Great Wall. 4G64S4N Gasoline Engine. Service Manual — part 2
11-13
NOTES FOR DISASSEMBLY
DISASSEMBLY OF TIMING TOOTHED-BELT
(1)
Record the rotation direction of toothed-belt for correct re-
mounting.
Notes:
Adhering of water or grease to the toothed-belt will sharply
shorten its service life. So, after disassembly, try your best to
avoid the toothed-belt, toothed-belt wheel and tensioner from
being contaminated and adhered by water or grease. No need to
clean these parts. Replace it if it is seriously contaminated.
In case water or grease is found on these parts, check the front cover
oil-seal, camshaft oil-seal and water pump if there exist leakage.
DISASSEMBLY OF OIL PUMP TOOTHED-BELT
WHEEL
(1)
Assemble the cock on the cylinder block.
(2)
Insert a cross point screwdriver of 8mm diameter to fasten
the balancing shaft on the left side.
(3)
Disassemble oil pump toothed-belt wheel nut.
(4)
Disassemble oil pump toothed-belt wheel.
DISASSEMBLY OF CRANKSHAFT BOLT
(1)
Fasten the flywheel with special tools.
(2)
NOTES FOR DISASSEMBLY
DISASSEMBLY OF TIMING TOOTHED-BELT
DISASSEMBLY OF CRANKSHAFT TOOTHED-BELT
WHEEL
(1)
In case difficult to disassemble due to adhesion, use special
tools.
DISASSEMBLY OF TIMING TOOTHED-BELT
WHEEL B
(1)
Record the rotation direction of toothed-belt for correct re-
mounting.
Notes:
Adhering of water or grease to the toothed-belt will sharply
shorten its service life. So, after disassembly, try your best to
avoid the toothed-belt, toothed-belt wheel and tensioner from
being contaminated and adhered by water or grease. No need to
clean these parts. Replace it if it is seriously contaminated.
D
C
A
B
6EN0662
6EN0663
6EN0634
MD998781
MD998778
6EN0642
DEN0601
ENGINE
TIMING TOOTHED-BELT WHEEL
E
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11-14
8EN0066
ENGINE
TIMING TOOTHED-BELT WHEEL
MD998785
6EN0636
MD998778
6EN0637
MD990767
MD998719
6EN0668
In case water or grease is found on these parts, check the front
cover oil-seal, camshaft oil-seal and water pump to see if there
exist leakage.
DISASSEMBLY OF BALANCING SHAFT TOOTHED-
BELT WHEEL
(1)
Fasten balancing shaft toothed-belt wheel with the tools as
shown in the figure.
(2)
Disassemble the balancing shaft toothed-belt wheel.
DISASSEMBLY OF CRANKSHAFT TOOTHED-BELT
WHEEL B
(1)
In case difficult to disassemble due to adhesion, use special
tools.
DISASSEMBLY OF CAMSHAFT TOOTHED-BELT
WHEEL BOLT
(1)
Fasten camshaft timing toothed-belt wheel with special tools.
(2)
Disassemble camshaft toothed-belt wheel bolt.
F
G
H
CHECK
TIMING TOOTHED-BELT WHEEL
Carefully check each part of the toothed-belt and replace a new
toothed-belt in case of the following damages:
(1)
The back rubber is aged and glistened, no trail left after scraping
with a finger nail, and no elasticity;
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11-15
ENGINE
TIMING TOOTHED-BELT WHEEL
(2)
There are cracks on the surface of back rubber;
(3)
There are cracks and peel-off on the surface of canvas
(4)
There are cracks at the bottom of the tooth
(5)
There are cracks on the side face of toothed-belt
(6)
The side face of toothed-belt is abnormally abraded. The normal
situation is the side face is as level as being cut with a sharp knife
(7)
Abnormal abrasion on the tooth surface.
(8)
Teeth broken off.
AUTOMATIC TENSIONER
(1)
Check automatic tensioner to see if there is leakage and replace
with a new one if necessary.
(2)
Check if there is abrasion or damages on the rod end and replace
with a new one if necessary.
cracks
canvas peel-off
side cracks
crack at bottom of tooth
1EN0249
belt margin roueded
abnormal abrasion (heat yarn of belt emposed)
8EN0067
canvas abrased ,rubber exposed
belt teeth broken off
8EN0068
6EN0280
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11-16
ENGINE
TIMING TOOTHED-BELT WHEEL
12mm
6EN0161
98~196N
rod
displacement
6EN1033
brass or aluminum vice jaw
cock
tieplate
brass or aluminum vice jaw
6EN1030
MD990767
6EN0669
MD998719
spacer
oil seal
chamfer
balancing
shafe
BEN0615
(3)
The overhang length of measuring rod. Replace if not conform
to standard.
Standard value
12mm
(4)
Measure the amount of displacement while pressing down the
rod with a force of 98~196N.
(5)
Replace the automatic tensioner if the displacement of rod is at
least 1mm lesser than the value as measured in item (3).
Standard value
1mm
(6)
Clamp automatic tensioner with a soft jaw plier.
Notes:
Because there is screw-plug outshot at the bottom of automatic
tensioner, a flat bearing plate should be inserted between the
plier and the screw-plug to avoid them from direct contacting.
(7)
Rotate handle of plier to thrust in the rod of automatic tensioner.
Replace automatic tensioner if it can be easily thrusted in.
Certain resistance should be apperceived while thrusting in.
NOTES FOR MOUNTING
TIGHTENING OF CAMSHAFT TOOTHED-BELT
WHEEL BOLT
(1)
Fixup camshaft toothed-belt wheel with special tools.
(2)
Tighten the camshaft toothed-belt wheel bolt to the specified
torque.
MOUNTING OF SPACER
(1)
While mounting the spacer, the side with chamfer should be
towards oil-seal.
A
B
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11-17
ENGINE
TIMING TOOTHED-BELT WHEEL
TOOTHED-BELT WHEEL
(1)
Fixup balancing shaft toothed-belt wheel with the tools as
shown in the figure.
(2)
Tighten the bolt to the specified torque.
MOUNTING OF TIMING TOOTHED-BELT B
(1)
Align the marks of crankshaft toothed-belt wheel B and
balancing toothed-belt wheel separately.
(2)
Mount timing toothed-belt onto the crankshaft toothed-belt
wheel B and balancing shaft toothed-belt wheel. The
tensioning side should remain tightened.
(3)
Ensure that the centers of tensioner wheel and the bolt are as
shown in the figure.
(4)
While applying force to the tensioner side of timing toothed-
belt with your finger, move tensioner B in the direction of the
arrow. At this moment, screw up the bolt to fixup tensioner
B. Don
t let the shaft rotate together with toothed-belt
wheel thus while screwing up the bolt, otherwise the toothed-
belt will be too tight.
(5)
Confirm to align the mark on the toothed-belt with the mark
on the front cover
(6)
Press down the central part of the tensioner side of timing
toothed-belt B with your forefinger. The toothed-belt is to be
pressed down by 5~7mm.
D
C
MD998785
6EN0636
timing
mark
front cover
timing mark
DEN0602
6EN0571
tensioner B
tensioner
center
bolt center
6EN0572
timing
mark
displacement being
pressed down
6EN0573
timing
mark
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11-18
ENGINE
TIMING TOOTHED-BELT
E
F
G
MD998781
6EN0634
6EN0564
6AE0049
6AE0050
6EN0350
TIGHTENING OF CRANKSHAFT BOLT
(1)
Fixup flywheel with special tools;
(2)
Mount crankshaft bolt.
MOUNTING OF OIL PUMP TOOTHED-BELT
WHEEL
(1)
Insert cross point screwdriver into the plug hole on the left
side of cylinder block to prevent balancing shaft from rotating.
(2)
Mount oil pump toothed-belt wheel.
(3)
Smear engine oil on the coupling face of nut and bearing.
(4)
Screw up the nut according to the specified torque.
MOUNTING OF AUTOMATIC TENSIONER
(1)
If the rod of automatic tensioner is extruded, the following
procedures should be taken to retract it.
(2)
Clamp automatic tensioner with a soft jaw plier.
Notes:
Because there is screw-plug outshot at the bottom of auto-
matic tensioner, a flat bearing plate should be inserted
between the plier and the screw-plug to avoid them from
direct contacting.
(3)
Use a plier to push it in slowly until hole
on the rod and
hole
on the oil cylinder is aligned.
(4)
Insert steel wire (diameter is 1.4mm) into the aligned holes.
(5)
Disassemble the automatic tensioner with a plier.
(6)
Mount the automatic tensioner onto the front cover, then
screw up the bolt according to the specified torque.
Notes:
Left the steel wire inside the automatic tensioner.
A
B
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11-19
ENGINE
TIMING TOOTHED-BELT
MOUNTING OF TIMING TOOTHED-BELT
(1)
Confirm the timing toothed-belt tensioner is properly mounted.
(2)
Align the timing mark on the camshaft toothed-belt wheel with
the mark on the cylinder head.
(3)
Align the timing mark on the crankshaft toothed-belt wheel with
the mark on the front cover.
(4)
Align the timing mark on the oil pump toothed-belt wheel with
its accordant mark.
(5)
Disassemble plug from cylinder block, then insert cross point
screwdriver (diameter: 8mm) into the hole. Going over 60mm
inwards means the timing mark is aligned; incase of failure to go
more than 20~25 inwards, you should turn the oil pump toothed-
belt wheel 180
(6)
Connect timing toothed-belt to crankshaft pulley, central pulley,
camshaft toothed-belt wheel and tensioner pulley in turn.
(7)
Uplift the tensioner pulley in the arrow direction, then screw
down the central bolt.
H
timing mark
6EN0673
timing mark
timing mark on oil pump gear
6EN0671
6EN0672
6EN0663
6EN0748
tensionere pulley
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11-20
ENGINE
TIMING TOOTHED-BELT
(8)
Verify that all timing marks are in a line.
(9)
Remove the screwdriver inserted at step (5) and mount the plug.
(10) Turn camshaft 1/4 circle counter-clockwise, then turn it clock-
wise until all timing marks come into line again.
(11) Assemble the special tools socket wrench and torque wrench
onto the tensioner pulley, then screw down the central bolt of
tensioner pulley.
Notes:
If special tools are unavailable, an ordinary torque wrench
capable of measuring the torque of 0~0.3 kg may be used.
(12) Use the torque wrench to screw down to a torque of 0.26~0.27
kg.m.
(13) While holding the tensioner pulley with special tools and torque
wrench, screw down the central bolt till the standard value is
reached.
(14) Place the crankshaft for about 15 minutes after turning it 2
circles clock-wise. Then check if the fixing steel wire of auto-
matic tensioner can glide freely.
Notes:
In case the steel wire can not glide freely, repeat the above
steps before step (10) till the steel wire can glide.
(15) Take off the fixing steel wire of the automatic tensioner.
(16) Measure the distance
A (between tensioner arm and auto-
matic tensioner body).
Standard value
3.8 4.5mm
MD998767
MD990685
6EN0749
6EN0750
fixing sttel wire
6EN0751
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11-21
FUEL SYSTEM
DISASSEMBLY AND MOUNTING
Disassembly Procedure
1.
water pipe
2.
water pipe
3.
throttle body
4.
cushion
5.
cover
6.
cushion
7.
fuel cistribution pipe assembly
20N.m
5
6
4
12N.m
ENGINE
FUEL OIL SYSTEM
Notes for Mounting
Mounting of Fuel Distribution Assembly
Before mounting fuel distribution assembly, carefully
lubricate the matching face of the manifold or the O-
ring with mineral lubricating oil, align the center lines
of the injector and the mounting hole, then insert the
intake manifold. Finally, screw down the bolt accord-
ing to the specified tightening torque.
(1)
Mineral lubricating oil: ISO 10 (10 cSt at 40
)
(2)
Prevent lubricant from entering into the injector
while using lubricant.
A
7
2
1
3
19N.m
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11-22
ENGINE
INTAKE MANIFOLD
INTAKE MANIFOLD
DISASSEMBLY AND MOUNTING
NOTES FOR MOUNTING
APPLICATION OF SEALANT FOR ENGINE WATER
TEMPERATURE SENSOR
Sealant Specification:
3M Nut locking parts No.4171 or the equivalent.
APPLICATION OF SEALANT FOR WATER OUTLET
Sealant Specification:
Genuine MITSUBISHI brand parts No.MD970389 or the
equivalent.
19N.m
19N.m
20N.m
1
20N.m
3
4
13N.m
13N.m
30N.m
2
A
B
sealant(diameter:3mm)
6
N
1. engine Link Ring
2. engine Water Temperature Sensor
3. water Outlet
4. intake Manifold Bracket
5. intake manifold
6. intake Manifold Gasket
Disassembly Procedure
A
B
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11-23
ENGINE
EXHAUST MANIFOLD & WATER PUMP
EXHAUST MANIFOLD, WATER PUMP
DISASSEMBLY AND MOUNTING
Disassembly Procedure
1.
oil level gauge
2.
oil level gauge tube
3.
o-ring
4.
heat shield
5.
engine link ring
6.
oxygen sensor
7.
exhaust manifold
8.
exhaust manifold gasket
9.
water inlet
10. thermostat
11. water temperature sensing plug
12. bypass water pipe fitting
13. water pipe assembly
14. water pipe O-ring
15. thermostat casing
16. water inlet
17. o-ring
18. water pump
19. water pump gasket
B
A
A
A
A
6
45N.m
4
14N.m
29N.m
8
5
49N.m
1
13N.m
2
24N.m
7
3
16
16
9
10
24N.m
15
13N.m
24N.m
14N.m
18
19
13
14
11
12
11N.m
N
N
N
N
N
N
N
N
13
N
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11-24
ENGINE
EXHAUST MANIFOLD & WATER PUMP
o-ring
squeeze out sealant of
3mm diameter
6EN0996
6EN0594
NOTES FOR MOUNTING
MOUNTING OF O RING SEAL
(1) Wet O ring seal with water in order to assemble.
Notes:
There shouldn
t be any oil or lubricating grease on the surface
of O
ring seal.
M O U N T I N G O F B Y P A S S W A T E R P I P E
CONNECTOR
Sealant Specification:
Genuine MITSUBISHI brand parts No.MD970389 or the equivalent.
Notes:
(1) Swiftly mount bypass water pipe connector while sealant is still
wet (within 15 minutes).
(2) May not add oil on the sealing part within 1 hour or so after
mounting.
A
B
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11-25
ROCKER ARM AND CAMSHAFT
DISASSEMBLY AND MOUNTING
1.
air hose
2.
PCV hose
3.
pressure control valve
4.
pressure control valve gasket
5.
oil filler cap
6.
rocker arm cover
7.
rocker arm cover gasket
8.
oil seal
9.
rocker arm and rocker shaft
10. rocker arm and rocker shaft
11. rocker shaft spring
12. A rocker arm A
13. B rocker arm B
14. rocker shaft (air intake side)
15. hydraulic lifter
16. rocker arm C
17. rocker shaft (air exhaust side)
18. hydraulic lifter
19. oil seal
20. thrust cover
21. o-ring
22. camshaft
1
5
3
4
6
7
8
3.9N.m
31N.m
17
16
16
16
16
18
11
11
11
11
15
12
13
12
13
12
13
12
13
14
9
22
21
20
18N.m
19
N
N
N
Smear engine oil on all moving
parts while mounting
6EN1762
10
ENGINE
ROCKER ARM AND CAMSHAFT
C
A
C
A
C
C
C
C
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11-26
ENGINE
ROCKER ARM AND CAMSHAFT
MD998448
6AE0160
9EN0058
roller end
7EN0064
outside claean
inside clean
fill didsel oil
A
B
C
6EN1698
diesel oil
6EN1699
NOTES FOR DISASSEMBLY
(1)
Before disassemble the rocker arm and rocker shaft
assembly, use the tools as shown in the figure to
prevent hydraulic lifter from falling.
CHECK
CAMSHAFT
(1)
Measure the height of camshaft
Standard value and operating limit are as follows:
Air intake
4G64-D-L3
37.39
36.89
Air exhaust
4G64-D-L3
36.83
36.33
ROCKER ARM
(1)
Check the roller surface, in case of existence of any trace
indicates there are damages or blockades, the rocker arm should
be replaced.
(2)
Check if the roller can rotate smoothly. If not or slacked, the
rocker arm should be replaced.
(3)
Check the inside diameter. In case of damages or blockages, the
rocker arm should be replaced.
HYDRAULIC LIFTER
NOTES:
1. Hydraulic lifter is a precise part. There shouldn
t be any
dust and foreign body, etc.
2. Do not disassemble the hydraulic lifter.
3. Clean the hydraulic lifter with clean diesel oil.
(1)
Prepare 3 vessels and about 5 litres of diesel oil. Pour enough
diesel oil into each vessel until the erect hydraulic lifter is
submerged, then take the following steps to operate the hydrau-
lic lifter:
(2)
Put the hydraulic lifter into vessel A to clean its external surface.
NOTES:
Use a nylon brush to remove hard attachments.
Type
Standard value
Limit value
A
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11-27
ENGINE
ROCKER ARM AND CAMSHAFT
MD998442
MD998441
diesel oil
6EN1700
MD998441
MD998442
diesel oil
6EN1701
MD998441
MD998442
6EN1700
MD998441
6EN1701
diesel oil
(3)
Mount the special tool MD998441 onto the hydraulic lifter.
(4)
Use the special tool MD998442 to lightly expel the steel ball
inside the lifter and make it move 5-10 strokes until it can move
smoothly. Additionally, it can also eliminate resistance of the
plunger. Such operation can remove dirty oil.
NOTES:
Since the steel ball spring is extremely soft, so do not overexert
while impelling steel ball with air leak wire lest the hydraulic
lifter is damaged.
If the plunger can
t move smoothly or mechanical devices
seem abnormal, replace the hydraulic lifter.
(5)
Take the hydraulic lifter out of the vessel, then lightly expel the
steel ball and move the plunger, remove diesel oil away from
pressure chamber.
(6)
Mount the special tool MD998441 onto the hydraulic lifter.
(7)
Put the hydraulic lifter into vessel B, then use the special tool
MD998442 to lightly expel the steel ball inside the lifter and
make it move 5-10 strokes until it can move smoothly. Such
operation can clean the pressure chamber of hydraulic lifter.
NOTES:
Since the steel ball spring is extremely soft, so do not overexert
while impelling steel ball with air leak wire lest the hydraulic
lifter is damaged.
(8)
Take the hydraulic lifter out of the vessel, then lightly expel the
steel ball and move the plunger, remove oil away from pressure
chamber.
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11-28
ENGINE
ROCKER ARM AND CAMSHAFT
(9)
Put the hydraulic lifter into vessel C, then use the special tool
MD998442 to lightly expel the steel ball inside the lifter.
NOTES:
Don
t clean the hydraulic lifter in vessel C. Otherwise foreign
body may enter the pressure chamber which is full of oil.
(10) Stick the hydraulic lifter up straight with its plunger at the top,
stably move the plunger downwards to its maximum stroke, then
pull it back slowly, and then release the steel ball to make the
pressure chamber full of diesel oil.
(11) Remove the special tool MD998441.
(12) Take the hydraulic lifter out of the vessel, stick it up straight with
its plunger at the top, stably impel the plunger until it can
t
move any more. Check and compare the height difference
between the plunger and the new hydraulic lifter.
NOTES:
If the hydraulic lifter becomes shorter, repeat step (9) to (12) and
fully fill the hydraulic lifter with diesel oil. If it still becomes
shorter after repetition of these steps, replace the hydraulic lifter.
(13) Mount the hydraulic lifter onto the special tool.
(14) After the plunger sink down (0.2~0.5mm), measure the time
taken for the plunger to sink down another 1mm.
Standard value: 3
20 sec./1mm ( use the diesel oil with a
temperature of 15
20)
Notes:
If the measured value doesn't conform to the standard, replace the
hydraulic lifter.
(15) Mount the special tool MD998441 onto the hydraulic lifter.
(16) Put the hydraulic lifter into vessel C again, then lightly impel the
steel ball inside the lifter downwards with special tool MD998442.
(17) Stick the hydraulic lifter up straight with its plunger at the top,
stably move the plunger downwards to its maximum stroke, then
pull it back slowly, and then release the steel ball to make the
pressure chamber full of diesel oil.
(18) Remove the special tool MD998441.
MD998442
6EN1702
MD998441
MD998442
MD998441
6EN1703
6EN1704
6EN1705
MD998440
scale=1mm
MD998442
MD998441
6EN1706
hydraulic
tappet
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