Chery Amulet Engine. Manual — part 2

3

Catalogue

Introduction. . . . . . . . . . . . . . . . …1
Engine configuration view and sectional view. . . . . . . . . … 3
Main engine technical indexes and operation parameters. . . . . . . …11
Engine structural features. . . . . . . . . . . . . …13
Engine removal and assembly procedure. . . . . . . . . 17
[1] Positioning no.1 cylinder top dead center (compression) . . . . . . …17
[2] Upper and lower timing gear cover assemblies removal and installation. . . . 18
[3] Crankshaft pulley removal and installation. . . . . . . . . …18
[4] Valve cover and seal gasket removal and installation. . . . . . . …19
[5] Timing belt removal, installation and adjustment. . . . . . . . …20
[6] Tension pulley, crankshaft gear and camshaft gear removal, check and installation. …22
[7] Camshaft oil seal removal and installation. . . . . . . . . …23
[8] Valve mechanism and cylinder head removal, check and installation. . . . …24
[9] Piston and connecting rod assembly removal and installation. . . . . . 33
[10] Flywheel assembly and rear oil seal bracket assembly removal and installation . . 36
[11] Crankshaft, crankshaft thrust washer, bearing bushing and main bearing cap removal and

installation . . . . . . . . . . . . . . …38

[12] Oil baffle assembly removal and installation. . . . . . . . …41
[13] Engine oiling system. . . . . . . . . . . . . …42
[14] Engine cooling system. . . . . . . . . . . . . 49
[15] Engine air intake and exhaust system. . . . . . . . . . 53
[16] Engine crankcase ventilation system. . . . . . . . . . …58
[17] Engine fuel supply system. . . . . . . . . . . . …62
Carburetor engine malfunction, cause and correction. . . . . . . …67

Introduction

CAC478, CAC480 series vehicle gasoline engines, which are the products introduced from Ford
(Britain) corporation CVH production line, are made by Anhui Chery automobile Corp. Products
are made up of carburetor type, single-point electric control fuel injection type and electric
control fuel injection type, which may meet the requirements for different performance and
emission.

Single-point electric control fuel injection system and multipoint electric control fuel injection
system of the above engines are developed though the joint effort with Italy M & M Corp.

With advanced product performance, reliable structure，CAC478、CAC480 series automobile
gasoline engines may be applied for both car and light-duty vehicles.

Specifications, covering major parameters, structural features, assembly and adjustment,
common operation repair and maintenance, trouble shooting for CAC478, CAC480 carburetor
and single-point electric control fuel injection engine, may be referred by mechanic, driver,
technologist and management section.

1.Temperature regulator seat assembly 11. Camshaft thrust plate
2.Temperature regulator seat 12. Camshaft timing gear

3. Distributor 13. Timing belt

4. Camshaft assembly 14. Upper\ lower timing gear cap assembly

5. Fuel pump assembly 15. Water pump assembly

6. Air intake manifold assembly 16. Camshaft timing gear

7. Fuel pressure switch 17. Tensioner pulley assembly

8. Oil filter assembly 18. Oil pump assembly

9. Rear oil sealing carrier assembly 19. Camshaft oil sealing

10. Oil collector assembly

Main engine technical indexes and operation parameters

SQR480

Type

Line, 4-cyl, four strokes, water-cooling

Cylinder bore diameter (mm)

79.94

Stroke (mm)

79.52

Total displacement (L)

1.596

Compression ratio

9.75 : 1

Nominal power/RPM

62/5500

(kW/r/min)(Total power)

Output maximum torque/RPM

(Nm/r/min)(Total power)

128/3000-2500

Minimum fuel consumption of total power

for external characteristic (g/KW·h)

290

Fuel supply system

Single-point

Combustion chamber shape

Hemisphere type

Cylinders Working Order

1-3-4-2

Direction of crankshaft rotation

Clockwise (Viewed from the front)

Lubrication

Mechanical lubrication+Splash feed

Weight (kg)(lbs)

108 (238)

Overall dimensions (mm)
(Length * width * height)

620×610×650

Ignition angle at idle

(Crankshaft angle Before top dead center)

10°±1°

Valve timing (Crankshaft angle)

Intake valve opened

Before top dead center 18°

Intake valve closed

After bottom dead center 57°

Exhaust valve opened

before bottom dead center 60°

Exhaust valve closed

After top dead center 15°