Chery A21 User manual

CHERY A21 SERVICEMANUAL MECHANISMOF2.0NALCENGINE

MECHANISMOF2.0NAENGINE

CONTENT

CHAPTER1ENGINEPARAMETERAND SPECIALMAINTENANCETOOLS....2

SECTION 1TECHNOLOGYDATAINSTRUCTION................................................2

SECTION 2SPECIALTOOLS...................................................................................5

SECTION 3ENGINENUMBERPOSITION.............................................................6

SECTION 4COLLATING METHOD OFENGINETIMING.....................................7

CHAPTER2ENGINEBODY........................................................................................9

SECTION 1WHEELTRAIN......................................................................................9

SECTION 2CYLINDERHEAD..............................................................................14

SECTION 3SHORTENGINE..................................................................................26

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CHERY A21 SERVICEMANUAL MECHANISMOF2.0NALCENGINE

CHAPTER1ENGINEPARAMETERAND SPECIALMAINTENANCETOOLS

SECTION1TECHNOLOGYDATAINSTRUCTION

ENGINECHARACTER

EngineModel SQR481H

EngineType

4-Cylinder,WaterCooled, In-lineDouble

OverheadCamshaft, 16 Valve,

ControllableBurning Rate,VariableValve

Timing

CylinderDiameter mm）83.5

PistonStroke(mm) 90

Displacement(L) 1.971

CompressionRatio 10

RatedPower Kw）95

RevatRatedPower r/min）5500

Max.Torque NM）180

RevatMax.Torque r/mim）4000

MinimumFuelConsumptionRate g/Kw.h）

301

CylinderPressure Bar）10±0.2

FuelPressure Bar）4

LowIdleSpeed

800±50r/min）

HighIdleSpeed

2000r/min）

EngineOil

Pressure Bar）

HighSpeed

4000r/min）

HighPressureCircuit 2--3

A/CCircuit

Pressure Bar）

LowPressureCircuit 12---16

PressureReliefValve

ReleasePressureto

Outside）88±14.5

ExpansionTank

Cap kpa）VacuumValve LeadAir

intoTank）-10~~~~-2

StartWorking

Temperature 87Thermostat

Working

Temperature ）

FullWorking

Temperature 104

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TECHNOLOGYDATAINSTRUCTION

Item StandardValue

Intakecam 37.15

CamHeight Exhaustcam 37.05

Intakecam

CamshaftDiameter Exhaustcam

Intakecam 0.15--0.20

Camshaft

Axialclearance ofCamshaft Exhaustcam 0.15--0.20

PlaneDegree ofLowerSurface 0.04

WholeHeight 140±0.41

Cylinder

Head SurfaceGrindLimit*TotalGrinding Quantityof

CylinderBlockandHead

IntakeValve 0.3±0.15

FringeThicknessonTopofValve

ExhaustValve 0.3±0.15

IntakeValve 5.98±0.008

ValveStemDiameter ExhaustValve 5.96±0.008

IntakeValve

SealBandwidth ExhaustValve

IntakeValve 0.02

GapBetweenValveStemAndGuide

ExhaustValve 0.04

IntakeValve 65°

TiltAngle ExhaustValve 68°

IntakeValve 107.998

Valve

Height ExhaustValve 106.318

Free Height 47.7

WorkingTensioninAdvance/WorkingHeightKg/mm

620N/32mm

Valve

Spring

VerticalDegree

ValveGuideLength 38±0.25

Valve

Guide InsideDiameter 5.4±0.1

040.0

053.0

−

040.0

053.0

−

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OuterDiameter

PressureHeight 16±0.3

ProtrudingPartofValveStem 47.5

Piston PistonSkirtDiameter 83.46±0.009

1st Ring 0.04--0.08

SideClearance

Ring

0.01

0.025

Ring

0.2--0.4

EndPlay

Ring

0.4

0.6

1st Ring

2nd Ring

Piston

Ring

Height

OilRing

1st Ring

2nd Ring

Ring

Groove Height/Depth

OilRing

2.5

Diameter

Length 60

PistonPin

DiameterofPistonPinHole

AxialClearance 0.076--0.265

RadicalClearance -0.0375

CoaxialDegree 0.05

Cylindricity 0.008

CrankshaftMainshaftDiameter

Roundness

0.005

Cylindricity

Crankshaft

ConnectingRodJournalDiameter

Roundness

WholeHeight 218±0.05

CylinderHoleRoundness/StraightnessAccuracy 0.008 /0.01

Cylinder

UpperSurface Planeness 0.04

RadialClearance ofConnectingRodBearing 0.016--0.051

Connectin

gRod AxialClearance ofBigEnd 0.15--0.4

051.0

040.0

05.0

03.0

04.0

02.0

03.0

01.0

005.0−

008.0

002.0

01.0

03.0

−

005.0

030.0

−

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CHERY A21 SERVICEMANUAL MECHANISMOF2.0NALCENGINE

SECTION2SPECIALTOOLS

Camshaft TimingTool

CrankshaftTimingTool

FlywheelTool

GuideSleeveofCrankshaftOil

Seal

GuideSleeveofCamshaft Oil

Seal

HydraulicHoist

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CHERY A21 SERVICEMANUAL MECHANISMOF2.0NALCENGINE

FuelPressureGauge

CylinderPressureGauge:whenmeasurethecylinder

pressure,firstlyremovethesparkplug,screwthepipe

endofinstrumentinsteadofit,andoperatetheengineby

starter, thentakethemaximumvalueincylinderpressure

gaugeascylinderpressure.

SECTION3ENGINENUMBERPOSITION

Position ofEngineCylinderBlockNumber

EngineOil Dipstick

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CHERY A21 SERVICEMANUAL MECHANISMOF2.0NALCENGINE

SECTION4COLLATINGMETHODOFENGINETIMING

1.Removetheuppercoverofenginetiming

belt.

2. Removethelowercoverofenginetiming

belt.

3. Loosenthecentralboltoftiming belt

tensionpulleyandremovethetiming

belt.

4. Drawoutthehighvoltageignitioncable.

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5. Loosentheboltofvalvecoverand

removethevalvecover.

6. Rotatethecamshaftinordertoclipthe

camshafttool intotheslotattheendof

camshaft.

7. Loosentheboltsofairintakeandexhaust

camshafttensionpulleyswithtorque

wrench.

Note:Itisnottoremovebutloosen.

8. Revolving thecrankshaft,youmayrotate

inthe crankshafttool soastoitcannot

moveinbothdirection.

Note:Doitwithpatience andcarefulness lest

thecrankshaftshouldbebroken.

CamshaftTool

CrankshaftTool

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9. Mountthetiming beltandrotatetension

pulleywithAllenwrenchinorderto

tensionthebeltandmakethefingerof

tensionerpointtothemiddleofUslot

opening.Fastentheboltoftensionpulley,

thefastening boltsofairintakeand

exhaustcamshafttensionpulleysand

camshaft.

Torque:120±5Nm.

10. Removethespecialtiming tool,and

mountthevalvecover,thehighvoltage

ignitioncableandthetiming beltcover.

CHAPTER2ENGINEBODY

SECTION1WHEELTRAIN

I. STRUCTURALDIAGRAM

PartName Torque valueNm Re-screwangle

1 Bolt–LowerPartOfTiming

FrontCover 8+3

2 Bolt–UpperPartOfTiming Front

Cover 8+3

3 Bolt–UpperPartOfTiming Front

Cover 8+3

4 LowerPartOfTiming Front

Cover

5 UpperPartOfTiming Front

Cover

6 Washer- LowerPartOfTiming

FrontCover

7 Bolt-CrankshaftTimingGear 130+10 65+5

8 Washer- CrankshaftTimingGear

9 CrankshaftTimingGear

10 TimingBelt

11 WaterPump

12 Bolt-Timing GearRearCover 5+1.5

13 TimingGearRearCover

14 CamshaftTiming Gear

15 Bolt-CamshaftTiming Gear 120+5

16 Bolt-Timing Tensioner 27+2.7

17 TimingTensioner

18 Bolt-Timing Idlerwheel 40+5

19 TimingIdlerwheel

20 ContactIdlerwheel

21 Bolt-ContactIdlerwheel 40+5

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II. MAINTENANCE

1. Replace upperandlowercoversoftiming

belt

1.1 Neededtoolsandauxiliarymaterials

Allenwrench,10#,13#sleeve,ratchetwheel

andratchetrod.

1.2 Removal

1) Loosenthefiveboltsontheuppercover

withAllenwrench.

2) Removetheuppercoveroftiming belt.

3) Cliptheflywheelwithflywheeltool.

4) Removethecrankshaftpulleywith13#

sleeve.

FlywheelTool

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