Manual de Taller de Chery Tiggo.pdf

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


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


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

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


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


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

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

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

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


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


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.


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


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


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.


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


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


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


2. New blade and new main ring shall be colorized to distinguish their sizes.

6L]H ,GHQWLILFDWLRQFRORU

6WDQGDUG 1LO,QFUHDVHPP 5HG,QFUHDVHPP


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


Installation of &RQQHFWLQJ5RG&DS :KHQLQVWDOOLQJconnecting rod cap, check

paint mark

paint

mark

cylinder number

anti-rotating gap


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


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


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

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)

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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


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.

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


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


wrench.


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.


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


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.


(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

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


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

Chery T11 Service Manual Electric Injection System

1

Chapter

Electric Fuel 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


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


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.


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


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


6

system consistency.

The three wires of the sensor are respectively: a. The 5V standard power supply wire;

Characteristic Parameters (Standard Value):


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.


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


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


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


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#).


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

Documents

Manual de Taller de Chery Tiggo.pdf