Chery A11. Manual — part 20
CAC Gasoline Engine Maintenance And Servicing Manual
35
position 19mm to the bottom skirt.
unit：mm
*
480M piston should be applied on 480E
engine
——Measure the diameter. of the hole of piston pin
unit：mm
478
diameter of the piston
pin hole
480
diameter. of the
piston pin hole
White
20.630—20.633
White
20.630—20.633
Red
20.633—20.636
Red
20.633—20.636
Blue
20.636—20.639
Blue
20.636—20.639
——Measure the diameter. of piston pin
unit：mm
478
diameter. of the
piston pin hole
480
diameter. of the piston
pin hole
White
20.622—20.625
White
20.622—20.625
Red
20.625—20.628
Red
20.625—20.628
Blue
20.628—20.631
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
478 dia. of piston
skirt(mm)
488 dia. of
piston skirt
(mm)
480E *dia. of
piston skirt (mm)
1
77.19—77.20
79.91—79.92
79.915—79.925
2
77.20—77.21
79.92—79.93
79.925—89.935
3
77.21—77.22
79.93—79.94
79.935—79.945
factory
group
4
77.22—77.23
79.94—79.95
79.945—79.955
A
77.48—77.49
80.20—80.21
80.205—80.215
B
77.49—77.50
80.21—80.22
80.215—80.225
Factory
repair
C
77.50—77.51
80.22—80.23
80.225—80.235
standard
77.21—77.23
5
79.93—79.95
5
79.965—79.975
oversize
0.29
77.49—77.51
5
80.21—80.23
5
80.245—80.255
Spare
parts
oversize
0.5
77.71—77.73
5
80.43—80.45
5
80.465—80.475
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
0.61±0.025
Oil control ring
blade
oil control ring
2.68±0.05
4.0
+0.03
0.01
0.01—0.23
Cast iron oil control
ring
4.0
-0.015
-0.025
4.0
+0.03
+0.01
0.025—0.055
Fig.51
Fig.52
CAC Gasoline Engine Maintenance And Servicing Manual
36
——Measure the crosshead end bore of the connecting rodФ20.589
+0.02
0
CAC Gasoline Engine Maintenance And Servicing Manual
37
——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.
478 piston ring
480 piston ring
Paint marker (group)
Size
of
gauge
Paint
marker
(group)
Size
of
gauge
Yellow paint +no paint
(standard)
77.22
No
paint
(standard)
79.94
Yellow paint+ purple
paint (oversize 0.29)
77.51
Purple
paint
(oversize 0.29)
80.23
Yellow
paint
+blue
paint (oversize 0.5)
77.72
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
CAC Gasoline Engine Maintenance And Servicing Manual
38
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
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