chery fengyun 2 service manual(power assembly).doc

Chery Fengyun 2 Service Manual(Power Assembly)

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

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ContentsSection 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 ListPart No. Part Name

A13-1001510FA Front suspension cushion assemblyA13-1001611FA Front suspension bracketA13-1001411FA Right suspension bracketA15-1001310BA Right suspension cushionA13-1001211FA Left suspension bracketA15-1001110BA Left suspension cushionA13-1001513FA Front suspension heat baffleA13-1200052FA Shackle bracket

Q1460825Hexagon bolt, spring washer and plain washer subassembly

A13-1205210FA Main catalytic converter assemblyA13-1201110FA Front muffler assemblyQ33010 Hexagon flange face locking nutA13-1201210FA Main muffler assemblyA13-1200013 Pipe clamp assemblyA13-1208711FA Heat shield - front wallA13-1208710FA Heat shield - middle passageA13-1208910 Rear heat shieldA13-1200052FA Shackle bracketN90335002 Clamping pieceB11-1205311 PackingQ1241026 StudA13-1109210FA Intake hoseA13-1109110FA Air cleaner assemblyA13-1109411FA Air cleaner bracket assemblyB11-1109167 Rubber sleeveB11-1109161 Rubber ringB11-1109163 Rubber damping ringA13-1109114 Resonant cavityA13-1109115 Air induction pipeB14-1117110 Fuel filter assemblyA13-1104110 Oil inlet pipe I assemblyA13-1104120FA Oil inlet pipe II assemblyA13-1104210FA Oil inlet and return pipe assemblyA13-1104311FA Fuel vapor pipe IA13-1100041 Two-slot pipe clampA13-1100042 Two-slot pipe clampS11-1100039 Two-slot pipe clampA13-1104320FA Fuel vapor pipe II assembly

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A13-1208217FA Charcoal canister solenoid valve air inlet pipeA13-1208219FA Charcoal canister solenoid valve air outlet pipeA13-1101001 Fuel tank with fuel pump assemblyA13-1101110 Fuel tank assemblyA13-1106610 Electric fuel pump assemblyA13-1100015 Fuel tank fixing strap assembly IA13-1100025 Fuel tank fixing strap assembly IIA13-1101310FA Filler pipe assemblyA13-1101315FA Filler hoseA13-1101317FA Filler vent hoseA13-1101121 Fuel tank guard boardS11-1103010BA Fuel tank cap assemblyT11-1208110BA Charcoal canister assemblyA13-1208321 Charcoal canister vent pipeA13-1104371FA Fuel vapor hose IIA13-1301110 Radiator assemblyA13-1308010 Radiator fan assemblyA13-1301310FA Radiator left tension plateA13-1301410FA Radiator right tension plateB11-1301313 Rubber bushingT11-1301217 Radiator lower support cushionA13-1303111FA Engine water inlet pipeA13-1303211FA Engine water outlet pipeA13-1303519FA Deaerator steel pipe assemblyA13-1303112FA Water pipe - from expansion tank to radiatorA13-1303417FA Heater water inlet pipeA13-1303419FA Heater water outlet pipeA11-1311110BA Expansion tank assembly

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Section III Mechanical Part of EngineMost 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 AssemblyThe 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.

1.5 Disassemble the cylinder head

assembly:

1.5.1 Remove the exhaust valve rocker

shaft and the rocker arm.

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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Exhaust valve rocker arm assembly

Intake valve rocker arm assembly

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.

1.6Remove the valve spring:Press one end of the special valve stripper

on the valve spring upper seat and the other

end on the valve to compress the spring,

and then take down the valve cotter. Later,

release the special tool and take down the

valve spring upper seat, valve spring and

valve in turn.

1.6.1 Remove the valve oil seal with a special tool.

II. Installation of the Cylinder Head and Valve Mechanism Assembly2.1Clean 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.

2.2Slip 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.

2.3Apply 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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①Valve cotter②Valve spring upper seat③Valve spring④Valve oil seal⑤Valve spring lower seat⑥Intake valve⑦Exhaust valve

guide properly.

2.4Turn 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 CotterClip 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

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 Seal5.1 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 SocketThe 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, 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.

VII. Installation of the Rocker Shaft with Rocker Arm Assembly

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

lead to abnormal sound or even damage of

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Apply a circle of sealant to the part 2cm away from the lower end.

Exhaust valve rocker shaft

Intake valve rocker shaft

Spark-plug socket

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.

7.2 Check whether the ball heads and

retainers of the intake and exhaust

valve rocker arms are normal. Apply

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

keyway faces down, and

then install the intake valve

rocker shaft with rocker arm

assembly. Next, adjust the

position of each rocker arm

so as to fit the rocker shaft

Intake valve left rocker arm

Intake valve right rocker arm

Exhaust valve rocker arm

The end with big chamfer

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Intake valve rocker arm retainer sleeve

The end with big chamfer of the rocker shaft faces towards the first camshaft bearing cover.

Camshaft keyway

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 Assembly8.1 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

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

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1 6 10

48

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.

3. Rotate them by 90 degrees again in the order of

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

consists in two adjacent or three or more cylinder head

bolts, loosen all cylinder head bolts and replace them

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

plug on the cylinder head after applying

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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Apply sealant to this area before assembling the semicircular rubber plug.

Make the end with chamfer of the semicircular rubber plug towards the inside of the cylinder head for its installation.

Semicircular rubber plug

Semicircular rubber plug limit groove

X. Installation of the Valve Chamber Cover Assembly10.1 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 EngineEngine model SQR477FFuel Gasoline

Engine typeVertical, four-in-line, water-cooled, four-stroke, single

overhead camshaftDisplacement (ml) 1497Bore × stroke (mm) 77.4×79.52Arrangement type and quantity of cylinders

L4

Max. power (kW (ps)/rpm) 80/6000Max. torque (N·m/rpm) 140/4500Body dimension (L/W/H) (mm) 4269/1686/1492Curb weight (kg) 1175

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Front/rear axle load (kg) 730/445Full-load weight (kg) 1550Front/rear axle load (kg) 835/715Front/rear wheel track (mm) 1448/1422Front/rear suspension length (mm) 866/876Wheelbase (mm) 2527Body structure Unitized three box type bodySeating capacity (person) 5Trunk capacity (L) 450Wheel model 195/55 R15Fuel tank capacity (L) 50Min. turning diameter (m) 10.5Approach angle (°) 14.2Departure angle (°) 15.3Min. ground clearance (mm) 139Emission standard GB18352.3-2005 National IVEmission level National IVEngine idle speed (r/min) 800±30High engine idle speed (r/min) 2000±50Engine ignition sequence 1-3-4-2Volumetric compression ratio of the engine

10.5 : 1

Engine rotation speed at the rated power (r/min)

6000

Max. torque of the engine (Nm) 140

Lubricant modelSummer: SAE 10W-40 (Grade SL or above)Winter: SAE 5W-40 (Grade SL or above)

Cylinder compression pressure (bar)

70

Fuel pressure (bar) 4

Engine oil pressure (bar)Low idle speed (800±50r/min) > 1.5 (oil temperature 90 )℃High idle speed (2000r/min) High speed (4000r/min) > 3.5 (oil temperature 100 )℃

Air conditioner pipeline pressure (bar)

High-pressure pipeline 15 (bar)Low-pressure pipeline 2 (bar)

Expansion water tank cap (bar)Relief valve (releasing the pressure outwards) 1.4 ~ 1.6Vacuum valve (introducing air into the tank) -0.02 ~ -0.1

Working temperature of the thermostat ( )℃

At the beginning of working 87Fully-opened thermostat 102

Standard pressure of each cylinder at standard idle speed

1.0 ~ 1.4MPa

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XIII. Main Service Parameter List for EngineCheck Item Value

Camshaft

Lift of the inlet cam/exhaust cam (mm) 5.09\5.34

Camshaft diameter (mm)

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

Cylinder headFlatness of the lower surface (mm) 0.03 ~ 0.08

Overall height (mm) 97

Valve

Valve top edge thickness (mm)

Intake valve 0.6

Exhaust valve 0.4

Valve stem diameter (mm)

Intake valve 5.98±0.008

Exhaust valve 5.96±0.008

Sealing band width (mm)Intake valve 2.83

Exhaust valve 2.26Clearance between the

valve stem and the valve guide (mm)

Intake valve 0.012 ~ 0.043

Exhaust valve 0.032 ~ 0.063

Inclination angleIntake valve 68°

Exhaust valve 70°

Height (mm)Intake valve 107.998

Exhaust valve 117.41

Valve spring Free height (mm) 47.7

Pretightening force (N)/installation height (mm) 260±11\41

Valve guide

Valve guide length (mm) 42±0.25

Inner diameter (mm)

(before processing)

(after

processing)

Outer diameter (mm)

Press-in height (mm) 12.5±0.2

Piston Piston skirt diameter (mm) 77.345±0.02

Piston ring

Side clearance (mm)1st ring 0.04 ~ 0.08

2nd ring 0.03 ~ 0.07

End clearance (mm)1st ring 0.2 ~ 0.35

2nd ring 0.4 ~ 0.55

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Height (mm)

1st ring

2nd ring

Oil ring

Piston ring groove Height/depth (mm)

1st ring∕

2nd ring

Oil ring ∕

Piston pin

Diameter (mm)

Three groups:W:20.622 ~ 20.625R:20.625 ~ 20.628L:20.628 ~ 20.631

Length (mm) 61.4±0.4

Piston pin hole diameter (mm)

Three groups:W 20.635 ~ 20.638R 20.638 ~ 20.641L 20.641 ~ 20.644

Crankshaft

Axial clearance (mm) 0.093 ~ 0.303mm

Radial clearance (mm) 0.0115 ~ 0.0575mm

Crank journal

Diameter (mm) 48.99±0.01mm

Radial runout (mm) 0.05

Cylindricity (mm) 0.008

Roundness (mm) 0.005

Connecting rod journalDiameter (mm) 44.9±0.01mm

Parallelism to the crank journal (mm)

0.008

Cylinder block

Overall height (mm)206±0.05mm

Bore hole roundness/linearity (mm) 0.008/0.01

Flatness of the upper surface (mm) 0.05

Connecting rodRadial clearance of the connecting rod bearing shell

(mm)0.006 ~ 0.06

Axial clearance of the big end (mm) 0.092 ~ 0.268

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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

Part Name Part No.Specificatio

nTorque (N·m)

Application

Bolt Q1840616M8×1.25 9~11

Connecting the deaerator steel pipe and the engine, the

tension plate and the body

Hexagon flange face bolt

Q1840820 M8×20 19~24Connecting the main catalytic converter hanger bracket and

the bodyHexagon flange face locking nut

Q33010 M10×1.25 45~55In front of and behind the pre-

catalytic converterHexagon flange face locking nut

Q330B12 M12×1.25 113~118In front of and behind the main

catalytic converterTapping screw Q2735532A 　 8±2 Fixing the fuel filterHexagon flange face bolt

Q1840825 M8×25 22±2Fixing the fuel tank fixing strap

assembly IHexagon flange face nut

Q32008 M8 22±2Fixing the fuel tank fixing strap

assembly IIHexagon flange face bolt

Q1840612 M6×12 8±2 Fixing the filler pipe bracket II


Q1840616 M6×16 8±2Fixing the charcoal canister

assemblyHexagon flange face bolt

Q1840816 M8×16 8±2 Fixing the filler pipe bracket I

Screw Q2734216 　 8±2Fixing the fuel tank guard

board


Q1841055 M10*1.5*55 41-51Fixing the front suspension

cushion assembly and the front cross beam

22



cushion assembly and the front cross beam



bracket and the transmissionHexagon flange face bolt


bracket and the engine

Hexagon flange face self-locking nut

Q33010 M10*1.5 41-51Fixing the front suspension

bracket and the front suspension cushion assembly


Q1841040 M10*1.5*40 41-51Fixing the right suspension

bracket and the engine


Q1840840 M8*1.25*40 21-25Fixing the right suspension

bracket and the right suspension cushion assembly


Q1841090 M10*1.5*90 41-51Fixing the right suspension cushion assembly and the

subframe


Q1841020 M10*1.5*20 41-51Fixing the right suspension cushion assembly and the

subframeHexagon flange face bolt

Q18410105M10*1.5*10

541-51

Fixing the left suspension bracket and the transmission


Q1841030 M10*1.5*30 41-51Fixing the left suspension

bracket and the left suspension cushion assembly


Q1840820 M8*1.25*20 21-25Fixing the left suspension cushion assembly and the

subframe

Worn clamp CQ67680 60~80 3~5Fixing both ends of the intake

hoseBolt 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 TransmissionDifferent Parts List for the QR515MHA (BA) TransmissionApplied Unapplied

Part No. Name Qty. Remarks Part No. Name Qty. Remarks

515MHA-1700010BAQR515MH

transmission assembly

1 513MHA-1700010Transmission

assembly1

515MHA-1701100Transmission

housing assembly

1 513MHA-1701100Transmission

housing assembly

1

515MHA-1701101Transmission

housing1 513MHA-1701101

Transmission housing

1

515MHA-1701105 Oil guide 1 513MHA-1701105 Oil guide 1

515MHA-1701200Clutch

housing assembly

1 513MHA-1701200Clutch

housing assembly

1

515MHA-1701201Clutch

housing1 513MHA-1701201

Clutch housing

1

515MHA-1702304Reverse shift

pin1 513MHA-1702304

Reverse shift pin

1

515MHA-1702500Release shaft and shift fork

assembly1 513MHA-1702500

Release shaft and shift fork

assembly1

515MHA-1702510Release fork


Release fork assembly

1

515MHA-1702502 Release fork 1 513MHA-1702502 Release fork 1

515MHA-1702520Release shaft


Release shaft assembly

1

515MHA-1702100 First/second 1 513MHA-1702100 First/second 1

24

speed shift fork assembly

speed shift fork assembly

515MHA-1702101Shift fork - first/second

speed1 513MHA-1702101

Shift fork - first/second

speed1

515MHA-1702430BASelector arm and bracket assembly

1513MHB-1702430

Selector arm and bracket assembly

1

515MHA-1702440Selector arm

assembly1 513MHB-1702440

Selector arm assembly

1

515MHA-1701207Bushing -

starter1 None None None

515MHA-1702010Gear shift fork


Gear shift fork assembly

1

515MHA-1702400BA

Gear selecting and shift

mechanism assembly

1 513MHA-1702400

Gear selecting and

shift mechanism assembly

1

515MHA-1702450BASelector arm

bracket assembly

1 519MHA-1702590Selector arm

bracket assembly

1

515MHA-1702410Shifting arm assembly

1 513MHA-1702410Shifting arm

assembly1

None None Q1860840Hexagon

flange face bolt

11

Q1860845Hexagon

flange face bolt

15 Q1860845Hexagon

flange face bolt

3

None None NoneHydraulic

clutch system

513MHA-1702504Release fork return torsion

spring1

None None None FQ1200840F3A Stud 1515MHC-1701401 Output shaft 1 513MHA-1701401 Output shaft 1

515MHC-1701400Output shaft


Output shaft assembly

1

515MHC-1701501Final reducer driven gear

1 513MHA-1701501Final reducer driven gear

1

515MHC-1701500Differential assembly

1 513MHA-1701500Differential assembly

1

II. Diagnostic Parameters for TransmissionModel QR515MHA QR513MHAType Mechanical-mesh type

25

Gear Gear ratioRatio of number

of teethGear ratio

Ratio of number of teeth

Gear 1 3.545 39/11 3.545 39/11Gear 2 2.05 41/20 2.05 41/20Gear 3 1.423 37/26 1.423 37/26Gear 4 1.065 33/31 1.065 33/31Gear 5 0.865 32/37 0.865 32/37

Reverse gear 3.364 37/11 3.364 37/11Final reduction

ratio3.55 71/20 4.056 73/18

Lubricating oil model

APIGL-4, 75W-90 GL-4, 75W-90

Lubricating oil capacity

2.3L 1.8L

III. Assembling Technical Conditions of the Different Parts

1. Put the clutch driven disc assembly on the

flywheel and use a central spindle for

positioning, then put the cover assembly on,

with the dowel pin hole on it aligned with the

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

cover assembly onto the flywheel with 6

bolts and tighten the bolts diagonally to the

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

Driven disc assembly

Cover assembly

Bolt

Fig. 27 Installation of the Clutch

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.

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chery fengyun 2 service manual(power assembly).doc

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