Value of Remark Interferenc A 021 Cylinder Head Hole T t 0 020 0 020 0 054 appe P28f6 0 033 51 pe Chery QQ Service Manual Mechanical Part of SQR 472Engine Remarks In the above tables the capital letter and suffix following the sizes For example H7 of 28H7 mean the process precision which are unconcerned with the maintenance and may be ignored in the course of maintenance Chapter 4 Table of Measurement Parameters of SQR472 EngineSQR472 e pd A A Measuring Items Axial clearance of crankshaft 0 089 0 21 1mm Assemble the crankshaft and tighten the main bearing cap bolt lt I Nm Mount the piston connecting rod No 1 Torque of crankshaft assembly and tighten the connecting od bolt lt 5 5Nm uniform speed y lt a lt 2 Installing timing belt and spark plug aus Mount the valve spring and camshaft excluding timing bel when rotating at and spark plug on the cyllinder head tighten the camshaf bolt and then measure the torque of the camshaft rotating a uniform speed lt 32 Nm Distance between the outer edge of steel ball and the front end of camshaft 5 65 0 5mm Distance between the outer edge of steel ball and the rear end of camshaft 8 65 0 5mm 5 Axial clearance of intake camshaft 0 10 0 179 Axial
5. 5 Rotate the crankshaft so that the crown head of the cam faces downwards and presses down the the valve Pick up the special tool 4 4 3 6 Rotate the crankshaft for 2 3 rounds and confirm once again the valve clearance If it is still beyond the scope of standard value adjust and inspect the valve clearance according to the operation specified in 4 1 4 4 3 Cylinder Head 1 Structure Diagram 22 Chery QQ Service Manual Mechanical Part of SQR 472Engine q 7 b x ii a N 9 l b O 8 14 E 9 A et A 13 10 O Spark plug 20 1Nm Cylinder Head Weather Strip I Cylinder cushion Adjustment gasket Valve tappet Valve spring retainer Valve spring seat O o JJ Dd nN BPW NY Valve Spring j Intake valve p pd Exhaust valve pl No Valve oil seal gt Components which may not be pad Oo Valve seat reused ay h Valve guide 2 Disassembly 2 1 Disassembly of spark plug 2 2 There are 8 boltes on the cylinder head In the course 23 gt Chery QQ Service Manual Mechanical Part of SQR 472Engine Bet ETHE EIA of the assembly of cylinder head slowly tighten these bolts in the order as indicated in the right figure for several times untill ther are tightened properly Notice Remove the cylinder head bolts with a torque socket wrench in the contrary order 2 3 Disassembly of cylinder head and cylinder head gasket Notice The cylinder head gask
6. Item Height mm 13 71 0 25 3 3 3 4 Rub the inside diameter with reamer to reach the standard clearance value 3 3 4 Assorted surface of valve 3 3 4 1 Spread with red lead on the assorted surface of valve Do not rotate the valve but press lightly and check the assortment and width 26 e gt Chery QQ Service Manual Bet ETHE EIA 3 3 4 2 Repair of valve seat insert Notice The repair of valve seat is always conducted in the course of the inspection of valve s fitting position The surface repaired should be free from any breakage Take it out slowly after the inspection 3 3 4 3 45wimble surface is assorted standard value 3 3 4 4 Inspect the fitting position of the valve The best position is the center of the valve If no the valve should be adjusted 3 3 4 5 Cut wimble surface at the center of assorted position with inner 70and outer 30 3 3 4 6 Prepare for polishing of valve seal 3 4 Assembly of cylinder head 3 4 1 Cylinder head Pay attention to the following for installing the other auxiliary part of cylinder head 3 4 2 Protective tube of spark plug l Press the protective tube of spark plug into the protective tube hole on the cylinder head with the special auxiliary tool Before pressing spread the protective tube with sealant The pressing depth is indicated in the right figure Notice Pay attention to the pressing depth and the uprightness to top of cylinder head when pressing Duri
7. brand The thickness of the connecting rod bushing which meets the requirements of clearance diameter of big end hold axial diameter of connecting rod standard value of bearing bushing clearance 2 2 6 Remove the connecting rod bearing cap and the connecting rod bearing bushing 2231 Put vinyl resin protecting jacket on the threaded part of the connecting rod bolt so as to prevent the bolts from scraping the cylinder hole and the crannkshaft connecting rod journal and then disassemble the piston connecting rod by using the hammer handle striking it out 2 3 Inspect the axial clearance of crankshaft 2 3 1 Measure the axial clearance of the crankshaft with a dial gauge if it is beyond the limit it is necessary to replace the axial thrust plate or the crankshaft Standard value 0 089 0 211mm Limit 0 30mm AT i 0 03 41 Mechanical Part of SQR 472Engine Connecting Rod Connecting Cover E E Ss a H m al p ji BEN E lEt E Lad i Lil A ie Rie ee A ink E LE ray THG EIE HE nas m m a Er ra A F I T Fe SS eee Bee ine Se ee ee et 1 E TT E La a A A El ai zz eo Miaa n a Protection Sleeve ie i a f A a f Fy a Fy Chery QQ Service Manual Mechanical Part of SQR 472Engine Pet ete ENA 2 4 Inspect the crankshaft for its radial clearance 2 4 1 Remove the crankshaft bearing cap by softly tapping with a resin hammer 2 4 2 Clean the in
8. clearance of exhaust camshaft 0 10 0 253 Jumping amount of installation surface of flywheel wearing piece 0 10mmmax Protrusion height of crankshaft woodruff key 2 2 20mm Intake valve clearance 0 18 0 05mm 10 Exhaust valve clearance 0 25 0 05mm Tension of timing belt When the middle part of the rigth side 1 is pressed down for 4 5mm 200 280N m 12 Compression pressure of cylinder 10 14bar Tension of generator belt When the part between the pod 3 generator and water pump is pressed down for 4 5mm 98N m 14 Refilling amount of engine oil including filter 3 5 Liter gt O O O ga O O O lt O TEE EEE EEE 32 DO Chery QQ Service Manual Mechanical Part of SQR 472Engine Chapter 5 Table of Main Fitting Torque for SQR472 EngineSQR472 IEA IN se es Di pnsan CTE s 2 meanen m a papas es DEI huaca II IC mt acc ones we et Ce CET TO ACUC ET MEA ECT IO E ETC IC a A FE CT Oo hexagonal 11 Exhaust camshaft Exhaust camshaft locking nut nut aoxisy 1 1008s ae os ae MN Error A ie frisrieccumirenenor mee aos Ti tera S m a a Ti pae ICO a EI E gina as Y s serte j a a a o e wf a o henon e 2 proa as e A 22 Thermoregulator shell bolt OM 2 101 Oil filter conncetor 3 4 16 H 23 402 5 24 201 5 F dl Oil filter 3 4 16 53 y Chery QQ Service Manual Mechanical Part of SQR 472Engine No Intake exhaust stud 10 1 Intake pipe nu
9. ring and finally mount the first gas ring Opening angles of rings are shown in the figure 47 Mechanical Part of SQR 472Engine 1 Ring Front Bushing Ring Upper Blade 2nd Ring Oil Ring 2nd Ring Rear gt Chery QQ Service Manual Mechanical Part of SQR 472Engine Bet ETE EIA 5 3 Resemble the crankshaft main bearing cap crankshaft crankshaft bearing bushing and the crankshaft axial thrust plate pay attention to the following 5 3 1 Assembling the bearing bushing its raised thrust block should fit into the locating groove in the cylinder body a i A Fi Notice The bearing bushing is from the same Oil Tank F manufacturer Spread Oil on the surface of p Beari H earing Bushing d 5 3 2 Spread the crankshaft bearing bushing upper piece with oil before assemble the crankshaft 5 3 3 Mount the thrust plate on the cylinder body bearing base and make sure that the side with oil gloove crankshaft shank face outwards Notice Spread the side of oil glove with oil 5 3 4 Fix the crankshaft bearing bushing lower piece in the bearing cap the bearing bushing should fit into the thrust groove 5 3 5 Spread engine oil over the friction surface of crankshaft bearing bushing lower piece assemble the bushing according to the mark forwards in the main bearing cap of the crankshaft 5 3 6 Spread oil over the bolts within three or two times tighten them with specif
10. the piston pin at several positions with a micrometer caliper shown in the figure make the maximum value as the diameter of pin 4 2 2 Measure the diameter of piston pin at several positions with an inner diameter dial gauge as shown in the figure make the minimum value as the diameter of the pin hole Work out the clearance with the difference between the pin diameter and pin hole diameter if the difference is beyond the standard value replace the piston pin or piston Standard value 0 004 0 009mm Limit 0 015mm 44 Mechanical Part of SQR 472Engine Upper Stopper Position of Piston Lower Stopper Position of Piston M Sum Measurement Position of Piston Pin poa Chery QQ Service Manual 4 2 4 Measure the diameter of the piston 4 2 4 1 Measure at about 11 mm to the bottom of the piston along the direction vertical to the piston pin 0 013 Standard ratas 2000 4 2 5 Inspect the clearance between the piston ring and the ring gloove 4 2 5 1 Measure around the ring gloove with a piston ring and a feeler gauge Standard value Limit mm mm Fistrine 0 03 0 06 ring 4 2 6 Inspect the end clearance of piston ring 4 2 6 1 Put the piston ring 45mm below the top surface of the cylinder hole Press down the piston ring with the piston head and then measure the opening with a feeler gauge 0 25 0 40 ena 0 35 0 50 ring Oil ring 0 20 0 70 45 Mechanical Part o
11. the piston pin with special tool as indicated in ind the right figure 1 As indicated in the right figure disassemble the piston which is at the state mentioned above with special O tools Remove the piston pin with special tool and then remove the piston and the connecting rod 3 Cleanup 3 1 Cylinder Body In the course of cleanup protect your eyes with eyeglass 3 1 1 Clean up the cylinder body cylinder head oil pan oil pump and the oil seal with a flat blade 3 2 Piston In the course of cleanup protect your eyes with eyeglass 3 2 1 Use an old ring to remove the carbon in ring groove 322 Remove the carbon of parts with scavenger Notice Don t use hard articles such as metal brush 43 gt Chery QQ Service Manual 4 Routine Inspection 4 1 Cylinder Body 4 1 1 Inspect the top surface of cylinder body for its flatness 1 Measure at the six points shown in the right figure with a ruler and a feeler gauge Limit 0 08mm 4 1 2 Use of bore gauge Measure the cylinder bore at the positions as indicated in the right figure with a bore gauge and figure out the difference between the maximum value and the miximum value If the difference exceeds the limit repair or replace the cylinder Limit 0 03mm Reference Roundness A B or a b Cylindric degree A a or Reference Standard diameter of cylinder p72 00 72 01mm 4 2 Piston 4 2 1 Inspect the piston pin hole for its clearance Measure
12. CHERY Chery QQ Service Manual Mechanical Part of SQR 472Engine SOR 472 Engine Service Manual for Mechanical Part After sales Department of Chery Automobile Sales Co Ltd LO Chery QQ Service Manual Mechanical Part of SQR 472Engine CONTENTS Chapter 1 Readins TNS ttl Oi ansia 2 1 Reading method of Maintenance INS GON adan o da a a a dad 2 2 Meaning of Marks and A DDreviations ciscriosisessorisssonns anoni gora eorne aser o araa Oesa ENO o ETU oo IU oc 3 e ea K ca MAP E EEA EEA EEA 4 Chapter 2 Disassembly Assembly and Maintenance sivicciineatvesswnastidernsdoossvanatsdennadacssunsctedawsadovnavaacdsdennsdesssvesalndsenedecnannds 6 PEE a e E E EE A RR S 6 Polo e Da E A A A nee ocavanshomecastenes 6 A le Y E A E E E A E A R A E E E A E E 7 Ds EANO esse e a iia 10 A TO T A AR 13 Te e D 6 14 1 PAP Pepi E T E 13 AP PI E ENES 14 dy RHI OM ss E S 16 d Routine Inspeccion A a Ea a OE E E E Eai 19 Ae E OO N A N A 22 Konene D A een o E OPE RE PO NE E E ORO 22 Za DISASS a sitial E E ETE 23 ROOT e AAA In A E A 23 e A AlCl e Y 10 0 E E A EET ASTE EAT E ATETEA ENTE ENAT EAT AATE T ATETEA CAR 29 obio iiaa B TAIN ERARA EET on 29 2 DISASS EMI crisis siii 29 SN CANN oso sodas E saute vases TEY 29 o A e PO A 29 A O 29 DOU PUD sitios 29 Mec SN UN TUE AAA e ee e E R E tabs maalnad Senetcah etme tonheeve nenseeas 30 Di WIISASGEMMOIY POE OPEN suanooeseaaooasauanasanteanenanauanaiestoraanasseananssiasabes E a 30 A PP A 30 4 Disassembly a
13. R 472Engine Bet ETHE EHA 2 Disassembly T Po il 2 1 Remove the water pump pulley as the view showing jo mee x A Ae It will be better of disassembling with special tool Torque 25 1 5 N m 2 2 Disassembly of Timing Belt Cover Torque 6 1N m 2 3 Disassembly of torsional damper Use special tools to prevent the gear ring from rotating When disassembling the fixing bolts of the torsional damper make sure that the marks on the crankshaft timing pulley match with the timing marks on the engine oil pump 2 4 Remove the timing belt back plate e Chery QQ Service Manual Mechanical Part of SQR 472Engine Bet ETHE Ee 2 5 Disassembly of tension pulley 2 5 1 Compress the top dead center at the first cylinder Timing Mark Clockwise piston After disassembly of timing cover pull the bolt and clockwise rotate the timing gear with wrench And then align the timing mark of camshaft timing gear and the raised mark on camshaft cover 2 5 2 Screw off the bolt of tension pulley and remove the tension pulley 2 6 Disassembly of timing belt Notice Do not use sharp tools like screwdriver during disassembly of belt Notice Pay attention to the following items during using the timing belt Do not bend the belt with small angle or the rigging in belt will break Do not pollute grease and water because the using expectancy of belt is short Only clockwise rotate the engine after mounting the belt 2 7 Disass
14. The position at which the measurement result exceeds the standard value as well as the measurement result should be recorded 4 4 1 Rotate the camshaft and make the cam head of the cylinder which exceeds the standard value faces upwards and the opening of the valve tappet face inwards 4 4 2 Rotate the crankshaft and press down the valve tappet with the crown head of the cylinder cam 4 4 3 As indicated in the right figure put special tools on and around the valve tappet from the inside of the cylinder head and then rotate the crankshaft so that the crown head of the cam face upwards Press the valve tappet with special tools and hold on 4 4 3 1 Pry out the adjustment gasket with screw driver remove the gasket inside with magnet 4 4 3 2 Adjust the thickness of adjustment gasket with 21 a e Chery QQ Service Manual Mechanical Part of SQR 472Engine E ETE ERA micrometer caliper 4 4 3 3 Select the gasket on the basis of the standard value of valve tappet 1 Intake valve Select gasket thickness Unload thickness Measured valve clearance 0 25mm 2 Exhaust valve Select gasket thickness Unload thickness Measured valve clearance 0 25mm Reference The 32 kinds of gasket with different thickness are listed in the following table 4 4 3 4 Adjust the valve clearance with selected adjustment gasket Notice Install the adjustment gasket with its identification mark facing downwards 4 4 3
15. ad engine oil over the lip of the new oil seal 5 4 2 Mount the oil seal with special tool as indicated in the right figure 6 Assembly 6 1 Assembly of the oil seal seat Spread sealant over the oil seal seat as shown in the right figure Grease Loctite 5699 Notice Spread the liquid sealant on the position of the oil seal base which is to contact with the cylinder body and make sure the width of the sealant is 3 4mm Torque 25 1 5N m 6 2 Assembly of the new engine oil pump gasket and the engine oil pump assembly Torque 20 1 5N m 6 3 Assemble the new engine oil collector gasket and the 37 Mechanical Part of SQR 472Engine Special Tool Special Tool ene Chery QQ Service Manual Mechanical Part of SQR 472Engine ETH Ele engine oil drainer Torque 6 1N m 6 4 Assembly of the oil pan 6 4 1 Clean up the joint surface between the oil pan with the cylinder 6 4 2 Spread sealant then assemble it Grease Loctite 5699 Notice The sealing line should be unbroken with its diameter being 3 4mm Assembly should take place fifteen minutes after glue spreading 6 4 3 Tighten the bolts in the middle first up to the specified torque then the bolts beside them as shown in the right figure Torque 6 1N m Front 38 gt Chery QQ Service Manual Mechanical Part of SQR 472Engine 6 Cr
16. ank Connecting Rod Mechanism 1 Structure Diagram r r vin L 5l D B e e e jil w Components which may not be reused 1 Connecting rod cover 2 Connecting rod bushing 3 Piston connecting rod assembly 4 Main bearing cap 5 Crankshaft 6 Crankshaft bearing bushing 7 Thrust plate Cylinder body 9 First ring Second ring 11 Steel tape combined oil ring 12 Piston Connecting rod 14 Piston pin 39 LO Chery QQ Service Manual Mechanical Part of SQR 472Engine 2 Disassemble of Crank Connecting Rod Mechanism 2 1 Inspect the axial momentum of the connecting rod 2 1 1 Measure the axial clearance with a dial gauge or feeler gauge Standard value 0 15 0 25mm Limit 1 2mm 2 2 Inspect the connecting rod bushing for its radial clearance 2 2 1 Remove the bushing cap Notice The components of each cylinder shall be placed in order 2 2 2 Clean the bearing bushing and the axle 2 2 3 Conduct radial adjustment for the axial diameter of connecting rod with clearance gauge Tighten the bushing cap with specified torque Torque 40 2N m Notice The crankshaft may not rotate 2 2 4 Remove the bushing cap measure the maximum thickness of the searcher Standard value 0 020 0 044 mm Limit 0 07 mm 40 pe Chery QQ Service Manual 225 If it is beyond the limit replace the bearing bushing Notice Replacing the bearing bushing with the product of the same manufacturer s
17. camshaft align the timing mark as can be seen from the right picture Gear of Gear of Intake camshaft 3 3 4 Spread oil fully on the cam of camshaft assembly gears and axial of cylinder head 3 4 Tighten the camshaft bearing cap by the order of right picture o For Fixing AE Kes a q 3 5 Screw off the fixing bolts for driven gear of intake AS Keta Ta E A i PF 8 SY e a camshaft assembly E AS is my a pr Py E Y w Fi E Fa he _ 3 a i 7 F 18 a Chery QQ Service Manual Mechanical Part of SQR 472Engine Bet ETE ERE 3 6 Assembly of camshaft cove Spread sealant on the position slot of camshaft cover as can be seen from the right picture 3 6 1 Assembly of Camshaft Cover Tighten the bolts in the order as indicated in the right figure and with the specified torque 3 6 2 After spreading oil on the blanking aperture of cylinder head and the mounting surface of blanking cover press the blanking cover with special tool Notice The blanking cover should be installed in the direction as indicated in the right figure After being pressed the blanking cover should be 1 lmm higher than the surface of thecylinder head 3 7 Spread the edge of the camshaft oil seal with oil and press it into the cylinder head with M10 bolt length 50 60mm and special tools Notice If the oil seal is reused spread it with oil before pressing it into the cylinder head After removing the bolt knock it with han
18. d of Connecting Rod Name of Component Size and Tolerance Clearance or Value of Remark Interferenc Connecting rod small end 0 026 Value of Interferenc hole ioe 0 021 0 043 50 Lo Chery QQ Service Manual Mechanical Part of SQR 472Engine 6 Fit Clearance between Connecting Rod Body Hole and Bolt Bar Name of Component Size and Tolerance Clearance or Value of Remark Interferenc The hole should be processed along Connecting rod body hole Value of Interferenc with the connecting rod body 0 008 0 032 40 032 Bolt Bar 08 08 S 40 023 7 Fit Clearance between Connecting Rod Cover Hole and Bolt Bar Name of Component Size and Tolerance Clearance or Value of Remark Interferenc l The hole should be processed along Connecting rod cover hole Clearance with the connecting rod body p 0 005 0 029 Bolt bar 08 08 fg 0 014 8 Radial Clearance of Camshaft Bearing Name of Dis Size and Tolerance Clearance or Value of Remark Interferenc 0 021 1 bearing cap Cylinder Head p26H70 Clearance 0 020 0 054 1 bearing cap Camshaft Intak _ Cylinder Head oo 2 3 4 amp 5 bearing caps inder Hea i pan Clearance Camshaft 0 020 0 020 0 054 2 3 4 amp 5 bearing caps amsha 23 f 0 033 0 021 1 bearing cap Cylinder Head p29H70 Clearance 0 020 0 020 0 054 1 bearing cap Camshaft P29 fe 0 033 Exhaust 0 021 2 3 4 amp 5 bearing caps Cylinder Head 23H Clearance 0 020 0 054 0 020
19. d so as to inspect and confirm it 3 8 Assembly of camshaft timing gear After spreading sealant on the bolt prevent it from rotating with special tool and screw down the bolt of camshaft timing gear in specified torque Torque 100 5N m Notice Process the special tools as indicated in the right figure before using them 19 LO Chery QQ Service Manual Mechanical Part of SQR 472Engine 3 9 Installation of cylinder head cover 3 9 1 The old cushion of the timing belt cover which contacts the cylinder head cover should be removed completely 3 9 2 Put the new cushion into the gloove of the timing belt cover accurately 3 9 3 Mount the cylinder head cover on the cylinder head and tighten the 8 bolts in the order as indicated in the right figure and with the specified torque Torque 6 1N m 4 Inspection of valve 4 1 Standard valve clearance Valve clearance 0 18 0 05 4 2 Make sure that the timing mark on the camshaft driving gear is aligned with that on the camshaft driven gear Gear of Exhaust of Intake 4 3 Inspect the valve clearance as specified in the figure below with the feeler gauge 4 4 Rotate the camshaft for a round to the position as indicated in the figure and then measure the valve Zo Chery QQ Service Manual Mechanical Part of SQR 472Engine clearance once again If the clearance exceeds the standard value adjust it by replacing the adjustment gasket Notice
20. dial gauge the outer diameter of valve stem with micrometer caliper 3 3 2 2 Figure out the difference of measured values and the clearance If the clearance is beyond the specified value replace valve or guide Notice As can be seen from the right picture at measuring point work out the clearance of last abrasion part Standard value Limit 0 10 Valve guide inside 05 0 diameter mm Valve guide outer 05 0 diameter mm 0 056 IN 0 07 0 020mm Clearance 0 066 EX 0 08 0 030mm 25 Mechanical Part of SQR 472Engine Ss eal Thickness of Measurement Top Position of Outer Diameter Measurement Point Measurement of Valve Guide Inside Diameter Measurement Point pe Chery QQ Service Manual Mechanical Part of SQR 472Engine 3 3 3 Replacement of valve guide 3 3 3 1 Heat the cylinder head with hot water to 80 100 C 3 3 3 2 Take out the valve guide from one side of combustion chamber with special tool as can be seen from the right picture Notice The removed valve guide may not be reused The intake valve guide and the exhaust valve guide may not be mis installed 3 3 3 3 Mount the new valve guide with special tool at the place as can be seen from the right picture Notice strike the conduit slowly to the position in the cylinder head do not strike too far and be careful for size The height of the part of valve guide struck into the cylinder head Type EF
21. e Chery QQ Service Manual Mechanical Part of SQR 472Engine 5 Oil Pump 1 Structure Diagram x Components which may not be reused 1 Torque for oil pan bolt 8 2 N m 2 Oil collector 3 Oil collector spacer nonreusable 4 Oil pump 5 Oil pump spacer nonreusable 6 Rear oil seal bracket 2 Disassembly 2 1 Screw off the bolts and nuts and then remove the oil ED don f HIEN pan from the cylinder body with special tool The engine is placed on the disassemble shelf upside down Notice Don t make the oil pan flange deform 31 ene Chery QQ Service Manual Mechanical Part of SQR 472Engine ETH EIE 2 2 Remove the engine oil drainer engine oil collector gasket Notice The oil collector gasket is nonreusable 2 3 Remove the engine oil pump assembly and the engine oil pump gasket 2 4 Remove the rear oil seal bracket 3 Cleanup 3 1 Remove the old cushion from the oil pan oil pump and oil pan bracket with a scraper or shovel Notice Don t let the fragment of the cushion fall into the cylinder 32 a Chery QQ Service Manual Mechanical Part of SQR 472Engine 4 Disassembly and Assembly of Engine Oil Pump 4 1 Structure Diagram T 2041 5 Nm Seal Ring Engine Oil Pump Cover Sheet Engine Oil Pump Inner Rotor Engine Oil Pump Outer Rotor Cotter Pin lt Components which may Oil Drain Valve Spring base en eee Oil Drain Valve Spring Slide Block Crankshaft Front Oil Seal
22. embly of crankshaft timing gear Chery QQ Service Manual Mechanical Part of SQR 472Engine Bet ETHE ERE 2 8 Inspect the timing belt carefully and replace new components under any of the following circumstances or when the mileage is up to the conditions of replacement 2 8 1 Chap of back side rubber 2 8 2 Chap of dedendum chap of separated cord fabric 2 8 3 Wearing gear missing and incomplete gear of cord fabric Chap Wearing 2 8 4 Abnormal wearing of belt flank Abnormal Fall off with 2 8 3 Notice Replace the belt as any following situation occurs even though abrasion cannot be found directly The water pump leaks water out and requires continuing infusion If the belt is spotted with much oil stains and the rubber may be damaged due to expansion you should replace the belt Timing belt model and type Tension Pulley of Timing BeltRotate the bolt of tension pulley bracket and hear if it is noisy check the contacting surface and look if it is damaged Model and type of tension pulley of timing belt 1 Check if the out 1S damaged Timing belt model and type Gin ZEL MAS Camshaft timing pulley diameter mm p110 7 95 Camshaft timing pulley diameter mm 54 65 9 13 10 pe Chery QQ Service Manual Mechanical Part of SQR 472Engine Check the timing belt back plate for any deformation Standard size of crankshaft timing gear 3 Installation 3 1 Assembly of crankshaft timing pulley
23. ench for camshaft timing gears o timing gears Assembly of camshaft Oil Spring bushing puller seal Valve keeper remove tool Assembly and disassembly of valve spring retainer lock Auxiliary tools Assembly and disassembly Flywheel clam 4 7 of crankshaft gear Disassembly and assembly Valve guide punch pin l of Valve guide Axial Oil seal replacing device Oil seal base drive pe Chery QQ Service Manual Mechanical Part of SQR 472Engine Disassembly and assembly Piston pin puller of piston pin Installation of oil seal gt _ 6 AE EA Embeded combination oil seal and helical E gear puller Disassembly and assembly Crankshaft pulley holding tool of crankshaft pulley Disassembly and assembly Wrench l of crankshaft driven gear Replace valve clearance adjustment gasket Water pump pulley locking wrench Assembly of coolant pump ene Chery QQ Service Manual Mechanical Part of SQR 472Engine ETH Ele Chapter 2 Disassembly Assembly and Maintenance Disassemble or assemble the engine with roll over stand Disassemble or assemble the engine parts on the roll over stand 1 Timing Belt 1 Structure Diagram 1 Water pump pulley 2 Timing shroud 3 Timing belt 4 Torsional damper Timing belt back plate 6 Tension pulley 7 Camshaft timing pulley X Components which may not be reused Unit N m kg cm e Chery QQ Service Manual Mechanical Part of SQ
24. et is nonreusable 2 4 Disassembly of valve adjustment gasket and valve tappet 2 5 Disassemble the valve spring retainer lock spring retainer spring seat valve spring intake valve and exhaust Valve etc with special tools 2 6 Disassembly of valve oil seal and valve spring gasket 2 7 Cleanup 2 7 1 Clean the carbon dust on the valve Dn a ee lr cc IE i 1 3 a A O ES A DA U f E ae EA J x oo os Es es AO tp Li 2 7 2 Clean the bottom surface of cylinder head and the Ed i surface of intake and exhaust manifold with scraper knife Notice The surface of the cylinder head may not be scratched in the course of cleanup Do not pollute the intake port and water passage 3 Routine Inspection 3 1 Cylinder Head Measure the flatness at each point with ring gauge as indicated in the figure Cylinder head 0 10mm Surface of intake exhaust manifold 0 10 mm 3 2 Valve Spring 3 2 1 Measure the square degree of valve spring with square Replace 1f 1t exceeds the specified value Limit 1 2mm 24 gt Chery QQ Service Manual 3 2 2 Measure the free state of the spring Standard value 37mm 3 3 Inspection of valve 3 3 1 Check if it is deformed or abrades Inspection of valve Unit mm Limit Item Standard value 0 10 IN 0 85 1 41 tides LE uN ax os 3 3 2 Check the clearance of valve guide and valve stem 3 3 2 1 Measure the inside diameter of valve guide with
25. f SQR 472Engine Seb ere es 4 2 7 Inspect the clearance between the piston and cylinder wall 4 2 7 1 Measure the inner diameter of the cylinder and the outer diameter of the piston at the positions as indicated in the right figure If the measurement results exceed the limit replace the piston or cylinder Standard value 0 018 0 030 Limit 0 10 Reference The clearance between the piston and cylinder bore is controlled by the difference between the minimum inside diameter of piston hole and the maximum outer diameter of piston 4 2 7 2 After replacing the piston or the cylinder body confirm the clearance again Standard value 0 018 0 030 4 3 Crankshaft 4 3 1 diameter 4 3 1 1 if the proper alignment is beyond the limit replace the crankshaft Limit 0 03mm Notice The bending value should be equal to one second the run out value of crankshaft rotating one Inspect the proper alignment of the main axle Measure the proper alignment with a dial gauge circle 4 3 2 Inspect the crankshaft for the abrasion 4 3 2 1 Measure the connecting rod journal at the positions indicated in the left figure with a microcaliper and figure out the roundness and cylindricity Limit 0 005mm 4 3 2 2 Measure the connecting rod journal at the positions indicated in the right figure with a microcaliper and figure out the roundness and cylindricity Limit 0 004mm 5 Assembly of Crank Connecting Rod mechanism
26. g strip at the position 3 should be mounted before tightening the water pump Install the timing cover screw in the bolts with hand and then tighten them Torque 6 1N m 3 7 Installation of water pump pulley Torque 6 1N m 13 Chery QQ Service Manual Mechanical Part of SQR 472Engine 2 Camshaft 1 Structure Diagram 1 2 3 4 5 6 7 8 9 a ait ris A ss 3 T Li ae ee eon vt p ms ne oe I pupa ES TAARI a 1 y DI l gee aih are L a eg a nee z oa a LA E r n o r z M m A hte rT Cylinder head chamber cover assembly Cylinder head cover gasket Camshaft timing belt Camshaft cover X Components which may Blanking cover i tb d Camshaft bearing cap not be reuse Unit N m kg Exhaust camshaft assembly nit N m kg cm Intake camshaft assembly Camshaft oil seal 10 Axial spring retainer ring 11 Saddle washer 12 Intake camshaft sub gear 13 Transmission ring 14 cH y Chery QQ Service Manual 2 Disassembly 2 1 Cylinder head chamber cover assembly 2 Disassembly sequence of cylinder head chamber cover 2 2 Remove the camshaft timing gear with special tool Notice The special tool should be made as indicated in the right figure Use the special tool to prevent the camshaft from rotating 2 3 Remove the camshaft bearing cap 2 3 1 The marks on the camshaft gear should match with each other as indicated in
27. ied torque Torque 70 3 5N m 5 3 7 Rotate the crankshaft after assembly it should rotates swiftly the rotating torque should be less than 1Nm 48 LO Chery QQ Service Manual Mechanical Part of SQR 472Engine CHERY Bet ETE ERE 5 4 Assemble the piston and connecting rod assembly connecting rod bearing bushing and the connecting rod bearing cap pay attention to the following 5 4 1 The opening of compression ring and the opening of oil ring should be in the specified direction 5 4 2 The bolts of the connecting rod should be covered with nylon sleeves for fear of scraping the cylinder body and the axle 5 4 3 The surfaces of piston and connecting rod and other surfaces where relative motion exists should be spread with engine oil 5 4 4 Confirm the mark forwards of the piston and strike it into the cylinder body with the piston ring striking tool Notice The cylinder number of the piston and connecting rod assembly should be in accordance with the cylinder number 5 4 5 Assemble the connecting rod bearing cap and the connecting rod bushing pay attention to the following 5 4 5 1 Put the cover on the bolt as per the mark forwards spread a little engine oil over the joint surface between the nut and its seat 5 4 5 2 Tighten the right nut and the left nut alternatively for several times with specified torque Torque 40 2N m Notice The connecting rod and the connecting rod bushing should be of the same suba
28. ioner and remove the saddle spring washer transmission ring and so on 2 7 Camshaft Chery QQ Service Manual 16 Mechanical Part of SQR 472Engine Zep ARE ee e Es de EA sp ES AN AO BESA A 1 aa a gt pa ON 5 VAN q Fixing Bolt I a a a Ta Pe La p E m ME Jf Es A aj E EOL pe Esa E PA Lh He ee ie E ul TESTA l d l 1 Fer ue de SST m For Fixing Bolt oo Chery QQ Service Manual ETH Ee 2 7 1 Measure the camshaft with micrometer caliper If it is below to the specified limit replace with a new one Camshaft journal Unit mm ZL RL GL GS ZS ia n Standard value EX p23 0 0 033 IN 22 9 22 Inspection of camshaft axial clearance 1 Replace the camshaft when the axial clearance value measured with dial gauge exceeds the standard value The axial clearance of intake camshaft is 0 1 0 170mm The axial clearance of exhaust camshaft is 0 1 0 173mm Limit 0 18mm 2 1 3 Inspect the clearance of the engaging tooth of camshaft 1 Install the camshaft into the cylinder head 2 Confirm the mark forwards on the bearing cap as well as the axle number and then tighten the bolts 3 Measure the clearance of engaging tooth of the intake camshaft with dia indicator Notice Measure at 4 points on the circle of the piston Turn the intake camshaft with special tools Make sure that the marks on the driven gear and the driving gear of the ca
29. l x2 The part screwed into I Nes fixing bolt the cylinder head 56
30. mitted in this Manual and they should be carried out in the actual operation 1 Operation relating to the lifter and the small sized elevator 2 Cleaning and wipping of common components 3 Relevant visual inspection pe Chery QQ Service Manual Mechanical Part of SQR 472Engine 1 4 Definitions Standard value Refers to allowed value during inspection maintenance and adjustment Refers to the maximum or minimum value that should not be exceeded during inspection maintenance and adjustment Set the standard value for simple measurement to prevent from its measuring difficulty and inconsistency to facts Difference Refers to the difference between maximum value and minimum value It carries the cases of damaging the vehicle and parts so you should pay attention to the operation description It records the operation descriptions of cases about person accident Right Hand Right Hand Left Hand Left Hand SPECIAL l Special Tool Special Tool TOOL Assembly Assembly Sub Assembly Sub Assembly Manual Transmission Manual Transmission Automatic Transmission Automatic Transmission Turbo Charger Turbo Charger RR LO Chery QQ Service Manual Mechanical Part of SQR 472Engine 3 Special Maintenance Tools ouside view Name oF symbol Engine disassembly and inspection auxiliary Mount on the engine service device stand Disassembly and assembly Engine service stand of engine o Disassembly of camshaft Clamp hole wr
31. mshaft match with each other Inspect the clearance of the engaging tooth of camshaft Standard value Single tootj 0 04 0 13 3 Installation 3 1 Under the circumstance that special tools are used 3 1 1 Fix the 2 holes 6 of the camshaft gear assembly with special tool 3 1 2 Rotate the driven gear to the right with special tool and tally the mark hole of driven gear with that of camshaft driving gear or their marking way complies with each other fix the driven gear with bolts Thread M5 Thread pitch 0 8 17 Mechanical Part of SQR 472Engine For Fixing pe Chery QQ Service Manual Mechanical Part of SQR 472Engine 3 2 Under the circumstance that special tools are not Fe uc AA available EPA Screw the M6 bolts into the camshaft driven gear at the position indicated in the right figure Insert a Bolt screwdriver into the gap between the M6 bolt and the camshaft journal and trun the driven gear rightwards so that the fitting mark of the 2 gears match with each other or the tooth head of the 2 gears accord with each other and then fix the driven gear with bolts M5x0 8 Notice Don t damage the journal adjust the operation 3 3 Assembly of camshaft Notice Pay attention to the axial clearance of the camshaft 3 3 1 Spread grease on the gear of camshaft and the axial of cylinder head Timing Mark 3 3 2 Remove the fixing bolts for camshaft driven gear after mounting the camshaft 3 3 3 Mount the
32. nd Assembly of Engine Oil PUMD ccccccccccccccccceecceaeesessesesseeeccececeseeeeeaaaeessssseeseeeeeeeess 43 AM SU Ce AMA E E 42 Ae MVS AGS MOY OP E 42 B D Rone 1S Me CHOU eenaa E N N EE AN R 42 AR IO tala O tdt 44 D ADISASSEMMOLY Ol CU e E E E covet E E 45 es oi D a EE5 E E N 45 eD lo AAPP E SEE E OEE EEE 46 520 LMS PE O AAA E E E O II E E EE E EE 46 AAS SO Ol Oil BEAM i E EEE E E EE E 46 ASD O O 46 6 Crank Conmectino Rod Mechanical acota octal cacaos tapas 46 dL SUC TUNE ID 1A OTA Misal idilio lis 48 2 Disassembly of Crank Connecting Rod mechanisM cccccccccnnnnnnnnnnninonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnos 48 DC Me e E A R A 49 PP Pon E EEEE E EESE SEE E 52 5 Assembly of Crank Connecting Rod Mechanist ssiinei ai otra o oan Punni e unitis 53 1 ene Chery QQ Service Manual Mechanical Part of SQR 472Engine Chapter 3 Table of Main Fit Clearance for SQR472 Engine cccccccccccccccceeceeeeesesessseseeecceeeeeeeeesaaaaaassssseseeeeeeeess 55 Chapter 4 Table of Measurement Parameters of SQR472 Engine cccccccccccsssssssesseseeeecceeeeeeeeesaaaaeesessseseeeeeeeess 59 Chapter 5 Table of Main Fitting Torque for SQR472 Engine ccccccccccccccccccceeaeesessseeeeeeeeeeeeeeeeeeaaaaaaeesseseeeeeeeeess 61 Chapter 6 Positions on SQR472 Engine to be Lubricated oooooooononnnnccnnnnnnnnnnnnnnonnonanononnnnnncnnnnnnnnnnnononnnananinnnnnnss 62 Chapter 7 Position
33. ng inside 2 Front oil seal and crankshaft front oil seal journal Rear oil seal and crankshaft rear oil seal journal Valve seat hole Valve tappet and valve pipe hole Excircle and hole of valve tappet 1 Camshaft journal and bearing base hole Camshaft driving gear 13 14 15 fuen ON p lt 9 Edge and excircle of oil seal 20 foil seal journal and oil seal base hole 21 Surface oil filter sealing gasket 11 Crankshaft thrust plate the side of oil gloove o 55 c 7 e Chery QQ Service Manual Mechanical Part of SQR 472Engine f ETE Ele Chapter 7 Positions on SQR472 Engine to be Spread with Sealant SQR472 Position to be spread with Form and amount of Type of sealant Remark sealant sealant reference pad oingt surface of oil pan Loctite 5699 p 3 4 mm 2 Rear o1l seal bracket Loctite 3699 p 3 4 mm 3 Valve chamber cover Loctite 5699 p 3 4 mm EN oint surface if timing gear chamber Loctite 5699 p 3 4 mm o cover os i oint surface of camshaft cover Loctite 5699 p 3 4 mm Sealing surface of the bowl shaped Loctite 11747 Spread uniformly plug of cylinder head eee eee eee ee Intake pipe stud Loctite 262 0 125 ml x 7 The part screwed into A A eer Exhaust pipe stud Loctite 262 0 125 ml x6 The part screwed into A A err EN IO 7 10 Camshaft timing gear bolt Loctite 243 1 j Oil collector stud Loctite 243 0 08 ml x2 The part screwed into the oil pump Screw of thermoregulator shell Loctite 243 0 08 m
34. ng pressing the protective tube can not be deformed or leaking will be occurred at the cylinder head cover 21 Mechanical Part of SQR 472Engine Protective Tube of Spark Plug be e Chery QQ Service Manual Mechanical Part of SQR 472Engine Bet ETE ERE 3 4 3 Installation 3 4 3 1 Assembly of valve spring washer and valve oil seal _ Auxilary Tool of Valve Spring Assembly 3 4 3 1 1 Clamp the special auxiliary tool on the top of Valve valve stem and spread oil around the auxiliary tool and the Valve Oil Seal 0 Assembly Lower Surface of Valve Spring inner of new valve oil seal Then mount it at the position as IN d 0 Arm EX 2 00 Er can be seen from the picture and pull out the mounting auxiliary tool of valve oil seal Reference After being pressed down the size of the oil seal should comply with the value indicated in the right figure 3 4 3 2 Assembly of intake valve and exhaust valve 3 4 3 2 1 Assembly of valve spring Notice The painting is used for recognizing the different suppliers so the same engine should use the valve spring Painting with same painting 3 4 3 3 Assembly of valve keeper Warning Operate with goggle for protecting the eyes Be care for spring jumping out After assembly of valve spring and its seat press the valve spring with special tool and mount the valve keeper 3 4 3 4 Assembly of valve tappet and valve clearance adjustment gasket 3 4 3 5 Mount
35. s on SQR472 Engine to be Spread with Sealandt ooccccccccccnnnnnnnnnnonnoncnncnnnnnnnnnnnnnononononananannnnnnos 65 pe Chery QQ Service Manual Mechanical Part of SQR 472Engine Chapter 1 Reading Instruction 1 Reading Method of Maintenance Instruction 1 1 Auxiliary Materials If 1t 1s required in the operation instruction to prepare the auxiliary materials such as special tools tools measuring instruments and grease in advance you should list all auxiliary materials required in a table before carrying out each operation Since the ordinary tools lifter and spare parts are conventional materials used in the maintenance they are omitted here 1 2 Operating Sequence and Structure Diagram 1 The diagram of structure and components name of components and installation status are set forth at the beginning of each chapter or section 2 The number in the figure refers to the disassembly sequence of each component The components which may not be reused and the tightening torque are indicated in the figure T 201 1 5 Nm DA lt n Sh Seal Ring Engine Oil Pump Cover Sheet Engine Oil Pump Outer Rotor Engine Oil Pump Inner Rotor Cotter Pin Oil Drain Valve Spring Seat Oil Drain Valve Spring Slide Block Crankshaft Front Oil Seal Engine Oil Pump Housing X Components which may not be reused Unit N m kg cm FORORO RORO OROS 1 3 Content Omitted in this Manual The following operating procedures have been o
36. side and surface of the bearing bushing the inside and surface of the bearing cap the cylinder wall and journal Inspect them for abrasion and damage carefully 2 4 3 Adjust the radial clearance of the crankshaft with a clearance gauge and tighten the bearing bushing cover bolts with the specified torque Torque 70 3 5N m Notice After tightening the bolts the rotating torque of the crankshaft should be less than 1Nm The torque of crankshaft without piston connecting rod 2 4 4 Remove the bearing cap and measure the maximum width with a clearance gauge If the measurement result exceeds the limit replace the bearing bushing Standard value 0 025 0 069mm Limit 0 10mm Width Compare of Clearance Gauge 2 4 5 Remove the main bearing bushing cap of the crankshaft crankshaft crankshaft bearing bushing and crankshaft axial thrust plate Notice Tighten the bolts for the crankshaft bearing cap in the order shown in the right figure Tighten the bolts for three times then the torque must be up to the specified value 42 oO Chery QQ Service Manual Mechanical Part of SQR 472Engine 2 5 Disassembly and assembly of the piston and connecting rod assembly 23d Remove the first ring second ring and the oil ring with a pair of piston ring moving pliers Notice Don t get the piston and piston ring of each cylinder confused LIZ Remove the piston connecting rod and the piston pin with special tool Disassemble
37. ssembly Forward Mark axa 49 c 7 e Chery QQ Service Manual Mechanical Part of SQR 472Engine i ETE ERA Chapter 3 Table of Main Fit Clearance for SQR472 Engine SQR472 Clearance between Cylinder Hole and Piston Skirt Piston to Cylinder Clearance Name of Component Size and Tolerance Clearance or Value of Remark Interferenc e 0 005 Divided into two groups Group X F 72 Cylinder hole 072 hi a Clearance for group X 0 019mm 0 03mm Grs F 72 Clearance of group 72 002 a eee 2 Clearance of Crankshaft Main Bearing Name of Component Size and Tolerance Clearance or Value of Remark Interferenc Crankshaft main journal 042h6_0 016 Bearing bushing Clearance 0 025 0 069 l 0 041 Bore of cylinder main bearing p46F6 40 025 3 Clearance of Crankshaft Connecting Rod Bearing Crankshaft connecting 0 journal 37h 9 91 Bore of connecting rodbig 40 041 end bearing P40F 5 10 025 4 Clearance between Piston Pin and Piston Pin Hole Name of Ee Size and Tolerance Clearance or Value of Remark Interferenc Divided into twogroups Notice When installed 0 007 p18 0 002 Clearance for group A with hand the piston pin 0 004 mm 0 0085mm may pass through the Piston Pin Hole Clearance for group B piston pin hole smoothly ani 0 0045mm 0 009 mm without any obvious Piston pin p18 0 004 obstruction otherwise the piston pin should be replaced 5 Inteference between Piston and Small En
38. t Ps a ON 27 llenition coil bracket assembly bolt 20 1 5 M 28 Front lifting lug bolt 20 1 5 29 Exhaust pipe nut 2541 5 30 Exhaust pipe thermal shroud bolt 6 1 1005 Bolt on crankshaft pulley amp torsional damper M12X1 25 assembly YN yo jab a ga p O 32 6 1 ater pump pulley bolt ETS ater temperature sensor M12X1 5 15 1 5 W 3 34 Oil pressure switch 302 Spark plug M14X1 25 35 201 36 Fixing Bolt of spark plug cover board 2 50 5 37 Bolt intake pipe front bracket 201 5 38 Bolt intake pipe rear bracket 201 5 Bolt throttle cable ELSE 39 6 1 40 Bolt gas oil spearator bracket 6 1 41 Bolt throttle valve casing 6 1 42 Oxygen sensor M18X1 5 402 43 Bolt intake temperature amp pressure sensor 3 1 71 Ignition coil bolt 16 2 2 3 1 4 1 1 4 1 4 2 2 4 1 1 44 Fixing bolt of fuel guide rail 2 3 8 8 8 8 8 6 6 6 8 8 6 6 6 A 6 6 P DI i 5 51 Nn 4 Lo Chery QQ Service Manual Mechanical Part of SQR 472Engine Chapter 6 Positions on SQR472 Engine to be Lubricated Type of lubricating oil Engine lubricating oil Designation of lubricating oil SAE10W 30 50 SF Class No Position to be lubricated Inner wall of cylinder hole 7 Piston and piston ring Crankshaft main neck Connecting rod shaft neck Upper amp lower main bearing bushing inside 10 Upper amp lower connecting rod bearing bushi
39. tched respectively and then tighten the crankshaft belt pulley bolts 3 3 3 The force required to press down the central position between the 2 pulleys at the in tension side of the timing belt for about 5mm is Reference 19 6 29 4N 2 0 3 0kg Notice when the deflection can not reach the standard it 1s necessary to adjust the fixing bolt of tension pulley mentioned above Tighten the fixing bolt of the tension pulley with the torque as specified The tightening torque is 254 3N m 3 4 Assembly of Timing Belt Back Plate Notice Install the timing belt back plate in the direction as indicated in the right figure Inside Outside e 3 5 Install the torsional damper with special tools 3 5 1 Without flywheel 3 5 1 1 Hitch the part of crankshaft pulley with the belt of special tool 3 5 1 2 Hold on the handle of the special tool and ita pa fiie ATT o d l prevent the toothed belt from rotating Tighten the bolts de with the specified torque Torque 98 0 10N m 10 1kgm 12 pe Chery QQ Service Manual Mechanical Part of SQR 472Engine 3 52 With flywheel 3 5 2 1 Prevent the gear from rotating with special tool 3 5 2 2 Then screw down the bolt of torsional damper 3 6 Assembly of timing cover Mount the sealing strips at the positions as indicated in the right figure The sealing strips at the position 1 and 2 should be mounted before the assembly of the cylinder head assembly and the sealin
40. the cylinder head gasket and recognize the direction of front and back 3 4 4 Assembly of dust seal and cylinder head 28 oo Chery QQ Service Manual assembly 3 4 4 1 Spread a little oil on the flange side of bolt and threaded part 3 4 4 2 Tighten the cylinder bolts in the order indicated in the right figure for 3 times till the torque reaches the specified value The tightening torque for each time is set forth as follows First time 30 2Nm second time 50 3Nm third time 70 3 5Nm Torque 70 3 5N m 3 4 4 3 Mount spark plug Torque 20 1Nm Notice Tools should be vertical to prevent the protective tube of spark plug from distorting or the oil will leak 29 Mechanical Part of SQR 472Engine Oil Position Spread cH y Chery QQ Service Manual 4 Water Pump 1 Structure Diagram 1 O ring nonreusable 2 Water pump body 3 Dust seal 2 Disassembly 2 1 6 Disassembly O ring Notice The O ring is nonreusable 2 2 Screw off 3 bolts and disassemble water pump body 2 3 Disassembly of dust seal 3 Cleanup 3 1 Clean water pump joint surface 4 Routine Inspection 4 1 Check if itis deformed 4 2 Rotate it with hand and inspect whether the rotor rotates and is lubricated well 5 Assembly 5 1 Mount Dust seal 5 2 Mount Water Pump Body torque 25 1 5N m 5 3 Mount The New O ring 30 Mechanical Part of SQR 472Engine A Components which may not be reused pe
41. the right figure Mechanical Part of SQR 472Engine Timing Mark Gear of Exhaust Gear of Intake 15 Camshaft Camshaft CHERY Bet ETE ERE 2 3 2 Position the main sub gear on intake camshaft with bolts as can be seen from the right picture Notice In order to eliminate the radial force of the camshaft the camshaft should be kept at the horizontal position in the course of disassembly so as to prevent the damage caused by the excessively high radial force 2 4 Disassemble the bolts in the order as indicated in the right figure and then disassembly the camshaft bearing cap 2 5 Remove the spark plug 2 6 Disassemble the sub gear of the camshaft 2 6 1 the right figure If using the special tools operate as indicated in Clamp the camshaft and plug the pins of special tool into the hole on gear rotate the gear to keep the meshing of driven gear and driving gear and then remove the fixing bolt of driven gear Notice The surface of the camshaft may not be damaged 2 6 2 If not using the special tools operate as indicated in the right figure 1 Screw M6 bolts onto the sub gear of the intake camshaft at the position as indicated in the right figure 2 Use the screwdriver to turn the gear as indicated in the figure and disassemble the fixing bolts of the sub gear Notice The surface of the camshaft may not be damaged 3 Disassemble the axial elastic retainer ring with tens
42. y QQ Service Manual Mechanical Part of SQR 472Engine Bet ETHE EIA 4 3 1 3 Measure the clearance between the rotor and pump body Standard value 0 10 0 18 1mm Limit 0 25 mm 4 3 2 Inspect the oil pressure relief valve 4 3 2 1 No abrasion or scrape shall be found on the oil pressure relief valve 4 4 Installation 4 4 1 After the lip of the new oil seal for front crankshaft Special Tool is spread with engine oil fix 1t with a special tool Notice Use new oil seal The oil seal should be left less than 0 5 mm at its outer edge after it is pressed down Pressed Direction 7 Ll Inner Side Oil Seal Below 0 5mm 4 4 2 Assembly of the oil pressure relief valve for engine oil pump and the cotter pin Notice The cotter pin is nonreusable 35 oo Chery QQ Service Manual ETH Ee 4 4 3 When the outer gear or inner gear is put into the engine oil pump its mark should be seen 4 4 4 The new weather strip should be fixed in the groove of oil pump cover 5 Disassembly of Oil Seal 5 1 Structure Diagram 36 Mechanical Part of SQR 472Engine Components which _ may not be reused oo Chery QQ Service Manual i ETE ERA 5 2 Disassembly 5 2 1 Remove the rear crankshaft oil seal with a screwdriver Notice The rear oil seal of the crankshaft is nonreusable 5 3 Inspection Inspect the oil seal for damage and the abrasion at its lip 5 4 Assembly of oil seal 5 4 1 Spre

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