Chery A11. Manual - part 25

CAC Gasoline Engine Maintenance And Servicing Manual

3) The removal and installation of thermostat seat with thermostat assembly

——Loosen three M6×40 bolts and remove them
——Remove thermostat seat with thermostat assembly
——Pry out spring clip by chisel or screwdriver

——Take out the thermostat

——Take out sealing gasket
——Remove sealing gasket of thermostat seat

Measure the opening temperature of thermostat in hot water.

Fig.96

Fig. 97

Fig. 98

Fig. 99

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CAC Gasoline Engine Maintenance And Servicing Manual

Assembly:

——Clip the thermostat seat, and put the rubber seal ring into the thermostat hole.
——Install the thermostat(with spring outward)
——Install spring clip, ensure that the clip is clipped in the thermostat seat groove.
——Install the sealing gasket of the new thermostat seat on the thermostat assembly with a bolt.
——Install the thermostat together with thermostat assembly into the rear end hole of cylinder head. Finger

screw in 3 bolts and tighten to 9-12Nm.

——Tighten the hex head plug with the sealing gasket on . tightening torque is 38-42Nm.
——For the engine equipped with electrical heater ,install air intake preheating switch .tightening torque is

38-42Nm.

3. removal and assembly of the water temperature sensor.
Removal:
——Remove the water temperature sensor(at the exhaust side , under the rear lug).

Assembly:

——Before installation, apply the lotite sealant 243 onto the bolt threads .finger screw in and tighten to

7.0-10.0Nm .

【15】: The intake and exhaust system of the engine.
1.  Description for the intake and exhaust system of carburetor engine.
The intake system of Carburetor Engine 478 and 480 includes: air filter, Intake hose, Guide cover, Carburetor,
Intake hose, Intake air preheating hose of Positive Crankcase Ventilation（PCV）, and so on.
——air filter type is 1GD129607G, and its basic parameters are as the following:
Filtering area: 100cm2              nominal air flow(L): 600±150
filtering efficiency:  ≥99%        filtering resistance: 2kPa

thermostat

Sealing gasket

Overflow pipe

Drainage pipe

Sealing gasket

Small recircula-

ting pipe

Plug screw

Spring clip

Sealing gasket

Tighten torque

Fig.100

Temperature seat assembly

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CAC Gasoline Engine Maintenance And Servicing Manual

The exhaust system of the carburetor engine 478 and 480 includes Exhaust Manifold, Heat Insulation
Cover, Exhaust Hose, Front Muffler, Rear Muffler.

2. Description for the Exhaust System of Engine 2.480M:

The Intake System of Engine 480M includes: air filter, Intake Hose, Guide Cover, Throttle Valve, Intake
Manifold, Intake air preheating hose of Positive Crankcase Ventilation（PCV）and so on.
——Air filter type is 1GD 129 607G, and its basic parameters are as follows:

Filtering area: 100cm2 nominal air flow(L): 600±150
filtering efficiency: ≥99% filtering resistance: 2kPa

Fig. 101 intake and exhaust system arrangement of carburetor engine

Intake hose

guide cover

carburetor

Air filter

Intake preheat hose

exhaust manifold

intake manifold

Exhaust hose

engine

front sound absorber back sound absorber

Fig.102 intake and exhaust system schematic drawing of engine 480M

3 way catalyst

front sound absorber back sound absorber

flexible hose

Oxygen sensor

Exhaust hose

engine

Intake hose

Air filter

guide cover

throttle valve

Intake preheat hose

insulating
cover

cylinder

cap cover

intake manifold

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CAC Gasoline Engine Maintenance And Servicing Manual

——The air filter is equipped with a intake air temperature controller. When the temperature is low, the hot air
intake valve controlled by the temperature controller will open and the hot air, flowing by the exhaust manifold,
will be directed into the air filter from the intake preheating hose to supply more hot air and facilitate the fuel
atomization during cold winter. As temperature is high , valve is shutted off and the hot air is not permitted to
enter the air filter.
——See “CAC480M Engine’s single port injection system” to know about the throttle valve.
The exhaust system of Engine 480M includes Exhaust Manifold, Heat Insulation Cover, Exhaust Hose,
Oxygen Sensor, Flexible Hose, Three-Way Catalyst Converter, Front Muffler, Rear Muffler.

Removal and assembly of the Intake Manifold Assembly and Front lifting Lug:

1. The Intake Manifold Assembly of the Carburetor Engine.

2. Description for the Intake Manifold Assembly of Engine 480M:

The  Intake  Manifold  Assembly  includes:  Water  Hose,  Vacuum  Fitting,  Water  Temperature  Gauge  Sensor,
and Electric Heater. The water hose fitting is connected to the water hose of the throttle valve body. The left
vacuum  fitting  is  connected  to  the  PCV  valve,  and  the  right  vacuum  fitting  is  connected  to  the  absolute
pressure  sensor.  And  the  vacuum  fitting  from  the  intake  manifold’s  branch  is  applied  on  the  entire  brake
system, the water temperature sensor is connected to ECU .

Fig 103 composing of intake manifold assembly of carburetor engine

Vacuum fitting (for brake boost) absolute pressure sensor connecting

pipe connector (connect to 3 way hose)

3/8” hexagonal cone plug screw

drainage

connector

intake manifold

Fig.104 composing of intake manifold assemble of electric injection engine

Vacuum fitting (for brake boost)

Vacuum fitting (for PCV valve)

absolute pressure sensor connecting pipe connector

Install water temperature
sensor here

intake manifold

drainage hose

connector

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