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SERVICE MANUAL
ENGINE-MECHANICAL
SERVICE CONTENT
TYPE:SQR7080R
Please write down the changes notice after each assembly numbers, the function is to remind
the users there are changes and the technical department will inform the correlated
department keep them in archives for checking.
TECHNICAL
ASSEMBLY
CHANGES NOTICE
3 Valve train
4 Cylinder head
5 Cooling System
6 Lubrication system
The service man must master the technical improvement conditions of this car to provide
better maintenance work.
PREFACE
Dear technicians and mechanics for SQR372 engine maintenance,
You are suggested to read this manual before service and operate in accordance with the
specification of manual.
1) The manual supplies you with the information of accessories, such as special tools,
measures and grease. You should, by all means, prepare for this kind of accessories fully
before service.
2) Of course, we leave out the general tools, such as lifter and spare parts, because they are
absolutely necessary for you.
3) We provide the structural diagrams of main machines, the assembly views of every part
and their names before their service introduction. It is the reference for you on
disassembly and assembly.
4) In structural diagrams, the numbers of parts, such as ①, ②, ③┄, is the sequence
numbers of disassembly; the assembly steps are reverse to those for disassembly.
5) The parts with a mark “*” in the structural diagrams can not reused and they should be
replaced in assembly.
6) We leave out the operations of related service tools in this manual but you should pay
attention to them during service.
7) We leave out the operation requirements for cleaning and checking the parts in this
manual. You should meet the operation requirements for cleaning and checking the parts
by all means.
8) There is no specification of visual inspection in the manual but it is a necessary element
for service personnel.
Pay attention to the items above and operate please.
Anyone should not new-model the manual, such as copy, edit and print without the
permission of authority by the editor and we reserve the right to amend any clause at any
given time.
TABLE OF CONTENTS
DEFINITION ................................................................................................................................................3
THE MEANING OF MARKS AND ABBREVIATIONS..........................................................................3
SQR372 ENGINE STRUCTURE AND PERFORMANCE PARAMETER............................................4
SPECIAL MAINTENANCE TOOLS.........................................................................................................5
REMOVE THE ENGINE FORM VEHICLE............................................................................................7
1 MOUNT THE ENGINE ON THE ROLL OVER STAND ...............................................................9
2 DISASSEMBLY , ASSEMBLY AND REPAIR OF FRONTAL DRIVE PARTSOF ENGINE.....10
2-1. STRUCTURE DIAGRAM OF FRONT TRANSMISSION PART....................................10
2-2 to 2-4. DISASSEMBLY & ASSEMBLY OF ENGINE FRONT TRANSMISSION PART...10
3. CAMSHAFT ...........................................................................................................................................17
3-1 STRUCTURAL DIAGRAM(DISASSEMBLY OF TIMING BELT AND ASSEMBLY
OPERATIONS ARE CARRIED AS THE FOLLOWING VIEW.) ................................................17
3-2 to 3-5. DISASSEMBLY & ASSEMBLY OF CAMSHAFT ......................................................18
4. CYLINDER HEAD ............................................................................................................................25
4-1 STRUCTURAL DIAGRAM OF CYLINDER HEAD.........................................................25
4-2 to 4-6. DISASSEMBLY & ASSEMBLY OF CYLINDER HEAD ...........................................26
5. WATER PUMP...................................................................................................................................33
5-1 STRUCTURAL DIAGRAM OF WATER PUMP................................................................33
5-2 to 5-5. DISASSEMBLY & ASSEMBLY OF WATER PUMP..................................................34
6. LUBRICATION SYSTEM.................................................................................................................34
6-1 STRUCTURAL DIAGRAM ..................................................................................................34
6-2 to 6-6. DISASSEMBLY & ASSEMBLY OF WATER PUMP..................................................36
7. CRANKSHAFT CONNECTING ROD MECHANISM..................................................................42
7-1 STRUCTURE DIAGRAM.....................................................................................................42
7-2 to 7-5. DISASSEMBLY & ASSEMBLY.....................................................................................43
1. DEFINITION
Set the standard value for simple measurement to prevent from its
[Reference]
measuring difficulty and inconsistency to facts.
It carries the cases of damaging the vehicle and parts so you should
Note
pay attention to the operation description.
Model SQR372
Lubricant(designation) 10W/30
Disassembly and
Crankshaft pulley
assembly of crankshaft
holding tool
pulley
Disassembly and
Wrench assembly of camshaft
driven gear
Measuri Feeler gauge. Micrometer caliper. Ruler. Dial gauge. Cylinder gauge. Caliber.
ng tools Pressure gauge. Torque wrench torque wrench
☆ Disassemble the connection for the ⑧ Take down the left / right inner side gear
lower support girder of radiator and the from differential.
vehicle frame and radiator; ☆ Remove the rocker outer ball section
☆ Remove the clutch cable and pry out the left/right side gear;
4# Left
Rear Engine ☆ Remove the coolant pipe and warm blast
Mounting pipe.
2-2. DISASSEMBLY
10
Special Tool
(2) Remove the fixing bolt of torsional
damper.
11
Timing Mark
12
2-3. INSPECTION
1. Check The Timing Belt Carefully; Replace With The New Parts If Any Following
Situation Occurs.
(1) Chap of back-side rubber
(2) Chap of dedendum, chap of separated cord fabric.
(3) Wearing, gear missing and incomplete gear of cord fabric.
Chap
Wearing
Chap
Gear Missing
Abnormal Wearing
Belt Core Desquamation
Note: Replace the belt as any following situation occurs, even though abrasion cannot be
found directly.
(1) The water pump leaks water out, and requires continuing infusion.
(2) If the belt is spotted with much oil stains, and the rubber may be damaged due to
expansion, you should replace the belt.
13
2-4. ASSEMBLY
Assembly
1. Aassembly Of Crankshaft timing gear
Timing Mark
2. Assembly Of Timing Belt
(1) Confirm about the position of first
cylinder compression top dead center.
Mount the camshaft timing gear on the
front of exhaust camshaft in order to align
the gear locating groove and the locating
pin on camshaft. Fix the camshaft timing
gear with bolts and the tightening torque
of bolt is 100±5Nm.
14
Timing Mark
Rotate Clockwise
15
Torque: 6±1N.m
Special tool
16
3. CAMSHAFT
3-1 STRUCTURAL DIAGRAM (DISASSEMBLY OF TIMING BELT AND
ASSEMBLY OPERATIONS ARE CARRIED AS THE FOLLOWING VIEW.)
17
3-2 DISASSEMBLY
1. ① Disassembly of cylinder head chamber
cover assembly Screw off the bolt of
cylinder head cover from both sides to the
middle in symmetry.
② Remove the cylinder head cover gasket.
2. Inspection Of Valve
Standard valve lash: IN 0.18±0.05
Valve lash EX 0.25±0.05
18
19
3-5 ASSEMBLY
Special Tool ① With special tools, fix the the 2 holes φ6 of
camshaft gear assembly.
② Rotate the driven gear to the right with special
tool and tally the mark hole of driven gear
with that of camshaft driving gear, or their
marking way complies with each other, fix the
driven gear with bolts.(Thread:M5;Thread
pitch:0.8)
2. Assembly Of Camshaft
Note: the size the camshaft axial clearance
(1) Spread grease on the gear of camshaft and
the axial of cylinder head.
(2) Remove the fixing bolts for camshaft driven
gear after mounting the camshaft.
(3) It is needed to measure the size of camshaft
axial clearance.
(4) Mount the camshaft; align the timing mark
as can be seen from the right picture.
Exhaust Intake
20
21
22
Downward
23
24
4. CYLINDER HEAD
4-1 STRUCTURAL DIAGRAM (ACCORDING TO THE OPERATING ORDERS OF
ASSEMBLY AND DISASSEMBLY FOR CAMSHAFT, OPERATE AS THE
FOLLOWING)
4-2 DISASSEMBLY
1. Disassembly Of Spark Plug
25
4-3 CLEAN
1. Clean The Carbon Dust On The Valve.
2. Clean The Bottom Surface Of
Cylinder Head And The Surface Of
Intake And Exhaust Manifold With
Scraper Knife.
Note: Do Not Damage The Surface Of
Cylinder Head During Cleaning.
Do Not Pollute The Intake Port And Water
Passage.
4-4 INSPECTION
1. Cylinder Head
Measure The Underside Planeness Of
Cylinder Head Assembly.
Cylinder Head 0.10mm
The Cylinder Head Is Always 0.10 Mm
On The Mounting Surface Of Intake And
Exhaust Manifold.
26
2. Valve Spring
(1) Measure the squareness of valve
spring with square. Replace if it
exceeds the specified value.
Limit: 1.2mm
3 Valve
(1) Inspection of valve
Check if it is deformed or abrased.
Inspection of valve Unit:mm
Standard
Item Limit
value
Measuring Point For Outside IN ___
0.85~1.41
Width of seal
EX 1.07~1.36 ___
Thickness of IN 1.0±0.2 0.75
valve EX 1.0±0.2 0.75
Measuring Point
27
28
29
30
31
32
5. WATER PUMP
5-1 STRUCTURAL DIAGRAM (ACCORDING TO THE FOLLOWING
OPERATIONS, DISASSEMBLE AND ASSEMBLE CYLINDER)
5-2 DISASSEMBLY
1. Disassembly Of O Ring
Note: O ring can not be reused.
2. Screw Off 3 Bolts And Disassemble
Water Pump Body.
3. Disassembly Of Dust Seal
5-3 CLEAN
1. Clean Of Water Pump Joint Surface
5-4 INSPECTION
1. Check If It Is Deformed.
2. Check If The Rotor Is Rotating By
Hand And Check The Lubricating
Condition.
5-5 ASSEMBLY
1. Mount Dust seal
2. Mount Water Pump Body
Torque 25±1.5N.m
3. Mount The New O Ring
33
6. LUBRICATION SYSTEM
6-1 STRUCTURAL DIAGRAM (ACCORDING TO THE FOLLOWING
OPERATIONS, DISASSEMBLE AND ASSEMBLE OIL PUMP)
6-2 DISASSEMBLY
1. Reverse The Engine On The
Disassembling Support And Screw Off
The Bolts.
34
35
6-3 CLEANUP
1. Clean up the joint surface between the
oil pan and the engine oil pump, oil
seal bracket and cylinder.
2. Clean up the joint surface between the
rear oil seal bracket and the cylinder.
A scraper or scraper knife can be used
for cleaning up the old shim.
Note: Don’t let the shim fragment fall into
the cylinder.
① Weather Strip
② Cover Plate Of Engine Oil Pump
③ Outer Rotor Of Engine Oil Pump
④ Inner Rotor Of Engine Oil Pump
⑤ Cotter pin
⑥ Spring Seat Of Oil Drain Valve
⑦ Spring Of Oil Drain Valve ※:The Parts Can Not Be Reused.
⑧ Slider
⑨ Front Crankshaft Oil Seal
⑩ Housing Of The Engine Oil Pump
36
6-4-2 DISASSEMBLY
1. Weather Strip
Note: The weather strip cannot be
repeatedly used.
2. Remove The Oil Pump Cover
Note: The bolt is assembled with glue;
tighten it with a screwdriver as shown in
the figure.
37
6-4-3 INSPECTION
Inspect the engine oil pump for clearance.
According to the marks for inner gear and
outer gear in the engine oil pump, put the
gears into the engine oil pump that is in
the cylinder block.
6-4-4 ASSEMBLY
Special Tool 1. After the lip of the new oil seal for
front crankshaft is spread with engine
oil, fix it with a special tool.
38
39
6-5-2 DISASSEMBLY
1. Remove The Rear Crankshaft Oil Seal
With A Screwdriver.
Note: The rear crankshaft oil seal cannot be
repeatedly used.
Special Tool
40
41
42
43
44
45
Special Tool
7-3 CLEANUP
7-3-1 CYLINDER BODY
Warning Wear glasses for protecting eyes
when the cleanup is being done.
1. Clean Up The Cylinder Body, Cylinder
Head, Oil Pan, Oil Pump And The Oil
Seal With A Flat Blade.
7-3-2 piston
Warning Wear glasses for protecting eyes
when the cleanup is being done.
1. Use An Old Ring To Remove The
Carbon In Ring Groove.
2. Remove The Carbon Of Parts With
Scavenger.
Note: It is not allowed to use a metal
brush here or some tool made of hard
material.
46
7-4 INSPECTION
7-4-1 CYLINDER BODY
1. Inspect The Top Surface Of Cylinder
Body For Its Flatness.
(1) Measure at the six points shown in
the right figure with a ruler and a
feeler gauge.
Limit: 0.08mm
2. How To Use The Cylinder Gauge
Top Dead Center Measure The Diameter Of The
Cylinder bore In The Directions
Shown In The Figure With A
Cylinder Gauge, Work Out The
Difference Between The Maximum
Bottom Dead Center And Minimum Values, If The
Difference Is Beyond The Limit,
Repair Or Replace The Cylinder.
Limit: 0.03mm
[reference] roundness:A-B or a-b
Cylindricity :A-a or B-b
[reference] standard value of cylinder
diameter 72.00-72.01mm
7-4-2 PISTON
1. Inspect The Piston Pin Hole For Its Clearance
(1) Measure the piston pin at several positions with a micrometer caliper shown in the
figure; make the maximum value as the diameter of pin.
(2) Measure the diameter of piston pin at several positions with an inner-diameter dial
gauge as shown in the figure; make the minimum value as the diameter of the pin
hole.
47
(3) Work out the clearance with the difference between the pin diameter and pin hole
diameter, if the difference is beyond the standard value, replace the piston pin or
piston.
Standard value: 0.004-0.009mm
Limit 0.015mm
48
49
50
7-4-4 CRANKSHAFT
1. Inspect The Proper Alignment Of The
Main Axle Diameter.
(1) Measure the proper alignment with a
dial gauge, if the proper alignment is
beyond the limit, replace the crankshaft.
Limit: 0.03mm
Note: The bending value should be equal to
one-second the run-out value of crankshaft
rotating one circle.
1. Inspect The Crankshaft For The
Abrasion.
(1) Measure the journal with a micrometer
caliper, work out the roundness and the
cylindricity.
Limit: 0.005mm
(2) Measure the diameter of the connecting
rod with a micrometer caliper, work out
the roundness and the cylindricity.
Limit: 0.004mm
The measured parts are shown in the figure:
51
Expander Rear
Front
Upper Segment
3. Resemble The Crankshaft Main Bearing
Cover, Crankshaft, Crankshaft Bearing
Bushing And The Crankshaft Axial
Thrust Plate, Pay Attention To The
Following:
(1) When assembling the bearing bushing,
its raised thrust block should fit into the
locating groove in the cylinder body.
Note: The bearing bushing is from the same
manufacturer.
52
Oil Duct Outwards (2) Spread engine oil over the surface of the
bearing bushing (upper piece)
contacting the crankshaft, then assemble
the crankshaft. Fix the crank arm in the
cylinder bearing housing, with the oil
duct in the thrust plate facing outwards.
Note: Spread engine oil over the side with
oil duct.
Fix the crankshaft bearing bushing (lower
piece) in the bearing cover, the bearing
bushing should fit into the thrust groove.
Spread Engine Oil Before (3) Spread engine oil over the friction
Assembly surface of crankshaft bearing bushing
(lower piece); assemble the bushing
according to the mark forwards in the
main bearing cover of the crankshaft.
53
54
55