Chery A1 2009 Service Manual

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2009

CHERY

Service Manual

FOREWORD

This manual contains on-vehicle service

and diagnosis procedures for the Chery A1.

A thorough familiarization with this manual

is important for proper repair and

maintenance. It should always be kept in a

handy place for quick and easy reference.

The contents of this manual, including

drawings and specifications, are the latest

available at the time of printing. As

modifications affecting repair or

maintenance occur, relevant information

supplementary to this volume will be made

available at Chery dealers. This manual

should be kept up-to-date.

Chery Automobile Company, Ltd. reserves the

right to alter the specifications and

contents of this manual without obligation

or advance notice.

may be reproduced or used in any form or

by any means, electronic or mechanical—

including photocopying and recording and the

use of any kind of information storage and

retrieval system—without permission in

writing.

NOTE:

This A1 service manual only applies to the follow-

ing engines and transaxles:

• 1.3L with M/T

• 1.3L with AMT

Chery Automobile Company, Ltd.

Wuhu, Anhui Province, CHINA

CONTENTS

Title

GENERAL INFORMATION

ENGINE

ELECTRONIC ENGINE CONTROLS

FUEL DELIVERY

STARTING & CHARGING

COOLING

EXHAUST

TRANSAXLE

DRIVELINE & AXLE

SUSPENSION

STEERING

BRAKES

HEATING & AIR CONDITIONING

RESTRAINTS

BODY & ACCESSORIES

WIRING

ALPHABETICAL INDEX

PRINTED NOVEMBER, 2009

Section

Table of Contents

Chapters

Table of Contents

Troubleshooting

Summary of Contents for Chery A1 2009

Page 1 ELECTRONIC ENGINE CONTROLS FOREWORD This manual contains on-vehicle service FUEL DELIVERY and diagnosis procedures for the Chery A1. A thorough familiarization with this manual STARTING & CHARGING is important for proper repair and maintenance. It should always be kept in a COOLING handy place for quick and easy reference.
Page 2 Adjustments 01-7 Preparation For Vehicle Service 01-3 Rubber Parts and Rubber Tubing 01-7 Tools and Testing Equipment 01-3 Hose Clamps 01-8 Special Tools 01-3 Vise 01-8 Disconnection of the Negative Battery Dynamometer 01-8 Cable 01-4 Chery Automobile Co., Ltd. 01–...
Page 3 • Symptom troubleshooting quickly determines the location of the malfunction according to symptom type. Specifications This manual contains specifications that are divided into the following groups: • Torque specifications • Clearance specifications • Capacity specifications 01– Chery Automobile Co., Ltd.
Page 4 • Be sure that all necessary tools and measuring equipment are available before starting any work. • Inspect the vehicle and reference any needed ser- vice information before starting any work. BESM010005 Special Tools • Use special tools when they are required. BESM010006T Chery Automobile Co., Ltd. 01–...
Page 5 • Disconnecting the battery cable deletes the memo- ries of the clock, audio and DTCs, etc. Therefore, it is necessary to verify those memories before dis- connecting the cable. PZSM010001 01– Chery Automobile Co., Ltd.
Page 6 Identify parts so reassembly can be performed easily and efficiently. BESM010008 Inspection of Parts • When removed, inspect each part for malfunction- ing, deformation, damage and other problems. BESM010009 Chery Automobile Co., Ltd. 01–...
Page 7 If removed, replace these parts with new ones: − Oil seals − Gaskets − O-rings − Lock washers − Cotter pins − Nylon nuts BESM010012 01– Chery Automobile Co., Ltd.
Page 8 (such as oil seals) before reassembly. BESM010013 Adjustments • Use suitable gauges and testers when making adjustments. BESM010014 Rubber Parts and Rubber Tubing • Prevent gasoline or oil from getting on rubber parts or tubing. BESM010015 Chery Automobile Co., Ltd. 01–...
Page 9 Exhaust gases can injure or kill. They contain carbon monoxide (CO), which is colorless and odorless. Breathing it can make you unconscious and can eventually poison you. − Cool the exhaust pipes with a fan. − Keep the area around the vehicle uncluttered. − Monitor the engine coolant temperature gauge. 01– Chery Automobile Co., Ltd.
Page 10: Table Of Contents
VEHICLE INFORMATION VEHICLE IDENTIFICATION NUMBER INTERNATIONAL SYMBOLS 01-13 (VIN) International Symbols 01-13 01-10 VIN Location 01-10 FASTENER USAGE VIN Identification Codes 01-11 01-14 Fastener Usage 01-14 Chery Automobile Co., Ltd. 01–...
Page 11: Vehicle Identification Number (Vin)
Vehicle Identification Number (VIN) Tag Location PZSM010002 The VIN is printed on a plastic tag attached to the top right corner of the upper instrument panel. The VIN is also found on the vehicle certification (VC) label. 01– Chery Automobile Co., Ltd.
Page 12: Vin Identification Codes
• Digit #4 The fourth digit of the VIN code represents the brand of the vehicle: − The brand Chery is represented by the letter D . • Digit #5 The fifth digit of the VIN code represents the body configuration of the vehicle: −...
Page 13 − 5 represents the year 2005. • Digit #11 The eleventh VIN position represents the assembly plant code: − D represents the Chery Automobile Co., Ltd. • Digits #12, #13, #14, #15, #16, #17 The last six VIN positions represent the production sequence number.
Page 14: International Symbols
20 - Parking Brake 9 - Windshield Defroster 21 - Hood 10 - Blower Motor Fan 22 - Trunk 11 - Rear Window Defroster 23 - Horn 12 - Rear Window Wiper 24 - Cigarette Lighter BESM010003 Chery Automobile Co., Ltd. 01–...
Page 15: Fastener Usage
Fasteners and torque specification references in this Service Manual are identified in metric format. During any maintenance or repair procedure, it is important to salvage all fasteners (nuts, bolts, etc.) for reassembly. If the fastener is not salvageable, a fastener of equivalent specification must be used. 01– Chery Automobile Co., Ltd.
Page 16 ELECTRICAL CIRCUIT DIAGNOSIS INFORMATION Electrical Circuit Simulation Tests 01-16 DIAGNOSING ELECTRICAL Precautions For Handling Control Modules FAILURES 01-16 and Electrical Components 01-18 Performing Efficient Electrical Circuit How To Check Electrical Connectors 01-19 Diagnosis and Troubleshooting 01-16 Chery Automobile Co., Ltd. 01–...
Page 17 A visual inspection may not reveal this without disconnecting the connector. If the problem occurs intermittently, per- haps the problem is caused by corrosion. It is a good idea to disconnect, inspect and clean the terminals on related connectors in the system. 01– Chery Automobile Co., Ltd.
Page 18 On some occasions an electrical incident may occur only when the vehicle is started cold, or it may occur when the vehicle is restarted hot shortly after being turned off. In these cases you may have to keep the vehicle overnight to make a proper diagnosis. Chery Automobile Co., Ltd. 01–...
Page 19 • When using a DMM, be careful not to let the test probes touch each other causing a short circuit. Prevent the power transistor in the control module from being shorted to damaging battery voltage. • When checking input and output signals of the con- trol module, use the specified test adapter (if applicable). LTSMD030028 01– Chery Automobile Co., Ltd.
Page 20 − While holding the wire of the male terminal, attempt to insert the male terminal into the female terminal. − While moving the connector, check whether the male terminal can be easily inserted or not. NOTE : If the male terminal can be easily inserted into the female terminal, replace the female terminal. Chery Automobile Co., Ltd. 01–...
Page 21 ELECTRICAL INFORMATION HOW TO READ ELECTRICAL HOW TO LOCATE ELECTRICAL SCHEMATICS SCHEMATICS IN THE SERVICE 01-21 Connector Symbols 01-21 MANUAL 01-25 Option Splices 01-22 Electrical Schematic Index 01-25 Electrical Schematic - Example 01-23 01– Chery Automobile Co., Ltd.
Page 22: How To Read Electrical Schematics
BESMW010003T • In electrical schematics, female terminal end views are shown at the bottom of the page for all compo- nents that are shown on the schematic page. PZSMW010009T Chery Automobile Co., Ltd. 01–...
Page 23: Option Splices
HOW TO READ ELECTRICAL SCHEMATICS Option Splices BESMW010002T • Option splices are shown with solid squared boxes with identification numbers inside. 01– Chery Automobile Co., Ltd.
Page 24: Electrical Schematic - Example
HOW TO READ ELECTRICAL SCHEMATICS Electrical Schematic - Example BESMW010001T Chery Automobile Co., Ltd. 01–...
Page 25 Y = Yellow BR = Brown O = Orange GR = Gray Shielded line The line enclosed by broken line circle represents shielded wire. Light-emitting diodes As an illumination tool, in the circuit and instrument cluster. 01– Chery Automobile Co., Ltd.
Page 26: How To Locate Electrical Schematics In The Service Manual
04 - Fuel Delivery • Fuel Level Sensor and Fuel Pump • Starter Motor • Ignition Switch 05 - Starting & Charging • Clutch Pedal Switch • Generator 06 - Cooling System • Cooling Fan Chery Automobile Co., Ltd. 01–...
Page 27 • Manual Temperature Control System • Blower Motor 13 - Heating & Air Conditioning • A/C Compressor • A/C Pressure Switch • Restraints Control Module • Seatbelt Buckle Switch 14 - Restraints • Driver Airbag • Passenger Airbag 01– Chery Automobile Co., Ltd.
Page 28 Diagnostic Trouble Code Engine Control Module Engine Coolant Temperature Sensor ECT Sensor Engine Speed Evaporative Emission EVAP Evaporative Emission Canister EVAP Canister Evaporative Emission System EVAP System Front Left Wheel Speed Sensor Front Right Wheel Speed Sensor Chery Automobile Co., Ltd. 01–...
Page 29 MAP Sensor Malfunction Indicator Lamp Oil Pressure Switch Output Shaft Speed Sensor OSS Sensor Positive Crankcase Ventilation Valve PCV Valve Power Supply SRS Airbag Control System Throttle Position Sensor Vehicle Identification Number Vehicle Speed Sensor 01– Chery Automobile Co., Ltd.
Page 30: 1.3L Engine Mechanical
Removal & Installation - Right Mount 02-31 Specifications 02-63 Removal & Installation - Front Mount 02-32 Disassembly 02-63 Removal & Installation - Rear Mount 02-32 Inspection 02-64 Assembly 02-65 Engine Assembly 02-33 Removal & Installation 02-33 Chery Automobile Co., Ltd. 02–...
Page 31 Disassembly 02-73 Specifications 02-66 Inspection 02-74 Disassembly 02-66 Assembly 02-75 Inspection 02-68 Valve Springs 02-76 Assembly 02-68 Specifications 02-76 Camshaft 02-69 Disassembly 02-77 Specifications 02-69 Inspection 02-78 Disassembly 02-70 Assembly 02-78 Inspection 02-70 Assembly 02-72 02– Chery Automobile Co., Ltd.
Page 32 73 mm Fuel Designation (Not less than) Engine Oil Quantity 3.5 L Fuel Supply Mode Multi-Point Electronic Controlled Gasoline Injection Engine Oil Designation SAE 10W-40 (Grade SL or above) Displacement 1297 cc Firing Order 1-3-4-2 Chery Automobile Co., Ltd. 02–...
Page 33: General Information
Newtons Of Pressure Intake Cam Lobe Height 37.09 mm Exhaust Cam Lobe Height 37.05 mm Camshaft Journal #1 Outer 31.934 - 31.95 mm Diameter Camshaft Journal #2, #3, 23.947 - 23.96 mm #4, #5, Outer Diameter 02– Chery Automobile Co., Ltd.
Page 34: Description
2nd Step: Tighten the bolt an additional 65 ± 5° 25 ± 5 Crankshaft Vibration Damper Bolts 2nd Step: Tighten the bolt an additional 30 ± 5° Camshaft Timing Belt Pulley Bolt 120 ± 5 Cylinder Head Cover Bolts 10 ± 2 Chery Automobile Co., Ltd. 02–...
Page 35 Timing Belt Tensioner Assembly 27 ± 3 Timing Belt Tensioner Pulley Bolt 45 ± 5 Shift Cable Bracket Bolts 25 ± 5 Throttle Body Bolts 8 ± 3 Upper Idler Pulley Bolt 45 ± 5 02– Chery Automobile Co., Ltd.
Page 36 GENERAL INFORMATION Special Tools Right Engine Mount Bolt Remover CH-20001 Camshaft Seal Installer CH-20002 Crankshaft Holder CH-20003 Valve Spring Compressor Adaptor CH-20004 Rear Crankshaft Oil Seal Installer CH-20005 Chery Automobile Co., Ltd. 02–...
Page 37 GENERAL INFORMATION Rear Crankshaft Oil Seal Guide CH-20006 Front Crankshaft Seal Installer CH-20007 Front Crankshaft Seal Guide CH-20008 Flywheel Fixture CH-20009 Camshaft Holder CH-20010 02– Chery Automobile Co., Ltd.
Page 38 GENERAL INFORMATION Valve Seal Installer CH-20011 Valve Stem Seal Installer Guide CH-20012 Valve Seal Remover CH-20013 Valve Keeper Installer CH-20017 Valve Spring Compressor CH-20018 Chery Automobile Co., Ltd. 02–...
Page 39 • The engine lubrication system is a full-flow filtration, pressure feed type. The oil pump body is mounted to the engine block. The pump inner rotor is driven by the crankshaft. Engine Oil Pressure Specifications Idle Speed (950 ± 10 RPM) 2.7 Bar 02– Chery Automobile Co., Ltd.
Page 40 27 - Crankshaft Front Oil Seal 13 - Oil Filter Connector 28 - Oil Pump Bolt 14 - Oil Filter 29 - Oil Pump Assembly 15 - Dowel Pin 30 - Oil Pump Assembly Gasket PZSM020035 Chery Automobile Co., Ltd. 02–...
Page 41 5 – Turbocharger Inlet Oil Passage (if equipped) 13 – Oil Filter Bracket 6 – To Cylinder Head 14 – Oil Pressure Switch 7 – Oil Return Passage 15 – Oil Filter 8 – To Front Bearing Cap PZSM020036 02– Chery Automobile Co., Ltd.
Page 42: Diagnosis & Testing
Engine Miss On Acceleration 2. Contamination in fuel system. 3. Replace valves. 3. Burned, warped, or pitted valves. 4. Test and replace if necessary. 4. Faulty ignition coil(s). (Refer to Appropriate Diagnostic Information) Chery Automobile Co., Ltd. 02–...
Page 43: Engine Mechanical Diagnostics
Oil Pressure Drop 4. Clogged oil filter. 4. Install new oil filter. 5. Thin or diluted oil. 5. Change oil to correct viscosity. 6. Excessive bearing clearance. 6. Measure bearings for correct clearance. 02– Chery Automobile Co., Ltd.
Page 44: Cylinder Compression Pressure Test
• Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are: − Engine overheating − Loss of coolant − Excessive steam (white smoke) emitting from exhaust − Coolant foaming Chery Automobile Co., Ltd. 02–...
Page 45: On-Vehicle Service
2 - Power Steering Pump 5 - Generator Belt 3 - A/C Compressor 6 - Generator PZSM020029 WARNING! Inspect the drive belt only when the engine is stopped. 1. Loosen the power steering pump adjustment bolt (1). PZSM020005 02– Chery Automobile Co., Ltd.
Page 46 • Use a deflection gauge and adjust the drive belt tension to 95 N·m with a limit deflection of 5 mm. NOTE : Measure the drive belt deflection in the middle of the drive belt. Chery Automobile Co., Ltd. 02–...
Page 47: Air Cleaner Element
4. Installation is in the reverse order of removal. Air Cleaner Housing Removal & Installation 1. Remove the two retaining bolts (1) on the air intake pipe. (Tighten: Air intake pipe bolts to 8 ± 3 N·m) PZSM020001 02– Chery Automobile Co., Ltd.
Page 48: Cylinder Head Cover
(Tighten: Air cleaner housing bolts to 10 ± 5 N·m) PZSM020002 6. Remove the air cleaner housing. 7. Installation is in the reverse order of removal. Cylinder Head Cover Removal & Installation 1. Disconnect the negative battery cable. Chery Automobile Co., Ltd. 02–...
Page 49 5. Disconnect the manifold air pressure (MAP) sensor electrical connector. 6. Remove the MAP sensor retaining bolt (1) and remove the MAP sensor. PZSM030004 7. Remove the four spark plug wires (1) and set them aside. PZSM030016 02– Chery Automobile Co., Ltd.
Page 50 9. Remove the fuel vapor return hose clamp (1) and remove the fuel vapor return hose from the throttle body. PZSM030018 10. Disconnect the Camshaft Position (CMP) sensor electrical connector. 11. Remove the CMP sensor retaining bolt (1) and remove the CMP sensor. PZSM030011 Chery Automobile Co., Ltd. 02–...
Page 51: Camshaft
1. Remove the accessory drive belt (See Accessory Drive Belt Removal & Installation in Section 02 Engine). 2. Remove the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine). 3. Remove the cylinder head cover (See Cylinder Head Cover Removal & Installation in Section 02 Engine). 02– Chery Automobile Co., Ltd.
Page 52 (1). (Tighten: Camshaft timing belt pulley bolt to 120 ± 5 N·m) PZSM020041 5. Remove the six rear timing cover bolts. (Tighten: Rear timing cover bolts to 10 ± 2 N·m) BESM020034 Chery Automobile Co., Ltd. 02–...
Page 53 • Pay attention to the division mark of the camshaft shell cover. • Use special tool CH-20010 (1), and install the cam- shaft holder to hold the camshafts in place. NOTE : The camshaft holder will prevent the camshafts from rotating in either direction. BESM020016 02– Chery Automobile Co., Ltd.
Page 54 • Install the camshaft seal in the required location and depth. LTSM020215 • Install the intake and exhaust camshaft bearing caps in the proper order. • Slowly tighten bolts to the specified torque. • Follow the torque sequence as shown. BESM020036 Chery Automobile Co., Ltd. 02–...
Page 55: Cylinder Head
4. Remove intake manifold (See Intake Manifold Removal & Installation in Section 02 Engine). 5. Remove exhaust manifold (See Exhaust Manifold Removal & Installation in Section 02 Engine). 6. Remove water pipe and thermostat assembly. 02– Chery Automobile Co., Ltd.
Page 56 • Position the new cylinder head gasket on the engine block with the part number facing up. Ensure gasket is seated over the locating dowels in the block. • Before installing the bolts, the threads should be lightly coated with engine oil. Chery Automobile Co., Ltd. 02–...
Page 57: Front Crankshaft Oil Seal
(1). (Tighten: Crankshaft vibration damper bolts to 25 ± 5 N·m and an additional 30 ± 5°) PZSM020017 3. Remove the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine). 02– Chery Automobile Co., Ltd.
Page 58: Rear Crankshaft Oil Seal
• CH-20006 - Rear Crankshaft Oil Seal Guide • CH-20043 - Flywheel Fixture 1. Remove the transaxle assembly (See Transaxle Assembly Removal & Installation in Section 08 Transaxle). 2. Using special tool CH-20043 (1), hold the flywheel. PZSM020026 Chery Automobile Co., Ltd. 02–...
Page 59 • Position the seal over the rear crankshaft seal guide. • Use special tool CH-20005 (2) and CH-20006 (1), to install the rear crankshaft oil seal. • Ensure that the lip of the seal is facing toward the crankcase during installation. LTSM020217 02– Chery Automobile Co., Ltd.
Page 60: Engine Mounts
6. Installation is in the reverse order of removal. PZSM020031 Removal & Installation - Right Mount NOTE : The following special tools are required to perform the repair procedure: • Engine Hoist 1. Use the engine hoist to support the engine. Chery Automobile Co., Ltd. 02–...
Page 61: Removal & Installation - Front Mount
2. Remove the rear engine mount retaining bolts (2) and the three rear engine mount bracket bolts (1). (Tighten: Engine rear mount bolt to 60 ± 5 N·m) PZSM020011 3. Installation is in the reverse order of removal. 02– Chery Automobile Co., Ltd.
Page 62: Engine Assembly
8. Remove the two retaining bolts (1) on the air intake pipe. (Tighten: Air intake pipe bolts to 8 ± 3 N·m) PZSM020001 9. Remove the clamps (1) between the intake mani- fold and the air cleaner housing. 10. Remove the intake manifold hose. PZSM020003 Chery Automobile Co., Ltd. 02–...
Page 63 Carbon canister solenoid valve Crankshaft position sensor Throttle body control A/C compressor Oil pressure sensor Power steering pump pressure switch Generator Backup lamp switch Vehicle speed sensor 14. Remove the pipe (1) from the canister control valve. PZSM080057 02– Chery Automobile Co., Ltd.
Page 64 16. Remove the vacuum line (1) from the brake booster. PZSM020044 17. Remove the dipstick. 18. Remove the transaxle shift cable (1). PZSM080002 19. Remove the shift cable clamp (1) from the shift cable bracket. VISM080026 Chery Automobile Co., Ltd. 02–...
Page 65 (Tighten: Catalytic converter to exhaust manifold bolts to 60 ± 5 N·m) PZSM020008 24. Remove the front axle shaft (See Front Axle Shaft Removal & Installation in Section 09 Driveline & Axle). 25. Drain the steering oil. 02– Chery Automobile Co., Ltd.
Page 66 28. Raise and support the vehicle. 29. Drain the engine oil. 30. Remove the exhaust pipe assembly (See Exhaust Pipe Assembly Removal & Installation in Section 07 Exhaust). 31. Remove the suction line retaining bolts on the front sub-frame. Chery Automobile Co., Ltd. 02–...
Page 67 (Tighten: Engine front mount bolt to 80 ± 5 N·m) PZSM020032 35. Remove the rear engine mount bolt (1) and the three rear engine mount bracket bolts (2). (Tighten: Engine rear mount bolt to 60 ± 5 N·m) PZSM020011 02– Chery Automobile Co., Ltd.
Page 68 40. Hoist the engine from the vehicle. CAUTION: Verify all electrical connectors are discon- nected prior to engine/transaxle removal. PZSM020006 41. Separate the engine and transaxle. 42. Installation is in the reverse order of removal. Chery Automobile Co., Ltd. 02–...
Page 69: Engine Timing Belt
The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may result in serious personal injury. 02– Chery Automobile Co., Ltd.
Page 70 7. Remove the accessory drive belt (See Accessory Drive Belt Removal & Installation in Section 02 Engine). 8. Remove the six crankshaft vibration damper bolts (1). (Tighten: Crankshaft vibration damper bolts to 25 ± 5 N·m and an additional 30 ± 5°) BESM020055 Chery Automobile Co., Ltd. 02–...
Page 71 (1) into the cylinder block and rotate the crankshaft until the crankshaft tool completely holds the crankshaft in place. (Tighten: Crankshaft holder to 28 N·m) NOTE: The crankshaft holder will prevent the crankshaft from rotating in either direction. BESM020015 02– Chery Automobile Co., Ltd.
Page 72 U-slot opening. • Tighten the tensioner pulley bolt (1) to 27 ± 3 N·m. • Tighten the intake and exhaust camshaft pulley bolts (2 ) & (4) to 120 ± 5 N·m. PZSM020037 Chery Automobile Co., Ltd. 02–...
Page 73: Exhaust Manifold
60 ± 5 N·m) 4. Disconnect the catalytic converter assembly from the manifold. PZSM020008 5. Remove the ten exhaust manifold nuts (1). (Tighten: Exhaust manifold nuts to 20 ± 5 N·m) BESM020033 02– Chery Automobile Co., Ltd.
Page 74 ON-VEHICLE SERVICE 6. Remove and discard the exhaust manifold gasket (1). LTSM020169 7. Installation is in the reverse order of removal. Installation Notes: • Clean all surfaces of manifold and cylinder head. Chery Automobile Co., Ltd. 02–...
Page 75: Intake Manifold
3. Remove the clamps (1) between the intake mani- fold and the air cleaner housing. PZSM020003 4. Remove the PCV return hose clamp (1) on the intake manifold hose. PZSM020046 5. Remove the air intake hose. 02– Chery Automobile Co., Ltd.
Page 76 7. Remove the MAP sensor retaining bolt (1), and then remove the MAP sensor. PZSM030004 8. Remove the intake manifold bracket retaining bolts (1). PZSM020051 9. Remove the fuel vapor return hose (1) from the throttle body. PZSM030018 Chery Automobile Co., Ltd. 02–...
Page 77 12. Remove the A/C compressor belt. 13. Remove the steering pump (See Steering Pump Removal & Installation in Section 11 Steering). 14. Remove the A/C compressor (See A/C Compressor Removal & Installation In Section 13 Heating & Air Condi- tioning). 02– Chery Automobile Co., Ltd.
Page 78: Oil Filter
Prolonged and repeated contact with engine oil will harm your skin. If engine oil is spilled on your skin, wash it off immediately with water. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Always use adequate skin protection when performing vehicle service. Chery Automobile Co., Ltd. 02–...
Page 79: Oil Pan
4. Remove oil pan bolts (1). (Tighten: Oil pan bolts to 18 N·m) LTSM020205 5. Using a putty knife, loosen the seal around the oil pan. 6. Remove the oil pan. 7. Installation is in the reverse order of removal. 02– Chery Automobile Co., Ltd.
Page 80: Oil Pump
(Tighten: Crankshaft timing belt pulley bolt to 130 ± 10 N·m and an additional 65 ± 5°) 5. Remove the key-way from the crankshaft. 6. Use an appropriate tool and remove the front crankshaft oil seal (1). LTSM020199 Chery Automobile Co., Ltd. 02–...
Page 81: Oil Strainer
3. Remove the three oil strainer retaining bolts (1). (Tighten: Oil strainer bolts to 18 N·m) BESM020018 4. Carefully remove the oil strainer. 5. Installation is in the reverse order of removal. Installation Notes: • Install new O-ring on the oil strainer pipe. 02– Chery Automobile Co., Ltd.
Page 82: Engine Unit Repair
3. For each connecting rod / piston assembly to be removed, rotate the crankshaft to the bottom dead center posi- tion for each cylinder. NOTE : Before removing the connecting rod / piston assembly, check the connecting rod side clearance. Chery Automobile Co., Ltd. 02–...
Page 83 7. Remove the connecting rod bearings (See Con- necting Rod Removal & Installation in Section 02 Engine). BESM020045 CAUTION: When removing the connecting rod side bearings, note the installation position. Keep them in the correct order. 02– Chery Automobile Co., Ltd.
Page 84: Inspection
Assemble all components in their original position. 1. Install the pistons to the connecting rods. 2. Using a piston ring expander, install the piston rings. 3. Assemble all components in the reverse order of disassembly. Chery Automobile Co., Ltd. 02–...
Page 85: Pistons
First Ring End Gap 0.2 - 0.4 mm 0.8 mm Second Ring End Gap 0.4 - 0.6 mm 1.0 mm Clearance Specifications - Piston to Piston Pin DESCRIPTION SPECIFICATION Piston To Piston Pin 0.002 - 0.013 mm 02– Chery Automobile Co., Ltd.
Page 86: Disassembly
BESM020046 • Piston Pin Snap Ring Removal − Using snap ring pliers, remove the snap ring (1). − Heat the pistons if necessary. BESM020048 Chery Automobile Co., Ltd. 02–...
Page 87: Inspection
− Push out the piston pin with a suitable tool. BESM020049 • Connecting Rod & Piston Disassembly − Remove the piston from the connecting rod. BESM020041 Inspection Check the piston diameter. BESM020050 PISTON DIAMETER All Pistons 72.965 ± 0.009 mm 02– Chery Automobile Co., Ltd.
Page 88 13 mm from bottom of cylinder bore and below the bottom of the oil ring travel where the cylinder bore has minimal wear. • Check the ring end gap with a feeler gauge. BESM020052 Chery Automobile Co., Ltd. 02–...
Page 89: Assembly
1. Install the piston to the connecting rod. Assemble the components in their original positions. 2. Using a piston ring expander, install the piston rings. Assemble the components in their original positions. 3. Assemble all components in the reverse order of disassembly. 02– Chery Automobile Co., Ltd.
Page 90: Connecting Rods
3. Using a hammer handle or similar tool, push the piston and connecting rod assembly (1) out through the cylinder head side of the engine block. BESM020044 NOTE: Before removing the piston and connecting rod assembly, check the connecting rod side clearance. Chery Automobile Co., Ltd. 02–...
Page 91: Inspection
3. Tighten the connecting rod bolts using the two step torque-turn method: • 1st Step: Tighten bolts to 25 ± 3 N·m • 2nd Step: Tighten the connecting rod bolts an additional 90 ± 5° LTSM020208 02– Chery Automobile Co., Ltd.
Page 92: Crankshaft
1. Remove the front crankshaft oil seal (See Front Crankshaft Oil Seal Removal & Installation in Section 02 Engine). 2. Remove the rear crankshaft oil seal (See Rear Crankshaft Oil Seal Removal & Installation in Section 02 Engine). 3. Remove the pistons with connecting rod assemblies. Chery Automobile Co., Ltd. 02–...
Page 93: Inspection
DO NOT nick the crank journals or bearing fillets. BESM020075 Check the axial clearance after installation: • Standard axial clearance should be 0.02 mm. • Limits of axial clearance should be held to 0.30 BESM020076 02– Chery Automobile Co., Ltd.
Page 94: Assembly
1. Install the main bearings and thrust bearings in the upper cylinder block and lower cylinder block. NOTE: Identify and number the bearings, if reusing them, so that they are assembled in the same position and direction. 2. Assemble the crankshaft and main bearings in the reverse order of disassembly. Chery Automobile Co., Ltd. 02–...
Page 95: Cylinder Head
Replacement cylinder head comes complete with valves, seals, springs, retainers, keepers, tappets, and camshafts. 1. Remove the camshafts (See Camshaft Removal & Installation in Section 02 Engine). 2. Remove the hydraulic tappet assembly (1). BESM020071 02– Chery Automobile Co., Ltd.
Page 96 5. Push the valve stem from the cylinder head and remove the valve (4). VISM080041 6. Using special tool CH-20013 (1), remove the valve oil seal. 7. Remove the valve guide if necessary. 8. Remove the spark plugs. LTSM020225 Chery Automobile Co., Ltd. 02–...
Page 97: Inspection
3. Using special tool CH-20011 (1) & CH-20012 (2), install the new valve oil seal. LTSM020224 4. Install the valves into the cylinder head (larger diameter on intake side). 5. Install the valve springs. 6. Install the valve spring retainers. 02– Chery Automobile Co., Ltd.
Page 98: Camshaft
Cam Bearing #2, #3, #4, #5, Inner Diameter 24 - 24.021 Journal #1 Clearance 0.05 - 0.090 Journal #2, #3, #4, #5 Clearance 0.04 - 0.074 Intake Camshaft Axial Clearance 0.15 - 0.20 Exhaust Camshaft Axial Clearance 0.15 - 0.20 Chery Automobile Co., Ltd. 02–...
Page 99: Disassembly
Inspection • Measure the camshaft cam lobe height. • If wear is beyond the limit, replace the camshaft. BESM020037 CAMSHAFT CAM LOBE HEIGHT Intake Cam Lobe Height 37.11 mm Exhaust Cam Lobe Height 37.09 mm 02– Chery Automobile Co., Ltd.
Page 100 • Calculation of camshaft journal clearance Journal clearance = (inner diameter of camshaft bearing) - (outer diameter of camshaft journal) CAMSHAFT JOURNAL CLEARANCE Journal #1 Clearance 0.05 - 0.090 mm Journal #2, #3, #4, #5 Clearance 0.04 - 0.074 mm Chery Automobile Co., Ltd. 02–...
Page 101: Assembly
2. Installation is in the reverse order of removal. Installation Notes: • Install the intake and exhaust camshaft bearing caps in the proper order. • Slowly tighten bolts to the specified torque. • Follow the torque sequence as shown. BESM020036 02– Chery Automobile Co., Ltd.
Page 102: Valve & Valve Guides
• CH-20013 - Valve Seal Remover • CH-20011 - Valve Seal Installer • CH-20012 - Valve Stem Seal Installer Guide • CH-20017 - Valve Keeper Installer 1. Using the special tool CH-20018 (1), compress the valve springs. BESM020067 Chery Automobile Co., Ltd. 02–...
Page 103: Inspection
• Clean all valves thoroughly and discard burned, warped and cracked valves. • Check valve seats and valve faces for damage. • When reconditioning valves follow the specifications outlined for both intake and exhaust valves. BESM020066 02– Chery Automobile Co., Ltd.
Page 104: Assembly
− If it exceeds the limit, replace valve or valve guide. BESM020073 VALVE TO VALVE GUIDE CLEARANCE STANDARD Intake Valve 0.012 - 0.043 mm Exhaust Valve 0.032 - 0.063 mm Assembly 1. Install the valves into the cylinder head (larger diameter on intake side). Chery Automobile Co., Ltd. 02–...
Page 105: Valve Springs
7. Strike the valve stem lightly with a plastic hammer after installation to verify proper assembly. Valve Springs Specifications Valve Spring Specifications DESCRIPTION SPECIFICATION Spring Free Length 49 mm Spring Height At 620 Newtons Of Pressure 32.0 mm 02– Chery Automobile Co., Ltd.
Page 106: Disassembly
1. Using the special tool CH-20018 (1), compress the valve springs. BESM020067 2. Remove the valve keeper (1), and the valve spring retainer (2). 3. Remove the valve springs (3) from the cylinder head. VISM080040 Chery Automobile Co., Ltd. 02–...
Page 107: Inspection
2. Install the valve spring retainers. 3. Using a valve spring compressor CH-20018 (1), compress the valve springs. 4. Install the valve keepers. BESM020067 5. Strike the valve stem lightly with a plastic hammer after installation to verify proper assembly. 02– Chery Automobile Co., Ltd.
Page 108 P0444 - Evaporative Emission System Barometric Pressure Low Input, P0108 Purge Control Valve Circuit Open 03-135 - Manifold Absolute Pressure Or P0506 - Idle Control System RPM Barometric Pressure High Input 03-52 Lower Than Expected 03-140 Chery Automobile Co., Ltd. 03–...
Page 109 Downstream Oxygen Sensor 03-171 Removal & Installation 03-176 Removal & Installation - Upstream Engine Control Module (ECM) 03-176 Oxygen Sensor 03-171 Description 03-176 Removal & Installation - Downstream Operation 03-176 Oxygen Sensor 03-171 Removal & Installation 03-177 03– Chery Automobile Co., Ltd.
Page 110 The ECM is a pre-programmed, microprocessor-based digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The ECM can adapt its programming to meet changing operating conditions. Chery Automobile Co., Ltd. 03–...
Page 111 • Air conditioner does not operate. • Fuel injector control failure. • Engine stalls out. • Unstable idle. • Lack of engine power. Ignition Coil • Poor fuel economy. Replace • Excessive exhaust emissions. • Weak spark. 03– Chery Automobile Co., Ltd.
Page 112 Oxygen Sensors Crankshaft Position (CKP) Sensor Camshaft Position (CMP) Sensor Air Flow Sensor Bolts Engine Control Module (ECM) Bolts Accelerator Pedal Position (APP) Sensor Electronic Throttle Control Actuator Vehicle Speed Sensor Manifold Absolute Pressure (MAP) Sensor Chery Automobile Co., Ltd. 03–...
Page 113: Special Tools
GENERAL INFORMATION Special Tools Diagnostic Scan Tool X-431 Engine Analyzer KES-200 Digital Multimeter Fluke 15B & 17B 03– Chery Automobile Co., Ltd.
Page 114 GENERAL INFORMATION Compression Gauge Fuel Pressure Gauge Chery Automobile Co., Ltd. 03–...
Page 115 Power Into 12 V DC Power To Diagnose Mitsubishi To Connect The Diagnostic Mitsubishi-12+16 Main Cable Electronic Control Systems Connector and Smartbox Pin Connector On Chery A1 Series To Perform Vehicle Smartbox To Diagnose Vehicles With Diagnosis Fiat-3 Pin Fiat-3 Pin Diagnostic Connector...
Page 116: Electrical Schematics
GENERAL INFORMATION Electrical Schematics Electronic Engine Controls (Page 1 of 11) PZSMW030024T Chery Automobile Co., Ltd. 03–...
Page 117 GENERAL INFORMATION Electronic Engine Controls (Page 2 of 11) PZSMW030029T 03– Chery Automobile Co., Ltd.
Page 118 GENERAL INFORMATION Electronic Engine Controls (Page 3 of 11) PZSMW030020T Chery Automobile Co., Ltd. 03–...
Page 119 GENERAL INFORMATION Electronic Engine Controls (Page 4 of 11) PZSMW030021T 03– Chery Automobile Co., Ltd.
Page 120 GENERAL INFORMATION Electronic Engine Controls (Page 5 of 11) PZSMW030022T Chery Automobile Co., Ltd. 03–...
Page 121 GENERAL INFORMATION Electronic Engine Controls (Page 6 of 11) PZSMW030023T 03– Chery Automobile Co., Ltd.
Page 122 GENERAL INFORMATION Electronic Engine Controls (Page 7 of 11) PZSMW030028T Chery Automobile Co., Ltd. 03–...
Page 123 GENERAL INFORMATION Electronic Engine Controls (Page 8 of 11) PZSMW030025T 03– Chery Automobile Co., Ltd.
Page 124 GENERAL INFORMATION Electronic Engine Controls (Page 9 of 11) PZSMW030026T Chery Automobile Co., Ltd. 03–...
Page 125 GENERAL INFORMATION Electronic Engine Controls (Page 10 of 11 PZSMW030027T 03– Chery Automobile Co., Ltd.
Page 126 GENERAL INFORMATION Electronic Engine Controls (Page 11 of 11) PZSMW030030T Chery Automobile Co., Ltd. 03–...
Page 127 A/C Pressure Sensor (GND) Power Steering Switch Sensor (GND) Headlamp Switch Manifold Absolute Pressure Sensor Sensor (GND) Electronic Throttle Control Actuator Camshaft Position Sensor Engine Coolant Temperature Sensor GND (Power) Accelerator Pedal Position Sensor CAN-L 03– Chery Automobile Co., Ltd.
Page 128: Diagnosis & Testing
The EPC lamp will light when the ignition switch is turned to the ON position and the engine is not running. After the engine is started, the EPC lamp will go off if there is no EPC DTCs that exist in the ECM. If the internal EPC self- check failed, the EPC lamp will continue to light. Chery Automobile Co., Ltd. 03–...
Page 129: Diagnostic Trouble Code (Dtc) List
Sensor Heater Control Circuit (Bank 1 Sensor 2) Low P0038 Sensor Heater Control Circuit (Bank 1 Sensor 2) High P0053 Sensor Heater Resistance (Bank 1 Sensor 1) P0054 Sensor Heater Resistance (Bank 1 Sensor 2) 03– Chery Automobile Co., Ltd.
Page 130 Cylinder 3 - Injector Circuit High P0270 Cylinder 4 - Injector Circuit Low P0271 Cylinder 4 - Injector Circuit High P0300 Random/Multiple Cylinder Misfire Detected P0301 Cylinder 1 Misfire Detected P0302 Cylinder 2 Misfire Detected Chery Automobile Co., Ltd. 03–...
Page 131 Fuel Pump A Control Circuit Low P0629 Fuel Pump A Control Circuit High P0645 A/C Clutch Relay Circuit P0646 A/C Clutch Relay Control Circuit Low P0647 A/C Clutch Relay Control Circuit High P0650 Malfunction Indicator Lamp Control Circuit 03– Chery Automobile Co., Ltd.
Page 132 Lost Communication with ECM U104 Lost Communication with Cruise Control Module U0121 Lost Communication with Anti-Lock Brake System (ABS) Control Module U0155 Lost Communication with Instrument Panel Cluster Control Module U0415 Invalid Data Received from ABS Control Module Chery Automobile Co., Ltd. 03–...
Page 133: Power Supply And Ground Circuit Test
DIAGNOSIS & TESTING Power Supply and Ground Circuit Test Power Supply and Ground Circuit PZSMW030001T 03– Chery Automobile Co., Ltd.
Page 134 Approximately 0 V Ignition switch: OFF More than a few seconds EMS Relay (Main Relay) Voltage (11 - 14 V) after turning ignition switch Switched Supply Voltage Ignition switch: ON Voltage (11 - 14 V) Chery Automobile Co., Ltd. 03–...
Page 135 DIAGNOSIS & TESTING PZSMW030002T 03– Chery Automobile Co., Ltd.
Page 136 • Turn ignition switch off and then on. • Check the voltage between ECM terminal 13 and ground, harness side. • Battery voltage should exist. Is the check result normal? >> Go to step 4. >> Go to step 3. LTSMD030061 Chery Automobile Co., Ltd. 03–...
Page 137 61, 80 and ground terminal side. • Continuity should exist. • Check harness for a short to power. Is the check result normal? >> Go to step 8. >> Go to the next step. PZSMD030001 03– Chery Automobile Co., Ltd.
Page 138 • Wait for at least 10 seconds. • Check the voltage between ECM terminal 14 and ground, harness side. • Battery voltage should exist. Is the check result normal? >> Go to the next step. >> Go to step 11. LTSMD030063 Chery Automobile Co., Ltd. 03–...
Page 139 Replace the ECM. NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> Replace the front fuse and relay box. 03– Chery Automobile Co., Ltd.
Page 140: Diagnostic Trouble Code (Dtc) Tests
DIAGNOSIS & TESTING Diagnostic Trouble Code (DTC) Tests P0016 - Camshaft Position-Crankshaft Position Correlation Error PZSMW030011T Chery Automobile Co., Ltd. 03–...
Page 141 DIAGNOSIS & TESTING PZSMW030004T 03– Chery Automobile Co., Ltd.
Page 142 • Inspect ground connections E-801 and E-802 mounting positions (See Vehicle Wiring Harness Layout - ECM Control Harness in Section 16 Wiring). Are the ground connections OK? >> Go to the next step. >> Repair or replace ground harness or connections. Chery Automobile Co., Ltd. 03–...
Page 143 • Refer to DTC Confirmation Procedure . Is DTC P0016 still present? >> Go to the next step. >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 144 • Approximately 6 V square wave signal should exist. CMP SENSOR SIGNAL OUTPUT CMP SENSOR SIGNAL WITH ENGINE ANALYZER (KES-200) Is the CMP output signal normal? >> Go to step 10. >> Go to the next step. Chery Automobile Co., Ltd. 03–...
Page 145 Monitor the CMP sensor signal on the KES-200 screen. − If the CMP sensor signals were normal, the system is OK. − If the CMP sensor signals were still irregular or missing, go to step 13. >> Replace CMP sensor. 03– Chery Automobile Co., Ltd.
Page 146 Is the sensor mounting area OK? >> Go to the next step. >> Repair or replace the sensor as necessary. PZSMD030002 Chery Automobile Co., Ltd. 03–...
Page 147 Were any problems found? >> Remove any debris and clean the camshaft signal plate or replace the camshaft. Reinstall the CMP sensor. >> Go to step 16. 03– Chery Automobile Co., Ltd.
Page 148 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 149 DIAGNOSIS & TESTING P0031 - O Sensor 1 Heater Control Circuit Low P0032 - O Sensor 1 Heater Control Circuit High PZSMW030012T 03– Chery Automobile Co., Ltd.
Page 150 • If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 03 Electronic Engine Controls for more information). NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. Chery Automobile Co., Ltd. 03–...
Page 151 • Check the voltage between terminal 2 and ground in the O sensor connector E-004 terminal side. • Battery voltage should exist. Is the check result normal? >> Go to Step 5. >> Go to the next step. LTSMD030029 03– Chery Automobile Co., Ltd.
Page 152 Repair or replace the circuit for an open, short to ground or short to power in harness or connectors. CHECK THE O SENSOR HEATER • Check resistance between the following O sensor terminals, component side: SENSOR HEATER RESISTANCE TERMINAL NO. RESISTANCE 1 & 2 (including wire Approximately and connector) 2.5 - 4.9 Chery Automobile Co., Ltd. 03–...
Page 153 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 154 DIAGNOSIS & TESTING P0105 - Manifold Absolute Pressure/Barometric Pressure Circuit P0106 - Manifold Absolute Pressure Or Barometric Pressure Range/Performance PZSMW030007T Chery Automobile Co., Ltd. 03–...
Page 155 • If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 03 Electronic Engine Controls for more information). NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. 03– Chery Automobile Co., Ltd.
Page 156 • Check the voltage between terminal 1 and 3 in the MAP sensor connector E-033 terminal side. • 5 V should exist. Is the check result normal? >> Go to step 5. >> Go to the next step. VISMD030010 Chery Automobile Co., Ltd. 03–...
Page 157 • Check the continuity between MAP sensor terminal 4 and ECM terminal 37. • Continuity should exist. Is the check result normal? >> Go to the next step. >> Repair or replace the circuit for an open or high resistance in harness or connectors. 03– Chery Automobile Co., Ltd.
Page 158 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 159 DIAGNOSIS & TESTING P0107 - Manifold Absolute Pressure Or Barometric Pressure Low Input P0108 - Manifold Absolute Pressure Or Barometric Pressure High Input PZSMW030007T 03– Chery Automobile Co., Ltd.
Page 160: High Input
• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 03 Electronic Engine Controls for more information). NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. Chery Automobile Co., Ltd. 03–...
Page 161 • Check the voltage between terminal 1 and terminal 3 in MAP sensor connector E-033 terminal side. • 5 V should exist. Is the check result normal? >> Go to step 5. >> Go to the next step. VISMD030010 03– Chery Automobile Co., Ltd.
Page 162 • Check harness for a short to ground or short to power. Is the check result normal? >> Go to the next step. >> Repair or replace the circuit for an open, short to ground or short to power in harness or connectors. Chery Automobile Co., Ltd. 03–...
Page 163 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 164 DIAGNOSIS & TESTING P0112 - Intake Air Temperature Circuit Low Input PZSMW030007T Chery Automobile Co., Ltd. 03–...
Page 165 • Inspect ground connections E-801 and E-802 mounting positions (See Vehicle Wiring Harness Layout - ECM Control Harness in Section 16 Wiring). Are the ground connections OK? >> Go to the next step. >> Repair or replace ground harness or connections. 03– Chery Automobile Co., Ltd.
Page 166 • Check the harness for a short to ground between MAP/IAT connector terminal 2 and ECM connector E-601, terminal 42. Is the check result normal? >> Go to the next step. >> Repair circuit for a short to ground in harness or connectors. Chery Automobile Co., Ltd. 03–...
Page 167 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 168 DIAGNOSIS & TESTING P0113 - Intake Air Temperature Circuit High Input PZSMW030007T Chery Automobile Co., Ltd. 03–...
Page 169 • Inspect ground connections E-801 and E-802 mounting positions (See Vehicle Wiring Harness Layout - ECM Control Harness in Section 16 Wiring). Are the ground connections OK? >> Go to the next step. >> Repair or replace ground harness or connections. 03– Chery Automobile Co., Ltd.
Page 170 • Turn ignition switch off. • Disconnect the ECM electrical connector. • Check the continuity between IAT sensor terminal 1 and ECM terminal 17 terminal side. CHECK SENSOR GROUND CIRCUIT IAT SENSOR ECM CONNECTOR CONNECTOR TERMINAL TERMINAL Chery Automobile Co., Ltd. 03–...
Page 171 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 172 DIAGNOSIS & TESTING P0117 - Engine Coolant Temperature Circuit Low Input PZSMW030006T Chery Automobile Co., Ltd. 03–...
Page 173 • Inspect ground connections E-801 and E-802 mounting positions (See Vehicle Wiring Harness Layout - ECM Control Harness in Section 16 Wiring). Are the ground connections OK? >> Go to the next step. >> Repair or replace ground harness or connections. 03– Chery Automobile Co., Ltd.
Page 174 2 and ground in sensor connector E-019 terminal side. • 4.5 - 4.9 V should exist. Is the check result normal? >> Go to step 5. >> Go to the next step. LTSMD030032 Chery Automobile Co., Ltd. 03–...
Page 175 Approximately 0 V ECT: 59°C 1.89 V Ignition switch: ON ECT sensor ECT: 78°C 1.25 V ECT: 90°C 0.94 V Is the check result normal? >> Go to the next step. >> Replace ECT sensor. 03– Chery Automobile Co., Ltd.
Page 176 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 177 DIAGNOSIS & TESTING P0118 - Engine Coolant Temperature Circuit High Input PZSMW030006T 03– Chery Automobile Co., Ltd.
Page 178 • Inspect ground connections E-801 and E-802 mounting positions (See Vehicle Wiring Harness Layout - ECM Control Harness in Section 16 Wiring). Are the ground connections OK? >> Go to the next step. >> Repair or replace ground harness or connections. Chery Automobile Co., Ltd. 03–...
Page 179 39. LTSMD030032 If harness is normal, replace the ECM. NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). 03– Chery Automobile Co., Ltd.
Page 180 CHECK ECT SENSOR • Check resistance between the ECT sensor terminals 1 and 2, component side: ECT RESISTANCE REFERENCE DATA ECT °C RESISTANCE K -10°C 8.62 - 10.28 20°C 2.37 - 2.63 80°C 0.299 - 0.345 Chery Automobile Co., Ltd. 03–...
Page 181 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 182 DIAGNOSIS & TESTING P0122 - Throttle Position Sensor A Circuit Low Input P0123 - Throttle Position Sensor A Circuit High Input PZSMW030003T Chery Automobile Co., Ltd. 03–...
Page 183 • With the scan tool, record and erase stored DTCs in the ECM. • Start the engine and warm it to normal operating temperature. • With the scan tool, select view DTCs in the ECM. 03– Chery Automobile Co., Ltd.
Page 184 >> Go to the next step. >> Repair circuit for an open, short to ground or short to power in harness or connec- tors. If the circuit is normal, go to the next LTSMD030035 step. Chery Automobile Co., Ltd. 03–...
Page 185 • Slowly open the throttle, the TPS resistance value should change in a linear movement with the throttle as it opens. Is the check result normal? >> Go to the next step. >> Replace the TPS. Perform the TPS self-learning procedure. 03– Chery Automobile Co., Ltd.
Page 186 Electronic throttle control actuator Regulated sensor Approximately 5 V supply 3 Sensor Approximately 0 V (GND) Is the check result normal? >> Go to the next step. >> Replace the TPS. Perform the TPS self-learning. Chery Automobile Co., Ltd. 03–...
Page 187 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 188 DIAGNOSIS & TESTING P0132 - O Sensor Circuit 1 High Voltage PZSMW030012T Chery Automobile Co., Ltd. 03–...
Page 189 • If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 03 Electronic Engine Controls for more information). NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. 03– Chery Automobile Co., Ltd.
Page 190 • Check the harness for an open and a short to power supply circuit. Is the check result normal? >> Go to the next step. >> Repair circuit for an open or short to power in harness or connectors. Chery Automobile Co., Ltd. 03–...
Page 191 100 - 900 • Warm-up Idle condition • Check with Approximately Approximately sensor 600 - 900 2500 RPM signal Is the check result normal? >> Go to the next step. >> Replace O sensor. 03– Chery Automobile Co., Ltd.
Page 192 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 193 DIAGNOSIS & TESTING P0171 - Fuel Trim System Too Lean PZSMW030007T 03– Chery Automobile Co., Ltd.
Page 194 DIAGNOSIS & TESTING PZSMW030009T Chery Automobile Co., Ltd. 03–...
Page 195 • If the DTC is detected, the condition is current. Go to Diagnostic Procedure - Step 1. • If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 03 Electronic Engine Controls for more information). 03– Chery Automobile Co., Ltd.
Page 196 Engine Temp: Warm-up 78°C Injector pulse Transaxle Position: N Idle Approximately 2.5 ms Air Conditioner: Off Engine load: No load Is the check result normal? >> Go to step 7. >> Go to the next step. Chery Automobile Co., Ltd. 03–...
Page 197 (DC VOLTAGE) Engine running: Idle Press accelerator Approximately 1.3 V pedal slowly Manifold Absolute Pressure (MAP) Engine: Running Engine running: Approximately 1.5 V sensor 2000 RPM Press accelerator Up to Approximately pedal quickly 4 V (instantaneous) 03– Chery Automobile Co., Ltd.
Page 198 Key Off 380 kPa (3.8 bar) in 10 minutes Engine Idle 400 - 420 kPa (4.0 - 4.2 bar) Is the check result normal? >> Go to step 9. >> Go to the next step. Chery Automobile Co., Ltd. 03–...
Page 199 • Turn ignition switch off. • Disconnect the injector electrical connector. • Inspect the electrical connector for damage. Is the electrical connector OK? >> Go to the next step. >> Repair or replace the electrical connector as necessary. LTSMD030024 03– Chery Automobile Co., Ltd.
Page 200 • Continuity should exist. • Check harness for a short to power. Is the check result normal? >> Go to the next step. >> Repair or replace circuit for an open, short to power in harness or connectors. Chery Automobile Co., Ltd. 03–...
Page 201 • Fuel should be sprayed evenly from each injector. Is the check result normal? >> Go to the next step. >> Clean any injector that sprays unevenly or replace any injector that does not spray fuel. 03– Chery Automobile Co., Ltd.
Page 202 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 203 DIAGNOSIS & TESTING P0172 - Fuel Trim System Too Rich PZSMW030007T 03– Chery Automobile Co., Ltd.
Page 204 DIAGNOSIS & TESTING PZSMW030009T Chery Automobile Co., Ltd. 03–...
Page 205 • If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 03 Electronic Engine Controls for more information). NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. 03– Chery Automobile Co., Ltd.
Page 206 • Disconnect the upstream O sensor (1) electrical connector. • Inspect the electrical connector for damage. Is the electrical connector OK? >> Go to the next step. >> Repair or replace the electrical connector as necessary. PZSMD030008 Chery Automobile Co., Ltd. 03–...
Page 207 • Observe the following fuel pressures when testing: FUEL PRESSURES Key On 400 kPa (4.0 bar) Key Off 380 kPa (3.8 bar) in 10 minutes Engine Idle 400 - 420 kPa (4.0 - 4.2 bar) 03– Chery Automobile Co., Ltd.
Page 208 • Select ACTIVE TEST menu. • Perform injector active test. • Make sure that each test produces a momentary drop in engine speed. Is the check result normal? >> Go to step 12. >> Go to the next step. Chery Automobile Co., Ltd. 03–...
Page 209 FUEL INJECTOR CIRCUITS INJECTOR INJECTOR NO. TERMINAL TERMINAL • Continuity should not exist. Is the check result normal? >> Go to the next step. >> Repair circuit for a short to ground in harness or connectors. 03– Chery Automobile Co., Ltd.
Page 210 • Make sure fuel does not drip from injectors. Is the check result normal? >> Go to the next step. >> Replace any injectors from which fuel is dripping. Always replace fuel injector O-rings when replacing the fuel injector(s). Chery Automobile Co., Ltd. 03–...
Page 211 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 212 DIAGNOSIS & TESTING P0201 - Cylinder 1 - Injector Circuit P0202 - Cylinder 2 - Injector Circuit P0203 - Cylinder 3 - Injector Circuit P0204 - Cylinder 4 - Injector Circuit PZSMW030009T Chery Automobile Co., Ltd. 03–...
Page 213 • Inspect ground connections E-801 and E-802 mounting positions (See Vehicle Wiring Harness Layout - ECM Control Harness in Section 16 Wiring). Are the ground connections OK? >> Go to the next step. >> Repair or replace ground harness or connections. 03– Chery Automobile Co., Ltd.
Page 214 • Turn ignition switch off. • Disconnect the injector electrical connector. • Inspect the electrical connector for damage. Is the electrical connector OK? >> Go to the next step. >> Repair or replace the electrical connector as necessary. LTSMD030024 Chery Automobile Co., Ltd. 03–...
Page 215 Go to the next step. DETECT MALFUNCTIONING PART • Turn ignition switch off. • Disconnect the ECM electrical connector. • Check the continuity between the following terminals: CHECK INJECTOR CIRCUIT INJECTOR INJECTOR NO TERMINAL TERMINAL 03– Chery Automobile Co., Ltd.
Page 216 INJECTOR NO CONDITION VOLTAGE) • Engine is running • Warm-up condition Voltage: 11 - 14 V • Idle • Accelerate suddenly Is the check result normal? >> Go to the next step. >> Replace injector. Chery Automobile Co., Ltd. 03–...
Page 217 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 218 DIAGNOSIS & TESTING P0221 - Throttle Position Sensor B Performance PZSMW030003T Chery Automobile Co., Ltd. 03–...
Page 219 DIAGNOSIS & TESTING PZSMW030008T 03– Chery Automobile Co., Ltd.
Page 220: Performance
• Start the engine and warm it to normal operating temperature. • With the scan tool, select view DTCs in the ECM. • If the DTC is detected, the condition is current. Go to Diagnostic Procedure - Step 1. Chery Automobile Co., Ltd. 03–...
Page 221 • Check voltage between TPS terminal 3 and ground in connector E-027, terminal side. • Approximately 5 V should exist. Is the check result normal? >> Go to step 8. >> Go to the next step. LTSMD030035 03– Chery Automobile Co., Ltd.
Page 222 APP sensor terminal 3 APP sensor terminal 6 Is the check result normal? >> Go to the next step. >> Repair circuit for a short to ground or short to power in harness or connectors. Chery Automobile Co., Ltd. 03–...
Page 223 • Check harness for a short to power and short to ground. Is the check result normal? >> Go to the next step. >> Repair circuit for an open, short to power or short to ground in harness or connectors. 03– Chery Automobile Co., Ltd.
Page 224 Position Sensor 1 Engine (TPS1) stopped Accelerator 4.62 V pedal: Fully depressed Is the check result normal? >> Go to the next step. >> Replace electronic throttle control actuator, and perform throttle valve position learning. Chery Automobile Co., Ltd. 03–...
Page 225 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 226 DIAGNOSIS & TESTING P0321 - Distributor Engine Speed In-Phase Circuit Performance PZSMW030004T Chery Automobile Co., Ltd. 03–...
Page 227 • Inspect ground connections E-801 and E-802 mounting positions (See Vehicle Wiring Harness Layout - ECM Control Harness in Section 16 Wiring). Are the ground connections OK? >> Go to the next step. >> Repair or replace ground harness or connections. 03– Chery Automobile Co., Ltd.
Page 228 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> Repair or replace the circuit for an open or short in harness or connectors. Chery Automobile Co., Ltd. 03–...
Page 229 − Remove the sensor. − Visually check the sensor for any damage. • Check resistance between the following CKP sensor terminals, component side: CKP SENSOR RESISTANCE RESISTANCE TERMINAL NO. (APPROXIMATELY) (20°C) Approximately 860 1 & 2 03– Chery Automobile Co., Ltd.
Page 230 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 231 DIAGNOSIS & TESTING P0324 - Knock Control System Error P0327 - Knock Sensor 1 Circuit Low Input P0328 - Knock Sensor 1 Circuit High Input PZSMW030005T 03– Chery Automobile Co., Ltd.
Page 232 • Inspect ground connections E-801 and E-802 mounting positions (See Vehicle Wiring Harness Layout - ECM Control Harness in Section 16 Wiring). Are the ground connections OK? >> Go to the next step. >> Repair or replace ground connections. Chery Automobile Co., Ltd. 03–...
Page 233 Replace the knock sensor. CHECK THE KNOCK SENSOR OUTPUT SIGNAL CIRCUIT • Disconnect the ECM electrical connector. • Check the knock sensor circuit resistance as shown in the following table: KNOCK SENSOR CIRCUIT KNOCK SENSOR ECM TERMINAL TERMINAL 03– Chery Automobile Co., Ltd.
Page 234 1 - 2 • Method 2: Knock at sensor slightly • Output signal voltage should exist. Is the check result normal? >> Go to the next step. >> Replace the knock sensor. Chery Automobile Co., Ltd. 03–...
Page 235 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 236 DIAGNOSIS & TESTING P0340 - Camshaft Position Sensor Circuit P0341 - Camshaft Position Sensor Performance P0342 - Camshaft Position Sensor Circuit Low Input P0343 - Camshaft Position Sensor Circuit High Input PZSMW030011T Chery Automobile Co., Ltd. 03–...
Page 237 • Inspect ground connections E-801 and E-802 mounting positions (See Vehicle Wiring Harness Layout - ECM Control Harness in Section 16 Wiring). Are the ground connections OK? >> Go to the next step. >> Repair or replace ground harness or connections. 03– Chery Automobile Co., Ltd.
Page 238 • Check harness for short to power. Is the check result normal? >> Go to the next step. >> Repair or replace the circuit for an open or short to power in harness or connectors. Chery Automobile Co., Ltd. 03–...
Page 239 • Approximately 6 V square wave signal should exist. CKP SENSOR SIGNAL CMP SENSOR SIGNAL WITH ENGINE ANALYZER (KES-200) Is the CMP output signal normal? >> Go to step 10. >> Go to the next step. 03– Chery Automobile Co., Ltd.
Page 240 • Check the installed clearance (See Camshaft Position (CMP) Sensor Removal & Installation in Section 03 Elec- tronic Engine Controls). NOTE : 0.8 - 1.2 mm gap should exist. Is the check result normal? >> Go to the next step. >> Reinstall the CMP sensor. Chery Automobile Co., Ltd. 03–...
Page 241 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 242 DIAGNOSIS & TESTING P0444 - Evaporative Emission System Purge Control Valve Circuit Open PZSMW030015T Chery Automobile Co., Ltd. 03–...
Page 243 • Inspect ground connections E-801 and E-802 mounting positions (See Vehicle Wiring Harness Layout - ECM Control Harness in Section 16 Wiring). Are the ground connections OK? >> Go to the next step. >> Repair or replace ground harness or connections. 03– Chery Automobile Co., Ltd.
Page 244 • Check the supply voltage between EVAP canister control valve terminal 1 and ground, terminal side. • 12 V should exist. Is the check result normal? >> Go to step 6. >> Go to the next step. LTSMD030046 Chery Automobile Co., Ltd. 03–...
Page 245 • Check air passage continuity and operation when applying 12 V to terminal 1 and ground to terminal 2. • The air passage should be opened. Is the check result normal? >> Go to the next step. >> Replace EVAP canister control valve. 03– Chery Automobile Co., Ltd.
Page 246 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 247: P0506 - Idle Control System Rpm Lower Than Expected
• Start the engine and let it idle. • Listen for an intake air leak after the mass air flow sensor. Is the check result normal? >> Go to the next step. >> Repair the air leak as necessary. 03– Chery Automobile Co., Ltd.
Page 248 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 249: P0562 - System Voltage Low Voltage P0563 - System Voltage High Voltage
DIAGNOSIS & TESTING P0562 - System Voltage Low Voltage P0563 - System Voltage High Voltage PZSMW030001T 03– Chery Automobile Co., Ltd.
Page 250 DIAGNOSIS & TESTING PZSMW030002T Chery Automobile Co., Ltd. 03–...
Page 251 • Inspect ground connections E-801 and E-802 mounting positions (See Vehicle Wiring Harness Layout - ECM Control Harness in Section 16 Wiring). Are the ground connections OK? >> Go to the next step. >> Repair or replace ground connections. 03– Chery Automobile Co., Ltd.
Page 252 • Measure the resistance between ECM terminal 44, 45 or 63 and battery positive terminal. • Continuity should exist. Is the check result normal? >> Go to the next step. >> Check fuse. Inspect the harness. Check all related components. Chery Automobile Co., Ltd. 03–...
Page 253 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 254: P0602 - Control Module Ecm Programming Error
• Check the ECM supply voltage circuit for voltage, ground circuit for an open, high resistance or any short cir- cuits that exist. Is the check result normal? >> Go to the next step. >> Repair circuit for an open or short in harness and connectors. Chery Automobile Co., Ltd. 03–...
Page 255 Reassemble the vehicle and road test to verify the customers complaint is repaired. >> Replace the ECM. NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). 03– Chery Automobile Co., Ltd.
Page 256: P0604 - Internal Controller Module
• Check the ECM supply voltage circuit for voltage, ground circuit for an open, high resistance or any short cir- cuits that exist. Is the check result normal? >> Go to the next step. >> Repair or replace the circuit for an open or short in harness and connectors. Chery Automobile Co., Ltd. 03–...
Page 257 Reassemble the vehicle and road test to verify the customers complaint is repaired. >> Replace the ECM. NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). 03– Chery Automobile Co., Ltd.
Page 258: P0645 - A/C Clutch Relay Circuit
DIAGNOSIS & TESTING P0645 - A/C Clutch Relay Circuit PZSMW030013T Chery Automobile Co., Ltd. 03–...
Page 259 • If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 03 Electronic Engine Controls for more information). NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. 03– Chery Automobile Co., Ltd.
Page 260 − Harness for an open or short between ECM terminal 14 and fuse EF5 − Harness for an open or short between ECM terminal 69 and fuse EF5 Is the check result normal? >> Go to the next step. >> Repair or replace malfunctioning part(s). Chery Automobile Co., Ltd. 03–...
Page 261 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 262: P1545 - Throttle Position Control Performance
DIAGNOSIS & TESTING P1545 - Throttle Position Control Performance PZSMW030003T Chery Automobile Co., Ltd. 03–...
Page 263 DIAGNOSIS & TESTING PZSMW030008T 03– Chery Automobile Co., Ltd.
Page 264 • Start the engine and warm it to normal operating temperature. • With the scan tool, select view DTCs in the ECM. • If the DTC is detected, the condition is current. Go to Diagnostic Procedure - Step 1. Chery Automobile Co., Ltd. 03–...
Page 265 • Check the voltage between terminal 3 and ground in the TPS electrical connector E-027, terminal side. • Approximately 5 V should exist. Is the check result normal? >> Go to step 8. >> Go to the next step. LTSMD030035 03– Chery Automobile Co., Ltd.
Page 266 • Connect all harness connectors that have been disconnected. • Turn ignition switch on. • Install a digital multimeter to the APP sensor as shown in the following: APP SENSOR CIRCUIT ECM TERMINAL APPS TERMINAL APP sensor terminal APP sensor terminal Chery Automobile Co., Ltd. 03–...
Page 267 • Check harness for a short to power and short to ground. Is the check result normal? >> Go to the next step. >> Repair or replace the open circuit or short to power or short to ground in harness or connectors. 03– Chery Automobile Co., Ltd.
Page 268 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 269: P2138 - Pedal Position Sensor Performance
DIAGNOSIS & TESTING P2138 - Pedal Position Sensor Performance PZSMW030008T 03– Chery Automobile Co., Ltd.
Page 270 DIAGNOSIS & TESTING PZSMW030003T Chery Automobile Co., Ltd. 03–...
Page 271 • If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 03 Electronic Engine Controls for more information). NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. 03– Chery Automobile Co., Ltd.
Page 272 • Check the voltage between terminal 6 and ground in the APPS1 electrical connector C-301, terminal side. • Approximately 5 V should exist. Is the check result normal? >> Go to step 5. >> Go to the next step. LTSMD030053 Chery Automobile Co., Ltd. 03–...
Page 273 Repair or replace the open or short circuit in harness or connectors. CHECK TPS POWER SUPPLY CIRCUIT • Check harness for short to power and short to ground between the following terminals: TPS POWER SUPPLY CIRCUIT ECM TERMINAL TPS TERMINAL 32 or 73 03– Chery Automobile Co., Ltd.
Page 274 • Continuity should exist. • Check harness for a short to power. Is the check result normal? >> Go to the next step. >> Repair or replace the open circuit or short to power in harness or connectors. Chery Automobile Co., Ltd. 03–...
Page 275 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 276: On-Vehicle Service
(Tighten: Engine coolant temperature sensor to 20 N·m) 5. Discard the O-ring. 6. Installation is in the reverse order of removal. Installation Notes: • After installing the ECT sensor, verify the cooling system is filled to proper specifications. PZSM030012 Chery Automobile Co., Ltd. 03–...
Page 277: Knock Sensor
The input from the upstream heated oxygen sensor tells the Engine Control Module (ECM) the oxygen content of the exhaust gas. Based on this input, the ECM fine tunes the air-fuel ratio by adjusting injector pulse width. 03– Chery Automobile Co., Ltd.
Page 278: Downstream Oxygen Sensor
CAUTION: Remove the oxygen sensor after the exhaust pipe has cooled. 3. Remove the downstream oxygen sensor (1). (Tighten: Downstream oxygen sensor to 45 N·m) PZSM030023 4. Installation is in the reverse order of removal. Chery Automobile Co., Ltd. 03–...
Page 279: Crankshaft Position Sensor
A signal is then sent to the Engine Control Module (ECM) and used for synchronizing the firing of sequential fuel injectors. Removal & Installation 1. Disconnect the negative battery cable. 2. Disconnect the CMP sensor electrical connector. 03– Chery Automobile Co., Ltd.
Page 280: Vehicle Speed Sensor
3. Remove the vehicle speed sensor mounting bolt (1). (Tighten: Vehicle speed sensor mounting bolt to 10 N·m) 4. Remove the vehicle speed sensor carefully. 5. Installation is in the reverse order of removal. PZSM030005 Chery Automobile Co., Ltd. 03–...
Page 281: Accelerator Sensor
2. Disconnect the MAP sensor electrical connector. 3. Remove the MAP sensor mounting bolt (1). (Tighten: MAP sensor mounting bolt to 6 N·m) 4. Remove the MAP sensor. 5. Installation is in the reverse order of removal. PZSM030004 03– Chery Automobile Co., Ltd.
Page 282: Accelerator Pedal Position Sensor
The throttle control motor is operated by the Engine Control Module (ECM) and it opens and closes the throttle valve. The throttle position sensor detects the throttle valve position. Chery Automobile Co., Ltd. 03–...
Page 283: Operation
The ECM is a pre-programmed, microprocessor-based digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The ECM can adapt its programming to meet changing operating conditions. 03– Chery Automobile Co., Ltd.
Page 284: Removal & Installation
− Choose input code . − Input the safety code. − Click the small keyboard. − Click OK . − Choose Immobilizer adapt . − Choose read Immobilizer to ECM immediately. − Click OK . Chery Automobile Co., Ltd. 03–...
Page 285 Back Fires 03-191 Engine Cranks Normal But Will Not Engine Poor Driveability 03-193 Start 03-180 Low Idle / Stalls During Deceleration 03-197 Engine Will Not Crank 03-182 Idle Speed Slow Return To Normal Idle 03-199 03– Chery Automobile Co., Ltd.
Page 286: Symptom Diagnostic Tests
Engine Will Not Crank Hard Start / Long Crank Time Fast Idle Lack / Loss Of Power Back Fires Engine Poor Driveability Low Idle / Stalls During Deceleration Idle Speed Slow Return To Normal Idle Chery Automobile Co., Ltd. 03–...
Page 287: Engine Cranks Normal But Will Not Start
>> Go to the next step. CHECK EXHAUST SYSTEM • Inspect the vehicles exhaust system for restriction. Is there a restriction in the exhaust system? >> Repair as necessary. >> Go to the next step. 03– Chery Automobile Co., Ltd.
Page 288 CHECK ENGINE CYLINDER COMPRESSION • Perform a compression test on the engine. Is engine compression correct? >> Verify test results. If OK, see Symptom Diagnostic Tests list to repair any additional symptoms. >> Check for cause. Chery Automobile Co., Ltd. 03–...
Page 289: Engine Will Not Crank
Check the charging system. CHECK DTC • Turn the ignition switch on. • With the X-431 scan tool, read the DTC. Are there any DTCs present? >> Check for cause. >> Go to the next step. 03– Chery Automobile Co., Ltd.
Page 290 ELECTRONIC ENGINE CONTROLS - ENGINE SYMPTOM DIAGNOSIS CHECK STARTING SYSTEM PRIMARY CIRCUITS • Check the starting system primary circuits as follows: − Starter relay − Ignition switch Are components/systems OK? >> Ensure customer’s concern has been resolved. >> Repair as necessary. Chery Automobile Co., Ltd. 03–...
Page 291: Hard Start / Long Crank / Erratic Start / Erratic Crank
Go to the next step. >> Check Camshaft Position (CMP) sensor signal at ECM. If CMP sensor is OK, check the following: − Crankshaft Position (CKP) sensor malfunction − Faulty spark plug wires − Faulty spark plugs 03– Chery Automobile Co., Ltd.
Page 292 >> Go to the next step. CHECK POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM • Remove the PCV valve and shake it. Does PCV valve rattle? >> Go to the next step. >> Replace the PCV valve. Chery Automobile Co., Ltd. 03–...
Page 293 >> Go to the next step. PZSMD030011 CHECK INTAKE AIR SYSTEM • Check for MAP/MAF sensor. Is there any contamination? >> Install a new MAF/IAT or MAP/IAT sensor. >> See Diagnostic Help for additional information. 03– Chery Automobile Co., Ltd.
Page 294: Fast Idle
• With the X-431 scan tool, select view DTC and data stream in ECM. Are there any DTCs present? >> Check for causes. See Diagnostic Trouble Code (DTC) index — Engine Control Module (ECM). >> See Diagnostic Help for additional information. Chery Automobile Co., Ltd. 03–...
Page 295: Lack / Loss Of Power
If the fuel pressure is less than 400 kPa (4 bar): − Check fuel supply system for restriction or leak. − If no problems are found, repair or replace fuel filter, pressure regulator or fuel pump assembly. 03– Chery Automobile Co., Ltd.
Page 296 Repair as necessary. >> Go to the next step. CHECK MANUAL TRANSAXLE OPERATION • Check the operation of the transaxle. Is the transaxle operation normal? >> Go to the next step. >> Repair as necessary. Chery Automobile Co., Ltd. 03–...
Page 297 • If the base timing is not correct, align the engine timing belt (See Engine Timing Belt Removal & Installation in 02 Engine). Are all checks OK? >> See Diagnostic Help for additional information. >> Repair as necessary. Verify the symptom no longer exists. 03– Chery Automobile Co., Ltd.
Page 298: Back Fires
− Spark plugs CHECK FUEL QUALITY • Check fuel quality (concerns such as correct octane, contamination). Is the fuel quality OK? >> Go to the next step. >> Repair as necessary. Verify the symptom no longer exists. Chery Automobile Co., Ltd. 03–...
Page 299 CHECK FOR BASE ENGINE CONCERNS • Check for base engine concerns (such as improper cylinder compression, worn camshaft/valve train, gasket leaks). Is a fault indicated? >> Repair as necessary. >> See Diagnostic Help for additional information. 03– Chery Automobile Co., Ltd.
Page 300: Engine Poor Driveability
− Clean the injectors − Fuel filter − Intake air filter − Throttle body − Spark plugs − Spark plug wires Does the engine now stall at idle? >> Repair as necessary. >> Go to the next step. Chery Automobile Co., Ltd. 03–...
Page 301 • While checking for RPM drop or engine stall, disconnect ETC actuator connector. Did RPM drop or engine stall when the ETC connector was disconnected? >> Connect ETC actuator connector. Go to the next step. >> Repair as necessary. 03– Chery Automobile Co., Ltd.
Page 302 Go to the next step. CHECK PCV SYSTEM • Check the Positive Crankcase Ventilation (PCV) system. • Remove PCV valve and shake it. Is PCV valve normal? >> Go to the next step. >> Replace the PCV valve. Chery Automobile Co., Ltd. 03–...
Page 303 • Check the following for possible additional causes: − Driveline − Transaxle − Charging system − A/C system (for surge with A/C on) Are the checks OK? >> See Diagnostic Help for additional information. >> Repair as necessary. 03– Chery Automobile Co., Ltd.
Page 304: Low Idle / Stalls During Deceleration
• Disconnect the ETC actuator connector and check for RPM drop or engine stall. Did RPM drop or engine stall when the ETC connector was disconnected? >> Connect ETC actuator connector. Go to the next step. >> Repair as necessary. Chery Automobile Co., Ltd. 03–...
Page 305 CHECK FOR BASE ENGINE CONCERNS • Check for base engine concerns (such as improper compression, worn camshaft/valve train, gasket leaks). Is a fault indicated? >> Repair as necessary. >> See Diagnostic Help for additional information. 03– Chery Automobile Co., Ltd.
Page 306: Idle Speed Slow Return To Normal Idle
Verify test results. If OK, see Symptom Diagnostic Tests list to repair any additional symptoms. >> Check for vacuum leaks, obstructions in the PCV system, oil cap, PCV valve, rocker cover bolt torque/gasket leak. Repair as necessary. Chery Automobile Co., Ltd. 03–...
Page 307 Removal & Installation 03-204 Operation 03-201 Specifications 03-201 Spark Plug Wire 03-205 Special Tools 03-202 Removal & Installation 03-205 Electrical Schematics 03-203 Spark Plug 03-206 Removal & Installation 03-206 ON-VEHICLE SERVICE 03-204 Ignition Coil 03-204 03– Chery Automobile Co., Ltd.
Page 308: General Information
Camshaft Position (CMP) Sensor to determine which ignition coil to energize. Specifications Torque Specifications DESCRIPTION TORQUE (N·m) Spark Plugs Ignition Coil Bolts Spark Plug Specifications DESCRIPTION SPARK PLUG GAP (mm) FR7DTC 0.7 - 1.1 Chery Automobile Co., Ltd. 03–...
Page 309: Special Tools
GENERAL INFORMATION Special Tools Diagnostic Scan Tool X-431 Engine Analyzer KES-200 03– Chery Automobile Co., Ltd.
Page 310: Electrical Schematics
GENERAL INFORMATION Electrical Schematics Ignition Control System (Page 1 of 1) PZSMW030016T Chery Automobile Co., Ltd. 03–...
Page 311: On-Vehicle Service
4. Remove the 4 ignition coil retaining bolts (2). (Tighten: Ignition coil retaining bolts to 6 N·m) PZSM030002 5. Remove the ignition coil. 6. Installation is in the reverse order of removal. 03– Chery Automobile Co., Ltd.
Page 312: Spark Plug Wire
4. Remove the spark plug wires (1). PZSM030007 Cylinder Number Length (mm) Resistance (k /m) 16 ± 20% 16 ± 20% 16 ± 20% 16 ± 20% Diameter (mm) 5. Installation is in the reverse order of removal. Chery Automobile Co., Ltd. 03–...
Page 313: Spark Plug
4. Inspect the spark plug condition. 5. Installation is in the reverse order of removal. Installation Notes: • Verify the proper spark plug gap before installing spark plugs. − Spark Plug Gap (A): 0.7-1.0 mm BESM030011 03– Chery Automobile Co., Ltd.
Page 314 Removal & Installation 03-211 Operation 03-208 Specifications 03-208 Vapor Canister 03-212 Special Tools 03-209 Description 03-212 Electrical Schematics 03-210 Operation 03-212 Diagnosis & Testing 03-212 ON-VEHICLE SERVICE 03-211 Removal & Installation 03-212 Vapor Canister Control Valve 03-211 Chery Automobile Co., Ltd. 03–...
Page 315: General Information
When de-energized, no vapors are purged. The pulse-width modulated canister control valve modulates the fuel vapor purge rate from the vapor canister and fuel tank to the engine intake manifold. Specifications Torque Specifications DESCRIPTION TORQUE (N·m) Vapor Canister Bolts 03– Chery Automobile Co., Ltd.
Page 316: Special Tools
GENERAL INFORMATION Special Tools Diagnostic Scan Tool X-431 Engine Analyzer KES-200 Chery Automobile Co., Ltd. 03–...
Page 317: Electrical Schematics
GENERAL INFORMATION Electrical Schematics Canister Control Valve (Page 1 of 1) PZSMW030015T 03– Chery Automobile Co., Ltd.
Page 318: On-Vehicle Service
2. Disconnect the vapor canister control valve electri- cal connector. 3. Disconnect the lines (1) from vapor canister control valve. PZSM080057 4. Remove the vapor canister control valve (1) from the bracket. 5. Installation is in the reverse order of removal. BESM030014 Chery Automobile Co., Ltd. 03–...
Page 319: Vapor Canister
3. Remove the three hose clamps (2) at the vapor canister. 4. Remove the vapor canister retaining bolts (1). (Tighten: Vapor canister retaining bolts to 10 N·m) 5. Remove the vapor canister. 6. Installation is in the reverse order of removal. PZSM080054 03– Chery Automobile Co., Ltd.
Page 320 Relieving Fuel System Pressure 04-11 Fuel Injector Inspection 04-18 Fuel Pump 04-11 Fuel Tank 04-18 Description 04-11 Description 04-18 Operation 04-11 Operation 04-18 Removal & Installation 04-11 Removal & Installation 04-18 Fuel Pump Inspection 04-13 Chery Automobile Co., Ltd. 04–...
Page 321 ECM to activate the fuel system. If the ECM does not receive the proper signal from the Immobilizer control module, the ECM will not allow the fuel system to operate. • The ACTECO engine utilizes a returnless fuel delivery system. 04– Chery Automobile Co., Ltd.
Page 322 350 kPa (3.5 bar) Fuel Pressure at Fuel Rail - Key Off 330 kPa (3.3 bar) in 10 minutes Fuel Pressure at Fuel Rail - Engine Idle 350 kPa (3.5 bar) - 370 kPa (3.7 bar) Chery Automobile Co., Ltd. 04–...
Page 323 GENERAL INFORMATION Special Tools Digital Multimeter Fluke 15B & 17B Fuel Pressure Gauge Fuel Pump Remover CH-20032 Service Jack 04– Chery Automobile Co., Ltd.
Page 324: Fuel Delivery System
GENERAL INFORMATION Electrical Schematics Fuel Delivery System (Page 1 of 4) PZSMW040001T Chery Automobile Co., Ltd. 04–...
Page 325 GENERAL INFORMATION Fuel Delivery System (Page 2 of 4) PZSMW040002T 04– Chery Automobile Co., Ltd.
Page 326 GENERAL INFORMATION Fuel Delivery System (Page 3 of 4) PZSMW040003T Chery Automobile Co., Ltd. 04–...
Page 327 GENERAL INFORMATION Fuel Delivery System (Page 4 of 4) PZSMW040004T 04– Chery Automobile Co., Ltd.
Page 328: Diagnosis & Testing
4. If operating pressure is above 350 kPa (3.5 bar), the fuel pump is OK, but the fuel pressure regulator is defec- tive. Replace the fuel pump (See Fuel Pump Removal & Installation in Section 04 Fuel Delivery). NOTE: The fuel pressure regulator is integrated into the fuel pump assembly and is not serviced separately. Chery Automobile Co., Ltd. 04–...
Page 329 · Replace the fuel injector(s) Injector(s) · Failure to start (starting difficulties) · An accumulation of contaminants · Clean injectors regularly with an Reasons For Fuel Injector Failure inside the injector due to lack of approved method maintenance 04– Chery Automobile Co., Ltd.
Page 330: Removal & Installation
1. Release the fuel system pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery). 2. Remove the negative battery cable. 3. Remove the rear seat cushion (See Rear Seat Removal & Installation in Section 15 Body & Accessories). 4. Remove the fuel pump cover. Chery Automobile Co., Ltd. 04–...
Page 331 • Turn the ignition switch to ON (without starting the engine) to apply fuel pressure to the fuel system, then check the fuel line connections for fuel leaks. • Start the engine and let it idle and check for fuel leaks at the fuel system connections. 04– Chery Automobile Co., Ltd.
Page 332: Fuel Pump Inspection
(+) probe to terminal – 2 < 130 Digital multimeter negative (-) probe to terminal – 3 Battery positive (+) to terminal – 2 8 - 16 V Battery negative (-) to terminal – 3 Chery Automobile Co., Ltd. 04–...
Page 333: Fuel Filter
3. Remove the fuel lines (1) and fuel filter retaining screw (2). PZSM040007 4. Remove the fuel filter. 5. Installation is in the reverse order of removal. Installation Notes: • Verify there are NO leaks at the fuel line connections of the fuel filter. 04– Chery Automobile Co., Ltd.
Page 334: Fuel Injector Rail
4. Disconnect the electrical connectors from the fuel injectors. 5. Remove the fuel line from the fuel rail. 6. Remove the two fuel rail bracket bolts (1). (Tighten: Fuel rail bracket bolts to 11 N·m) PZSM040004 Chery Automobile Co., Ltd. 04–...
Page 335: Fuel Injector
2. Disconnect the negative battery cable. 3. Disconnect the electrical connectors from the fuel injectors. 4. Remove the intake manifold (See Intake Manifold Removal & Installation in Section 02 Engine). 5. Remove the fuel line from the fuel rail. 04– Chery Automobile Co., Ltd.
Page 336 • Use care to match the correct fuel injector with the correct fuel injector electrical connector when reconnecting the fuel injector electrical connectors. • Place each fuel injector in the injector bracket vertically, then attach the injector to the bracket with the retaining clips. Chery Automobile Co., Ltd. 04–...
Page 337: Fuel Injector Inspection
3. Remove the rear seat cushion (See Rear Seat Removal & Installation in Section 15 Body & Accessories). 4. Remove the fuel pump (See Fuel Pump Removal & Installation in Section 04 Fuel Delivery). 5. Drain the fuel from the tank. 04– Chery Automobile Co., Ltd.
Page 338 6. Disconnect the two fuel tank hoses (1). PZSM040009 7. Disconnect the vapor canister line (1). 8. Disconnect the fuel line (2). PZSM040005 9. Raise and support the vehicle. 10. Using a service jack, support the fuel tank. Chery Automobile Co., Ltd. 04–...
Page 339 ON-VEHICLE SERVICE 11. Remove the four retaining bolts (1) from the fuel tank straps. PZSM040006 12. Remove the fuel tank from the vehicle. 13. Installation is in the reverse order of removal. 04– Chery Automobile Co., Ltd.
Page 340 Negative Battery Cable 05-9 Starter Motor Bench Test 05-5 Removal & Installation 05-9 Starter Solenoid Test 05-5 Starter Motor Assembly 05-9 Description 05-9 ON-VEHICLE SERVICE 05-6 Operation 05-9 Battery 05-6 Removal & Installation 05-10 Description 05-6 Chery Automobile Co., Ltd. 05–...
Page 341 These components form two separate circuits. A high amperage circuit that feeds the starter motor up to 150 amps, and a control circuit that operates on less than 20 amps. Specifications Torque Specifications DESCRIPTION TORQUE (N·m) Starter Mounting Bolts Battery Positive Cable Nut 05– Chery Automobile Co., Ltd.
Page 342 GENERAL INFORMATION Special Tools Digital Multimeter Fluke 15B & 17B Chery Automobile Co., Ltd. 05–...
Page 343: Starting System
GENERAL INFORMATION Electrical Schematics Starting System (Page 1 of 1) PZSMW050001T 05– Chery Automobile Co., Ltd.
Page 344 If there is continuity, go to Step 4. If not, replace the faulty starter motor assembly. 4. Using a continuity tester, check for continuity between the solenoid terminal and the solenoid case. There should be continuity. If not, replace the faulty starter motor assembly. VISM050007 Chery Automobile Co., Ltd. 05–...
Page 345 This movement of electrons produces a flow of electrical current through the load device attached to the battery terminals. Removal & Installation 1. Loosen the negative and positive battery cable retaining nuts (1) and disconnect the cables. PZSM050001 05– Chery Automobile Co., Ltd.
Page 346 PZSM050005 3. Remove the battery. 4. Installation is in the reverse order of removal. Battery Tray Removal & Installation 1. Loosen the negative and positive battery cable retaining nuts (1) and disconnect the cables. PZSM050001 Chery Automobile Co., Ltd. 05–...
Page 347 3. Remove the four bolts (1) from the battery tray. PZSM050004 4. Lift the battery tray out of the engine compartment and remove from the vehicle. 5. Installation is in the reverse order of removal. 05– Chery Automobile Co., Ltd.
Page 348 This feature makes it possible to reduce the dimensions of the starter. At the same time, it allows higher armature rotational speed and delivers increased torque through the starter pinion gear to the starter ring gear. Chery Automobile Co., Ltd. 05–...
Page 349 6. Remove the two starter mounting bolts (1) connect- ing the starter and transaxle. (Tighten: Starter mounting bolts to 30 N·m) PZSM050002 7. Remove the starter from the engine. 8. Installation is in the reverse order of removal. 05– Chery Automobile Co., Ltd.
Page 350: Charging System
CHARGING SYSTEM GENERAL INFORMATION ON-VEHICLE SERVICE 05-12 05-15 Description 05-12 Generator 05-15 Operation 05-12 Removal & Installation 05-15 Specifications 05-12 Generator Inspection 05-15 Special Tools 05-12 Electrical Schematics 05-13 DIAGNOSIS & TESTING 05-14 Generator Noise 05-14 Chery Automobile Co., Ltd. 05–...
Page 351: General Information
From the diodes, rectified DC current is delivered to the vehicle’s electrical system through the generator, battery, and ground terminals. Specifications Torque Specifications DESCRIPTION TORQUE (N·m) Generator Cable Nut Generator Mounting Bolt Special Tools Digital Multimeter Fluke 15B & 17B 05– Chery Automobile Co., Ltd.
Page 352: Electrical Schematics
GENERAL INFORMATION Electrical Schematics Charging System (Page 1 of 1) PZSMW050002T Chery Automobile Co., Ltd. 05–...
Page 353: Diagnosis & Testing
• Worn, loose or defective bearings • Loose or defective drive pulley • Incorrect, worn, damaged or misadjusted drive belt • Loose mounting bolts • Misaligned drive pulley • Defective stator • Damaged internal fins 05– Chery Automobile Co., Ltd.
Page 354: Removal & Installation
NOTE: If the battery warning lamp lights, there may be a problem with the charging system. 2. With the engine running, check the output voltage of the generator with a digital multimeter (note the voltage). 3. If the voltage is between 14.1 - 14.7 V, the generator is good. Chery Automobile Co., Ltd. 05–...
Page 355 06-11 ON-VEHICLE SERVICE 06-8 Cooling Fan 06-12 Cooling System Draining and Filling 06-8 Description 06-12 Cooling System Draining Procedure 06-8 Operation 06-12 Cooling System Filling Procedure 06-9 Removal & Installation 06-13 Cooling Fan Inspection 06-14 Chery Automobile Co., Ltd. 06–...
Page 356: Operation
TORQUE (N·m) Coolant Pump Mounting Bolts 8 ± 3 Radiator Support Mounting Bolts Coolant Fan Mounting Bolts Thermostat Mounting Bolts 8 ± 3 Fluid Specifications DESCRIPTION CAPACITY (L) Cooling System Special Tools Cooling System Pressure Tester 06– Chery Automobile Co., Ltd.
Page 357: Cooling System
GENERAL INFORMATION Electrical Schematics Cooling System (Page 1 of 3) PZSMW060001T Chery Automobile Co., Ltd. 06–...
Page 358 GENERAL INFORMATION Cooling System (Page 2 of 3) PZSMW060002T 06– Chery Automobile Co., Ltd.
Page 359 GENERAL INFORMATION Cooling System (Page 3 of 3) PZSMW060003T Chery Automobile Co., Ltd. 06–...
Page 360: Diagnosis And Testing
The coolant mixture offers optimum engine cooling and protection against corrosion when mixed to a freeze point of -37°C to -46°C. The use of a hydrometer or a refractometer can be used to test coolant concentration. 06– Chery Automobile Co., Ltd.
Page 361: Cooling System Troubleshooting Chart
· Cooling fan motor(s) · Replace cooling fan motor(s) · Wiring · Repair wiring Electric Cooling Fan(s) On All The · Relay(s) · Replace relay(s) Time · Engine Control Module (ECM) · Replace the ECM Chery Automobile Co., Ltd. 06–...
Page 362: On-Vehicle Service
4. Attach one end of a hose to the drain plug (1). Put the other end into a clean container. Remove the drain plug (1) and drain the coolant from the radiator. PZSM060006 5. After the radiator is empty, install the radiator drain plug. 06– Chery Automobile Co., Ltd.
Page 363: Cooling System Filling Procedure
Failure to follow these instructions may result in serious personal injury. 1. Drain the cooling system (See Cooling System Draining Procedure in Section 06 Cooling System). 2. Remove the coolant hose. Chery Automobile Co., Ltd. 06–...
Page 364: Coolant Pump
1. Drain the cooling system (See Cooling System Draining Procedure in Section 06 Cooling System). 2. Remove the timing belt (See Timing Belt Removal & Installation in Section 02 Engine). 06– Chery Automobile Co., Ltd.
Page 365: Coolant Pump Inspection
1. Disconnect the negative battery cable. 2. Drain the cooling system (See Cooling System Draining and Filling in Section 06 Cooling System). 3. Remove the air intake pipe retaining bolt. Chery Automobile Co., Ltd. 06–...
Page 366: Cooling Fan
• If the water temperature is greater than 94°C after the fan is switched off, the fan will continue to operate for 0.5 minute. • If the water temperature is less than 85°C after the fan is switched off, the fan will stop operating. 06– Chery Automobile Co., Ltd.
Page 367 8. Installation is in the reverse order of removal. Installation Notes: • Verify the cooling system is filled to proper specifications. • Start the engine and verify there are no leaks in the cooling system. Chery Automobile Co., Ltd. 06–...
Page 368: Cooling Fan Inspection
Battery positive (+) to terminal – 1 Turns smoothly with high Battery negative (-) to speed terminal – 3 Battery positive (+) to terminal – 2 Turns smoothly with low Battery negative (-) to speed terminal – 3 06– Chery Automobile Co., Ltd.
Page 369 Operation 07-2 Catalytic Converter 07-7 Specifications 07-3 Description 07-7 Operation 07-7 DIAGNOSIS AND TESTING 07-4 Removal & Installation 07-7 Exhaust System Diagnostic Chart 07-4 ON-VEHICLE SERVICE 07-5 Exhaust Pipe Assembly 07-5 Removal & Installation 07-5 Chery Automobile Co., Ltd. 07–...
Page 370: Exhaust System
The exhaust system channels exhaust gases from the engine and away from the vehicle. 07– Chery Automobile Co., Ltd.
Page 371: Specifications
GENERAL INFORMATION Specifications Torque Specifications DESCRIPTION TORQUE (N·m) Catalytic Converter Mounting Nuts 60 ± 5 Exhaust Flange Bolts 60 ± 5 Chery Automobile Co., Ltd. 07–...
Page 372: Diagnosis And Testing
· Leaks at pipe joints. joints. · Ignition timing incorrect. · Adjust the timing. Excessive Exhaust Temperature · Poor fuel quality. · Change and clean the fuel tank. · Engine running rich. · Repair as needed. 07– Chery Automobile Co., Ltd.
Page 373: On-Vehicle Service
2. Remove the exhaust manifold (See Exhaust Manifold Removal & Installation in Section 02 Engine). 3. Remove the catalytic converter to exhaust manifold connecting bolts (1). 4. Remove the oxygen sensor (2). PZSM070002 5. Raise and support the vehicle. 6. Remove all the support isolators and connecting bolts. Chery Automobile Co., Ltd. 07–...
Page 374: Muffler
5. Clean exhaust pipe ends and ensure all exhaust components fit properly. 6. Discard broken or worn isolators, rusted or overused clamps, supports, and attaching parts. 7. Installation is in the reverse order of removal. Installation Note: • Replace the gasket between two pipes. 07– Chery Automobile Co., Ltd.
Page 375: Catalytic Converter
The temperature of the converter rises to a high level after a short period of engine oper- ating time. 1. Disconnect the negative battery cable. 2. Remove the heat shield retaining bolt (1). PZSM070004 3. Remove the exhaust manifold (See Exhaust Manifold Removal & Installation in Section 02 Engine). Chery Automobile Co., Ltd. 07–...
Page 376 10. Clean exhaust pipe ends and ensure all exhaust components fit properly. 11. Discard broken or worn isolators, rusted or overused clamps, supports, and attaching parts. 12. Installation is in the reverse order of removal. Installation Note: • Replace the gasket between two pipes. 07– Chery Automobile Co., Ltd.
Page 377 08-15 Disassembly 08-32 Removal & Installation 08-15 1st-2nd Shift Fork 08-33 Disassembly 08-33 TRANSAXLE UNIT REPAIR 08-19 3rd, 4th, 5th & Reverse Fork Shaft 08-34 Transaxle 08-19 Disassembly 08-34 Specifications 08-19 Disassembly 08-19 Assembly 08-23 Chery Automobile Co., Ltd. 08–...
Page 378 The transaxle consists of three major sub-assemblies: • Input shaft • Output shaft • Differential assembly The transaxle shift system consists of the following components: • Mechanical shift cover • Shift rails • Shift forks • Shift cables 08– Chery Automobile Co., Ltd.
Page 379 GENERAL INFORMATION QR513 Internal View 1 – Transaxle Housing 4 – Output Shaft 2 – Clutch Housing 5 – Differential 3 – Input Shaft PZSM080007 Chery Automobile Co., Ltd. 08–...
Page 380 5-R fork moves the 5-R synchronizer sleeve towards the output shaft reverse gear. The synchronizer sleeve engages the reverse gear clutch teeth, engaging the gear to the output shaft, and allowing power to transmit through the output shaft to the differential. 08– Chery Automobile Co., Ltd.
Page 381 26 – 5th Driven Gear BESM080033 Transaxle Identification-Number The transaxle serial number can be found on a metal tag (1) fastened to the transaxle case on the clutch housing. The third row data is transaxle serial number. PZSM080008 Chery Automobile Co., Ltd. 08–...
Page 382 Engine To Transaxle Bolts 70 ± 5 Gear Ratio Specifications GEAR RATIO 3.545 2.05 1.423 1.065 0.865 Reverse 3.364 Speedometer 0.806 Final Drive Ratio 4.056 Lubrication Specifications DESCRIPTION ITEM Transaxle Fluid Quantity 1.8L Fluid Type 75W-90 GL-4 08– Chery Automobile Co., Ltd.
Page 383 GENERAL INFORMATION Special Tools Clutch Pressure Plate Installer CH-20014 Flywheel Fixture CH-20009 Differential Seal Installer CH-30002 Chery Automobile Co., Ltd. 08–...
Page 384 GENERAL INFORMATION Bearing Remover MB-998801 Bearing Remover MB-998917 08– Chery Automobile Co., Ltd.
Page 385 • Transaxle noise is most often a result of worn or damaged components. Chipped, broken gear or synchronizer teeth, and worn bearings all cause noise. Inspect the following: − Insufficient lubrication − Incorrect lubricant − Improperly assembled or damaged internal components Chery Automobile Co., Ltd. 08–...
Page 386 (Tighten: Air intake pipe bolts to 8 ± 3 N·m) PZSM020001 3. Remove the clamps (1) on each side of the intake manifold hose. PZSM020003 4. Remove the clamp (1) on the intake manifold hose. PZSM020046 5. Remove the intake manifold hose. 08– Chery Automobile Co., Ltd.
Page 387 8. Remove the battery and battery tray (See Battery Removal & Installation in Section 05 Starting & Charging). 9. Remove the two shift cables (1) from the transaxle. PZSM080002 10. Remove the shift cable clamp (1) from the shift cable bracket. VISM080026 11. Remove the shift cable bracket retaining bolts (1). VISM080025 Chery Automobile Co., Ltd. 08–...
Page 388 16. Support the engine using an engine support fixture or suitable jack. 17. Raise the vehicle. 18. Remove the engine undercover and splash shields. 19. Remove the drain plug (1) and drain the transaxle fluid. PZSM080031 08– Chery Automobile Co., Ltd.
Page 389 21. Remove the left transaxle mount bolts (1) and bracket bolts (2). PZSM020031 22. Remove the transaxle front mount bolts (1) and bracket bolts (2). (Tighten: Transaxle front mount bolts to 80 ± 5 N·m) PZSM020032 Chery Automobile Co., Ltd. 08–...
Page 390 (1) and fill the transaxle fluid to the proper level. NOTE : When filling the transaxle with fluid, fill the transaxle until the fluid is even with the fill hole plug. − Transaxle fluid quantity: 1.8L VISM080013 08– Chery Automobile Co., Ltd.
Page 391 3. Remove the retaining bolts (1) from the air intake pipe. (Tighten: Air intake pipe bolts to 8 ± 3 N·m) PZSM020001 4. Remove the clamps (1) on each side of the intake manifold hose. PZSM020003 Chery Automobile Co., Ltd. 08–...
Page 392 8. Remove the air cleaner housing. 9. Remove the battery and battery tray retaining bolts (1) (See Battery Removal & Installation in Section 05 Starting & Charging). PZSM020021 10. Remove the two shift cables (1) from the transaxle. BESM080051 08– Chery Automobile Co., Ltd.
Page 393 15. Remove the lower console (See Lower Console Removal & Installation in Section 15 Body). 16. Remove the crossover cable and the selector cable (1) from the gearshift mechanism. PZSM020049 17. Remove the four bolts (1) and then remove the gearshift mechanism from the bracket. BESM080053 Chery Automobile Co., Ltd. 08–...
Page 394 (2). 19. Remove the gear selector & shift cable assembly. VISM080006 20. Installation is in the reverse order of removal. NOTE : Selector cables can be adjusted with the adjustment bolt (1). LTSM080180 08– Chery Automobile Co., Ltd.
Page 395 Reverse Lock Mechanism Bolt 18 ± 2 Disassembly 1. Remove the oil drain plug (1) and drain the trans- axle oil. (Tighten: Drain Plug to 44 ± 3 N·m) 2. Place the transaxle on a work bench. PZSM080031 Chery Automobile Co., Ltd. 08–...
Page 396 7. Remove the backup lamp switch (1). (Tighten: Backup lamp switch to 20 ± 2 N·m) PZSM080037 8. Remove the idle gear shaft retaining bolt (1). (Tighten: Idle gear shaft bolt to 38 ± 2.5 N·m) PZSM080010 08– Chery Automobile Co., Ltd.
Page 397 12. Remove the three locating seat retaining bolts (1) of the 3rd-4th fork shaft, reverse fork shaft and the 1st-2nd fork shaft. (Tighten: Fork shaft seat bolts to 44 ± 3 N·m) NOTE: The 1st-2nd location bolt is longer. PZSM080009 Chery Automobile Co., Ltd. 08–...
Page 398 (Tighten: Clutch housing and transaxle housing bolt to 25 ± 2 N·m) PZSM080013 15. Using a copper bar, tap the transaxle housing. PZSM020045 16. Separate the transaxle housing (1) from clutch housing (2). PZSM080014 08– Chery Automobile Co., Ltd.
Page 399 20. Separate the 3rd-4th gear shift fork and shift fork rail, 5th-reverse gear shift fork and shift fork rail from input and output shaft together. PZSM080016 Assembly 1. Assemble in the reverse order of disassembly. Chery Automobile Co., Ltd. 08–...
Page 400 TRANSAXLE UNIT REPAIR Input Shaft Specifications Clearance Specifications SYNCHRONIZER RING VALUE OF A (mm) WEARING LIMIT (mm) 1st-2nd Gear 1.10 - 1.17 0.05 3rd-4th Gear 1.35 - 1.90 0.05 5th Gear 1.10 - 1.17 0.05 08– Chery Automobile Co., Ltd.
Page 401 TRANSAXLE UNIT REPAIR Disassembly PZSM080020 Chery Automobile Co., Ltd. 08–...
Page 402 7. Remove the gear baffle thrust clamp hoop and remove the gear baffle. 8. Remove the 4th driving gear. 9. Remove the 3rd and 4th needle roller bearing. 10. Remove 3rd-4th gear synchronizer. 11. Using snap-ring pliers remove the front snap ring. 08– Chery Automobile Co., Ltd.
Page 403 Any damage or wear on the tooth surfaces of helical gear and clutch gear. Any damage, wear or coarsening on the syn- chronizer’s conical surface. Any damage or wear on the inner-diameter, front and rear surfaces. BESM080016 Chery Automobile Co., Ltd. 08–...
Page 404 SYNCHRONIZER RING VALUE OF A (mm) WEARING LIMIT (mm) 1st-2nd Gear 1.10 - 1.17 0.05 3rd-4th Gear 1.35 - 1.90 0.05 5th Gear 1.10 - 1.17 0.05 Assembly 1. Assemble in the reverse order of disassembly. 08– Chery Automobile Co., Ltd.
Page 405 TRANSAXLE UNIT REPAIR Output Shaft Disassembly Chery Automobile Co., Ltd. 08– PZSM080021...
Page 406 3. Using special tool MB-998801 (2), remove the 4th and 5th driven gear (1) with press. LTSM080064 4. Using special tool MB-998801 (2), remove the gear sleeve (1) with press. LTSM080065 5. Remove the 3rd driven gear. 6. Remove the 2nd driven gear. 08– Chery Automobile Co., Ltd.
Page 407 Damage on the tooth surfaces and conical surfaces Assembly 1. Assemble in the reverse order of disassembly. Idler Gear Disassembly 1 – Idler Gear Shaft 3 – Idler Gear Gasket 2 – Reverse Idler Gear VISM080042 Chery Automobile Co., Ltd. 08–...
Page 408 PZSM010008 Assembly 1. Assemble in the reverse order of disassembly. Reverse Shift Fork Disassembly 1. Remove the reverse shift arm bracket retaining bolts (1) and the reverse shift arm assembly (2) . VISM010008 08– Chery Automobile Co., Ltd.
Page 409 2. Use a suitable tool to remove the shift fork spring pin from the shift fork and the shift fork shaft. VISM020015 3. Remove the shift fork shaft (1) from the shift fork (2). VISM010011 Chery Automobile Co., Ltd. 08–...
Page 410 7 – Interlock Pin 3 – Spring Pin 8 – 5th-Reverse Shift Fork Shaft 4 – 3rd-4th Shift Fork 9 – 5th-Reverse Shift Fork 5 – Split Baffle Ring 10 – Spring Pin for Fork Shaft BESM080026 08– Chery Automobile Co., Ltd.
Page 411 4. Separate the 3rd-4th shift fork shaft (1) and 3rd-4th shift fork (4). 5. Separate the reverse shaft (6). 6. Remove the interlock pin (7) and spring pin (10) 7. Separate the 5th-reverse shift fork shaft (8) from 5th-reverse shift fork (9). Chery Automobile Co., Ltd. 08–...
Page 412 DIFFERENTIAL GENERAL INFORMATION DIFFERENTIAL UNIT REPAIR 08-37 08-39 Description 08-37 Differential Carrier 08-39 Operation 08-38 Removal & Installation 08-39 Specifications 08-38 Disassembly 08-39 Special Tools 08-38 Inspection 08-40 Assembly 08-40 08– Chery Automobile Co., Ltd.
Page 413: General Information
1 – Differential Bearing 4 – Side Gear 2 – Planetary Gear 5 – Planetary Gear Shaft 3 – Final Drive Driven Gear 6 – Bolts - Final Drive Driven Gear and Differential Housing LTSM080199 Chery Automobile Co., Ltd. 08–...
Page 414: Operation
The side gears are connected to the axle shafts. Specifications Clearance Specifications DESCRIPTION CLEARANCE (mm) Clearance between side gear and planetary gear 0.025 - 0.150 Adjusting washer 0.93 - 1.00 Special Tools Bearing Remover MD-998801 Differential Seal Installer CH-30002 08– Chery Automobile Co., Ltd.
Page 415: Differential Unit Repair
10 – Side Gear 5 – Driving Gear - Odometer 11 – Planetary Gear 6 – Spherical Washer Planetary Gear BESM080028 1. Mount the differential in a vice. 2. Remove the eight drive gear bolts (1). LTSM080117 Chery Automobile Co., Ltd. 08–...
Page 416: Inspection
The adjusting washer for any new side gear should be the appropriate thickness (0.93-1.00 mm). Engage two planetary gears with side gears behind the spherical washers on the backs of the planetary gears (rotate the gears for proper alignment). 08– Chery Automobile Co., Ltd.
Page 417 0.93 - 1.00 mm • If any measured clearance is not within specifications, select and install the appropriate adjusting washer(s) and then measure the clearances again. NOTE : Adjust the side clearance equally on both sides. Chery Automobile Co., Ltd. 08–...
Page 418 GENERAL INFORMATION 08-43 Removal & Installation 08-47 Description 08-43 Operation 08-43 Clutch Cable 08-47 Specifications 08-43 Removal & Installation 08-47 Special Tools 08-44 CLUTCH ASSEMBLY SERVICE 08-45 Clutch and Pressure Plate 08-45 Removal & Installation 08-45 08– Chery Automobile Co., Ltd.
Page 419: General Information
Specifications Torque Specifications DESCRIPTION TORQUE (N·m) Slave Cylinder Bolts 20 ± 2 Clutch Pressure Plate Bolts 30 ± 5 Flywheel Bolts 80 ± 5 Chery Automobile Co., Ltd. 08–...
Page 420: Special Tools
GENERAL INFORMATION Special Tools Flywheel Fixture CH-2009 Clutch Pressure Plate Installer CH-20014 08– Chery Automobile Co., Ltd.
Page 421: Clutch Assembly Service
(Tighten: Clutch pressure plate bolts to 30 ± 5 N·m) 4. Remove the modular clutch assembly. PZSM080006 5. Remove the flywheel-to-crankshaft bolts (1) and remove the flywheel (if necessary for resurfacing). (Tighten: Flywheel-to-crankshaft bolts to 80 ± 5 N·m) BESM020058 Chery Automobile Co., Ltd. 08–...
Page 422 • If found abnormal, replace the clutch plate assembly. Never separate the clutch plate assembly into the dia- phragm spring and clutch plate. • Check the contact surface of the flywheel and friction lining for irregular wear or hot spots. Repair or replace if necessary. 08– Chery Automobile Co., Ltd.
Page 423: Clutch Release Mechanism
(3). 4. Remove the release bearing (1). 5. Installation is in the reverse order of removal. PZSM080022 Clutch Cable Removal & Installation 1. Remove the clutch cable to clutch pedal clamp (1). PZSM080046 Chery Automobile Co., Ltd. 08–...
Page 424 (Tighten: Clutch cable retaining bolt to 10 ± 2 N·m) PZSM080045 3. Remove the clutch cable (1) to the release shaft arm assembly. 4. Remove the clutch cable. 5. Installation is in the reverse order of removal. PZSM080034 08– Chery Automobile Co., Ltd.
Page 425 Step 1: Stability Test 08-62 Automated Manual Transaxle (AMT) Step 2: Self-Learning Test 08-62 Control Module 08-105 Step 3: Road Test 08-62 Removal & Installation 08-105 Diagnostic Trouble Code (DTC) List 08-63 Automated Manual Transaxle DTC List 08-63 Chery Automobile Co., Ltd. 08–...
Page 426: General Information
(ECM). The gear position is determined by the gearshift lever. • Automatic Mode: The AMT control module performs gear changes according to a predetermined vehicle control strategy. • Manual Mode: The driver controls the gear changes through the use of the gearshift lever. 08– Chery Automobile Co., Ltd.
Page 427: Amt Hydraulic Fluid Inspection
When refilling the AMT system hydraulic fluid, only use approved hydraulic fluid specifically designed for the AMT system (Chery Part No. QR512E-4004011) available in one liter containers. No other fluids such as transmission fluid, brake fluid or power steering fluid can be used. If any other type of fluid is used, the AMT system could expe- rience the following failures: •...
Page 428: Special Tools
GENERAL INFORMATION Special Tools Diagnostic Scan Tool X-431 Engine Analyzer KES-200 Digital Multimeter Fluke 15B & 17B CAN-BUS Diagnostic Connector 08– Chery Automobile Co., Ltd.
Page 429: Electrical Schematic
GENERAL INFORMATION Electrical Schematic AMT Control System (Page 1 of 6) PZSMW080001T Chery Automobile Co., Ltd. 08–...
Page 430 GENERAL INFORMATION AMT Control System (Page 2 of 6) PZSMW080002T 08– Chery Automobile Co., Ltd.
Page 431 GENERAL INFORMATION AMT Control System (Page 3 of 6) PZSMW080003T Chery Automobile Co., Ltd. 08–...
Page 432 GENERAL INFORMATION AMT Control System (Page 4 of 6) PZSMW080004T 08– Chery Automobile Co., Ltd.
Page 433 GENERAL INFORMATION AMT Control System (Page 5 of 6) PZSMW080005T Chery Automobile Co., Ltd. 08–...
Page 434 GENERAL INFORMATION AMT Control System (Page 6 of 6) PZSMW080006T 08– Chery Automobile Co., Ltd.
Page 435: Automated Manual Transaxle (Amt) Control Module Connector Pin-Out Table
Gear 1 Command CAN-L External Sensor Power Supply Gear Selection Lever Bit 2 Cranking Input Switch ECO/Normal Mode Input Switch Clutch Speed Positive Door Switch Input Gear Position Sensor External Sensor Power Supply Hydraulic Pressure Sensor Chery Automobile Co., Ltd. 08–...
Page 436: Diagnosis & Testing
If multiple wires are crimped to one eyelet, make sure no excess wire insulation has been crimped creating a bad ground. Diagnostic Tools 1. Diagnostic Scan Tool X-431 2. Digital Multimeter 3. Jumper Wire 08– Chery Automobile Co., Ltd.
Page 437: Procedure
• The failure is stored in the EPROM automatically when the system is shut down, and it can be viewed with the scan tool. • The failure is confirmed during operation. • The system will resume when the failure is confirmed. Chery Automobile Co., Ltd. 08–...
Page 438: Amt Re-Calibration And Self-Learning Procedure
6. Press the accelerator pedal 30%, and increase the engine speed to more than 2500 RPM, and allow the vehi- cle to self-learn. 7. Turn the ignition switch off. 8. After several seconds, the system will be shut off automatically. 08– Chery Automobile Co., Ltd.
Page 439: Diagnostic Trouble Code (Dtc) List
P0932 Hydraulic Pressure Sensor P0933 Hydraulic Circuit P0942 Hydraulic Circuit P0945 Hydraulic Pump Electrical Supply and Relay P1215 Door Switch From Wire P1749 Paddles Input P2712 Hydraulic Circuit Leakage P2900 ECO Switch P2901 Hydraulic Circuit Chery Automobile Co., Ltd. 08–...
Page 440 Engine Maximum Torque From CAN P2908 Clutch Error P2909 Gearbox Error P290A Gear Position Sensor Error P290D Shift Electro Valves For Low Rank P290E Shift Electro Valves For High Rank U1601 NCR State U1700 NBC State U1701 NCM State 08– Chery Automobile Co., Ltd.
Page 441: Diagnostic Trouble Code (Dtc) Tests
DIAGNOSIS & TESTING Diagnostic Trouble Code (DTC) Tests P0560 - Battery Voltage Too Low PZSMW080007T Chery Automobile Co., Ltd. 08–...
Page 442 DIAGNOSIS & TESTING PZSMW080008T 08– Chery Automobile Co., Ltd.
Page 443 Section 08 Transaxle for more information). NOTE : • Troubleshoot any Engine Control Module (ECM) charging/cranking DTCs before proceeding. • The following tools are required to perform the following test: • X-431 Scan Tool • Digital Multimeter Chery Automobile Co., Ltd. 08–...
Page 444 • Disconnect the AMT control module electrical con- nector (1). • Inspect the electrical connector for damage. Is the electrical connector OK? >> Go to the next step. >> Repair or replace the electrical connector as necessary. PZSMD080002 08– Chery Automobile Co., Ltd.
Page 445 • Start the engine, raise the engine speed to above 1000 RPM. • Measure the charging system voltage at the battery positive and negative terminals. Is the voltage less than 9 V? >> Check the charging system. >> Go to the next step. Chery Automobile Co., Ltd. 08–...
Page 446 Replace the AMT control module (See AMT control module Removal & Installation in Section 08 Transaxle). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 08– Chery Automobile Co., Ltd.
Page 447: P0604 - Micro Processor Error, P060C
Section 08 Transaxle for more information). NOTE : • Troubleshoot any Engine Control Module (ECM) charging/cranking DTCs before proceeding. • The following tools are required to perform the following test: • X-431 Scan Tool • Digital Multimeter Chery Automobile Co., Ltd. 08–...
Page 448 Replace the AMT control module (See AMT Control Module Removal & Installation in Section 08 Transaxle). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 08– Chery Automobile Co., Ltd.
Page 449: P0715 - Clutch Speed
DIAGNOSIS & TESTING P0715 - Clutch Speed PZSMW080009T Chery Automobile Co., Ltd. 08–...
Page 450 • If DTC P0720 or P0805 are also present, diagnose and repair them before continuing with this test. • Using the appropriate diagnostic test tool, you can diagnose the AMT control module harness while the AMT con- trol module is still connected. This will help prevent electrical connector terminal damage. 08– Chery Automobile Co., Ltd.
Page 451 • Stop the vehicle and turn ignition switch off. • Disconnect clutch speed sensor electrical connector. • Inspect the electrical connector for damage. Is the electrical connector OK? >> Go to the next step. >> Repair or replace the electrical connector as necessary. Chery Automobile Co., Ltd. 08–...
Page 452 AMT CONTROL CONTINUITY SENSOR MODULE TERMINAL • Check the continuity between the clutch speed sensor terminal 2 and the AMT control module electrical connec- tor terminal 50. CLUTCH SPEED AMT CONTROL CONTINUITY SENSOR MODULE TERMINAL 08– Chery Automobile Co., Ltd.
Page 453 Replace the clutch speed sensor and repair the AMT signal ring if needed (excessive run-out of the signal ring in the AMT could result in interference between the signal ring and the sensor causing damage to the sensor). Chery Automobile Co., Ltd. 08–...
Page 454 The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. >> Replace the AMT control module (See AMT Control Module Removal & Installation in Section 08 Transaxle). 08– Chery Automobile Co., Ltd.
Page 455: P0904 - Gear Position Sensor
DIAGNOSIS & TESTING P0904 - Gear Position Sensor PZSMW080012T Chery Automobile Co., Ltd. 08–...
Page 456 Section 08 Transaxle for more information). NOTE : • Using the appropriate diagnostic test tool, you can diagnose the AMT control module harness while the AMT con- trol module is still connected. This will help prevent electrical connector terminal damage. 08– Chery Automobile Co., Ltd.
Page 457 Vehicle is driving Is the check result normal? >> The conditions that caused this DTC to set are not present at this time (See Diagnostic Help in Section 08 Transaxle). >> Go to the next step. Chery Automobile Co., Ltd. 08–...
Page 458 P-008, terminal side and ground. • 5 V should exist. Is the check result normal? >> Go to the next step. >> Repair or replace the circuit for an open, short to power or short to ground. PZSMD080011 08– Chery Automobile Co., Ltd.
Page 459 • Start the vehicle and monitor the value of GEAR POSITION with the X-431 scan tool. Is the check result normal? >> Go to the next step. >> Check the AMT gear condition, the gap between the sensor and the signal component, the gear selection lever. Chery Automobile Co., Ltd. 08–...
Page 460 The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. >> Replace the AMT control module (See AMT Control Module Removal & Installation in Section 08 Transaxle). 08– Chery Automobile Co., Ltd.
Page 461: P0914 - Shift Position Sensor
DIAGNOSIS & TESTING P0914 - Shift Position Sensor PZSMW080012T Chery Automobile Co., Ltd. 08–...
Page 462 Section 08 Transaxle for more information). NOTE : • Using the appropriate diagnostic test tool, you can diagnose the AMT control module harness while the AMT con- trol module is still connected. This will help prevent electrical connector terminal damage. 08– Chery Automobile Co., Ltd.
Page 463 Vehicle is driving Is the check result normal? >> The conditions that caused this DTC to set are not present at this time (See Diagnostic Help in Section 08 Transaxle). >> Go to the next step. Chery Automobile Co., Ltd. 08–...
Page 464 P-007, terminal side and ground. • 5 V should exist. Is the check result normal? >> Go to the next step. >> Repair or replace the circuit for an open, short to power or short to ground. PZSMD080012 08– Chery Automobile Co., Ltd.
Page 465 • Start the vehicle and monitor the value of SHIFT POSITION with the X-431 scan tool. Is the check result normal? >> Go to the next step. >> Check the AMT gear condition, the gap between the sensor and the signal component, the gear selection lever. Chery Automobile Co., Ltd. 08–...
Page 466 The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. >> Replace the AMT control module (See AMT Control Module Removal & Installation in Section 08 Transaxle). 08– Chery Automobile Co., Ltd.
Page 467: P0932 - Hydraulic Pressure Sensor
DIAGNOSIS & TESTING P0932 - Hydraulic Pressure Sensor PZSMW080011T Chery Automobile Co., Ltd. 08–...
Page 468 • If the DTC is detected, the DTC condition is current. Go to Diagnostic Procedure - Step 1. • If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 08 Transaxle for more information). 08– Chery Automobile Co., Ltd.
Page 469 • Disconnect the hydraulic pressure sensor electrical connector P-009. • Inspect the electrical connector for damage. Is the electrical connector OK? >> Go to the next step. >> Repair or replace the electrical connector as necessary. PZSMD080001 Chery Automobile Co., Ltd. 08–...
Page 470 • Check the signal circuit for a short to ground and a short to power supply. Is the check result normal? >> Go to step 6. >> Check the harness for an open, short to ground or short to power supply in the harness. 08– Chery Automobile Co., Ltd.
Page 471 Replace the AMT control module (See AMT Control Module Removal & Installation in Section 08 Transaxle). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 08–...
Page 472: P2904 - Clutch Error
DIAGNOSIS & TESTING P2904 - Clutch Error PZSMW080010T 08– Chery Automobile Co., Ltd.
Page 473 • If DTC P0805 is present, diagnose and repair it before continuing with this test. • Using the appropriate diagnostic test tool, you can diagnose the AMT control module harness while the AMT con- trol module is still connected. This will help prevent electrical connector terminal damage. Chery Automobile Co., Ltd. 08–...
Page 474 Go to the next step. ACTUATE TEST • With the X-431, perform the solenoid actuate test. • The solenoid should be heard. Is the check result normal? >> Go to step 8. >> Go to the next step. 08– Chery Automobile Co., Ltd.
Page 475 With the X-431, perform the solenoid actuate test. − If the solenoid can be heard, the system is normal. − If the solenoid can’t be heard, go to the next step. >> Replace the clutch solenoid valve. Chery Automobile Co., Ltd. 08–...
Page 476 • Check the harness for a short to power. Is the check result normal? >> Go to the next step. >> Repair or replace the circuit for an open, short to power or short to ground. 08– Chery Automobile Co., Ltd.
Page 477 The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. >> Replace the AMT control module (See AMT control module Removal & Installation in Section 08 Transaxle). Chery Automobile Co., Ltd. 08–...
Page 478: On-Vehicle Service
Hydraulic Pressure Sensor Clutch Position Sensor Crankshaft Position Sensor 3. Loosen the transaxle control shaft cover retaining bolt (1) and rotate the cover. 4. Rotate the shaft a quarter turns by using a screwdriver. PZSM100038 08– Chery Automobile Co., Ltd.
Page 479 (1). (Tighten: Control shaft cover retaining bolts to 44 ± 2 N·m) PZSM080050 6. Remove the two clutch control actuator retaining bolts (1). (Tighten: Clutch control actuator retaining bolts to 24 ± 2 N·m) PZSM080051 Chery Automobile Co., Ltd. 08–...
Page 480 Installation Notes: • During assembly, ensure that the clutch cable is installed in a loose state, with the distance between clutch cable control actuator to clutch control arm at 38 mm - 42 mm. PZSM080063 08– Chery Automobile Co., Ltd.
Page 481: Automated Manual Transaxle (Amt) Gearshift Mechanism
3. Disconnect the three AMT control module electrical connectors. 4. Remove the AMT control module retaining bolts (1). (Tighten: AMT control module retaining bolts to 10 ± 2 N·m) PZSM020053 5. Remove the AMT control module. Chery Automobile Co., Ltd. 08–...
Page 482 Front Hub and Bearing 09-5 DIAGNOSIS & TESTING 09-4 Removal & Installation 09-5 Vehicle Inspection 09-4 Front Axle Shaft 09-6 Noise Or Vibration On Turns 09-4 Removal & Installation 09-6 Clunking Noise During Acceleration 09-4 Chery Automobile Co., Ltd. 09–...
Page 483 The outer joint has a splined connection to the wheel hub and is retained with a lock nut. For further information on the front axle assembly see Front Sub-Frame Assembly Description & Operation in Section 10 Suspension. 09– Chery Automobile Co., Ltd.
Page 484 Brake Caliper Adapter To Steering Knuckle Bolts Brake Caliper To Adapter Bolts Dust Shield Bolts Hub And Bearing Mounting Bolts Outer Tie Rod End To Steering Knuckle Nut Lower Strut Mounting Nut Wheel Mounting Nuts Chery Automobile Co., Ltd. 09–...
Page 485 Vibration At High Speeds This problem could be a result of: • Foreign material (mud, etc.) packed on the backside of the wheel(s). • Out of balance tires or wheels. • Improper tire or wheel runout. 09– Chery Automobile Co., Ltd.
Page 486 4. Remove the front brake rotor (See Brake Rotor Removal & Installation in Section 12 Brakes). 5. Using a bearing puller, remove the hub (1) and bearing from the front knuckle. PZSM090001 6. Installation is in the reverse order of the removal. Chery Automobile Co., Ltd. 09–...
Page 487 6. Remove the nut (1) attaching the outer tie rod end to the steering knuckle. (Tighten: Outer tie rod end nut to 40 ± 5 N·m) 7. Using special tool CH-10002, separate the tie rod from the steering knuckle. LTSM110034 09– Chery Automobile Co., Ltd.
Page 488 • Move joint up/down, left/right, and in axial direction, check for any rough movement or significant looseness. • Check boot for cracks or other damage, and for grease leakage. • If damaged, disassemble axle shaft to verify damage, and repair or replace as necessary. Chery Automobile Co., Ltd. 09–...
Page 489 REAR AXLE Vibration At High Speeds 09-11 GENERAL INFORMATION 09-9 Description 09-9 ON-VEHICLE SERVICE Operation 09-10 09-12 Specifications 09-10 Rear Hub and Bearing 09-12 Removal & Installation 09-12 DIAGNOSIS & TESTING 09-11 Vehicle Inspection 09-11 09– Chery Automobile Co., Ltd.
Page 490 This independent action offers improved isolation from the effects of jounce and rebound. The rear axle consists of the following components: • Wheel hub • Wheel studs • Wheel bearing • Knuckle Chery Automobile Co., Ltd. 09–...
Page 491 For further information on the rear axle assembly see Rear Suspension Description & Operation in Section 10 Sus- pension. Operation The rear axle utilizes a sealed wheel bearing housed in the rear knuckle assembly. Specifications Torque Specifications DESCRIPTION TORQUE (N·m) Rear Axle Hub Nut Wheel Mounting Nuts 09– Chery Automobile Co., Ltd.
Page 492 Vibration At High Speeds This problem could be a result of: • Foreign material (mud, etc.) packed on the backside of the wheel(s). • Out of balance tires or wheels. • Improper tire or wheel runout. Chery Automobile Co., Ltd. 09–...
Page 493 4. Remove the rear axle hub nut (1). (Tighten: Rear axle hub nut to 135 N·m) 5. Remove the rear brake drum (2). PZSM090002 6. Remove the rear hub and bearing (1). 7. Installation is in the reverse order of removal. PZSM090003 09– Chery Automobile Co., Ltd.
Page 494 Front Strut 10-23 Operation 10-9 Disassembly 10-23 Removal & Installation 10-9 Inspection 10-24 Front Stabilizer Bar 10-11 Disposal Notice 10-24 Removal & Installation 10-11 Assembly 10-25 Front Stabilizer Bar Link 10-12 Removal & Installation 10-12 Chery Automobile Co., Ltd. 10–...
Page 495: General Information
1 - Front Strut Assembly 5 - Front Strut Rod 2 - Front Sub-Frame 6 - Front Steering Knuckle 3 - Front Stabilizer Bar 7 - Front Stabilizer Bar Link 4 - Front Lower Control Arm PZSM100002 10– Chery Automobile Co., Ltd.
Page 496: Operation
Stabilizer Bar Clamp Bolts 50 ± 5 Stabilizer Bar Link Nuts 110 ± 10 Strut-To-Tower Nuts 60 ± 5 Sub-Frame Mounting Bolts 150 ± 10 Strut To Steering Knuckle Bolts 110 ± 10 Wheel Mounting Nuts Chery Automobile Co., Ltd. 10–...
Page 497 GENERAL INFORMATION Special Tools Ball Joint Separator CH-10002 10– Chery Automobile Co., Ltd.
Page 498: Diagnosis & Testing
· Check and reset front wheel · Incorrect front wheel camber. camber. Lateral Pull · Wheel braking. · Correct braking condition causing · Excessive cross-caster. lateral pull. · Check wheel alignment and adjust if necessary. Chery Automobile Co., Ltd. 10–...
Page 499: Removal & Installation
2. Remove the wheel mounting nuts and the wheel assembly. (Tighten: Wheel mounting nuts to 110 N·m) 3. Use a suitable tool and un-stake the front axle shaft hub nut (1) from the groove in the front axle shaft. PZSM100037 10– Chery Automobile Co., Ltd.
Page 500 (Tighten: Outer tie rod end to the steering knuckle nut to 40 ± 5 N·m) LTSM110034 8. Using special tool CH-10002, separate the outer tie rod end from the steering knuckle. LTSM110027 Chery Automobile Co., Ltd. 10–...
Page 501 11. While holding the bolt heads stationary, remove the two nuts (1) from the bolts attaching the strut assembly to the steering knuckle. (Tighten: Strut to steering knuckle bolts to 110 ± 10 N·m) PZSM100025 10– Chery Automobile Co., Ltd.
Page 502 If damaged, the lower control arm is serviced only as a complete component. 1. Raise and support the vehicle. 2. Remove the wheel mounting nuts and the wheel assembly. (Tighten: Wheel mounting nuts to 110 N·m) Chery Automobile Co., Ltd. 10–...
Page 503 110 ± 10 N·m) PZSM100026 5. Remove the two lower control arm to the strut rod bolts (1). (Tighten: Lower control arm to the strut rod bolt to 75 ± 5 N·m) PZSM100016 10– Chery Automobile Co., Ltd.
Page 504 (Tighten: Wheel mounting nuts to 110 N·m) 3. Remove the stabilizer bar link nuts (1) attaching the stabilizer bar to the stabilizer bar link. (Tighten: Stabilizer bar link nuts to 110 ± 10 N·m) PZSM100012 Chery Automobile Co., Ltd. 10–...
Page 505 (Tighten: Lower control arm to the stabilizer bar link nut to 110 ± 10 N·m) PZSM100026 5. Installation is in the reverse order of removal. Installation Notes: • After installation, each bolt must be tightened to the required tightening torque. 10– Chery Automobile Co., Ltd.
Page 506 4. Remove the strut rod nut (1) attaching the strut rod to sub-frame. (Tighten: Strut rod nut to 105 ± 5 N·m) PZSM100024 5. Remove the strut rod. 6. Installation is in the reverse order of removal. Chery Automobile Co., Ltd. 10–...
Page 507 The top of the strut mounts directly to the strut tower of the vehicle using the three threaded studs on the strut assembly’s upper mount. BESM100012 10– Chery Automobile Co., Ltd.
Page 508 3. Remove the wheel mounting nuts and the wheel assembly. (Tighten: Wheel mounting nuts to 110 N·m) 4. Remove the brake fluid hose bracket retaining bolt (1). (Tighten: Brake oil hose bracket bolt to 10 ± 2 N·m) PZSM100015 Chery Automobile Co., Ltd. 10–...
Page 509 A coil-over front strut assembly supports each front coil spring. The top of the strut assembly mounts to the strut tower. Operation Coil springs are designed to store energy and subsequently release it and to absorb shock and maintain a force between contacting surfaces. Coil springs are rated for specific vehicle applications. 10– Chery Automobile Co., Ltd.
Page 510 9. Remove the upper mounting bracket. 10. Remove the upper spring seat and isolator. 11. Release the tension from the coil spring by backing off the compressor drive completely. Release the compressor hooks and remove the coil spring. Chery Automobile Co., Ltd. 10–...
Page 511 3. Support the engine using an engine support fixture or suitable jack. 4. Remove the engine undercover and splash shields. 5. Remove the intermediate shaft coupling bolt (1) at the steering gear. (Tighten: Intermediate shaft coupling bolt to 25 ± 5 N·m) PZSM110016 10– Chery Automobile Co., Ltd.
Page 512 (1) attaching the outer tie rod end to the steering knuckle. (Tighten: Outer tie rod end nut to 40 ± 5 N·m) LTSM110034 10. Using special tool CH-10002, separate the outer tie rod ends from both steering knuckles. LTSM110027 Chery Automobile Co., Ltd. 10–...
Page 513 (Tighten: Steering knuckle pinch bolt to 110 ± 10 N·m) PZSM100013 12. Raise and support the vehicle. 13. Remove the A/C pipe bracket retaining bolts (1) on the sub-frame (See Suction Line Removal & Instal- lation in 13 Heating And Air Conditioning). PZSM100001 10– Chery Automobile Co., Ltd.
Page 514 (Tighten: Low pressure line to steering gear 25 ± 5 N·m) PZSM110013 16. Remove the steering gear retaining bolts (1) to the sub-frame. (Tighten: Steering gear and sub-frame bolt to 100 ± 10 N·m) PZSM110023 Chery Automobile Co., Ltd. 10–...
Page 515 20. Remove the front sub-frame. 21. Separate the front lower control arm and the front stabilizer bar from sub-frame assembly. 22. Separate the front strut rod from the sub-frame. 23. Installation is in the reverse order of removal. 10– Chery Automobile Co., Ltd.
Page 516 6. Compress the coil spring until all coil spring tension is removed from the upper mount and bearing. CAUTION: Never use impact or high speed tools to remove the strut rod nut. Damage to the strut internal bearings can occur. Chery Automobile Co., Ltd. 10–...
Page 517 • Inspect the coil spring for any sign of damage to the coating. LTSM100011 Disposal Notice NOTE : Follow the procedure below to properly dispose of the strut assembly. • Pull the strut rod to extend the strut rod out as far as possible. 10– Chery Automobile Co., Ltd.
Page 518 2. Mount the new strut assembly into the fixture. LTSM100017 3. Insert the coil spring into the spring compressor. 4. Compress the coil spring to a distance of 120 mm between the two clamps. LTSM100018 Chery Automobile Co., Ltd. 10–...
Page 519 8. Install the upper spring holder with the index posi- tion of 180° angle between the punched hole and the spring strut mounting position (1). LTSM100021 9. Install the upper spacer and bearing. 10. Install the strut rod nut to the strut rod. 10– Chery Automobile Co., Ltd.
Page 520 10-33 Vibration At High Speed 10-30 Removal & Installation 10-33 Rear Cross Stay 10-34 ON-VEHICLE SERVICE 10-31 Removal & Installation 10-34 Trailing Arm 10-31 Rear Suspension 10-35 Removal & Installation 10-31 Removal & Installation 10-35 Chery Automobile Co., Ltd. 10–...
Page 521: General Information
Only frame contact or wheel lift hoisting equipment can be used on this vehicle. It cannot be hoisted using equipment designed to lift a vehicle by the rear axle. If this type of hoisting equipment is used, damage to rear suspension components will occur. 10– Chery Automobile Co., Ltd.
Page 522: Operation
Specifications Torque Specifications DESCRIPTION TORQUE (N·m) Strut Assembly Lower Mounting Bolt 110 ± 10 Strut Assembly Upper Mounting Nuts 110 ± 10 Cross Stay Assembly 110 ± 10 Trailing Arm Mounting Bolts 110 ± 10 Chery Automobile Co., Ltd. 10–...
Page 523: Diagnosis & Testing
Vibration At High Speed This problem could be a result of: • Foreign material (mud, etc.) packed on the backside of the wheel(s). • Out of balance tires or wheels. • Improper tire or wheel runout. 10– Chery Automobile Co., Ltd.
Page 524: On-Vehicle Service
(Tighten: Wheel mounting nuts to 110 N·m) 3. Remove the rear coil spring. (See Rear Coil Spring Removal & Installation in Section 10 Suspension). 4. Remove the two brake oil hose clamps (1) on the rear trailing arm. PZSM100017 Chery Automobile Co., Ltd. 10–...
Page 525 8. Separated the rear trailing arm to the trailing arm bracket bolts (1). (Tighten: Rear trailing arm to the vehicle retaining bolt to 110 ± 10 N·m) PZSM100019 9. Installation is in the reverse order of removal. 10– Chery Automobile Co., Ltd.
Page 526: Rear Shock Absorber
Coil springs are designed to store energy and subsequently release it. They absorb shock and maintain a force between contacting surfaces. Coil springs are rated for specific vehicle applications. Removal & Installation 1. Raise and support the vehicle. 2. Use a jack to support the rear axle. Chery Automobile Co., Ltd. 10–...
Page 527: Rear Cross Stay
6. Installation is in the reverse order of removal. Rear Cross Stay Removal & Installation 1. Raise and support the vehicle. 2. Remove the wheel mounting nuts and the wheel assembly. (Tighten: Wheel mounting nuts to 110 N·m) 10– Chery Automobile Co., Ltd.
Page 528 5. Loosen the two brake oil hose clamps (1) on the rear trailing arm and remove it. PZSM100017 6. Remove the rear brake shoes (See Rear Brake Shoes Removal & Installation in Section 12 Brakes). Chery Automobile Co., Ltd. 10–...
Page 529 7. Remove the rear shock absorber (1) (See Rear Shock Absorber Removal & Installation in Section 10 Suspension). PZSM100034 8. Remove the rear coil spring (1) (See Rear Coil Spring Removal & Installation in Section 10 Suspen -sion). PZSM100021 10– Chery Automobile Co., Ltd.
Page 530 12 Brakes). 11. Remove the rear trailing arm (See Trailing Arm Removal & Installation in Section 10 Suspension). 12. Lower the jack and remove the rear axle. 13. Installation is in the reverse order of removal. Chery Automobile Co., Ltd. 10–...
Page 531 Front Wheel Alignment 10-44 Specifications 10-40 Front Axle Toe-In Adjustment 10-44 Front Camber Adjustment 10-44 DIAGNOSIS & TESTING 10-42 Rear Wheel Alignment 10-44 Vehicle Inspection 10-42 Rear Toe-In & Rear Camber Adjustment 10-44 Tire Wear 10-42 10– Chery Automobile Co., Ltd.
Page 532: Front Axle
1. Verify the fuel tank is full of fuel. If the fuel tank is not full, the reduction in weight will affect the curb height of the vehicle and the alignment specifications. 2. The passenger and luggage compartments of the vehicle should be free of any load that is not factory equip- ment. Chery Automobile Co., Ltd. 10–...
Page 533: Specifications
The bumper should always be released when vehicle is at the bottom of the jounce cycle. Specifications Torque Specifications DESCRIPTION TORQUE (N·m) Camber Adjustment Bolts 110 ± 10 Inner Tie Rod Adjuster Jam Nut 35 ± 3 Wheel Mounting Nuts 10– Chery Automobile Co., Ltd.
Page 534 +52’ +1°40’ to +2’ Caster +3°24’ +3°54’ to +2°54’ Toe-Individual +6’ 0’ to +12’ Rear Axle Alignment Specifications REAR WHEEL ALIGNMENT PREFERRED SETTING ACCEPTABLE RANGE Camber 0’ -30’ to +30’ Toe-Individual 0’ -10’ to +10’ Chery Automobile Co., Ltd. 10–...
Page 535: Diagnosis & Testing
(17) Adjust (18) Adjust (19) Replace Pressure To Pressure To Replace Camber To Toe-In To Balance Tires / Correction: Specifications Specifications Tire Specifications Specifications Wheels Check / Rotate / Rotate Alignment / Tires Tires Suspension 10– Chery Automobile Co., Ltd.
Page 536: Alignment Troubleshooting Chart
· Incorrect tire pressure Bad Alignment Return Of Steering · Check the wheel alignment and · Failure of steering system Wheel then adjust. · Failure of suspension system · Repair or install new suspension component as necessary. Chery Automobile Co., Ltd. 10–...
Page 537: On-Vehicle Service
If the vehicle has been in an accident causing the rear axle components to be damaged, the damaged components must be replaced before performing a rear wheel alignment. REAR WHEEL ALIGNMENT ALIGNMENT ANGLE PREFERRED SETTING ACCEPTABLE RANGE Camber 0’ - 30’ to + 30’ Toe-Individual 0’ -10’ to +10’ 10– Chery Automobile Co., Ltd.
Page 538: Wheels And Tires
Tire and Wheel Vibration 10-47 Wheel Balance Procedure 10-50 Tire Wear Patterns 10-47 Wheel Out-Of-Round Inspection 10-47 Tire Rotation 10-50 Description 10-50 ON-VEHICLE SERVICE 10-48 Non-Directional Tires 10-51 Directional Tires 10-51 Tire Replacement & Repair 10-48 Description 10-48 Chery Automobile Co., Ltd. 10–...
Page 539: Description
STANDARD COLD INFLATION PRESSURE (kPa) Front Wheel Rear Wheel Spare Wheel Tire Specifications TIRE SPECIFICATION TIRE SIZE - 175 Sectional Width Aspect Ratio Wheel Radius Speed Rating Rim Out-Of-Round Specifications DESCRIPTION MAXIMUM RUN-OUT (mm) Steel Rim Aluminum Rim 10– Chery Automobile Co., Ltd.
Page 540: Diagnosis & Testing
• Replace the rim if necessary. NOTE : On both edges of the rim, the maximum allowed average value of the unevenness should not exceed the following: MAXIMUM RIM OUT-OF-ROUND Steel Rim 5 mm Aluminum Rim 3 mm Chery Automobile Co., Ltd. 10–...
Page 541: On-Vehicle Service
6. Use tools free of burrs or sharp edges which could damage the tire or wheel rim. 7. Before mounting tire on wheel, make sure all rust is removed from the rim bead and repaint if necessary. 10– Chery Automobile Co., Ltd.
Page 542: Description
• If the vibration persists, continue with Diagnosis & Testing procedure. NOTE : • Wheel balance equipment must be calibrated and maintained as outlined by the equipment manufacturer’s spec- ifications. • Wheel weight must fit the rim. Chery Automobile Co., Ltd. 10–...
Page 543: Wheel Balance Procedure
For these reasons they wear at unequal rates and tend to develop irregular wear patterns. These effects can be reduced by rotating the tires at regular intervals. The benefits of tire rotation are: • Increase tread life • Maintain traction levels • A smooth, quiet ride 10– Chery Automobile Co., Ltd.
Page 544: Non-Directional Tires
2. Rotate the tire to the desired location. CAUTION: Use caution not to damage wheel weights during tire and wheel installation. 3. Install the tire and wheel assembly and install the wheel mounting nuts. (Tighten: Wheel mounting nuts to 110 N·m) Chery Automobile Co., Ltd. 10–...
Page 545 11-2 Power Steering Filling and Flushing 11-6 Operation 11-3 Filling 11-6 Specifications 11-3 Flushing 11-6 Special Tools 11-3 Inspection 11-7 DIAGNOSIS & TESTING 11-4 Power Steering Troubleshooting Chart 11-4 Power Steering Fluid Troubleshooting Chart 11-5 Chery Automobile Co., Ltd. 11–...
Page 546 1 - Power Steering Fluid Reservoir 4 - Power Steering Gear Assembly 2 - Power Steering Fluid Pressure Hose Bracket 5 - Power Steering Fluid Return Hose 3 - Power Steering Fluid Pressure Hose 6 - Power Steering Pump PZSM110019 11– Chery Automobile Co., Ltd.
Page 547: Operation
Fluid level should be checked with the engine off to prevent personal injury from moving parts. Specifications Fluid Specifications DESCRIPTION CAPACITY (L) Power Steering Fluid (ATF III) Special Tools Steering Wheel Puller Ball Joint Separator CH-10002 Chery Automobile Co., Ltd. 11–...
Page 548 Replace steering column, coupling or intermediate shaft if necessary. · Perform power steering flow and pressure test. Look for low or erratic flow or pressure. Replace power steering pump if necessary. 11– Chery Automobile Co., Ltd.
Page 549 System should not lose more than 1 psi in 2 minutes (make sure vacuum pump is sealed well to the reservoir). Replace steering component if necessary. Chery Automobile Co., Ltd. 11–...
Page 550 10. Let the engine idle until the return hose discharges clean power steering fluid. 11. Stop the engine and remove the plug from the power steering reservoir. 12. Reinstall the power steering return hose to the power steering reservoir. 11– Chery Automobile Co., Ltd.
Page 551 (2) and engine running (1). If the fluid level varia- tion exceeds 5 mm, air is in the system and the air should be bled from the power steering system. LTSM110030 Chery Automobile Co., Ltd. 11–...
Page 552: Disassembly
11-10 Steering Column Shroud 11-14 DIAGNOSIS & TESTING Removal & Installation 11-14 11-11 Vehicle Inspection 11-11 Steering Column 11-15 Loose Steering / Vehicle Leads / Drifts Removal & Installation 11-15 Troubleshooting Chart 11-11 Disassembly 11-18 11– Chery Automobile Co., Ltd.
Page 553: General Information
PZSM100028 Specifications Torque Specifications DESCRIPTION TORQUE (N·m) Steering column shroud upper bolt 4 ± 2 Steering column shroud lower bolt 5 ± 2 Steering Wheel Lock Nut 30 ± 3 Chery Automobile Co., Ltd. 11–...
Page 554 GENERAL INFORMATION Special Tools Steering Wheel Puller 11– Chery Automobile Co., Ltd.
Page 555: Diagnosis & Testing
· Brakes dragging. · Repair if necessary. Straight Ahead Direction On · Wheel alignment. · Align vehicle. Uncrowned Road. · Weak or broken spring. · Replace spring. · Loose or worn steering/suspension · Repair if necessary. components. Chery Automobile Co., Ltd. 11–...
Page 556: On-Vehicle Service
• The spiral cable could be damaged if installed in an improper position. • Do not rotate the spiral cable quickly or beyond the limit of turns (this can cause the cable to snap). • Verify the airbag system is operating properly after the repair is complete. 11– Chery Automobile Co., Ltd.
Page 557: Inspection - Steering System
− Standard steering force: Less than 34 N·m − Fluctuation tolerance: Less than 5.9 N·m • If the measured force exceeds the standard value, see the trouble shooting section for inspection and adjust- ment. Chery Automobile Co., Ltd. 11–...
Page 558: Steering Column Shroud
1. Turn the steering wheel until it show the steering column upper shroud retaining bolt. 2. Remove the steering column upper shroud retain- ing bolt (1). (Tighten: Steering column upper shroud retaining bolt to 4 ± 2 N·m) PZSM110010 11– Chery Automobile Co., Ltd.
Page 559: Steering Column
4. Disconnect the spiral cable electrical connector. 5. Remove the steering wheel (See Steering Wheel Removal & Installation in Section 11 Steering). 6. Remove the steering shroud (See Steering Shroud Removal & Installation in Section 11 Steering). Chery Automobile Co., Ltd. 11–...
Page 560 (1). (Tighten: Multi-function switch & wiper and washer switch assembly bolts to 7 ± 2 N·m) PZSM110001 10. Remove the multi-function switch & wiper and washer switch assembly. 11. Disconnect the ignition switch electrical connector. 11– Chery Automobile Co., Ltd.
Page 561 (Tighten: Steering column upper mounting bolts to 25 ± 3 N·m) PZSM110015 13. Remove the two lower mounting bolts (1) from the steering column. (Tighten: Steering column lower mounting bolts to 25 ± 3 N·m) PZSM110003 Chery Automobile Co., Ltd. 11–...
Page 562 • When installing the spiral cable, slowly wind the spiral cable to the end of its travel and then unwind the spiral cable two and a half turns. Disassembly 1. Remove the two ignition switch retaining bolts (1) with inner hex wrench. PZSM110017 11– Chery Automobile Co., Ltd.
Page 563 3. Using snap-ring pliers, remove the outer snap ring (1). PZSM110002 4. Remove the retainer and spring. 5. Remove the upper end cap of steering column. PZSM110018 6. Assembly is in the reverse order of disassembly. Chery Automobile Co., Ltd. 11–...
Page 564 Steering Gear - RHD 11-29 Removal & Installation 11-29 DIAGNOSIS & TESTING 11-22 Tie Rod 11-34 Binding and Sticking Troubleshooting Removal & Installation 11-34 Chart 11-22 Inspection 11-36 Insufficient Assist / Poor Return To Center Troubleshooting Chart 11-22 11– Chery Automobile Co., Ltd.
Page 565: General Information
Steering Gear to Sub-Frame Bolts 100 ± 10 Sub-Frame Assembly Bolts 180 ± 15 Tie Rod End Nut 40 ± 5 Tie Rod Jam Nut 35 ± 3 Wheel Mounting Nuts Special Tools Ball Joint Separator CH-10002 Chery Automobile Co., Ltd. 11–...
Page 566: Diagnosis & Testing
· Inspect and lubricate steering and · Lack of lubrication. Return To Center Position suspension components. · High friction in steering gear. · Test and adjust if necessary. · Ball joints binding. · Inspect and repair if necessary. 11– Chery Automobile Co., Ltd.
Page 567: On-Vehicle Service
Prolonged and repeated contact with power steering fluid will damage skin. If steering fluid is spilled on your skin, wash it off immediately with water. 2. Raise and support the vehicle. 3. Remove the front wheel mounting nuts and the wheel assemblies from both sides. (Tighten: Wheel mounting nuts to 110 N·m) Chery Automobile Co., Ltd. 11–...
Page 568 6. Stop the engine. 7. Use a service jack to support the engine. 8. Remove the intermediate shaft coupling bolt (1) at the steering gear. (Tighten: Intermediate shaft coupling bolt to 25 ± 5 N·m) PZSM110016 11– Chery Automobile Co., Ltd.
Page 569 12. Remove the vehicle speed sensor retaining bolt (1) and set it aside. (Tighten: Vehicle speed sensor bolt to 10 ± 1 N·m) PZSM100011 13. Remove the pinch bolt (1) from the steering knuckle. (Tighten: Steering knuckle pinch bolt to 110 N·m) PZSM100013 Chery Automobile Co., Ltd. 11–...
Page 570 17. Remove the high pressure line nut (2) and the low pressure line nut (1) from the steering gear. (Tighten: High pressure line nut to steering gear 25 ± 5 N·m) (Tighten: Low pressure line nut to steering gear 25 ± 5 N·m) PZSM110013 11– Chery Automobile Co., Ltd.
Page 571 (Tighten: Front engine mount bolt to 80 ± 5 N·m) PZSM020032 20. Remove the rear engine mount bolts (1) and the rear engine mount bracket bolt (2). (Tighten: Rear engine mount bolts to 60 ± 5 N·m) PZSM020011 Chery Automobile Co., Ltd. 11–...
Page 572 23. Remove the steering gear retaining bolts (1). (Tighten: Steering gear retaining bolts to 100 ± 10 N·m) PZSM110023 24. Remove the steering gear assembly. 25. Installation is in the reverse order of the removal. 11– Chery Automobile Co., Ltd.
Page 573: Steering Gear - Rhd
Prolonged and repeated contact with power steering fluid will damage skin. If steering fluid is spilled on your skin, wash it off immediately with water. 2. Raise and support the vehicle. 3. Remove the front wheel mounting nuts and the wheel assemblies from both sides. (Tighten: Wheel mounting nuts to 110 N·m) Chery Automobile Co., Ltd. 11–...
Page 574 6. Stop the engine. 7. Use a service jack to support the engine. 8. Remove the intermediate shaft coupling bolt (1) at the steering gear. (Tighten: Intermediate shaft coupling bolt to 25 ± 5 N·m) PZSM110016 11– Chery Automobile Co., Ltd.
Page 575 12. Remove the vehicle speed sensor retaining bolt (1) and set it aside. (Tighten: Vehicle speed sensor bolt to 10 ± 1 N·m) PZSM100011 13. Remove the pinch bolt (1) from the steering knuckle. (Tighten: Steering knuckle pinch bolt to 110 N·m) PZSM100013 Chery Automobile Co., Ltd. 11–...
Page 576 17. Remove the high pressure line nut (2) and the low pressure line nut (1) from the steering gear. (Tighten: High pressure line nut to steering gear 25 ± 5 N·m) (Tighten: Low pressure line nut to steering gear 25 ± 5 N·m) PZSM110013 11– Chery Automobile Co., Ltd.
Page 577 (Tighten: Front engine mount bolt to 80 ± 5 N·m) PZSM020032 20. Remove the rear engine mount bolts (1) and the rear engine mount bracket bolt (2). (Tighten: Rear engine mount bolts to 60 ± 5 N·m) PZSM020011 Chery Automobile Co., Ltd. 11–...
Page 578: Tie Rod
The following special tools are required to perform the repair procedure: • CH-10002 - Ball Joint Separator 1. Raise and support the vehicle. 2. Remove the front wheel mounting nuts and the wheel assembly. (Tighten: Wheel mounting nuts to 110 N·m) 11– Chery Automobile Co., Ltd.
Page 579 7. Installation is in the reverse order of removal. Installation Notes: • After installing the new tie rod end, perform a front end alignment procedure to reset the toe-in (See Front Wheel Alignment in Section 10 Suspension). Chery Automobile Co., Ltd. 11–...
Page 580: Inspection
• Standard value: 0.98-3.92 N·m 2. When the starting torque is less than the standard value, inspect the ball joint for excessive play or wear problem. If there is no problem found, the ball joint can be used. LTSM110028 11– Chery Automobile Co., Ltd.
Page 581 11-39 Steering System Noise Troubleshooting Power Steering Pressure Line 11-44 Chart 11-39 Removal & Installation 11-44 Insufficient Assist / Poor Return To Center Power Steering Return Line 11-45 Troubleshooting Chart 11-39 Removal & Installation 11-45 Chery Automobile Co., Ltd. 11–...
Page 582: General Information
Power Steering Pressure Line To Power Steering Pump 45 ± 5 Power Steering Pump Mounting Bolts 25 ± 5 Pressure/Return Hose Routing Clamp Screws To Cross Member Fluid Specifications DESCRIPTION CAPACITY (L) Power Steering Fluid (ATF III) 11– Chery Automobile Co., Ltd.
Page 583: Diagnosis & Testing
· Inspect and lubricate steering and · Lack of lubrication. Return To Center Position suspension components. · High friction in steering gear. · Test and adjust if necessary. · Ball joints binding. · Inspect and repair if necessary. Chery Automobile Co., Ltd. 11–...
Page 584: On-Vehicle Service
PZSM110007 4. Start the engine and turn the steering wheel from lock-to-lock until all power steering fluid has been removed from the system. 5. Stop the engine. 11– Chery Automobile Co., Ltd.
Page 585 ON-VEHICLE SERVICE 6. Loosen the power steering pump drive belt adjust- ment bolt (1). PZSM020005 7. Loosen the two bolts (1) on the steering pump bracket. PZSM020050 8. Remove the A/C compressor belt. Chery Automobile Co., Ltd. 11–...
Page 586: Power Steering Fluid Reservoir
• Fill the power steering fluid reservoir to the proper level. • Check the system for leaks. Power Steering Fluid Reservoir Removal & Installation 1. Siphon as much fluid as possible from the power steering fluid reservoir. 11– Chery Automobile Co., Ltd.
Page 587 3. Slide the hose off the end of the reservoir fitting. PZSM110024 4. Installation is in the reverse order of removal. Installation Notes: • Fill the power steering reservoir to the proper level. • Check the system for leaks. Chery Automobile Co., Ltd. 11–...
Page 588: Power Steering Pressure Line
6. Remove the pressure line. 7. Installation is in the reverse order of removal. Installation Notes: • Fill the power steering fluid reservoir to the proper level. • Check the power steering system for leaks. 11– Chery Automobile Co., Ltd.
Page 589: Power Steering Return Line
1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Loosen the clamps (1), and remove the return hose from the power steering fluid reservoir. PZSM110007 3. Remove the clamp (1) from the power steering return hose. PZSM110030 Chery Automobile Co., Ltd. 11–...
Page 590 (Tighten: Return line bolt to 20 ± 5 N·m) PZSM110029 7. Remove the return line. 8. Installation is in the reverse order of removal. Installation Notes: • Fill the power steering reservoir to the proper level. • Check the system for leaks. 11– Chery Automobile Co., Ltd.
Page 591 Removal & Installation 12-20 Operation 12-9 Removal & Installation 12-10 UNIT REPAIR 12-21 Power Brake Booster 12-10 Front Brake Caliper 12-21 Description 12-10 Disassembly 12-21 Operation 12-10 Inspection 12-22 Removal & Installation 12-10 Assembly 12-23 Chery Automobile Co., Ltd. 12–...
Page 592: Parking Brake
The parking brakes carry out the same function except that they are mechanically actuated by a cable that connects only to the rear brakes. 12– Chery Automobile Co., Ltd.
Page 593 250 ± 10 Rear Brake Drum to Hub Mounting Screw Wheel Mounting Nuts Rotor Specifications ROTOR ROTOR MINIMUM ROTOR BRAKE ROTOR THICKNESS ROTOR RUNOUT THICKNESS THICKNESS VARIATION Front Rotor 17 mm 15 mm 0.03 mm 0.03 mm Chery Automobile Co., Ltd. 12–...
Page 594: Special Tools
GENERAL INFORMATION Special Tools Dial Indicator Brake Measuring Gauge Digital Multimeter Fluke 15B & 17B 12– Chery Automobile Co., Ltd.
Page 595: Electrical Schematics
GENERAL INFORMATION Electrical Schematics Brake System (Page 1 of 1) PZSMW120010T Chery Automobile Co., Ltd. 12–...
Page 596 Disc Brake Squeak At Low Speed (While Applying Light Brake Pedal · Brake shoe linings. · Replace brake pads. Effort) · ABS wheel speed sensor hitting · Inspect, correct or replace faulty Scraping Or Whirring tone wheel. component(s). 12– Chery Automobile Co., Ltd.
Page 597 · Replace piston seal or brake · Suspension problem. caliper. · See the Suspension section. Parking Brake—Excessive Handle · Adjust rear parking brake shoes on · Rear brakes out of adjustment. Travel vehicles with rear disc brakes. Chery Automobile Co., Ltd. 12–...
Page 598 • Left rear wheel • Right front wheel • Right rear wheel • Left front wheel Manual Bleeding NOTE : To bleed the brakes manually, the aid of a helper will be required. BESM120001 12– Chery Automobile Co., Ltd.
Page 599 When the brake pedal is pressed, the master cylinder pistons apply brake pressure through the chassis brake tubes to each brake assembly. The brake fluid reservoir supplies the brake hydraulic system with the necessary fluid to operate properly. Chery Automobile Co., Ltd. 12–...
Page 600 This can be done by pumping the brake pedal while the engine is not running until a firm brake pedal is achieved. 1. Remove the master cylinder (See Master Cylinder Removal & Installation in Section 12 Brakes). 2. Disconnect the vacuum hose from the check valve on the power brake booster. 12– Chery Automobile Co., Ltd.
Page 601 2. Raise and support the vehicle. 3. Remove the wheel mounting nuts and the tire and wheel assembly. (Tighten: Wheel mounting nuts to 110 N·m) Chery Automobile Co., Ltd. 12–...
Page 602 PZSM120004 9. Installation is in the reverse order of removal. Installation Notes: • Completely retract the caliper piston back into the bore of the caliper. • After installation bleed the caliper as necessary. 12– Chery Automobile Co., Ltd.
Page 603: Rear Wheel Cylinder
9. Remove the lower return spring (6). 10. Remove the brake shoe hold-down springs (4) and pins. Rotate the pins 90° to disengage. 11. Remove the two brake shoes. 12. Remove the spring (2) and separate the brake shoes. PZSM120010 Chery Automobile Co., Ltd. 12–...
Page 604: Front Brake Rotor
If the ridges on the rotor are not removed before new brake pads are installed, improper wear of the shoes will result. Some discoloration or wear of the rotor surface is normal and does not require resurfacing when linings are replaced. If cracks or burned spots are evident, the rotor must be replaced. 12– Chery Automobile Co., Ltd.
Page 605 15 mm 0.03 mm Rear Brake Drum Removal & Installation 1. Raise and support the vehicle. 2. Remove the wheel mounting nuts and the tire and wheel assembly. (Tighten: Wheel mounting nuts to 110 N·m) Chery Automobile Co., Ltd. 12–...
Page 606: Front Brake Pads
PZSM120016 Front Brake Pads Removal & Installation 1. Raise and support the vehicle. 2. Remove the wheel mounting nuts and the tire and wheel assembly. (Tighten: Wheel mounting nuts to 110 N·m) 12– Chery Automobile Co., Ltd.
Page 607 − Replace both disc brake pads (inboard and outboard) on each caliper. − It is necessary to replace the pads on the opposite side of the vehicle as well as the pads failing inspection to maintain proper braking characteristics. Chery Automobile Co., Ltd. 12–...
Page 608: Rear Brake Shoes
4. Remove the brake drum bearing dust cap. 5. Rotate the brake drum and remove the brake drum from the axle hub. 6. Remove the rear hub and bearing nut. (Tighten: Rear hub and bearing nut to 250 ± 10 N·m) PZSM120005 12– Chery Automobile Co., Ltd.
Page 609 − Replace the adjuster screw if it is corroded. − Inspect the return springs and hold-down spring clips for overheating or damage (Overheating indications are paint discoloration or distorted end coils). Replace the brake hardware if needed. Chery Automobile Co., Ltd. 12–...
Page 610 7. Remove the remaining nut attaching the brake pedal (3) to the dash panel. (Tighten: Brake pedal/Power brake booster mount- ing nut to 25 N·m) PZSM120011 8. Remove the brake pedal. 9. Installation is in the reverse order of removal. 12– Chery Automobile Co., Ltd.
Page 611: Unit Repair
4. Remove the dust boot from the piston and discard CAUTION: Do not use a screwdriver or other metal tool for seal removal. Using such tools can scratch the bore or leave burrs on the seal groove edges. LTSM120010 Chery Automobile Co., Ltd. 12–...
Page 612: Inspection
(grit size 380 to 500). 3. Inspect the caliper guide sleeves for smooth oper- ation. Repair and grease caliper sleeves as necessary. VISM120033 12– Chery Automobile Co., Ltd.
Page 613: Assembly
1. Lubricate the caliper piston, piston seals and piston bore with clean brake fluid. 2. Install the new piston seal into the seal groove. NOTE : Verify seal is fully seated into seal groove and not twisted. LTSM120014 Chery Automobile Co., Ltd. 12–...
Page 614 6. Seat the dust boot in caliper. 7. Install the new caliper bleed screw. 8. Install the caliper (See Front Brake Caliper Removal & Installation in Section 12 Brakes). 12– Chery Automobile Co., Ltd.
Page 615 Removal & Installation 12-77 C1203 - Right Front Wheel Speed Rear Wheel Speed Sensor 12-78 Sensor Circuit Open or Shorted 12-47 Removal & Installation 12-78 C1205 - Right Front Wheel Speed Sensor Gap Error 12-51 Chery Automobile Co., Ltd. 12–...
Page 616 Each wheel circuit is designed with a set of electric solenoids to allow modulation. The system can build and release pressure at 12– Chery Automobile Co., Ltd.
Page 617 ABS Mounting Bracket Screw and Nut (To Frame) ABS Wheel Speed Sensor Mounting Bolt Brake Tube Nuts 16 ± 3 Wheel Mounting Nuts 110 ± 10 Special Tools Diagnostic Scan Tool X-431 Digital Multimeter Fluke 15B & 17B Chery Automobile Co., Ltd. 12–...
Page 618 GENERAL INFORMATION Electrical Schematics Antilock Brake System (Page 1 of 3) PZSMW120001T 12– Chery Automobile Co., Ltd.
Page 619 GENERAL INFORMATION Antilock Brake System (Page 2 of 3) PZSMW120002T Chery Automobile Co., Ltd. 12–...
Page 620 GENERAL INFORMATION Antilock Brake System (Page 3 of 3) PZSMW120003T 12– Chery Automobile Co., Ltd.
Page 621 Left Rear Wheel Speed Sensor (-) Right Front Wheel Speed Sensor (+) Diagnostic Link K Right Front Wheel Speed Sensor (-) Continuous Supply Voltage (Motor) Right Rear Wheel Speed Sensor (-) Right Rear Wheel Speed Sensor (+) Continuous Supply Voltage Chery Automobile Co., Ltd. 12–...
Page 622 If multiple wires are crimped to one eyelet, make sure no excess wire insulation has been crimped creating a bad ground. Diagnostic Tools • Diagnostic Scan Tool X-431 • Digital Multimeter • Jumper Wire 12– Chery Automobile Co., Ltd.
Page 623 Right Rear Wheel Speed Sensor or Sensor Ring C1211 Right Rear Wheel Speed Sensor Gap Error C1604 ECU Defect, Internal Errors or Solenoid Fault C2112 Solenoid Fuse or Solenoid Relay Fault C2402 Motor Fuse or Motor Fault Chery Automobile Co., Ltd. 12–...
Page 624 DIAGNOSIS & TESTING Diagnostic Trouble Code (DTC) Tests C1101 - Battery Voltage High C1102 - Battery Voltage Low PZSMW120004T 12– Chery Automobile Co., Ltd.
Page 625 DIAGNOSIS & TESTING PZSMW120005T Chery Automobile Co., Ltd. 12–...
Page 626 • Inspect the ground connection A-201 mounting position (See Vehicle Wiring Harness Layout - Engine Room Harness in Section 16 Wiring). Is the ground connection OK? >> Go to the next step. >> Repair or replace the ground connection. 12– Chery Automobile Co., Ltd.
Page 627 • Measure the continuity between the ABS module terminals 9 & 25 and the battery positive terminal. • Continuity should exist. Is the check result normal? >> Go to the next step. >> Check the fuse. Check the harness. Check all related components. Chery Automobile Co., Ltd. 12–...
Page 628 Replace the ABS module (See ABS Module Removal & Installation in Section 12 Brakes). >> The system is now operating properly. Erase all codes and test drive the vehicle to verify the repair is complete. 12– Chery Automobile Co., Ltd.
Page 629 DIAGNOSIS & TESTING C1200 - Left Front Wheel Speed Sensor Circuit Open or Shorted PZSMW120006T Chery Automobile Co., Ltd. 12–...
Page 630 Is DTC C1200 present and the Left Front Wheel Speed signal abnormal? >> Go to the next step. >> The condition that caused this DTC to set is currently not present (See Diagnostic Help and Intermit- tent DTC Troubleshooting in Section 12 Brakes for more information). 12– Chery Automobile Co., Ltd.
Page 631 • Check the wheel speed sensor resistance between the sensor terminals 1 and 2, component side. Is the sensor resistance 700 - 1500 ohms? >> Go to the next step. >> Replace the Left Front wheel speed sensor. VISMD120005 Chery Automobile Co., Ltd. 12–...
Page 632 Replace the ABS module (See ABS Module Removal & Installation in Section 12 Brakes). >> The system is now operating properly. Erase all codes and test drive the vehicle to verify the repair is complete. 12– Chery Automobile Co., Ltd.
Page 633 DIAGNOSIS & TESTING C1202 - Left Front Wheel Speed Sensor Gap Error PZSMW120006T Chery Automobile Co., Ltd. 12–...
Page 634 • This DTC must be active for the results of this test to be valid. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. 12– Chery Automobile Co., Ltd.
Page 635 • Inspect for mismatched tires on the vehicle. Is the Left Front tire improperly inflated or mismatched tires on the vehicle? >> Repair the Left Front tire as necessary. >> Go to the next step. Chery Automobile Co., Ltd. 12–...
Page 636 >> Replace the ABS module (See ABS Module Removal & Installation in Section 12 Brakes). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 12– Chery Automobile Co., Ltd.
Page 637 DIAGNOSIS & TESTING C1203 - Right Front Wheel Speed Sensor Circuit Open or Shorted PZSMW120007T Chery Automobile Co., Ltd. 12–...
Page 638 Is DTC C1203 present and the Right Front Wheel Speed signal abnormal? >> Go to the next step. >> The condition that caused this DTC to set is currently not present (See Diagnostic Help and Intermit- tent DTC Troubleshooting in Section 12 Brakes for more information). 12– Chery Automobile Co., Ltd.
Page 639 • Check the wheel speed sensor resistance between the sensor terminals 1 and 2, component side. Is the sensor resistance 700 - 1500 ohms? >> Go to the next step. >> Replace the Right Front wheel speed sensor. VISMD120005 Chery Automobile Co., Ltd. 12–...
Page 640 Replace the ABS module (See ABS Module Removal & Installation in Section 12 Brakes). >> The system is now operating properly. Erase all codes and test drive the vehicle to verify the repair is complete. 12– Chery Automobile Co., Ltd.
Page 641 DIAGNOSIS & TESTING C1205 - Right Front Wheel Speed Sensor Gap Error PZSMW120007T Chery Automobile Co., Ltd. 12–...
Page 642 • This DTC must be active for the results of this test to be valid. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. 12– Chery Automobile Co., Ltd.
Page 643 • Check and adjust all other tire pressures. • Inspect for mismatched tires on the vehicle. Is the Right Front tire improperly inflated or mismatched tires on the vehicle? >> Repair Right Front tire as necessary. >> Go to the next step. Chery Automobile Co., Ltd. 12–...
Page 644 >> Replace the ABS module (See ABS Module Removal & Installation in Section 12 Brakes). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 12– Chery Automobile Co., Ltd.
Page 645 DIAGNOSIS & TESTING C1206 - Left Rear Wheel Speed Sensor Circuit Open or Shorted PZSMW120008T Chery Automobile Co., Ltd. 12–...
Page 646 Is DTC C1206 present and the Left Rear Wheel Speed signal abnormal? >> Go to the next step. >> The condition that caused this DTC to set is currently not present (See Diagnostic Help and Intermit- tent DTC Troubleshooting in Section 12 Brakes for more information). 12– Chery Automobile Co., Ltd.
Page 647 • Voltage should exist (less than 1.0 V). Is the proper voltage present? >> Go to the next step. >> Repair or replace the circuit for an open, short to ground or short to battery in connector or harness. VISMD120003 Chery Automobile Co., Ltd. 12–...
Page 648 Rear wheel speed sensor connector A-021, terminal side and ground. • Continuity should not exist. Is the check result normal? >> Go to the next step. >> Repair or replace the circuit for a short to ground. PZSMD120003 12– Chery Automobile Co., Ltd.
Page 649 Replace the ABS module (See ABS Module Removal & Installation in Section 12 Brakes). >> The system is now operating properly. Erase all codes and test drive the vehicle to verify the repair is complete. Chery Automobile Co., Ltd. 12–...
Page 650 DIAGNOSIS & TESTING C1208 - Left Rear Wheel Speed Sensor Gap Error PZSMW120008T 12– Chery Automobile Co., Ltd.
Page 651 • This DTC must be active for the results of this test to be valid. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. Chery Automobile Co., Ltd. 12–...
Page 652 • Check and adjust all other tire pressures. • Inspect for mismatched tires on the vehicle. Is the RL tire improperly inflated or mismatched tires on the vehicle? >> Repair Left Rear tire as necessary. >> Go to the next step. 12– Chery Automobile Co., Ltd.
Page 653 >> Replace the ABS module (See ABS Module Removal & Installation in Section 12 Brakes). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 12–...
Page 654 DIAGNOSIS & TESTING C1209 - Right Rear Wheel Speed Sensor Circuit Open or Shorted PZSMW120009T 12– Chery Automobile Co., Ltd.
Page 655 Is DTC C1209 present and the Right Rear Wheel Speed signal abnormal? >> Go to the next step. >> The condition that caused this DTC to set is currently not present (See Diagnostic Help and Intermit- tent DTC Troubleshooting in Section 12 Brakes for more information). Chery Automobile Co., Ltd. 12–...
Page 656 • Voltage should exist (less than 1.0 V). Is the proper voltage present? >> Go to the next step. >> Repair or replace the circuit for an open, short to ground or short to battery in connector or harness. VISMD120003 12– Chery Automobile Co., Ltd.
Page 657 Right Rear wheel speed sensor connector A-022, terminal side and ground. • Continuity should not exist. Is the check result normal? >> Go to the next step. >> Repair or replace the circuit for a short to ground. PZSMD120003 Chery Automobile Co., Ltd. 12–...
Page 658 Replace the ABS module (See ABS Module Removal & Installation in Section 12 Brakes). >> The system is now operating properly. Erase all codes and test drive the vehicle to verify the repair is complete. 12– Chery Automobile Co., Ltd.
Page 659 DIAGNOSIS & TESTING C1211 - Right Rear Wheel Speed Sensor Gap Error PZSMW120009T Chery Automobile Co., Ltd. 12–...
Page 660 • This DTC must be active for the results of this test to be valid. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. 12– Chery Automobile Co., Ltd.
Page 661 • Check and adjust all other tire pressures. • Inspect for mismatched tires on the vehicle. Is the Right Rear tire improperly inflated or mismatched tires on the vehicle? >> Repair Right Rear tire as necessary. >> Go to the next step. Chery Automobile Co., Ltd. 12–...
Page 662 >> Replace the ABS module (See ABS Module Removal & Installation in Section 12 Brakes). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 12– Chery Automobile Co., Ltd.
Page 663 • Check the ABS module voltage supply circuit and ground circuit for an open, high resistance or short circuit. Is the check result normal? >> Go to the next step. >> Repair circuit for an open or short in harness and connectors. Chery Automobile Co., Ltd. 12–...
Page 664 >> Replace the ABS module (See ABS Module Removal & Installation in Section 12 Brakes). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 12– Chery Automobile Co., Ltd.
Page 665 7. Fill the master cylinder fluid reservoir to the MAX level. 8. Test drive the vehicle to be sure the brakes are operating correctly and that the brake pedal does not feel spongy. Chery Automobile Co., Ltd. 12–...
Page 666 5. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in the system. Re-bleed the brakes as necessary. 6. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. 12– Chery Automobile Co., Ltd.
Page 667 Front Wheel Speed Sensor Removal & Installation 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. 3. Remove the wheel mounting nuts and the tire and wheel assembly. (Tighten: Wheel mounting nuts to 110 N·m) Chery Automobile Co., Ltd. 12–...
Page 668 3. Remove the wheel mounting nuts and the tire and wheel assembly. (Tighten: Wheel mounting nuts to 110 N·m) 4. Remove the rear wheel speed sensor mounting bolt (1). (Tighten: Rear wheel speed sensor mounting bolts to 10 N·m) PZSM120021 12– Chery Automobile Co., Ltd.
Page 669 ON-VEHICLE SERVICE 5. Remove the rear wheel speed sensor (1). 6. Installation is in the reverse order of removal. VISM080033 Chery Automobile Co., Ltd. 12–...
Page 670 ON-VEHICLE SERVICE Specifications 12-81 12-85 Special Tools 12-81 Parking Brake Lever 12-85 Electrical Schematics 12-82 Removal & Installation 12-85 DIAGNOSIS & TESTING Parking Brake Cable 12-85 12-83 Removal & Installation 12-85 Parking Brake Warning Light 12-83 12– Chery Automobile Co., Ltd.
Page 671: General Information
The parking brake cables are made of flexible steel cable. Specifications Torque Specifications DESCRIPTION TORQUE (N·m) Parking Brake Cable Bracket Bolts 9 - 12 Wheel Mounting Nuts Special Tools Brake Measuring Gauge Chery Automobile Co., Ltd. 12–...
Page 672 GENERAL INFORMATION Electrical Schematics Parking Brake System (Page 1 of 1) PZSMW120011T 12– Chery Automobile Co., Ltd.
Page 673: Parking Brake Warning Light
2. Raise and support the vehicle. 3. Remove the wheel mounting nuts and the rear tire and wheel assemblies. 4. Remove the rear brake drum. 5. Adjust the parking brake shoes by turning the adjuster (1). VISM120027 Chery Automobile Co., Ltd. 12–...
Page 674 8. With the parking brake lever in the released (down) position, attempt to rotate the rear rotors by hand (to ensure that the parking brake shoes are not dragging). 9. Install both rear tire and wheel assemblies and the wheel mounting nuts. (Tighten: Wheel mounting nuts to 110 N·m) 10. Lower the vehicle. 12– Chery Automobile Co., Ltd.
Page 675: Parking Brake Lever
2. Remove the rear wheel mounting nuts and both rear tire and wheel assemblies. (Tighten: Wheel mounting nuts to 110 N·m) 3. Remove the rear brake drum (See Rear Brake Drum Removal & Installation in Section 12 Brake). Chery Automobile Co., Ltd. 12–...
Page 676 (Tighten: Parking brake cable bracket bolts to 9 - 12 N·m) 6. Remove the lower console (See Lower Console Removal & Installation in Section 15 Body & Accessories). 7. Release and lower the parking brake lever. 8. Remove the parking brake adjustment nut (1). PZSM120020 12– Chery Automobile Co., Ltd.
Page 677 NOTE: Remove the parking brake cable at another side in accordance with the same method. 13. Installation is in the reverse order of removal. Installation Notes: • After installation, adjust the parking brake cable as necessary (See Parking Brake Adjustment in Section 12 Brakes). Chery Automobile Co., Ltd. 12–...
Page 678 13-3 13-10 Specifications 13-4 Manual Temperature Control Module 13-10 Special Tools 13-4 Removal & Installation 13-10 Electrical Schematics 13-5 Blower Motor Resistor 13-13 DIAGNOSIS & TESTING Removal & Installation 13-13 13-7 A/C System Performance 13-7 Chery Automobile Co., Ltd. 13–...
Page 679 To maintain the performance level of the HVAC system, the engine cooling system must be properly maintained. Any obstructions in front of the radiator or A/C condenser will reduce the performance of the A/C and engine cooling systems. 13– Chery Automobile Co., Ltd.
Page 680 It will automatically engage when the mode control is set in any Mix to Defrost position. This will remove heat and humidity from the air before it is directed through or around the heater core. The mode control on the A/C-heater control is used to direct the conditioned air to the selected system outlets. Chery Automobile Co., Ltd. 13–...
Page 681 32.2°C 14.0-21.8 kgf/cm 1.9-2.1 kgf/cm 200-310 psi 28-31 psi 37.7°C 16.1-23 kgf/cm 1.9-2.4 kgf/cm 230-330 psi 28-35 psi 43.3°C 18.9-25.3 kgf/cm 1.9-2.6 kgf/cm 270-360 psi 28-38 psi Special Tools Digital Multimeter Fluke 15B & 17B 13– Chery Automobile Co., Ltd.
Page 682 GENERAL INFORMATION Electrical Schematics Climate Control System (Page 1 of 2) PZSMW130001T Chery Automobile Co., Ltd. 13–...
Page 683 GENERAL INFORMATION Climate Control System (Page 2 of 2) PZSMW130002T 13– Chery Automobile Co., Ltd.
Page 684 262 to 290 kPa 269 to 296 kPa 275 to 303 kPa 262 to 290 kPa Charge Port Compressor 1241 to 1792 1380 to 1930 1380 to 1930 1655 to 2206 1567 to 2068 Discharge Pressure Chery Automobile Co., Ltd. 13–...
Page 685 · Engine overheating. level, if required. · Test the refrigerant system for leaks. Repair, evacuate and charge the refrigerant system, if required. · Test the cooling system and repair as necessary. 13– Chery Automobile Co., Ltd.
Page 686 • The HVAC control panel. • The blend door actuator(s). • The wire harness circuits for the HVAC control or the blend door actuator(s). • The blend door(s). • Improper engine coolant temperature. Chery Automobile Co., Ltd. 13–...
Page 687 ON-VEHICLE SERVICE Manual Temperature Control Module Removal & Installation 1. Disconnect the negative battery cable. 2. Open the upper storage box and remove the two screws (1). PZSM150179 13– Chery Automobile Co., Ltd.
Page 688 ON-VEHICLE SERVICE 3. Remove the upper storage box (1). PZSM150180 4. Remove the two upper cover retaining screws (1). PZSM150181 5. Using a trim stick, pry the lower cover. Chery Automobile Co., Ltd. 13–...
Page 689 ON-VEHICLE SERVICE 6. Remove the center instrument panel cover (1). PZSM150182 7. Disconnect the hazard warning switch electrical connector. 8. Remove the HVAC control panel cover (1). PZSM150184 13– Chery Automobile Co., Ltd.
Page 690 Do not operate the blower motor with the blower motor resistor removed from the circuit. Failure to take this precaution can result in vehicle damage. 1. Disconnect the negative battery cable. 2. Disconnect the blower motor resistor electrical connector from the bottom of the left side of the instrument panel. Chery Automobile Co., Ltd. 13–...
Page 691 ON-VEHICLE SERVICE 3. Remove the two screws (1) attaching the blower motor resistor to the HVAC housing. PZSM130012 4. Remove the blower motor resistor. 5. Installation is in the reverse order of removal. 13– Chery Automobile Co., Ltd.
Page 692 SYSTEM CONTROLS Temperature Control 13-17 GENERAL INFORMATION 13-16 Description 13-16 ON-VEHICLE SERVICE Operation 13-16 13-18 Specifications 13-16 Recirculation Door Actuator 13-18 Special Tools 13-16 Removal & Installation 13-18 DIAGNOSIS & TESTING 13-17 Mechanical Problems 13-17 Chery Automobile Co., Ltd. 13–...
Page 693 • Mode control • Blower motor speed switch • A/C compressor switch • Recirculation switch • Rear defogger switch Specifications Torque Specifications DESCRIPTION TORQUE (N·m) Recirculation Door Actuator Screws Special Tools Digital Multimeter Fluke 15B & 17B 13– Chery Automobile Co., Ltd.
Page 694 • The HVAC control panel. • The blend door cable. • The mode door cable. • The electrical circuits for the HVAC control panel. • Improper engine coolant temperature. Chery Automobile Co., Ltd. 13–...
Page 695 • Close the air conditioner panel until the motor stops. • Adjust the mixing damper manually to HOTTEST or COLDEST temperature setting. • Adjust the rod to align with the recirculation door actuator. • Attach the rod to the recirculation door actuator. 13– Chery Automobile Co., Ltd.
Page 696 Removal & Installation 13-23 Specifications 13-20 Special Tools 13-21 Blower Motor 13-26 Description 13-26 DIAGNOSIS & TESTING Operation 13-26 13-22 Removal & Installation 13-26 Blower Motor Electrical Troubleshooting 13-22 Blower Motor Noise 13-22 Blower Motor Vibration 13-22 Chery Automobile Co., Ltd. 13–...
Page 697 All General Service Screw Accumulator Bolts Condenser Nuts HVAC Housing Nuts To Front Wall HVAC Housing Nuts Pipeline Stent Refrigerant Lines To A/C Accumulator Nut Refrigerant Lines To A/C Compressor Bolt Refrigerant Lines To A/C Evaporator Nut 13– Chery Automobile Co., Ltd.
Page 698 GENERAL INFORMATION Special Tools Digital Multimeter Fluke 15B & 17B Chery Automobile Co., Ltd. 13–...
Page 699: Blower Motor Electrical Troubleshooting
• Worn blower motor bearings or brushes Blower Motor Vibration Possible causes of a blower motor vibration include: • Incorrect blower motor mounting • Foreign material in blower wheel • Deformed or damaged blower wheel • Worn blower motor bearings 13– Chery Automobile Co., Ltd.
Page 700: Hvac Housing
4. Remove the two A/C pressure line mounting nuts (1). 5. Remove the three HVAC housing retaining nuts (2). PZSM130013 6. Remove the instrument panel (See Instrument Panel Removal & Installation in Section 15 Body & Accessories). Chery Automobile Co., Ltd. 13–...
Page 701 ON-VEHICLE SERVICE 7. Remove the mode door and the blend door cable clamps (1) and remove the two cables. PZSM130021 8. Remove the steering assembly mounting bolts and nuts (1). PZSM130023 13– Chery Automobile Co., Ltd.
Page 702 11. Remove the eight HVAC housing assembly retain- ing nuts (1). PZSM130024 12. Remove the inlet and outlet A/C pressure line snap rings from the evaporator, and remove the A/C pressure lines. 13. Remove the HVAC housing assembly. Chery Automobile Co., Ltd. 13–...
Page 703: Blower Motor
NOTE : The blower motor is located on the bottom of the HVAC housing. The blower motor can be removed from the vehicle without having to remove the HVAC housing. 1. Disconnect the negative battery cable. 13– Chery Automobile Co., Ltd.
Page 704 (1) from the bottom of the left side of the instru- ment panel. PZSM130025 3. Push down on the clip (1) and remove the blower assembly clockwise. PZSM130010 4. Remove the blower motor. 5. Installation is in the reverse order of removal. Chery Automobile Co., Ltd. 13–...
Page 705 A/C System Recharge 13-34 Operation 13-42 Removal & Installation 13-43 A/C Compressor 13-35 Description 13-35 Heater Core 13-44 Operation 13-35 Description 13-44 Removal & Installation 13-35 Operation 13-44 Removal & Installation 13-44 Evaporator 13-37 Description 13-37 13– Chery Automobile Co., Ltd.
Page 706: General Information
Do not overcharge the refrigerant system. Overcharging will cause excessive compressor head pressure and can cause compressor noise and A/C system failure. Specifications Torque Specifications DESCRIPTION TORQUE (N·m) A/C Compressor Bracket Bolts A/C Compressor Line Bolts Chery Automobile Co., Ltd. 13–...
Page 707: Special Tools
GENERAL INFORMATION A/C Refrigerant Charge Specifications DESCRIPTION CAPACITY (g) R-134a Refrigerant 500 ± 10 Special Tools Refrigerant Recovery/Recycling Station 13– Chery Automobile Co., Ltd.
Page 708: A/C Compressor Noise Testing
A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Use only approved service equipment meeting SAE requirements to discharge an R-134a system. If accidental system discharge occurs, ventilate work area before resuming service. Chery Automobile Co., Ltd. 13–...
Page 709: Refrigerant System Empty
A dye for R-134a is available to aid in leak detection. Use only approved refrigerant dye. CAUTION: A leak detector only designed for R-12 refrigerant will not detect leaks in an R-134a refrigerant sys- tem. 13– Chery Automobile Co., Ltd.
Page 710: A/C System Evacuation And Recharge
ON-VEHICLE SERVICE A/C System Evacuation and Recharge Connecting Refrigerant Recovery/Recycling Station PZSM130026 WARNING! The A/C system is under high pressure, use caution when servicing the A/C system. Chery Automobile Co., Ltd. 13–...
Page 711: A/C System Evacuation
Before charging the A/C system, you MUST replenish any oil lost dur- ing the recovery process. 1. Evacuate the refrigerant system (See A/C System Evacuation and Recharge in Section 13 Heating & Air Con- ditioning). 13– Chery Automobile Co., Ltd.
Page 712: A/C Compressor
A/C compressor has occurred, the A/C accumulator and the A/C liquid line must also be replaced. Removal & Installation WARNING! Review safety precautions and warnings in this group before performing this procedure. Failure to follow the warnings and cautions could result in possible personal injury or death. Chery Automobile Co., Ltd. 13–...
Page 713 After removing the A/C lines, plug the A/C lines to prevent any debris from entering the A/C system. 6. Remove the A/C compressor upper mounting bolt (1). (Tighten: A/C compressor upper mounting bolt to 20 + 5 N·m) PZSM130002 13– Chery Automobile Co., Ltd.
Page 714: Evaporator
An electric actuator-positioned temper- ature blend door to direct airflow through or around the heater core. Removal & Installation 1. Evacuate the A/C system (See A/C System Evacuation and Recharge in Section 13 Heating and Air Condition- ing). Chery Automobile Co., Ltd. 13–...
Page 715 • Use only the specified O-rings as they are made of a special material for the R-134a system. • Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 13– Chery Automobile Co., Ltd.
Page 716: Condenser
A/C system. 7. Remove the two condenser mounting nuts (1). (Tighten: Condenser mounting nuts to 6 N·m) PZSM130017 8. Remove the condenser from the engine compartment. 9. Installation is in the reverse order of removal. Chery Automobile Co., Ltd. 13–...
Page 717: Accumulator
A/C pressure lines. NOTE: After removing the A/C lines, plug the A/C lines to prevent any debris from entering the A/C system. 4. Remove and discard the O-ring seals and gaskets. PZSM130015 13– Chery Automobile Co., Ltd.
Page 718: Liquid Line
2. Evacuate the A/C system (See A/C System Evacuation and Recharge in Section 13 Heating and Air Condition- ing). 3. Remove the A/C accumulator (See Accumulator Removal & Installation in Section 13 Heating & Air Conditioning). Chery Automobile Co., Ltd. 13–...
Page 719: Suction Line
Air conditioning hoses are designed to control liquid and gas at high pressures and temperatures. The hoses are usually flexible and equipped with special metal fittings at the ends to prevent leaks and provide a sure seal and connection between components. 13– Chery Automobile Co., Ltd.
Page 720 6. Remove the retaining nut (1) on the accumulator and remove the A/C pressure lines. NOTE: After removing the A/C lines, plug the A/C lines to prevent any debris from entering the A/C system. PZSM130015 Chery Automobile Co., Ltd. 13–...
Page 721: Heater Core
Failure to follow these instructions may result in serious personal injury. 1. Drain the cooling system (See Cooling System Draining Procedure in Section 06 Cooling System). 13– Chery Automobile Co., Ltd.
Page 722 (1) and remove the two cables. PZSM130021 7. Loosen the two heat exchanger shield retaining screws and remove the heat exchanger shield. PZSM130005 8. Remove the eight screws on the heater shield, and disassemble the evaporator shield. Chery Automobile Co., Ltd. 13–...
Page 723 10. Pry the clips off and remove the air conditioner cover plate assembly. PZSM130006 11. Remove the heater core. 12. Installation is in the reverse order of removal. Installation Notes: • Verify the cooling system is filled to proper specifications. 13– Chery Automobile Co., Ltd.
Page 724 14-37 Restraints Control Module DTC List 14-9 Restraints Control Module (RCM) 14-38 Diagnostic Trouble Code (DTC) Tests 14-11 Removal & Installation 14-38 B1200 - ECU Internal Errors 14-11 B1400 - Power Supply Under Volt 14-16 Chery Automobile Co., Ltd. 14–...
Page 725 The front seat belt tensioners are provided with a deployment signal by the RCM in conjunction with the front airbags. Specifications Torque Specifications DESCRIPTION TORQUE (N·m) Driver Side Airbag Mounting Bolt Restraints Control Module Mounting Nut Front Passenger Side Airbag Mounting Bolt 14– Chery Automobile Co., Ltd.
Page 726 Fluke 15B & 17B General Airbag Special Load Tool - Resistor Harness (For Driver’s and Passenger’s (Front) Airbag) General Airbag Special Load Tool - Dummy Resistor(For Driver’s and Passenger’s (Front) Airbag and Seat Belt Pre-Tensioner Circuit Check) Chery Automobile Co., Ltd. 14–...
Page 727 GENERAL INFORMATION Electrical Schematics Airbag Control System (Page 1 of 3) PZSMW140001T 14– Chery Automobile Co., Ltd.
Page 728 GENERAL INFORMATION Airbag Control System (Page 2 of 3) PZSMW140003T Chery Automobile Co., Ltd. 14–...
Page 729 GENERAL INFORMATION Airbag Control System (Page 3 of 3) PZSMW140002T 14– Chery Automobile Co., Ltd.
Page 730 Driver Seat Belt Pretensioner Hi Front Passenger Seat Belt Pretensioner Lo Front Passenger Seat Belt Pretensioner Hi Ignition-Switch Airbag Lamp Diagnostic Link K Driver Airbag Lo Driver Airbag Hi To BCM Front Passenger Airbag Hi Front Passenger Airbag Lo Chery Automobile Co., Ltd. 14–...
Page 731 • The DLC is located on the driver side compartment under the steering column (it is attached to the instrument panel and accessible from the driver seat). • The DLC is rectangular in design and capable of accommodating up to 16 terminals. • The electrical connector has keying features to allow easy connection. 14– Chery Automobile Co., Ltd.
Page 732 Front Passenger Sidebag Short To GND B1267 Front Passenger Sidebag Short To Vbatt B1268 Front Passenger Sidebag Short Circuit Or Below Lower Limit Or Ground Lost B1269 Front Passenger Sidebag Open Circuit Or Over Upper Limit Or Vbatt Voltage Lost Chery Automobile Co., Ltd. 14–...
Page 733 Front Passenger Side Impact Sensor Defective Signal B1295 Front Passenger Side Impact Sensor Internal Errors B2212 Warning Lamp Short To Battery B2213 Inhibition Lamp Short To Battery B2214 Warning Lamp Short To Ground B2215 Inhibition Lamp Short To Ground 14– Chery Automobile Co., Ltd.
Page 734 DIAGNOSIS & TESTING Diagnostic Trouble Code (DTC) Tests B1200 - ECU Internal Errors PZSMW140004T Chery Automobile Co., Ltd. 14–...
Page 735 DIAGNOSIS & TESTING PZSMW140005T 14– Chery Automobile Co., Ltd.
Page 736 Is DTC B1200 present? >> Go to the next step. >> The condition that caused this DTC to set is currently not present (See Diagnostic Help and Intermit- tent DTC Troubleshooting in Section 14 Restraints for more information). Chery Automobile Co., Ltd. 14–...
Page 737 • Check voltage between terminal 5 and terminal 6 in the RCM electrical connector J-001 terminal side. RESTRAINTS CONTROL MODULE (RCM) VOLTAGE CONNECTOR TERMINAL 5 & 6 Less than 9 V Is the voltage less than 9 V? >> Go to step 5. >> Replace the RCM. 14– Chery Automobile Co., Ltd.
Page 738 • Refer to DTC Confirmation Procedure . Is DTC B1200 still present? >> Replace the Restraints Control Module (RCM). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 14–...
Page 739 DIAGNOSIS & TESTING B1400 - Power Supply Under Volt PZSMW140004T 14– Chery Automobile Co., Ltd.
Page 740 DIAGNOSIS & TESTING PZSMW140005T Chery Automobile Co., Ltd. 14–...
Page 741 • The following tools are required to perform the following test: − X-431 Scan Tool − Airbag Special Load Tool − Digital Multimeter NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. 14– Chery Automobile Co., Ltd.
Page 742 • Check voltage between terminal 5 and terminal 6 in the RCM electrical connector J-001 terminal side. RESTRAINTS CONTROL MODULE (RCM) VOLTAGE CONNECTOR TERMINAL 5 & 6 Less than 9 V Is the voltage less than 9 V? >> Go to step 4. >> Replace the RCM. Chery Automobile Co., Ltd. 14–...
Page 743 Check the electrical harness for an open or high resistance. CHECK DTC • With the X-431 scan tool, read RCM DTCs. • Refer to DTC Confirmation Procedure . Is DTC B1400 still present? >> Replace the RCM. >> The system is now operating properly. 14– Chery Automobile Co., Ltd.
Page 744 DIAGNOSIS & TESTING B1241 - Front Driver Airbag I °STAGE Open Circuit or Over Upper Limit or Vbatt Voltage Lost PZSMW140008T Chery Automobile Co., Ltd. 14–...
Page 745 • The following tools are required to perform the following test: − X-431 Scan Tool − Airbag Special Load Tool − Digital Multimeter 14– Chery Automobile Co., Ltd.
Page 746 Is DTC B1241 present? >> Go to the next step. >> Replace the driver airbag (See Driver Airbag Removal & Installation in Section 14 Restraints). Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 14–...
Page 747 • Check the continuity of the driver airbag circuit between the RCM electrical connector terminal 10 and the spiral cable electrical connector terminal 1. SPIRAL CABLE CONTINUITY TERMINAL TERMINAL • Check the continuity of the driver airbag circuit between the RCM electrical connector terminal 11 and the spiral cable electrical connector terminal 2. 14– Chery Automobile Co., Ltd.
Page 748 • Check the continuity of the driver airbag circuit between the driver airbag electrical connector terminal 1 and the spiral cable electrical connector terminal 1. SPIRAL DRIVER CABLE AIRBAG CONTINUITY TERMINAL TERMINAL Chery Automobile Co., Ltd. 14–...
Page 749 • Refer to DTC Confirmation Procedure . Is the DTC B1241 still present? >> Replace the RCM. >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 14– Chery Automobile Co., Ltd.
Page 750 DIAGNOSIS & TESTING B1245 - Front Passenger Airbag I °STAGE Open Circuit or Over Upper Limit or Vbatt Voltage Lost PZSMW140009T Chery Automobile Co., Ltd. 14–...
Page 751 • The following tools are required to perform the following test: − X-431 Scan Tool − Airbag Special Load Tool − Digital Multimeter 14– Chery Automobile Co., Ltd.
Page 752 Is DTC B1245 present? >> Go to the next step. >> Replace the passenger airbag (See Passenger Airbag Removal & Installation in Section 14 Restraints). Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 14–...
Page 753 • Check the continuity of the passenger airbag circuit between the RCM electrical connector terminal 13 and pas- senger airbag electrical connector terminal 1. FRONT PASSENGER AIRBAG CONNECTOR CONTINUITY CONNECTOR J-001 J-002 TERMINAL TERMINAL 14– Chery Automobile Co., Ltd.
Page 754 • Refer to DTC Confirmation Procedure . Is the DTC B1245 still present? >> Replace the RCM. >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 14–...
Page 755 DIAGNOSIS & TESTING B2214 - Warning Lamp Short to Ground PZSMW140010T 14– Chery Automobile Co., Ltd.
Page 756 • The following tools are required to perform the following test: − X-431 Scan Tool − Airbag Special Load Tool − Digital Multimeter Chery Automobile Co., Ltd. 14–...
Page 757 To avoid serious or fatal injury, turn ignition switch off, disconnect the negative battery cable and wait two min- utes before proceeding. Disconnect the instrument cluster electrical connector C-001. Disconnect the body fuse and relay box C-020. NOTE : Check connectors - Clean and repair as necessary. 14– Chery Automobile Co., Ltd.
Page 758 Refer to DTC Confirmation Procedure . I s DT C B 2214 still present? >> Replace the RCM. >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 14–...
Page 759 Failure to do so may result in accidental airbag development, serious or fatal injury (See Airbag System Disarming Procedure in Section 14 Restraints). 3. Loosen the two driver airbag retaining bolts. (Tighten: Driver airbag retaining bolts to 10 N·m) 4. Remove the driver side airbag. PZSM140010 14– Chery Automobile Co., Ltd.
Page 760 4. Remove the front passenger airbag mounting bolts (1). PZSM150189 5. Remove the instrument panel (See Instrument Panel Removal & Installation in Section 15 Body & Accessories). 6. Disconnect the front passenger airbag squib electrical connector. Chery Automobile Co., Ltd. 14–...
Page 761 (2). 4. Remove the RCM retaining bolts (1). (Tighten: RCM retaining bolts to 10 N·m) PZSM140008 5. Remove the RCM from the vehicle. 6. Installation is in the reverse order of the removal. 14– Chery Automobile Co., Ltd.
Page 762 14-40 Description 14-40 Adjustable Shoulder Belt Anchor 14-43 Operation 14-40 Removal & Installation 14-43 Specifications 14-40 Rear Seat Belt and Tensioner 14-45 Removal & Installation 14-45 ON-VEHICLE SERVICE 14-41 Front Seat Belt and Pre-Tensioner 14-41 Chery Automobile Co., Ltd. 14–...
Page 763 Specifications Torque Specifications DESCRIPTION TORQUE (N·m) Adjustable Shoulder Belt Anchor Bolt Front Seat Belt Buckle Retaining Bolt Front Seat Belt Pre-Tensioner Lower Retaining Bolt Rear Seat Belt Retaining Bolt Rear Seat Belt Pre-Tensioner Retaining Bolt 14– Chery Automobile Co., Ltd.
Page 764 ON-VEHICLE SERVICE Front Seat Belt and Pre-Tensioner Removal & Installation 1. Remove the seat belt upper mounting bolt (1). 2. Remove the seat belt lower mounting bolt (2). pzsm140014 PZSM140014 Chery Automobile Co., Ltd. 14–...
Page 765 4. Remove the front seat belt pre-tensioner retaining bolt (1). (Tighten: Front seat belt retaining bolt to 50 N·m) PZSM140016 5. Remove the front seat belt and pre-tensioner. 6. Installation is in the reverse order of removal. 14– Chery Automobile Co., Ltd.
Page 766 ON-VEHICLE SERVICE Adjustable Shoulder Belt Anchor Removal & Installation 1. Remove the B-pillar lower trim panel (1). PZSM140015 2. Remove the front seat belt bracket retaining screws (1). PZSM140017 Chery Automobile Co., Ltd. 14–...
Page 767 4. Remove the two adjustable shoulder belt anchor mounting bolts (1). (Tighten: Adjustable shoulder belt anchor bolts to 50 N·m) PZSM140013 5. Remove the adjustable shoulder belt anchor. 6. Installation is in the reverse order of the removal. 14– Chery Automobile Co., Ltd.
Page 768 1. Remove the rear seat (See Rear Seat Removal & Installation in Section 15 Body & Accessories). 2. Remove the rear seat belt mounting bolts (1). (Tighten: Rear seat belt mounting bolts to 50 N·m) PZSM140006 3. Remove the two side seat belt mounting bolts (1). PZSM140018 Chery Automobile Co., Ltd. 14–...
Page 769 4. Remove the C-pillar (See C-Pillar Removal & Installation in Section 15 Body & Accessories). 5. Remove the rear seat tensioner mounting bolt (1). (Tighten: Rear seat belt tensioner mounting bolt to 50 N·m) PZSM140011 6. Remove the tensioner. 7. Installation is in the reverse order of the removal. 14– Chery Automobile Co., Ltd.
Page 770 CAN VEHICLE COMMUNICATIONS 15-18 Low Current 15-63 Description 15-18 Operation 15-18 ON-VEHICLE SERVICE 15-67 Electrical Schematics 15-19 Body Control Module (BCM) 15-67 CHIME 15-20 Removal & Installation 15-67 Description 15-20 Operation 15-20 Electrical Schematics 15-21 Chery Automobile Co., Ltd. 15–...
Page 771 Power Window Switch 15-103 Removal & Installation 15-103 Remote Keyless Entry (RKE) Inoperative 15-150 Power Window Motor 15-103 No Response From Remote Keyless Removal & Installation 15-103 Entry (RKE) Transmitter 15-150 Power Window Motor Inspection 15-113 15– Chery Automobile Co., Ltd.
Page 772 OFF position. Operation With audio system on, radio signals are received by the antenna, the audio unit then sends audio signals to front speakers, rear speakers and front tweeters. Chery Automobile Co., Ltd. 15–...
Page 773 AUDIO SYSTEM Electrical Schematics Audio System (Page 1 of 2) PZSMW150034T 15– Chery Automobile Co., Ltd.
Page 774 AUDIO SYSTEM Audio System (Page 2 of 2) PZSMW150037T Chery Automobile Co., Ltd. 15–...
Page 775 Removal & Installation 1. Disconnect the negative battery cable. 2. Open the storage box over the console, and remove the two retaining screws (1). PZSM150179 3. Using a trim stick, remove the storage box (1). PZSM150180 15– Chery Automobile Co., Ltd.
Page 776 4. Remove the two upper cover retaining screws (1). PZSM150181 5. Using a trim stick, pry the lower cover. 6. Remove the center instrument panel cover (1). PZSM150182 7. Disconnect the emergency switch electrical connector. Chery Automobile Co., Ltd. 15–...
Page 777 10. Disconnect the two electrical connectors behind the HVAC control panel. 11. Remove the two control cables from the HVAC control panel. 12. Remove the HVAC control panel. 13. Remove the two upper CD player retaining bolts (1). PZSM150183 15– Chery Automobile Co., Ltd.
Page 778 3. Disconnect the antenna electrical connector (4). 4. Disconnect the antenna to CD player cable (3). 5. Remove the antenna retaining nut (2). 6. Remove the antenna (1). PZSM150166 7. Installation is in the reverse order of removal. Chery Automobile Co., Ltd. 15–...
Page 779 2. Remove the A-pillar trim panel. 3. Installation is in the reverse order of removal. Installation Notes: • The A-pillar trim panel clips should be installed to allow the trim panel a tight fit between the roof and the weatherstrip. 15– Chery Automobile Co., Ltd.
Page 780 1. Remove the seat belt upper mounting bolt (1). 2. Remove the seat belt lower mounting bolt (2). PZSM140014 3. Using a trim stick, pry the B-pillar trim panel (1) to release the retaining clips. PZSM140015 Chery Automobile Co., Ltd. 15–...
Page 781 BODY INTERIOR TRIM 4. Remove the front seat belt bracket retaining screws (1). PZSM140017 5. Using a trim stick, remove B-pillar upper trim panel (1). PZSM140012 6. Installation is in the reverse order of removal. 15– Chery Automobile Co., Ltd.
Page 782 C-Pillar Trim Panel Removal & Installation 1. Remove the two side seat belt mounting bolts (1). PZSM140018 2. Disconnect the rear speaker electrical connector (2). 3. Remove the three rear speaker retaining screws (1). PZSM150107 Chery Automobile Co., Ltd. 15–...
Page 783 6. Remove the two rear hatch kick plates. 7. Remove the C-pillar lower trim panel retaining clips (1). PZSM150203 8. Remove the C-pillar lower trim panel and discon- nect the rear hatch lamp electrical connector (1). PZSM150109 15– Chery Automobile Co., Ltd.
Page 784 2. Grasp the scuff plate and gently pull it away to release the retaining clips. 3. Using a trim stick, remove the scuff plate from the front door sill. PZSM150177 4. Installation is in the reverse order of removal. Chery Automobile Co., Ltd. 15–...
Page 785 3. Remove the A/B/C pillar (See A/B/C Pillar Removal & Installation in Section 15 Body & Accessories). 4. Remove the left and right sun visor (See Sun Visor Removal & Installation in Section 15 Body & Accessories). 15– Chery Automobile Co., Ltd.
Page 786 • The headliner should fit tight with the weatherstrip around the door openings and the luggage compartment. • The headliner should fit tight to the roof around the arcs of the upper trim panels (A, B, and C pillars) with a clearance less than 0.2 mm. Chery Automobile Co., Ltd. 15–...
Page 787 The CAN bus uses low and high voltage levels to generate signals. The voltage on the bus varies between zero and two and one-half volts. The low and high voltage levels are generated by means of variable-pulse width modulation to form signals of varying length. 15– Chery Automobile Co., Ltd.
Page 788 CAN VEHICLE COMMUNICATIONS Electrical Schematics CAN Vehicle Communications (Page 1 of 1) PZSMW151010T Chery Automobile Co., Ltd. 15–...
Page 789 • Low oil pressure • Low brake fluid level • Doors unlocked • Charging system fault • Engine performance fault • Airbag system fault • Low coolant level • Immobilizer control module fault • Engine overheating 15– Chery Automobile Co., Ltd.
Page 790 CHIME Electrical Schematics Chime (Page 1 of 3) PZSMW150039T Chery Automobile Co., Ltd. 15–...
Page 791 CHIME Chime (Page 2 of 3) PZSMW150041T 15– Chery Automobile Co., Ltd.
Page 792 CHIME Chime (Page 3 of 3) PZSMW150044T Chery Automobile Co., Ltd. 15–...
Page 793 The power door locks can also be operated by the Remote Keyless Entry (RKE) trans- mitter. Operation The power lock system receives non-switched battery current, so that the power locks remain operational, regardless of the ignition switch position. 15– Chery Automobile Co., Ltd.
Page 794 DOOR LOCKS Electrical Schematics Power Door Lock System (Page 1 of 3) PZSMW150021T Chery Automobile Co., Ltd. 15–...
Page 795 DOOR LOCKS Power Door Lock System (Page 2 of 3) PZSMW150022T 15– Chery Automobile Co., Ltd.
Page 796 DOOR LOCKS Power Door Lock System (Page 3 of 3) PZSMW150023T Chery Automobile Co., Ltd. 15–...
Page 797 1. Turn the ignition switch off. 2. Using a trim stick, remove the outside mirror switch panel (1) from the door trim panel. PZSM150120 3. Disconnect the outside mirror switch electrical con- nector (1). PZSM150121 15– Chery Automobile Co., Ltd.
Page 798 DOOR LOCKS 4. Using a trim stick, remove the power window switch assembly (1). PZSM150126 5. Disconnect the power window switch electrical con- nector (1). PZSM150073 Chery Automobile Co., Ltd. 15–...
Page 799 DOOR LOCKS 6. Using a trim stick, remove the inside door handle panel retaining screw cover (1). PZSM150122 7. Remove the inside door handle panel retaining screw (1). PZSM150123 15– Chery Automobile Co., Ltd.
Page 800 DOOR LOCKS 8. Using a trim stick, remove the inside door handle panel (1). PZSM150125 9. Loosen the inside door handle panel control cable (1). PZSM150130 Chery Automobile Co., Ltd. 15–...
Page 801 DOOR LOCKS 10. Remove the small storage compartment retaining screw (1) on the door trim panel. PZSM150127 11. Using a trim stick, remove the small storage com- partment (1). PZSM150128 15– Chery Automobile Co., Ltd.
Page 802 12. Remove the door switch (1). PZSM150124 13. Disconnect the door switch electrical connector (1). PZSM150145 14. Remove the four retaining screws (1) from the door trim panel. PZSM150129 15. Remove the door trim panel. Chery Automobile Co., Ltd. 15–...
Page 803 16. Remove the outside mirror retaining nuts (1), and remove the outside mirror electrical connector. (Tighten: Outside mirror mounting nuts to 7 ± 1 N·m) PZSM150134 17. Remove the two door trim panel mounting bracket retaining screws (1). PZSM150131 15– Chery Automobile Co., Ltd.
Page 804 DOOR LOCKS 18. Remove the protective film (1) from the front door. PZSM150133 19. Remove the power lock motor retaining screws (1). (Tighten: Power lock motor retaining screws to 8 ± 1 N·m) PZSM150143 Chery Automobile Co., Ltd. 15–...
Page 805 3. If the test results are not as specified, replace the motor. MEASURING CONDITION OPERATION Battery positive (+) to terminal – 1 Lock Battery negative (-) to terminal – 3 Battery positive (+) to terminal – 3 Unlock Battery negative (-) to terminal – 1 15– Chery Automobile Co., Ltd.
Page 806 • Front combination lamps • Rear combination lamps • Dome lamps • Turn signal lamps • Security lamp • Step lamps • Front power window motor • Power door lock motor • Washer motor • Wiper motor Chery Automobile Co., Ltd. 15–...
Page 807 BODY CONTROL MODULE - BCM Electrical Schematics Body Control Module (Page 1 of 4) PZSMW150051T 15– Chery Automobile Co., Ltd.
Page 808 BODY CONTROL MODULE - BCM Body Control Module (Page 2 of 4) PZSMW150052T Chery Automobile Co., Ltd. 15–...
Page 809 BODY CONTROL MODULE - BCM Body Control Module (Page 3 of 4) PZSMW150053T 15– Chery Automobile Co., Ltd.
Page 810 BODY CONTROL MODULE - BCM Body Control Module (Page 4 of 4) PZSMW150055T Chery Automobile Co., Ltd. 15–...
Page 811 Left Front Window Up Input Left Front Window Up Input Left Rear Window Up Output Start Input Left Rear Window Down Output Turn Signal Light Power Input Unlock/Lock Input Left Turn Signal Output Continuous Supply Voltage 15– Chery Automobile Co., Ltd.
Page 812 If multiple wires are crimped to one eyelet, make sure no excess wire insulation has been crimped creating a bad ground. Diagnostic Tools • Diagnostic Scan Tool X-431 • Digital Multimeter • Jumper Wire Chery Automobile Co., Ltd. 15–...
Page 813 RL Window Up Control Circuit Stuck On B1332 RL Window Down Control Circuit Low Current B1334 RL Window Down Control Circuit Stuck On B1337 RR Window Up Control Circuit Low Current B1341 RR Window Down Control Circuit Low Current 15– Chery Automobile Co., Ltd.
Page 814 DIAGNOSIS & TESTING Diagnostic Trouble Code (DTC) Tests B1000 - Left Turn Lights Control Circuit Low Current PZSMW150064T Chery Automobile Co., Ltd. 15–...
Page 815 • If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 15 Body & Accessories for more information). NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. 15– Chery Automobile Co., Ltd.
Page 816 12 V (21 W) Lamp Bulb PZSM150086 Is the front LH or rear LH turn signal bulb OK? >> Install the bulbs, go to the next step. >> Replace the LH turn signal bulb(s) as necessary. Chery Automobile Co., Ltd. 15–...
Page 817 • Check resistance between the rear LH turn signal lamp harness connector B-004, terminal 1 and ground. • Continuity should exist. Is the check result normal? >> Go to the next step. >> Repair or replace the ground circuit for an open or high resistance in harness or connectors. 15– Chery Automobile Co., Ltd.
Page 818 • With the X-431 scan tool, read BCM DTCs. • Refer to DTC Confirmation Procedure . Is DTC B1000 present? >> Replace BCM. >> The system is now operating properly. Reassemble the vehicle and verify the customers complaint is repaired. Chery Automobile Co., Ltd. 15–...
Page 819 DIAGNOSIS & TESTING B1004 - Right Turn Lights Control Circuit Low Current PZSMW150063T 15– Chery Automobile Co., Ltd.
Page 820 • If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 15 Body & Accessories for more information). NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. Chery Automobile Co., Ltd. 15–...
Page 821 12 V (21 W) Lamp Bulb PZSM150086 Is the front LH or rear LH turn signal bulb OK? >> Install the bulbs, go to the next step. >> Replace the RH turn signal bulb(s) as necessary. 15– Chery Automobile Co., Ltd.
Page 822 • Check resistance between the rear RH turn signal lamp harness connector B-005, terminal 1 and ground. • Continuity should exist. Is the check result normal? >> Go to the next step. >> Repair or replace the ground circuit for an open or high resistance in harness or connectors. Chery Automobile Co., Ltd. 15–...
Page 823 • Refer to DTC Confirmation Procedure . Is DTC B1004 still present? >> Replace BCM. >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 15– Chery Automobile Co., Ltd.
Page 824 DIAGNOSIS & TESTING B1100 - Dome Light Control Circuit Low Voltage PZSMW150066T Chery Automobile Co., Ltd. 15–...
Page 825 >> Replace the damaged fuse. Go to step 3. NOTE : Inspect the fuses. If an open fuse is found, use the electrical schematics as a guide and inspect the wiring and connectors for damage. 15– Chery Automobile Co., Ltd.
Page 826 Go to the next step. >> Repair or replace the circuit for an open or a short in harness or connectors between the front dome lamp harness connector and fuse F18. Check the body fuse and relay box C-020. Chery Automobile Co., Ltd. 15–...
Page 827 • Refer to DTC Confirmation Procedure . Is DTC B1100 still present? >> Replace the BCM. >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 15– Chery Automobile Co., Ltd.
Page 828 DIAGNOSIS & TESTING B1301 - Central Lock Control Circuit Low Current PZSMW150062T Chery Automobile Co., Ltd. 15–...
Page 829 • If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 15 Body & Accessories for more information). NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. 15– Chery Automobile Co., Ltd.
Page 830 Is the check result normal? >> Go to the next step. >> Repair or replace the lock control circuit between BCM connector B-002, terminal 28 and door lock actuator connectors for an open or high resistance. Chery Automobile Co., Ltd. 15–...
Page 831 • With the X-431 scan tool, read the BCM DTCs. • Refer to DTC Confirmation Procedure . Is DTC B1301 still present? >> Replace the BCM. >> The system is now operating properly. Reassemble the vehicle and verify the customers complaint is repaired. 15– Chery Automobile Co., Ltd.
Page 832 DIAGNOSIS & TESTING B1310 - FL Window Up Control Circuit Low Current PZSMW150058T Chery Automobile Co., Ltd. 15–...
Page 833 • If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 15 Body & Accessories for more information). NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. 15– Chery Automobile Co., Ltd.
Page 834 Go to the next step. >> Repair or replace the circuit between the BCM connector B-002, terminal 30 and front LH power win- dow motor connectors D-002, terminal 2 for an open or high resistance. Chery Automobile Co., Ltd. 15–...
Page 835 • With the X-431 scan tool, read the BCM DTCs. • Refer to DTC Confirmation Procedure . Is DTC B1310 present? >> Replace the BCM. >> The system is now operating properly. Reassemble the vehicle and verify the customers complaint is repaired. 15– Chery Automobile Co., Ltd.
Page 836 2. Remove the left front seat (See Front Seat Removal & Installation in Section 15 Body & Accessories). 3. Remove the two BCM retaining bolts (1). 4. Disconnect the BCM electrical connector. 5. Remove the BCM. 6. Installation is in the reverse order of removal. PZSM150204 Chery Automobile Co., Ltd. 15–...
Page 837: Instrument Panel
2. Remove the instrument cluster (See Instrument Cluster Removal & Installation in Section 15 Body & Accesso- ries). 3. Remove the retaining bolt (1). PZSM150209 4. Remove the driver airbag (See Driver Airbag Removal & Installation in Section 14 Restraints). 15– Chery Automobile Co., Ltd.
Page 838 10. Remove the CD player (See CD Player Removal & Installation in Section 15 Body & Accessories). 11. Remove the HVAC control panel (See HVAC Control Panel Removal & Installation in Section 13 HVAC). 12. Remove the power outlet (See Power Outlet Removal & Installation in Section 15 Body & Accessories). Chery Automobile Co., Ltd. 15–...
Page 839 14. Remove the dimmer control switch electrical con- nectors (1) and remove the dimmer control switch. PZSM150191 15. Remove the following harnesses from the main harness: • Body harness • Front end module harness • Engine control harness • A/C harness 15– Chery Automobile Co., Ltd.
Page 840 INSTRUMENT PANEL 16. Remove the wiper switch and high beam switch. PZSM150117 17. Remove the glove box assembly and the passen- ger side airbag retaining bolts (1). PZSM150189 Chery Automobile Co., Ltd. 15–...
Page 841 (1). 21. Remove the right instrument panel cover assembly and remove the retaining screw. PZSM150206 22. Remove the A-pillar panel (See A-Pillar Panel Removal & Installation in Section 15 Body & Accessories). 15– Chery Automobile Co., Ltd.
Page 842 23. Remove the left instrument panel side retaining bolt (1). 24. Remove the right instrument panel side retaining bolt. PZSM150205 25. Remove the hood release lever (1). 26. Remove the retaining bolt (2). PZSM150207 27. Remove the instrument panel assembly. Chery Automobile Co., Ltd. 15–...
Page 843: Lower Console
INSTRUMENT PANEL 28. Disconnect the front tweeter electrical connectors (1). PZSM150208 29. Installation is in the reverse order of removal. Lower Console Removal & Installation 1. Remove the lower console panel retaining screws (1). PZSM150170 15– Chery Automobile Co., Ltd.
Page 844 INSTRUMENT PANEL 2. Remove the shield (1) from the hand brake. PZSM150171 3. Remove the shield (1) from the gearshift selector. PZSM150172 Chery Automobile Co., Ltd. 15–...
Page 845 5. Pull the gear selector shield upward by hand (the shield and the lower console are attached with clips and no retaining screws are used). 6. Remove the lower console. 7. Installation is in the reverse order of removal. 15– Chery Automobile Co., Ltd.
Page 846: Instrument Cluster
• Temperature Gauge - The IC displays the engine coolant temperature as determined by the Engine Control Module (ECM) indicating engine coolant temperature. • Fuel Gauge - The IC displays the amount of fuel in the fuel tank as determined by the fuel level sensor. Chery Automobile Co., Ltd. 15–...
Page 847 INSTRUMENT CLUSTER Specifications Torque Specifications DESCRIPTION TORQUE (N·m) Instrument Cluster Bezel Fasteners Instrument Cluster Fasteners Special Tools Diagnostic Scan Tool X-431 Digital Multimeter Fluke 15B & 17B 15– Chery Automobile Co., Ltd.
Page 848 INSTRUMENT CLUSTER Electrical Schematics Instrument Cluster (Page 1 of 6) PZSMW150012T Chery Automobile Co., Ltd. 15–...
Page 849 INSTRUMENT CLUSTER Instrument Cluster (Page 2 of 6) PZSMW150018T 15– Chery Automobile Co., Ltd.
Page 850 INSTRUMENT CLUSTER Instrument Cluster (Page 3 of 6) PZSMW150013T Chery Automobile Co., Ltd. 15–...
Page 851 INSTRUMENT CLUSTER Instrument Cluster (Page 4 of 6) PZSMW150014T 15– Chery Automobile Co., Ltd.
Page 852 INSTRUMENT CLUSTER Instrument Cluster (Page 5 of 6) PZSMW150015T Chery Automobile Co., Ltd. 15–...
Page 853 INSTRUMENT CLUSTER Instrument Cluster (Page 6 of 6) PZSMW150016T 15– Chery Automobile Co., Ltd.
Page 854 GND (Power) Seat Belt Buckle Switch LH GND (Sensor) Fuel Level Input Speed Output Reserve Oil Pressure Switch Brake Fluid Level Input Continuous Supply Voltage Vehicle Speed Input Illumination Lamp Ignition Switch CAN-L CAN-H Charge Chery Automobile Co., Ltd. 15–...
Page 855: Diagnosis & Testing
If multiple wires are crimped to one eyelet, make sure no excess wire insulation has been crimped creating a bad ground. Diagnostic Tools • Digital Multimeter • Jumper Wire 15– Chery Automobile Co., Ltd.
Page 856: On-Vehicle Service
Removal & Installation 1. Disconnect the negative battery cable. 2. Remove the steering wheel (See Steering Wheel Removal & Installation in Section 11 Steering). 3. Remove the two instrument cluster cover retaining screws (1). PZSM150063 Chery Automobile Co., Ltd. 15–...
Page 857 4. Remove the instrument cluster cover (1). PZSM150175 5. Remove the retaining screws (1) around the cluster. PZSM150064 6. Disconnect the instrument cluster electrical connector. 7. Remove the instrument cluster. 8. Installation is in the reverse order of removal. 15– Chery Automobile Co., Ltd.
Page 858: Interior Lamps
• Rear Power Window Switch • Rear Hatch Lamp Operation The Body Control Module (BCM) receives switch inputs and controls voltage output to the interior lamps. The supply voltage is transmitted from the fuse box to the lamps. Chery Automobile Co., Ltd. 15–...
Page 859 INTERIOR LAMPS Electrical Schematics Interior Lamps (Page 1 of 5) PZSMW150045T 15– Chery Automobile Co., Ltd.
Page 860 INTERIOR LAMPS Interior Lamps (Page 2 of 5) PZSMW150046T Chery Automobile Co., Ltd. 15–...
Page 861 INTERIOR LAMPS Interior Lamps (Page 3 of 5) PZSMW150048T 15– Chery Automobile Co., Ltd.
Page 862 INTERIOR LAMPS Interior Lamps (Page 4 of 5) PZSMW150049T Chery Automobile Co., Ltd. 15–...
Page 863 INTERIOR LAMPS Interior Lamps (Page 5 of 5) PZSMW150050T 15– Chery Automobile Co., Ltd.
Page 864 2. Using a trim tool, remove the lamp cover. 3. Remove the lamp retaining screws (1). PZSM150084 4. Disconnect the electrical connector (1). PZSM150194 5. Remove the front dome lamp assembly. 6. Installation is in the reverse order of removal. Chery Automobile Co., Ltd. 15–...
Page 865: Power Outlet
CAUTION: This power outlet is designed for 12V (120W) only. Do not use any type of accessory above this rating. Operation The power outlet is powered when the ignition switch is on the ACC/ON position. 15– Chery Automobile Co., Ltd.
Page 866 POWER OUTLET Electrical Schematics Power Outlet (Page 1 of 1) PZSMW150031T Chery Automobile Co., Ltd. 15–...
Page 867 4. Remove the power outlet panel. 5. Remove the four power outlet retaining screws (1). PZSM150187 6. Disconnect the power outlet electrical connector. 7. Remove the power outlet. 8. Installation is in the reverse order of removal. 15– Chery Automobile Co., Ltd.
Page 868: Power Windows
Reversing current through these same two connections will cause the motor to rotate in the opposite direction. Each individual motor is grounded through their respective switch. Chery Automobile Co., Ltd. 15–...
Page 869 POWER WINDOWS Electrical Schematics Power Window System (Page 1 of 3) PZSMW150024T 15– Chery Automobile Co., Ltd.
Page 870 POWER WINDOWS Power Window System (Page 2 of 3) PZSMW150025T Chery Automobile Co., Ltd. 15–...
Page 871 POWER WINDOWS Power Window System (Page 3 of 3) PZSMW150026T 15– Chery Automobile Co., Ltd.
Page 872: Power Window Motor
3. Disconnect the power window switch electrical con- nector (1). PZSM150073 4. Remove the power window switch assembly. 5. Installation is in the reverse order of removal. Power Window Motor Removal & Installation 1. Turn the ignition switch off. Chery Automobile Co., Ltd. 15–...
Page 873 (1) from the door trim panel. PZSM150120 3. Disconnect the outside mirror switch electrical con- nector (1). PZSM150121 4. Using a trim stick, remove the power window switch assembly (1) on the left front door. PZSM150126 15– Chery Automobile Co., Ltd.
Page 874 POWER WINDOWS 5. Disconnect the power window switch electrical con- nector (1). PZSM150073 6. Using a trim stick, remove the inside door handle panel retaining screw cover (1). PZSM150122 Chery Automobile Co., Ltd. 15–...
Page 875 POWER WINDOWS 7. Remove the inside door handle panel retaining screw (1). PZSM150123 8. Remove the inside door handle panel (1). PZSM150125 15– Chery Automobile Co., Ltd.
Page 876 POWER WINDOWS 9. Loosen the inside door handle panel control cable (1). PZSM150130 10. Remove the small storage compartment retaining screw (1) on the door trim panel. PZSM150127 Chery Automobile Co., Ltd. 15–...
Page 877 POWER WINDOWS 11. Using a trim stick, remove the small storage com- partment (1). PZSM150128 12. Remove the door switch (1). PZSM150124 15– Chery Automobile Co., Ltd.
Page 878 14. Remove the four door trim panel retaining screws (1). PZSM150129 15. Remove the door trim panel. 16. Remove the outside mirror retaining nuts (1), and remove the outside mirror electrical connector. (Tighten: Outside mirror retaining nuts to 7 ± 1 N·m) PZSM150134 Chery Automobile Co., Ltd. 15–...
Page 879 POWER WINDOWS 17. Remove the two door trim panel mounting bracket retaining screws (1). PZSM150131 18. Remove the protective film (1) from the front door. PZSM150133 15– Chery Automobile Co., Ltd.
Page 880 POWER WINDOWS 19. Lower the glass to a proper position, remove the two glass retaining screws (1). PZSM150137 20. Remove the window glass (1). PZSM150139 Chery Automobile Co., Ltd. 15–...
Page 881 21. Disconnect the window motor electrical connector (1). PZSM150138 22. Remove the two guide rail mounting nuts (2). 23. Remove the three window regulator retaining nuts (1). (Tighten: Window regulator retaining nuts to 9 ± 1 N·m) PZSM150136 15– Chery Automobile Co., Ltd.
Page 882: Power Window Motor Inspection
MEASURING OPERATIONAL INSPECTION DIAGRAM CONDITION DIRECTION Battery positive (+) to terminal – 1 Down Battery negative (-) to terminal – 2 Battery positive (+) to terminal – 2 Battery negative (-) to terminal – 1 Chery Automobile Co., Ltd. 15–...
Page 883 3. Move the seat to the furthest frontward position and remove the protective cover from the guide rail. 4. Remove the front seat mounting bolts (2) from the back of the seat guide rail. PZSM150103 15– Chery Automobile Co., Ltd.
Page 884: Rear Seat
6. Installation is in the reverse order of removal. Rear Seat Removal & Installation 1. Remove the rear seat cushion retaining bolts (1). (Tighten: Rear seat cushion retaining bolts to 25 ± 3 N·m) PZSM150077 Chery Automobile Co., Ltd. 15–...
Page 885 25 ± 3 N·m) PZSM150105 5. Remove the two right side rear seat mounting bolts. (Tighten: Right rear seat mounting bolts to 25 ± 3 N·m) 6. Open the rear hatch. 7. Remove the spare tire. 15– Chery Automobile Co., Ltd.
Page 886 8. Remove the two middle bolts (1) from the rear seat. (Tighten: Rear seat middle mounting bolts to 25 ± 3 N·m) PZSM150106 9. Remove the rear seats. 10. Installation is in the reverse order of removal. Chery Automobile Co., Ltd. 15–...
Page 887: Immobilizer Control Module
When an incorrect key is inserted into the ignition switch, the Immobilizer Coil senses the incorrect key and sends a signal to the Immobilizer control module. The Engine Control Module (ECM) receives the signal from Immobilizer control module via the R-line. The ECM then disables the engine from starting. 15– Chery Automobile Co., Ltd.
Page 888 IMMOBILIZER CONTROL MODULE Electrical Schematics Immobilizer Control Module (Page 1 of 1) PZSMW150035T Chery Automobile Co., Ltd. 15–...
Page 889 IMMOBILIZER CONTROL MODULE Immobilizer Control Module Connector Pin-Out Table CIRCUIT IDENTIFICATION CIRCUIT IDENTIFICATION Continuous Supply Voltage Diagnostic Link K W-Line — Coil (GND) Ignition Switch Coil (ANT B) R-Line Coil (ANT A) — 15– Chery Automobile Co., Ltd.
Page 890: Diagnosis & Testing
If multiple wires are crimped to one eyelet, make sure no excess wire insulation has been crimped creating a bad ground. Diagnostic Tools • Diagnostic Scan Tool X-431 • Digital Multimeter • Jumper Wire Chery Automobile Co., Ltd. 15–...
Page 891: Diagnostic Trouble Code (Dtc) List
No Transponder Modulation Or No Transponder B3056 No Transponder Fix Code Programmed B3057 No Security Code Programmed B3060 Unprogrammed Transponder Fix Code Received B3061 Disturbed Or No Challenge / Response Transponder Communication B3077 Read-Only Transponder Detected 15– Chery Automobile Co., Ltd.
Page 892: Diagnostic Trouble Code (Dtc) Tests
DIAGNOSIS & TESTING Diagnostic Trouble Code (DTC) Tests B1000 - ECU Defect, Internal Errors PZSMW150035T Chery Automobile Co., Ltd. 15–...
Page 893 • Inspect ground connection C-202 mounting position (See Vehicle Wiring Harness Layout - Main Harness in Section 16 Wiring). Is the ground connection OK? >> Go to the next step. >> Repair or replace ground connection. 15– Chery Automobile Co., Ltd.
Page 894 • Check voltage between the Immobilizer control module connector C-025, terminal 4, 1 and ground. IMMOBILIZER CONTROL GROUND VOLTAGE MODULE TERMINAL 12 V should Ground exist Is the check result normal? >> Go to step 7. >> Go to the next step. Chery Automobile Co., Ltd. 15–...
Page 895 • Disconnect the Immobilizer control module electrical connector C-026 (1). • Inspect the electrical connector for damage. Is the electrical connector OK? >> Go to the next step. >> Repair or replace the electrical connector as necessary. LTSMD150019 15– Chery Automobile Co., Ltd.
Page 896 (See Immobilizer Control Module Removal & Installation in Section 15 Body & Accessories). Refer to DTC B3077 Diagnostic Procedure. >> The system is now operating properly. Reassemble the vehicle and verify the customers complaint is repaired. Chery Automobile Co., Ltd. 15–...
Page 897 DIAGNOSIS & TESTING B3042 - W-Line Short Circuit To Ground B3043 - W-Line Short Circuit To Battery Immobilizer Control Module PZSMW150035T 15– Chery Automobile Co., Ltd.
Page 898 Is the warning light flashing and DTC B3042 or B3043 present? >> Go to the next step. >> The conditions that caused this code to set are not present at this time (See Diagnostic Help in Sec- tion 15 Body & Accessories). Chery Automobile Co., Ltd. 15–...
Page 899 CHECK IMMOBILIZER CONTROL MODULE AND ECM COMMUNICATION CIRCUIT • For DTC B3042, check the resistance of W-Line between the Immobilizer control module connector C-025, ter- minal 8 and ground. IMMOBILIZER CONTROL TERMINAL RESULT MODULE TERMINAL Continuity Ground should not exist 15– Chery Automobile Co., Ltd.
Page 900 Replace the ECM and match the Immobilizer control module to the new ECM (See ECM Removal & Installation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 15–...
Page 901 DIAGNOSIS & TESTING B3050 - Relay External Line Short Circuit To Ground Or Open Circuit, Relay External Line Malfunction B3053 - Relay External Line Short Circuit To Battery PZSMW150035T 15– Chery Automobile Co., Ltd.
Page 902: Relay External Line Short Circuit To
• Inspect ground connection C-202 mounting position (See Vehicle Wiring Harness Layout - Main Harness in Section 16 Wiring). Is the ground connection OK? >> Go to the next step. >> Repair or replace ground connection. Chery Automobile Co., Ltd. 15–...
Page 903 Replace the Immobilizer control module and match the ECM to the Immobilizer control module (See Immobilizer Control Module Removal & Installation in Section 15 Body & Accessories). >> For DTC B3050, go to the next step. For DTC B3053, go to the step 6. 15– Chery Automobile Co., Ltd.
Page 904 • Check resistance between Immobilizer control module ignition switch circuit and other power circuits. Is the check result normal? >> Go to the step 8. >> Repair or replace short to power circuits in harness or connectors. Chery Automobile Co., Ltd. 15–...
Page 905 Replace the Immobilizer control module and match the ECM to the new Immobilizer control module (See Immobilizer Control Module Removal & Installation in Section 15 Body & Accessories). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 15– Chery Automobile Co., Ltd.
Page 906 DIAGNOSIS & TESTING B3055 - No Transponder Modulation Or No Transponder B3056 - No Transponder Fixed Code Programmed PZSMW150035T Chery Automobile Co., Ltd. 15–...
Page 907: B3055 - No Transponder Modulation Or
Is DTC B3055 present? >> Go to the next step. >> The conditions that caused this code to set are not present at this time (See Diagnostic Help in Sec- tion 15 Body & Accessories). 15– Chery Automobile Co., Ltd.
Page 908 • Check the resistance between the Immobilizer coil connector C-026, terminal 9 and terminal 11. IMMOBILIZER COIL IMMOBILIZER COIL TERMINAL TERMINAL Does the resistance range from 5 to 20 ohms? >> Go to the next step. >> Replace the Immobilizer coil. Chery Automobile Co., Ltd. 15–...
Page 909 Is the check result normal? >> Go to the next step. >> Replace the Immobilizer coil. REPLACE AND MATCH TRANSPONDER • Reconnect the Immobilizer control module electrical connector C-026. • Replace the chip (1) with a new one. VISMD150018 15– Chery Automobile Co., Ltd.
Page 910 (See Immobilizer Control Module Removal & Installation in Section 15 Body & Accessories). >> No problem found at this time. This concern may have been caused by a loose or corroded terminal or connector. Erase all codes before returning the vehicle to the customer. Chery Automobile Co., Ltd. 15–...
Page 911 DIAGNOSIS & TESTING B3060 - Unprogrammed Transponder Fixed Code Received B3061 - Disturbed Or No Challenge/Response Transponder Communication B3077 - Read-Only Transponder Detected PZSMW150035T 15– Chery Automobile Co., Ltd.
Page 912: B3060 - Unprogrammed Transponder
• Inspect ground connection C-202 mounting position (See Vehicle Wiring Harness Layout - Main Harness in Section 16 Wiring). Is the ground connection OK? >> Go to the next step. >> Repair or replace ground harness or connections. Chery Automobile Co., Ltd. 15–...
Page 913 • Check the resistance between the Immobilizer coil connector C-026, terminal 9 and terminal 11. IMMOBILIZER COIL IMMOBILIZER COIL TERMINAL TERMINAL Does the resistance range from 5 to 20 ohms? >> Go to the next step. >> Replace the Immobilizer coil. 15– Chery Automobile Co., Ltd.
Page 914 • Check the resistance between the Immobilizer coil connector C-026, terminal 11 and terminal 10. IMMOBILIZER IMMOBILIZER COIL COIL CONTINUITY TERMINAL TERMINAL None Is the check result normal? >> Go to the next step. >> Replace the Immobilizer coil. Chery Automobile Co., Ltd. 15–...
Page 915 >> Go to the next step. >> No problem found at this time. This concern may have been caused by the transponder fault. Erase all codes before returning the vehi- VISMD150018 cle to the customer. 15– Chery Automobile Co., Ltd.
Page 916 Installation in Section 03 Electronic Engine Controls). >> No problem found at this time. This concern may have been caused by a loose or corroded terminal or connector. Erase all codes before returning the vehicle to the customer. Chery Automobile Co., Ltd. 15–...
Page 917: On-Vehicle Service
PZSM150101 4. Remove the Immobilizer control module. 5. Installation is in the reverse order of removal. Installation Notes: NOTE : The Immobilizer control module must be matched to the ECM before the vehicle will start. 15– Chery Automobile Co., Ltd.
Page 918 − Choose input code . − Input the safety code. − Click the small keyboard. − Click OK . − Choose Immobilizer adapt . − Choose read EMS to Immobilizer immediately. − Click OK . Chery Automobile Co., Ltd. 15–...
Page 919: Remote Keyless Entry (Rke) Inoperative
• Pull the ignition key out of the ignition switch. • Try to operate the RKE transmitter. Does the RKE transmitter operate properly? >> Erase all codes before returning the vehicle to the customer. >> Go to the next step. 15– Chery Automobile Co., Ltd.
Page 920 • Connect the X-431 scan tool to the Data Link Connector (DLC), press the POWER key to start the X-431 (use the most current software available). • Turn ignition switch on. − Enter the Diagnostic Program. − Select Chery main program. − Select diagnostic version. − Enter download program. − Select A1 series, and then select ISU.
Page 921 Electrical Schematics 15-196 Removal & Installation 15-224 Front Combination Lamp Assembly 15-205 PAINT 15-226 Removal & Installation 15-205 Headlamp Adjustment Procedure 15-206 Paint Codes 15-226 Specification 15-226 Rear Combination Lamp Assembly 15-207 Removal & Installation 15-207 15– Chery Automobile Co., Ltd.
Page 922 Removal & Installation 15-252 Radiator Support 15-238 Washer Bottle & Pump 15-254 Removal & Installation 15-238 Removal & Installation 15-254 Wiper Switch 15-255 STATIONARY GLASS 15-239 Removal & Installation 15-255 Description 15-239 Electrical Schematics 15-240 Chery Automobile Co., Ltd. 15–...
Page 923 • Monitor the upper body structure for excessive stress or movement while making any corrections to the under- body structure. • Remove all the necessary glass to prevent breakage. • All dimensions are shown in millimeters (mm). Front View Body Front View Dimensions (Units: mm) PZSM150001 15– Chery Automobile Co., Ltd.
Page 924 4 - Front Compartment 2 - Latch Supporting Plate Cover Seal Strip PZSM150002 Clearance between front hood and headlamp at 2-2: 5 ± 1 mm 2 - Front 3 - Front Bumper 1 - Headlamp compartment cover PZSM150003 Chery Automobile Co., Ltd. 15–...
Page 925 1 ± 1 mm 2 - Headlamp 1 - Air Inlet Grille PZSM150004 Clearance between the front windshield and the vehicle roof at 4-4: 6 ± 1 mm 1 - Front Windscreen 2 - Vehicle Roof PZSM150005 15– Chery Automobile Co., Ltd.
Page 926 BODY DIMENSIONS Left-Front View Body Left-Front Dimensions (Units: mm) PZSM150006 Clearance between front bumper and front fender at 5-5: 0 + 0.5 mm 1 - Front Bumper 2 - Front Fender PZSM150007 Chery Automobile Co., Ltd. 15–...
Page 927 7-7: 3 mm 1 - A-pillar 2 - Front Fender PZSM150009 Clearance between front fender and front vehicle doors at 8-8: 4 + 1 mm 1 - Front Fender 2 - Front Door PZSM150010 15– Chery Automobile Co., Ltd.
Page 928 10-10: 4 + 1 mm 1 - Vehicle Roof 2 - Front Door PZSM150012 Clearance between front door and rear door at 11-11: 4 + 1 mm 2 - Rear Door 1 - Front Door PZSM150013 Chery Automobile Co., Ltd. 15–...
Page 929 4 + 1 mm 2 - Rear Door 1 - Front Door PZSM150014 Clearance between rear door and rear fender (side wall) at 13-13: 4 + 1 mm 1 - Rear Door 2 - Rear Fender PZSM150015 15– Chery Automobile Co., Ltd.
Page 930 Clearance between rear door and C-pillar at 15-15: 4 + 1 mm 1 - Rear Door 2 - C Pillar PZSM150017 Clearance between rear windshield and C-pillar at 16-16: 5 ± 1 mm 2 - C Pillar 1 - Rear Windscreen PZSM150018 Chery Automobile Co., Ltd. 15–...
Page 931 1 - Rear Fender 2 - Rear Bumper PZSM150020 Clearance between front fender and sill decorative board (side wall) at 20-20: 2 + 1 mm 2 - Sill Decorative Board 1 - Rear Fender PZSM150021 15– Chery Automobile Co., Ltd.
Page 932 BODY DIMENSIONS Clearance between front door and sill decorative board (side wall) at 21-21: 6 ± 1 mm 2 - Sill Decorative Board 1 - Front Fender PZSM150022 Back View Body Back Dimensions PZSM150023 Chery Automobile Co., Ltd. 15–...
Page 933 23-23: 4 ± 1 mm 1 - Rear Windscreen 2 - Trunk Door PZSM150025 Clearance between trunk door and rear bumper at 24-24: 21 ± 1 mm 1 - Trunk Door 2 - Rear Bumper PZSM150026 15– Chery Automobile Co., Ltd.
Page 934 1 - Rear Fender 2 - Tail Lamp 3 - Rear Fender PZSM150028 Clearance between tail lamp and rear bumper at 27-27: 2 ± 1 mm 1 - Tail Lamp 2 - Rear Bumper PZSM150029 Chery Automobile Co., Ltd. 15–...
Page 935 Engine Compartment Engine Compartment Dimensions (Units: mm) NAME DIAMETER NAME DIAMETER Front Bumper Installation Of Cross Beam Fender Mounting Hole Shock Absorber Headlight Mounting Hole C/D/E/F Mounting Hole Engine Right Suspension Bracket Mounting Hole PZSM150030 15– Chery Automobile Co., Ltd.
Page 936 BODY DIMENSIONS Body Openings Body Opening Dimensions PZSM150031 Chery Automobile Co., Ltd. 15–...
Page 937 BODY DIMENSIONS Windshield Windshield Dimensions (Units: mm) PZSM150032 15– Chery Automobile Co., Ltd.
Page 938 2. Remove the front combination lamp (See Front Combination Lamp Removal & Installation in Section 15 Body & Accessories). 3. Remove the bumper retaining clips (2) under the combination lamp and the two bumper side retain- ing bolts (1). PZSM150162 Chery Automobile Co., Ltd. 15–...
Page 939 (Tighten: Lower bumper retaining bolts to 11 ± 1 N·m) PZSM150164 8. Lower the vehicle and remove the front bumper. 9. Disconnect the front fog lamp (left and right). 10. Installation is in the reverse order of removal. 15– Chery Automobile Co., Ltd.
Page 940 2. Remove the four left and right bumper retaining bolts. 3. Raise the vehicle and remove the bumper lower connecting retainers (1). 4. Lower the vehicle and remove the bumper upper retaining clips (1). PZSM150167 Chery Automobile Co., Ltd. 15–...
Page 941 BUMPERS 5. Remove the rear bumper (1). PZSM150113 6. Remove the parking sonar (1). PZSM150114 15– Chery Automobile Co., Ltd.
Page 942 BUMPERS 7. Disconnect the parking sonar and remove the sonar sensor (1). PZSM150116 8. Disconnect the license plate lamp electrical con- nector (1). PZSM150115 9. Installation is in the reverse order of removal. Chery Automobile Co., Ltd. 15–...
Page 943 1. Turn the ignition switch off. 2. Using a trim stick, remove the outside mirror switch panel (1) from the door trim panel. PZSM150120 3. Disconnect the outside mirror switch electrical con- nector (1). PZSM150121 15– Chery Automobile Co., Ltd.
Page 944 DOORS 4. Using a trim stick, remove the power window switch assembly (1) on the left front door. PZSM150126 5. Disconnect the power window switch electrical con- nector (1). PZSM150073 Chery Automobile Co., Ltd. 15–...
Page 945 DOORS 6. Using a trim stick, remove the inside door handle retaining screw cover (1). PZSM150122 7. Remove the inside door handle retaining screw (1). PZSM150123 15– Chery Automobile Co., Ltd.
Page 946 DOORS 8. Remove the inside door handle (1). PZSM150125 9. Loosen the inside door handle control cable (1). PZSM150130 Chery Automobile Co., Ltd. 15–...
Page 947 DOORS 10. Remove the small storage compartment retaining screw (1) on the door trim panel. PZSM150127 11. Using a trim stick, remove the small storage com- partment (1). PZSM150128 15– Chery Automobile Co., Ltd.
Page 948 DOORS 12. Remove the door switch (1). PZSM150124 13. Disconnect the door switch electrical connector (1). PZSM150145 14. Remove the door trim panel four retaining screws (1). 15. Remove the door trim panel. PZSM150129 Chery Automobile Co., Ltd. 15–...
Page 949 16. Remove the outside mirror retaining nuts (1), and remove the outside mirror electrical connector. (Tighten: Outside mirror retaining nuts to 7 ± 1 N·m) PZSM150134 17. Remove the two door trim panel mounting bracket retaining screws (1). PZSM150131 15– Chery Automobile Co., Ltd.
Page 950 DOORS 18. Remove the protective film (1) from the front door. PZSM150133 19. Remove the front speaker retaining screws (1). PZSM150132 Chery Automobile Co., Ltd. 15–...
Page 951 DOORS 20. Disconnect the speaker electrical connector (1). PZSM150135 21. Remove the speaker. 22. Lower the door glass to a proper position, remove the two door glass retaining screws (1). PZSM150137 15– Chery Automobile Co., Ltd.
Page 952 DOORS 23. Remove the door glass (1). PZSM150139 24. Disconnect the window motor electrical connector (1). PZSM150138 Chery Automobile Co., Ltd. 15–...
Page 953 25. Remove the two guide rail mounting nuts (2). 26. Remove the three window regulator retaining nuts (1). (Tighten: Window regulator retaining nuts to 9 ± 1 N·m) PZSM150136 27. Remove the window regulator and guide rail assembly. PZSM150140 15– Chery Automobile Co., Ltd.
Page 954 8 ± 1 N·m) PZSM150143 29. Disconnect the power lock motor electrical connec- tor (1). 30. Disconnect the door lock motor connecting rod to the outside door handle. 31. Remove the power door lock motor. PZSM150144 Chery Automobile Co., Ltd. 15–...
Page 955 2. Check the power window motor working condition. 3. Check the window channel for any abrasive debris that could effect the window operation. 4. Check the window regulator and guide rails for any condition that could effect window operation. 15– Chery Automobile Co., Ltd.
Page 956 3. Remove the four rear door mounting bolts (1). (Tighten: Rear door mounting bolts to 36 ± 4 N·m) PZSM150074 4. Installation is in the reverse order of removal. Installation Notes: • Adjust the door in the left, right and vertical directions. Chery Automobile Co., Ltd. 15–...
Page 957 2. Remove the power window switch (2) and discon- nect the electrical connector. 3. Remove the small storage compartment (1) retain- ing screw on the door trim panel and remove the small storage compartment. PZSM150151 15– Chery Automobile Co., Ltd.
Page 958 DOORS 4. Remove the inner door handle panel retaining screw cover (1). PZSM150149 5. Remove the inner door handle retaining screw (1). PZSM150150 Chery Automobile Co., Ltd. 15–...
Page 959 CAUTION: While servicing the door panels, care should be taken to maintain a clean work environment. 9. Remove the two door mounting bracket retaining screws (1) and remove the bracket. 10. Remove the protective film (2) from the rear door. PZSM150152 15– Chery Automobile Co., Ltd.
Page 960 14. Remove the three window regulator retaining nuts (1). (Tighten: Window regulator retaining nuts to 9 ± 1 N·m) 15. Remove the two window guide rail retaining nuts (2). 16. Remove the window regulator and guide rail assembly. PZSM150153 Chery Automobile Co., Ltd. 15–...
Page 961 DOORS 17. Remove the power lock motor retaining screws (1). PZSM150157 18. Disconnect the power lock motor electrical connec- tor (1). 19. Remove the power lock motor. PZSM150155 15– Chery Automobile Co., Ltd.
Page 962 3. Remove the rear wiper motor (See Rear Wiper Motor Removal & Installation in Section 15 Body & Accessories). 4. Remove the high mounted lamp (See High Mounted Stop Lamp Removal & Installation in Section 15 Body & Accessories). Chery Automobile Co., Ltd. 15–...
Page 963 (Tighten: Rear hatch bolts to 20 ± 1 N·m) 8. Disconnect the rear hatch electrical connector (3). PZSM150100 9. Remove the rear hatch. 10. Installation is in the reverse order of removal. 15– Chery Automobile Co., Ltd.
Page 964 • Backup Lamp: When the transaxle is shifted into reverse, voltage is applied to the backup lamp. Specification Torque Specification DESCRIPTION TORQUE (N·m) Front Combination Lamp Retaining Bolt 8 ± 1 Rear Combination Lamp Retaining Screw 8 ± 1 Chery Automobile Co., Ltd. 15–...
Page 965 EXTERIOR LAMPS Electrical Schematics Headlamp System (Page 1 of 2) PZSMW150001T 15– Chery Automobile Co., Ltd.
Page 966 EXTERIOR LAMPS Headlamp System (Page 2 of 2) PZSMW150002T Chery Automobile Co., Ltd. 15–...
Page 967 EXTERIOR LAMPS Parking, License Plate and Tail Lamps (Page 1 of 2) PZSMW150003T 15– Chery Automobile Co., Ltd.
Page 968 EXTERIOR LAMPS Parking, License Plate and Tail Lamps (Page 2 of 2) PZSMW150004T Chery Automobile Co., Ltd. 15–...
Page 969 EXTERIOR LAMPS Fog Lamps (Page 1 of 1) PZSMW150005T 15– Chery Automobile Co., Ltd.
Page 970 EXTERIOR LAMPS Turn Signal and Hazard Warning Lamps (Page 1 of 2) PZSMW150007T Chery Automobile Co., Ltd. 15–...
Page 971 EXTERIOR LAMPS Turn Signal and Hazard Warning Lamps (Page 2 of 2) PZSMW150008T 15– Chery Automobile Co., Ltd.
Page 972 EXTERIOR LAMPS Stop Lamp (Page 1 of 1) PZSMW150006T Chery Automobile Co., Ltd. 15–...
Page 973 EXTERIOR LAMPS Backup Lamps (Page 1 of 1) PZSMW030062T 15– Chery Automobile Co., Ltd.
Page 974 Removal & Installation 1. Open the hood. 2. Disconnect the front combination lamp assembly electrical connector. 3. Remove the grille retaining screws (1). PZSM150081 4. Remove the three front combination lamp assem- bly retaining bolts (1). PZSM150085 Chery Automobile Co., Ltd. 15–...
Page 975 2. Park the vehicle on a level surface approximately 10 meters from the vertical wall or screen directly in front of it. NOTE: The vertical wall or screen must be a minimum of 2.4 meters wide. 3. Use a screwdriver into the two adjustment holes (1) to adjust the headlamp to proper specifications. PZSM150213 15– Chery Automobile Co., Ltd.
Page 976 EXTERIOR LAMPS Rear Combination Lamp Assembly Removal & Installation 1. Open the rear hatch. 2. Removal the two rear combination lamp retaining screws (1). PZSM150078 3. Disconnect the rear combination lamp electrical connector (1). PZSM150111 Chery Automobile Co., Ltd. 15–...
Page 977 5. Replace the bulbs. 6. Installation is in the reverse order of removal. Front Fog Lamp Removal & Installation 1. Disconnect the negative battery cable. 2. Remove the three front fog lamp retaining screws (1). PZSM150158 15– Chery Automobile Co., Ltd.
Page 978 4. Remove the high mounted stop lamp mounting screws (1). 5. Disconnect the high mounted stop lamp electrical connector (2). PZSM150095 6. Remove the high mounted stop lamp. 7. Replace the bulb. 8. Installation is in the reverse order of removal. Chery Automobile Co., Ltd. 15–...
Page 979 Removal & Installation 1. Using a plastic trim stick, remove the license plate lamp (1). PZSM150168 2. Disconnect the license plate lamp electrical connector. 3. Replace the bulb. 4. Installation is in the reverse order of removal. 15– Chery Automobile Co., Ltd.
Page 980 2. Remove the bolts connecting the fender and the dust shield. 3. Remove the bolts (1) on the fender apron. PZSM150072 4. Remove the bolts connecting the fender to the body. 5. Installation is in the reverse order of removal. Chery Automobile Co., Ltd. 15–...
Page 981 FUEL DOOR Fuel Door Removal & Installation 1. Open the fuel door. 2. Remove the two fuel door retaining bolts (1). PZSM150092 3. Remove the fuel door. 4. Installation is in the reverse order of removal. 15– Chery Automobile Co., Ltd.
Page 982 GRILLE Grille Removal & Installation 1. Open the hood. 2. Remove the grille retaining screws (1). PZSM150081 3. Remove the grille from the vehicle. 4. Installation is in the reverse order of removal. Chery Automobile Co., Ltd. 15–...
Page 983 HOOD Hood Removal & Installation 1. Loosen the windshield washer hose and then remove the spray nozzle (1). PZSM150119 2. Remove the washer hose (1). PZSM150070 15– Chery Automobile Co., Ltd.
Page 984 1. Remove the left fender inner lining (See Fender Removal & Installation in Section 15 Body & Accessories). 2. Remove the hood lock retaining screws (1) and remove the hood release cable from the hood lock. PZSM150211 Chery Automobile Co., Ltd. 15–...
Page 985 3. Remove the hood release lever retaining bolt (2). 4. Remove the hood release lever (1). PZSM150207 5. Remove the hood release cable from the hood release lever. 6. Installation is in the reverse order of removal. 15– Chery Automobile Co., Ltd.
Page 986 LUGGAGE RACK Luggage Rack Removal & Installation 1. Remove the luggage rack bolt covers and then remove the mounting bolts (1). PZSM150088 2. Remove the luggage rack. 3. Installation is in the reverse order of removal. Chery Automobile Co., Ltd. 15–...
Page 987 The horns operate on voltage supplied by the horn relay in the Body Fuse and Relay Box. The horn system circuit is designed so that the system will remain operational, regardless of the ignition switch position. 15– Chery Automobile Co., Ltd.
Page 988 HORN Electrical Schematics Horn (Page 1 of 1) PZSMW150030T Chery Automobile Co., Ltd. 15–...
Page 989 Removal & Installation 1. Disconnect the negative battery cable. 2. Disconnect the horn electrical connectors (2). 3. Remove the horn retaining bolts (1) and remove the horns. PZSM150192 4. Installation is in the reverse order of removal. 15– Chery Automobile Co., Ltd.
Page 990 Use the mirror select switch, located on the driver’s door trim panel, to adjust the view obtained in the outside mir- rors. Rotate the joystick for Left or Right mirror selection. Select a mirror and press the joystick that correspond with the direction that you want the mirror to move. Chery Automobile Co., Ltd. 15–...
Page 991 MIRRORS Electrical Schematics Power Mirrors (Page 1 of 2) PZSMW150033T 15– Chery Automobile Co., Ltd.
Page 992 MIRRORS Power Mirrors (Page 2 of 2) PZSMW150038T Chery Automobile Co., Ltd. 15–...
Page 993 1. Turn the ignition switch off. 2. Using a trim stick, remove the outside mirror switch panel (1) from the door trim panel. PZSM150120 3. Disconnect the outside mirror switch electrical con- nector (1). PZSM150121 15– Chery Automobile Co., Ltd.
Page 994 N·m) PZSM150134 5. Remove the outside mirror. 6. Installation is in the reverse order of removal. Installation Notes: • If replacing the outside mirror lens, remove the lens and replace it before reinstalling the mirror. Chery Automobile Co., Ltd. 15–...
Page 995 PAINT Paint Codes Specification COLOR ITEM CODE Jade Blue Indicolite Gold Dark Iron Gray Cuprite Red Aegean Blue Azure Blue 15– Chery Automobile Co., Ltd.
Page 996 (BCM). The BCM communicates this signal to the instrument cluster to activate the buzzer. The vehicle operator is notified of obstacles by a varied rate of tone from the sonar buzzer depending on the distance of the obstacle being sensed. Chery Automobile Co., Ltd. 15–...
Page 997 PARKING SONAR Electrical Schematics Parking Sonar (Page 1 of 1) PZSMW150067T 15– Chery Automobile Co., Ltd.
Page 998 PARKING SONAR Sonar Sensor Removal & Installation 1. Disconnect the negative battery cable. 2. Remove the rear bumper (1) (See Rear Bumper Removal & Installation in Section 15 Body & Accessories). PZSM150113 Chery Automobile Co., Ltd. 15–...
Page 999 PARKING SONAR 3. Remove the parking sonar (1). PZSM150114 4. Disconnect the parking sonar and remove the sonar sensor (1). 5. Installation is in the reverse order of removal. PZSM150116 15– Chery Automobile Co., Ltd.
Page 1000 1. Remove the C-pillar trim panel (See C-Pillar Trim Panel Removal & Installation in Section 15 Body & Accesso- ries). 2. Remove the sonar module retaining bolts (1). 3. Disconnect the sonar module electrical connector. PZSM150093 4. Remove the sonar module. 5. Installation is in the reverse order of removal. Chery Automobile Co., Ltd. 15–...

Chery A1 2009 Service Manual

Vehicle Information

Electrical Information

Engine 02

Electronic Engine Controls 03

Engine Symptom Diagnosis

Ignition Control

Evaporative Emissions

Fuel Delivery 04

Starting & Charging 05

Charging System

Cooling 06

Exhaust 07

Differential

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Chery A1 2009