2005 Sail （SGM7165, SGM7165 Series）

Service Manual

The service manual has provided information on diagnostic, repair procedures, adjustment and
specification about Sail SGM 7165 (SL, SE,SEAT) and SGM7166 (SL, SE, SXAT).

Titles in the service manual without A or B is adaptable to both SGM7165 and SGM7166 series.While
those marked with A is only adaptable to SGM7165 series, and marked with B is only adaptable to
SGM7166 series.

ASCs of Shanghai General Motors will be able to provide to owners of SGM7165 and SGM7166 with
better services after they have the servicemen understand the manual as well as the service bulletins
released by SGM.

When the manual refers to products, part number or special tools with registered marks, we strongly
recommend you purchase such products, parts and special tools through Shanghai General Motors.

2004 Shanghai General Motors

Copyright Reserved.
Information is due at October, 2004.

Without prior written approval by Shgnahai general Motors, no part of the manual may be copied, stored in
searching system at any means or medias (including but not limited to electronic, mechanical, photocopy
or record).This also applies to all texts, illustrations and tables.
 Engine

Engine Engine Mechanical 6-5

6.1 Engine Mechanical

6.1.1 Specifications

6.1.1.1Technical Specification
Application Specification
Engine ASM (C16NE)
Type FQ
Cylinder 4 Cylinders
Main bearings 5
Ignition order 1-3-4-2
Cylinder bore 79 mm
Stroke 81.5 mm
Displacement 1598 cm3
Compression ratio 9.4:1
Idling speed 900 ± 300 rpm
Net power 65 kw/5600 rpm
Net torque 128 Nm/2800 rpm
Crankshaft
Journal maximum taper 0.005 mm
Journal maximum out-of round 0.004 mm
Crankshaft maximum deflection 0.03 mm
Journal diameter 54.93 -54.997 mm
Trunnion diameter 42.971 -42.987 mm
Maximum distance between journal enclosure 0.013 -0.043 mm
distance between trunnion and connecting rod
0.019 -0.071 mm
cap
Axial distance between trunnion connection 0.11 -0.24 mm
Possible number of main shafts 2
Crankshaft wheelbase 0.1 -0.2 mm
Cylinder head

The angles of the valve seats （all） 90° ± 1°

Intake valve and Exhaust valve
The angle of the valve seat 92° ± 15'
Distance between valve stem and guide 0.018 to 0.052 mm （intake）， 0.038 to 0.072 （exhaust）
Eccentricity tolerance of valve seat （Difference 0.050 mm
between Min. reading and Max. reading）
The width of the valve seat
Intake 1.3 -1.4 mm
Exhaust 1.7 -1.8 mm
Cylinder and piston
6-6 Engine Mechanical Engine

6.1.1.1Technical Specification(Cont’ d)
Application Specification
Distance between piston and cylinder (piston
0.010 to 0.030 mm
skirt)
Journal maximum out-of round 0.013 mm
Cylinder maximum taper 0.013 mm
Distance between TDC piston head and cylinder
0
head
Angle of pressure ring clearance 90°
Distance of pressure rings 0.3 to 0.5 mm
Distance between pressure ring and guide
Upper guide 0.060 -0.092 mm
Lower guide 0.030 -0.062 mm
Distance between scrapper ring 0.40 -1.40 mm
Camshaft
Wheelbase 0.04 -0.16 mm
Camshaft maximum deflection 0.04 mm
Oil pump
Distance between gear and pump bonnet 0.03 to 0.10 mm
Pressure at 1400 rpm 282-324 kPa
Pressure at 3000 rpm 365-407 kpa

6.1.1.2 Fastener Tightening Torque

Application Specification
Accessory pulley bolt 95N m+ (30°-45°)
Accessory tension pulley bolt 26 ± 4N m
Camshaft housing cover bolt 8 ± 2N m
Camshaft timing belt bolt 45 ± 5 N m
Camshaft baffle plate bolt 7±3N m
Connecting rod bearing cover bolt 25N m + ( 30-60) or 30N m
Coolant Temperature Sensor 15 ± 3N m
Crankshaft main bearing cover bolt 50N m+ (45°-60°)
Crankshaft Position (CKP) Sensor Bolt 9 ± 1N m
Crankshaft Position (CKP) Sensor Bracket Bolt 9 ± 1N m
Cylinder head bolt 25N m+ (180°-190°)
Engine flywheel bolt(automatic shift engine) 60 ± 5N m
Engine flywheel bolt(automatic shift engine) 35N m(30°-45) or 50N m
Exhaust manifold pipe heat shield bolt 9 ± 1N m
Exhaust manifold pipe nut 20 ± 2N m
Fuel Pressure Regulator 6N m
Fuel Rail Bolt 10N m
Engine Engine Mechanical 6-7

6.1.1.2 Fastener Tightening Torque(Cont’ d)

Application Specification
Generator bolt(bracket-upper) 18-22N m
Generator bolt(upper control bar) 18-22N m
Generator bracket-upper bolt 18-22N m
Idle Air Control (IAC) Valve Bolt 3N m
Ignition coil module bolt 8.5 ± 1.5N m
Ignition coil module bracket bolt 12 ± 2N m
Knock Sensor Bolt 20 ± 4N m
Intake Manifold Absolute Pressure (MAP) Sensor
3N m
Nut
Exhaust manifold pipe nut 20 ± 2N m
Oil filter 10N m
Oil filter adapter 15N m
Oil pan bolt 10N m
Oil pan drain plug 50N m
Oil pressure switch 30 ± 10N m
Oil pump bypass valve 22.5 ± 2.5N m
Oxygen Sensor 42 ± 4N m
Oil pump bolt 7 ± 3N m
Spark plug 27.5 ± 7.5N m
Suction pipe bolt 8 ± 2N m
Suction pipe bracket bolt 8 ± 2N m
Thermostat bolt 11 ± 3N m
Throttle body bolt 9N m
Throttle Position (TP) Sensor Bolt 3N m
Timing belt upper front cover bolt 4 ± 1N m
Timing belt lower front cover bolt 4 ± 1N m
Timing belt rear cover bolt 12 ± 2N m
Timing belt accessory tension pulley bolt 20 ± 2N m
Water pump bolt 7 ± 3N m
Fuel clamp return hose 2.5N m
Fuel tank feed hose clip 1N m
Left suspension connected to front side member 65N m
Left engine bracket connected to Automatic 62.5N m （*must use new bolts， which shall be painted with reinforcing
Transmission compos， prior to installation）
Left engine bracket connected to engine
60N m
suspension
Left engine bracket connected to Manual
Transmission 60.5N m （*Use new fastening bolts）

Rear suspension connected to body bottom plate 67.5N m

Rear engine suspension connected to engine
60N m
bracket
6-8 Engine Mechanical Engine

6.1.1.2 Fastener Tightening Torque(Cont’ d)

Application Specification
Fuel return hose clamp 2.5N m
Right suspension connected to front side member 20N m
Right engine bracket connected to engine
65N m
suspension （nut and bolt）
Upper screw of oil filler pipe 1N m
Oil pump safety valve sealing bolt 50N m

6.1.1.3Bearing Technical Specification

Main bearing standard dimension

Standard dimensions
Cylinder block with standard dimensions Oversized cylinder block

Cylinder block 59.000-59.0065 59.0065-59.013

Identification 0 1
Crankshaft - standard dimensions
Crankshaft 54.9885-54.9970 54.9800-54.9885 54.9885-54.9970 54.9800-54.9885
Identification Brown Green Brown Green
Bearing - standard dimensions
Upper bearing 1.989-1.995 1.989-1.995 1.995-2.001 1.995-2.001
Identification Brown Brown Green Green
Lower bearing 1.989-1.995 1.995-2.001 1.989-1.995 1.995-2.001
Identification Brown Green Brown Green
0.040 0.0425 0.0405 0 ． 043 （max）
Clearance
0 ． 013 （min） 0.0155 0.0135 0.016

Main bearing - dimensions over 0.25

Standard dimensions
Cylinder block with standard dimensions Oversized cylinder block
Cylinder block 62.0000-62.0065 62.0065-62.013
Identification 0 1
Crankshaft - standard dimensions
Crankshaft 54.7385-54.7470 54.7300-54.7385 54.7385-54.7470 54.7300-54.7385
Identification Brown/blue Brown/blue Brown/blue Brown/blue
Bearing - standard dimensions
Upper bearing 2.114-2.120 2.114-2.120 2.120-2.126 2.123-2.126
Identification Brown/blue Brown/blue Brown/blue Brown/blue
Lower bearing 2.114-2.120 2.120-2.126 2.114-2.120 2.120-.2.126
Identification Brown/blue Brown/blue Brown/blue Brown/blue
Engine Engine Mechanical 6-9

Main bearing - dimensions over 0.25(Cont’ d)

0.040 0.0425 0.0405 0 ． 043 （max）
Clearance
0 ． 013 （min） 0.0155 0.0135 0.016

Connecting rod bearing - standard dimensions

Connecting rod 46.000-46.020
Identification Colorless
Crankshaft 42.971-42.987
Identification Colorless
Upper cover 1.489-1.497
Identification Colorless
Lower cover 1.489-1.497
Identification Colorless
Distance 0.019-0.071

Connecting rod bearing - dimensions over 0.25

Connecting rod 46.000-46.020
Identification Colorless
Crankshaft 42.721-42.737
Identification Blue
Upper cover 1.614-1.622
Identification Blue
Lower cover 1.614-1.622
Identification Blue
Clearance 0.019-0.071