Table of Contents
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Chery QQ Service Manual
465 Engine Mechanical System
CONTENTS
Chapter 1.........................................................2
Chapter 2.........................................................5
CHAPTER 3.........................................................21
Chapter 4.........................................................31
Chapter 5.........................................................34
CHAPTER 6.........................................................35
CHAPTER 7.........................................................37
CHAPTER 8.........................................................39
CHAPTER 9.........................................................41
CHAPTER 10...................................................... 43
Chapter 11...................................................... 45
Chapter 12...................................................... 46
Chapter 13...................................................... 49
Chapter 14...................................................... 50
Chapter 15......................................................51
Chapter 16......................................................52
- 1 –
Chery Automobile Co., Ltd
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Summary of Contents for Chery DA465Q-1A2/D
- Page 1 Chery QQ Service Manual 465 Engine Mechanical System CONTENTS CHAPTER 1…………………………………………………2 CHAPTER 2…………………………………………………5 CHAPTER 3…………………………………………………21 CHAPTER 4…………………………………………………31 CHAPTER 5…………………………………………………34 CHAPTER 6…………………………………………………35 CHAPTER 7…………………………………………………37 CHAPTER 8…………………………………………………39 CHAPTER 9…………………………………………………41 CHAPTER 10……………………………………………… 43 CHAPTER 11……………………………………………… 45 CHAPTER 12……………………………………………… 46 CHAPTER 13……………………………………………… 49 CHAPTER 14……………………………………………… 50 CHAPTER 15………………………………………………51...
- Page 2 Chery QQ Service Manual 465 Engine Mechanical System CHAPTER 1 Technical Parameters of Engine 1 Specification 1.1 Technical specification Model DA465Q-1A2/D Four cylinders. Four stroke. Water-cooling. Inline. Mode .Breadthways. Overhead camshaft. EFI Bore 65.5mm Stroke 78mm Pressure ratio 9. 0: 1...
- Page 3 Chery QQ Service Manual 465 Engine Mechanical System Oil quantity 3.5L Transmission oil Base on local temperature; select GL-4、or GL-5 Transmission oil； quantity：2.1 L Suction filter Dry type Spark F6RTC Generator Silicon rectify generator Start-mode Electric start-up Cooling method Pump circulation water-cooling...
- Page 4 Chery QQ Service Manual 465 Engine Mechanical System Engine rear overhang and vehicle body 100±5 Engine rear overhang and bracket 100±5 Engine right overhang and vehicle body 50±2.5 Engine right overhang and bracket 100±5 2 Engine lubricant Viscosity of oil is decided by outer temperature of gasoline or diesel engine, it is acceptable for engine temperature to be much higher or lower than given temperature in a short time.
- Page 5 Chery QQ Service Manual 465 Engine Mechanical System <-30 >+40 A3/B3 SJ/CF 0W—30 <-30 >+40 A3/B3 SJ/CF 0W—40 Notice: It is applicable only under the circumstance of ACEA and API standard being listed ACEA standard can not replace API standard, on the contrary ,API standard can take the place of ACEA standard.
- Page 6 Chery QQ Service Manual 465 Engine Mechanical System c It is probably due to valve if pressure of the first stroke is too low and it remains low in afterwards strokes or the pressure keep the former state after being injected with oil.
- Page 7 Chery QQ Service Manual 465 Engine Mechanical System l Bearing clearance is too big. l Crankshaft connecting rod journal wear l The oil is too thin or/and oil filter is too dirty l Oil pressure is too low l The shaft journal of crankshaft connecting rod is out of round.
- Page 8 Chery QQ Service Manual 465 Engine Mechanical System relationship between the knock and bearing. 5 Valve train noise Valve train malfunction can be shown by means of slight slapping sound of any frequency or frequency is equal to half of engine speed, the noise will go up along with acceleration of the engine.
- Page 9 Chery QQ Service Manual 465 Engine Mechanical System to the regulation l Tighten or replace exhaust manifold washer. l Exhaust expansion connection parts damage or wear. l Replace parts if necessary. l Exhaust pipe is burned or rusty. l Replace the exhaust pipe if necessary.
- Page 10 Chery QQ Service Manual 465 Engine Mechanical System tappet will make noise. Make the oil being put in correct oil level. Oil level is too low. If oil level is lower than ADD(add mark),the atmosphere will be pumped in by oil pump, it will result in tappet noise, add oil if necessary.
- Page 11 Chery QQ Service Manual 465 Engine Mechanical System Check the engine to see if it is under the following circumstances: l Driving belt wear l Check tension , replace driving belt if necessary. The compressor of air condition system Replace parts if necessary .
- Page 12 Chery QQ Service Manual 465 Engine Mechanical System while increasing the torque. circumstances: l Crankshaft balancer or pulley nave is broken. l Replace parts if necessary l Transmission belt of auxiliary is too tight or there are some scratching marks on it.
- Page 13 Chery QQ Service Manual 465 Engine Mechanical System See the specification of fastener for reference. Is there still any whispering noise? Check to see whether or not the belt pulley flange is bent. To step8 To step9 Is there any bent belt pulley flange? Replace belt pulley.
- Page 14 Chery QQ Service Manual 465 Engine Mechanical System whether or not there are some blocked bearing. 6 Hooting noise of driving belt Step Operation Definition: Successive high pitch noise can be generated because of bearing malfunction. Check to see whether or not there is some damage of accessories bearing.
- Page 15 Chery QQ Service Manual 465 Engine Mechanical System Is there any loose or lost fastener? Fasten it or replace new parts according to the actual request. System — Is the maintenance completed? normal Check to see whether or not the belt pulley is damaged or bent.
- Page 16 Chery QQ Service Manual 465 Engine Mechanical System Is the pulley of power steering-wheel pump is malposition or not? Realign or replace pulley of power steering-wheel pump， To step9 System normal See “Replacement of pulley of power steering-wheel pump” for reference.
- Page 17 Chery QQ Service Manual 465 Engine Mechanical System The following diagnosis touches upon the common problems or possible causes. You can fix a breakdown through adjustment and maintenance or replacement according to the request, after carrying out the correct diagnosis.
- Page 18 Chery QQ Service Manual 465 Engine Mechanical System 4 Check the following conditions if the cylinder pressure test shows that there is any damage of valve or valve guide: Valve stem seal wear, chip or installation is not properly. Valve guide wear Valve stem wear Valve or valve seat wear or burnt.
- Page 19 Chery QQ Service Manual 465 Engine Mechanical System IVFuel consumption 1 General description Engine oil consumption of engine refers to amount of oil used, never to confuse fuel consumption and oil leakage of oil pan and cylinder head. Engine oil is used for: 1.1 Depart the contacting surface away with oil film, prevent dry friction.
- Page 20 Chery QQ Service Manual 465 Engine Mechanical System minutes. 2.4 Displace oil to state of guttate. 2.5 Cool the engine oil of displacement to 20 for 1 to 2 hours. 2.6 Measure oil amount after cooling with measuring graduated flask . Refill enough new oil accordingly.
- Page 21 Chery QQ Service Manual 465 Engine Mechanical System V Diagnosis of oil leakage Maintain, replace the parts or seal the gasket surface after finding out the leak position before maintenance. 1. Determine the leakage oil whether or not are listed as follows with eyes: ●...
- Page 22 Chery QQ Service Manual 465 Engine Mechanical System (6) Check suspicious position with eyes, use a mirror if necessary. (7) Judge the possible cause of leakage. Adopt powder method if you can not make sure the cause of leakage yet.
- Page 23 Chery QQ Service Manual 465 Engine Mechanical System II. Cylinder head - 23 – Chery Automobile Co., Ltd...
- Page 24 Chery QQ Service Manual 465 Engine Mechanical System 1 cylinder head 2 valve guide bushing 3 restricted flow valve 4 bowl shape plug 5 cylinder head gasket 6 locating bush 7 bolt 8 valve chamber cover 9 baffle 10 gasket 11 screw 12 gasket 13 gasket assy 14 screw 15 oil filler cap 16 spark 17...
- Page 25 Chery QQ Service Manual 465 Engine Mechanical System 1 cylinder block assy 2 bowl shape plug; gasket； 15 screw； 16 timing bracket； 17 3 bowl shape plug； 4 plug； 5 plug； 6 oil upper baffle 18 front baffle assy 19 bolt 20 oil filter assy 21 join screw pipe pressure sensor；7 bolt；...
- Page 26 Chery QQ Service Manual 465 Engine Mechanical System IV. Crankshaft，piston and connecting rod assembly 12.shield ring 13.crankshaft gear 1.piston 2-1.No.1piston ring 14.woodruff key 15.crankshaft pulley 2-2. No.2 piston ring 16.fastening screw 17.crankshaft rear oil 2-3.piston oil ring assembly 3.piston pin seal 18 rear oil seal retainer 19.gasket...
- Page 27 Chery QQ Service Manual 465 Engine Mechanical System V. Camshaft，valve and rocker 1 camshaft 2 cup ring seal 3 camshaft thrust baffle 4 screw 5 valve rocker shaft 6 screw 7- valve rocker 8 spring 9 adjusting screw 10 nut 11 intake valve...
- Page 28 Chery QQ Service Manual 465 Engine Mechanical System VI. Oil pan 1. oil pan assembly 2. oil pan gasket 7. rubber ring 3. screw 8. screw 4. oil drain plug 9. oil dipstick guide 5. gasket 10 oil dipstick guide bracket 6.
- Page 29 Chery QQ Service Manual 465 Engine Mechanical System 12 “o” ring 13 oil dipstick assembly VII. Timing belt, outside cover and inside cover assembly 1 timing belt inside cover assembly 2 outer cap 3 rubber pad 4 flat rubber ring...
- Page 30 Chery QQ Service Manual 465 Engine Mechanical System spring 18 screw 19 gasket 20 washer VIII. Engine identification Engine No. - 2 – Chery Automobile Co., Ltd...
- Page 31 Chery QQ Service Manual 465 Engine Mechanical System Chapter 4 Maintenance of Intake Pipe procedures of disassemble 1 Dismount the cable of negative pole from battery。 2 Disconnect wire plug from intake temperature sensor. 3 Remove intake hose and crankshaft ventilation pipe from throttle body and intake pressure-stabilized box.
- Page 32 Chery QQ Service Manual 465 Engine Mechanical System the fuel pipe with spring clamp after making marks. 11. Remove all kinds of hose from intake pipe assembly 12. Remove construction bolt of intake manifold. 13. Remove intake manifold and gasket Procedures of installation from cylinder for clean.
- Page 33 Chery QQ Service Manual 465 Engine Mechanical System Chapter 5 Replacement of Exhaust Pipe Gasket of disassemble Procedures 1 Lift vehicle, remove the protective plate of engine oil pan 2 Remove exhaust pipe from exhaust manifold. 3 Loosen and remove oxygen sensor from exhaust manifold.
- Page 34 Chery QQ Service Manual 465 Engine Mechanical System Chapter 6 Replacement of Camshaft Bracket Cover Procedures of disassemble 1 Take off venting hose between throttle body and camshaft bracket cover. 2 Loosen camshaft cover bolt in requested order. 3 Take off camshaft cover Procedures of installation 1 Reinstall camshaft bracket cover with new gasket.
- Page 35 Chery QQ Service Manual 465 Engine Mechanical System Chapter 7 Replacement of Timing Belt Install timing belt according to following order： 1) Connect the tensioner assembly to torsion spring to the pump(in front of rear cover),fasten the bolts and nuts until the tensioner assembly is easy for you to move.
- Page 36 Chery QQ Service Manual 465 Engine Mechanical System regulated value. to a straight line after installing tensioner. Notice: Smear GY-340 anaerobic glue on Repeat above-mentioned steps until accord the screw thread of the tensioner bolts. request. Fasten the adjusting bolts first, then fasten...
- Page 37 Chery QQ Service Manual 465 Engine Mechanical System front to the rear, intake side 6237,exhaust 17 Fill the coolant in the cooling system, side 5148. see relevant content of article 6.3. 3 Install camshaft. 18 Install air filter and intake hose, then 4 Install rocker shaft and rocker.
- Page 38 Chery QQ Service Manual 465 Engine Mechanical System 0.020-0.050 mm, intake and exhaust 0.030 and 0.060 mm, you should enlarge the hole in order that you can install the valve of much larger size. 5 Check the concentricity of maximal ring and minimal ring of valve seat.
- Page 39 Chery QQ Service Manual 465 Engine Mechanical System 1 Exhaust valve seat: Use the taper rymer to cut 3 times as shown in figure. First cut at a angle of 15°,Then 75°and then 45°to create ideal touch width 2 Angle of exhaust valve seat...
- Page 40 Chery QQ Service Manual 465 Engine Mechanical System 3 Install one side of piston pin by means of Chapter 10 Replacement of Piston I Procedures of disassemble See content of relevant chapters for making the piston lean against the reference connecting rod, then stuff the piston pin 1.
- Page 41 Chery QQ Service Manual 465 Engine Mechanical System Notice: Put oil to surface of piston ring and 4. Put the circlip in the cylinder and use the cylinder hole, at the same time, install piston to push it in cylinder wall at a bank connecting rod.
- Page 42 Chery QQ Service Manual 465 Engine Mechanical System CHAPTER 11 Replacement I Procedures of disassemble 1 Take off timing gear of camshaft, shown of Oil Pump as the illustration. 2 Take off crankshaft timing gear. 3 Take off set bolt of timing belt rear cover.
- Page 43 Chery QQ Service Manual 465 Engine Mechanical System 8 Install camshaft timing gear according to the illustration. Attention: Align the oil level, fill SAE 10 W 30 oil in the engine. Side clearance Use thickness gauge, make sure the side...
- Page 44 Chery QQ Service Manual 465 Engine Mechanical System Chapter 12 Replacement of Rear Oil Seal of Engine Flywheel and Crankshaft I Procedures of disassemble 1 Disconnect the transmission assembly, see the relevant explanation of Chapter7. 2 Start ring gear, lock-up flywheel.
- Page 45 Chery QQ Service Manual 465 Engine Mechanical System Chapter 13 Replacement of Crankshaft I procedures of disassemble 1 Remove engine and transmission assembly from vehicle 2 Remove transmission from engine , put it on the bracket. III Measurement 3 Remove oil drain plug of oil pan to drain oil and collect the oil.
- Page 46 Chery QQ Service Manual 465 Engine Mechanical System V Measurement 1 Measure axial clearance of crankshaft as the following methods. 2 Install a dial gauge with sensing pin and the sensing pin contact crankshaft end face. 3 Move the crankshaft along its direction...
- Page 47 Chery QQ Service Manual 465 Engine Mechanical System grinding, you use rough particles stones first, Chapter 14 Replacement of then use fine particles Put the hone stone in the cylinder and make the hone stone close Engine Body to the cylinder wall as possible as you can,...
- Page 48 Chery QQ Service Manual 465 Engine Mechanical System CHAPTER 15 Replacement of Oil Cleaner I procedures of disassemble 1 Loosen oil cleaner with SST 2 Collect the oil. 3 Check oil level of engine，tune up if necessary. II Procedures of installation 1 Lubricate the sealing washer of oil cleaner with oil slightly, tighten the bolt by hand.
- Page 49 Chery QQ Service Manual 465 Engine Mechanical System CHAPTER 16 Cooling System I Maintenance guide driving 50000 km or 24 months. Drainage and refilling of cooling system Drainage Proportion of ethylene-glycol is definite, so Notice: It is not right to drain the coolant to...
- Page 50 Attention: Add ethylene-glycol coolant ratified for use manufacturer’s directions for reference. by Chery Company while refilling, you Cleaning of radiator should use mixture of 50% ethylene-glycol Caution: Don’t spray the water to the hot and 50% drinking water to fill in the...
- Page 51 Chery QQ Service Manual 465 Engine Mechanical System 2 Remove intake hose of thermostat cover 3 Remove intake hose of radiator 4 Remove intake hose procedures of installation 1 Install the intake hose to the right position aligning the hose mark.
- Page 52 Chery QQ Service Manual 465 Engine Mechanical System procedures of installation 1 Install thermostat and new gasket, tighten the bolt if necessary. Notice: Place the gasket properly on the entrance. 2 Tighten the bolt 3 Connect hose to the thermostat.
- Page 53 Chery QQ Service Manual 465 Engine Mechanical System VI Replacement of water pump procedures of disassemble procedures of installation 1 Remove timing belt, see the disassemble 1 Install new sealing washer, parts serial illustration for reference. number is 9158173,lubricate the parts with...
- Page 54 Chery QQ Service Manual 465 Engine Mechanical System Loosen 2 bolts: Loosen wire harness and take out fan assembly Loosen 4 bolts and pull out the fan Pay attention to the notices relating to fastener. 6 Install radiator bracket and bolt Bolt to 6.0—8.0 Nm...
- Page 55 Chery QQ Service Manual 465 Engine Mechanical System absorbed in the radiator for sake of vacuum. add excessive coolant, you are not allowed to use antifreeze solution exceeding 70,because it will freeze from this point, 2 Cooling recycling system Water pump is driven by belt, coolant flow...
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