Great Wall. 4G64S4N Gasoline Engine. Service Instruction - page 3

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.
NOTES:
If the hydraulic lifter becomes shorter, repeat step (15) to (19)
and fully fill the hydraulic lifter with diesel oil. If it still becomes
shorter after repetition of these steps, replace the hydraulic lifter.
(20) Keep the hydraulic lifter vertical lest the diesel oil overflows.
Prevent the hydraulic lifter from being contaminated by dirt or
foreign body and mount the hydraulic lifter onto the engine as
quickly as possible.
NOTES FOR MOUNTING
MOUNTING OF OIL SEAL
MOUNTING OF HYDRAULIC LIFTER
(1)
Insert the hydraulic lifter into the rocker arm (be careful not let
diesel oil overflow), then use the special tool to prevent it from
falling.
NOTES:
If the hydraulic lifter is used repeatedly, it must be cleaned.
6EN1704
9EN0060
MD998713
6AE0161
MD998443
hydraulic lifter
A
B
MOUNTING OF ROCKER SHAFT SPRING,
ROCKER ARM AND ROCKER SHAFT
(1)
Temporarily screw down the intake rocker shaft with bolt until
the rocker arm doesn
t push and press the valve.
(2)
Mount the rocker arm spring from the top and make it perpen-
dicular to the spark plug guide.
NOTES:You should mount rocker shaft spring first, and then the
exhaust rocker arm and rocker shaft.
(3)
Remove the special tool which is mounted for the purpose of
holding the hydraulic lifter.
(4)
Confirm that the cutting edge on the rocker shaft is in the
location as shown in the figure.
6AE016
6AE016
C
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11-30
ENGINE
CYLINDER HEAD AND VALVE
CYLINDER HEAD AND VALVE
DISASSEMBLY AND ASSEMBLY
78N.m
thorough
looseness
20N.m 90
+90
1
2
8
9
10
14
17
15
20
5
4
6
13
16
18
7
19
11
3
12
All parts inside should be
coated with enging oil in
assembly
6EN1386
N
N
N
N
N
N
N
B
1.
cylinder head bolts
2.
cylinder head cluster
3.
head gasket
4.
valve lock clamp
5.
upper site of valve spring
6.
valve spring
7.
inlet valve
8.
valve lock clamp
9.
upper site of valve spring
10. valve spring
11. exhaust valve
11. valve oil seal
12. valve spring seat
13. valve spring
14. valve spring seat
15. inlet valve guide
16. exhaust valve guide
17. inlet valve seat
18. exhaust valve seat
19. cylinder head
B
C
B
B
C
C
A
C
A
A
D
Disassembly Procedure
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11-31
ENGINE
CYLINDER HEAD AND VALVE
MB991654
MD998772
9EN0062
9EN0063
MD998774
Notices after Disassembly
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.
Dism Dismantle of Valve Lock Clamp
(1)
The dismantled parts such as the valve and spring should be
marked with the cylinder number and signboard of mounting
position and kept well so as to prepare the later reuse in assembly.
Dismantle of Valve Oil Seal
(1)
The valve oil seal must not be reused.
Mount of Valve Oil Seal
(1)
Mount the lower site of valve spring.
(2)
Mount the valve oil on the valve guide with SST tools. Incorrect
mount will lead to leakage.
Notice:
The valve oil seal must not be reused.
A
A
C
B
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11-32
ENGINE
CYLINDER HEAD AND VALVE
Mount of Valve Lock Clamp
(1)
In case the valve spring is over compressed, it will contact the
bottom of the valve spring and thus damage the valve oil seal.
Mount of Cylinder head Bolts
(1)
When assembling the bolts of cylinder head, the bolt length
should be identified to meet the limit value, otherwise, change the
bolts.
Limit Value (A): 99.4 mm (Max)
(2)
Coat the engine oil on the threaded part of the bolts and on the
gasket.
(3)
Tighten the bolts in the tightening order to the specified torque
with SST (MB991654).
Tightening Moment: 78N.m
(4)
Loosen all parts thoroughly.
(5)
Tighten the bolts with the torque of 20N.m in the tightening
order.
upper site of
spring
valve oil seal
lower site of
spring
identifi cation
6EN0437
MD998772
9EN0062
bolt length
6EN0782
6EN0695
C
D
Mount of Valve Spring
(1)
The valve spring shall be mounted in such way that the spring end
with identification color faces the upper site of the valve spring.
B
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11-33
ENGINE
CYLINDER HEAD AND VALVE
paint marks
6AE0297
90
90
9EN0064
contatc position
(the center of slope)
edge thickness
6EN0542
(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.
Notice:
If the screwing angle of the bolt is less than 90, correct
tightening moment cannot be expected. Therefore, sufficient
importance should be attached to whether the screwing
angle is correct when tightening the bolts.
In case the bolts are over tightened, they should be
loosened thoroughly and then re-tighten them from Step (1).
Inspection on Cylinder head
(1)
Inspect the Planeness of the surface of cylinder head with ruler
and feeler.
Standard value: 0.03mm
Limit value: 0.2mm
(2)
The deformation should be corrected by grinding in case it
exceeds the limit value.
Grinding limit value: * 0.2mm
Total grinding amount of the cylinder head with the
cylinder block together.
Height of cylinder head (standard value for the new): 119.9
120.1mm
Valve
(1)
Check whether work faces of valve contact correctly. If not,
polish the valve applied and regrinding it. The contact face of
valve seat should be in consistency with the center of work face
of the valve.
(2)
In case the edge thickness exceeds the limit value, change the valve.
Standard edge thickness value:
Intake value ........................... 1.0 mm
Exhaust value ........................ 1.2 mm
Application limit value:
Intake value ........................... 0.5 mm
Exhaust value ........................ 0.7 mm
(3)
Measure the total valve height, in case it is less than the limit
value, change the valve.
Standard value:
Intake value ........................... 112.30mm
Exhaust Value ........................ 114.11mm
Limit Value:
Intake value ........................... 111.80mm
Exhaust Value ........................ 113.61mm
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11-34
ENGINE
CYLINDER HEAD AND VALVE
Valve Spring
(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
(2)
Measure the perpendicularity of the center line with the surface
of the spring, if the gradient exceeds the limit, change the spring.
Standard value:
2
Limit value: 4
Valve Guide
(1)
Measure the clearance between the valve guide and the valve
stern, if the clearance exceeds the limit value, Change the valve
guide or valve or both of them.
Standard value:
Intake value ........................... 0.02
0.05mm
Exhaust value ........................ 0.03
0.07mm
Limit value:
Intake value ........................... 0.10mm
Exhaust value ........................ 0.15mm
Valve Seat
1) Assemble the valve and measure the protruding height of the
valve stern between the end of valve stern and valve spring seat.
In case the measured value exceeds the specified limit, change
the valve seat.
Standard value:
Intake value ........................... 49.30mm
Exhaust valve ........................ 49.30mm
Limit value:
Intake value ........................... 49.80mm
Exhaust value ........................ 49.80m
Main Points on Trimming of Valve Seat
(1)
Before trimming the valve seat, check the clearance between the
valve guide and the valve rod, conduct the trimming where
necessary.
(2)
Trim the width and angle of the valve seat to the specified value
with the Muller.
(3)
Grind the valve seat with the corresponding valve with grinding
paste after trimming the valve seat. Then check the protruding
height of the valve stern (refer to inspection items of valve seat).
angle belwee cerrter line of spring and plun bine
of subface
free spring height
1EN0264
valve
guide
inside diamter of
valve guide
outside diameter
of valve guide
1EN0279
endof valve stern
protruding height
of valve stern
seat face of valve
spring
DEN0212
0.9
1.3mm
43.5
44
6EN0491
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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.
(2)
Trim the valve seat holes on the cylinder head as per the outside
diameter of the enlarged valve seat.
Diameter of valve seat ring:
Enlarged dimension: 0.30
34.435-34.455
Enlarged dimension: 0.60
34.735-34.755
Enlarged dimension: 0.30
31.935-31.955
Enlarged dimension: 0.60
32.235-32.255
Diameter of valve guide hole on cylinder head:
Dimension plus 0.05:
11.05-11.068
Dimension plus 0.25:
1.25-11.268
Dimension plus 0.50:
1.50-11.518
(3)
Press the valve guide as shown in the figure until its protrusion
meets the specification.
Standard value: 14mm
0.3
Notice:
Press down the valve guide from the superface of the cylinder
head.
The length of the inlet valve guide is different from that of the
exhaust valve guide. (inlet valve: 45.5, exhaust valve: 50.5
(4)
Inset the new valve after mounting the valve guide and inspect
whether it can move smoothly.
0.5
1mm
1EN0274
0.5
1mm
cut out
height of valve
seat ring
enlarged lnside diameter
1EN0275
protrusion
1EN0106
(3)
Before assembling the valve seat ring, heat the cylinder head to
250 or so, or cool the valve seat ring in the liquid nitrogen so as
to prevent it from being seizing in the cylinder head.
(4)
Trim the valve seat to the specified width and angle with the
milling cutter of valve seat (refer to the Main Points for Trimming
of Valve Seat)
Main Points for Change of Valve Guide
(1)
Press the valve guide out toward the cylinder block with the
presser.
(2)
Process the valve guide hole of the cylinder head to make it reach
the dimension of the enlarged valve guide to be mounted.
Notice:
Do not apply the new valve guide with same dimension with the
dismantled one.
Inlet valve seat
Exhaust valve seat
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11-36
ENGINE
CYLINDER HEAD AND VALVE
10N.m
1.0Kgft
27
29
24
26
23
18
19
17
24N.m
2.4Kgifm
22
16
15
14
13
12
11
44N.m
4.5Kgfm
7
8
2
3
6
25
23N.m
2.4Kgfm
36N.m
3.7Kgfm
5
9
39N.m
4.0Kgfm
7N.m
0.7Kgfm
4
19N.m
1.9Kgfm
20
16N.m
1.7Kgfm
10N.m
1.0Kgfm
28
10
N
N
N
N
N
N
21
N
N
N
N
N
N
All inside parts should be
coated with the engine oil
19N.m
1.9Kgifm
Disassembly Process
1. lubricating oil filter
2. drain plug
3. drain plug washer
4. oil sump
5. oil collector and filter
6. washer of oil collector and filter
7. plug
8. o-ring
9. flange bolt
10. oil pressure switch
11. relieve pug
12. gasket
13. pressure relief spring
14. pressure relief plunger
15. oil filter bracket
16. washer of oil filter bracket
17. lubricating pump cover
18. driven gear of lubricating pump
19. driving gear of lubricating pump
20. front oil seal of crankshaft
21. oil seal of lubricating pump
22. oil seal of balancing shaft
23. front cover
24. front cover washer
25. left balancing shaft
26. right balancing shaft
27. front bearing of right balancing shaft
28. left balancing shaft bearing
29. rear bearing of right balancing shaft
N
M
L
A
K
B
I
G
H
H
F
D
E
J
C
C
D
B
E
A
E
FRONT COVER, OIL PUMP, BALANCE SHAFT ,OIL PAN
DISMANTLE AND ASSEMBLY
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11-37
Main Points of Disassembly
Disassembly of Oil Sump
(1)
Disassemble all of the bolts of oil sump.
(2)
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.
Disassembly of Plug
(1)
In case the plug is over tight, tap it lightly with hand hammer
for two or three times, and it will become loose.
Disassembly of Flange Bolt
(1)
Tear down the plug from the side of cylinder block.
(2)
Insert the screwdriver (with pole diameter of 8mm) in the plug
hole to fasten the balancing shaft.
A
B
C
MD998727
6EN0698
MD998162
6EN0909
6EN1026
screwdrive
plug
ENGINE
CYLINDER HEAD AND VALVE
6EN0565
3EN0207
front bearing
MD998372
D
(3)
Loosen the flange bolts
Disassembly of Front bearing of Right Balancing
shaft
(1)
Dismantle the front bearing of the right balancing shaft from
the cylinder block with the SST.
Remark: The front bearing must be dismantled first, otherwise, the
puller for rear bearing cannot be applied.
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11-38
ENGINE
CYLINDER HEAD AND VALVE
MB991603
MB998372
6EN0207
MD998705
6EN1034
A
MB991603
MD998705
MB991603
MD998705
rear bearing
6EN0557
B
Disassembly of Rear Bearing of Balancing Shaft
(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.
Main Points in Assembly
Mount of Rear Bearing of Right Balancing Shaft
(1)
Coat the engine oil at the outside of the bearing.
(2)
Mount the right rear bearing with SST. The oil hole of the
bearing should be confirmed in alignment with that on the
cylinder block.
Mount of Rear Bearing of Left Balancing Shaft
(1)
Mount the SST (guide plate) on the cylinder block.
(2)
Coat the engine oil at the outer circumference of rear bearing
and the inside of the bearing hole of the cylinder block.
(3)
Mount the rear bearing with SST.
Remark:
There is no engine oil in the left rear bearing hole.
E
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11-39
ENGINE
CYLINDER HEAD AND VALVE
MD998705
MD998705
cylinderblock
bearing
6EN1035
MD998285
6EN0746
C
D
Mount of Front Bearing of Balancing Shaft
(1)
Mount the front bearing with SST.
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.
MD998285
socket wrench
front cover
oil seal
E
(2)
Mount on the front cover assembly with a new front gasket,
and tighten the flange bolts temporarily (excluding the bolts of
oil filter that must be tightened).
Mount of Oil Seal of Balancing Shaft
(1)
Press the oil seal into the front cover with the socket wrench.
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11-40
socket wrench
front cover
oil seal
ENGINE
CYLINDER HEAD AND VALVE
socket
front cover
oil seal
Matching
marks
6LU0015
Mount of Oil Seal of Lubricating Pump
(1)
Press the oil seal into the front cover with the socket wrench.
Mount of Front Oil Seal of Crankshaft
(1)
Mount the front oil seal of crankshaft on the front cover with
SST.
Mount of Driven/Driving Gear of Oil Pump
(1)
Coat the engine oil on the surface of the gear and align the
matching marks
F
G
H
9EN0094
6EN0564
I
J
Coat Sealant on Oil Pressure Switch
(1)
Coat the sealant on the threaded part of the oil pressure switch
and mount the switch with SST.
Specified Sealant: 3M ATD Par No. 8660 or corresponding
substitute
Notice:
Keep the end of the threaded part clean and do not coat
it with sealant.
Do not over tighten the bolts.
Mount of Flange Bolt
(1)
Insert the cross screwdriver in the hole at left side of cylinder
block to lock the balancing shaft.
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11-41
ENGINE
CYLINDER HEAD AND VALVE
6EN0565
6EN0909
MD998783
MD998162
K
(2)
Tighten the flange bolt with specified torque and ensure the
driven gear of oil pump is fastened on the left balancing shaft.
Mount of Plug
(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.
bolt hole
groove
6EN0213
crankshaft pulley side
8mm-long bolts
bottom view of oil sump
6EN0449
7EN0307
oil sump side
oil drain plug
washer
L
M
Mount of Oil Sump
(1)
Clean the matching face of the oil sump and the cylinder block
thoroughly.
(2)
Coat the sealant of 4 mm in diameter on the full circumference
of the oil sump flange.
Specified Sealant:
Genuine Mitsubishi brand Sealant MD970389 or the
equivalents.
Remark:
(1)
The oil sump must be mounted at the moment the sealant is
still humid (15 min or so).
(2)
The sealing part should not be stained by the humid oil within
1 hour after the mount.
(3)
Confirm the length and mounting place of the bolt.
Mount of Oil Drain Plug
(1)
Mount the oil drain plug in the direction shown in the figure.
Notice:
The mount in wrong direction will cause oil leakage.
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11-42
ENGINE
CYLINDER HEAD AND VALVE
bracket side
6EN0591
DEN0711
6LU0013
Inspection
Front Cover
(1)
Check whether the oil hole is blocked, and clean it where
necessary.
(2)
Inspect whether there is abrasion, damage or sintering at the
front bearing of left balancing shaft, if any, change the front
cover.
(3)
Check whether the front cover has crack or other damages, if
it has, change the front cover assembly.
Oil Seal
(1)
Check whether the lip of oil seal has abrasion or damage.
Change the oil seal if necessary.
(2)
Check whether the lip of oil seal has deterioration. Change the
oil seal where necessary.
Balancing Shaft
(1)
Check whether the oil hole is blocked.
(2)
Inspect whether the journal has sintering or damage, or
whether it interferences with the bearing. Change the balanc-
ing shaft, bearing or the front cover assembly in case any
defect is found.
Lubricating Oil Pump
(1)
Mount the gear of oil pump on the front cover, and then rotate
the gear to check whether it can runs smoothly and fixedly.
(2)
Ensure the contact face of the front cover and the gear flanks
of oil pump cover has no lophodont abrasion.
(3)
Check the side clearance.
Standard value:
Driving gear: 0.08-0.14mm
Driven gear: 0.06-0.12mm
Piston and Connecting Rod
Mount of Oil Filter
(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)
N
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11-43
ENGINE
CYLINDER HEAD AND VALVE
DISASSEMBLY AND ASSEMBLY
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. first air ring
7. second air ring
8. oil ring
9. piston pin
10. piston
11. connecting rod
12. connecting rod bolt
All inside parts must be
coated with engine oil
6EN0526
G
F
A
E
D
E
C
C
B
A
B
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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
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.
marked on.
Disassembly of Piston Pin
(1)
Insert the SST of compression bar from the side with arrow
mark at the piston top, then mount the guide block C at the end
of compression bar.
(2)
Keep the mark for forward face of the piston to face upwardly,
and mount the piston and connecting rod cluster on the base
seat (SST) of the assembler of piston pin.
(3)
Press the piston pin out with the pressure.
Notice:
Put aside the dismantled piston, piston pin and connecting
rod as per the cylinder No. marked on.
A
B
cylinder No.
DEN0050
Assembler for Piston Pin MD998780
pressing rod guide block B
conduit A=17.9mm
conduit A=18.9mm
conduit A=20.9mm
conduit A=21.9mm
guide block C
base seat
pressing rod
mark for forward
face
guide block C
base seat
mark for
f o r w a r d
face
7EN0390
7EN0431
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