Chery TIGGO User manual

Service Manual for Chery·Tiggo(T11) Engine Section
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Contents
Chapter 1 Overview。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。3
I. Technical Data。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。3
II. Special Tools。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。8
Chapter 2 Structural Features of Engine。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。12
Chapter 3Admission Gear。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。23
I. Timing Gear Belt。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。23
II. Rocker and Camshaft。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。32
III. Cylinder Cover and Valve。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。36
Chapter 4 Crank Gear。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。42
Chapter 5 Lubricating System。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。 54
Chapter 6 Cooling System。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。62

Service Manual for Chery·Tiggo(T11) Engine Section
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Chapter 1 Overview
Engine used in Chery Tiggo car is MITSUBISHI 4G64 (2.4L) and 4G63 (2.0L)
model engine, which adapt single-overhead-camshaft, 4-cylinder 16-valve and multi-point
sequential injection.
I. Technical Data
1. Engine Mode Number Indication
多点顺序喷射系统：Multi-point sequential injection
4气门结构：4 valve structure
单顶置凸轮轴：Single-overhead-camshaft
设计序号：Design serial number
产品系列：Product serial
汽油发动机：Gasoline engine
4气缸结构：4 cylinder structure
2.Engine Number Position
Engine No.
Position

Service Manual for Chery·Tiggo(T11) Engine Section
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3．Related Engine Data
Item
Specification
4G63 S4 MPI
4G64 S4 MPI
Engine type
Four cylinder in-line, 4 stroke, water-cooled,
single-overhead-camshaft,16 valve multi-point sequential
injection
Cylinder number
4
4
Combustion chamber
Ridge chamber
Ridge chamber
Total displacement
ml
1,997
2,351
Cylinder diameter
mm
85.0
86.5
Stroke mm
88.0
100.0
Output power kw
92（6000r/min）
95（5500r/min）
Max torque N.m
167.7
198.1
Compression ratio
10
9
Lubrication system
Pressure supply, full filter
Pressure supply, full filter
Fuel pump type
Gear type
Gear type
Water pump type
Centrifugal impeller
Centrifugal impeller
4. Maintenance Standard
UOM：mm
Item
Standard Value
Usage Limit
Value
Engine gear
belt
Tensioner arm protrusion
12
——
Tensioner arm depression (98～196N)
≤1
——
Camshaft
Cam height
Air-in
4G63
37.50
37.00
Air-out
4G63
36.99
36.49
Shaft diameter
45.0
Cylinder
cover
Lower surface flatness
0.03
0.2
Surface grinding limit* total grinding of cylinder body and
cylinder cover
——
* 0.2
Full height
119.9－120.1
97.4
≤99.4
Valve
Edge thickness
Air-in
1.0
0.5
Air-out
1.2
0.7
Valve rod diameter
6.0
——
Crest clearance between valve rod and
duct
Air-in
0.02－0.05
0.10
Air-out
0.03－0.07
0.15
Inclination angle
45°－45.5°
——

Service Manual for Chery·Tiggo(T11) Engine Section
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Item
Standard Value
Usage Limit
Value
Height
Air-in
112.30
111.80
Air-out
114.11
113.61
Valve
spring
Free height
51.0
50.0
Pre-loading force/Operation height Km/mm
27.2/44.2
——
Verticality
≤2°
≤4°
Valve duct
Contact bandwidth
0.9－1.3
——
Internal diameter
6.0
——
External diameter
11.0
——
Depression depth
14.0
——
Valve rod protrusion height
49.3
49.8
Engine oil
pump
Side clearance
Driving gear
0.08－0.14
——
Driven gear
0.06－0.12
——
Piston
Piston clearance
0.02－0.04
——
Piston ring
Lateral clearance
No.1 ring
0.02－0.06
0.1
No.2 ring
0.02－0.06
0.1
End clearance
No.1 ring
0.25－0.35
0.8
No.2 ring
0.40－0.55
0.8
Oil ring
0.10－0.40
1.0
Piston pin
External diameter
22.0
——
Depressing force (Kg)
755－1750
——
Depressing temperature
Room
temperature
——
Crank
Crank pin clearance
0.02－0.05
0.1
Connecting
rod
Bigger end clearance
0.10－0.25
0.4
Crank
Axial clearance
0.05－0.18
0.25
Main axle diameter
57
——
Connecting axle diameter
45
——
Main axle diametral clearance
0.02－0.04
0.1
Cylinder
body
Upper surface flatness
0.05
0.1
Upper surface grinding limit*Total grinding of cylinder body
and cylinder cover
——
* 0.2
Full height 4G63
284±0.1
——
Internal diameter of cylinder hole 4G63
85.00－85.03
——
Cylinder
body
Cylinder hole cylindricity
0.01
——
Motor
Rotor coil resistance
3－5
——
Cylinder
Cover
Secondary processing size of valve conduit
installation hole (air-in and air-out valve)
enlargement
0.05 O.S.
11.05－11.07
0.25 O.S.
11.25－11.27
0.50 O.S.
11.50－11.52

Service Manual for Chery·Tiggo(T11) Engine Section
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Item
Standard Value
Usage Limit
Value
Secondary processing size of air-in valve
seating hole enlargement
0.30 O.S.
34.435－34.455
0.60 O.S.
34.735－34.755
Secondary processing size of air-out valve
seating hole enlargement
0.30 O.S.
31.935－31.955
0.60 O.S.
32.235－32.255
Remarks:
O.S.: Enlarged diameter
5. Tightening torque
Tightened Part
Torque (kgf .M)
Alternator, Ignition system
Water pump belt gear
Adjusting bolt
Locking bolt
Alternator bracket screw bolt
Alternator center axle nut
Crank belt gear
Ignition coil
Spark piston
Camshaft position sensor cylinder
Camshaft position sensor bracket
Camshaft position sensor
0.9
1.0
2.2
2.4
4.5
2.5
1.0
2.5
2.2
1.4
1.0
Timing Belt
Protruded screw bolt on timing belt cover
Tensioner wheel screw bolt
Tensioner arm screw bolt
Automatic tensioner screw bolt
Central belt wheel screw bolt
Tensioner bracket
Timing belt rear cover
Timing belt indicator
Engine oil pump belt gear
Screw bolt of crank belt gear
Tensioner “B”
Belt gear of balance axle
Screw bolt of camshaft belt gear
Belt gear of balance axle
1.1
4.9
2.2
2.4
3.6
4.9
1.1
0.9
5.5
12.0
1.9
4.6
9.0
4.6
Fuel System
Throttle
1.9

Service Manual for Chery·Tiggo(T11) Engine Section
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EGR valve
Injector and distribution pipe
Fuel oil return pipe
Fuel pressure regulator
2.2
1.2
0.9
0.9
Intake Manifold
Screw bolt of engine flying rings
Engine coolant temperature sensor
Connecting bolt of outflow pipe
Manifold bolt
Coolant temperature sensor
Manifold bracket
1.9
3.0
2.0
2.0
1.1
1.4
Exhaust Manifold
Screw bolt of emission manifold cover
Screw bolt of inflow duct joint
Exhaust manifold nut ( M8)
Exhaust manifold nut ( M10)
Screw bolt of coolant bypass duct joint
Screw bolt of coolant duct component
Thermostat housing bolt
Water pump screw bolt
1.4
2.4
3.0
5.0
2.4
1.3
2.4
1.4
Rocker and Camshaft
Rocker cover screw bolt
Screw bolt of rocker and camshaft assembly
Trust bearing cover bolt
0.4
3.2
1.9
Cylinder Cover and Valve
Cylinder cover bolt
2.0＋90°＋90°
Front cover & Engine oil pump
Drain plug
Oil pan
Screw bolt and nut of oil strainer
Oil pressure switch
Pressure relief plug
Screw bolt of oil cleaner bracket
Front cover bolt
Plug
Flange bolt
Engine oil pump cover bolt
Engine oil pump cover screw
4.5
0.7
1.9
1.0
4.5
1.9
2.4
2.4
3.7
1.6
1.0
Piston and Connecting Rod Assembly
Connecting rod nut
2.0＋90°～100°
Crank, Cylinder Body, Flywheel
Flywheel screw bolt
13.5

Service Manual for Chery·Tiggo(T11) Engine Section
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Installation screw bolt of rear cover
Installation screw bolt of bell jar
Installation screw bolt of oil seal cover
Screw bolt of main bearing cover
1.1
0.9
1.1
2.5＋90°～100°
Throttle Body
Bracket screw bolt
0.5
Throttle Position Sensor
0.35
Screw bolt of idle speed air valve
0.35
Idle speed adjustment bolt and installation nut
0.3
II. Special Tools
Tool
Number
Name
Purpose
MB990767
Spanner for crankshaft belt
gear
Use MD998719 when fixing
camshaft belt gear
MB990938
Handle
Use it together with
MD998776 to install
crankshaft rear oil seal.
MB991603
Balance axle bearing puller
limiter
Use it with MD998372
together to disassemble
reverse balance axle rear
bearing and install guiding
limiter.
MB991654
Cylinder cover bolt spanner
(12)
Disassemble and assemble
cylinder cover bolt.
MD998162
Plug spanner
Disassemble and assemble
front cover plug cock.
MD998285
Crankshaft front oil seal duct
MD998375 Use MD998375
to install crankshaft front oil
seal

Service Manual for Chery·Tiggo(T11) Engine Section
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Tool
Number
Name
Purpose
MD998371
Balance axle bearing puller
Disassemble reverse balance
axle front bearing
MD998372
Balance axle bearing puller
Disassemble reverse balance
axle rear bearing
MD998375
Crank shaft front oil seal
installer
Install crankshaft front oil
seal
MD998440
Leakage check tester
Leakage test for hydraulic
post.
MD998441
Hydraulic post keeper
Exhaust air from hydraulic
post
MD998442
hydraulic post wiring
Exhaust air from hydraulic
post
MD998443
hydraulic post keeper
Use it when disassembling
or assembling rocker shaft
component
MD998705
Balance axle bearing installer
Install balance axle front and
rear bearing.
MD998713
Camshaft oil seal installer
Install camshaft oil seal

Service Manual for Chery·Tiggo(T11) Engine Section
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Tool
Number
Name
Purpose
MD998719
Fixing pin for belt gear
Use MB990767 to fix
camshaft belt gear.
MD998727
Oil pan remover
Disassemble oil pan
MD998735
Valve spring compressor
Disassemble and assemble
valve and related parts
MD998767
Tensioner puller sleeve
Timing belt tension
adjustment
MD998772
Valve spring compressor
Disassemble and assemble
valve and related parts
MD998774
Valve oil seal installer
Install valve oil seal
MD998776
Crankshaft rear oil seal
installer
MB990938 Use MB990938
to install crankshaft rear oil
seal.
MD998778
Crankshaft belt gear puller
Disassemble crankshaft belt
gear
MD998780
Piston disassembling and
assembling tool
Disassemble and assemble
piston pin.

Service Manual for Chery·Tiggo(T11) Engine Section
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Tool
Number
Name
Purpose
MD998781
Flywheel stopper
Fix flywheel and driving
disk
MD998783
Plug spanner fixer
Disassemble and assemble
front cover plug
MD998785
Timing belt gear stopper
Keep balance axle belt gear.