Chery Amulet Engine. Manual — part 8

Fig.51

Fig.52

Unit: mm

480E *dia. of piston skirt (mm)

Factory

group

1

79.915 – 79.925

2

79.925 – 89.935

3

79.935 – 79.945

4

79.945 – 79.955

Factory

repair

A

80.205 – 80.215

B

80.215 – 80.225

C

80.225 – 80.235

Spare

parts

Standard

79.965 – 79.975

Oversize 0.29

80.245 – 80.255

Oversize 0.5

80.465 – 80.475

* 480M piston should be applied on 480E engine

– Measure the diameter. of the hole of piston pin

Unit: mm

480 diameter of the piston pin hole

White

20.630 – 20.633

Red

20.633 – 20.636

Blue

20.636 – 20.639

– Measure the diameter of piston pin

Unit: mm

480 diameter of the piston pin hole

White

20.622 – 20.625

Red

20.625 – 20.628

Blue

20.628 – 20.631

– Measure cotter intermission of piston ring

First compression ring

0.30 – 0.50mm

Second compression ring

0.30 – 0.50mm

Steel combination oil ring

0.40 – 1.40mm

– Measure the piston ring end play in the piston groove

Unit: mm

Piston ring

height

Piston ring

groove size

Fit clearance

First compression

ring

1.60

0

- 0.012

1.6

+ 0.06

+ 0.04

0.050 – 0.082

Second track

compression ring

2.0

0

- 0.012

2.0

+ 0.06

+ 0.04

0.050 – 0.082

Oil control ring

blade

0.61 ± 0.025

4.0

+ 0.03

0.01

0.01 – 0.23

Oil control ring

2.68 ± 0.05

Cast iron oil control

ring

4.0

- 0.015

- 0.025

4.0

+ 0.03

+ 0.01

0.025 – 0.055

——Check and make sure that the oil injection hole of the
connecting rod large end is not blocked. The outside diameter
is φ1mm.
Installation:
——Need not to divide into groups for the piston weight,
piston pin holes and the accessory piston skirt. Before
assembling, check the piston head mark and make sure that it is
in accord with cylinder No.4.
——Heat the small end of connecting rod to 230°—400℃,
and apply SAE50 engine oil or graphite colloid oil on the outer
circumference of the piston pin hole. Then press the piston pin
into the hole of connecting rod small end and piston pin. One
end of the piston pin may be 0.7mm mostly out of the pin hole
or 0.3mm mostly in the seat. And plug the other end of it into
the pin seat.

The piston head means the front arrow. The outer end
of piston pin means the front lug, which should has a
same direction with “F” near the large end of the
connecting rod.(with ‘480’ mark on some blanks and
the mark side forward.)

——After the piston, piston pin, and the connecting rod are put
together, print and sculpture the cylinder numbers with the
3mm words on the top of piston, the connecting rod and the left
side of rod cap (viewed from the front). Be sure not to be
deformed on the connecting side during printing.
——The dimension of piston ring.

480 piston ring

Paint

marker

(group)

Size

of

gauge

No

paint

(standard)

79.94

Purple

paint

(oversize 0.29)

80.23

Blue

paint

(oversize 0.5)

80.44

——When installing the piston ring, the mark side should
be put up and the second compression ring outside cut section
should be put down and remember not to the contrary. Firstly
the oil controlling ring, then the second compression ring, and
finally the first compression ring. As assembling the ring, its
maximum tension should be inferior to the diameter of the
cylinder(+1. 65mm), or the ring would be deformed and broken.
The two cotters of the steel band combination oil ring and oil
control spacer ring should be parted with a angle of 120°.And
the cotters of cast iron oil ring and screw spacer ring should be
parted with a interval of 180°. The piston should rotate freely
in the ring groove without blocking.

Fig.53

Fig.54

Fig.55

Front

lug

No.1 compressing
ring

No.2 compressing ring

Steel

band

combination oil ring

Cost iron oil ring

Only one side

Installation of the piston and rod assembly：

Apply engine oil on piston, piston ring and cylinder bore.
Stagger 120°among the first compression ring, the second ring
and oil ring cotter, then install piston rod into cylinder bore. push
the piston an rod assembly by hammer into the cylinder bore.
——Apply engine oil on the connecting rod bushing. Mount
connecting rod cap. Retain connecting rod body and cap with two
elastic retaining pins.
——Tighten connecting rod bolt to 30—36Nm. apply engine oil
on the bolt head and bolt threads before installation.
——The side play of big end is 0.092—0.268mm。

【10】. The removal and installation of flywheel assembly and
carrier assembly of real crankshaft oil seal

1). The removal and installation of flywheel assembly
removal：
——Remove six M10 bolts and replace bolts.
——Remove flywheel. Check if there is crack in the
surface of clutch plate. Check ring gear teeth for crack,
wear, pitting.
Installation：
——The press fit clearance of gear ring and flywheel is
0.48—0.86mm. The gear ring should be pressed when
heated to 300℃.
——The retaining hole of flywheel and the retaining
journal of crankshaft is of clearance fit. clearance is
0.012—0.074mm. Try to push it lightly after centering.
Don’t strike the crankshaft by the hammer.
——During assembling, align the installation mark hole
and fabrication hole on the crankshaft. Screw in 6 new
bolts by hand. Bolts should have sealant on them.
Tightening torque is 82—92Nm.

Fig.56

Fig.57

Gage hole

Install mark bore

Flywheel
assembly

Retaining
pin

2). The removal and installation of carrier assembly of the real oil
seal:
Removal：
——Remove 4 bolts (as arrow indicates).
——Take out carrier assembly of the real oil seal
——Remove carrier sealing gasket of the real oil seal





——Use chisel or screwdriver to pry the real oil seal from the
carrier of the real seal oil. Note: please don’t damage the carrier of
real oil seal.

Installation：
——Position the carrier on the vise which is equipped with wood
on the jaw.
——Align rear oil seal carrier hole with the part number side of oil
seal outward. Press oil seal into rear oil seal carrier with vise.. The
magnitude of interference for real oil seal and carrier hole is
0.26—0.50mm.
——Install new sealing gasket of real oil seal carrier.
——Install real oil seal carrier assembly. Before assembling, wrap
a piece of plastic piece on the crankshaft to avoid damaging oil seal.
At the same time, apply engine oil on oil seal edge and journal for
oil seal.
——Measure the roughness of lower oil seal carrier surface and oil
pan flange surface of cylinder block. It should be adjusted to the
range of ±0.26mm.

Fig.58

Fig.59

Fig.60

Fig.61