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Great Wall 4G64S4M Service Manual

Gasoline engine
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Summary of Contents for Great Wall 4G64S4M

  • Page 2 Preface This manual is specially made for those who GENERAL engage in automobile maintenance and repairing. Following general rules of system division of vehicles ENGINE (engine, clutch, etc.), this manual adopts the division methods by major assembly. In order to describe all parts belonging to an assembly, assemblies are further divided into several parts.
  • Page 3 00-1 General Contents page Guide on Using the Manual .......... 00-3 Engine ................00-5 Tightening Torque............00-6 Sealant (FIPG) ............. 00-7...

  • Page 4: Guide On Using The Manual

    00-2 GENERAL GUIDE ON USING THE MANNUAL Guide on Using the Manual Grouping name Section Name Page Engine Front cover, Oil pump 11-33 Maintaining Steps Front Cover, Oil Pump (1) Profile plots are provided for you to Dismantling Steps: Corresponding number of parts to the Dismantling and Mounting understand the installation of each number in the figure of composing parts to show...

  • Page 5: Engine

    00-5 OVERVIEW ENGINE ENGINE MODEL VEHICLE MODEL ENGINE MODEL DISPLACEMENT TYPE HOVER CUV 4G64-D-Y7 2,351 ML FOUR CYLINDERS, IN-LINE, SOHC...

  • Page 6: Tightening Torque

    00-6 OVERVIEW TIGHTENING TORQUE Tightening Torque The common tightening torque is shown in the list. Tightening torque of special parts is shown at the beginning of each group. Tightening torque of bolts and nuts Torque (Kg. M) Diameter Thread Bolt (with spring washer) Valve bolt of bolt pitch...

  • Page 7: Sealant (Fipg)

    00-7 OVERVIEW SEALANT(FIGP) Sealant (FIPG) Sealant is used on many parts of the engine and gearbox. The using of sealant is for the purpose of adequately sealing, therefore, much attention should be paid to the dosage, position and the surface of sealant. Insufficient dosage of sealant may result in leakage, while superfluous dosage of sealant may result in the overflow of sealant and jam the passage of water or oil, or narrow the passage.

  • Page 8: Table Of Contents

    11-1 Engine Contents page General ................ 11-2 Specifications ............... 11-3 Maintaining Standard ........... 11-3 Tightening Torque ............11-5 Sealant ................. 11-7 Special Tools..............11-8 AC Generator and Ignition System ......11-11 Timing Toothed-belt ............. 11-14 Fuel System ..............11-23 Intake Manifold ............. 11-25 Exhaust Manifold and Water Pump......

  • Page 9: General

    11-2 ENGINE SPECIFICATION General Specifications Items 4G64 S4 MPI Type In-line OHV, SOHC Number of Cylinders Combustion Chamber Single Pitch Roof Total Displacement ml 2,351 Cylinder Bore mm 86.5 Stroke mm 100.0 Compression Ratio 18 before top dead center Intake valve after bottom dead center Valve Timing before bottom dead center...

  • Page 10: Specifications

    11-3 ENGINE SPECIFICATION Specifications Maintenance Standard Unit mm Items Standard Value Limit Value Generator Convex value of tensioner arm Toothed-belt Press-in value of tensioner arm (98~196N) Height of cam Air intake 37.39 36.89 Camshaft Air exhaust 36.83 36.33 Shaft diameter 45.0 Planeness of Bottom Surface 0.03...
  • Page 11 11-4 ENGINE SPECIFICATION Items Standard Value Limit Value Axial clearance 0.05 0.18 0.25 Main shaft diameter Crankshaft Connecting rod shaft diameter Radial clearance of main shaft 0.02 0.04 Planeness of top surface 0.05 * 0.2 Top surface lapping limit*Total lapping Cylinder Block of cylinder block and head Total Height...

  • Page 12: Tightening Torque

    11-5 ENGINE SPECIFICATION Tightening Torque Fastening Location Torque (Kg.M) Generator and Ignition System Fastening bolt of AC generator Stay bolt Pivot nut Crankshaft pulley bolt Spark plug Ignition coil bolt Timing toothed-belt Lower front cover of timing toothed-belt Tensioning pulley bolt Tensioning wheel arm bolt Automatic tensioning wheel bolt Central pulley bolt...

  • Page 13: Sealant

    11-6 ENGINE SPECIFICATION Fastening Location Torque (Kg.M) Front cover and oil pump Oil drain plug Oil pan Oil suction filter bolt and nut Oil pressure switch Pressure relief plug Oil suction filter bracket bolt Front cover bolt Plug Flange bolt Oil pump cover bolt Oil pump cover screw Piston and connecting rod assembly...

  • Page 14: Special Tools

    11-7 ENGINE SPECIAL TOOLS SPECIAL TOOLS Tools REF. NO. NAME PURPOSE Use MD998719 for Fastening CRANKSHAFT PULLEY MB990767 camshaft toothed-belt wheel WRENCH MB990938 HANDLE Use together with MD998776 Use MD998767 for timing MD990685 TORQUE WRENCH toothed-belt tensioning Disassembly and mounting of SCREW-PLUG front cover plug MD998162...
  • Page 15 11-8 ENGINE SPECIAL TOOLS Tools REF. NO. NAME PURPOSE MD998727 OIL PAN DETACHER Disassembly of oil pan BALANCING SHAFT Disassembly of reverse balanc- MD998371 BEARING PULLER ing shaft front bearing BALANCING SHAFT Disassembly of reverse bal- MD998372 BEARING PULLER ancing shaft rear bearing Disassembly and mounting of MD998772 VALVE SPRING...
  • Page 16 11-9 ENGINE SPECIAL TOOLS Tools REF. NO. NAME PURPOSE Guide limit for disassembly and BALANCING SHAFT assembly of reverse balancing MB991603 BEARING PULLER shaft rear bearing (used with MD998372 together) CYLINDER HEAD BOLT Disassembly and mounting of MB991654 WRENCH cylinder head bolt Hydraulic lifter leakage-detect LEAKAGE-DETECTING MD998440...

  • Page 17: Ac Generator And Ignition System

    11-10 ENGINE AC GENERATOR AND IGNITIONSYSTEM AC GENERATOR AND IGNITION SYSTEM DISASSEMBLY AND MOUNTING 25N.m 23N.m 11N.m 23N.m 11N.m 25N.m Disassembly Procedure 1. driving belt 7. spark plug cable 2. water pump pulley 8. spark plug 3. power steering pump pulley 9.
  • Page 18 11-11 ENGINE TIMING TOOTHED-BELT NOTES FOR DISASSEMBLY DISASSEMBLY OF CRANKSHAFT BOLT MD998781 (1) Fasten flywheel with special tools (2) Disassemble crankshaft bolt. 9EN0268 NOTES FOR MOUNTING MOUNTING OF CRANKSHAFT BOLT MD998781 (1) Fasten flywheel with special tools. (2) Mount crankshaft bolt. 9EN0268 ADJUST DRIVING BELT TENSION TO STANDARD VALUE WITH DEFLECTION INDICATOR OR...

  • Page 19: Timing Toothed-Belt

    11-12 ENGINE TIMING TOOTHED-BELT TIMING TOOTHED-BELT DISASSEMBLY AND MOUNTING 11N.m 162N.m 48N. 48N. 24N. 54N. 8.8N.m 11N.m 35N. 22N. 6EN1769 Disassembly Procudure 1. front lower cover of timing thoothed-belt 11. crakshaft bolt** 12. crankshaft toothed-belt wheel 2. timing toothed-belt 3. temsioning pulley 13.
  • Page 20 11-13 ENGINE TIMING TOOTHED-BELT WHEEL 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 6EN0662 being contaminated and adhered by water or grease.
  • Page 21 11-14 ENGINE TIMING TOOTHED-BELT WHEEL 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. MD998785 DISASSEMBLY OF BALANCING SHAFT TOOTHED- BELT WHEEL (1) Fasten balancing shaft toothed-belt wheel with the tools as shown in the figure.
  • Page 22 11-15 ENGINE TIMING TOOTHED-BELT WHEEL (2) There are cracks on the surface of back rubber; cracks (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 canvas peel-off side cracks crack at bottom of tooth...
  • Page 23 11-16 ENGINE TIMING TOOTHED-BELT WHEEL (3) The overhang length of measuring rod. Replace if not conform 12mm to standard. Standard value 12mm 6EN0161 (4) Measure the amount of displacement while pressing down the 98~196N rod with a force of 98~196N. (5) Replace the automatic tensioner if the displacement of rod is at displacement least 1mm lesser than the value as measured in item (3).
  • Page 24 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. MD998785 (2) Tighten the bolt to the specified torque. 6EN0636 MOUNTING OF TIMING TOOTHED-BELT B (1) Align the marks of crankshaft toothed-belt wheel B and timing balancing toothed-belt wheel separately.
  • Page 25 11-18 ENGINE TIMING TOOTHED-BELT TIGHTENING OF CRANKSHAFT BOLT (1) Fixup flywheel with special tools; (2) Mount crankshaft bolt. MD998781 6EN0634 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.
  • Page 26 11-19 ENGINE TIMING TOOTHED-BELT MOUNTING OF TIMING TOOTHED-BELT timing mark (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. 6EN0673 (3) Align the timing mark on the crankshaft toothed-belt wheel with the mark on the front cover.
  • Page 27 11-20 ENGINE TIMING TOOTHED-BELT (8) Verify that all timing marks are in a line. MD990685 MD998767 (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.

  • Page 28: Fuel System

    11-21 ENGINE FUEL OIL SYSTEM FUEL SYSTEM DISASSEMBLY AND MOUNTING 19N.m 20N.m 12N.m Notes for Mounting Disassembly Procedure Mounting of Fuel Distribution Assembly 1. water pipe Before mounting fuel distribution assembly, carefully 2. water pipe lubricate the matching face of the manifold or the O- 3.

  • Page 29: Intake Manifold

    11-22 ENGINE INTAKE MANIFOLD INTAKE MANIFOLD DISASSEMBLY AND MOUNTING 19N.m 20N.m 20N.m 19N.m 13N.m 13N.m 30N.m Disassembly Procedure 1. engine Link Ring 2. engine Water Temperature Sensor 3. water Outlet 4. intake Manifold Bracket 5. intake manifold 6. intake Manifold Gasket NOTES FOR MOUNTING APPLICATION OF SEALANT FOR ENGINE WATER TEMPERATURE SENSOR...

  • Page 30: Exhaust Manifold And Water Pump

    11-23 ENGINE EXHAUST MANIFOLD & WATER PUMP EXHAUST MANIFOLD, WATER PUMP DISASSEMBLY AND MOUNTING 45N.m 14N.m 29N.m 11N.m 24N.m 13N.m 49N.m 24N.m 24N.m 13N.m 14N.m Disassembly Procedure 11. water temperature sensing plug 1. oil level gauge 2. oil level gauge tube 12.
  • Page 31 11-24 ENGINE EXHAUST MANIFOLD & WATER PUMP NOTES FOR MOUNTING o-ring 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.

  • Page 32: Rocker Arm And Camshaft

    11-25 ENGINE ROCKER ARM AND CAMSHAFT ROCKER ARM AND CAMSHAFT DISASSEMBLY AND MOUNTING 3.9N.m 31N.m 18N.m Smear engine oil on all moving parts while mounting 6EN1762 1. air hose 12. A rocker arm A 2. PCV hose 13. B rocker arm B 3.
  • Page 33 11-26 ENGINE ROCKER ARM AND CAMSHAFT 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. MD998448 6AE0160 CHECK CAMSHAFT (1) Measure the height of camshaft Standard value and operating limit are as follows: Type Standard value...
  • Page 34 11-27 ENGINE ROCKER ARM AND CAMSHAFT (3) Mount the special tool MD998441 onto the hydraulic lifter. MD998441 (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.
  • Page 35 11-28 ENGINE ROCKER ARM AND CAMSHAFT (9) Put the hydraulic lifter into vessel C, then use the special tool MD998442 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.
  • Page 36 11-29 ENGINE ROCKER ARM AND CAMSHAFT (19) 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.

  • Page 37: Cylinder Head And Valve

    11-30 ENGINE CYLINDER HEAD AND VALVE CYLINDER HEAD AND VALVE DISASSEMBLY AND ASSEMBLY 78N.m thorough looseness 20N.m All parts inside should be coated with enging oil in assembly 6EN1386 Disassembly Procedure 1. cylinder head bolts 11. exhaust valve 2. cylinder head cluster 11.
  • Page 38 11-31 ENGINE CYLINDER HEAD AND VALVE Notices after Disassembly MB991654 The disassembled parts should be sorted as per the cylinder number and the intake/exhaust parts. Dismantle of Cylinder head Bolts (1) Loosen the bolts of each cylinder heads with SST. The looseness should be even and gradual.
  • Page 39 11-32 ENGINE CYLINDER HEAD AND VALVE Mount of Valve Spring identifi cation upper site of (1) The valve spring shall be mounted in such way that the spring end spring with identification color faces the upper site of the valve spring. valve oil seal lower site of spring...
  • Page 40 11-33 ENGINE CYLINDER HEAD AND VALVE (6) Mark a straight line with paint on the heads of cylinder head bolts and the cylinder head. (7) Tighten the cylinder head bolts by 90 in tightening order. (8) Tighten the bolts by another 90 , ensuring the paint marks on the heads of cylinder head bolts and the cylinder head should be in alignment.
  • Page 41 11-34 ENGINE CYLINDER HEAD AND VALVE Valve Spring angle belwee cerrter line of spring and plun bine of subface (1) Measure the free spring height, in case it is less than the limit value, change the spring. Standard value: 51.0 mm Limit value: 50.0 mm free spring height (2) Measure the perpendicularity of the center line with the surface...
  • Page 42 11-35 ENGINE CYLINDER HEAD AND VALVE Main Points in Change of Valve Seat (1) Cut out part of the valve seat to be changed so as to thin and remove it. cut out 1EN0274 (2) Trim the valve seat holes on the cylinder head as per the outside diameter of the enlarged valve seat.
  • Page 43 11-36 ENGINE CYLINDER HEAD AND VALVE FRONT COVER, OIL PUMP, BALANCE SHAFT ,OIL PAN DISMANTLE AND ASSEMBLY 10N.m 1.0Kgft All inside parts should be coated with the engine oil 24N.m 2.4Kgifm 10N.m 19N.m 1.0Kgfm 1.9Kgifm 16N.m 1.7Kgfm 39N.m 4.0Kgfm 36N.m 3.7Kgfm 23N.m 2.4Kgfm...
  • Page 44 11-37 ENGINE CYLINDER HEAD AND VALVE Main Points of Disassembly MD998727 Disassembly of Oil Sump Disassemble all of the bolts of oil sump. Tap the SST into the clearance between the cylinder block and the oil sump. Notice: Do not replace the SST with screwdriver or chisel, otherwise the oil sump will deform and leak oil.
  • Page 45 11-38 ENGINE CYLINDER HEAD AND VALVE Disassembly of Rear Bearing of Balancing Shaft MB991603 (1) Tear down the rear bearing of the left balancing shaft from the cylinder block with SST. Remark:The SST (MB991603) should be mounted in front of the cylinder block when dismantling the rear bearing of the left balanc- ing shaft.
  • Page 46 11-39 ENGINE CYLINDER HEAD AND VALVE Mount of Front Bearing of Balancing Shaft (1) Mount the front bearing with SST. MD998705 MD998705 bearing cylinderblock 6EN1035 Mount of Front Cover (1) Mount the SST on the front end of the crankshaft and coat the engine oil on the face of outer circumference of the SST, then mount on the front cover.
  • Page 47 11-40 ENGINE CYLINDER HEAD AND VALVE Mount of Oil Seal of Lubricating Pump socket wrench (1) Press the oil seal into the front cover with the socket wrench. oil seal front cover Mount of Front Oil Seal of Crankshaft (1) Mount the front oil seal of crankshaft on the front cover with socket SST.
  • Page 48 11-41 ENGINE CYLINDER HEAD AND VALVE (2) Tighten the flange bolt with specified torque and ensure the driven gear of oil pump is fastened on the left balancing shaft. 6EN0565 Mount of Plug MD998162 (1) Mount the new O-ring in the grooves at the front cover. (2) Mount the plug with SST and tighten it to the specified torque.

  • Page 49: Piston And Connecting Rod

    11-42 ENGINE CYLINDER HEAD AND VALVE Mount of Oil Filter bracket side (1) Clean the mounting face of the oil filter bracket. (2) Coat the engine oil on the O-ring of oil filter. (3) Screw in the oil filter, when the O-ring contacts the mounting face, screw another 3/4 round (tightening moment: 1.4 kg.m) 6EN0591 Inspection...

  • Page 50: Disassembly And Assembly

    11-43 ENGINE CYLINDER HEAD AND VALVE DISASSEMBLY AND ASSEMBLY All inside parts must be coated with engine oil 6EN0526 Disassembly Procedure 1. connecting rod nut 2. connecting rod cap 3. connecting rod bearing 4. piston and connecting rod cluster 5. connecting rod bearing 6.
  • Page 51 11-44 ENGINE CYLINDER HEAD AND VALVE Main Points in Disassembly Disassembly of Connecting Rod Cap (1) Mark the cylinder No. on the side face of the larger end of the cylinder No. connecting rod so as to ensure the correct assembly. (2) Put aside the dismantled connecting rod, connecting rod cap and connecting rod bearing in order as per the cylinder No.
  • Page 52 11-45 ENGINE CYLINDER HEAD AND VALVE Main Points for Mount piston Mount of Piston Pin (1) Measure the following dimensions of the piston, piston pin and connecting rod; A) Length of inserting hole of the piston pin; B) Width between the keyway C) Length of piston pin D) Width of smaller end of connecting rod.
  • Page 53 11-46 ENGINE CYLINDER HEAD AND VALVE (10) Check whether the piston can rotate freely. 6EN0 298 Mount of oil ring upper scraper blade (1) Put the main ring of oil ring in the oil ring groove. main ring Remark: 1. The scraper blade and the main ring has the specified upper./lower lower scraper blade face.
  • Page 54 11-47 ENGINE CYLINDER HEAD AND VALVE Mount of Piston and Connecting Rod Cluster upper scraper blade (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.
  • Page 55 11-48 ENGINE CYLINDER HEAD AND VALVE 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 cylinder No. mark, the anti-rotary gap shown in the figure should be mounted at the same side anti-rotary gap DEN0051...
  • Page 56 11-49 ENGINE CYLINDER HEAD AND VALVE 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.

  • Page 57: Crankshaft, Cylinder Block And Flywheel

    11-50 ENGINE CYLINDER HEAD AND VALVE CRANKSHAFT, CYLINDER BLOCK AND FLYWHEEL DISASSEMBLY AND ASSEMBLY 132N.m 11N.m 11N.m 8.8N.m Smear the engine oil on all moving parts 25N.m+90 ~100 Disassembly Procedure 1. flywheel bolt 8. main bearing cap 2. flywheel 9. low bearing of crankshaft 3.

  • Page 58: Cylinder Block

    11-51 ENGINE CYLINDER HEAD AND VALVE Inspection clearance gauge of Measurement for Crankshaft Play (clearance gauge of plastic plastic cord cord) (1) Clean the oil on the main journal and the inner race of bearing. (2) Mount the crankshaft. (3) Cut the clearance gauge of plastic cord in the length that is the same with the width of bearing, then put them on the crankshaft 6EN0703 journal and ensure them are parallel with the axial center line.
  • Page 59 11-52 ENGINE CYLINDER HEAD AND VALVE Re-boring of Cylinder Diameter (1) The diameter for the enlarged piston should be determined according to the max cylinder diameter. Identification of piston diameter dimension Identification mark thrusting Plus 0.50 0.50 direction Plus 1.00 1.00 piston diameter Remark: Dimension mark is printed on the top of piston.
  • Page 60 11-53 ENGINE CYLINDER HEAD AND VALVE Mount of crankshaft bearing (1) Select the bearing that meets the dimension of crankshaft main No.3 journal as per the form below. No.2 Combination of crankshaft main journal and Identification main shaft aperture No.4 I d e n t i f i c a t i o n marks and marks and colors...
  • Page 61 11-54 ENGINE CYLINDER HEAD AND VALVE Mount of Main Bearing Cap/ Main Bearing Bolt (1) Mount the main bearing cap with the arrow mark thereof directing to the side of timing toothed belt. (2) Be sure the length of bolt is less than the limit value before mounting the main bearing cap bolt.
  • Page 62 11-55 ENGINE CYLINDER HEAD AND VALVE Mount of Oil Seal MD990938 MD998376 6EN0709 Mount of Rear Oil Seal Cover Specified sealant Brand: Genuine Mitsubishi brand sealant MD970389 or the equivalents. Notice: (1) The rear oil seal cover should be mounted quickly on the condition the sealant is not dry ( 15 min).

  • Page 63: Ac Generator

    11-56 ENGINE AC GENERATOR AC GENERATOR DISASSEMBLY AND ASSEMBLY 9EN0187 Disassembly Procedure 1. generator pulley 2. rotor assembly 3. rear bearing 4. bearing block 5. front bearing 6. front cap 7. stator assembly 8. retaining plate 9. adjustor and brush stand 10.
  • Page 64 11-57 ENGINE AC GENERATOR NOTES FOR DISASSEMBLY SEPARATION OF STATOR AND FRONT CAP (1) Insert the screwdriver into the gap between front cap and stator to separate the front cap from the stator. (2) If it is hard to separate them, lightly hit the front cap with a plastic hammer and prize it with screwdriver at the same time.
  • Page 65 11-58 ENGINE AC GENERATOR STATOR (1) Conduct on stator examination over the stator and confirm whether the conduction exists with the lead-wire of the winding, if not, replace the stator assembly. 3EN0208 (2) Check the grounding of stator winding. Confirm whether con- duction exists between the winding and stator iron core, if yes, replace the stator assembly.
  • Page 66 11-59 ENGINE AC GENERATOR BRUSH (1) If the brush is worn out to the wear limit line, replace brush by taking the following steps: wear limit line wite 9EN0192 (2) The brush may be taken off by burning off the soldering joint of the brush lead-wire.

  • Page 67: Starter

    11-60 ENGINE STARTER STARTER DISASS0.EMBLY AND ASSEMBLY 6EN1412 Disassembly Process 1. bolt 12. washer B 2. magnet valve 13. plate 3. bolt 14. ball 4. bolt 15. planetary gear 5. rear carrier 16. rod 6. brush holder 17. snap spring 7.
  • Page 68 11-61 ENGINE STARTER magnetic switch terminal S ESSENTIALS FOR DISASSEMBLY DISASSEMBLY OF MAGNET VALVE terminal B (1) Knock down exciting coil from terminal M of the magnet valve. terminal exciting coil wiring 6EN0616 DISASSEMBLY OF ROTOR AND BALL casing tube (1) Do not drop the ball mounted on the end of bearing while disassemble the rotor.
  • Page 69 11-62 ENGINE STARTER (2) Check the outside diameter of the . commutator Standard value: 29.4mm Limit value: 28.4mm 1EN0298 depth (3) Check the drop depth of mica between commutator separators. Standard value: 0.5mm brush holder mica Limit value: 0.2mm 1EN0296 BRUSH HOLDER (1) Check whether conduction exists between brush holder plate and brush holder, if not, it is normal.
  • Page 70 11-63 ENGINE STARTER (3) While crumbing worn battery with a plier, be careful not to new brush damage the soft pigtail. soft pigtail sodering (no (4) In order to make soldering tin easy to be adhered, scrape the soft soldering tin pigtail end with a piece of sand paper.

  • Page 71: Throttle Body

    11-64 ENGINE THROTTLE BODY THROTTLE BODDY DISASSEMBLY AND ASSEMBLY 2.9N.m 3.4N.m 3.4N.m 4.9N.m 6EN1782 Disassembly Procedure 1. holder 2. throttle position transducer 3. idle air valve 4. o-ring 5. throttle body 6. SAS speed adjusting screw SAS Remarks 1. SAS has been adjusted before leaving factory, so no adjustment is needed.

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