Great Wall. 4G64S4N Gasoline Engine. Service Manual - part 2

11-13

NOTES FOR DISASSEMBLY

DISASSEMBLY OF TIMING TOOTHED-BELT

(1)

Record the rotation direction of toothed-belt for correct re-

mounting.

Notes:

 Adhering of water or grease to the toothed-belt will sharply

shorten its service life. So, after disassembly, try your best to

avoid the toothed-belt, toothed-belt wheel and tensioner from

being contaminated and adhered by water or grease. No need to

clean these parts. Replace it if it is seriously contaminated.

 In case water or grease is found on these parts, check the front cover

oil-seal, camshaft oil-seal and water pump if there exist leakage.

DISASSEMBLY OF OIL PUMP TOOTHED-BELT

WHEEL

(1)

Assemble the cock on the cylinder block.

(2)

Insert a cross point screwdriver of 8mm diameter to  fasten

the balancing shaft on the left side.

(3)

Disassemble oil pump toothed-belt wheel nut.

(4)

Disassemble oil pump toothed-belt wheel.

DISASSEMBLY OF CRANKSHAFT BOLT

(1)

Fasten the flywheel with special tools.

(2)

NOTES FOR DISASSEMBLY

DISASSEMBLY OF TIMING TOOTHED-BELT

DISASSEMBLY OF CRANKSHAFT TOOTHED-BELT

WHEEL

(1)

In case difficult to disassemble due to adhesion, use special

tools.

DISASSEMBLY OF TIMING TOOTHED-BELT

WHEEL B

(1)

Record the rotation direction of toothed-belt for correct re-

mounting.

Notes:

 Adhering of water or grease to the toothed-belt will sharply

shorten its service life. So, after disassembly, try your best to

avoid the toothed-belt, toothed-belt wheel and tensioner from

being contaminated and adhered by water or grease. No need to

clean these parts. Replace it if it is seriously contaminated.

D

C

A

B

6EN0662

6EN0663

6EN0634

MD998781

MD998778

6EN0642

DEN0601

ENGINE

 TIMING TOOTHED-BELT WHEEL

E

11-14

8EN0066

ENGINE

 TIMING TOOTHED-BELT WHEEL

MD998785

6EN0636

MD998778

6EN0637

MD990767

MD998719

6EN0668

 In case water or grease is found on these parts, check the front

cover oil-seal, camshaft oil-seal and water pump to see if there

exist leakage.

DISASSEMBLY OF BALANCING SHAFT TOOTHED-

BELT WHEEL

(1)

Fasten balancing shaft toothed-belt wheel with the tools as

shown in the figure.

(2)

Disassemble the balancing shaft toothed-belt wheel.

DISASSEMBLY OF CRANKSHAFT TOOTHED-BELT

WHEEL B

(1)

In case difficult to disassemble due to adhesion, use special

tools.

DISASSEMBLY OF CAMSHAFT TOOTHED-BELT

WHEEL BOLT

(1)

Fasten camshaft timing toothed-belt wheel with special tools.

(2)

Disassemble camshaft toothed-belt wheel bolt.

F

G

H

CHECK

TIMING TOOTHED-BELT WHEEL

Carefully check each part of the toothed-belt and replace a new

toothed-belt in case of the following damages:

(1)

The back rubber is aged and glistened, no trail left after scraping

with a finger nail, and no elasticity;

11-15

ENGINE

 TIMING TOOTHED-BELT WHEEL

(2)

There are cracks on the surface of back rubber;

(3)

There are cracks and peel-off on the surface of canvas

(4)

There are cracks at the bottom of the tooth

(5)

There are cracks on the side face of toothed-belt

(6)

The side face of toothed-belt is abnormally abraded. The normal

situation is the side face is as level as being cut with a sharp knife

(7)

Abnormal abrasion on the tooth surface.

(8)

Teeth broken off.

AUTOMATIC TENSIONER

(1)

Check automatic tensioner to see if there is leakage and replace

with a new one if necessary.

(2)

Check if there is abrasion or damages on the rod end and replace

with a new one if necessary.

cracks

canvas peel-off

side cracks

crack at bottom of tooth

1EN0249

belt margin roueded

abnormal abrasion (heat yarn of belt emposed)

8EN0067

canvas abrased ,rubber exposed

belt teeth broken off

8EN0068

6EN0280

11-16

ENGINE

 TIMING TOOTHED-BELT WHEEL

12mm

6EN0161

98~196N

rod

displacement

6EN1033

brass or aluminum vice jaw

cock

tieplate

brass or aluminum vice jaw

6EN1030

MD990767

6EN0669

MD998719

spacer

oil seal

chamfer

balancing

shafe

BEN0615

(3)

The overhang length of measuring rod. Replace if not conform

to standard.

Standard value

12mm

(4)

Measure the amount of displacement while pressing down the

rod with a force of 98~196N.

(5)

Replace the automatic tensioner if the displacement of rod is at

least 1mm lesser than the value as measured in item (3).

Standard value

 1mm

(6)

Clamp automatic tensioner with a soft jaw plier.

Notes:

Because there is screw-plug outshot at the bottom of automatic

tensioner, a flat bearing plate should be inserted between the

plier and the screw-plug to avoid them from direct contacting.

(7)

Rotate handle of plier to thrust in the rod of automatic tensioner.

Replace automatic tensioner if it can be easily thrusted in.

Certain resistance should be apperceived while thrusting in.

NOTES FOR MOUNTING

TIGHTENING OF CAMSHAFT TOOTHED-BELT

WHEEL BOLT

(1)

Fixup camshaft toothed-belt wheel with special tools.

(2)

Tighten the camshaft toothed-belt wheel bolt to the specified

torque.

MOUNTING OF SPACER

(1)

While mounting the spacer, the side with chamfer should be

towards oil-seal.

A

B

11-17

ENGINE

 TIMING TOOTHED-BELT WHEEL

TOOTHED-BELT WHEEL

(1)

Fixup balancing shaft toothed-belt wheel with the tools as

shown in the figure.

(2)

Tighten the bolt to the specified torque.

MOUNTING OF TIMING TOOTHED-BELT B

(1)

Align the marks of crankshaft toothed-belt wheel B and

balancing toothed-belt wheel separately.

(2)

Mount timing toothed-belt onto the crankshaft toothed-belt

wheel B and balancing shaft toothed-belt wheel. The

tensioning side should remain tightened.

(3)

Ensure that the centers of tensioner wheel and the bolt are as

shown in the figure.

(4)

While applying force to the tensioner side of timing toothed-

belt with your finger, move tensioner B in the direction of the

arrow. At this moment, screw up the bolt to fixup tensioner

B. Don

t let the shaft rotate together with toothed-belt

wheel thus while screwing up the bolt, otherwise the toothed-

belt will be too tight.

(5)

Confirm to align the mark on the toothed-belt with the mark

on the front cover

(6)

Press down the central part of the tensioner side of timing

toothed-belt B with your forefinger. The toothed-belt is to be

pressed down by 5~7mm.

D

C

MD998785

6EN0636

timing

mark

front cover

timing mark

DEN0602

6EN0571

tensioner B

tensioner

center

bolt center

6EN0572

timing

mark

displacement being

pressed down

6EN0573

timing

mark

11-18

ENGINE

 TIMING TOOTHED-BELT

E

F

G

MD998781

6EN0634

6EN0564

6AE0049

6AE0050

6EN0350

TIGHTENING OF CRANKSHAFT BOLT

(1)

Fixup flywheel with special tools;

(2)

Mount crankshaft bolt.

MOUNTING OF OIL PUMP TOOTHED-BELT

WHEEL

(1)

Insert cross point screwdriver into the plug hole on the left

side of cylinder block to prevent balancing shaft from rotating.

(2)

Mount oil pump toothed-belt wheel.

(3)

Smear engine oil on the coupling face of nut and bearing.

(4)

Screw up the nut according to the specified torque.

 MOUNTING OF AUTOMATIC TENSIONER

(1)

If the rod of automatic tensioner is extruded, the following

procedures should be taken to retract it.

(2)

Clamp automatic tensioner with a soft jaw plier.

Notes:

 Because there is screw-plug outshot at the bottom of auto-

matic tensioner, a flat bearing plate should be inserted

between the plier and the screw-plug to avoid them from

direct contacting.

(3)

Use a plier to push it in slowly until hole 

 on the rod and

hole 

 on the oil cylinder is aligned.

(4)

Insert steel wire (diameter is 1.4mm) into the aligned holes.

(5)

Disassemble the automatic tensioner with a plier.

(6)

Mount the automatic tensioner onto the front cover, then

screw up the bolt according to the specified torque.

Notes:

 Left the steel wire inside the automatic tensioner.

A

B

11-19

ENGINE

 TIMING TOOTHED-BELT

MOUNTING OF TIMING TOOTHED-BELT

(1)

Confirm the timing toothed-belt tensioner is properly mounted.

(2)

Align the timing mark on the camshaft toothed-belt wheel with

the mark on the cylinder head.

(3)

Align the timing mark on the crankshaft toothed-belt wheel with

the mark on the front cover.

(4)

Align the timing mark on the oil pump toothed-belt wheel with

its accordant mark.

(5)

Disassemble plug from cylinder block, then insert cross point

screwdriver (diameter: 8mm) into the hole. Going over 60mm

inwards means the timing mark is aligned; incase of failure to go

more than 20~25 inwards, you should turn the oil pump toothed-

belt wheel 180

(6)

Connect timing toothed-belt to crankshaft pulley, central pulley,

camshaft toothed-belt wheel and tensioner pulley in turn.

(7)

Uplift the tensioner pulley in the arrow direction, then screw

down the central bolt.

H

timing mark

6EN0673

timing mark

timing mark on oil pump gear

6EN0671

6EN0672

6EN0663

6EN0748

tensionere pulley

11-20

ENGINE

 TIMING TOOTHED-BELT

(8)

Verify that all timing marks are in a line.

(9)

Remove the screwdriver inserted at step (5) and mount the plug.

(10) Turn camshaft 1/4 circle counter-clockwise, then turn it clock-

wise until all timing marks come into line again.

(11) Assemble the special tools socket wrench and torque wrench

onto the tensioner pulley, then screw down the central bolt of

tensioner pulley.

Notes:

If special tools are unavailable, an ordinary torque wrench

capable of measuring the torque of 0~0.3 kg may be used.

(12) Use the torque wrench to screw down to a torque of 0.26~0.27

kg.m.

(13) While holding the tensioner pulley with special tools and torque

wrench, screw down the central bolt till the standard value is

reached.

(14) Place the crankshaft for about 15 minutes after turning it 2

circles clock-wise. Then check if the fixing steel wire of auto-

matic tensioner can glide freely.

Notes:

In case the steel wire can not glide freely, repeat the above

steps before step (10) till the steel wire can glide.

(15) Take off the fixing steel wire of the automatic tensioner.

(16) Measure the distance 

A
 (between tensioner arm and auto-

matic tensioner body).

Standard value

3.8 
 4.5mm

MD998767

MD990685

6EN0749

6EN0750

fixing sttel wire

6EN0751

11-21

FUEL SYSTEM

DISASSEMBLY AND MOUNTING

Disassembly Procedure

1.

water pipe

2.

water pipe

3.

throttle body

4.

cushion

5.

cover

6.

cushion

7.

fuel cistribution pipe assembly

20N.m

5

6

4

12N.m

ENGINE

 FUEL OIL SYSTEM

Notes for Mounting

Mounting of Fuel Distribution Assembly

Before mounting fuel distribution assembly, carefully

lubricate the matching face of the manifold or the O-

ring with mineral lubricating oil, align the center lines

of the injector and the mounting hole, then insert the

intake manifold. Finally, screw down the bolt accord-

ing to the specified tightening torque.

(1)

Mineral lubricating oil: ISO 10 (10 cSt at 40

)

(2)

Prevent lubricant from entering into the injector

while using lubricant.

A

7

2

1

3

19N.m

11-22

ENGINE

 INTAKE MANIFOLD

INTAKE MANIFOLD

DISASSEMBLY AND MOUNTING

NOTES FOR MOUNTING

APPLICATION OF SEALANT FOR ENGINE WATER

TEMPERATURE SENSOR

Sealant Specification:

3M Nut locking parts No.4171 or the equivalent.

APPLICATION OF SEALANT FOR WATER OUTLET

Sealant Specification:

Genuine MITSUBISHI brand parts No.MD970389 or the

equivalent.

19N.m

19N.m

20N.m

1

20N.m

3

4

13N.m

13N.m

30N.m

2

A

B

sealant(diameter:3mm)

6

N

1. engine Link Ring

2.  engine Water Temperature Sensor

3. water Outlet

4.  intake Manifold Bracket

5. intake manifold

6.  intake Manifold Gasket

Disassembly Procedure

A

B

11-23

ENGINE

 EXHAUST MANIFOLD & WATER PUMP

EXHAUST MANIFOLD, WATER PUMP

DISASSEMBLY AND MOUNTING

Disassembly Procedure

1.

oil level gauge

2.

oil level gauge tube

3.

o-ring

4.

heat shield

5.

engine link ring

6.

oxygen sensor

7.

exhaust manifold

8.

exhaust manifold gasket

9.

water inlet

10. thermostat

11. water temperature sensing plug

12. bypass water pipe fitting

13. water pipe assembly

14. water pipe O-ring

15. thermostat casing

16. water inlet

17. o-ring

18. water pump

19. water pump gasket

B

A

A

A

A

6

45N.m

4

14N.m

29N.m

8

5

49N.m

1

13N.m

2

24N.m

7

3

16

16

9

10

24N.m

15

13N.m

24N.m

14N.m

18

19

13

14

11

12

11N.m

N

N

N

N

N

N

N

N

13

N

11-24

ENGINE

 EXHAUST MANIFOLD & WATER PUMP

o-ring

squeeze out sealant of

3mm diameter

6EN0996

6EN0594

NOTES FOR MOUNTING

MOUNTING OF O RING SEAL

(1) Wet O ring seal with water in order to assemble.

Notes:

There shouldn

t be any oil or lubricating grease on the surface

of O

ring seal.

M O U N T I N G   O F   B Y P A S S   W A T E R P I P E

CONNECTOR

Sealant Specification:

Genuine MITSUBISHI brand parts No.MD970389 or the equivalent.

Notes:

(1)  Swiftly mount bypass water pipe connector while sealant is still

wet (within 15 minutes).

(2) May not add oil on the sealing part within 1 hour or so after

mounting.

A

B

11-25

ROCKER ARM AND CAMSHAFT

DISASSEMBLY AND MOUNTING

1.

air hose

2.

PCV hose

3.

pressure control valve

4.

pressure control valve gasket

5.

oil filler cap

6.

rocker arm cover

7.

rocker arm cover gasket

8.

oil seal

9.

rocker arm and rocker shaft

10. rocker arm and rocker shaft

11. rocker shaft spring

12. A rocker arm A

13. B rocker arm B

14. rocker shaft (air intake side)

15. hydraulic lifter

16. rocker arm C

17. rocker shaft (air exhaust side)

18. hydraulic lifter

19. oil seal

20. thrust cover

21. o-ring

22. camshaft

1

5

3

4

6

7

8

3.9N.m

31N.m

17

16

16

16

16

18

11

11

11

11

15

12

13

12

13

12

13

12

13

14

9

22

21

20

18N.m

19

N

N

N

Smear engine oil on all moving
parts while mounting

6EN1762

10

ENGINE

 ROCKER ARM AND CAMSHAFT

C

A

C

A

C

C

C

C

11-26

ENGINE

 ROCKER ARM AND CAMSHAFT

MD998448

6AE0160

9EN0058

roller end

7EN0064

outside claean

inside clean

fill didsel oil

A

B

C

6EN1698

diesel oil

6EN1699

NOTES FOR DISASSEMBLY

(1)

Before disassemble the rocker arm and rocker shaft

assembly, use the tools as shown in the figure to

prevent hydraulic lifter from falling.

CHECK

CAMSHAFT

(1)

Measure the height of camshaft

Standard value and operating limit are as follows:

Air intake

4G64-D-L3

37.39

36.89

Air exhaust

4G64-D-L3

36.83

36.33

ROCKER ARM

(1)

Check the roller surface, in case of existence of any trace

indicates there are damages or blockades, the rocker arm should

be replaced.

(2)

Check if the roller can rotate smoothly. If not or slacked, the

rocker arm should be replaced.

(3)

Check the inside diameter. In case of damages or blockages, the

rocker arm should be replaced.

HYDRAULIC LIFTER

NOTES:

1. Hydraulic lifter is a precise part. There shouldn

t be any

dust and foreign body, etc.

2. Do not disassemble the hydraulic lifter.

3. Clean the hydraulic lifter with clean diesel oil.

(1)

Prepare 3 vessels and about 5 litres of diesel oil. Pour enough

diesel oil into each vessel until the erect hydraulic lifter is

submerged, then take the following steps to operate the hydrau-

lic lifter:

(2)

Put the hydraulic lifter into vessel A to clean its external surface.

NOTES:

Use a nylon brush to remove hard attachments.

Type

Standard value

Limit value

A

11-27

ENGINE

 ROCKER ARM AND CAMSHAFT

MD998442

MD998441

diesel oil

6EN1700

MD998441

MD998442

diesel oil

6EN1701

MD998441

MD998442

6EN1700

MD998441

6EN1701

diesel oil

(3)

Mount the special tool MD998441 onto the hydraulic lifter.

(4)

Use the special tool MD998442 to lightly expel the steel ball

inside the lifter and make it move 5-10 strokes until it can move

smoothly. Additionally, it can also eliminate resistance of the

plunger. Such operation can remove dirty oil.

NOTES:

Since the steel ball spring is extremely soft, so do not overexert

while impelling steel ball with air leak wire  lest the hydraulic

lifter is damaged.

If the plunger can

t move smoothly or mechanical devices

seem abnormal, replace the hydraulic lifter.

(5)

Take the hydraulic lifter out of the vessel, then lightly expel the

steel ball and move the plunger, remove diesel oil away from

pressure chamber.

(6)

Mount the special tool MD998441 onto the hydraulic lifter.

(7)

Put the hydraulic lifter into vessel B, then use the special tool

MD998442 to lightly expel the steel ball inside the lifter and

make it move 5-10 strokes until it can move smoothly. Such

operation can clean the pressure chamber of hydraulic lifter.

NOTES:

Since the steel ball spring is extremely soft, so do not overexert

while impelling steel ball with air leak wire  lest the hydraulic

lifter is damaged.

(8)

Take the hydraulic lifter out of the vessel, then lightly expel the

steel ball and move the plunger, remove oil away from pressure

chamber.

11-28

ENGINE

 ROCKER ARM AND CAMSHAFT

(9)

Put the hydraulic lifter into vessel C, then use the special tool

MD998442 to lightly expel the steel ball inside the lifter.

NOTES:

Don

t clean the hydraulic lifter in vessel C. Otherwise foreign

body may enter the pressure chamber which is full of oil.

(10) Stick the hydraulic lifter up straight with its plunger  at the top,

stably move the plunger downwards to its maximum stroke, then

pull it back slowly, and then release the steel ball to make the

pressure chamber full of diesel oil.

(11) Remove the special tool MD998441.

(12) 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 (9) to (12) and

fully fill the hydraulic lifter with diesel oil. If it still becomes

shorter after repetition of these steps, replace the hydraulic lifter.

(13) Mount the hydraulic lifter onto the special tool.

(14) After the plunger sink down (0.2~0.5mm), measure the time

taken for the plunger to sink down another 1mm.

Standard value: 3

20 sec./1mm ( use the diesel oil with a

temperature of 15

20
)

Notes:

If the measured value doesn't conform to the standard, replace the

hydraulic lifter.

(15) Mount the special tool MD998441 onto the hydraulic lifter.

(16) Put the hydraulic lifter into vessel C again, then lightly impel the

steel ball inside the lifter downwards with special tool MD998442.

(17) Stick the hydraulic lifter up straight with its plunger  at the top,

stably move the plunger downwards to its maximum stroke, then

pull it back slowly, and then release the steel ball to make the

pressure chamber full of diesel oil.

(18) Remove the special tool MD998441.

MD998442

6EN1702

MD998441

MD998442

MD998441

6EN1703

6EN1704

6EN1705

MD998440

scale=1mm

MD998442

MD998441

6EN1706

hydraulic

tappet