Chery A series. Manual - part 14

PISTON AND CONNECTING ROD ASSEMBLY 

PISTON REMOVAL, MEASURE AND INSTALLATION 

 

Removal 

 
Rotate the crank shaft to the bottom dead 
center (BDC) of the removed cylinder, check 
whether there is a cylinder number on the 
connecting rod body and cap, which shall be 
on the left of the rod (seeing from the front). 
If there is no such a number, number each 
cylinder before removal. 

 

 

 

Remove the connecting rod bolts to dismantle 
the connecting rod cap, take the 
connecting-rod bearing shell out and label the 
cylinder number and bottom and top shell on 
the back of the shell. 

 

 

 

 

Push the connecting rod and piston out from 
the cylinder block with a wooden club and 
take the cylinder rod out.   

Remove the piston ring with a special tool or 
the leaf of a clearance gauge and label each 
cylinder and bottom and top leaf. 

 

 

 

 

 

 

Press the piston pin out of the piston and the 
small end of the connecting rod with a press 
machine and put the piston, piston ring and 
pin of each cylinder together. 

 

 

 

 

 

 

 

 

 

B-33

Rinsing and inspection 

 
Rinse and clean the carbon deposit on the 
piston, piston ring and pin.   

Rinse and clean the carbon deposit on the 
bottom of the cylinder bore. 

Measure the diameter of the cylinder bore. 

 

 

 

 

 

 

480 M cylinder bore (unit: mm)

480 E cylinder bore (unit: mm)

1 79.94-79.95

1

79.94-79.95

2 79.95-79.96

2

79.95-79.96

3 79.96-79.97

3

79.96-79.97

Ex-factory 

grouping 

4 79.97-79.98

4

79.97-79.98

A 80.23-80.24

A

80.23-80.24

B 80.24-80.25

B

80.24-80.25

Ex-factory 

repair 

C 80.25-80.26 C 80.25-80.26 

Standard 79.965-77.975 Standard 79.965-77.975 

Oversized by 0.29 

80.245-80.255 

Oversized by 0.29 

80.245-80.255 

For 

Maintenance 

Oversized by 0.5 

80.466-80.475 

Oversized by 0.5 

80.466-80.475 

 

 

Grind the cylinder bore according to the size for 
maintenance with the grinding angle to be 50°
~60°. 

 

 

 

 

 

 

 

 

 

 

Measure the piston from the point that is 19mm 
away from the bottom of the skirt. 

 

 

 

 

 

 

 

 

B-34

 

Diameter of 480M piston skirt 

(unit: mm) 

Diameter of 480E 

piston skirt (unit: mm) 

Diameter of UAES’s 

new two-valve piston 

skirt (unit: mm) 

1 79.91-79.92

79.915-79.925

79.915-79.925

2 79.92-79.93

79.925-79.935

79.925-79.935

3 79.93-79.94

79.935-79.94

79.935-79.94

Ex-factory 

grouping 

4 79.94-79.95

79.945-79.955

79.945-79.955

A 80.20-80.21

80.205-80.215

80.205-80.215

B 80.21-80.22

80.215-80.225

80.215-80.225

Ex-factory 

repair 

C 80.22-80.23 

80.225-80.235 

80.225-80.235 

Standard 79.93-79.955

79.965-79.975

 

Oversized by 0.29 

80.21-80.235 

80.245-80.255 

 

Spare 

parts 

Oversized by 0.5 

80.43-80.455 

80.465-80.475 

80.435-80.455 

 

Measure the diameter of piston pin bore 
 

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

 

Measure the diameter of the piston pin 

 

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 

 

Measure the end clearance of the piston 
ring 
First compression ring: 0.30-0.50mm 

Second compression ring: 0.30-0.50mm 

Oil ring: 0.40-1.40mm 

 

 

 

 

 

 

 

 

 

 

 

 

B-35

Measure the axial clearance of piston ring in the piston groove 

 

 

Height of the piston 

ring (unit: mm) 

Size of piston ring 
groove (unit: mm)

Fit clearance 

(unit: mm) 

First compression ring 

1.60 1.6 

0.050-0.082 

Second compression 

ring 

2.0 2.0 

0.050-0.082 

0.61±0.025 

Sealing strip of oil ring 

Spring of oil ring 

2.68±0.05 

 

4.0 

0.01-0.23 

Cast iron oil ring 

4.0 4.0 

0.025-0.055 

 

480 UAES’s new two-valve   
 

 

Height of the piston ring 

(unit: mm) 

Size of piston ring groove 

(unit: mm) 

First compression 

ring 

1.2（-0.03～-0.01） 1.2（0.03～0.05） 

Second 

compression ring 

1.5（-0.03～-0.01） 1.5（0.02～0.04） 

0.46±0.02 

Sealing strip of 

oil ring 

Spring of oil ring 

2.75±0.05 

2.0±0.02 

3（0.01～0.03） 

 

Measure the small-end bore diameter of the 
connecting rodΦ20.589 

Check whether the big-end injection hole of the
connecting rod is blocked, with the outlet
diameter to be  Φ1mm. 

 

 
 

 

 

 

 

 

 

 

+0.06
+0.04

+0.06
+0.04

+0.03
+0.01

+0.03
+0.01

-0.015 
-0.025

0 
-0.012

0 
-0 012

B-36