Great Wall engine 4G64S4M. Manual — part 13
11-46
(10)
Check whether the piston can rotate freely.
Mount of oil ring
(1)
Put the main ring of oil ring in the oil ring groove.
Remark:
1. The scraper blade and the main ring has the specified upper./lower
face.
2. The new main ring and scraper are colorful to identify its dimension.
(2)
Put in the upper scraper blade. When mounting the scraper blade,
press one end of the scraper blade in the piston oil ring groove, then
press the remaining part of scraper blade in the oil ring groove
shown as the figure by thumb.
Different from other piston ring, the use of ring pliers to expand the
scraper blade will break the scraper blade.
Notice:
Do not use the ring pliers to expand the scraper blade.
(3)
Mount the lower scraper blade in the same procedure of Step (2).
(4)
The scraper blade should be confirmed whether can rotate freely
to left and right after the mount.
Mount of First and Second Air Ring
(1)
The first air ring should be mounted after the second air ring is
mounted with the ring pliers.
Remark:
1. There is identification mark at the ring end.
Identification mark:
First ring
1R
Second ring
2R
2. Mount the piston ring and be sure the identification mark should face
upwardly to the top of the piston.
3. The dimension marks of piston ring are as follows:
6EN0 298
upper scraper blade
main ring
lower scraper blade
6EN1019
Dimension
Identification Color
Standard value
None
0.50mm larger
Red
1.00mm larger
Yellow
clearance of scraper blade
1EN0269
C
Dimension
Dimension mark
Standard value
None
0.50mm larger
50
1.00mm larger
100
ring pliers
7EN0452
identification mark
identification mark
direction mark
first ring
second ring
9EN0524
B
ENGINE
CYLINDER HEAD AND VALVE
11-47
upper scraper blade
crankshaft
pulley side
openings of second and
main rings
lower balde
6ENO549
D
Mount of Piston and Connecting Rod Cluster
(1)
Coat enough engine oil on the piston, air ring and oil ring.
(2)
Adjust the openings of the air ring and oil ring (scraper blade
and the main ring) to the place shown in the figure.
(3)
Rotate the crankshaft until the crank pin locates the position of
the cylinder hole.
(4)
Threaded protective device should be adopted on the connect-
ing rod bolt before the insertion of the piston and connection
rod cluster in the cylinder. Carefulness is needed not to
damage the crank pin.
(5)
Insert the piston and connecting rod cluster in the cylinder
with the suitable press fitting SST for piston ring.
Notice:
There is a mark for forward face on the top of piston, which should
direct to the front of the engine (timing toothed belt side).
Mount of Connecting rod bearing
Where the bearing is needed to change, it should be selected and
mounted as per the following procedure.
(1)
Measure the outside diameter of the crank pin and determine
which group it belongs as per the following form, the crank-
shaft to be maintained should be marked at the position shown
in the figure with color paint to identify its dimension.
(2)
The identification mark of the connecting rod is printed at the
position shown in the figure.
Inside diameter of connecting rod; 48.000
48.015mm
(3)
Select the bearing from the group determined as per the Step
(1) and (2).
Bearing Selection, for example:
In case the outside diameter of the crank pin is measured as 44.
996mm, it belongs to the Group 1 in the above form. If the
repairing element for crankshaft needs to be changed, inspect
the identification color coated on the new crank pin. If the
color is yellow, the crank pin should belong to the first group,
therefore, the connecting rod bearing marked with
1
should be selected.
E
timing toothed belt
mark for forward face
1EN0247
NO.1
NO.2
NO.3
NO.4
6EN0700
6AE0115
identification mark
Crank pin
Connecting rod bearing
Yellow
44.995
45.000
1
Yellow
1.487
1.491
None
44.985
44.995
2
None
1.491
1.495
White
44.980
44.985
3
Blue
1.495
1.499
Identification
color
Outside
diameter
(mm)
Identification
mark
Identification
color
Thickness
(mm)
Group
ENGINE
CYLINDER HEAD AND VALVE
11-48
Mount of Connecting Rod Cap
(1)
When mounting the connecting rod cap, align the marks made
in disassembly well, if mounting the new member without
mark, the anti-rotary gap shown in the figure should be
mounted at the same side
(2)
Be sure the axial clearance at the larger end of connecting rod
is suitable.
Standard value: 0.10
0.25mm
Limit value: 0.4mm
Mount of Connecting Rod Nut
Notice:
In case the cylinder head is mounted before the mount of
connecting rod cap, dismantle the spark plug and then
mount on the connecting rod cap nut.
(1)
The connecting rod bolts and nuts should be tightened with the
method of tightening bolt at plastic zone. Before reusing the
bolt, check whether the bolt is expanded. Inspection method:
tighten the nut to the threaded part of the bolt by hand until it
passes the full thread. In case the nut cannot be screwed down
to the bottom, it can be judged the threaded part of the bolt may
be protracted, change the bolt on such condition.
(2)
Coat the oil on the threaded part and the seat face of the nut
before tightening the nut.
(3)
Tighten the nut on the bolt by hand and then screw the nuts down
in turns so as to assemble the connecting rod cap correctly.
(4)
Tighten the nut with the torque of 20N.M.
(5)
Coat the paint mark on each nut head.
(6)
Make paint mark on the bolt at the position 90
100
forward from the paint mark at nut head.
(7)
Tighten the nut by a angle of 90
100, until the marks on
the nut and the bolt are in alignment.
Notice:
If the screwing angle is less than 90, the tightening
property specified is cannot be guaranteed. Therefore,
attention should be paid to the screwing angle when
tightening.
In case the nut is over tightened, (the screwing angle is
more than 100
), loosen it thoroughly, and then re-
tighten it from the Step (1).
F
G
cylinder No.
anti-rotary gap
DEN0051
6EN0621
paint
marks
paint marks
90
100
6AE0298
ENGINE
CYLINDER HEAD AND VALVE
11-49
Inspection
Piston Ring
(1)
Check whether the piston ring has damage, over abrasion
or breakage, if it has, change it, in the case of changing the
piston, the piston ring needs to be changed too.
(2)
Check the clearance between the piston ring and the piston
ring groove, if it is over large, change the piston ring or the
both parts.
Standard value: 0.02
0.06mm
Limit value: 0.1mm
(3)
Put the piston ring in the cylinder and locate it with the
crown face of the piston, then measure the opening clear-
ance with the feeler. If the opening clearance is over large,
change the piston ring.
Standard value:
First ring
0.250.35mm
Second ring
0.400.55mm
Oil ring
0.100.40mm
Limit value:
First and second ring
0.8mm
Oil ring
1.0mm
Play of Crank Pin (clearance gauge of plastic cord)
(1)
Clear away the oil on the journal and bearing of the
connecting rod thoroughly.
(2)
Cut the clearance gauge of plastic cord in the length that is
the same with the bearing width, and then put them on the
crank handle and parallel them with the axial center line.
(3)
Mount on the connecting rod cap carefully and tighten the
nut as per the specified torque.
(4)
Dismantle the connecting rod cap carefully.
(5)
Measure the max width of the flattened plastic cord with
the gauging ruler printed on the package bag of the clear-
ance gauge of plastic cord, thus obtaining the clearance
value.
Standard value: 0.02
0.05mm
Limit value: 0.1mm
5EN0066
press it in with piston
priston ring
opening clearance
5EN0548
1EN0246
clearance gauge of plastic cord
1EN0271
ENGINE
CYLINDER HEAD AND VALVE
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