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CAMSHAFT … … …… … …… … …… … …… … …… … …… … …… … …… A-25
CRANKSHAFT … … …… … …… … …… … …… … …… … …… … …… … …A-28
A-2
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LOCATION INDEX
MECHANICAL LOCATION INDEX
TIMING BELT
1
(SEE A-4 ENGINE TIMING)
VALVE MECHANISM COMPONENTS
2
(SEE A-9 VALVE CLEARANCE)
CYLINDER HEAD GASKET
3
(SEE A-19 CYLINDER HEAD GASKET REPLACEMENT)
FRONT OIL SEAL
4
(SEE A-21 FRONT OIL SEAL REPLACEMENT)
REAR OIL SEAL
5
(SEE A-23 REAR OIL SEAL REPLACEMENT)
CAMSHAFT
6
(SEE A-25 CAMSHAFT)
CRANKSHAFT
7 (SEE A-28 CRANKSHAFT, CRANKSHAFT THRUST SPACER, BEARING SHELL AND
MAIN BEARING CAP)
PISTON AND CONNECTING ROD
8
(SEE A-33 PISTON AND CONNECTING ROD ASSEMBLY)
A-3
Installation
Clean the bottom timing gear cover and fix the
new gasket on the bottom timing gear cover with
glue. Install the bottom timing gear cover and
gasket assembly on the crank shaft, screw in two
bolts by hands and tighten them for a moment of
9.0~11N.m.
Clean the top timing gear cover and fix the new
gasket on the top timing gear cover with glue. Fix
the top timing gear cover and gasket assembly on
the cylinder head with two bolts for a tightening
moment of 9~11N.m.
A-4
A-5
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Hold the middle of the right belt that is away
from both the crankshaft gear and camshaft gear
with the thumb and the first finger. If the tension
of the belt is up to standard, the belt shall be
able to twist at 90°at this point.
Timing gear
Bush
Key
Bolt: M12*1.5*30
Tightening torque: 52~60Nm
Tension Pulley
Bolt: M8*25
Tightening torque: 16~20Nm
Key
Crankshaft Gear
A-6
A-7
A-8
A-9
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VALVE COVER AND GASKET
Cupped gasket
Valve Cover
Cupped
Removal gasket
Installation
A-10
Removal
Loosen the rocker nuts to take them out.
Installation:
Check whether theire is abnormal abrasion on
the contact surface of the rocker. Replace it if
necessary.
Put the rocker seat gasket into the stud.
Lubricate the rocker arm and rocker seat by
motor oil.
Install the rocker arm and seat, screw in the
new nuts by hands, then tighten them for the
moment of 25—29N.m.
A-11
Removal
Take the hydraulic tappets out and place them
into an oil-filled vessel to prevent the hydraulic
tappet oil from leaking out.
Check the top and bottom contact surfaces of
the hydraulic tappet to observe whether there
are abnormal abrasion or scrapes. If yes,
replace it with new one if necessary.
Installation
Apply hyperbolic gear oil or motor oil on the
tappet and external diameter as well as its two
ends and place the tappet into the cylinder
head hole in the original order.
Tappet
A-12
CYLINDER
1
Put one set of valve, valve cotter, spring and spring
seat into one plastic bag, each of which shall be
tagged with numbers for installing them back to the
original position.
A-13
Intake(mm) Exhaust(mm)
Class Inner Diameter
Diameter of Inner Diameter
Diameter of Clearance of valve Clearance
valve stem of valve guide
valve guide stem
Free Length
Compression Spring load
of Spring
length (mm) (N)
(mm)
L1=37.084 422
L3=27.0 945
A-14
UAES’s new
two-valve
Installation
Before installation, the cylinder head shall be
completely cleaned and there shall be no any trace
of abrasive dust on the cylinder head, valve or
valve guide.
Lubricate the valve stem and valve guide bore with
clean motor oil.
Install the valve. The assembly shall be completed
according to the original valve indicators.
Note: The intake valves are interchangeable, but
the exhaust valves are not.
A-15
Size of exhaust valve seat ring and cylinder head seat ring bore
Diameter of exhaust valve Diameter of cylinder head Interference
Class
seat ring (mm) seat ring bore (mm) (mm)
Standard 38.877 +−00..01
01 38.263 0+0.025
Oversized
39.377 +−00..01
01 38.763 0+0.025 0.079—0.124
0.5
Oversized
39.877 +−00..01
01 39.263 0+0.025
1.0
UAES’s
new 38.377 +−00..01
01 38.263 0+0.025
two-valve
Oversized 0.079—0.124
38.877 +−00..01
01 38.763 0+0.025
0.5
Oversized
39.377 +−00..01
01 39.263 0+0.025
1.0
A-16
Warning
·Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage.
Always keep sparks and flames away from fuel.
·Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries
or death and damage. Fuel can also irritate skin and eyes. To prevent this, always
complete the “Fuel Line Safety Procedure”.
·If the measured value is less than the limited value, or there is a cylinder whose
compression value varies from that of other cylinders, add a small amount of engine oil
through the spark plug hole. Then measure the compression pressure and perform the
respective operations for the following cases.
— If the compression increases, the piston, the piston rings, or cylinder wall may be worn
and overhaul is required.
— If the compression stays low, a valve may be stuck or improperly seated and overhaul is
required.
— If the compression in adjacent cylinders stays low, the cylinder head gasket may be
damaged or the cylinder head distorted and overhaul is required.
A-17
A-18
Removal
Rotate the cam shaft clockwise until the key slot
goes downwards vertically.
Loosen the bolts on the cylinder head in the order
illustrated in the figure.
A-19
A-20
CRANKSHAFT PULLEY
Removal
Installation
Bolt: M12*35
Clean the pulley and crankshaft journals and wipe Tightening torque: 100~115Nm
clean the lube in the pulley groove. Install the
pulley on the crank shaft journal, with the key slot
to line up with the whiney key.
Put the washer over the bolts and screw it in by
hands. Fasten the flywheel ring gear to disenable
Pulley
the crank shaft to rotate. Tighten the bolts for a
moment of 100-115N.m
A-21
Removal
Fix the crankshaft to disenable it to rotate and
remove the pulley.
Pull the crankshaft gear out by a wheel puller or
two large-size screw drivers and remove the
whiney key.
Installation
Check whether there are abrasion, pit corrosion or
scrapes on the gear.
Install the whiney key, with a protrusion height of
1.392-1.739mm.
Install the gasket and pay attention to its direction
(with the warped surface forward).
Install the crank shaft gear (with the convex
surface forward), place it on the locating abutment
with a auxiliary pulley and bolts.
A-22
Removal
Remove 9 fixing bolts. New bolts shall be used
for installation.
Remove the fly wheel to check whether there
are cracks on the friction surface of the clutch
plate and there is abrasion and pit corrosion on
the teeth of the ring gear, etc.
Installation
The clearance of the ring gear and the fly
wheel is 0.48-0.86mm. The ring gear shall be
pressed into the fly wheel after heating.
The gauge holes of the fly wheel and the
locating journal are easy fit at a clearance of
0.012-0.074mm. It shall be gently pushed into
the journal after alignment. Do not hammer at
the crank shaft.
During the assembly process, align the
installation mark bore and the manufacturing
bore on the crank shaft. Tighten 9 new bolts
applied with a coat of glue in advance at a
moment of 82-92Nm.
Removal
Remove 4 bolts (as indicated by arrows).
Take the rear oil seal support assembly out.
Take the rear oil seal support gasket.
A-23
Installation
Put the support on the vice clamp whose jaw
has a piece of wood.
Make the side with the part numbers of the rear
oil seal outward and align the rear oil seal with
the rear oil seal support bore. Press the rear oil
seal into its support with a vice clamp, with the
clearance between the rear oil seal and oil seal
support bore to be 0.26—0.50mm.
Seal
Bolt: M6*20(4 pcs)
washer
Tightening torque: 8~11Nm
A-24
CAMSHAFT GEAR
Removal
Rotate the crankshaft to the compression TDC
position of the first cylinder.
Remove the belt.
Put one pole into one hole of the cam shaft gear to
lock it. Loosen the gear bolts and remove them and
the gasket.
Note:
New bolts shall be used for reinstallation. The
camshafts of different engines are not
interchangeable. In case the cam shaft shall be
replaced, replace it with a new one according to
the indicators on the original gear.
Installation
Check whether there are abrasion, pit corrosion or
scrapes on the gear.
Install the whitney key of the cam shaft, with a
protrusion height of 1.64-2.11mm.
Install the camshaft gear onto the camshaft and put
new bolts into the gasket. The new bolts that
haven’t been applied with a coat of glue in
advance shall be applied with a coat of glue first
and be tightened for a moment of 52-60N.m.
Check whether the crank shaft is in the
compression TDC position.
Removal
Measure the axial clearance of the cam shaft,
which shall be between 0.049~0.129mm.
Loosen the bolts of the thrust spacer to take them
out.
Take the thrust spacer out (as illustrated in the
figure).
A-25
Inspection
Check whether there is any abrasion on the cam
and the journal of the cam shaft. Change the one
with serious abrasion.
Change the thrust space if the axial clearance of
the cam shaft is above the specification.
Measure the bore diameter of the cam shaft of the
cylinder head or check the relative displacement of
the journal and bore with the cam shaft. Change the
cam shaft if the bore is excessively wore.
Cam Height
Engine model Admission cam T (unit: mm) Exhaust cam T (unit: mm)
480 38.602 37.586
480E 37.559 37.559
A-26
1. Standard size
Number of cam shaft Diameter of cam shaft journal Diameter of the cam shaft hold of the
journal (unit: mm) cylinder head (unit: mm)
1 44.74—44.76 44.783—44.808
2 44.99—45.01 45.033—45.058
3 45.24—45.26 45.283—45.308
4 45.49—45.51 45.533—45.558
5 45.74—45.76 45.783—45.808
2. Oversized (0.38)
Number of cam shaft Diameter of cam shaft journal Diameter of the cam shaft hold of the
journal (unit: mm) cylinder head (unit: mm)
1 45.12—45.14 45.163—45.188
2 45.37—45.39 45.413—45.438
3 45.62—45.64 45.663—45.688
4 45.87—45.89 45.913—45.938
5 46.12—46.14 45.163—45.188
A-27
Inspection
Check the main journal and main bearing shell
clearance.
Clean the main journal of the crank shaft, the
internal bore of the main bearing cap and main
bearing shell with a non-woven fabrics. Place the
plastic clearance gauge (its length slightly shorter
than the length of the main journal) on the main
journal, which shall be in parallel with the
generator of the main journal.
Note: Do not rotate the crank shaft!
A-28
Diameter of Thickness of
connecting rod connecting-rod
Class journal bearing shell
(unit: mm) (unit: mm)
Standard 47.89—47.91 1.480—1.487
Downsized
47.89—47.91 1.492—1.499
by 0.025
Downsized
47.64—47.66 1.605—1.612
by 0.25
Downsized
47.39—47.41 1.730—1.737
by 0.5
Downsized
47.14—47.16 1.855—1.862
by 0.75
Downsized
47.89—46.91 1.980—1.987
by1.0
A-29
Size of crank shaft thrust, thrust spacer and cylinder block thrust
Size of cylinder block thrust Size of crank shaft thrust Thickness of thrust
Class
(unit: mm) (unit: mm) spacer (unit: mm)
Standard 24+0.03 28.825-28.875 2.326+0.025
Oversized
24+0.03 29.205-29.255 2.516+0.025
by 0.38
2 thrust spacers
A-30
A-31
A-32
Removal
A-33
480 M cylinder bore (unit: mm) 480 E cylinder bore (unit: mm)
1 79.94-79.95 1 79.94-79.95
Ex-factory 2 79.95-79.96 2 79.95-79.96
grouping 3 79.96-79.97 3 79.96-79.97
4 79.97-79.98 4 79.97-79.98
A 80.23-80.24 A 80.23-80.24
Ex-factory
B 80.24-80.25 B 80.24-80.25
repair
C 80.25-80.26 C 80.25-80.26
Standard 79.965-77.975 Standard 79.965-77.975
For
Oversized by 0.29 80.245-80.255 Oversized by 0.29 80.245-80.255
Maintenance
0.29by 0.5
Oversized 80.466-80.475 Oversized by 0.5 80.466-80.475
A-34
Diameter of 480M piston pin bore (unit: mm) Diameter of 480E piston pin bore (unit: mm)
White 20.630-20.633 White 20.630-20.633
Red 20.633-20.636 Red 20.633-20.636
Blue 20.636-20.639 Blue 20.636-20.639
Diameter of 480M piston pin bore (unit: mm) Diameter of 480E piston pin bore (unit: mm)
White 20.622-20.625 White 20.622-20.625
Red 20.625-20.628 Red 20.625-20.628
Blue 20.628-20.631 Blue 20.628-20.631
A-35
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Measure the axial clearance of piston ring in the piston groove
A-36
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Installation
A-37
A-38