H13 Engine

H13 Maintenance Manual
(SQR484B Engine Mechanical Part)
After-Sales Service Department of Chery Automobile Co., Ltd.

Contents
Chapter I The Engine Parameters and Special Tools..........................................................................2
Section 1 Technical Data...............................................................................................................2
I. Characteristic Parameters...................................................................................................2
II. Maintenance Technical Parameters..................................................................................3
Section 2 Special Tools...................................................................................................................5
Section 3 Engine Number...............................................................................................................8
I. Position of the Engine Number...........................................................................................8
II. Meaning of the Engine Number...........................................................................................8
1. Engine model...............................................................................................................8
2. Factory Number.......................................................................................................10
Chapter II Engine Body Maintenance...............................................................................................12
Section 1 Engine Timing Adjustment...........................................................................................12
Section 2 Gear System...................................................................................................................14
I. Structural Drawing...............................................................................................................14
II. Maintenance guide...........................................................................................................14
1. Replacement of the upper and lower cover of timing belt.........................................14
2. Replacement of the timing belt..................................................................................15
3. Replacement of the idler pulley, tensioner and pulley.............................................16
Section 3 Cylinder Head...............................................................................................................18
1. Replacement of the intake manifold, fuel rail and fuel injector.................................19
2. Replacement of the camshaft, bearing shell, valve and valve oil seal....................20
3. Replacement of the thermostat..................................................................................24
Section 4 Short Engine...................................................................................................................25
1. Replacement of oil pan...............................................................................................26
2. Replacement of the engine oil strainer......................................................................27
3. Replacement of the piston, piston ring, piston pin and connecting rod bearing shell28
4. Replacement of the front oil seal of crankshaft.........................................................35
5. Replacement of the engine oil pump..........................................................................36
6. Replacement of the crankshaft real oil seal..............................................................37
7. Replacement of the crankshaft and thrust gasket.....................................................38
8. Replacement of the water pump..............................................................................41
Chapter III Turbocharger...................................................................................................................42
Section 1 Turbocharger Technical Characteristics......................................................................42
Section 2 Turbocharger System...................................................................................................43
I. Schematic diagram for structure and assembly..................................................................43
II. Description of supercharged pressure..............................................................................46
Section 3 The Common Faults and Maintenance Procautions of Turbocharger Engine............47
I. Common faults...................................................................................................................47
II. Maintenance Procautions...................................................................................................47
1． Chapter I Engine Parameters and Special Tools
Section 1 Technical Data
I. Characteristic Parameters
Engine model SQR484B

Four-cylinder, water-cooled, in-line double-
Engine type
overhead camshaft, 16-valve
Cylinder diameter (mm) 83.5
Piston stroke (mm) 90
Displacement (L) 1.971
Compression ratio 10
Rated power (Kw) 95
Speed at rated power (r/min) 5750
Max. torque (N·M) 180
Speed at max. torque (r/min) 4300—4500
Min. fuel consumption (g/Kw·h) 275
Cylinder compression pressure (Bar) 10—15
Fuel pressure (bar) 4

Low idle speed
1.2—1.5
(800±50r/min)
Engine oil
pressure(bar) High idle speed (2000r/min) 3.2—3.5
High speed (4000r/min) 3.7±0.5
A/C pipeline High-pressure pipeline 13—18

pressure (bar) Low-pressure pipeline 2.6—3.3
Relief valve (release air
88±14.5
Expansion water outwards)
tank cap(kPa) Vacuum valve (intake air into
-10—-2
the tank)
Thermostat Initial working temperature 87
working Temperature when opened
104
temperature(℃) fully
1
II. Maintenance Technical Parameters
Item Standard Value
Inlet cam 37.15
Camshaft height
Exhaust cam 37.05
Inlet cam
Camshaft
Camshaft diameter
(mm)
Exhaust cam
Inlet cam 0.15--0.20

Axial clearance between camshafts
Exhaust cam 0.15--0.20
Lower surface flatness 0.04
Cylinder
head Total eight 140±0.41
(mm) Surface wear limit* total wear of cylinder body and cylinder
0.15*0.20
head
Intake valve 0.3±0.15
Top edge thickness of valve
Exhaust valve 0.3±0.15
Intake valve 5.98±0.008
Valve stem diameter
Exhaust valve 5.96±0.008
Intake valve 1.158
Sealing band width
Valve Exhaust valve 1.306
(mm) Intake valve 0.02
Clearance between valve stem and guide
Exhaust valve 0.04
Intake valve 65°
Inclination angle
Exhaust valve 68°
Intake valve 107.998
Height
Exhaust valve 106.318
Free height (mm) 47.7
Valve
spring Working pretightening force/working height (kilogram /mm) 620N/32 mm
Valve guide length 38±0.25

Internal diameter 5.4±0.1
Valve
guide External diameter
(mm)
Pressing height 16±0.3
Valve stem projection 47.5
Piston Piston skirt diameter (mm) 83.46±0.009
st
Piston ring 1 ring 0.04--0.08
(mm) Side clearance nd
2 ring 0.01--0.025
st
1 ring 0.2--0.4
End clearance nd
2 ring 0.4--0.6
Height
1st ring
2nd ring
2
Item Standard Value
Oil ring
1st ring
Piston ring
groove Height/depth
2nd ring
(mm)
Oil ring 2.5
Diameter
Piston pin
Length 60
(mm)
Piston pin hole diameter
Axial clearance 0.07-- 0.265

Radial clearance 0.0035--0.034
Diameter
Crank journal Axiality 0.05

Crankshaft Cylindricity 0.008
(mm) Roundness 0.005
Diameter
Connecting rod journal Parallelism between

connecting rod
0.008
journal and main
journal
Total height 218±0.05
Cylinder Bore hole roundness/ linearity 0.008/0.01
body Upper surface flatness 0.04
(mm)
Surface wear limit* total wear of cylinder body and cylinder
0.15*0.20
head
Connectin Radial clearance of connecting rod bearing shell 0.016--0.051
g rod
(mm) Axial clearance of connecting rod big end 0.15--0.4
3
Section 2 Special Tools
Removal tool for engine mounting bracket bolt: for removing
engine.
Mounting tool for camshaft oil seal: for installing camshaft oil
seal.
Engine timing tool: for timing camshaft.
Adaptor: for installing and removing valve spring.
Mounting tool for crankshaft rear oil seal: for installing

crankshaft rear oil seal
Mounting handle for crankshaft rear oil seal: for installing

crankshaft rear oil seal
Mounting sleeve for crankshaft front oil seal: for installing

crankshaft front oil seal
Mounting sleeve for crankshaft front oil seal: for installing

crankshaft front oil seal
4
Valve spring contractor
Mounting tool for valve cotter
Spinning tool for engine oil filter
Removal tool for valve cotter
Setting tool for flywheel: for setting flywheel.
Timing tool for camshaft: for timing camshaft.
Guide bush for valve oil seal: for installing valve oil seal.
5
Removal tool for valve oil seal: for removing valve oil seal.
Mounting tool for clutch driven disc: for installing and setting
driven disc.
Removal clamp for belt pulley bolt: for clamping belt pulley
bolt in removal.
Lifter: for lifting engine.
Fuel pressure gauge: for measuring engine oil pressure.
Cylinder pressure gauge: for measuring cylinder pressure.

Before measurement, remove the spark plug, screw the
instrument connector into the spark plug position, use a
starter to drive the engine and take the maximum value
shown by pressure gauge of as the cylinder pressure.
6
Section 3 Engine Number
I. Position of the Engine Number
Number position on engine

cylinder body
Oil dipstick
II. Meaning of the Engine Number

As shown in the figure above, the engine number marked on the engine cylinder body is composed of
the engine model and factory number.
1. Engine model
The engine model conforming to the requirement of GB725 is composed of enterprise code, number of
cylinders, cylinder diameter, characteristic code and differentiation code.
A complete engine number is as designated as follows:
□□□ ○ ○○ □ □
Differentiation code
Characteristic code
Cylinder diameter
Number of cylinders
Enterprise code
Where, ○ denotes an Arabic numeral, and □ denotes a letter.

1.1 The enterprise code fixed as SQR;
1.2 The number of engine cylinders is a one-digit or two-digit integer;
1.3 The bore refers to the diameter of cylinder barrel, expressed as a two-digit or three-digit integer,
and the decimal portion is rounded to the nearest 1 mm.
1.4 Characteristic code: It refers to the most basic characteristic of the engine, expressed as a capital
letter. Its definition is given in Table 1. If the engine combines several items of such characteristics as
in Table 1, the priority in Table 2 should be applied. For the in-line engine whose characteristic code L
is omitted in the engine number, another characteristic code can be selected to hold the place
according to the priority in Table 2.
Table 1 Engine Characteristic Codes

7
Engine
In-line engine V-type engine
characteristic
Characteristic
L V
code
Controllable
gasoline
Engine Direct injection in
combustion rate,
characteristic cylinder
variable valve
timing
Characteristic J H
code
Diesel, Gasoline,
Engine Diesel, natural Diesel,
supercharged, supercharged,
characteristic aspiration supercharged
intercooled intercooled
Characteristic D T A B
code
Two-valve Four-valve
Engine Single-point
Carburetor multipoint multipoint
characteristic injection
injection injection
Characteristic C M E F
code
Table 2 Engine Characteristic Codes Priority
In-line L V
1st in line Structure type (omitted)
Special J H
2nd in line
technology
3rd in line Air intake type D T A B
4th in line Oil supply type C M E F
1.5 Differentiation code: It is expressed as a capital letter and used to differentiate the engines that are
identical in the number of cylinders, bore and characteristic code but different in the structure, main
parameters or oil supply type (e.g., engine with variable stroke, and engine adopting two kinds of fuel).
The engine assembly number is used to differentiate the engines that are identical in the engine model
but different in the engine outside components (like intake and exhaust manifold).
1.6 Example of engine model: “SQR484F” refers to the four-in-line gasoline engine (84-mm bore, four-
valve multipoint injection) manufactured by Chery Automobile Co., Ltd. (as the characteristic code L for
in-line gasoline engine is omitted, the code for four-valve multipoint injection is used to hold the place.
And the first kind of structure differentiation code A is omitted).
8
2. Factory Number
The factory number of this engine is composed of engine characteristic code, code for manufacturer of
electronic fuel injection system, code for production year, code for production month, sequential
number of the product among the output of this engine model in that month and the note *. A complete
factory number is as follow:
□ □ □ ○○○
Sequential number of the product among the output

in that month
Code for production month
Code for production year
Code for manufacturer of electronic fuel

injection system
Characteristic code
Where: ○ denotes an Arabic numeral, □ denotes a letter, and denotes an Arabic numeral or a letter.
2.1 The engine characteristic code should be used in accordance with 2.1.4.
2.2 Manufacturers of electronic fuel injection system:
C – Motorola; D - Magnetic Marelli; E – Delphi; F – UAES; G – Siemens; H – TROITEC; B - BOSCH
2.3 The codes for year and month should be used in accordance with Table 3 and Table 4.
Table 3 Codes for Year (with codes recycled)
Year 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
Letter 1 2 3 4 5 6 7 8 9 A
code
Year 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020
Letter B C D
E F G H J K L
code
Year 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030
Letter
M N P R S T V W X Y
code
Table 4 Letter Codes for Month
Year Januar Februar Marc Apri Ma Jun Jul Augus Septembe Octobe Novembe Decembe
y y h l y e y t r r r r
Lette
r A B C D E F G H J K L M
code
2.4 Example of factory number:

“＊FF5H00106＊”
9
It refers to the 106th UAES engine with four-valve multipoint electronic fuel injection system
manufactured in August 2005.
Chapter II Engine Body Maintenance

Section 1 Engine Timing Adjustment
1. Remove the upper cover of engine timing belt. The
timing gear cover is divided into the upper and lower
assemblies in which the lower one is equipped with a
sealing gasket. Install the sealing gasket on the front
cover and fix it onto the rear cover with four hexagon
socket head cap bolts (M6×16). Fix the front cover onto
the cylinder body with six hexagonal flange face bolts
(M6×24) and fasten the upper end of the cover with a
hexagon socket head cap bolt (M6×30) with the
tightening torque of 8±3 Nm.
Socket: No. 8.
2. Remove the lower cover of engine timing belt.
3. Unscrew the center bolt in timing belt pulley and

remove the timing belt.
4. Disconnect the high-voltage ignition cable.
10
11
5. Unscrew the bolt of valve chamber cover and
remove the valve chamber cover.
6. Use a torque spanner to unscrew the bolts of intake

and exhaust camshaft belt wheel.
Note: Loosen but don’t remove it.
7. Turn the crankshaft as you are screwing in the

special tool until the crankshaft can not turn forward
and reversely.
Note: Be patient in the process. The action of turning
the crankshaft should be gentle to avoid damage to the
crankshaft.
8. Install the timing belt, turn the tensioner pulley to get

it tightened by means of hexagon socket spanner and
get the arrow of tensioner pointing at the middle of the
U-slot opening. Fasten the tensioner bolt and screw
down the fastening bolts of intake and exhaust
camshaft pulleys and the camshaft bolts.
Torque: 120±5Nm.
10. Remove the special tool for timing and install the
valve chamber cover, high-voltage ignition cable and
timing belt cover.
12
Section 2 Gear System
I. Structural Drawing
Component Torque Re-tightening

value angle
Nm
1 Bolt - Lower body of 8+3 -
timing gear front cover
4 Lower body of timing gear - -
front cover
5 Upper body of timing gear - -
front cover
6 Gasket - Lower body of - -
7 Bolt – Crankshaft timing 130+10 65+5
gear
8 Gasket – Crankshaft - -
timing gear
9 Crankshaft timing gear - -
10 Timing belt - -
11 Water pump - -
12 Bolt - Timing gear rear 5+1.5 -
cover
13 Timing gear rear cover - -
14 Camshaft timing gear - -
15 Bolt – Camshaft timing 120+5 -
gear
16 Bolt – Timing tensioner 27±2.7 -
17 Timing tensioner - -
18 Bolt – Timing gear 40+5 -
19 Timing gear - -
20 Contact idle gear - -
21 Bolt – Contact idle gear 40+5 -
II. Maintenance Guide

1. Replacement of the upper and lower covers of timing belt
1.1. The required tools and auxiliary materials
Hexagon socket spanner, 10# and 13# sockets,
ratchet extension bar.
1.2 Removal procedure
1.2.1 Loosen the five bolts in the cover using the
hexagon socket spanner.
1.2.2. Remove the timing belt cover.
13
1.2.3. Stick the flywheel using the special tool.
1.2.4. Remove the lower crank pulley using the 13# socket.
1.2.5. Remove the five bolts in the lower timing

belt cover using the ratchet extension bar and 10#
socket.
1.2.6. Remove the cover.
1.3. Check
Check the timing cover carefully for cracks and check the timing belt for interference and friction with
the cover. Replace the timing belt cover or adjust the timing belt if there are any of the above problems.
1.4. Installation procedure.
The installation is in the reverse order of the removal. Refer to the removal procedure for installation.
Note: The lower cover should be installed prior to the upper cover.
2. Replacement of the timing belt
2.1. The required tools and auxiliary materials:
Hexagon socket spanner, 10# and 13# sockets, ratchet extension bar.
2.2.1. Remove the upper and lower covers of timing belt. (See the “Replacement of the timing belt
cover” for specific method.)
2.2.2. Unscrew the center bolt in timing belt pulley and remove the timing belt.
14
2.3. Check
Carefully check the whole timing belt. Replace the belt if any of the following symptoms is found:
(1) Cracked back rubber,
(2) Cracked tooth root or separated or cracked fabric,
(3) Worn fabric, tooth loss or defective,
(4) Abnormal wear of belt side part.
Crack Wear
Crack
Tooth loss
Abnormal
wear Falling-off
If any of the following phenomena is found, the belt should also be replaced even though there is no
confirmed external damage:
(1) The water pump becomes leaky and requires continuous water replenishment;
(2) There are many oil stains on the belt. It should be replaced in the consideration of rubber damage
caused by expansion.
2.4. Installation procedure.
Note: The engine should be retimed after replacement.
3. Replacement of the idler pulley, tensioner and pulley
3.1. The required tools and auxiliary materials: hexagon socket spanner, 10#, 13# and 15# sockets,
ratchet extension bar.
15
3.2.1. Remove the timing belt. (See the “Replacement of the timing belt” for specific method.)
3.2.2. Remove the tensioner, idler pulley and pulley. Idler pulley
.
Tensioner
Timing belt
3.3. Check
3.3.1. Appearance check
Carefully check the tensioner, idler pulley and pulley for appearance damages (like pits, scratches,
etc.).
3.3.2. Performance check
Turn the tensioner, idler pulley and pulley to check if they can work smoothly and if they are seized.
Replace the one from with such phenomena.
3.4. Installation procedure
3.4.1. Install the tensioner, idler pulley and pulley respectively in the reverse order of the removal.
3.4.2. Install the timing belt pulley and calibrate the engine timing.
3.4.3. Install the other components.
16
Section 3 Cylinder Head
10 9 8
1
1
6
19
12 5
4
13
3
14 2
18 1
15
16 7
17
1. Intake valve 11. Camshaft front oil seal

2. Valve oil seal 12. Exhaust camshaft assembly
3. Lower seat of valve spring 13. Rocker arm assembly
4. Valve spring 14. Hydraulic tappet assembly
5. Upper seat of valve spring 15. Double-end bolt (9 in total)
6. Valve cotter 16. Cylinder head gasket
7. Exhaust valve 17. Shackle
8. Air intake camshaft assembly 18. Cylinder head bolt
9. Camshaft bearing cap assembly 19. Cylinder head assembly
st
10. The 1 bearing cap assembly
17
1. Replacement of intake manifold, fuel rail and fuel
injector
1.1. The required tools and auxiliary materials: ratchet,
extension bar, 10# socket and Phillips screwdriver.
1.2. Removal procedure
1.2.1. Set the ignition key at OFF position.
1.2.2. Loosen the fuel injector plug.
1.2.3. Remove the connecting bolt between oil dipstick

tube and intake manifold.
1.2.4. Remove the clamp at the joint between intake

hose and throttle valve body.
1.2.5. Remove the connecting bolt of throttle valve

body and take off the throttle valve body.
Note: This throttle valve body is an electronic throttle
valve body. Don’t rotate the blade in the center of the
valve body with hands or other things.
1.2.6. Loosen the oil inlet pipe connector.
1.2.7. Remove the fastening nut of intake manifold and

take off the intake manifold.
1.3 Installation procedure

18
2. Replacement of camshaft, bearing shell, valve and valve oil seal
2.1. The required tools and auxiliary materials: a special tool for valve oil seal, a set of pulling tool for
valve spring and oil seal, an adjustable spanner, a special tool for timing and a set of hexagon socket
spanner.
2.2.1. Remove the generator belt (see the “Replacement of the generator belt” for specific method).
2.2.2. Remove the timing belt (see the “Replacement of the generator timing belt and timing calibration”
for specific method).
2.2.3. Remove the engine valve chamber cover.
2.2.4. Insert the special tool for timing into a camshaft

dent and fix it with bolt.
2.2.5. Remove the pulleys of intake and exhaust

camshafts using a torque spanner.
2.2.6. Remove the rear protective cover of timing belt.

2.2.7. Remove the cylinder head assembly.
2.2.8. Remove the bearing caps of intake and exhaust

camshafts in turn and place them in order.
Note: There are I1, I2, I3 and I4 (E1,E2,E3 and E4)
marked on the second, third, fourth and fifth camshaft
bearing cap, indicating the correspondence of bearing
caps with cylinders 1, 2, 3 and 4 respectively (“I” stands
for the intake camshaft and the “E” stands for the
exhaust camshaft).
Torque: 9.5±1.5 Nm.
19
2.2.9. The removal sequence diagram of bearing caps
of intake and exhaust camshafts.
2.2.10. Take out the camshaft and hydraulic tappet.
2.2.11. Remove valve spring using the special tool.
2.2.12. Remove the old valve using the special tool for
valve oil seal.
2.3. Check
2.3.1. Check of valve spring
Use a caliper to measure the free length and verticality
of valve spring and its length under special pressure.
Standard Value (mm)

Free length 47.70
Length at 620N 32
Replace it if the measured values exceed the limit.
2.3.2. Check of camshaft diameter

Use a micrometer to measure the camshaft diameter.
Standard Value (mm)

Diameter
Φ
Replace it when exceeding the limit.
20
2.3.3. Check of cam height
Use a micrometer to measure the cam height.
Standard Value (mm)

Intake cam 37.15
Exhaust cam 37.05
Replace it when exceeding the limit.
2.3.4. Check of valve

A: Use a micrometer to measure the diameter of the
Valve
valve stem at the measuring points respectively 26 mm, guide
52 mm and 78 mm away from the bottom of the valve,

as shown in the figure.
Internal dia. of valve External dia. of
guide valve stem
B: Use an inside dial indicator to measure the internal Measuring point
diameter of the valve guide at the quartering points of

the valve guide.
C: Obtain the difference between the measured values Measuring point

to calculate the clearance. If the clearance exceeds the
specified limit, replace the valve or valve guide.
D: Check the contact bandwidth of the valve.
Contact position (at the Plate

center of the inclined plane) thickness
E: Check the valve seat ring.
21
Standard
Value
External diameter of valve IN ￠5.98±0.008
stem (mm) EX ￠5.96±0.008
Internal diameter of valve IN ￠5.4±0.1
guide (mm) EX ￠5.4±0.1
Clearance (mm) IN 0.02
EX 0.04
Thickness of valve top (mm) IN 0.3±0.15
EX 0.3±0.15
Width of sealing band IN 1.158
(mm) EX 1.306
F: Check of valve stem projection

Use a vernier caliper to measure the projection height of
valve stem (see the right figure). Valve stem top
Valve stem
Standard Value (mm) projection height
Intake valve stem

47.5 Valve spring seat
projection face
Exhaust valve stem

47.5
projection
2.3.5. Check of axial clearance of camshaft

Use a micrometer to measure the axial clearance. If it is
higher than the reference value, replace the camshaft.
Standard Value
Intake camshaft 0.015—0.02
Exhaust camshaft 0.015—0.02
2.3.6. Check of flatness of cylinder head
A: Clean the lower surface of cylinder head.
B: Use a ruler and a plug gauge to check whether the
lower surface of the cylinder head warps. (Measure it in
the sequence of A, C, D, E, F and G as shown in the
figure.)
Standard Value
Flatness of cylinder head 0.04
C: Adjust it if the flatness is excessive. And
replace the cylinder head when exceeding the
limit.
The maximum allowable wear thickness of cylinder head: 0.15 mm.
The maximum allowable wear thickness of cylinder body and head: 0.20 mm.
22
2.4.1. Installation sequence
2.4.2. Precautions for installation
1) The valve spring should adopt the pocket disassembly. Cylinders 1 and 4 make a group and
cylinders 2 and 3 make another group. Turn the piston to the top dead center of cylinders 1 and 4,
remove the valve spring of cylinders 1 and 4 and then install the valve spring immediately. Turn the
piston to the top dead center of cylinders 2 and 3 and replace the valve oil seal. This can prevent the
valve from falling into the cylinder and causing unwanted troubles.
2) The oil seal lip should be coated with engine lubricating oil when installing valve.
3) The tightening sequence of cylinder head bolts 8 4 1 5 9
is as shown in the right figure and they should be
tightened in the following procedure.
A: Apply a little engine oil on the head and root of the
bolts.
B: Tighten the bolts to 40±5 Nm in sequence.
C: Tighten the bolts for 90±5 degree clockwise.
D: Tighten the bolts for 90±5 degree clockwise. 7 3 2 6 10
Note: The bolts installed this way can not be used
again.
3. Replacement of the thermostat
3.1. The tools and auxiliary materials required: open mouth tongs, socket spanner etc.
3.2.1. Loosen the clamp on water outlet pipe of thermostat using the open mouth tongs and drain the
coolant.
Note: It should be carried out after the water temperature falling to avoid scalds.
3.2.2. Remove the 4 bolts in thermostat cover using the 10# socket spanner.
3.2.3. Take out the thermostat.
3.3. Check
Boil the thermostat in water in conjunction with a thermometer. Observe the thermostat temperature
when the thermostat is being open normally and has been open completely.
Temperature
Temperature when starting to open it normally 87℃
Temperature when it is opened fully. 104℃
Replace it if the measured thermostat temperature is abnormal.
3.4.2. Precautions
The engine coolant should be added to the required volume after installation.
23
Section 4 Short Engine
1) Piston 2) Connecting rod upper bearing shell 3) Timing hole blank plug
4) Connecting rod lower bearing shell 5) Gasket 6) Bolt
7) Engine oil filter 8) Engine oil cooler 9) Engine oil filter holder
10) Connecting rod bolt 11) Connecting rod bearing shell cover 12) Engine oil pump
13) Bolt 14) Washer 15) Crankshaft timing belt pulley
16) Washer 17) Bolt 18) Crankshaft pulley
19) Bolt 20) Bolt 21) Water pump
22) Water pump gasket
24
23) Main bearing bolt of crank shaft 24) Frame bolt 25) Frame
26) O-ring 27) Crankshaft 28) Cylinder body
1. Replacement of oil pan
1.1. The required tools and auxiliary materials:
Wash the installation surface of oil pan and frame with the acetaldehyde, install a ellipse seal ring to
the oil outlet of engine oil pump, install an O-ring (φ22×2.5) to the oil duct porthole connecting the
frame and oil pan and install two dowel pins (φ6×10). Install two screw plugs (M18, coated with
LOCTITE 243 adhesive before installation) to the main oil duct of oil pan with the tightening torque of
25
20+5 Nm. Screw down the drain plug (M16×1.5) with a copper gasket to the tightening torque of 25+3
Nm.

1.2.1. Unscrew the drain bolt of oil pan and drain the
engine oil.
Note: The engine oil should be stored in a special
container in an environment-friendly way.
1.2.2. Remove the fastening bolt using 17 mm sockets.

(18 of M7×25, 1 of M7×40 and 6 of M7×95)
1.2.4. Remove the hollow bolt connecting oil return

pipe of oil-gas separator using 10# socket spanner and
oil pan and note the tightening torque of hollow bolt
should be 18±3 NM.
1.2.5. Knock around the oil pan lightly with the rubber
hammer before taking off the oil pan.
Note: Take caution to the potential that the oil pan may
fall suddenly in the process of knocking. Clear away
the aged LOCTITE adhesive on engine frame using the
right-angled tool.
Note: Don’t get the frame surface scratched.
1.3.1. Paint over through the frame and the junction
surface of oil pan with LOCTITE adhesive 5910, close
the oil pan and install the tightening bolt of oil pan.
Note: The adhesive should be painted on the inside of
mounting bolt hole of oil pan.
1.3.2. Screw down the bolt. Pretighten to fit it adequately and tighten it to the required torque. The
tightening sequence is as shown in the figure.
Torque: 15±3 N·M.
1.3.3. Add the engine oil to the required volume.
2. Replacement of engine oil strainer
2.1. The required tools and auxiliary materials: 10# open end spanner, 10#, 15#, 17# sockets, ratchet
extension bar, LOCTITE adhesive 5901, engine oil, etc.
26
2.2.1. Remove the oil pan. (See “Replacement of oil pan” for removal method).
2.2.2. Remove the bolts (8 in total) connecting engine oil
strainer and frame using 10# socket spanner.
2.2.3. Pull out the engine oil strainer carefully.

2.3.1. Screw the pipe mouth of engine oil strainer into
frame carefully.
2.3.2. Install and tighten the 8 bolts of engine oil strainer.
Note: All the bolts should be coated with LOCTITE adhesive 243.
Torque: 8±3Nm
2.3.3. Install the oil pan (See “Installation of oil pan” for specific method).
3. Replacement of piston, piston ring, piston pin and connecting rod bearing shell
3.1. The required tools and auxiliary materials: 10# open end spanner, 10#, 15#, 17# socket s, ratchet
extension bar, LOCTITE adhesive 5901, engine oil, torque spanner, special tool for installing piston,
feeler gauge, clearance gauge and micrometer.
3.2.1. Remove the timing belt. (See the “Remove the timing belt” in section of “Replacement of the
timing belt” for specific method)
3.2.2. Remove the oil pan. (See the section of “Replacement of oil pan” for specific method)
3.2.3. Remove the cylinder head. (See the section of “Removal of cylinder head” for specific method)
3.2.4. Remove the engine oil strainer. (See the section
of “Replacement of engine oil strainer” for specific
method)
3.2.5. Unscrew the bolts of connecting rod big end.
3.2.6. Remove the lower cover of connecting rod

bearing shell.
27
3.2.7. Jack up the connecting rod and piston lightly
using a wooden handle. Take off the piston and
connecting rod.
3.2.8. Take off the piston ring.
3.2.9. Take off the positioning snap ring of piston pin

and pull out the piston pin.
Note: The tension of positioning snap ring is strong. Be
careful when removal.
3.3. Check
3.3.1. Check of piston diameter
Use a micrometer to measure in the vertical direction of
the piston pin at about 11 mm of the lower part of piston
skirt.
Cylinder No. Standard Size (mm)

1 83.46±0.009
2 83.46±0.009
3 83.46±0.009
4 83.46±0.009
Replace it if the wear exceeds the limit.
3.3.2. Check the clearance between piston ring and ring

groove
A. Clean the accumulated carbon in ring groove using
the piston ring.
B. Use a feeler gauge to measure the clearance
between the piston ring and the ring groove.
Reference Value (mm)

The 1st ring 0.04--0.08
nd
The 2 ring 0.01--0.025
28
Replace it if the measured clearance exceeds the limit.
3.3.3. Check the end clearance of the piston ring
A. Place the piston ring at the place 45 mm under the

top surface of the bore hole, and press the piston ring
into the cylinder block by means of the piston top
surface.
B. Use a plug gauge to measure the axial clearance.
Reference Value (mm)

The 1st ring 0.2--0.4
nd
The 2 ring 0.4--0.6
Replace it with a new set of piston ring if the measured

clearance exceeds the limit.
3.3.4. Check the diameters of piston pin and piston pin

hole
At the positions shown in the following figure, use a

micrometer to measure the piston pin. Take the
maximum measured value as the diameter of the piston
pin.
At the positions shown in the following figure, use an

inside dial indicator to measure the piston pin hole. Take
the minimum measured value as the diameter of the
piston pin hole.
Standard Size (mm)
Internal diameter of
12(+0.1/-0.2)
piston pin hole
External diameter of
piston pin
10 00..12
29
Replace it with a new set of piston and pin if the
measured clearance exceeds the limit.
3.3.5. Check the connecting rod journal and connecting

rod bearing shell
A. Check the diameter of the connecting rod

journal and the parallelism between the
connecting rod journal and the main
journal. Use a micrometer to measure the
connecting rod journal.
Standard Value (mm)
0
Diameter 47.9  0.016
Parallelism to main journal

0.008
B. Check the radial clearance of connecting rod bearing

shell
Check the radial clearance of the connecting rod

bearing shell. Use a clearance gauge to measure the
radial clearance of the connecting rod bearing shell.
Clean the connecting rod journal and connecting rod
bearing shell, put the clearance gauge on the journal;
install the bearing shell, and screw down the bolts to the
specified tightening torques.
Note: Do not move the crankshaft in this process.
Loosen the connecting rod bolt, remove the bearing

shell, use the ruler on the clearance gauge package to
measure the size of the widest part of the flattened
clearance gauge, and obtain the clearance value.
Standard Value (mm)

Plastic clearance gauge
Clearance 0.016—0.051
30
Replace it if the measured clearance exceeds the limit.
Note: The bearing shell used for replacement should be
from the same manufacturer with the same brand and
number.
3.3.6. Methods for selecting connecting rod bearing

shell
A. Method for selecting the upper connecting rod
bearing shell:
When selecting the upper connecting rod bearing shell,

check the marks (consisting of a series of Arabic
numerals and letters A and B) on the connecting rod big
end firstly. Select the model of the upper connecting rod
bearing shell according to letters A and B.
A---Red bearing shell
B---Blue bearing shell
B. Method for selecting the lower connecting rod bearing

shell:
When selecting the lower connecting rod bearing shell,
check the marks (consisting of Arabic numerals 1 and 2
and letters A and B) on the first balance block at the
front end of the crankshaft. The first Arabic numeral
following the letter refers to the model of the first lower
connecting rod bearing shell of the crankshaft
connecting rod journal, and the fourth Arabic numeral
refers to the model of the fourth lower connecting rod
bearing shell.
1---Red bearing shell

2---Blue bearing shell
3.3.7. Check the flatness of cylinder body upper surface
A: Clean the upper surface of cylinder body.
31
B: Use a ruler and a plug gauge to check the lower
surface of cylinder head for warps. (Measure them in the
sequence of A, B, C, D, E, F and G, as shown in the
figure.)
Standard Value (mm)
Warp 0.04
C: Adjust it if the warp is excessive. Replace the cylinder

if the warp exceeds the limit.
The maximum allowable wear thickness of cylinder
body: 0.15mm.
The maximum allowable wear thickness of cylinder body
and head: 0.20mm.
3.3.8. Check of cylinder barrel
A: Check the cylinder wall for scratches or dents.
If so, rebore the cylinder, embed a sleeve or replace the
cylinder. 12 mm
B: Use a cylinder measuring meter to measure the Center

internal diameter and cylindricity of the cylinder.
Bottom
Standard Value (mm)

Internal diameter 83.5
Cylindricity 0.008
Cylindricity= (Maximum Bore – Minimum Bore)/2

Respectively measure the bores in directions A and B
on three planes as shown in the figure. Select the
maximum and the minimum values among these six
measured values, and halve the difference between the
maximum value and the minimum value to obtain the
cylindricity.
3.3.9. Check of axial clearance of the connecting rod

Use a dial indicator or a plug gauge to measure the axial
clearance.
Standard Value (mm)

Clearance 0.15—0.50
32
33
3.4.1. Coat the piston pin and the interior of piston
pin hole with engine oil, connect the piston and
connecting rod with a piston pin and install a clip
onto the piston pin clip.
3.4.2. Install the piston ring. Install the rings to

From up to bottom
piston in the sequence of lower blade, bushing 1st ring
ring of oil ring, upper blade, the 2nd compression 2nd ring
st
ring and the 1 compression ring; note the facing Upper blade
Bushing ring
of piston ring to be installed, whose side marked
Lower blade
with “top” should facing upward. Stagger the two Opening angle of rings:
Lower blade
blades and bushing ring by a certain angle, the
1st ring 2nd ring
sharp angle of bushing ring connector should
point at the top of piston, and the 1st ring and the
Front Rear
2nd ring should form an angle of 1200. Bushing
ring
Upper blade
3.4.3. Install the connecting rod upper bearing

shell onto the connecting rod.
Note: The gap on shell should be aligned with that
on the connecting rod.
3.4.4. Coat the interior of engine cylinder with

engine lubricating oil, hold the piston ring with the
special tool and knock the head of piston gently
with a wooden handle to install the piston
connecting rod assembly.
34
Note: The end with points on of the connecting rod
should face cylinder 1 and should conform to the
arrow direction on piston top surface.
3.4.5. Install the connecting rod lower bearing

shell onto the connecting rod and coat the shell
with engine lubricating oil.
Note: The gap on shell should be aligned with that
on the connecting rod.
3.4.6. Install the cover of connecting rod and screw down

the bolts.
Torque: 25±3N·m.
Then go on to screw it by 90°±5°.
3.4.7. Install the engine oil strainer.
3.4.8. Install the oil pan.
3.4.9. Install the cylinder head.
3.4.10. Retime the engine timing.
3.4.11. Install the timing belt.
4. Replacement of the front oil seal of crankshaft
4.1. The required tools and auxiliary materials: ratchet extension bar, 13#, 15#, 17# and 22# sockets,
13# open end spanner, hexagon socket spanner, special tool for installation of engine oil seal .
4.2.1. Remove the timing belt (See the “Replacement of the
timing belt” for specific removal procedure)
4.2.2. Engage gear 5, step the brake, use a torque
spanner to remove the bolts connecting the timing
belt pulley and crankshaft, and then take off the
timing belt pulley.
Torque: 130±10Nm.
Then go on to screw it by 65°±5°.
35
4.2.3. Stick up the old oil seal carefully using a slotted screwdriver.
Note: Be careful not to damage the oil seal seat
ring when removing the oil seal.

4.3.1. Clear away the oil dirt on oil seal and coat
the seat ring with lubricating oil.
4.3.2. Apply engine lubricating oil on the oil seal lip.
4.3.3. Fit a new lubricated oil seal into special tool.
4.3.4. Press the oil seal into oil seal seat ring
carefully and knock it into the right position using
a hammer.
5. Replacement of the engine oil pump

5.1. The required tools and auxiliary materials: a set of big socket set, a set of small socket set and a
set of open end spanner.
5.2.1. Remove the engine timing belt. (See the “Removal of engine timing belt” for specific method)
5.2.2. Press the brake with no gear engaged and remove the timing belt pulley.
36
5.2.3. Remove the fastening bolts of engine oil
pump using a 10# socket and take out the engine
oil pump.
Torque: 8+3NM
5.2.4. Lift up the oil seal.
5.2.5. Clean the seat ring of engine oil pump.

5.3.1. Coat the seal ring of engine oil pump with engine oil.
5.3.2. Install the engine oil pump to the seat ring of engine oil pump.
Note: The projection on engine oil pump should face downward; otherwise the bolt can not be screwed
in.
5.3.3. The sealing gasket of engine oil pump can only be used once and should be replaced when
reinstalling the engine oil pump. Note that the gasket should not be coated with adhesive when
installing.
5.3.4. Install the oil seal.
5.3.5. The bolt head should be coated with sealant when installing the engine oil pump bolt.
6. Replacement of crankshaft real oil seal

6.1. The required tools and auxiliary materials: a set of socket set, a slotted screwdriver, a small-size
lifter and engine oil.
6.2.1. Lift the engine assembly out of vehicle. (See the “Lift of engine” for specific method)
6.2.2. Remove the clutch pressure plate.
6.2.3. Remove the flywheel. Use the special tool

to stick the flywheel and use the socket spanner to
remove the fastening bolt.
6.2.4. Lift up the old oil seal with a slotted screwdriver.

Note: Don’t damage the oil seal seat ring.
6.3.1. Clean oil seal seat ring. Use the clean
gauze dipping engine oil and clear the foreign
matters inside the oil seal seat ring.
37
6.3.2. Apply engine lubricating oil evenly on the rear oil seal
lip of crankshaft, coat the oil seal outer ring evenly with
engine oil, fit the oil seal into special tool and press it into oil
seal seat ring.
6.3.3. Install the flywheel and clutch pressure plate and install the engine to vehicle.
Torque: 25±5NM。
Turn it by 30°±5°
7. Replacement of Crankshaft and Thrust Gasket
7.1. The required tools and auxiliary materials: a set of open end spanner, a set of socket set, a small
crane, LOCTITE adhesive 243, engine oil, feeler gauge, plug gauge, micrometer.
7.2.1. Lift the engine out of vehicle. (See the “Lift of engine” for specific method)
7.2.2. Drain the engine oil.
7.2.3. Remove the engine timing belt. (See the “Replacement of timing belt” for specific method)
7.2.4. Remove the engine accessories like generator, A/C compressor, boost steering pump and
bracket. (See the “Replacement of engine accessories” for specific method)
7.2.5. Remove the engine cylinder head assembly. (See the “Replacement of the engine cylinder head”
for specific method)
7.2.6. Remove the engine clutch pressure plate, flywheel and timing belt pulley.
7.2.7. Remove the oil pan and engine oil strainer. (See the “Replacement of oil pan and engine oil
strainer” for specific method)
7.2.8. Remove the piston connecting rod assembly of four cylinders and place them in order.
Note: It is recommended to label each piston connecting rod with its corresponding cylinder number to
avoid mistake when installing.
7.2.9. Remove the engine oil pump assembly.
7.2.10. Remove the lower frame assembly of lower cylinder body and take out the crankshaft and
thrust gasket.
7.3. Check
7.3.1. Check the radial clearance of crankshaft
a): Clean the journal and bearing shell.
b): Install the crankshaft.
Plastic clearance gauge
c): Cut the plastic clearance gauge into the
sections whose lengths equal to the bearing width,
put it on the crankshaft journal and align it with the
center line.
d): Carefully install the main bearing cap, and screw down the
bolts to the specified torques.
e): Carefully remove the main bearing cap.
38
f): Use the ruler on the plastic clearance gauge
package to measure the size of the widest part of
the flattened plastic clearance gauge, and obtain
the clearance value.
Standard Value (mm)

Clearance 0.0035-0.034
Replace the bearing shell when the clearance exceeds the limit.
Note: A set of bearing shell should be replaced at the same time.
7.3.2. Methods for selecting main bearing shell of

crankshaft
① Selection of upper main bearing shell of crankshaft

Check the marks on the cylinder block (as shown in the
figure), and you will find from the figure five A marks
there, each of which refers to the model of the upper
main bearing shell of each crankshaft correspondingly
(from left to right).
② Selection of the lower main bearing shell of crankshaft

When selecting the lower main bearing shell of
crankshaft, check the marks on the first balance block
at the front end of the crankshaft (consisting of Arabic
numerals 1 and 2 as well as letters A and B). The first
letter refers to the model of the first lower main bearing
shell of the crankshaft, and the fifth letter refers to the
model of the fifth lower main bearing shell of the
crankshaft.
7.3.3. Check of axial clearance of crankshaft

Install the crankshaft and use a micrometer to measure
the axial clearance of the crankshaft.
Replace the thrust gasket if it exceeds the limit.
39
The standard thickness of thrust gasket (mm):
7.3.4. Check of coaxiality and abrasion of crankshaft

a. Check the coaxiality of main bearing journal of
crankshaft
Use a dial indicator to measure the coaxiality and
replace the crankshaft if the coaxiality exceeds the limit.
Note: The bending value equals to ½ of the run-out
when the crankshaft has rotated for one circle.
Standard Value(mm)
Coaxiality 0.05
b. Check of crankshaft abrasion
Use a micrometer to measure the crankshaft diameter.
Rotate the crankshaft for 90°, and carry out the
measurement once again. Calculate the roundness and
cylindricity by these two measurements. (The measured
position is as shown in the right figure)
①Roundness = (Maximum Diameter – Minimum

Diameter) / 2
As shown in the figure, measure the diameter of two
positions that is vertical to the same plane and the
roundness is half of the value left by the maximum
value minus the minimum value;
②Cylindricity = (Maximum Diameter – Minimum
Diameter) /2
Respectively measure the diameters in directions A and
B on two planes as shown in the figure, and take the
maximum value and the minimum value among these
four measured values. The cylindricity is half of the
value left by the maximum value minus the minimum
value;
Standard Value (mm)

Roundness 0.005
Cylindricity 0.008
40
7.4.1. Clean the short engine and coat the crankshaft
journal with engine lubricating oil.
7.4.2. Install the crankshaft correctly and install the
thrust gasket into the right position.
7.4.3. Install the upper cylinder body frame, screw in the

crankshaft tightening bolts.
The tightening sequence is as shown in the figure.
Tightening method and torque:
A: Pretighten the bolts in the sequence shown in the
figure.
B: Tighten the bolts to 45±5 Nm in the sequence shown
in the figure.
C: Turn it for another 180±50.
7.4.4. Install and tighten the frame outer bolts.
Torque: 23 Nm
7.4.5. Install the engine oil strainer, oil pan, front and
real oil seal of crankshaft, engine oil pump.
7.4.6. Install the engine accessories, mount the engine
into vehicle, install the water pipe and connect all the
electrical appliance plugs.
8. Replacement of water pump
8.1.1. Remove the engine timing belt. (See the “Engine timing calibration” for specific method)
8.1.2. Loosen the engine water outlet pipe to drain the coolant.
8.1.3. Remove the water pump.
8.2.1.1. The installation is in the reverse order of the removal. Refer to the removal procedure for
installation.
8.2.1.2. Fill enough coolant after installation.
8.2.2. Precautions
Don’t get the timing belt and skin splashed with the coolant.
41
Chapter III Turbocharger
Section 1 Turbocharger Technical Characteristics
The turbocharger system is actually a kind of air compressor used to increase the air input by
compressing the air. The turbine in the turbine chamber is driven by the inertial force of exhaust gas
from engine. Then the turbine drive its coaxial vane, which compresses the air from air cleaner
pipeline, so as to make the air supercharged and get into the cylinder. When the engine speed
increases, the speed of both exhaust and turbine rotation will increase with it and the vane will
compress and conduct more air into the cylinder. The increase of air pressure and density will increase
the fuel combustion and, consequently, will increase the engine output power. Generally, the power
and torque of engine with exhaust turbocharger is 20 %-30 % higher than the engines without it. The
exhaust turbocharger has something must be noted. The pump wheel and turbine are coaxial (to form
the rotor). The gas exhausted from engine drives the pump wheel, which then drives the turbine to
rotate, so as to supercharge intake system. The turbocharger is equipped at the exhaust side of
engine, so the turbocharger working temperature is high. Besides, when the turbocharger is working,
the rotor speed is high, which may reach tens of thousand turns per minute. At such a high speed and
temperature, the common mechanical needle and ball bearing can not work for the rotor, so generally
the turbocharger is equipped with full floating bearing, lubricated by engine oil lubrication and get
cooled by coolant.
42
Section 2 Turbocharger System
I. Schematic Diagram for Structure and Assembly
Hollow bolt M10X1

Water return pipe assembly
Washer - Oil inlet pipe assembly
Oil inlet pipe assembly
Washer - Water inlet pipe assembly
Hollow screw
M14x1.5
Water inlet pipe assembly

Turbocharger
Gasket - Oil return pipe

assembly
Hexagon bolt M6X20
Oil return pipe assembly
O-ring Φ17x2.65
Drawing of Disassembled Turbocharger
43
Hexagon bolt M8X20
Exhaust manifold
Gasket - exhaust manifold
Turbocharger assembly
Hexagon bolt M8X16
Bracket - Turbocharger assembly
Hexagon flange face bolt M8X20
Hollow screw gasket
Hollow screw M10
Hexagon flange bolt M6X14
Drawing of Turbocharger Assembly
44
To vacuum pipe assembly –
Vacuum source
Solenoid valve 1
To WASTEGATE
Solenoid valve 2
To supercharger case
connector
To intake hose
To relief valve
Drawing of Control System Assembly
To WASTEGATE To intake hose (AQ60211)
To supercharger case
To solenoid valve 1
To relief valve connector To solenoid valve 2
To solenoid valve 1
To solenoid valve 2
To solenoid valve
2
Drawing of Control Pipeline Assembly
45
II. Description of Supercharged Pressure
The supercharged pressure is controlled by the exhaust bypass valve and relief valve.
The exhaust bypass valve uses a connecting rod to control the turbocharger valve in exhausting. When
the supercharged air pressure value reaches the limit the intake pressure will push the bypass valve
connecting rod to open the bypass valve of the turbine exhaust side. Part of the exhaust is released
from the exhaust pipe directly without getting through turbine vane. This can reduce the exhaust gas
flow which may “blow” the turbine vane and then reduce the turbine vane speed, so as to lower the
compressor vane speed and keep the supercharged pressure stable at turbine intake side.
When the engine is idle or stopped, the relief valve is used to produce the constantly increased
pressure in turbocharger intake pipeline (the air hardly flow) and put the turbine under great resistance
if the throttle almost is closed nearly or completely; when the throttle is open, it is expected the
turbocharger will achieve its working speed as soon as possible. The recirculation valve is adopted to
avoid over-supercharging. The recirculation valve is a pneumatic component that is open by the
diaphragm spring operated by air pressure. When there is too much vacuum, the diaphragm spring will
be open to intake air with the valve being open, contrarily, the relief valve will be closed.
46
Section 3 The Common Faults and Maintenance Precautions of
Turbocharger Engine
I. Common Faults
1. Turbine scream, engine scream when accelerating; high turbine speed. Causes: 1. Improper
turbocharger pressure sensor signal which cause the relief valve unopenable; 2. Deactivation of
relief valve which cause relief deactivation of actuator; 3. Air leak or damage of actuator; 4. Air leak
of pipeline.
2. Engine oil burning and blue smoke. Possible causes: blocked pipeline of crankshaft vent system
which causes a high crankcase pressure; ingress of lubricating oil around turbocharger bearing
into the intake pipeline, which result in engine oil ingress in intercooler, blue smoke and high
engine oil consumption. Other causes: bearing oil seal damage; poor sealing.
3. Abnormal sound of turbine. If foreign matter enters into the turbocharger because of poor air
cleaner effect, as the rotation speed of supercharger can be up to tens of thousands rmp, there will
be abnormal sound caused by the impact of foreign matters with blade. So the air cleaner should
be checked routinely.
4. Turbine and compressor hesitation. Because of the blockage of intake system, the air amount
transported by turbocharger can not meet the requirement of diesel engine, which cause
insufficient air intake and, as a result, the changes or abrupt reduction of supercharged air
pressure in air intake pipe, so there are compressor hesitate and sound like air vibration. The main
cause of compressor hesitation is the blocked air cleaner filter core or flatness of seriously aged
intake pipe.
5. Poor acceleration, poor acceleration performance and rotation speed. Causes: The ECU will limit
the engine speed and the engine will enter into the protection mode when the ECU detects any
high supercharged pressure. The power then will reduce.
6. Damaged turbine or pump wheel shaft. When having the accelerator pedal stepped to its limit
position and then return to idle state rapidly, if the internal relief valve hasn’t open normally or the
leak-off pipeline is blocked, the turbine and pump wheel may get damaged or even ruptured due to
the impact force from opposite direction.
II. Maintenance Precautions

1. Don’t drive immediately after starting the vehicle.
Keep the vehicle running at idle speed for a moment after starting the engine, in order to get the
bearing lubricated sufficiently before the turbocharger rotor reaching a high speed. Don’t make the
throttle fully open suddenly after starting the vehicle; otherwise it may damage the turbocharger oil
seal.
2. Don’t stop the engine immediately.
Keep the engine at idle speed for 3-5min before stopping it after it has worked at high speed for a long
time. When the engine is working, there is part engine oil supplied to turbocharger rotor bearing for
lubrication and cooling. When the running engine stops suddenly, the engine oil pressure reduces to
47
zero rapidly, the heat from turbocharger turbine is transported to the middle part, but the heat in the
bearing housing can not be take away immediately, moreover, the turbocharger rotor still works at high
speed under the inertia effect, all these can cause damage to the bearing or shaft due to overheated
engine oil left in turbocharger. Especially avoid flameout immediately after having stepped the pedal
forcefully for several times.
3. Keep clean.
Clear the air cleaner routinely to protect the compressor impeller at high speed from dust or other
foreign matters which may cause unstable speed or aggravating wear of shaft sleeve and seal. The
engine oil and filter should be cleaned to protect it against ingress of foreign matters, or the engine oil
lubrication performance will decrease which may cause the early scrapping of turbocharger. The
lubricating oil pipeline should be cleaned after operating for some time.
4. Check the turbocharger working state frequently
Before and after driving, check the connection of all the air path pipes for looseness or drop which may
cause turbocharger failure and air ingress into the cylinder due to short circuit. In case of dirty engine
oil, rapidly increased crankcase pressure or high engine oil consumption, there may be faults in
turbinecharger and it should be dismounted for check and maintenance.
5. Precautions after replacing engine oil and filter
After replacing engine oil and filter, the engine should run at idle speed for a while after starting, so as
to enable the turbocharger to establish oil pressure and ensure sufficient lubrication before running at
high speed. It should be maintained and the engine oil should be changed in time. Avoid the engine oil
going bad, other wise the turbocharger may get poor lubrication or even the bearing may be ruptured.
Don’t run with the throttle fully opened after cold start.
48

H13 Engine

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

H13 Engine

Uploaded by

Copyright:

Available Formats

H13 Maintenance Manual

(SQR484B Engine Mechanical Part)

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

Engine model SQR484B

Rated power (Kw) 95

Speed at rated power (r/min) 5750

Max. torque (N·M) 180

Speed at max. torque (r/min) 4300—4500

Min. fuel consumption (g/Kw·h) 275

Cylinder compression pressure (Bar) 10—15

Fuel pressure (bar) 4

High speed (4000r/min) 3.7±0.5

A/C pipeline High-pressure pipeline 13—18

Inlet cam 0.15--0.20

Valve guide length 38±0.25

Axial clearance 0.07-- 0.265

Crank journal Axiality 0.05

Connecting rod journal Parallelism between

Engine timing tool: for timing camshaft.

Adaptor: for installing and removing valve spring.

Mounting tool for crankshaft rear oil seal: for installing

Mounting handle for crankshaft rear oil seal: for installing

Mounting sleeve for crankshaft front oil seal: for installing

Mounting sleeve for crankshaft front oil seal: for installing

Mounting tool for valve cotter

Spinning tool for engine oil filter

Removal tool for valve cotter

Setting tool for flywheel: for setting flywheel.

Timing tool for camshaft: for timing camshaft.

Lifter: for lifting engine.

Fuel pressure gauge: for measuring engine oil pressure.

Cylinder pressure gauge: for measuring cylinder pressure.

Number position on engine

II. Meaning of the Engine Number

Where, ○ denotes an Arabic numeral, and □ denotes a letter.

Table 1 Engine Characteristic Codes

Table 2 Engine Characteristic Codes Priority

Sequential number of the product among the output

Code for manufacturer of electronic fuel

Table 3 Codes for Year (with codes recycled)

Table 4 Letter Codes for Month

2.4 Example of factory number:

Chapter II Engine Body Maintenance

2. Remove the lower cover of engine timing belt.

3. Unscrew the center bolt in timing belt pulley and

4. Disconnect the high-voltage ignition cable.

6. Use a torque spanner to unscrew the bolts of intake

7. Turn the crankshaft as you are screwing in the

8. Install the timing belt, turn the tensioner pulley to get

Component Torque Re-tightening

II. Maintenance Guide

1.2.5. Remove the five bolts in the lower timing

1. Intake valve 11. Camshaft front oil seal

1.2.3. Remove the connecting bolt between oil dipstick

1.2.4. Remove the clamp at the joint between intake

1.2.5. Remove the connecting bolt of throttle valve

1.2.6. Loosen the oil inlet pipe connector.

1.2.7. Remove the fastening nut of intake manifold and

1.3 Installation procedure

2.2.4. Insert the special tool for timing into a camshaft

2.2.5. Remove the pulleys of intake and exhaust

2.2.6. Remove the rear protective cover of timing belt.

2.2.8. Remove the bearing caps of intake and exhaust