Page 93 of 1903
Downloaded from www.Manualslib.com manuals search engine 3. Using the special tool CH-20018 (1), compress thevalve spring.
4. Remove the valve keeper (1), valve spring retainer (2) and valve spring (3).
5. Push the valve stem from the cylinder head and remove the valve (4).
6. Using special tool CH-20013 (1), remove the valve oil seal.
7. Remove the valve guide.
8. Remove the spark plugs.
CYLINDER HEAD UNIT REPAIR
BESM020067
VISM080041
LTSM020225
02–64Chery Automobile Co., Ltd.
Page 94 of 1903
Downloaded from www.Manualslib.com manuals search engine Inspection
•Cylinder head must be flat within 0.04 mm.
• Inspect camshaft bearing journals for scoring.
• Remove carbon and varnish deposits from inside of
valve guides with a valve guide cleaner.
• Verify the valve tappets move freely in their bores,
and that they have been rotating.
• Check the valve guide height.
Assembly
1. Install new valve guide if necessary.
2. Install new valve seat if necessary.
3. Using special tool CH-20011 (1) and CH-20012 (2),
install the new valve oil seal.
4. Install the valves into the cylinder head (larger diameter on intake side).
5. Install the valve springs.
6. Install the valve spring retainers.
CYLINDER HEAD UNIT REPAIR
BESM020068
LTSM020224
02
02–65Chery Automobile Co., Ltd.
Page 95 of 1903
Downloaded from www.Manualslib.com manuals search engine 7. Using valve spring compressor CH-20018 (1), com-press the valve springs.
8. Install the valve keepers.
9. Strike the valve stem lightly with a plastic hammer after installation to verify proper assembly.
10. Install valve tappets in the head.
11. Install the camshafts.
Installation Notes:
• Coat the valve oil seal with engine oil.
Camshaft
Specifications
Camshaft Specifications
DESCRIPTION SPECIFICATION (mm)
Intake Cam Lobe Height 37.15
Exhaust Cam Lobe Height 37.05
Journal #1 Outer Diameter 31.934 - 31.95
Journal #2, #3, #4, #5, Outer Diameter 23.947 - 23.96
Cam Bearing #1 Inner Diameter 32 - 32.025
Cam Bearing #2, #3, #4, #5, Inner Diameter 24 - 24.021
Journal #1 Clearance 0.05 - 0.091
Journal #2, #3, #4, #5 Clearance 0.04 - 0.074
Intake Camshaft Axial Clearance 0.15 - 0.20
Exhaust Camshaft Axial Clearance 0.15 - 0.20
CYLINDER HEAD UNIT REPAIR
BESM020067
02–66Chery Automobile Co., Ltd.
Page 105 of 1903
Downloaded from www.Manualslib.com manuals search engine 2.0L ENGINE MECHANICAL
GENERAL INFORMATION02-77
Description 02-77
Operation 02-77
Specifications 02-77
Special Tools 02-81
Lubrication System 02-84
DIAGNOSIS & TESTING02-87
Engine Performance Diagnostics 02-87
Engine Mechanical Diagnostics 02-88
Cylinder Compression Pressure Test 02-90
Cylinder Head Gasket Test 02-90
ON-VEHICLE SERVICE02-91
Accessory Drive Belt 02-91
Removal & Installation 02-91
Air Cleaner Element 02-92
Removal & Installation 02-92
Air Cleaner Housing 02-93
Removal & Installation 02-93
Cylinder Head Cover 02-93
Removal & Installation 02-93
Camshaft 02-94
Removal & Installation 02-94
Cylinder Head 02-97
Removal & Installation 02-97
Front Crankshaft Oil Seal 02-99
Removal & Installation 02-99
Rear Crankshaft Oil Seal 02-100
Removal & Installation 02-100
Engine Mounts 02-103
Removal & Installation - Left Mount 02-103
Removal & Installation - Right Mount 02-104
Removal & Installation - Front Mount 02-104
Removal & Installation - Rear Mount 02-105
Engine Assembly 02-105
Removal & Installation 02-105
Engine Timing Belt 02-112
Removal & Installation 02-112
Exhaust Manifold 02-115
Removal & Installation 02-115
Intake Manifold 02-117
Removal & Installation 02-117
Idler Pulley 02-119
Removal & Installation 02-119
Oil Filter 02-119
Removal & Installation 02-119Oil Pan
02-120
Removal & Installation 02-120
Oil Pump 02-121
Removal & Installation 02-121
Oil Strainer 02-122
Removal & Installation 02-122
ENGINE UNIT REPAIR02-123
Engine Block 02-123
Specifications 02-123
Disassembly 02-123
Inspection 02-125
Assembly 02-125
Pistons 02-126
Specifications 02-126
Disassembly 02-127
Inspection 02-128
Assembly 02-130
Connecting Rods 02-131
Specifications 02-131
Disassembly 02-131
Inspection 02-132
Assembly 02-132
Crankshaft 02-133
Specifications 02-133
Disassembly 02-133
Inspection 02-134
Assembly 02-135
CYLINDER HEAD UNIT REPAIR02-136
Cylinder Head 02-136
Specifications 02-136
Disassembly 02-136
Inspection 02-138
Assembly 02-138
Camshaft 02-139
Specifications 02-139
Disassembly 02-140
Inspection 02-140
Assembly 02-142
Valve & Valve Guides 02-143
Specifications 02-143
Disassembly 02-143
Inspection 02-144
Assembly 02-145
Valve Springs 02-146
Specifications 02-146
Disassembly 02-146
Inspection 02-147
Assembly 02-148
02–76Chery Automobile Co., Ltd.
Page 106 of 1903
Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION
Description
The 2.0L in-line four cylinder engine has the following features:
•Dual overhead camshafts
• Four valves per cylinder
• Aluminum cylinder head
• Aluminum cylinder block
Operation
The 2.0L engine utilizes 4 valve-per-cylinders and a dual overhead camshaft design. The engine uses an individual
coil ignition system. The cylinder block is made of aluminum and the bearing caps are integrated into the lower cyl-
inder block assembly. An aluminum oil pan bolts to the bottom of the lower cylinder block. The camshafts are
mounted in the cylinder head and act against valve tappets to open and close the valves. The camshafts are driven
off the front of the cylinder head by one timing belt. The belt is driven by a sprocket that is located on the crankshaft.
The piston assembly is an aluminum piston with a cast iron connecting rod.
The aluminum cylinder head contains dual overhead camshafts with 4 valve-per-cylinder construction. The valves are
arranged in two in-line banks. The cylinder head incorporates powdered metal valve guides and seats. The cylinder
head is sealed to the block using a multi-layer steel head gasket and retaining bolts.
Specifications
2.0L Engine Specifications
DESCRIPTION SPECIFICATION
Type In-Line OHV, DOHC
Number of Cylinders 4
Compression Ratio 10:1
Compression Pressure 10 - 15 bar
Max. Compression Pressure Variation Between
Cylinders 25%
Stroke 90 mm
Bore 83.5 mm
Displacement 1971 cc
Firing Order 1-3-4-2
Mechanical Specifications
DESCRIPTIONITEMSTANDARD LIMIT
Engine Oil Pressure Lower Idle Speed (800 ±
50 RPM) 1.2 - 1.5 bar
-
High Idle Speed (2000 RPM) 3.2 - 3.5 bar
-
High Speed (4000 RPM) 3.7 ± 0.5 bar -
Engine Block Clearance Surface Distortion
-0.15 mm
Inner Diameter 83.500 - 83.510 mm -
Out-Of-Round -< 0.008 mm
Taper -< 0.01 mm
Piston Ring Groove
Clearance First Ring
0.04 - 0.08 mm -
Second Ring 0.0251 - 0.01 mm -
02
02–77Chery Automobile Co., Ltd.
Page 107 of 1903
Downloaded from www.Manualslib.com manuals search engine DESCRIPTIONITEMSTANDARD LIMIT
Piston Ring End Gap
Clearance First Ring
0.2 - 0.4 mm 0.8 mm
Second Ring 0.4 - 0.6 mm 1.0 mm
Piston To Piston Pin
Clearance -
0.002 - 0.013 mm -
Piston Diameter -83.451 - 83.469 mm -
Ring Groove Clearance First Ring
0.04 - 0.08 mm -
Second Ring 0.01 - 0.0251 mm -
Connecting Rod Radial
Clearance -
0.016 - 0.051 mm -
Connecting Rod Axial
Clearance -
0.002 - 0.013 mm -
Diameter Of Crankshaft
Main Journals -
53.981 - 54 mm -
Diameter Of Crankshaft
Rod Journals -
47.884 - 47.9 mm -
Out-Of-Round Maximum
Of Crankshaft Main
Journals -
-< 0.008 mm
Axial Clearance Of
Crankshaft -
0.07 - 0.265 mm -
Radial Clearance Of
Crankshaft -
0.0035 - 0.034 mm -
Coaxality Crankshaft Main
Journal -
-< 0.005 mm
Thrust Washer Thickness -2.4 - 2.405 mm -
Oil Clearance Of
Crankshaft Rod and Main
Journals -
0.022 mm 0.058 mm
Cylinder Head Flatness --< 0.04 mm
Intake Valve Deflection --< 0.02 mm
Exhaust Valve Deflection --< 0.04 mm
Spring Height -47.7 mm -
Spring Height At 620
Newtons Of Pressure -
32.0 mm -
Intake Cam Lobe Height -37.15 mm -
Exhaust Cam Lobe Height -37.05 mm -
Camshaft Journal #1 Outer
Diameter -
31.934 - 31.95 mm -
Camshaft Journal #2, #3,
#4, #5, Outer Diameter -
23.947 - 23.96 mm -
Camshaft Cam Bearing #1
Inner Diameter -
32 - 32.025 mm -
Camshaft Cam Bearing
#2, #3, #4, #5, Inner
Diameter -
24 - 24.021 mm -
Camshaft Journal #1
Clearance -
0.05 - 0.091 mm -
Camshaft Journal #2, #3,
#4, #5 Clearance -
0.04 - 0.074 mm -
GENERAL INFORMATION
02–78Chery Automobile Co., Ltd.
Page 109 of 1903
Downloaded from www.Manualslib.com manuals search engine DESCRIPTIONTORQUE (N·m)
Engine To Transaxle Bolts 80
Exhaust Manifold Nuts 25
Exhaust Manifold Heat Shield Bolts 15
Exhaust Camshaft Timing Belt Pulley Bolt 120
Flywheel Bolts (manual transaxle) 75
Fuel Rail Bracket Bolts 11
Idler Pulley Bolt 40
Intake Camshaft Timing Belt Pulley Bolt 120
Intake Manifold Bolts 10
Intake Manifold Nuts 11
Intake Manifold Bracket Bolts 25
Lower Idler Pulley Bolt 45
Lower Cylinder Block Bolts 23
Oil Filter 25
Oil Pan Bolts 18
Oil Drain Plug 40
Oil Strainer Bolts 18
Oil Pump Bolts 11
(Apply with Loctite 5910 Thread-Locker)
Rear Timing Cover Bolts 7
Timing Belt Upper Cover Bolts 11
Timing Belt Lower Cover Bolts 11
Timing Belt Tensioner Assembly 27
Timing Belt Tensioner Pulley Bolt 30
Throttle Body Bolts 11
Upper Idler Pulley Bolt 45
GENERAL INFORMATION
02–80Chery Automobile Co., Ltd.
Page 110 of 1903
Downloaded from www.Manualslib.com manuals search engine Special Tools
Right Engine Mount Bolt RemoverCH-20001
Camshaft Seal InstallerCH-20002
Crankshaft HolderCH-20003
Valve Spring Compressor Adaptor CH-20004
Rear Crankshaft Oil Seal InstallerCH-20005
GENERAL INFORMATION
02
02–81Chery Automobile Co., Ltd.
