Chery A21 Service Manual

CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE

MECHANISM OF 2.0NA ENGINE

CONTENT

CHAPTER 1 ENGINE PARAMETER AND SPECIAL MAINTENANCE TOOLS....2

SECTION 1 TECHNOLOGY DATA INSTRUCTION................................................2

SECTION 2 SPECIAL TOOLS...................................................................................5

SECTION 3 ENGINE NUMBER POSITION.............................................................6

SECTION 4 COLLATING METHOD OF ENGINE TIMING.....................................7

CHAPTER 2 ENGINE BODY........................................................................................9

SECTION 1 WHEEL TRAIN......................................................................................9

SECTION 2 CYLINDER HEAD..............................................................................14

SECTION 3 SHORT ENGINE..................................................................................26

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CHAPTER 1 ENGINE PARAMETER AND SPECIAL MAINTENANCE TOOLS SECTION 1 TECHNOLOGY DATA INSTRUCTION ENGINE CHARACTER

Engine Model SQR481H

Engine Type

4-Cylinder, Water Cooled, In-line Double

Overhead Camshaft, 16 Valve,

Controllable Burning Rate, Variable Valve

Timing

Cylinder Diameter（mm） 83.5 Piston Stroke (mm) 90

Displacement (L) 1.971 Compression Ratio 10

Rated Power（Kw） 95 Rev at Rated Power（r/min） 5500 Max. Torque（N●M） 180 Rev at Max. Torque（r/mim） 4000 Minimum Fuel Consumption Rate（g/Kw.h）

301 Cylinder Pressure（Bar） 10±0.2 Fuel Pressure（Bar） 4

Low Idle Speed

（800±50r/min）

High Idle Speed

（2000r/min）

Engine Oil

Pressure（Bar）

High Speed

（4000r/min）

High Pressure Circuit 2--3

A/C Circuit

Pressure（Bar）

Low Pressure Circuit 12---16

Pressure Relief Valve

（Release Pressure to

Outside）

88±14.5

Expansion Tank

Cap（kpa）

Vacuum Valve（Lead Air

into Tank）

-10~~~~-2

Start Working

Temperature

87 Thermostat

Working

Temperature（℃）

Full Working

Temperature

104

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CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE

TECHNOLOGY DATA INSTRUCTION

Item Standard Value

Intake cam 37.15

Cam Height

Exhaust cam 37.05

Intake cam

Camshaft Diameter

Exhaust cam

Intake cam 0.15--0.20

Camshaft

Axial clearance of Camshaft

Exhaust cam 0.15--0.20

Plane Degree of Lower Surface 0.04

Whole Height 140±0.41

Cylinder

Head

Surface Grind Limit* Total Grinding Quantity of

Cylinder Block and Head

Intake Valve 0.3±0.15

Fringe Thickness on Top of Valve

Exhaust Valve 0.3±0.15

Intake Valve 5.98±0.008

Valve Stem Diameter

Exhaust Valve 5.96±0.008

Intake Valve

Seal Bandwidth

Exhaust Valve

Intake Valve 0.02

Gap Between Valve Stem And Guide

Exhaust Valve 0.04

Intake Valve 65°

Tilt Angle

Exhaust Valve 68°

Intake Valve 107.998

Valve

Height

Exhaust Valve 106.318

Free Height 47.7

Working Tension in Advance/ Working Height Kg /mm

620N/32mm

Valve

Spring

Vertical Degree

Valve Guide Length 38±0.25

Valve

Guide

Inside Diameter 5.4±0.1

040.0

053.0−−

040.0

053.0−−

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Outer Diameter

Pressure Height 16±0.3

Protruding Part of Valve Stem 47.5

Piston Piston Skirt Diameter 83.46±0.009

1st Ring 0.04--0.08

Side Clearance

Ring

0.01--0.025

1st Ring

0.2--0.4

End Play

2nd Ring

0.4--0.6

1st Ring

2nd Ring

Piston

Ring

Height

Oil Ring

1st Ring

2nd Ring

Ring

Groove

Height/ Depth

Oil Ring

2.5

Diameter

Length 60

Piston Pin

Diameter of Piston Pin Hole

Axial Clearance 0.076--0.265

Radical Clearance -0.0375

Coaxial Degree 0.05

Cylindricity 0.008

Crankshaft Mainshaft Diameter

Roundness

0.005

Cylindricity

Crankshaft

Connecting Rod Journal Diameter

Roundness

Whole Height 218±0.05

Cylinder Hole Roundness / Straightness Accuracy 0.008 / 0.01

Cylinder

Upper Surface Planeness 0.04

Radial Clearance of Connecting Rod Bearing 0.016--0.051

Connectin

g Rod

Axial Clearance of Big End 0.15--0.4

051.0

040.0++

2.1

05.0

03.0++

5.1

04.0

02.0++

5.2

03.0

01.0++

005.0−

008.0

002.0

2.1

01.0

03.0−−

5.1

005.0

030.0−−

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CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE

SECTION 2 SPECIAL TOOLS

Camshaft Timing Tool

Crankshaft Timing Tool

Flywheel Tool

Guide Sleeve of Crankshaft Oil

Seal

Guide Sleeve of Camshaft Oil

Seal

Hydraulic Hoist

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Fuel Pressure Gauge

Cylinder Pressure Gauge: when measure the cylinder pressure, firstly remove the spark plug, screw the pipe end of instrument instead of it, and operate the engine by starter, then take the maximum value in cylinder pressure gauge as cylinder pressure.

SECTION 3 ENGINE NUMBER POSITION

Position of Engine Cylinder Block Number

Engine Oil Dipstick

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SECTION 4 COLLATING METHOD OF ENGINE TIMING

1. Remove the upper cover of engine timing belt.

2. Remove the lower cover of engine timing belt.

3. Loosen the central bolt of timing belt tension pulley and remove the timing belt.

4. Draw out the high voltage ignition cable.

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CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE

5. Loosen the bolt of valve cover and remove the valve cover.

6. Rotate the camshaft in order to clip the

camshaft tool into the slot at the end of

camshaft.

7. Loosen the bolts of air intake and exhaust camshaft tension pulleys with torque wrench.

Note: It is not to remove but loosen.

8. Revolving the crankshaft, you may rotate in the crankshaft tool so as to it cannot move in both direction.

Note: Do it with patience and carefulness lest the crankshaft should be broken.

Camshaft Tool

Crankshaft Tool

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9. Mount the timing belt and rotate tension pulley with Allen wrench in order to tension the belt and make the finger of tensioner point to the middle of U slot opening. Fasten the bolt of tension pulley, the fastening bolts of air intake and exhaust camshaft tension pulleys and camshaft.

Torque: 120±5Nm.

10. Remove the special timing tool, and mount the valve cover, the high voltage ignition cable and the timing belt cover.

CHAPTER 2 ENGINE BODY SECTION 1 WHEEL TRAIN I. STRUCTURAL DIAGRAM

Part Name Torque value Nm Re-screw angle

Bolt– Lower Part Of Timing Front Cover

8+3

Bolt– Upper Part Of Timing Front Cover

8+3

Bolt– Upper Part Of Timing Front Cover

8+3

Lower Part Of Timing Front Cover

Upper Part Of Timing Front Cover

Washer- Lower Part Of Timing

Front Cover 7 Bolt- Crankshaft Timing Gear 130+10 65+5 8 Washer- Crankshaft Timing Gear 9 Crankshaft Timing Gear 10 Timing Belt 11 Water Pump 12 Bolt- Timing Gear Rear Cover 5+1.5 13 Timing Gear Rear Cover 14 Camshaft Timing Gear 15 Bolt- Camshaft Timing Gear 120+5 16 Bolt- Timing Tensioner 27+2.7 17 Timing Tensioner 18 Bolt- Timing Idler wheel 40+5 19 Timing Idler wheel 20 Contact Idler wheel 21 Bolt- Contact Idler wheel 40+5

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CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE

II. MAINTENANCE

1. Replace upper and lower covers of timing belt

1.1 Needed tools and auxiliary materials

Allen wrench, 10#, 13# sleeve, ratchet wheel and ratchet rod.

1.2 Removal

1) Loosen the five bolts on the upper cover

with Allen wrench.

2) Remove the upper cover of timing belt.

3) Clip the flywheel with flywheel tool.

4) Remove the crankshaft pulley with 13#

sleeve.

Flywheel Tool

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CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE

5) Remove the 5 bolts on the lower cover

of timing belt with 10# sleeve, ratchet wheel and ratchet rod.

6) Remove the lower cover.

1.3 Inspection

Observe the timing cover and the timing belt. Replace the timing belt cover or adjust the position of timing belt if any trail from crack or friction is found.

1.4 Installation

The installing steps are reverse to those for removal.

Note: Install the lower cover first and then install the upper one.

2. Replace timing belt

2.1 Needed tools and auxiliary materials

Allen wrench, 10#, 13# sleeve, ratchet wheel and ratchet rod.

2.2 Removal

1) Remove the upper and lower covers of

timing belt (see “replace covers of

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timing belt” for details).

2) Loosen the central bolt of tension pulley

and remove the timing belt.

2.3 Inspection

Check the timing belt carefully; replace the parts if any following situation occurs.

(1) Chap of back-side rubber (2) Chap of dedendum, chap of separated

cord fabric. (3) Wearing, gear missing and incomplete

gear of cord fabric.

(4) Abnormal wearing of belt flank.

Replace the belt as any following situation occurs, even though abrasion cannot be found directly.

1) The water pump leaks water out, and requires continuing infusion.

2) If the belt is spotted with much oil stains, and the rubber may be damaged due to

expansion, you should replace the belt.

Chap

Wearing

Abnormal Wearing

Gear Missing

Belt Core Desquamation

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2.4 Installation

The installing steps are reverse to those for removal.

Note: Do engine timing.

3. Replace idler wheel, tensioner and contact belt pulley

3.1 Needed tools and auxiliary materials

Allen wrench, 10#, 13# and 15# sleeve, ratchet wheel and ratchet rod.

3.2 Removal

1) Remove the timing belt (see “replace

timing belt” for details).

2) Remove idler wheel, tension pulley and

contact belt pulley.

3.3 Inspection

1) Check from appearance

Check idler wheel, tension pulley and contact belt pulley carefully for any damages, such as sunken trace and sliding damage etc.

2) Check performance

Revolve tension pulley, idler wheel and contact belt pulley respectively to insure that they can run freely without stagnancy.

Replace it with the spare part if any above problem is found.

3.4 Installation

1) The installing steps of tension pulley,

idler wheel and contact belt pulley are reverse to those for removal.

2) Mount the timing belt and collate engine

timing.

3) Mount other parts.

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CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE

SECTION 2 CYLINDER HEAD

I. STRUCTURAL DIAGRAM

1. Gasket—Intake Manifold

2. Intake Manifold Assembly

3. Hexagonal Flange Bolt

4. Throttle Valve Body Assembly

5. Gasket—Throttle Valve Body Assembly

6. Oil injector Assembly

7. Fuel Distribution Pipe Assembly

8. Bracket

2 1

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Chery A21 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual