manual de taller de chery tiggo.pdf
TRANSCRIPT
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Service Manual for CheryTiggo(T11) Engine Section
Contents
Chapter 1 Overview3
I. Technical Data3
II. Special Tools8
Chapter 2 Structural Features of Engine12
Chapter 3 Admission Gear23
I. Timing Gear Belt23
II. Rocker and Camshaft32
III. Cylinder Cover and Valve36
Chapter 4 Crank Gear42
Chapter 5 Lubricating System54
Chapter 6 Cooling System62
1
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Service Manual for CheryTiggo(T11) Engine Section
Chapter 1 Overview Engine used in Chery Tiggo car is MITSUBISHI 4G64 (2.4L) and 4G63 (2.0L)
model engine, which adapt single-overhead-camshaft, 4-cylinder 16-valve and multi-point sequential injection.
I. Technical Data
1. Engine Mode Number Indication
Multi-point sequential injection
4 4 valve structure
Single-overhead-camshaft
Design serial number
Product serial
Gasoline engine
4 4 cylinder structure
2.Engine Number Position
2
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Service Manual for CheryTiggo(T11) Engine Section
3Related Engine Data Specification
Item 4G63 S4 MPI 4G64 S4 MPI
Engine type Four cylinder in-line, 4 stroke, water-cooled, single-overhead-camshaft,16 valve multi-point sequential injection
Cylinder number 4 4 Combustion chamber Ridge chamber Ridge chamber Total displacement ml
1,997 2,351
Cylinder diameter mm
85.0 86.5
Stroke mm 88.0 100.0
Output power kw 926000r/min 955500r/min
Max torque N.m 167.7 198.1 Compression ratio 10 9 Lubrication system Pressure supply, full filter Pressure supply, full filter Fuel pump type Gear type Gear type Water pump type Centrifugal impeller Centrifugal impeller
4. Maintenance Standard UOMmm
Item Standard Value Usage Limit
Value Tensioner arm protrusion 12
Engine gearbelt Tensioner arm depression (98196N) 1
Engine No.
3
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Service Manual for CheryTiggo(T11) Engine Section Item Standard Value
Usage Limit Value
Air-in 4G63 37.50 37.00 Cam height
Air-out 4G63 36.99 36.49 Camshaft Shaft diameter 45.0 Lower surface flatness 0.03 0.2 Surface grinding limit* total grinding of cylinder body and cylinder cover
* 0.2
Full height 119.9120.1
Cylinder cover
97.4 99.4 Air-in 1.0 0.5
Edge thickness Air-out 1.2 0.7
Valve rod diameter 6.0
Air-in 0.020.05 0.10 Crest clearance between valve rod and duct
Air-out 0.030.07 0.15
Inclination angle
Valve
4545.5
Air-in 112.30 111.80 Height
Air-out 114.11 113.61 Free height 51.0 50.0 Pre-loading force/Operation height Km/mm 27.2/44.2
Valve spring
Verticality 2 4
Contact bandwidth 0.91.3
Internal diameter 6.0 External diameter 11.0 Depression depth 14.0
Valve duct
Valve rod protrusion height 49.3 49.8
Driving gear 0.080.14 Engine oil pump
Side clearance Driven gear 0.060.12
Piston Piston clearance 0.020.04
No.1 ring 0.020.06 0.1 Lateral clearance
No.2 ring 0.020.06 0.1
Piston ring
End clearance No.1 ring 0.250.35 0.8
4
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Service Manual for CheryTiggo(T11) Engine Section Item Standard Value
Usage Limit Value
0.400.55 No.2 ring 0.8
Oil ring 0.100.40 1.0
External diameter 22.0
Depressing force (Kg) 7551750 Piston pin
Depressing temperature Room temperature
Crank Crank pin clearance 0.020.05 0.1
Connecting rod
Bigger end clearance 0.100.25 0.4
Axial clearance 0.050.18 0.25
Main axle diameter 57 Connecting axle diameter 45
Crank
Main axle diametral clearance 0.020.04 0.1
Upper surface flatness 0.05 0.1 Upper surface grinding limit*Total grinding of cylinder bodyand cylinder cover
* 0.2
Full height 4G63 2840.1 Cylinder body
Internal diameter of cylinder hole 4G63 85.0085.03
Cylinder body
Cylinder hole cylindricity 0.01
Motor Rotor coil resistance 35
11.0511.07 0.05 O.S.
0.25 O.S. 11.2511.27 Secondary processing size of valve conduit installation hole (air-in and air-out valve) enlargement
0.50 O.S. 11.5011.52
0.30 O.S. 34.43534.455 Secondary processing size of air-in valve seating hole enlargement
0.60 O.S. 34.73534.755
Cylinder Cover
Secondary processing size of air-out valve seating hole enlargement
0.30 O.S. 31.93531.955
5
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Service Manual for CheryTiggo(T11) Engine Section Item Standard Value
Usage Limit Value
0.60 O.S. 32.23532.255
Remarks: O.S.: Enlarged diameter
5. Tightening torque Tightened Part Torque (kgf .M) Alternator, Ignition system Water pump belt gear Adjusting bolt Locking bolt Alternator bracket screw bolt Alternator center axle nut Crank belt gear Ignition coil Spark piston Camshaft position sensor cylinder Camshaft position sensor bracket Camshaft position sensor
0.9 1.0 2.2 2.4 4.5 2.5 1.0 2.5 2.2 1.4 1.0
Timing Belt Protruded screw bolt on timing belt cover Tensioner wheel screw bolt Tensioner arm screw bolt Automatic tensioner screw bolt Central belt wheel screw bolt Tensioner bracket Timing belt rear cover Timing belt indicator Engine oil pump belt gear Screw bolt of crank belt gear Tensioner B Belt gear of balance axle Screw bolt of camshaft belt gear Belt gear of balance axle
1.1 4.9 2.2 2.4 3.6 4.9 1.1 0.9 5.5 12.0 1.9 4.6 9.0 4.6
Fuel System Throttle EGR valve Injector and distribution pipe
1.9 2.2 1.2
6
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Service Manual for CheryTiggo(T11) Engine Section Fuel oil return pipe Fuel pressure regulator
0.9 0.9
Intake Manifold Screw bolt of engine flying rings Engine coolant temperature sensor Connecting bolt of outflow pipe Manifold bolt Coolant temperature sensor Manifold bracket
1.9 3.0 2.0 2.0 1.1 1.4
Exhaust Manifold
Screw bolt of emission manifold cover Screw bolt of inflow duct joint Exhaust manifold nut ( M8) Exhaust manifold nut ( M10) Screw bolt of coolant bypass duct joint Screw bolt of coolant duct component
1.4
Thermostat housing bolt Water pump screw bolt
2.4 3.0 5.0 2.4 1.3 2.4 1.4
Rocker and Camshaft Rocker cover screw bolt Screw bolt of rocker and camshaft assembly
0.4 3.2
Trust bearing cover bolt 1.9 Cylinder Cover and Valve
Cylinder cover bolt 2.09090
Front cover & Engine oil pump Drain plug Oil pan Screw bolt and nut of oil strainer Oil pressure switch Pressure relief plug Screw bolt of oil cleaner bracket Front cover bolt Plug Flange bolt Engine oil pump cover bolt
4.5 0.7 1.9 1.0 4.5 1.9 2.4 2.4 3.7 1.6
Engine oil pump cover screw 1.0 Piston and Connecting Rod Assembly Connecting rod nut
2.090100
Crank, Cylinder Body, Flywheel Flywheel screw bolt 13.5
7
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Service Manual for CheryTiggo(T11) Engine Section Installation screw bolt of rear cover Installation screw bolt of bell jar Installation screw bolt of oil seal cover Screw bolt of main bearing cover
1.1 0.9 1.1
2.590100
Throttle Body Bracket screw bolt 0.5 Throttle Position Sensor 0.35 Screw bolt of idle speed air valve 0.35 Idle speed adjustment bolt and installation nut 0.3
II. Special Tools Tool Number Name Purpose
MB990767 Spanner for crankshaft belt gear
Use MD998719 when fixing camshaft belt gear
Use it together with MD998776 to install crankshaft rear oil seal.
MB990938 Handle
Use it with MD998372 together to disassemble reverse balance axle rear bearing and install guiding limiter.
MB991603 Balance axle bearing puller limiter
MB991654 Cylinder cover bolt spanner (12)
Disassemble and assemble cylinder cover bolt.
MD998162 Plug spanner Disassemble and assemble front cover plug cock.
Crankshaft front oil seal duct MD998375 Use MD998375 to install crankshaft front oil seal
MD998285
8
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Service Manual for CheryTiggo(T11) Engine Section Tool Number Name Purpose
MD998371 Balance axle bearing puller Disassemble reverse balance axle front bearing
MD998372 Balance axle bearing puller Disassemble reverse balance axle rear bearing
MD998375 Crank shaft front oil seal installer
Install crankshaft front oil seal
MD998440 Leakage check tester Leakage test for hydraulic post.
MD998441 Hydraulic post keeper Exhaust air from hydraulic post
MD998442 hydraulic post wiring Exhaust air from hydraulic post
MD998443 hydraulic post keeper Use it when disassembling or assembling rocker shaft component
MD998705 Balance axle bearing installer Install balance axle front and rear bearing.
MD998713 Camshaft oil seal installer Install camshaft oil seal
9
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Service Manual for CheryTiggo(T11) Engine Section Tool Number Name Purpose
MD998719 Fixing pin for belt gear Use MB990767 to fix camshaft belt gear.
MD998727 Oil pan remover Disassemble oil pan
MD998735 Valve spring compressor Disassemble and assemble valve and related parts
MD998767 Tensioner puller sleeve Timing belt tension adjustment
MD998772 Valve spring compressor Disassemble and assemble valve and related parts
MD998774 Valve oil seal installer Install valve oil seal
MD998776 Crankshaft rear oil seal installer
MB990938 Use MB990938 to install crankshaft rear oil seal.
MD998778 Crankshaft belt gear puller Disassemble crankshaft belt gear
MD998780 Piston disassembling and assembling tool
Disassemble and assemble piston pin.
10
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Service Manual for CheryTiggo(T11) Engine Section Tool Number Name Purpose
MD998781 Flywheel stopper Fix flywheel and driving disk
MD998783 Plug spanner fixer Disassemble and assemble front cover plug
MD998785 Timing belt gear stopper Keep balance axle belt gear.
11
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Service Manual for CheryTiggo (T11) Engine Section
Chapter 4 Crank Connecting Rod Mechanism
Piston and connecting rod component
Daub oil on all theinner parts when installing.
-
Service Manual for CheryTiggo (T11) Engine Section
Disassembling steps
1. Connecting rod nut Connecting rod cap Connecting rod bearing
Piston and connecting rod component
5 Connecting rod bearing No.1 compression ring No.2
compression ring Oil control ring
Piston pin Piston Connecting rod Connecting
-
Service Manual for CheryTiggo (T11) Engine Section
piperA=21.9mm
cylinder number
Disassembling NoticeConnecting Rod Cap Disassemble (1) Mark cylinder number on the side of
compression rod
piston pin installer
piperA=17.9mm
guide block B
forward mark
forward mark
piperA=18.9mm
guide block C
guide block C
piperA=20.9mm base
base
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Service Manual for CheryTiggo (T11) Engine Section
connecting rod big end to prepare for correct installation.
(2) Take turns putting connecting rod, connecting rod cap and connecting rod bearing away, according to cylinder number.
Piston Pin Disassemble
(1) After inserting compression rod of the special tool from the top of piston marked with the arrowhead, install guide block C in the top of compression rod. Keep forward mark of piston upward. Install piston and connecting rod component in base of piston pin installer (special tool).
)RUFH piston pin out with pressure.
&DXWLRQTake turns putting piston, piston pin and connecting rod disassembled away according to cylinder number.
-
Service Manual for CheryTiggo (T11) Engine Section
piston
piston
guide block B guide block A
compression rod
piston pin
forward mark
forward mark
connecting rod
Guide pipe A
base
3mm+L
Guide block B
-
Service Manual for CheryTiggo (T11) Engine Section
Installation NoticePiston Pin Installation
(1) Measure the following sizes of piston, piston pin and connecting rod. $ Length of inserting piston pin in the hole. %Width of pin sockets &Length of piston pin 'Width of small end of connecting rod.
(2) Put measured sizes above into following formula to calculate L.
L[(AC)(BD)] / 2 (3) After inserting compression
rod of the special tool into piston pin, install pipe A in the top of compression rod.
(4) Install forward marks of piston and connecting rod towards the same direction.
(5) Daub engine oil on the external diameter of piston pin
(6) Through Pipe A, insert compression rod, piston pin and pipe component installed according to (3) into piston pin hole from the side of forward mark.
(7) Screw on guide block B
into guide pipe A to make clearance value between guide block A and guide block B equal to the value of Value L got from (3) plus 3mm.
(8) Keep forward mark of piston upward. Install piston and connecting rod component in base of piston pin installer.
)RUFH SLVWRQ 3LQ LQ XQGHU SUHVVXUH :KHQWKH SUHVVXUH LV OHVV WKDQ VWDQGDUG YDOXHUHSODFH SLVWRQ SLQ DQG SLVWRQ FRPSRQHQWDQGRUUHSODFHFRQQHFWLQJURG
standard value 1
-
Service Manual for CheryTiggo (T11) Engine Section
ring clamp
Upper blade
Lower blade
Main ring
Identification mark2R
Identification mark1R Direction
mark
1R
2R
blade clearance
Check if piston can rotate freely.
Oil Control Ring Installation (1) Put the main ring of oil control ring into oil
ring groove. Remarks: Theres no difference of upper and lower
surface between blade and main ring
-
Service Manual for CheryTiggo (T11) Engine Section
2. New blade and new main ring shall be colorized to distinguish their sizes.
6L]H ,GHQWLILFDWLRQFRORU
6WDQGDUG 1LO,QFUHDVHPP 5HG,QFUHDVHPP
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Service Manual for CheryTiggo (T11) Engine Section
Piston and Connecting Rod Component Installation (1) Daub enough engine oil on piston, compression
ring and oil control ring. $GMXVW RSHQ SRVLWLRQ RI compression ring and
oil control ring (blade and main ring) to the position as shown.
(3) Rotate crankshaft to make crank pin located in the middle of cylinder
(4) Before inserting piston and connecting rod
component into cylinder, proper screw-mounted protector is applied in connecting rod bolt. Be careful and dont damage crank pin.
(5) Use suitable piston ring compressor to insert piston and connecting rod component into cylinder.
Caution: Theres a forward mark on the top of piston,
make it point to straight position of the engine (the side of timing belt).
&RQQHFWLQJ5RG%HDULQJInstallationIf it is necessary to replace bearing, choose and install bearing according to the following steps. Measure external diameter of crank pin and
confirm the groups according to the following table. As crankshaft for maintenance, distinguish sizes by painting color in the position as shown.
(2) Identification mark of connecting rod bearing is
imprinted in the position as shown. Crank pin Connecting rod bearing
GroupsIdentification
colorExternaldiameterPP
Identification mark
Identification color
7KLFNQHVVPP
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Service Manual for CheryTiggo (T11) Engine Section
Installation of &RQQHFWLQJ5RG&DS :KHQLQVWDOOLQJconnecting rod cap, check
paint mark
paint
mark
cylinder number
anti-rotating gap
-
Service Manual for CheryTiggo (T11) Engine Section
marks of disassembling. If installing new parts which have no marks, install anti-rotating gap as shown on one side.
(2) Ensure if axial
clearance of big end of connecting rod is suitable. Standard value PP/LPLWYDOXHPP
&RQQHFWLQJ 5RG 1XWInstallationCaution:z Before installing
connecting rod cap, disassemble spark plug and install connecting rod nut, if having installed cylinder cap.
(1) As for connecting rod nut and bearing, plastic-zone screw-on method shall be adopted. Before reusing the bearing, check if the bearing is expanded. Checking method: screw nuts into screw thread of bearing with fingers till the whole length of screw thread. If nuts cant be screwed on smoothly, screw thread may be expanded and bearing should be replaced.
(2) Before screwing nuts on, daub oil on screw thread of nuts and seat surface.
Screw nuts into bearing with fingers and screw nuts on alternatively to install connecting rod cap correctly.
Screw nuts on by torque of 10
(5) Daub paint mark on every nut head.
(6) Daub paint mark on bolts of which the
position is from paint mark on every nut head to screwing direction of90100rand note down the paint mark.
(7) Screw nuts on from 90100runtil marks on nuts and bearing are aligned. Caution:z ,f screwing angle is less than 90r,
screwing specified capability cant be assured. When screwing it on, notice screwing angle.
z If screwing nuts are excessively tightened (exceed angle of 100r) , screw nuts off totally. And restart to screw nuts from step 1
-
Service Manual for CheryTiggo (T11) Engine Section
Check Piston ring (1) Check if theres damage, excessive wear and
breach on piston ring. If any, replace it. If replacing piston, it is necessary to replace piston ring.
Check clearance between piston ring and piston ring groove. If its too wide, replace piston ring or both of them.Standard value PP/LPLWYDOXH PP
(3) Put piston ring into cylinder. After using top surface of piston to put it away, measure open clearance with clearance gauge. When open clearance is too wide, replace piston ring. Standard value
No.1 ringPP No.2 ringPP Oil control ring PP/LPLWYDOXHNo.1 ring and No.1 ringPP Oil control ringPP
press in with piston
open clearancepiston ring
plastigauge
-
Service Manual for CheryTiggo (T11) Engine Section
Oil clearance of crank pin (Plastigauge ) (1) Clean the oil on connecting
rod neck and bearing out. (2) Divide plastigauge into the
same length of rearing width and put it on crank pin and make it parallel to axle center line.
Install connecting rod cap
carefully, and screw nuts on according to the regulated torque.
(4) Disassemble connecting rod cap carefully.
(5) Use measuring rule imprinted on the package of plastigauge to measure the width of the widest part of staved plastic line and get clearance value. Standard value PP/LPLWYDOXHPP
-
Crankshaft, cylinder block and flywheel
Disassembling steps
1. Screw rearing of flywheel
2. Jointing board
3. Flexible flywheel
4. Jointing board
5. Crankshaft bushing
6. Rear cover board 7. Bell housing 8. Rear oil seal cap 9. Rear oil seal
0DLQEHDULQJFDSEROW
Daub engine oil on all the operationparts wheninstalling.
11.Main bearing cap 12. Lower bearing of crankshaft 13.Crankshaft
1P 14.Upper bearing of crankshaft 15.Crankshaft thrust rearing 16.Cylinder block
17.Drive boardA/T
18.Crankshaft sleeveA/T
18 J i ti b dA/T
25N.m+90oto100o 'LVDVVHPEOLQJLOOXVWUDWLRQ2.5kgf.m
19
18
20
17
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Check
plastigauge
12mm
center
bottom
Oil clearance of crankshaft (Plastigauge )
(1) Clean the oil on main journal and internal diameter of bearing out.
(2) Install crankshaft. (3) Divide plastigauge into the same
-
length of bearing width and put it on crankshaft journal and make it parallel to axle center line.
Install main bearing cap
carefully, and screw nuts on according to the regulated torque.
(5) Disassemble main bearing cap carefully.
(6) Use measuring rule imprinted on the package of plastigauge to measure the width of the widest part of staved plastic line and get clearance value. Standard value PP/LPLWYDOXHPP
Cylinder block(1) Observe if there are defects like
scratch, rust and corrosion with eyes. Use defect detector to check breach. If any, fix or replace it.
(2) Check if the surface of cylinder block warps and assure theres no pad scraps or other foreign matters. Standard valuePP/LPLWYDOXHPP
(3) If warping excessively, revise or replace it within the permitting range. $brasive limit0.2mm Maximum sum of abrasive thickness of cylinder block and cylinder cap permitted is o.2mm. +HLJKW RI F\OLQGHU EORFNQHZ*PP*PP
(4) Check if theres scratch and cylinder sticking. If its disqualified, revise (increase the size) or replace it.
(5) Check internal diameter of cylinder and cylindricality with cylinder bore gauge.
Revise cylinder according to increased diameter, replace piston and piston ring if wearing badly. Checking position as shown.
Standard valueinternal diameter of cylinder *PP
*00
CylindricalityPP
-
thrust direction
Piston external diameter
Cylinder reboring (1).Choose diameter of piston increased according to the maximum cylinder bore. Identification of piston sizes
Size Identification mark Increase 0.50 0.50 Increase 1.00 1.00
-
Note: Imprint size marks on the top of piston (1).External diameter of piston used in the measurement should be measured in the thrust direction as shown. (2).According to measuring value of external diameter of piston, calculate the size of cylinder reboring. size of cylinder reboring external diameter of pistonclearance between piston and cylinder)0.02mm(Abrasive capacity) (1) Rebore every cylinder bore to size of
cylinder reboring 1RWLFH When boring out cylinder,
process according to the following procedures to avoid errors because of temperature raising :1R1R1R1R(2) Cylinder bore which is abrasive to the
ultimate. (diameter of pistonclearance between piston and cylinder)
&KHFN clearance between piston and cylinder
Standard value PP
Remarks: When boring out cylinder, four cylinders should be bored in the same size which is increased, instead of only bore one cylinder.
Installation notice Installation of crankshaft bearing(1) Choose bearings that conform
to crankshaft main journal according to the following table.
Combination of crankshaft main journal and spindle bore
Crankshaft main journal
Groups
Identification color
External diamete
r (mm)
Identification
mark of spindle bore
Identification mark and
color of No. 1, 2, 4, 5 journal
bearing
Identification mark and color of No. 3 journal bearing
0 1green 0black 1 2yellow 1green Yellow 56.99457.000 2 3nil 2yellow0 2yellow 1green 1 3nil 2yellow Nil 56.98856.994 2 4blue 3nil 0 3nil 2yellow1 4blue 3nil White 56.98256.988 2 5red 4blue
-
Main bearing bore sizeidentification mark
Cylinder block bottom
Rear face ofcylinder body
Cylinder inner diameter sizemark
Main bearingbore identification mark
oil ditch oil ditch
Crankshaft bearing size identificationmark or color
Identification mark orcolor
Examples for bearings choosing z If identification color of crankshaft
main journal is yellow and identification mark of spindle bore is 1, choose the No. 1,2,4,5 bearing of which identification mark is 2 and identification color is yellow and No.3
-
bearing of which identification mark is 1 and identification color is green.
z If theres no identification paint color on crankshaft, measure main journal and choose corresponding groups of bearing according to measurement value.
(2) Install bearing with grooves on one side of cylinder block.
(3) Install bearing without grooves on one side of main bearing cap.
(4) Install two of thrust bearing of crankshaft in No. 3 main bearing hole of cylinder block. For convenient installation, apply a little oil on the surface of thrust bearing.
(5) One side of thrust bearing with groove should face towards crankshaft crank arm.
0ain bearing cap and main bearing cap bolt installation (1) Install arrowhead of main
bearing cap towards the side of timing belt.
(2) Before screwing main bearing
cap bolt on, assure that length of bolts is less than value limit. If not, replace the bolt. /LPLWYDOXH$PP
(3) Daub oil on screw thread of nuts and seat surface.
Screw main bearing cap bolt on by torque of 10DFFRUGLQJWRUHJXODWHGRUGHU
-
Arrow
Paint mark Paint mark
-
(5) Daub paint mark on every nut head.
(6) Daub paint mark on the main bearing cap of which the position is from paint mark on bolts to screwing direction of
90100r
(7) Screw nuts on from 90100r
regulated in the picture above, according to screwing order till paint mark on bolts aligns paint mark on main bearing cap.
1RWLFH
z ,f screwing angle is less than
90 r , screwing specified
capability cant be assured. When screwing it on, pay much attention to screwing angle.
z If screwing nuts are excessively tightened (exceed
angle of 100r) , screw nuts off
totally. And restart to screw nuts from Step 1.
(8) After installing main bearing cap, assure if crankshaft can turn smoothly and check axial clearance. If axial clearance exceeds usage limit value, replace NO.3 crankshaft thrust bearing of crankshaft.
Standard valuePP
/LPLWYDOXHPP
Oil seal installation
5HDURLOVHDOFDSLQVWDOODWLRQ
6SHFLILHGVHDODQW
%UDQGMitsubishi pure components
0' or corresponding
equivalents.
1RWLFHV
(1) (QVXUHrear oil seal cap is installed
quickly when sealant is still wet.
( PLQ)
$IWHU LQVWDOOLQJ NHHS VHDOHG DUHD
DZD\ IURP OXEULFDWH JUHDVH DQG
FRRODQWIRURQHKRXU
-
Service Manual for CheryTiggo(T11) Engine Section Chapter 5 Lubrication System Front cover, oil pump, balance axle and oil pan
Disassembling Steps 1.Oil cleaner 2.Oil drain plug 3.Oil drain plug cushion 4.Oil pan 5. Oil collect filter 6. Oil collect filter cushion 7. Plug 8. O-shape ring 9. Flange bolt 10. Oil pressure switch 11. Pressure relief plug 12. Seal cushion 13. Pressure relief spring 14. Pressure-relief plunger
Daub oil on all internalcomponents whenassembling
Disassembling illustration
15. Oil cleaner bracket 16. Oil cleaner bracket cushion 17. Oil pump cover 18. Oil pump driven gear 19. Oil pump drive gear 20. Crankshaft front oil seal 21. Oil pump oil seal 22. Balance axle oil seal 23. Front cover 24. Front cover cushion 25. Left balance axle 26. Right balance axle 27. Right balance axle front bearing 28. Left balance axle bearing 29. Right balance axle rear bearing
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Service Manual for CheryTiggo(T11) Engine Section
MD998727
Disassemble Notice Oil pan disassemble (1) Disassemble all oil pan bolts (2) Insert special tool between cylinder body and
oil pan.
Remarks
Do not use screwdriver or chisel instead of
special tool, otherwise the edge of oil pan
may be distorted and oil leakage will occur. MD998162
Plug disassemble Disassemble plug cock with special tool. If
plug is tightened, tap the plug top with
hammer several times and the plug will loose.
Flange bolt disassemble (1) Disassemble plug from cylinder body. (2) Insert cross screwdriver (pole diameter is
8mm) into the plug hole and lock balance
axle.
plug Screwdriver
(3) Loosen flange bolt
Right balance axle front bearing disassemble (1)Disassemble balance axle right-front bearing
with special tool from cylinder body.
MD998371
Front bearing
Remarks
Front bearing must be disassembled firstly. If it is
not disassembled, rear bearing puller can not be
used.
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Maintenance Manual for CheryOriental Son Engine Section
Balance axle rear bearing disassemble
Disassemble left balance axle rear bearing with special tool from cylinder body.
Remarks
Special tool (MB991603) should be installed in front of cylinder body when disassembling left balance axle rear bearing.
Installation Notice Right balance axle rear bearing installation (1) Daub oil on bearing surface. (2) Install right rear bearing with special tool.
Make sure that oil holes on bearing and cylinder body are aligned.
Left balance axle rear bearing installation (1) Install special tool (conducting board) on
cylinder body. (2) Daub oil on rear bearing edges and inside
cylinder body bearing holes. (3) Install rear bearing with special tool
Remarks
MB991603
MB998372
MD998705
MB991603
MD998705
Rear bearing
MB991603
MD998705
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Maintenance Manual for CheryOriental Son Engine Section
There is no oil hole in left rear bearing.
MD998705
MD998705
Cylinder body
Bearing
Balance axle front bearing installation Install front bearing with special tool
Front cover installation (1)Install special tool on crankshaft front end .
daub oil slightly on the exterior circle surface of special tool and then install front cover
(2)Use new front cover oil seal cushion and
install front cover component. Tighten flange bolt temporarily (Except for oil cleaner bracket locking bolt)
Balance axle oil seal installation
Press oil seal into front cover with socket
MD998285
MD998285
Socket wrench
Front coverOil seal
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Maintenance Manual for CheryOriental Son Engine Section
wrench.
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Maintenance Manual for CheryOriental Son Engine Section
socket wrench Oil
seal Oil pump oil seal installation Press oil seal into front cover with socket
wrench. Front
cover
Oil seal
Frontcover
MD998375
Crankshaft front oil seal installation
Install crankshaft oil seal on front cover with special tool.
Fitting mark
Oil pump driven/drive gear installation
Daub oil on gear surface and align the fitting marks.
Daub sealant on oil pressure switch Daub sealant on oil pressure switch screw thread parts and then install the said switch with special tool. Special sealant: 3M ATV or relevant
equivalents.
Caution
Keep the top of screw thread clean and
do not daub sealant.
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Maintenance Manual for CheryOriental Son Engine Section
Excessive tightening should
be avoided.
Screwdriver
Flange bolt installation (1)Insert cross screwdriver into the hole in the
left side of cylinder body and lock balance axle.
(2)Tighten flange bolt with specified torque to
ensure driven gear of oil pump is fixed on left balance axle.
Plug installation
MD998162
MD998783
(1) Install O-shape ring in front cover slot. (2) Install plug with special tool and tight it to
specified torque.
Oil pan installation (1) Keep the fitting surface of oil pan and
cylinder body clean. (2) Daub 4mm-diameter sealant on the edge
of oil pan flange surface.
Specified sealant
Mitsubishi pure product MD970389 or relevant equivalents.
Slot section Bolt hole
section
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Maintenance Manual for CheryOriental Son Engine Section
Remarks
(1) Install oil pan quickly when sealant is still wet (about 15 minutes)
(2) Do not make the sealed part bedewed with oil in an hour or so after installation.
8mm-length bolt
Crankshaft pulley side
Oil pan bottom view
(3) Confirm the bolt length and their
installation locations are a little different.
Drain plug cushion
Oil pan side
Drain plug cushion installation Install drain plug cushion according to the
direction as shown. Caution The incorrect installation direction may result in oil leakage. Oil cleaner installation (1) Make installation surface of oil cleaner
bracket clean. Bracket side
(2) Daub engine oil on O-shape ring of oil cleaner.
(3) Screw on oil cleaner. When the O-shape ring reaches installation surface, screw 3/4 cycle further. (Tighten torque: 1.4kg.m)
Check
Front cover (1) Check if oil hole is jammed. If necessary,
clear it up.
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Maintenance Manual for CheryOriental Son Engine Section
(2) Check if there is abrasion, damnification or sinter on left balance axle front bearing. If necessary, replace front cover.
(3) Check if there is crack or other damnification. If any, replace front cover component.
Oil seal (1) Check if there is abrasion or
damnification on oil seal lip. If necessary, replace oil seal.
(2) Check if there is deterioration on oil seal lip. If necessary, replace oil seal.
Balance axle (1) Check if oil hole is jammed. (2) Check if there is sinter, damnification or
interposition of bearing. If any badness, replace balance axle, bearing or front cover component.
Oil pump
(1) Install oil pump gear on front cover and then screw on the gear. Check if it can rotate smoothly and is tightened.
(2) Ensure there is no ridge shape abrasion on the contact surface of front cover and oil pump cover gear surface.
(3) Check side clearance.
Standard value
Drive gear 0.08-0.14mm Driven gear 0.06-0.12mm
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Maintenance Manual for CheryOriental Son Engine Section
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Service Manual for CheryTiggo(T11) Engine Section Chapter 6 Cooling System
Intake Manifold, Water Pump
Remove Steps
Water soft tube Water soft tube Engine coolant temperature sensor Engine coolant induction plug Inflow tube joint Thermostat
1 P
Thermostat shell Inflow Tube 9. O-shape seal ring 10. Water pump 11. Water pump seal ring 12. Oil gauge 13. Oil gauge duct 14. O-shape seal ring 15. Manifold bracket 16. Intake manifold 17. Manifold gasket 18. Engine flying ring
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Service Manual for CheryTiggo(T11) Engine Section
Hose
O-shape seal ring
Installation Notice
O-shape seal installation (1)Make seal ring wet to install it easily.
Caution There must be no engine oil or lubricate grease
on seal ring. Daub thermostat shell with sealant
Sealant of diameter 3mm shall be piled out
Specific sealant Component of Mitsubishi brand 3M ATD
or equivalent.
Note (1) Thermostat shell should be installed
immediately when the sealant is still wet (in 15 minutes).
(2) Don't daub oil on the sealed part in about 1
hour after installation.
Daub engine coolant induction plug with sealant Specific sealant
3M ATD or equivalent
Daub engine coolant temperature sensor with
sealant Specific sealant
3M ATD nut fastening or equivalent
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Service Manual for CheryTiggo(T11) Engine Section
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Chery T11 Service Manual Electric Injection System
1
Chapter
Electric Fuel Injection System
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Chery T11 Service Manual Electric Injection System
2
Section Operating Principle of Key Components 1. Pressure and Intake Temperature Sensor (TEMP)
MT 20 electronic fuel injection system employs the velocity-density-air metrological method to detect the air capacity that flow into the engine, and further accurately control the power output of the engine. At the same time, this system applies the Intake Pressure Cylinder Detection technology. The intake pressure sensor is mounted near the air intake of No. 1 cylinders intake manifold. There is an instantaneous pressure drop in the position of sensor on the moment when the air intake opens. The value of pressure drop is approximate 1Kpa. The ECU can detect this instantaneous pressure drop, receive this signal from the sensor, and then determine the signal of compression upper dead center after the signal is analyzed and processed by software.
The Intake Pressure Sensors internal pressure membrane connects with the magnetic core placed in a coil. The membrane will move together with the iron core when the intake air pressure in the intake pipe changes. In this case, the output voltage of the sensor will also change. The ECU can convert the output voltage of sensor to the intake capacity of the engine. Based on this signal, another signals will be referred to control the fuel injection volume of the engine.
The intake temperature sensor element is a resistor with negative temperature coefficient (NTC), the resistance value of which will decrease as the increase of the intake temperature. The ECU of engine can monitor the change of intake temperature through its internal comparison circuit.
Installation: Installed on the No 1 cylinders intake manifold, and the cylinders are detected based on the instantaneous pressure drop when the air intake opens.
Absolute pressure/intake temperature sensor for
intake manifold
Circuit Diagram of the absolute pressure/intake
temperature sensor for intake manifold
T11 Intake pressure /temperature sensor
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Chery T11 Service Manual Electric Injection System
3
2. Throttle Position Sensor (TPS)
Application: MT20U TPS (Throttle Position) sensor is available to provide the ECU with the information about the throttles opening angle and angular velocity and the idle position of the engine. Based on the information, ECU can obtain the engines information on load and operating condition (such as startup, idle, reverse towing, part load and full load) as well as acceleration and deceleration. This sensor is a three-wire sensor. And the ECU detects the opening of throttle through the monitoring on the voltage change.
Profile of a throttle position sensor
Troubleshooting:
1) Mainly examine the short or open circuit between the four wires on sensor and the ECU.
2) Examine the clog of the sensors detection hole.
3) Examine the short or open circuit and the grounding among the harnesses of sensor.
4) Examine the sensors impact received to cause the sensor failure.
5) Detection pressure range: 10kPa to 110 kPa
Trouble Diagnosis:
1) Short circuit of the sensors wire (shorted to earth, or shorted to supply);
2) Open circuit of the sensors wire;
3) The intake pressure detected by sensor is greater than its upper limit;
4) The intake pressure detected by sensor is less than its upper limit;
Pin:
1) No.1 (A) for the signal from intake pressure sensor (to ECU 42#);
2) No.2 (B) for the standard 5V power supply (to ECU 4#);
3) No.3 (C) for the signal from the intake temperature sensor (to ECU 27#);
4) No.4 (D) for the ground wire of sensor (to ECU 21#).
Operating temperature range: -40 to 125
Operating Voltage: 5.0V s0.1V
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Chery T11 Service Manual Electric Injection System
4
Structure and Principle: This sensor is with the slip resistance structure (i.e. the linear variable resistance structure). The ECU monitors the voltage among the signal output terminals and gets the opening signal of the throttle through the circuits comparison conducted inside the computer. In the ECU, the voltage signal is not received directly but rather the input-to-output signal ratio is detected, which can avoid the signal fluctuation generated due to the voltage fluctuation.
Trouble Diagnosis:
The signal from throttle position sensor is greater than the measuring range;
The signal from throttle position sensor is less than the measuring range;
Short circuit of the throttle position sensor signal connection;
Open circuit of the throttle position sensor signal connection;
WARNING: It is generally prohibited to disassemble the throttle position sensor which has adjusted to its optimal position before it leaves factory.
Installation: The allowable tightening torque of the tightening screw is 1.5 Nm to 2.5 Nm.
Troubleshooting:
1) Mainly examine the short or open circuit between the three wires on sensor and the ECU.
2) Examine the short or open circuit and the grounding among the harnesses of sensor.
3) Examine the jump between the sensor signal terminal and the ground wire, which is detected with the universal meter.
4) Examine the sensors resistance which is evidently greater than the standard value, the season of which may be that the interior of sensor is dirty.
T11 Throttle Position Sensor
Circuit diagram of the throttle position sensor
Pin:
1) No.1 (A) for the standard 5V power supply (to ECU 20#);
2) No.2 (B) for the ground wire of sensor (to ECU 5#).
3) No.3 (C) for the signal from the sensor (to ECU 24#);
Operating Voltage: 5s0.1 V
Opening Range: 7% to 93%
Resistance of Sensor: 3 k to 12 k
Output signal during the close of throttle: 0.612 to 0.588 V
Output signal during the full open of throttle: 4.15 to 4.65 V
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Chery T11 Service Manual Electric Injection System
5
3. Coolant Temperature Sensor (THW, CTS) Application: This sensor is used to provide the information about the coolants temperature. It can offer an engines ECU the water temperature signal which is available to control the startup, idle, ignition timing during the normal operation, and fuel injection pulse width. At the same time, it also offers instruments the water temperature signal which is applied for the water temperature display of the instruments. The water temperature signal is the most signal for the cold start of the engine. During the period of cold start, the fuel injection quantity depends on the signal proved by the water temperature sensor.
Structure and Principle: This sensor is a thermistor with negative temperature coefficient (NTC), whose resistance reduces as the coolant temperature rises, and increases as the coolant temperature drops, but it isnt linear. Based on the output signal from the sensor, the ECU monitors the change of water temperature through its internal comparison circuit.
Trouble Diagnosis:
1) The water temperature signal is higher than the limit value;
2) The water temperature signal is lower than the limit value;
3) The open or short circuits of the water temperature sensor.
Resistance value data at normal temperature:
2.5s5%K
Installation Hint: The max. tightening torque is 20 Nm.
Hint: This vehicle is equipped with the three-wire water temperature sensor. This kind of sensor features with the cost-effective and the
Profile of a coolant temperature sensor
T11 Water Temperature Sensor
Circuit diagram of coolant temperature sensor
Pin:
This sensor has three pins in total, which can be exchanged each other.
1) No1 (A) for the sensor grounding wire (to Ecu 5#);
2) No 2 (B) for the water temperature sensor signal wire (to ECU 43#);
3) No 2 (C) for the water temperature gauge of the instruments;
To instrument
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Chery T11 Service Manual Electric Injection System
6
system consistency.
The three wires of the sensor are respectively: a. The 5V standard power supply wire;
Characteristic Parameters (Standard Value):
-
Chery T11 Service Manual Electric Injection System
7
b. The sensor signal wire (for ECU); c. The sensor signal wire (for
instruments).
Troubleshooting:
1) Mainly examine the short or open circuit between the three wires on sensor and the ECU or instruments.
2) Examine the short or open circuit and the grounding among the harnesses of sensor.
3) Examine the bad wire earth or earth, which easily cause the over-high temperature indicated on the water temperature gauge of the engine.
-10 16120
0 9399
20 3511
60 671
90 241
Operating Voltage: 5V DC
Opening Temperature Range: -40 to 135
4. Knock Sensor (KS, KNK)
Application: This sensor is used to provide the ECU with the knock information of the engine to conduct the knock control.
Structure and Principle: The knock sensor is a kind of vibration acceleration sensor mounted on the cylinder body of an engine. It is generally installed between the No 2 cylinder and the No 3 cylinder, which is in favor of the knock balance of the engine. The ECU utilizes the vibration frequency signal output from the knock sensor to determine the knock of the engine through the wave filtering inside the ECU. When the knock signal is detected, the ECU will gradually reduce the knock till there is no knock, and then gradually resume the knock till up to the upper limit of knock. Repeat this procedure above.
Profile of a knock sensor with cable
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Chery T11 Service Manual Electric Injection System
8
Trouble Diagnosis: The ECU monitors the knock sensor, power amplification circuit and testing circuit. The fault flag of the knock sensor will be set if one of the following conditions occurs:
1) The knock sensor fails;
2) The knock control data processing circuit fails;
3) There are some insincere cylinder detection signals;
4) The sensor wire fails.
After the fault flag of the knock sensor is set, the closed-loop control for knocking closes and then the ignition advance angle stored in the ECU is identified as a safety angle by the software program. The fault flag resets when the error frequency drops down to the setting value below.
Installation Hint: The tightening torque is 20s
5Nm.
Troubleshooting:
1) Mainly examine the short or open circuit between these two wires on sensor and the corresponding ECU pins.
2) Examine the installation torque of sensor and whether the gaskets are added when the sensor is installed.
3) Examine the bad press fit between the sensor and the cylinder body, or the foreign material between the sensor and the cylinder body.
T11 Knock Sensor
Circuit diagram of the knock sensor
Pin: 1) No 1 (A) for the knock sensor signal 1 (to
ECU 5#) 2) No 2 (B) for the knock sensor signal 2 (to
ECU 69#)
Operating temperature range: -40 to 150
Resistance value: > 1M
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Chery T11 Service Manual Electric Injection System
9
5. Oxygen Sensor (O2S) Application: This sensor is used to provide the information about weather the oxygen is superfluous after the fuel injected into the engine cylinder fully combust together with air intake. Based on these information, the ECU can conduct the fuel quantitative closed-loop control to convert and purify three main toxic components, i.e. HC, CO and Nox which exist in the engine exhaust, with the help of three-way catalytic converter.
Structure and Principle: The sensing element of the oxygen sensor is a kind of ceramic tube with small holes, which the outside of tube wall is surrounded by the engine exhaust while the inside is full of air. Based on the oxygen concentration difference between the inside and the outside, the sensor indirectly figure out the pulse width of the fuel injection, transmit the width to the ECU, and then the ECU controls the fuel injection again. At the same time, The output data from the rear oxygen sensor are detected, and, in the ECU, the data from the front and rear oxygen sensors are compared to monitor the operation of three-way catalytic converter.
The operating voltage of the oxygen sensor fluctuates at the range of 0.1 to 0.9 V, and changes 5 to 8 times every 10 seconds. If the change frequency is less than this specified frequency, it indicates that the sensor is aged which needs to replace. This sensor is difficult to repair.
Trouble Diagnosis:
The ECU detects the oxygen sensor, wires and the power amplification circuit and testing circuit inside ECU. The fault flag of oxygen sensor will be set if one of the following conditions occurs:
Profile of a oxygen sensor
T11 Oxygen Sensor
Circuit diagram of front oxygen sensor
All front oxygen sensors have the cables. The other end of a cable is the electrical connection. There is a layer of asbestos fireproof covering around the outside of the sensor
Main Relay
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Chery T11 Service Manual Electric Injection System
10
1) There is the insincere battery voltage; 2) There are some insincere intake manifold
absolute pressure signals; 3) There are some insincere engine coolant
temperature signals; 4) The fuel injector driving level fails. After the fault flag of the oxygen sensor is set, the fuel quantitative closed-loop control closes, and then the basic injection time stored in the ECU is applied to determine the fuel injection quantity. Installation Hint: The tightening torque of the oxygen sensor is 50 to 60 Nm. After the oxygen sensor is replaced, apply a layer of antirust oil on the new oxygen sensor to avoid that the sensor is difficult to be disassembled after rustiness. Troubleshooting: Mainly examine the good connection of several wires on the sensor, and the short or open circuit among them. The damage of sensor is generally caused due to the lead or phosphorus poisoning. So, you shall pay more attention to the fuel quality. At the same time, the excessive consumption of the engine oil also easily creates the sensor failure. During the specified time interval, the number of the oxygen sensor change shall not be less than the specified number.
Any connection has four pins:
1) No 1 (A) for the oxygen sensor signal low level (to ECU 6#);
2) No 2 (B) for the oxygen sensor signal high level (to ECU 62#);
3) No 3 (C) for the power supply of the main relay;
4) No 4 (D) for the sensor heater wire control (to ECU 61#).
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Chery T11 Service Manual Electric Injection System
11
Rear Oxygen Sensor (RO2S)
The structure and detection of the rear oxygen sensor are similar to the front oxygen sensor, but the purpose that a vehicle equips with the front/rear oxygen sensor is considerably different Purpose: Front Oxygen Sensor is mainly used to detect the oxygen content of the exhaust and further determine the fuel injection quantity. The sensor converts the oxygen content of exhaust after combustion into the electric signal, and then transmits the signal to the ECU. The ECU utilizes these signals to control the pulse width of fuel injection, regulate the air-fuel ratio, and indirectly control the exhaust emission of the engine. Rear Oxygen Sensor is mainly used to detect the oxygen content of exhaust after the completion of three-way catalytic conversion. The sensor converts this signal into the point signal, and transmits it to the ECU. The ECU compares the signals from the front and rear oxygen sensors and then determines the operation of the three-way catalytic converter. The trouble diagnosis, troubleshooting, signal detection and other characteristics of the rear oxygen sensor are the same as the front oxygen sensor.
Internal structural diagram of a oxygen sensor
T11 Oxygen Sensor
Circuit diagram of rear oxygen sensor Any connection