Chery TIGGO User manual

Service Manual for Chery·Tiggo(T11) Engine Section

Contents

Chapter 1 Overview。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。3

I. Technical Data。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。3

II. Special Tools。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。8

Chapter 2 Structural Features of Engine。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。12

Chapter 3Admission Gear。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。23

I. Timing Gear Belt。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。23

II. Rocker and Camshaft。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。32

III. Cylinder Cover and Valve。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。36

Chapter 4 Crank Gear。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。42

Chapter 5 Lubricating System。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。 54

Chapter 6 Cooling System。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。62

Service Manual for Chery·Tiggo(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

多点顺序喷射系统：Multi-point sequential injection

4气门结构：4 valve structure

单顶置凸轮轴：Single-overhead-camshaft

设计序号：Design serial number

产品系列：Product serial

汽油发动机：Gasoline engine

4气缸结构：4 cylinder structure

2.Engine Number Position

Engine No.

Position

Service Manual for Chery·Tiggo(T11) Engine Section

3．Related Engine Data

Item

Specification

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

Combustion chamber

Ridge chamber

Total displacement

1,997

2,351

Cylinder diameter

85.0

86.5

Stroke mm

88.0

100.0

Output power kw

92（6000r/min）

95（5500r/min）

Max torque N.m

167.7

198.1

Compression ratio

Lubrication system

Pressure supply, full filter

Fuel pump type

Gear type

Water pump type

Centrifugal impeller

4. Maintenance Standard

UOM：mm

Item

Standard Value

Usage Limit

Value

Engine gear

belt

Tensioner arm protrusion

——

Tensioner arm depression (98～196N)

≤1

——

Camshaft

Cam height

Air-in

4G63

37.50

37.00

Air-out

4G63

36.99

36.49

Shaft diameter

45.0

Cylinder

cover

Lower surface flatness

0.03

0.2

Surface grinding limit* total grinding of cylinder body and

cylinder cover

——

* 0.2

Full height

119.9－120.1

97.4

≤99.4

Valve

Edge thickness

Air-in

1.0

0.5

Air-out

1.2

0.7

Valve rod diameter

6.0

——

Crest clearance between valve rod and

duct

Air-in

0.02－0.05

0.10

Air-out

0.03－0.07

0.15

Inclination angle

45°－45.5°

——

Service Manual for Chery·Tiggo(T11) Engine Section

Item

Standard Value

Usage Limit

Value

Height

Air-in

112.30

111.80

Air-out

114.11

113.61

Valve

spring

Free height

51.0

50.0

Pre-loading force/Operation height Km/mm

27.2/44.2

——

Verticality

≤2°

≤4°

Valve duct

Contact bandwidth

0.9－1.3

——

Internal diameter

6.0

——

External diameter

11.0

——

Depression depth

14.0

——

Valve rod protrusion height

49.3

49.8

Engine oil

pump

Side clearance

Driving gear

0.08－0.14

——

Driven gear

0.06－0.12

——

Piston

Piston clearance

0.02－0.04

——

Piston ring

Lateral clearance

No.1 ring

0.02－0.06

0.1

No.2 ring

0.02－0.06

0.1

End clearance

No.1 ring

0.25－0.35

0.8

No.2 ring

0.40－0.55

0.8

Oil ring

0.10－0.40

1.0

Piston pin

External diameter

22.0

——

Depressing force (Kg)

755－1750

——

Depressing temperature

Room

temperature

——

Crank

Crank pin clearance

0.02－0.05

0.1

Connecting

rod

Bigger end clearance

0.10－0.25

0.4

Crank

Axial clearance

0.05－0.18

0.25

Main axle diameter

——

Connecting axle diameter

——

Main axle diametral clearance

0.02－0.04

0.1

Cylinder

body

Upper surface flatness

0.05

0.1

Upper surface grinding limit*Total grinding of cylinder body

and cylinder cover

——

* 0.2

Full height 4G63

284±0.1

——

Internal diameter of cylinder hole 4G63

85.00－85.03

——

Cylinder

body

Cylinder hole cylindricity

0.01

——

Motor

Rotor coil resistance

3－5

——

Cylinder

Cover

Secondary processing size of valve conduit

installation hole (air-in and air-out valve)

enlargement

0.05 O.S.

11.05－11.07

0.25 O.S.

11.25－11.27

0.50 O.S.

11.50－11.52

Service Manual for Chery·Tiggo(T11) Engine Section

Item

Standard Value

Usage Limit

Value

Secondary processing size of air-in valve

seating hole enlargement

0.30 O.S.

34.435－34.455

0.60 O.S.

34.735－34.755

Secondary processing size of air-out valve

seating hole enlargement

0.30 O.S.

31.935－31.955

0.60 O.S.

32.235－32.255

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

1.9

Service Manual for Chery·Tiggo(T11) Engine Section

EGR valve

Injector and distribution pipe

Fuel oil return pipe

Fuel pressure regulator

2.2

1.2

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

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

Thermostat housing bolt

Water pump screw bolt

1.4

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

Trust bearing cover bolt

0.4

3.2

1.9

Cylinder Cover and Valve

Cylinder cover bolt

2.0＋90°＋90°

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

Engine oil pump cover screw

4.5

0.7

1.9

1.0

4.5

1.9

2.4

3.7

1.6

1.0

Piston and Connecting Rod Assembly

Connecting rod nut

2.0＋90°～100°

Crank, Cylinder Body, Flywheel

Flywheel screw bolt

13.5

Service Manual for Chery·Tiggo(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

2.5＋90°～100°

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

MB990938

Handle

Use it together with

MD998776 to install

crankshaft rear oil seal.

MB991603

Balance axle bearing puller

limiter

Use it with MD998372

together to disassemble

reverse balance axle rear

bearing and install guiding

limiter.

MB991654

Cylinder cover bolt spanner

(12)

Disassemble and assemble

cylinder cover bolt.

MD998162

Plug spanner

Disassemble and assemble

front cover plug cock.

MD998285

Crankshaft front oil seal duct

MD998375 Use MD998375

to install crankshaft front oil

seal

Service Manual for Chery·Tiggo(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

Service Manual for Chery·Tiggo(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.

Service Manual for Chery·Tiggo(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.

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