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SERVICE MANUAL
ENGINE-MECHANICAL
372 ENGINE-MECHANICAL
SERVICE CONTENT
TYPESQR7080R
SQR7080R ENGINE-MECHANICAL
DECEMBER 2005
Please write down the changes notice after each assembly numbers, the function is to remind
the users there are changes and the technical department will inform the correlated
department keep them in archives for checking.
ASSEMBLY
1
TECHNICAL
CHANGES NOTICE
Valve train
Cylinder head
Cooling System
Lubrication system
The service man must master the technical improvement conditions of this car to provide
better maintenance work.
372 ENGINE-MECHANICAL
PREFACE
Dear technicians and mechanics for SQR372 engine maintenance,
You are suggested to read this manual before service and operate in accordance with the
specification of manual.
1)
The manual supplies you with the information of accessories, such as special tools,
measures and grease. You should, by all means, prepare for this kind of accessories fully
before service.
2)
Of course, we leave out the general tools, such as lifter and spare parts, because they are
absolutely necessary for you.
3)
We provide the structural diagrams of main machines, the assembly views of every part
and their names before their service introduction. It is the reference for you on
disassembly and assembly.
4)
5)
The parts with a mark * in the structural diagrams can not reused and they should be
replaced in assembly.
6)
We leave out the operations of related service tools in this manual but you should pay
attention to them during service.
7)
We leave out the operation requirements for cleaning and checking the parts in this
manual. You should meet the operation requirements for cleaning and checking the parts
by all means.
8)
372 ENGINE-MECHANICAL
TABLE OF CONTENTS
DEFINITION ................................................................................................................................................3
THE MEANING OF MARKS AND ABBREVIATIONS..........................................................................3
SQR372 ENGINE STRUCTURE AND PERFORMANCE PARAMETER............................................4
SPECIAL MAINTENANCE TOOLS.........................................................................................................5
REMOVE THE ENGINE FORM VEHICLE............................................................................................7
1
MOUNT THE ENGINE ON THE ROLL OVER STAND ...............................................................9
2
DISASSEMBLY , ASSEMBLY AND REPAIR OF FRONTAL DRIVE PARTSOF ENGINE.....10
2-1. STRUCTURE DIAGRAM OF FRONT TRANSMISSION PART....................................10
2-2 to 2-4. DISASSEMBLY & ASSEMBLY OF ENGINE FRONT TRANSMISSION PART...10
3. CAMSHAFT ...........................................................................................................................................17
3-1 STRUCTURAL DIAGRAM(DISASSEMBLY OF TIMING BELT AND ASSEMBLY
OPERATIONS ARE CARRIED AS THE FOLLOWING VIEW.) ................................................17
3-2 to 3-5. DISASSEMBLY & ASSEMBLY OF CAMSHAFT ......................................................18
4. CYLINDER HEAD ............................................................................................................................25
4-1
STRUCTURAL DIAGRAM OF CYLINDER HEAD.........................................................25
4-2 to 4-6. DISASSEMBLY & ASSEMBLY OF CYLINDER HEAD ...........................................26
5. WATER PUMP...................................................................................................................................33
5-1
STRUCTURAL DIAGRAM OF WATER PUMP................................................................33
5-2 to 5-5. DISASSEMBLY & ASSEMBLY OF WATER PUMP..................................................34
6. LUBRICATION SYSTEM.................................................................................................................34
6-1
STRUCTURAL DIAGRAM ..................................................................................................34
6-2 to 6-6. DISASSEMBLY & ASSEMBLY OF WATER PUMP..................................................36
7. CRANKSHAFT CONNECTING ROD MECHANISM..................................................................42
7-1
STRUCTURE DIAGRAM.....................................................................................................42
7-2 to 7-5. DISASSEMBLY & ASSEMBLY.....................................................................................43
2.
372 ENGINE-MECHANICAL
DEFINITION
Standard
Limit
[Reference]
Set the standard value for simple measurement to prevent from its
measuring difficulty and inconsistency to facts.
Difference
Note
It carries the cases of damaging the vehicle and parts so you should
pay attention to the operation description.
Warning
Original words
Translated words
RH
Right Hand
LH
Left Hand
FR
Front
RR
Rear
IN
Intake
EX
Exhaust
SAE
API
SST
Torque
Ay
Assembly
S/A
Sub Assembly
W/
With
M/T
Manual Transmission
A/T
Automatic Transmission
T/C
Turbo Charger
372 ENGINE-MECHANICAL
SQR372
Type
72
66.5
Displacement (ml)
812
Compression ratio
9.5:1
38
6000
70
3500~4000
275
Lubricant(designation)
10W/30
Lubricant volume(L)
2.4
Fuel RON
93#
372 ENGINE-MECHANICAL
Symbol/Name
Purpose
Disassembly of camshaft
timing gears
Flywheel clamp
Outside view
372 ENGINE-MECHANICAL
Name or symbol
Purpose
Crankshaft pulley
holding tool
Disassembly and
assembly of crankshaft
pulley
Wrench
Disassembly and
assembly of camshaft
driven gear
Replace valve lash
adjustment shim
Measuri
ng tools
Assembly of coolant
pump
Feeler gauge. Micrometer caliper. Ruler. Dial gauge. Cylinder gauge. Caliber.
Pressure gauge. Torque wrench torque wrench
Tool
Oil
372 ENGINE-MECHANICAL
Ground
Remove the
transmission;
Disassemble
the
conjunction
pipeline and the control cables.
Transmission Cable
control
cable
of
372 ENGINE-MECHANICAL
Take down the left / right inner side gear
from differential.
Remove the rocker outer ball section
and pry out the left/right side gear;
3# Right Front
Engine
Mounting
1# Right Rear
Engine
Mounting
4# Left
Rear Engine
Mounting
2# Left Front Engine
Mounting
372 ENGINE-MECHANICAL
372 ENGINE-MECHANICAL
2-2. DISASSEMBLY
1. Disassemble The Water Pump Pulley
Remove the water pump pulley as the view
showing.
It will be better of disassembling with special
tool.
10
372 ENGINE-MECHANICAL
Special Tool
11
372 ENGINE-MECHANICAL
MakeTiming Mark
Rotate Clockwise
Timing Mark
5.
12
372 ENGINE-MECHANICAL
2-3. INSPECTION
1. Check The Timing Belt Carefully; Replace With The New 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.
Chap
Wearing
Chap
Gear Missing
Abnormal Wearing
Belt Core Desquamation
Note: 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.
372-1007081
25.3mm
13
372 ENGINE-MECHANICAL
Rotate the bolt of tension pulley bracket and hear if it is noisy; check the contacting surface
and look if it is damaged.
Model and type of tension pulley of timing belt
Part number
Width
Outer diameter
372-1007030
27.0mm
50mm
3.
EF
GL. ZL. GS. ZS
110.7+0.1-0.2
54.65+0.7-0.13
Check if it is deformed.
Standard size of
Width
28.6mm
2-4. ASSEMBLY
Assembly
1. Aassembly Of Crankshaft timing gear
Timing Mark
14
372 ENGINE-MECHANICAL
Timing Mark
Timing Mark
Rotate Clockwise
About 8mm
15
372 ENGINE-MECHANICAL
When pressing the mid of right 5mm,
the force should be:
[Reference] 2030
Inside
Damper
(With
Special Tool
Torque: 98.010N.m{101kgm}
(2) With flywheel
Special tool
16
372 ENGINE-MECHANICAL
3. CAMSHAFT
3-1 STRUCTURAL DIAGRAM (DISASSEMBLY OF TIMING BELT AND
ASSEMBLY OPERATIONS ARE CARRIED AS THE FOLLOWING VIEW.)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
17
372 ENGINE-MECHANICAL
3-2 DISASSEMBLY
1. Disassembly of cylinder head chamber
cover assembly Screw off the bolt of
cylinder head cover from both sides to the
middle in symmetry.
2.
Inspection Of Valve
IN
0.180.05
EX
0.250.05
Intake
18
372 ENGINE-MECHANICAL
Special Tool
Unit:mm
Type
Item
Standard
value
Limit
IN
EX
IN
EX
EF
ZL.RL GL.GS.ZS
23.0-0.02-0.033
23.0-0.02-0.033
22.9
22.9
19
372 ENGINE-MECHANICAL
3-5 ASSEMBLY
Special Tool
Assembly Of Camshaft
Intake
20
372 ENGINE-MECHANICAL
Special Tool
372 ENGINE-MECHANICAL
IN
EX
0.180.05
0.250.05
2.18
2.20
2.22
2.24
2.26
2.28
2.30
2.36
2.32
2.38
2.40
2.42
2.44
2.46
2.48
2.50
2.52
2.58
2.54
2.6
2.62
2.64
2.66
2.68
2.70
2.72
2.74
2.80
2.76
22
372 ENGINE-MECHANICAL
Special Tool
23
372 ENGINE-MECHANICAL
Special Tool
Special Tool
24
372 ENGINE-MECHANICAL
CYLINDER HEAD
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
4-2 DISASSEMBLY
1.
25
372 ENGINE-MECHANICAL
Special Tool
4-3 CLEAN
1. Clean The Carbon Dust On The Valve.
2. Clean The Bottom Surface Of
Cylinder Head And The Surface Of
Intake And Exhaust Manifold With
Scraper Knife.
Note: Do Not Damage The Surface Of
Cylinder Head During Cleaning.
Do Not Pollute The Intake Port And Water
Passage.
4-4 INSPECTION
1.
Cylinder Head
26
372 ENGINE-MECHANICAL
Valve Spring
Valve
Standard
value
Limit
IN
0.851.41
___
EX
1.071.36
1.00.2
1.00.2
___
Item
Measuring Point For Outside
Width of seal
Thickness of
valve
Unit:mm
IN
EX
0.75
0.75
Measuring Point
Thickness Of Top
27
Measuring point
372 ENGINE-MECHANICAL
Figure out the difference of measured
values and the clearance. If the
clearance is beyond the specified value,
replace valve or guide.
IN
EX
Standard
value
Limit
5.0
___
5.0
___
0.056
0.020mm
0.066
0.030mm
0.07
0.08
Special Tool
Special Tool
28
372 ENGINE-MECHANICAL
EF
GL,ZL,RL,GS,ZS
IN
13.710.25
EX
12.110.25
29
372 ENGINE-MECHANICAL
30
Painting Mark
372 ENGINE-MECHANICAL
Special Tool
31
372 ENGINE-MECHANICAL
Torque 201Nm
Note: Tools should be vertical to prevent the
protective tube of spark plug from distorting,
or the oil will leak.
32
372 ENGINE-MECHANICAL
WATER PUMP
FOLLOWING
5-2 DISASSEMBLY
1. Disassembly Of O Ring
Note: O ring can not be reused.
2. Screw Off 3 Bolts And Disassemble
Water Pump Body.
3. Disassembly Of Dust Seal
5-3 CLEAN
1. Clean Of Water Pump Joint Surface
5-4 INSPECTION
1. Check If It Is Deformed.
2. Check If The Rotor Is Rotating By
Hand And Check The Lubricating
Condition.
5-5 ASSEMBLY
1. Mount Dust seal
2. Mount Water Pump Body
Torque 251.5N.m
3. Mount The New O Ring
33
372 ENGINE-MECHANICAL
LUBRICATION SYSTEM
FOLLOWING
6-2 DISASSEMBLY
1. Reverse The Engine On The
Disassembling Support And Screw Off
The Bolts.
34
372 ENGINE-MECHANICAL
Special Tool
35
372 ENGINE-MECHANICAL
6-3 CLEANUP
1. Clean up the joint surface between the
oil pan and the engine oil pump, oil
seal bracket and cylinder.
2. Clean up the joint surface between the
rear oil seal bracket and the cylinder.
A scraper or scraper knife can be used
for cleaning up the old shim.
Note: Dont let the shim fragment fall into
the cylinder.
STRUCTURE DIAGRAM
Weather Strip
Cover Plate Of Engine Oil Pump
Outer Rotor Of Engine Oil Pump
Inner Rotor Of Engine Oil Pump
Cotter pin
Spring Seat Of Oil Drain Valve
Spring Of Oil Drain Valve
Slider
Front Crankshaft Oil Seal
Housing Of The Engine Oil Pump
36
372 ENGINE-MECHANICAL
6-4-2 DISASSEMBLY
1. Weather Strip
Note: The weather strip cannot be
repeatedly used.
2. Remove The Oil Pump Cover
Note: The bolt is assembled with glue;
tighten it with a screwdriver as shown in
the figure.
Slider
Spring Seat
37
372 ENGINE-MECHANICAL
6-4-3 INSPECTION
Inspect the engine oil pump for clearance.
According to the marks for inner gear and
outer gear in the engine oil pump, put the
gears into the engine oil pump that is in
the cylinder block.
6-4-4 ASSEMBLY
1. After the lip of the new oil seal for
front crankshaft is spread with engine
oil, fix it with a special tool.
Special Tool
Inside
38
372 ENGINE-MECHANICAL
Mark
39
372 ENGINE-MECHANICAL
6-5-2 DISASSEMBLY
1. Remove The Rear Crankshaft Oil Seal
With A Screwdriver.
Note: The rear crankshaft oil seal cannot be
repeatedly used.
6-5-3 INSPECTION
6-6 ASSEMBLY
1.
40
372 ENGINE-MECHANICAL
4.
Rear
41
372 ENGINE-MECHANICAL
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
42
372 ENGINE-MECHANICAL
cap
with
Torque: 402N.m
43
372 ENGINE-MECHANICAL
Connecting Rod
Bearing
Connecting Rod Cap
Protective Tube
Standard
value
Thickness of thrust
plate
1.9-0.11-0.03
44
372 ENGINE-MECHANICAL
45
372 ENGINE-MECHANICAL
Pressed Mark
Standard value:0.025-0.069mm
Limit: 0.10mm
5.
Special Tool
Special Tool
7-3 CLEANUP
7-3-1 CYLINDER BODY
Warning Wear glasses for protecting eyes
when the cleanup is being done.
1. Clean Up The Cylinder Body, Cylinder
Head, Oil Pan, Oil Pump And The Oil
Seal With A Flat Blade.
7-3-2 piston
Warning Wear glasses for protecting eyes
when the cleanup is being done.
1. Use An Old Ring To Remove The
Carbon In Ring Groove.
2. Remove The Carbon Of Parts With
Scavenger.
Note: It is not allowed to use a metal
brush here or some tool made of hard
material.
46
372 ENGINE-MECHANICAL
7-4 INSPECTION
7-4-1 CYLINDER BODY
1.
Limit: 0.03mm
[reference] roundnessA-B or a-b
Cylindricity A-a or B-b
[reference] standard value of cylinder
diameter 72.00-72.01mm
7-4-2 PISTON
1. Inspect The Piston Pin Hole For Its Clearance
(1) Measure the piston pin at several positions with a micrometer caliper shown in the
figure; make the maximum value as the diameter of pin.
(2) Measure the diameter of piston pin at several positions with an inner-diameter dial
gauge as shown in the figure; make the minimum value as the diameter of the pin
hole.
47
372 ENGINE-MECHANICAL
(3) Work out the clearance with the difference between the pin diameter and pin hole
diameter, if the difference is beyond the standard value, replace the piston pin or
piston.
Standard value: 0.004-0.009mm
Limit 0.015mm
48
372 ENGINE-MECHANICAL
First ring
Second ring
Standard value
(mm)
0.03~0.06
0.03~0.06
Limit (mm)
0.12
0.11
First ring
Second ring
Oil ring
segment
Standard value
(mm)
0.25-0.40
0.35~0.50
Limit
(mm)
0.65
0.65
0.20~0.70
1.00
49
372 ENGINE-MECHANICAL
50
372 ENGINE-MECHANICAL
7-4-4 CRANKSHAFT
1. Inspect The Proper Alignment Of The
Main Axle Diameter.
(1) Measure the proper alignment with a
dial gauge, if the proper alignment is
beyond the limit, replace the crankshaft.
Limit: 0.03mm
Note: The bending value should be equal to
one-second the run-out value of crankshaft
rotating one circle.
1.
Inspect The
Abrasion.
Crankshaft
For
The
Mark Forwards
51
372 ENGINE-MECHANICAL
Special Tool
Special Tool
Front
Expander
Rear
Upper Segment
372 ENGINE-MECHANICAL
53
372 ENGINE-MECHANICAL
Nylon Stick
Special Tool
Raised Forward
Torque 402N.m
Note: The connecting rod and the
connecting rod bearing cover belong to the
same component.
54
372 ENGINE-MECHANICAL
55