Chery Fengyun 2 Service Manual

(Power Assembly)

After-Sales Service Department, Chery Automobile Sales Co., Ltd.

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 Contents
Section I Introduction.................................................................................................................................4
Section II Different Parts List for Fengyun 2..............................................................................................5
Section III Mechanical Part of Engine........................................................................................................7
I. Disassembly of the Cylinder Head with Valve Gear Assembly.......................................................7
1.1 Removal method...........................................................................................................................7
1.2 Remove the timing cover:.............................................................................................................7
1.3 Loosen the tensioner pulley and take down the timing belt..........................................................7
1.4 Remove the cylinder head assembly from both sides to center...................................................8
1.5 Disassemble the cylinder head assembly.....................................................................................8
1.6 Remove the valve spring..............................................................................................................9
II. Installation of the Cylinder Head and Valve Mechanism Assembly................................................9
III. Installation of the Valve Spring, Valve Spring Upper Seat and Valve Cotter...............................10
IV. Installation of the Camshaft Assembly and Camshaft Bearing Cap............................................10
4.1 Install the camshaft woodruff key:..............................................................................................10
4.2 Install the camshaft assembly:....................................................................................................11
4.3 Install the camshaft bearing cap:................................................................................................11
V. Installation of the Camshaft Oil Seal.............................................................................................12
VI. Pressfit of the Spark-plug Socket................................................................................................12
VII. Installation of the Rocker Shaft with Rocker Arm Assembly.......................................................12
VIII. Installation of the Cylinder Head Assembly...............................................................................14
IX. Installation of the Semicircular Rubber Plug...............................................................................15
X. Installation of the Valve Chamber Cover Assembly......................................................................16
10.3 Install the valve chamber cover assembly................................................................................16
10.5 Install the camshaft position sensor..........................................................................................16
XI. Installation of the Crankshaft Timing Gear and Camshaft Timing Gear......................................17
11.1 Install the crankshaft timing gear..............................................................................................17
11.2 Install the camshaft timing gear................................................................................................17
11.3 Install the timing belt and tensioner pulley................................................................................17
11.4 Install the flywheel assembly.....................................................................................................18
XII. Common Diagnostic Parameter List for Engine.........................................................................18
XIII. Main Service Parameter List for Engine....................................................................................20
XIV. Structural Characteristics and Parameters of Main Assemblies...............................................21
XV. Torque List for the Power Assemblies........................................................................................22
XVI. Engine Capacity.........................................................................................................................23
Section IV Transmission..........................................................................................................................23
I. Different Parts List for the QR515MHA Transmission....................................................................24
II. Diagnostic Parameters for Transmission......................................................................................25

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III. Assembling Technical Conditions of the Different Parts................................................................26
IV. Descriptions on the Transmission Oil Filling Volume...................................................................27
V. Precautions for Maintenance.........................................................................................................27

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 Section I Introduction

To meet the market demand, speed up the product update, increase the product
diversity and expand the market share, we developed Fengyun 2 series car which can
rival the world mid- and high-grade cars and becomes a new generation of national
car from the Chery Automobile Co., Ltd. The Fengyun 2 series car conforms to the
National IV standard.
The Fengyun 2 series car is provided with a 1.5L power assembly system which is
developed by our company based on the very mature technology and equipped with
Chery’s self-developed SQR477F engine and QR515MHA transmission.
The SQR477F engine is developed on the basis of SQR480 series engine, both of
which are of the same design concept and product structure, namely, featured by the
engine type (vertical, four-in-line, water-cooled, four-stroke, single overhead
camshaft) and sequential multiport electronically controlled gasoline injection. The
SQR477F engine is of advanced performance and reliable structure, with an emission
and noise performance better than those specified in the national standard.
The QR515MHA transmission, whose final reduction ratio is 3.55, is developed on the
basis of QR513 series transmission, both of which are of the same structural
characteristics.

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 Section II Different Parts List for Fengyun 2

Different Parts List

Part No. Part Name
A13-1001510FA Front suspension cushion assembly
A13-1001611FA Front suspension bracket
A13-1001411FA Right suspension bracket
A15-1001310BA Right suspension cushion
A13-1001211FA Left suspension bracket
A15-1001110BA Left suspension cushion
A13-1001513FA Front suspension heat baffle
A13-1200052FA Shackle bracket
Hexagon bolt, spring washer and plain washer
Q1460825
subassembly
A13-1205210FA Main catalytic converter assembly
A13-1201110FA Front muffler assembly
Q33010 Hexagon flange face locking nut
A13-1201210FA Main muffler assembly
A13-1200013 Pipe clamp assembly
A13-1208711FA Heat shield - front wall
A13-1208710FA Heat shield - middle passage
A13-1208910 Rear heat shield
A13-1200052FA Shackle bracket
N90335002 Clamping piece
B11-1205311 Packing
Q1241026 Stud
A13-1109210FA Intake hose
A13-1109110FA Air cleaner assembly
A13-1109411FA Air cleaner bracket assembly
B11-1109167 Rubber sleeve
B11-1109161 Rubber ring
B11-1109163 Rubber damping ring
A13-1109114 Resonant cavity
A13-1109115 Air induction pipe
B14-1117110 Fuel filter assembly
A13-1104110 Oil inlet pipe I assembly
A13-1104120FA Oil inlet pipe II assembly
A13-1104210FA Oil inlet and return pipe assembly
A13-1104311FA Fuel vapor pipe I
A13-1100041 Two-slot pipe clamp
A13-1100042 Two-slot pipe clamp
S11-1100039 Two-slot pipe clamp
A13-1104320FA Fuel vapor pipe II assembly

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A13-1208217FA Charcoal canister solenoid valve air inlet pipe
A13-1208219FA Charcoal canister solenoid valve air outlet pipe
A13-1101001 Fuel tank with fuel pump assembly
A13-1101110 Fuel tank assembly
A13-1106610 Electric fuel pump assembly
A13-1100015 Fuel tank fixing strap assembly I
A13-1100025 Fuel tank fixing strap assembly II
A13-1101310FA Filler pipe assembly
A13-1101315FA Filler hose
A13-1101317FA Filler vent hose
A13-1101121 Fuel tank guard board
S11-1103010BA Fuel tank cap assembly
T11-1208110BA Charcoal canister assembly
A13-1208321 Charcoal canister vent pipe
A13-1104371FA Fuel vapor hose II
A13-1301110 Radiator assembly
A13-1308010 Radiator fan assembly
A13-1301310FA Radiator left tension plate
A13-1301410FA Radiator right tension plate
B11-1301313 Rubber bushing
T11-1301217 Radiator lower support cushion
A13-1303111FA Engine water inlet pipe
A13-1303211FA Engine water outlet pipe
A13-1303519FA Deaerator steel pipe assembly
A13-1303112FA Water pipe - from expansion tank to radiator
A13-1303417FA Heater water inlet pipe
A13-1303419FA Heater water outlet pipe
A11-1311110BA Expansion tank assembly

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 Section III Mechanical Part of Engine
Most parts of the SQR477F engine are the same as those of the SQR480 engine. In
particular, their cylinder blocks are very similar, so the assembling technical
conditions and working principles are basically identical, only with slight difference in
the assembling. However, the cylinder head, valve mechanism, intake manifold, valve
chamber cover, flywheel and oil pan are developed newly, so their assembling
requirements need to be redefined. In addition, the increase of compression ratio and
the change in the port timing also propose new requirements for timing adjustment.
The assembling sequence and requirements of these parts will be introduced in the
following part of “Assembling Technical Requirements of Different Parts”, and the
engine shall be assembled and maintained as specified in this text; otherwise, it may
lead to abnormal operation or even damage of the engine.
I. Disassembly of the Cylinder Head
with Valve Mechanism Assembly
The 477 series engine is of 4-valve
structure. Each cylinder is provided with
two intake valves and two exhaust valves,
and the intake valve head is of larger area than that of the
exhaust valve head.
1.1 Removal method
Remove the valve chamber cover with a 10# socket spanner.
1.2 Remove the timing cover:

2.1 Loosen and take out the two bolts for the upper timing gear
cover assembly.

2.2 Remove the upper timing gear cover with packing assembly.

2.3 Remove the crank pulley, and loosen and take down the two
bolts for the timing gear cover assembly.

1.3 Loosen the tensioner pulley and remove the timing

belt.

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1.4 Remove the cylinder head assembly from both
sides to center.

Exhaust valve rocker

arm assembly

1.5 Disassemble the cylinder head

assembly:
1.5.1 Remove the exhaust valve rocker
shaft and the rocker arm.

Intake valve rocker arm

assembly

1.5.2 Remove the intake valve rocker

shaft and the rocker arm.

1.5.3 Remove the first to fifth bearing caps and put

them in order.

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1.5.4 Remove the camshaft and put it on the
working table horizontally. Then check
its bearing hole and the cam surface for
scratch and check its cover for sand hole or crack which may affect the
performance.

1.5.5 Check whether the burrs at the valve

guide hole and cylinder head bolt hole
have been removed completely, and
check the cylinder head.

1.6 Remove the valve spring:

Press one end of the special valve stripper
on the valve spring upper seat and the other
①Valve cotter
end on the valve to compress the spring, ②Valve spring
upper seat
and then take down the valve cotter. Later, ③Valve spring
④Valve oil seal
release the special tool and take down the ⑤Valve spring
lower seat
valve spring upper seat, valve spring and ⑥Intake valve
⑦Exhaust valve
valve in turn.
1.6.1 Remove the valve oil seal with a special tool.
II. Installation of the Cylinder Head and Valve Mechanism Assembly
2.1 Clean each oil duct and cavity of the cylinder head, and then check whether all oil
ducts are unblocked and whether each connecting part of the oil duct is free of burr.
2.2 Slip the valve spring lower seat (with the base plane towards the cylinder head) into the
valve guide. The base plane of the valve spring lower seat shall cling to the finished
surface of the cylinder head valve spring lower seat.
2.3 Apply lubricating oil to the valve oil seal lip, install the valve oil seal assembly on the
valve guide, and then knock it gently with a pressure sleeve and a hand hammer to
install the oil seal properly. Next, check whether the valve oil seal is fit to the valve

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 guide properly.
2.4 Turn the cylinder head for a certain angle, clean the intake valve, exhaust valve and
valve seat ring with a piece of non-woven or silk cloth, and apply a little engine oil to
the valve stem. Then, install the intake valve and exhaust valve into the cylinder head
as specified. Slide the valve up and down and the valve oil seal shall not move. The fit
clearance between the intake valve stem and the valve guide hole is +0.012 ~
+0.043mm, and between the exhaust valve stem and the valve guide hole is +0.032 ~
+0.063mm.

III.Installation of the Valve Spring, Valve Spring Upper Seat and

Valve Cotter
Clip the cylinder head with installed valve
mechanism on the working table and fix the
press-fit tool for valve cotter on the upper plane
of the cylinder head. Later, fit the valve spring
and valve spring upper seat in turn through the
valve guide. (Note: The valve spring is a
variable-pitch spring, so it is necessary to make the end coated with paint
towards the valve spring base.) Put the pressure head on the upper seat to press
down the valve spring and assemble the valve cotter into the valve cotter groove with a
pair of forceps. Afterwards, release the pressure head to let the valve cotter clamp the
valve, and then knock the top of each intake valve stem and exhaust valve stem with a
copper hammer to fit the valve cotter properly so as to facilitate good sealing.
IV. Installation of the Camshaft Assembly and Camshaft Bearing
Cap
4.1 Install the camshaft woodruff key:
The camshaft woodruff key and the camshaft keyway are assembled together by
means of transition fit in the direction of width, with a fit clearance of -0.051 ~
0.004mm. After installing the woodruff key, check its projection height which shall be
1.64 ~ 2.11mm.

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4.2 Install the camshaft assembly:
Clean the cylinder head camshaft hole with a
piece of silk cloth and coat it with a little engine
oil, then assemble the camshaft assembly with
installed woodruff key into the bearing seat
hole on the cylinder head.

4.3 Install the camshaft bearing cap:

4.3.1 Clean each hole of the camshaft bearing cap and
apply Loctite 574 sealant to the junction surface
of the first bearing cap, with a diameter less than
1mm. The sealant applying area is as shown in
the figure.

4.3.2 Apply a little engine oil to the surfaces of 5 4 3 2 1

the cam and journal of the camshaft, and
install the first to fifth bearing caps in
order. The camshaft cover and the dowel
pin on the cylinder head are assembled
together by means of clearance fit, with a
fit clearance of +0.005 ~ + 0.028mm. For
the installation, align the camshaft cover location hole with the dowel pin, and then
press it down gently till they cling to each other.
4.3.3 Rotate the camshaft by hand, and it shall rotate smoothly. The rotating torque shall
be less than 1Nm; otherwise, it is required to remove the camshaft cover for check.
4.3.4 Use a dial indicator to check the axial clearance of the assembled camshaft by
pushing it back and forth which shall be +0.095 ~ +0.153mm.

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V. Installation of the Camshaft Oil Seal
5.1 The camshaft journal and the oil seal inner ring are assembled together by means of
interference fit, with an interference of 1.425 ~ 2.15mm.
5.2 The oil seal seat hole inner ring and the oil seal outer ring are assembled together by
means of interference fit, with an interference of 0.17 ~ 0.40mm.
5.3 Coat the oil seal inner and outer rings and the camshaft oil seal journal with a layer of
engine lubricating oil, with the side with part no. towards outside, and then press the oil
seal into the cylinder head with special tools. Afterwards, level the oil seal outer
surface with the oil seal seat hole on the cylinder head, with a deflection of -0.5 ~
0mm.

VI. Press-fit of the Spark-plug Socket

The spark-plug socket and the spark-plug
socket hole on the cylinder head are
assembled together by means of interference
fit, with an interference of 0.067 ~ 0.101mm.
Apply Loctite 648 sealant to one end of the Spark-plug
socket
spark-plug socket, and then press it into the
bottom hole with special tools till it levels with the stepped surface of the bottom hole.
The upper and lower ends of the spark-plug socket are interchangeable.

Apply a circle of sealant to the part 2cm

VII. Installation of the Rocker Shaft away from the lower end.

with Rocker Arm Assembly Exhaust valve rocker

shaft

7.1The rocker shaft includes intake valve rocker

shaft and exhaust valve rocker shaft. Note:
Wrong installation of the intake valve rocker
shaft and the exhaust valve rocker shaft will
Intake valve rocker
lead to abnormal sound or even damage of shaft

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 the rocker arm due to oil shortage. The intake valve rocker shaft is provided with four
processed grooves (for giving way to the spark-plug socket), so it is necessary to check
whether there is no burr at each oil hole or oil groove on the rocker shaft when
assembling it. The rocker shaft surface shall be kept clean, without any residue or
foreign substance.

Intake valve left Intake valve right

rocker arm rocker arm

The end
with big
chamfer

Exhaust valve
rocker arm

7.2 Check whether the ball heads and

retainers of the intake and exhaust
valve rocker arms are normal. Apply Camshaft keyway

engine oil to the rocker shaft, and

then install the rocker arm onto the
rocker shaft as shown in the figure. (For the installation of the intake/exhaust valve
rocker shaft, the end with big chamfer shall face towards the first bearing cover;
otherwise, it will fail to install the rocker shaft.)
7.3 Confirm the camshaft Intake valve rocker
arm retainer sleeve
keyway faces down, and
then install the intake valve
rocker shaft with rocker arm
assembly. Next, adjust the The end with big
chamfer of the
rocker shaft faces
position of each rocker arm towards the first
camshaft bearing
so as to fit the rocker shaft cover.

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 on the bearing seat bracket properly.
7.4 Check the intake valve rocker arm to see whether the axial clearance is free of seizure
and interference. Press an intake valve rocker arm stopper between the left and right
intake valve rocker arms.
7.5 Afterwards, install the exhaust valve rocker shaft with rocker arm assembly. Adjust the
position of each rocker arm so as to fit the rocker shaft on the bearing seat bracket
properly.
7.6 Check whether each rocker arm has been installed properly.
7.7 Install the rocker shaft bolts:
Tighten the bolts at twice. Tighten the bolts to 15±1.5Nm from center to both sides for
the first time, and after the cylinder head assembly and the cylinder block are
assembled, retighten the bolts to 30±1.5Nm in the same order as above.
7.8 After pretightening the rocker shaft bolts, tighten the bolts (480-1007161) on both
sides of the first bearing cap to the tightening torque of 9.5±1Nm.
VIII. Installation of the Cylinder Head Assembly
8.1 Two dowel pins are installed on the upper plane of the cylinder block. The cylinder
head dowel pins are on the second and fourth threaded holes on the left side of the
cylinder block (viewing from the front) and they are elastic dowel pins. The interference
between the dowel pin and the cylinder block is 0.053 ~ 0.203mm. The dowel pin and
the cylinder head are assembled together by means of transition fit, with a clearance
of -0.016 ~ 0.084mm.
8.2 Check the cylinder head gasket which shall be even and clean, without any bumping
or scratch. Install the cylinder head gasket on the cylinder block plane with dowel pins,
with the side with part no. upward.
8.3 Clean the junction surface of the cylinder head combustion chamber, the top plane of
the cylinder block, and the threaded holes. The bottoms of the cylinder block threaded
holes shall be free of accumulated oil; otherwise, it may lead to hydraulic crack.
8.4 Install the cylinder head bolts: Install the 8 4 1 6 1
0
cylinder head bolt washer on the cylinder head
bolt, with the side with chamfer upward and the
other even side towards the cylinder head. Next,
put the head support surface and the threaded
part of the bolt into the cylinder bolt hole, and

14 7 3 2 5 9
 then pre-tighten it for 3 ~ 4 threads. The cylinder head bolts are tightened manually by
four times in the order as shown in the figure.
Tighten them to 20~25Nm in order.
1. Tighten them to 40~45Nm in order.
2. Rotate them by 90 degrees in the order of
tightening. Apply sealant to
this area before
assembling the
3. Rotate them by 90 degrees again in the order of semicircular
rubber plug.
tightening.
Note: When any monitored parameter is unacceptable,
carry out repair by the following method: if the
unacceptable parameter consists in one cylinder head
bolt or two nonadjacent cylinder head bolts, replace the
cylinder head bolts; if the unacceptable parameter
Make the end with
chamfer of the
consists in two adjacent or three or more cylinder head semicircular rubber plug
towards the inside of the
bolts, loosen all cylinder head bolts and replace them cylinder head for its
installation.

with new ones. Replace the cylinder head gasket as

well. After that, retighten all the new cylinder head bolts
manually. All replaced cylinder head bolts shall be scrapped with a mark instead of being
used again. Note: For repairing the engine, after removing the cylinder head, it is
necessary to replace the cylinder head gasket and all cylinder head bolts before
reassembling it in the above order.
IX. Installation of the
Semicircular Rubber Plug

Before installing the valve chamber

cover, install the semicircular rubber Semicircular
rubber plug
plug on the cylinder head after applying Semicircular rubber plug
limit groove

Loctite 5910 sealant to the area as

shown in the figure, with a diameter of 2 ~ 3mm. For the
installation, align the semicircular rubber plug limit groove with
the cylinder head upper rabbet and then press it down.

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X. Installation of the Valve Chamber Cover Assembly
10.1 Fit the valve chamber cover sealing gasket into the cover groove and then evenly
flatten it with force.
10.2 Apply Loctite 5910 sealant to the front gantry at the front end of the valve chamber
and the fit surface of the semicircular rubber plug at the rear end of the valve
chamber cover evenly to reinforce the sealing effect, with a diameter of 3 ~ 5mm.
10.3 Install the valve chamber cover assembly:
Hold the valve chamber cover with hands and use the
spark-plug sleeve for positioning, then fit the valve
chamber cover on the cylinder head and press it down
gently. Take care to prevent the packing from falling out
during the assembling. Install the valve chamber cover
properly in one step to avoid deflection of the applied
sealant.
10.4 Install 12 Q1460625 bolts and 1 Q1460640 bolt onto the
valve chamber cover and tighten them by the following methods:
a. Multi-axis tightening method: tighten all the 13 bolts to 7±1Nm in one step.
b. Single-axis tightening method: pre-tighten them to 4±1Nm at first, and then retighten
them to 7±1Nm in the order as shown in the figure.
10.5 Install the camshaft position sensor:

Coat the camshaft position sensor seal ring with a layer of oil, then install it together with
the O-ring onto the valve chamber cover, and at last, fix the sensor with a hexagon socket
head cap bolt, and tighten the bolt to 8±0.5Nm. The standard clearance between the
camshaft position sensor and the rotation speed sensor signal gear is 0.8 ~ 1.0mm.

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XI. Installation of the Crankshaft Timing
Gear and Camshaft Timing Gear
11.1 Install the crankshaft timing gear:
Confirm the camshaft woodruff key on the cylinder head
assembly faces down at first, and then rotate the
crankshaft to the top dead center of cylinder 1. At this
time, the crankshaft woodruff key is at the upper part. Fit
the crankshaft timing gear gasket on the crankshaft, with the convex side towards the front,
and then fit the crankshaft timing gear on the crankshaft,
with the side with “FRONT” towards the front and the
mark of top dead center on the gear upward.

11.2 Install the camshaft timing gear:

Install the camshaft timing gear in the direction as shown
in the figure, and check whether the top dead center on
the gear is aligned with the timing mark on the first
bearing cap of the cylinder head. (Note: The timing mark on the first bearing cap of the
cylinder head is not on the top of it.) Install the gear gasket and bolt, and then screw down
the bolt to 95±5Nm by hand. The camshaft must be locked when tightening the bolt.
11.3 Install the timing belt and tensioner pulley:
Note: Don’t rotate the crankshaft and camshaft before tensioning the timing belt.

Installation Procedure of the Timing Gear

1. Use a spanner to tighten the tensioner pulley fixing bolt to 16 ~ 20Nm.

2. Confirm the crankshaft is at the top dead center of cylinder 1 and the mark of top dead
center on the camshaft timing gear is aligned with the mark “FRONT” on the cylinder
head.

3. Install the timing belt. Pull up the tensioner pulley with a 15# open end spanner and put
the timing belt under it, then release the tensioner pulley slowly. (Note: This tensioner
pulley is tensioned automatically.)

4. Rotate the crankshaft for two circles to check the camshaft and crankshaft for their
timing marks.

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11.4 Install the flywheel assembly:
Tighten the bolts to 60Nm first, and then tighten them to
105 ~ 115Nm. The removed flywheel bolts shall be
scrapped instead of being reused. Note: The flywheel
location hole and the crankshaft location journal are
assembled together by means of clearance fit, with a
clearance of 0.009 ~ 0.064mm. Push the crankshaft
location journal into the flywheel location hole gently
after aligning them. Don’t knock the crankshaft. The six flywheel bolt holes are arranged
asymmetrically and the flywheel is provided with an assembly mark hole. When the timing
gear is at the top dead center of cylinder 1, make the mark hole on the top of the flywheel.
At this time, the six bolts on the flywheel and the bolt holes on the crankshaft front flange
are aligned respectively.

What described above are the technical descriptions on the assembling adjustment of the
main different parts of the SQR477F engine, and the assembling requirements and
principles of other parts and different parts are basically the same as those of the SQR480
engine. The service stations are required to carry out test and overhaul by reference to the
Service Manual for the Mechanical Part of the SQR480 Series Engine issued
previously as well as the supplied Main Service Parameter List for the SQR477F Engine,
Common Diagnostic Parameter List for Engine and Main Torque List for Engine.

XII. Common Diagnostic Parameter List for Engine

Engine model SQR477F
Fuel Gasoline
Vertical, four-in-line, water-cooled, four-stroke, single
Engine type
overhead camshaft
Displacement (ml) 1497
Bore × stroke (mm) 77.4×79.52
Arrangement type and quantity of
L4
cylinders
Max. power (kW (ps)/rpm) 80/6000
Max. torque (N·m/rpm) 140/4500
Body dimension (L/W/H) (mm) 4269/1686/1492
Curb weight (kg) 1175

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Front/rear axle load (kg) 730/445
Full-load weight (kg) 1550
Front/rear axle load (kg) 835/715
Front/rear wheel track (mm) 1448/1422
Front/rear suspension length (mm) 866/876
Wheelbase (mm) 2527
Body structure Unitized three box type body
Seating capacity (person) 5
Trunk capacity (L) 450
Wheel model 195/55 R15
Fuel tank capacity (L) 50
Min. turning diameter (m) 10.5
Approach angle (°) 14.2
Departure angle (°) 15.3
Min. ground clearance (mm) 139
Emission standard GB18352.3-2005 National IV
Emission level National IV
Engine idle speed (r/min) 800±30
High engine idle speed (r/min) 2000±50
Engine ignition sequence 1-3-4-2
Volumetric compression ratio of the
10.5 : 1
engine
Engine rotation speed at the rated
6000
power (r/min)
Max. torque of the engine (Nm) 140
Summer: SAE 10W-40 (Grade SL or above)
Lubricant model
Winter: SAE 5W-40 (Grade SL or above)
Cylinder compression pressure 70
(bar)
Fuel pressure (bar) 4
Low idle speed (800±50r/min) > 1.5 (oil temperature 90℃)
Engine oil pressure (bar) High idle speed (2000r/min)
High speed (4000r/min) > 3.5 (oil temperature 100℃)
Air conditioner pipeline pressure High-pressure pipeline 15 (bar)
(bar) Low-pressure pipeline 2 (bar)
Relief valve (releasing the pressure outwards) 1.4 ~ 1.6
Expansion water tank cap (bar)
Vacuum valve (introducing air into the tank) -0.02 ~ -0.1
Working temperature of the At the beginning of working 87
thermostat (℃) Fully-opened thermostat 102
Standard pressure of each cylinder
1.0 ~ 1.4MPa
at standard idle speed

19
XIII. Main Service Parameter List for Engine
Check Item Value
Lift of the inlet cam/exhaust cam (mm) 5.09\5.34
-0.02
Camshaft Camshaft diameter (mm) 26 -0.033

Axial clearance of the camshaft (mm) +0.095 ~ +0.153

Flatness of the lower surface (mm) 0.03 ~ 0.08
Cylinder head
Overall height (mm) 97
Valve top edge thickness Intake valve 0.6
(mm) Exhaust valve 0.4
Valve stem diameter Intake valve 5.98±0.008
(mm) Exhaust valve 5.96±0.008
Intake valve 2.83
Sealing band width (mm)
Exhaust valve 2.26
Valve Clearance between the Intake valve 0.012 ~ 0.043
valve stem and the valve
guide (mm) Exhaust valve 0.032 ~ 0.063

Intake valve 68°

Inclination angle
Exhaust valve 70°
Intake valve 107.998
Height (mm)
Exhaust valve 117.41

Free height (mm) 47.7

Valve spring
Pretightening force (N)/installation height (mm) 260±11\41
Valve guide length (mm) 42±0.25
5.4  0.1 (before
processing)
Inner diameter (mm) 0.015
Valve guide 6 0
(after

processing)
0.04
Outer diameter (mm) 11  0.051

Press-in height (mm) 12.5±0.2

Piston Piston skirt diameter (mm) 77.345±0.02
1st ring 0.04 ~ 0.08
Side clearance (mm)
2nd ring 0.03 ~ 0.07

Piston ring 1st ring 0.2 ~ 0.35

End clearance (mm)
2nd ring 0.4 ~ 0.55
-0.01
Height (mm) 1st ring 1.2 -0.03

20
 -0.01
2nd ring 1. 5 - 0.03
-0.13
Oil ring 2 - 0.02
0.05
1. 2  0.03
∕
st
1 ring 0
70.5 -0.2
0.04

Piston ring groove Height/depth (mm) 2nd ring

1 .5  0.02
0
69.8 -0.2
0.03

Oil ring
2 ∕ 0.01
0
71.5 - 0 .2

Three groups:
Diameter (mm) W:20.622 ~ 20.625
R:20.625 ~ 20.628
L:20.628 ~ 20.631
Piston pin Length (mm) 61.4±0.4
Three groups:
W 20.635 ~ 20.638
Piston pin hole diameter (mm) R 20.638 ~ 20.641
L 20.641 ~ 20.644

0.093 ~ 0.303mm
Axial clearance (mm)
Radial clearance (mm) 0.0115 ~ 0.0575mm

Diameter (mm) 48.99±0.01mm

Crankshaft Radial runout (mm) 0.05

Crank journal Cylindricity (mm) 0.008
Roundness (mm) 0.005
Diameter (mm) 44.9±0.01mm
Connecting rod journal Parallelism to the crank
0.008
journal (mm)

206±0.05mm
Overall height (mm)

Cylinder block 0.008/0.01

Bore hole roundness/linearity (mm)

0.05
Flatness of the upper surface (mm)
Radial clearance of the connecting rod bearing shell
0.006 ~ 0.06
Connecting rod (mm)
Axial clearance of the big end (mm) 0.092 ~ 0.268

21
XIV.Structural Characteristics and Parameters of Main Assemblies
Water pump centrifugal type

Gasoline pump electric pump

Engine oil pump rotor type

Engine oil filter integral spin-on type

Spark plug FR7DTC

Starter permanent-magnet gear-reduction type

Generator 14V, 90A integral alternator

XV. Torque List for the Power Assemblies of A13+477F Engines

Specificatio Torque
Part Name Part No. Application
n (N·m)
Connecting the deaerator steel
M8×1.25 9~11 pipe and the engine, the
Bolt Q1840616 tension plate and the body
Connecting the main catalytic
Hexagon flange face
Q1840820 M8×20 19~24 converter hanger bracket and
bolt
the body
Hexagon flange face In front of and behind the pre-
Q33010 M10×1.25 45~55
locking nut catalytic converter
Hexagon flange face In front of and behind the main
Q330B12 M12×1.25 113~118
locking nut catalytic converter
Tapping screw Q2735532A 　 8±2 Fixing the fuel filter
Hexagon flange face Fixing the fuel tank fixing strap
Q1840825 M8×25 22±2
bolt assembly I
Hexagon flange face Fixing the fuel tank fixing strap
Q32008 M8 22±2
nut assembly II
Hexagon flange face
Q1840612 M6×12 8±2 Fixing the filler pipe bracket II
bolt
Hexagon flange face Fixing the charcoal canister
Q1840616 M6×16 8±2
bolt assembly
Hexagon flange face
Q1840816 M8×16 8±2 Fixing the filler pipe bracket I
bolt
Fixing the fuel tank guard
Screw Q2734216 　 8±2
board
Fixing the front suspension
Hexagon flange face
Q1841055 M10*1.5*55 41-51 cushion assembly and the front
bolt
cross beam

22
 Fixing the front suspension
Hexagon flange face
Q1840820 M8*1.25*20 21-25 cushion assembly and the front
bolt
cross beam
Hexagon flange face Fixing the front suspension
Q1841025 M10*1.5*25 41-51
bolt bracket and the transmission
Hexagon flange face Fixing the front suspension
Q1841045 M10*1.5*45 41-51
bolt bracket and the engine
Fixing the front suspension
Hexagon flange face
Q33010 M10*1.5 41-51 bracket and the front
self-locking nut
suspension cushion assembly
Hexagon flange face Fixing the right suspension
Q1841040 M10*1.5*40 41-51
bolt bracket and the engine
Fixing the right suspension
Hexagon flange face
Q1840840 M8*1.25*40 21-25 bracket and the right
bolt
suspension cushion assembly
Fixing the right suspension
Hexagon flange face
Q1841090 M10*1.5*90 41-51 cushion assembly and the
bolt
subframe
Fixing the right suspension
Hexagon flange face
Q1841020 M10*1.5*20 41-51 cushion assembly and the
bolt
subframe
Hexagon flange face M10*1.5*10 Fixing the left suspension
Q18410105 41-51
bolt 5 bracket and the transmission
Fixing the left suspension
Hexagon flange face
Q1841030 M10*1.5*30 41-51 bracket and the left suspension
bolt
cushion assembly
Fixing the left suspension
Hexagon flange face
Q1840820 M8*1.25*20 21-25 cushion assembly and the
bolt
subframe
Fixing both ends of the intake
Worn clamp CQ67680 60~80 3~5
hose
Bolt Q1840830 M8×30 10±1 Fixing the air cleaner body

XVI. Engine Capacity

Fuel grade: 93# gasoline or above

Engine oil grade: Summer: Mobile Esso, SAE 10W-40 (Grade SL or above);

Winter: SAE 5W-40 (Grade SL or above)

Engine oil capacity: 3.6L

Coolant type: 50% glycol + 50% soft water (by volume ratio)

23
 Section IV Transmission

The QR515MHA transmission, whose final reduction ratio is 3.55, is developed on the
basis of QR513 series transmission, both of which are of the same structural
characteristics. Except the final reduction ratio, the gear ratio and ratio of number of
teeth of each gear are identical for the QR515MHA and QR513 transmissions.
Therefore, for the QR515MHA transmission, the main different parts include the output
shaft assembly, the final reducer driven gear and the differential assembly.

For the disassembly, assembly, adjustment and common troubleshooting of the

QR515MHA transmission, please refer to the Chery QQ6 Service Manual - QR513
Transmission previously issued by our department.
I. Different Parts List for the QR515MHA Transmission
Different Parts List for the QR515MHA (BA) Transmission
Applied Unapplied
Part No. Name Qty. Remarks Part No. Name Qty. Remarks
QR515MH
Transmission
515MHA-1700010BA transmission 1 513MHA-1700010 1
assembly
assembly
Transmission Transmission
515MHA-1701100 housing 1 513MHA-1701100 housing 1
assembly assembly
Transmission Transmission
515MHA-1701101 1 513MHA-1701101 1
housing housing
515MHA-1701105 Oil guide 1 513MHA-1701105 Oil guide 1
Clutch Clutch
515MHA-1701200 housing 1 513MHA-1701200 housing 1
assembly assembly
Clutch Clutch
515MHA-1701201 1 513MHA-1701201 1
housing housing
Reverse shift Reverse shift
515MHA-1702304 1 513MHA-1702304 1
pin pin
Release shaft Release shaft
515MHA-1702500 and shift fork 1 513MHA-1702500 and shift fork 1
assembly assembly
Release fork Release fork
515MHA-1702510 1 513MHA-1702510 1
assembly assembly
515MHA-1702502 Release fork 1 513MHA-1702502 Release fork 1
Release shaft Release shaft
515MHA-1702520 1 513MHA-1702520 1
assembly assembly
515MHA-1702100 First/second 1 513MHA-1702100 First/second 1

24
 speed shift speed shift
fork assembly fork assembly
Shift fork - Shift fork -
515MHA-1702101 first/second 1 513MHA-1702101 first/second 1
speed speed
Selector arm Selector arm
515MHA-1702430BA and bracket 513MHB-1702430 and bracket
1 1
assembly assembly
Selector arm Selector arm
515MHA-1702440 1 513MHB-1702440 1
assembly assembly
Bushing -
515MHA-1701207 1 None None None
starter
Gear shift fork Gear shift
515MHA-1702010 1 513MHA-1702010 1
assembly fork assembly
Gear
Gear selecting
selecting and
and shift
515MHA-1702400BA 1 513MHA-1702400 shift 1
mechanism
mechanism
assembly
assembly
Selector arm Selector arm
515MHA-1702450BA bracket 1 519MHA-1702590 bracket 1
assembly assembly
Shifting arm Shifting arm
515MHA-1702410 1 513MHA-1702410 1
assembly assembly
Hexagon
None None Q1860840 flange face 11
bolt
Hexagon Hexagon
Q1860845 flange face 15 Q1860845 flange face 3
bolt bolt
Release fork
Hydraulic
None None None 513MHA-1702504 return torsion 1
clutch
spring
system
None None None FQ1200840F3A Stud 1
515MHC-1701401 Output shaft 1 513MHA-1701401 Output shaft 1
Output shaft Output shaft
515MHC-1701400 1 513MHA-1701400 1
assembly assembly
Final reducer Final reducer
515MHC-1701501 1 513MHA-1701501 1
driven gear driven gear
Differential Differential
515MHC-1701500 1 513MHA-1701500 1
assembly assembly
II. Diagnostic Parameters for Transmission
Model QR515MHA QR513MHA
Type Mechanical-mesh type

25
 Ratio of number Ratio of number of
Gear Gear ratio Gear ratio
of teeth teeth
Gear 1 3.545 39/11 3.545 39/11
Gear 2 2.05 41/20 2.05 41/20
Gear 3 1.423 37/26 1.423 37/26
Gear 4 1.065 33/31 1.065 33/31
Gear 5 0.865 32/37 0.865 32/37
Reverse gear 3.364 37/11 3.364 37/11
Final reduction
3.55 71/20 4.056 73/18
ratio
Lubricating oil
APIGL-4, 75W-90 GL-4, 75W-90
model
Lubricating oil
2.3L 1.8L
capacity

III. Assembling Technical Conditions of the Different Parts

1. Put the clutch driven disc assembly on the

Driven disc
flywheel and use a central spindle for assembly

Cover
positioning, then put the cover assembly on, assembly

with the dowel pin hole on it aligned with the Bolt

dowel pin on the flywheel, and at last, fix the

cover assembly onto the flywheel with 6
Fig. 27 Installation
bolts and tighten the bolts diagonally to the of the Clutch
specified torque of 23±2N.m.

2. Install the clutch release slave cylinder:

2.1 Fix the storage battery ground wire and
the clutch slave cylinder bracket with
Q1840816 bolts and tighten the bolts to
25±3N.m;

26
27
2.2 Assemble the clutch release slave cylinder onto the clutch slave cylinder bracket with
fixing bolts, and tighten the bolts to 25±3N.m.

The assembling technical conditions of other

different parts are the same with those of the
QR513 transmission. Please refer to the
Chery QQ6 Service Manual - QR513
Transmission previously issued by our
department.

IV. Descriptions on the Transmission Oil

Filling Volume
The QR515MHA transmission requires 2.3L
of APIGL-475W-90 gear oil. It is
recommended to fill oil at the odometer
sensor directly.

V. Precautions for Maintenance

1. For the disassembly/assembly methods & technical conditions, adjusted parameters,

capacity specifications, torque requirements, etc. of the QR515MHA transmission,
please refer to the Chery QQ6 Service Manual - QR513 Transmission previously
issued by our department.

2. If the relevant defective parts are those different parts listed in this manual (see the
Different Parts List for the QR515MHA (BA) Transmission), do select the
interchangeable parts with the same part no. or those specified by Chery Automobile
Co., Ltd. for replacement.

3. Don’t bump the transmission assembly or knock it with hard objects. The connecting

28
 end face between the transmission assembly and the engine shall be free of bruise.
Handle the transmission assembly gently for transportation.

4. Don’t damage the differential oil seal when inserting or pulling the drive shaft into or out
of the differential, and do install the oil seal with special tools.

5. To ensure the maintenance quality of the transmission, be careful and keep each
component of the transmission clean during operation.

6. Do lift the transmission from the hook instead of any other part.

7. Select suitable tools or special tools which are listed in the Special Removal/Installation
Tools for Transmission issued by Chery Automobile Co., Ltd.

29