Chery A11 2003 Repair Manual

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New style wiring harness is designed upon

approved by Chery Auto Co., LTD in July 2001. According to updated plan, concentrated control

in central electrical box is replaced with a nearby control method in design, enhancing circuit

performance, avoiding internal resistance and heat sources interference between electrical

devices and increasing the whole vehicle wiring harness reliability and endurance.

During updating, some structures and features on home and abroad famous brand name

vehicles are used for reference or equivalently taken as follows:

1. Adding whole vehicle electrical devices problem automatic safety-protect unit, which

ensure whole circuit system being cut off when sudden accident occurs to avoid possible fire

hazard or other injury from short problem.

2. Selecting a new central electrical box mainly used for whole vehicle control circuit, in

which there are 6 built-in mini relays, 24 type fuses, 3 intensive safety protect units and 58

external connecting points.

3. High current and power electrical devices are nearby controlled, such as fan and A/C

control circuit are directly completed at front compartment harness, shortening the current path.

Comparing with old wiring harness, main changes in wiring harness and electrical devices

are as follows:

Interior harness, front compartment harness, I/P (instrument panel) harness, battery positive

harness, central electrical box, two front and rear fog light switches instead of one switch on old

vehicle, and also relevant changes in ABS harness connector.

But control theory and whole vehicle harness routing mainly keep unchanged.

Only whole vehicle electrical devices theory illustrations are available in this manual and

there exists difference with actual electrical devices circuit. For convenience of compiling and

printing, some big circuits page are divided into several small pages, which will take

inconveniences when reading and therefore will require the user have a good command of

circuits on SQR710 sedan.

For compilers' knowledge and time limits as well as rapid technology updating, some

errors and oversights are hard to avoid and kindly appreciate for users' pointing out with the idea

of improving together. Electrical system are rapidly updated, therefore some new circuit are not

compiled on this manual on the time of publishing and will be supplemented timely.

This manual is compiled by Chang Yongjiu, Yao Shen and reference books are supplied by

product department.

FOREWORD

chery sedan wiring harness-updating plan

CIRCUIT

Written by compilers

November 2002

Table of Contents

Chapters

Table of Contents

Summary of Contents for Chery A11 2003

Page 1 New style wiring harness is designed upon approved by Chery Auto Co., LTD in July 2001. According to updated plan, concentrated control in central electrical box is replaced with a nearby control method in design, enhancing circuit performance, avoiding internal resistance and heat sources interference between electrical devices and increasing the whole vehicle wiring harness reliability and endurance.
Page 2 CIRCUIT TOTAL CONTENT No.1 Central Electrical Box Fuse And Relay Position (2 Pages) No.2 Central Electrical Box Connector Position And Function (3 Pages) No.3 Circuit Manual Explanation (2 Pages) No.4 Circuit (23 Pages) No.5 ET Vehicle Circuit (25 Pages)
Page 3 No.1 CIRCUIT Central Electrical Box Position (In Cabin, Under Steering Wheel) A/C Clutch Sunroof Cab License Plate Lamp Headlight Rear Window Ceiling Light Luggage Switch Heater Compartment Light Sound Wiper Gauge Horn Fog light Glass Lifter Brake Light Thermo Switch Central Locking Emergency Gauge...
Page 4 CIRCUIT Relay, Fuse Layout, Central Electrical Box Fuse Position (In cabin, Under Steering Wheel) — 2 —...
Page 5 CIRCUIT Central Electrical Box Connector Position Central Electrical Box Connector Position ( FRONT SIDE VIEW ) ( BACK SIDE VIEW ) — 1 —...
Page 6 CIRCUIT Central Electrical Box Connector Position Central Electrical Box Connector, Pin and Function Circuit Connector Connector Pin Function 01.Sunroof, Cab Freight Calculator (+15) — 02.ECUA/C Signal Input 03.—— — 04.Luggage Compartment Lamp, Radio, Ceiling Lamp 05.—— — 06.—— — 07.—— —...
Page 7 CIRCUIT Central Electrical Box Connector Position CIRCUIT__Central Electrical Box Connector, Pin and Function Circuit Connector Connector Pin Function 17.—— — 18.Wiper Intermittent Relay 19.Lincense Plate Lamp 20.Mileage Gauge Sensor 01.—— 02.Cigar Lighter — 03.Turn Light Switch, Headlight Adjustment Switch 04.—— —...
Page 8 No.3 CIRCUIT CIRCUIT MANUAL EXPLANATION — 1 —...
Page 9 CIRCUIT Compiling Explanation 1. Central Electrical Box Main Circuit Board Circuit No. 30：No Fuse, Positive Goes Directly From Battery 15：No Fuse, Positive Goes To Ignition----Start Switch X：No Fuse, Positive Goes To Ignition ----Start Switch, And Being Cut Off During Starting 31：Fictitious Ground, This wire actually exists or does not actually exist.
Page 10: Table Of Contents
CIRCUIT CONTENT ——Battery, Alternator, Starter Motor, Ignition Switch ········································································· ——SPI EI System (MARELLI) ··········································································································· ——MPI EI(Electronic Injection) (MARELLI) ····················································································· ——A/C Unit, Control Head, Cooling System ······················································································ ——A/C Switch, Interior Circulate Solenoid, High & Low Pressure Switch ········································· ——Oil Pressure Switch, Coolant Temperature Sensor, Manual Brake Indicator Switch, Mileage Gauge Sensor ····················································································································································...
Page 11: Battery, Alternator, Starter Motor, Ignition Switch
CIRCUIT Battery, Alternator, Starter Motor, Ignition Switch B=White N=Black R=Red M=Brown V=Green A=Blue H=Grey Z=Purple G=Yellow A Battery ○ G round, At Ground Carrier Beside Central Electrical Box B Starter Motor ○ Body Ground, Near Battery C Alternator ○ Engine Ground Point, Located Beside Transmission C1 Voltage Regulator TQ4 2 Holes Match Connector D Ignition Switch...
Page 12 SPI Electronic Injection (Marelli) B=White N=Black R=Red M=Brown V=Green A=Blue H=Grey Z=Purple G=Yellow J=Orange F=Pink J200 SPI controller unit G42 Air Intake Temperature Sensor G62 Water Temperature Sensor G69 Throttle Position Sensor G19 Air Intake Pressure Sensor N30 Active Carbon Canister Solenoid G28 Crankshaft Position Sensor G39 Oxygen Sensor G35 System Fuse...
Page 13 Blue yellow －2a－...
Page 14: Mpi Ei(Electronic Injection) (Marelli)
CIRCUIT MPI Electronic Injection (Marelli) B=White N=Black R=Red M=Brown V=Green A=Blue H=Grey Z=Purple G=Yellow J=Orange F=Pink J300 MPI Controller Unit Air Intake Pressure Sensor Air Intake Temperature Sensor JS14 Water Temperature Sensor Knock Sensor Crankshaft Position Sensor Power Relay FS 35 System Fuse FS 36 ECU Power Fuse FS 37 Oxygen Sensor Fuse Battery Positive...
Page 15 CIRCUIT －2b－...
Page 16: A/C Unit, Control Head, Cooling System
CIRCUIT A/C Unit, Control Head, Cooling System B=White N=Black R=Red M=Brown V=Green A=Blue H=Grey Z=Purple G=Yellow A+ battery positive E9 blower switch A/C blower relay (in electrical box) F18 thermo switch Rear Window preheat relay ○ N23 blower in-line speed ground, in wiring harness in boot I ○...
Page 17 CIRCUIT A/C UNIT SWITCH, INTERIOR CIRCULATION SOLENOID, HIGH & LOW PRESSURE SWITCH B=White N=Black R=Red M=Brown V=Green A=Blue H=Grey Z=Purple G=Yellow E35 A/C unit switch E36 Interior circulation switch ○ ○ K84 A/C operating illumination switch 8 Main circuit ground N63 Interior circulation solenoid 5 holes connector F38 Outside temperature switch...
Page 18: Sensor
CIRCUIT OIL PRESSURE SWITCH, COOLANT TEMPERATURE SENSOR, MANUAL BRAKE INDICATOR SWITCH, ODOMETER SENSOR B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW ○ Coolant temperature sensor ground, on engine cylinder ○ F22 Oil pressure switch (low pressure) ground connection, in headlight wiring harness Manual brake indicator switch TQ1 10 holes connector F34 Brake fluid level warning switch...
Page 19: Radio And 6 Speakers
CIRCUIT RADIO AND 6 SPEAKERS B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLO R radio R2 front left speaker T8 8 holes connector R3 front right speaker T1 single hole connector R4 right rear speaker R5 left rear speaker R6 left front speaker R7 right front speaker R1 antenna...
Page 20: Ip (Instrument Panel) And Mfa
CIRCUIT INSTRUMENT PANEL AND MFA B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW F10 multi way converter K3 right turn indicator digital clock F15 voltage stabilizer K4 engine charging indicator single hole connector G20 fuel sensor K5 manual brake warning light G25 coolant temperature sensor K6 engine self-check indicator G30 RPM sensor...
Page 21: Front Fog Light, Cigar Lighter, A/C Panel Indicator
CIRCUIT FRONT FOG LIGHT, CIGAR LIGHTER, A/C PANEL INDICATOR B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW L16 A/C Control Panel Indicator ○ L22 Left Front Fog Light 11 Ground, In headlight wiring harness L23 Right Front Fog Light F66 Coolant Level Switch L28 Cigar Lighter Illumination Light Cigar Lighter...
Page 22: Rear Window Heating System, Dual Pitch Horn, Compressor Magnetic Clutch
CIRCUIT REAR WINDOW HEATING SYSTEM, DUAL PITCH HORN, A/C COMPRESSOR MAGENETIC CLUTCH B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW Idle Up Relay (in electrical box) Dual Pitch Horn J39 Rear Window Heating Switch Illumination Light K10 Rear Window Heating Indicator E15 Rear Window Heater Switch ○...
Page 23: Wiper, Horn Button, Washer
CIRCUIT WIPER, HORN BUTTON, WASHER B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW E22 wiper switch horn button intermittent wiper relay fuse 15A wiper motor washer...
Page 24: Headlight, Front Position Light, Light Relay
CIRCUIT HEADLIGHT, FRONT POSITION LIGHT, LIGHT RELAY B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW ○ J55 Light Relay A+ Battery Positive 13 Ground, In headlight wiring harness S27 Right High Beam Headlight Fuse 10A L1 Left High Beam Headlight S28 Left Low Beam Headlight Fuse 10A L2 Left Low Beam Headlight S29 Left Position Light Fuse 10A...
Page 25: Turn Light, Parking Light Switch, Emergency Warning Relay
CIRCUIT TURN LIGHT, PARKING LIGHT SWITCH, EMERGENCY WARNING RELAY B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW Turn Light Switch Emergency Warning Light Switch Dimmer and Turn Light Switch E19 Parking Light Switch Emergency Warning Light Relay K6 Emergency Warning Light S17 Fuse 10A...
Page 26: Taillight, Sidelight, Brakelight
CIRCUIT TAILLIGHT, SIDELIGHT, BRAKELIGHT B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW F18 brake light switch left brake light S20 Fuse 10A L15 left taillight right brake light Fuse 10A L20 right taillight M501 right side turn light Fuse 10A M2 rear right position light M701 left side turn light 3 holes connector...
Page 27: Light Switch
CIRCUIT LIGHT SWITCH B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW E1 Light Switch E20 Panel indicator / instruments illumination light variable resistance L9 Panel indicator S3 Fuse 10A...
Page 28: Backlight, Rear Fog Light
CIRCUIT BACKLIGHT, REAR FOG LIGHT B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW ○ S10 Fuse 15A E23 Front Fog Lamp Switch In Rear Taillight Moving Parts Wiring S14 Fuse 10A Back Light Switch 3 Holes Connector E24 Rear Fog Lamp Switch Fog Lamp Relay (in electrical box) T3a 3 Holes Connector K17 Rear Fog Lamp Indicator...
Page 29 CIRCUIT HEADLIGHT ADJUSTMENT Light Adjustment Illumination Light B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW ○ 16 Ground, Located Beside Central Electrical Box E102 Headlight Height Adjustment Switch ○ 15 Ground, at headlight Light Adjustment Illumination Light T1 Single Hole Connector Left Front Headlight Adjustment Motor Right Front Headlight Adjustment Motor...
Page 30 CIRCUIT FRONT AND REAR INTERIOR LIGHT, LUGGAGE COMPARTMENT LIGHT, SUN VISOR LIGHT, LICENSE PLATE LAMP, DOOR TOUCH SWITCH B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW Left Front Door Touch Switch TAa 2 Holes Connector, on left side of luggage compartment Right Front Door Touch Switch Rear Interior Ceiling Lamp Luggage Compartment Illumination Light Switch...
Page 31: Central Locking
CIRCUIT CENTRAL LOCKING B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW Central Locking Control Unit ( in left front door) TB1 4 Holes Connector (left B pillar side) V28 Right Front Door Lock Control Motor TB2 4 Holes Connector (right B pillar side) V29 Left Rear Door Lock Control Motor TK1 12 Holes Connector (left A pillar Side) V30 Right Rear Door Lock Control Motor...
Page 32: Power Mirror
CIRCUIT POWER MIRROR B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREN Z=PURPLE G=YELLOW F77 Mirror Switch TK1 12 Holes Connector (left A pillar side ) Z4 Left Mirror Defogger X1 Left Adjust TK2 12 Holes Connector (right A pillar side) Z5 Right Mirror Defogger X2 Right Adjust TZ 2 Holes Connector (beside central electrical box) Y1 Up Adjust...
Page 33: Abs
CIRCUIT B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW J104 ABS Controller Battery ○ N55 ABS Solenoid 18 Ground point, at ground carrier on central electrical box VG4 ABS Hydraulic Pump G44 Right Rear Wheel RPM Sensor G45 Left Front Wheel RPM Sensor G46 Left Rear Wheel RPM Sensor G47 Right Front Wheel RPM Sensor S33 ABS Solenoid Valve Power Fuse...
Page 34: Power Glass Lifter Control Unit
CIRCUIT POWER GLASS LIFTER CONTROL UNIT B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW ○ Window Glass Lifter Module Beside Central Electrical Box Left Front Window Lifter Switch 12 Holes Connector (Left B Pillar Side) Right Front Window Lifter Switch 12 Holes Connector (Right B Pillar Side) Left Front Window Lifter Motor Right Front Window Lifter Motor...
Page 35: Power Glass Lifter Control Switch
CIRCUIT POWER GLASS LIFTER CONTROL SWITCH B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW Left Rear Window Glass Lifter Motor Rear Window Glass Lifter Lock –Out Switch Right Rear Window Glass Lifter Motor Left Rear Dorr Upper Window Lifter Switch 4 Holes Connector Glass (Left B Pillar Side) Right Rear Dorr Upper Window Lifter Switch 4 Holes Connector Glass (Right B Pillar Side)
Page 36 New style wiring harness is designed upon approved by Chery Auto Co., LTD in July 2001. According to updated plan, concentrated control in central electrical box is replaced with a nearby control method in design, enhancing circuit performance, avoiding internal resistance and heat sources interference between electrical devices and increasing the whole vehicle wiring harness reliability and endurance.
Page 37 CIRCUIT Central Electrical Box Connector, Pin And Function TOTAL CONTENT No.1 Central Electrical Box Fuse And Relay Position (2 Pages) No.2 Central Electrical Box Connector Position And Function (3 Pages) No.3 Circuit Manual Explanation (2 Pages) No.4 Circuit (23 Pages) No.5 ET Vehicle Circuit (25 Pages) —...
Page 38 CIRCUIT Central Electrical Box Connector Position — 3 —...
Page 39 CIRCUIT Central Electrical Box Connector, Pin And Function — 4 —...
Page 40 CIRCUIT Central Electrical Box Connector Position Central Electrical Box Connector Position ( FRONT SIDE VIEW ) ( BACK SIDE VIEW ) Central Electrical Box Connector, Pin and Function — 5 —...
Page 41 CIRCUIT Central Electrical Box Connector, Pin And Function Connector Connector Pin Function Circuit No. — 01.Sunroof, Cab Freight Calculator (+15) 02.ECUA/C Signal Input — 03.—— 04.Luggage Compartment Lamp, Radio, Ceiling Lamp — 05.—— — 06.—— — 07.—— — 08.—— 09.Rear Window Preheat Switch, Rear Mirror Defrost Switch —...
Page 42 CIRCUIT Central Electrical Box Connector Position Connector Connector Pin Function Circuit No. 17.—— — 18.Wiper Intermittent Relay 19.Lincense Plate Lamp 20.Mileage Gauge Sensor 01.—— 02.Cigar Lighter — 03.Turn Light Switch, Headlight Adjustment Switch 04.—— 05.Combination Instrument Positive (+15) — 06.Sunroof, Cab Freight Calculator (+30) 07.Ground —...
Page 43 CIRCUIT CIRCUIT MANUAL EXPLANATION...
Page 44 CIRCUIT Compiling Explanation 1. Central Electrical Box Main Circuit Board Circuit No. 30：No Fuse, Positive Goes Directly From Battery 15：No Fuse, Positive Goes To Ignition----Start Switch X：No Fuse, Positive Goes To Ignition ----Start Switch, And Being Cut Off During Starting 31：Fictitious Ground, This wire actually exists or does not actually exist.
Page 45 CIRCUIT CONTENT ——Battery, Alternator, Starter Motor, Ignition Switch ················································································· ——SPI EI System (MARELLI) ··················································································································· ——MPI EI(Electronic Injection) (MARELLI) ···························································································· ——A/C Unit, Control Head, Cooling System ······························································································ ——A/C Switch, Interior Circulate Solenoid, High & Low Pressure Switch ················································· ——Oil Pressure Switch, Coolant Temperature Sensor, Manual Brake Indicator Switch, Mileage Gauge Sensor ····················································································································································...
Page 46 CIRCUIT SPI Electronic Injection (Marelli) B=White N=Black R=Red M=Brown V=Green A=Blue H=Grey Z=Purple G=Yellow J=Orange F=Pink J200 SPI controller unit G42 Air Intake Temperature Sensor G62 Water Temperature Sensor G69 Throttle Position Sensor G19 Air Intake Pressure Sensor N30 Active Carbon Canister Solenoid G28 Crankshaft Position Sensor G39 Oxygen Sensor G35 System Fuse...
Page 47 CIRCUIT...
Page 48: Mpi Ei(Electronic Injection) (Marelli)
CIRCUIT MPI Electronic Injection (Marelli) B=White N=Black R=Red M=Brown V=Green A=Blue H=Grey Z=Purple G=Yellow J=Orange F=Pink J300 MPI Controller Unit Air Intake Pressure Sensor Air Intake Temperature Sensor JS14 Water Temperature Sensor Knock Sensor Crankshaft Position Sensor Power Relay FS 35 System Fuse FS 36 ECU Power Fuse FS 37 Oxygen Sensor Fuse Battery Positive...
Page 49 CIRCUIT...
Page 50: A/C Unit, Control Head, Cooling System
CIRCUIT A/C Unit, Control Head, Cooling System B=White N=Black R=Red M=Brown V=Green A=Blue H=Grey Z=Purple G=Yellow A+ battery positive E9 blower switch A/C blower relay (in electrical box) F18 thermo switch Rear Window preheat relay ○ N23 blower in-line speed ground, in wiring harness in boot I ○...
Page 51 CIRCUIT A/C UNIT SWITCH, INTERIOR CIRCULATION SOLENOID, HIGH & LOW PRESSURE SWITCH B=White N=Black R=Red M=Brown V=Green A=Blue H=Grey Z=Purple G=Yellow E35 A/C unit switch E36 Interior circulation switch ○ ○ K84 A/C operating illumination switch 8 Main circuit ground N63 Interior circulation solenoid 5 holes connector F38 Outside temperature switch...
Page 52: Sensor
CIRCUIT OIL PRESSURE SWITCH, COOLANT TEMPERATURE SENSOR, MANUAL BRAKE INDICATOR SWITCH, ODOMETER SENSOR B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW ○ Coolant temperature sensor ground, on engine cylinder ○ F22 Oil pressure switch (low pressure) ground connection, in headlight wiring harness Manual brake indicator switch TQ1 10 holes connector F34 Brake fluid level warning switch...
Page 53: Radio And 6 Speakers
CIRCUIT RADIO AND 6 SPEAKERS B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLO R radio R2 front left speaker T8 8 holes connector R3 front right speaker T1 single hole connector R4 right rear speaker R5 left rear speaker R6 left front speaker R7 right front speaker R1 antenna...
Page 54: Ip (Instrument Panel) And Mfa
CIRCUIT INSTRUMENT PANEL AND MFA B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW F10 multi way converter K3 right turn indicator digital clock F15 voltage stabilizer K4 engine charging indicator single hole connector G20 fuel sensor K5 manual brake warning light G25 coolant temperature sensor K6 engine self-check indicator G30 RPM sensor...
Page 55: Front Fog Light, Cigar Lighter, A/C Panel Indicator
CIRCUIT FRONT FOG LIGHT, CIGAR LIGHTER, A/C PANEL INDICATOR B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW L16 A/C Control Panel Indicator ○ L22 Left Front Fog Light 11 Ground, In headlight wiring harness L23 Right Front Fog Light F66 Coolant Level Switch L28 Cigar Lighter Illumination Light Cigar Lighter...
Page 56: Rear Window Heating System, Dual Pitch Horn, Compressor Magnetic Clutch
CIRCUIT REAR WINDOW HEATING SYSTEM, DUAL PITCH HORN, A/C COMPRESSOR MAGENETIC CLUTCH B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW Idle Up Relay (in electrical box) Dual Pitch Horn J39 Rear Window Heating Switch Illumination Light K10 Rear Window Heating Indicator E15 Rear Window Heater Switch ○...
Page 57: Wiper, Horn Button, Washer
CIRCUIT WIPER, HORN BUTTON, WASHER B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW E22 wiper switch horn button intermittent wiper relay fuse 15A wiper motor washer...
Page 58: Headlight, Front Position Light, Light Relay
CIRCUIT HEADLIGHT, FRONT POSITION LIGHT, LIGHT RELAY B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW ○ J55 Light Relay A+ Battery Positive 13 Ground, In headlight wiring harness S27 Right High Beam Headlight Fuse 10A L1 Left High Beam Headlight S28 Left Low Beam Headlight Fuse 10A L2 Left Low Beam Headlight S29 Left Position Light Fuse 10A...
Page 59: Turn Light, Parking Light Switch, Emergency Warning Relay
CIRCUIT TURN LIGHT, PARKING LIGHT SWITCH, EMERGENCY WARNING RELAY B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW Turn Light Switch Emergency Warning Light Switch Dimmer and Turn Light Switch E19 Parking Light Switch Emergency Warning Light Relay K6 Emergency Warning Light S17 Fuse 10A...
Page 60: Taillight, Sidelight, Brakelight
CIRCUIT TAILLIGHT, SIDELIGHT, BRAKELIGHT B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW F18 brake light switch left brake light S20 Fuse 10A L15 left taillight right brake light Fuse 10A L20 right taillight M501 right side turn light Fuse 10A M2 rear right position light M701 left side turn light 3 holes connector...
Page 61: Light Switch
CIRCUIT LIGHT SWITCH B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW E1 Light Switch E20 Panel indicator / instruments illumination light variable resistance L9 Panel indicator S3 Fuse 10A...
Page 62: Backlight, Rear Fog Light
CIRCUIT BACKLIGHT, REAR FOG LIGHT B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW ○ S10 Fuse 15A E23 Front Fog Lamp Switch In Rear Taillight Moving Parts Wiring S14 Fuse 10A Back Light Switch 3 Holes Connector E24 Rear Fog Lamp Switch Fog Lamp Relay (in electrical box) T3a 3 Holes Connector K17 Rear Fog Lamp Indicator...
Page 63 CIRCUIT HEADLIGHT ADJUSTMENT Light Adjustment Illumination Light B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW ○ 16 Ground, Located Beside Central Electrical Box E102 Headlight Height Adjustment Switch ○ 15 Ground, at headlight Light Adjustment Illumination Light T1 Single Hole Connector Left Front Headlight Adjustment Motor Right Front Headlight Adjustment Motor...
Page 64 CIRCUIT FRONT AND REAR INTERIOR LIGHT, LUGGAGE COMPARTMENT LIGHT, SUN VISOR LIGHT, LICENSE PLATE LAMP, DOOR TOUCH SWITCH B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW Left Front Door Touch Switch TAa 2 Holes Connector, on left side of luggage compartment Right Front Door Touch Switch Rear Interior Ceiling Lamp Luggage Compartment Illumination Light Switch...
Page 65: Central Locking
CIRCUIT CENTRAL LOCKING B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW Central Locking Control Unit ( in left front door) TB1 4 Holes Connector (left B pillar side) TB2 4 Holes Connector (right B pillar side) V28 Right Front Door Lock Control Motor TK1 12 Holes Connector (left A pillar Side) V29 Left Rear Door Lock Control Motor V30 Right Rear Door Lock Control Motor...
Page 66: Power Mirror
CIRCUIT POWER MIRROR B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREN Z=PURPLE G=YELLOW F77 Mirror Switch TK1 12 Holes Connector (left A pillar side ) Z4 Left Mirror Defogger X1 Left Adjust TK2 12 Holes Connector (right A pillar side) Z5 Right Mirror Defogger X2 Right Adjust TZ 2 Holes Connector (beside central electrical box) Y1 Up Adjust...
Page 67: Abs
CIRCUIT B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW J104 ABS Controller Battery ○ N55 ABS Solenoid 18 Ground point, at ground carrier on central electrical box VG4 ABS Hydraulic Pump G44 Right Rear Wheel RPM Sensor G45 Left Front Wheel RPM Sensor G46 Left Rear Wheel RPM Sensor G47 Right Front Wheel RPM Sensor S33 ABS Solenoid Valve Power Fuse...
Page 68: Power Glass Lifter Control Unit
CIRCUIT POWER GLASS LIFTER CONTROL UNIT B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW ○ Window Glass Lifter Module Beside Central Electrical Box Left Front Window Lifter Switch 12 Holes Connector (Left B Pillar Side) Right Front Window Lifter Switch 12 Holes Connector (Right B Pillar Side) Left Front Window Lifter Motor Right Front Window Lifter Motor...
Page 69: Power Glass Lifter Control Switch
CIRCUIT POWER GLASS LIFTER CONTROL SWITCH B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW Left Rear Window Glass Lifter Motor Rear Window Glass Lifter Lock –Out Switch Right Rear Window Glass Lifter Motor Left Rear Dorr Upper Window Lifter Switch 4 Holes Connector Glass (Left B Pillar Side) Right Rear Dorr Upper Window Lifter Switch 4 Holes Connector Glass (Right B Pillar Side)
Page 70 ．．．．．．．．．．．．．．．．．．．．．．．．．． 1. Sunroof Model and Functions Chery SQR7160 and SQR7162 cars adopt the Agate Super 300 sunroof, which is the latest product manufactured by Webasto Sunroof Germany.
Page 71 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof 2. Components Page 2 of 37...
Page 72 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof Part List Position No. Name Glass panel Glass panel fixing part...
Page 73 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof 3.Functions of Sunroof 3.1 Control panel button resumes preset position 1...
Page 74 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof 3.3 Selection of tilting height 3.3.1 Press and hold...
Page 75 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof 3.4.3 Lightly press ① or ② button (for a period of time less than 0.1 second), sunroof will...
Page 76 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof 3.6.2 If any obstacle occurs during automatic shutting, sunroof will fully reopen and repeat trying to shut until the obstacle is removed.
Page 77 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof 4. Maintenance Instruction 4.1 Replacing module/motor assembly 4.1.1 Open sunroof.
Page 78 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof 4.1.5 Remove the interior decorative frame (pull it down in the direction shown in the figure).
Page 79 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof 4.1.9 Proceed with installation in the reverse order in step 6.
Page 80 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof 4.2 Disassembling/assembling sunroof Disassembling procedure 4.2.1 Open sunroof. 4.2.2 Turn off ignition switch and press and hold control button to prevent sunroof from automatically shutting.
Page 81 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof 4.2.5 Remove the interior decorative frame (pull it down in the direction shown in the figure).
Page 82 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof 4.2.9 Take off sunroof as shown in the figure.
Page 83 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof 4.2.13 Tighten all fixing bolts in the reverse order in step 8: the one in middle part of front end, and then black ones on both sides.
Page 84 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof 4.2.17 Fix control panel cover plate. Page 15 of 37...
Page 85 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof Replacing glass plate 4.3.1 Fully open sunroof. 4.3.2 Detach the glass plate lock pin from fixed driving...
Page 86 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof Assembling procedure 4.3.5 Slide a new glass plate into mechanism group with both sides being parallel.
Page 87 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof 4.4.2 Detach the glass plate lock pin from fixed driving...
Page 88 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof 4.4.6 Remove the residual sealant and clean the slot.
Page 89 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof 4.4.10 Fully push the sealing strip into the slot. Make sure the sealing strip is installed in position.
Page 90 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof 4.4.14 Remove excessive silica gel. 4.4.15 Wait for at least 2 hours before operating sunroof.
Page 91 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof 4.5.3 Take off the control panel cover plate. 4.5.4 Remove the two fixing bolts in front part of interior decorative frame.
Page 92 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof Assembling procedure 4.5.7 Install the right guiding device and rear support of sunshade.
Page 93 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof 4.5.11 Reel the string on left guiding roller. 4.5.12 Insert the string into sliding fixing cap and guiding device.
Page 94 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof 4.5.15 Fix interior decorative frame (push it up in the direction shown in the figure with clip aligned with clip slot).
Page 95 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof 4.6 Replacing mechanism group, upper frame and guiding lock rod or chain Disassembling procedure 4.6.1 Fully open sunroof.
Page 96 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof 4.6.4 Carefully pull the glass plate out of mechanism group with both sides being parallel.
Page 97 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof 4.6.8 Unfix hinge holding piece and chain chute. 4.6.9 Take off horseshoe locating cap and horseshoe locating piece.
Page 98 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof 4.6.12 Push out guiding lock rod as shown in the figure.
Page 99 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof 4.6.16 Disconnect front raiser and rail slider, then take out rail slider.
Page 100 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof 4.6.20 Install in the reverse order in step 10.
Page 101 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof 4.6.24 Install in the reverse order in step 6.
Page 102 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof 4.6.28 Fix glass plate fixing pin and turn it to a 90º...
Page 103 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof 4.7 Instruction Reprogramming will be necessry to resume all sunroof functions after power cut or maintenance of sunroof module.
Page 104 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof 5. Maintenance and Precaustions 5.1 Maintenance 5.1.1 The glass plate is designed to insulate heat and UV radiation.
Page 105 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof 5.2 Precautions 5.2.1 Do not open sunroof when it is ranining or sunroof is being cleaned.
Page 106 Maintenance Manual for Chery·Windcloud ．．．．．．．．．．．．．．．．．．．．．．．．．． Sunroof 5.2.5 Never fully shut sunshade with sunroof being open during high-speed running.
Page 107 Drawing of Transmission AQ015...
Page 108 Technical Parameter Transmission AQ015 Model AA AQ015 Model AB Transmission Ratio: Z2:Z1 Master Drive: 62:15=4.133 61:16=3.813 38:11=3.455 38:11=3.455 Gear 1 Gear 2 37:18=2.056 37:18=2.056 Gear 3 37:27=1.370 37:27=1.370 Gear 4 32:31=1.032 32:31=1.032 Gear 5 34:40=0.850 34:40=0.850 Reverse gear 38:12=3.167 38:12=3.167 Speedometer 16:7=2.286 16:7=2.286...
Page 109 Sketch of Transmission System Name: 1. Engine 2. Clutch 3.Transmission 4. Input shaft 5. Output shaft 6. Differential gear Transmission Ratio: I-gear 1 II-gear2 III-gear 3 IV-gear 4 V-gear 5 R-reverse gear A. Master drive T. transmission of speedometer ·The arrow in the above drawing indicates running direction of the car...
Page 110 Maintenance Instruction In order to assure the maintenance quality of transmission, operate carefully and keep the transmission clean. Select proper tools. General safety rules are also applicable to the maintenance of transmission AQ015. In order to avoid repetition, the same instructions during the whole maintenance are described as follows: Transmission When installing new transmission, add sufficient lubricant.
Page 111 Synch Ring Except for gear 4 and gear 5, the synch ring of each gear cannot be replaced with each other. When using the synch rings again, they should match the original gear. Check the wear and tear, and replace them if necessary. When installing, use transmission lubricant.
Page 112 Assembly Sketch of Transmission 1. Clutch housing 2. Differential gear 3. Input shaft 4. Output shaft 5. Gear 1 6. Reverse gear 7. Gear 2 8. Gear 3 9. Gear 4 10. Gear 5 11. Transmission housing 12. Rear housing...
Page 113 Disassembly and Assembly of Transmission Fastening screw CQ1500885 (4 pieces with torque at 25 Nm) Fastening screw CQ1500865 (2 pieces with torque at 25 Nm) 3. Draining plug 4. Rear housing of transmission 5. Gear-5 synchronizer assembly 6. Gear-5 driven gear snap ring 7.
Page 114 1. Rear baffle screws of input shaft (4 pieces with torque at 15Nm) 2. Transmission housing assembly 3. Fastening screws Q1830845 (12 pieces with torque at 25Nm) 4. O seal ring 5. Screw plug cap of shifting gear 6. Big spreader spring of shifting gear 7.
Page 115 1. Gear-4 driven gear snap ring 17. Damping ring 2. Gear-4 driven gear 18. Spreader spring—damping ring 3. Gear-3 driven snap ring 19. Output flange 4. Gear-3 driven gear 20. Disk-shape gasket of output flange 5. Gear-2 driven gear 21. Snap ring of output flange 6.
Page 116 Disassembly and Assembly of Transmission Disassembly Support up the transmission, unscrew the draining plug of Unscrew the joint bolt of rear housing and transmission clutch at side of differential gear, and unscrew the housing, dismantle the rear housing assembly and take out draining plug of rear cover.
Page 117 Special tool Unscrew the screw plug of shifting shaft with Take out the snap ring and disk-shape closing special tool, take out spreader spring and ring, and remove the output flange. shifting shaft assy. Remove the stoppers of reverse gear shaft (as Shift to gear 5 and reverse gear indicated by arrow) —Slide the synchronizer down as indicated by...
Page 118 Special tool Special tool Pry up the gear-5 fork locking board to let it Unscrew the clamping bolt of rear shaft gasket of loosened; left unscrew the gear-5 fork bush with input shaft with special tool. special tool and remove gear-5 fork assy. Special tool Remove gear-5...
Page 119 Special tool Remove the snap ring of gear-4 driven gear, with Up knock the reverse gear shaft with reverse gear special tool if necessary idler until knocking down the reverse gear idler and shaft from the clutch housing. Special tool Take out assy.
Page 120 Assembly of Transmission The procedures to assemble transmission are the basically reverse to that of dismantlement. Pay attention to the followings: When mounting differential gear assy. onto clutch housing, do not install the output flange first. Mount the output shaft and put on the fore bearing baffle of output shaft, put on fixing bolts and tighten with 40Nm torque.
Page 121 Allowable Types of Snap Ring Article No. Thickness (mm) 015-1700381AA 015-170038AB 015-1700381AC 015-1700381AD 015-1700381AE When mounting fork shaft, pay attention to putting the When mounting idler shaft, Value X should be equal. counterpoise spring into the fork shaft hole of clutch housing.
Page 122 Adjustment of gear-5 fork Adjust the gear-5 fork by the following procedures Screw M7 bolt-1 into the threaded hole as indicated in the figure; hold the fork shaft, knock slightly the transmission housing with plastic hammer until the bearing comes out and at the correct position.
Page 123 Special tool Support the shifting fork with a tool 12mm thick and knock tight the locking plate of gear-5 fork. Put on seal washers of rear housing and then mount the rear housing assy. Apply a coat of grease onto the top of separating jogger of clutch and insert it.
Page 124 Repair Repair of Rear Housing 1. Snap ring—separate arm 2. Separate arm assy. 3. Oil seal assy.—separate shaft 4. Rear housing—transmission 5. Fastening screw (CQ1500885) 6. Fastening screw of rear housing (CQ1500865) 7. Separate shaft of clutch 8. Release spring 9.
Page 125 The rear housing can be repaired without removing the The separate shaft of clutch can be taken down. transmission from the car. Use deift punch to flush down the oil seal assy. of separate shaft, pay attention not to damage the contact surface. Procedures of Dismantlement Put the car on a platform Procedures of Assembly:...
Page 126 Assembly: Special tool Special tool Special tool Apply grease onto the lips of oil seal, and press the seal Assembly: Mount the bearing in the part of housing fully into transmission housing with special tool. where the shifting shaft is contained. Press the bearing onto its due position with special tool.
Page 127 Dismantlement, Disassembly and Assembly of Shifting Shaft When doing this, it is not necessary to disassemble the transmission assy. Dismantlement: Dismantlement: Press spring-1 by arrow direction to compress the spring inside. Keep it at the position until snap ring-2 is removed. Assembly: the procedures are reverse to the above.
Page 128 Assembly Assembly Special tool Special tool Special tool As indicated, mount the needle roller bearing of input Apply grease onto the lips of oil seal and press the oil shaft with special deift punch and be sure it is pressed seal onto its due position with special tool.
Page 129 Disassembly of Input Shaft 1. Fastening bolts of gear-5 synchronizer 17. Gear-3 and gear-4 tooth drum 2. Gasket of fastening bolt 18. Guide block 3. Gear-5 synchronizer assy. 19. Wire spring 4. Guide board stand of gear-5 synchronizer. 20. Input shaft 5.
Page 130 Disassembly of Output Shaft 1. Rear housing 15. Gear-1 and gear-2 tooth bush 2. Snap ring of gear-5 driven gear 16. Gear-1 and gear-2 tooth drum 3. Gear-5 driven gear 17. Guide block 4. Transmission housing 18. Gear-1 synch ring 5.
Page 131 Adjustment Table When repairing the transmission assy., if any one of parts in the following table needs replacement, please consider to readjust the installation sizes output shaft or differential gear assy. To avoid useless adjustment, the following table is given: Items to be adjusted Parts to be replaced Differential...
Page 132 Calculate the thickness of installed adjusting shim Use gear lubricant to grease the bearing, insert the output shaft. When pre-tightening the bearing here, the thickness Put on bearing baffle and screw and fasten the bolts with of adjusting shim should be 0.20mm. if the 40Nm torque.
Page 133 Note: When measuring, never rotate the differential assy. to avoid affecting the accuracy of measurement. Calculate the thickness of adjusting shim to be installed. When pre-tightening the bearing here, the thickness of adjusting shim should be 0.40mm. If the micrometer reads 0.90mm, the thickness of adjusting shim to be installed should be: 0.4mm+0.9mm=1.30mm...
Page 134 Disassembly of Differential Gear Assy. 1. Driven gear of master speed reducer 15. Snap ring of output flange 2. Rivet 16. Disk-shape washer of output flange 3. Needle roller bearing 17. Output flange 4. Outer loop of needle roller bearing 18.
Page 135 Dismantlement and Assembly of Oil Seal and Output Flange It can be done without disassembling the transmission assy. Dismantlement and Assembly of Left Oil Seal and Output Flange Take out snap ring and disk-shape washer Special tool Remove the joining bolts of driving shaft and output flange, As indicated in figure, fix M8 bolt onto the flange with remove the driving shaft and fix it at given position.
Page 136 Assembly of Left Oil Seal Note: The right oil seal of output flange is fixed on oil seal seat. When dismantling the seat, knock it Special tool down slightly with end wrench. When mounting, press it fully in with special tool. Take the oil seal of correct type, apply grease on its lips, put it on the due position with special tool, rotate the nut of special tool until the oil seal is installed firmly onto its proper...
Page 137 Usage, repair and maintenance specification of CAC gasoline engine Remove main bearing bolt. Take out the main bearing cap carefully. Arrange them according to the sequence. Read the bearing clearance according to the proportion stated in the cover of plastic clearance gauge. Check the bearing clearance from the third main bearing and extending to the two sides.
Page 138 Usage, repair and maintenance specification of CAC gasoline engine —the size of crankshaft thrust, thrust washer and cylinder block thrust： unit：mm The size of size The thickness of level cylinder body crankshaft thrust thrust washer thrust standard 24±0.03 28.825—28.875 2.326±0.025 oversize 24±0.03 29.205—29.255...
Page 139 Usage, repair and maintenance specification of CAC gasoline engine ——Nine main bearing bolts are hex head flange side bolts, and one is stud. For horizontal engine, the stud is mounted in the left threaded hole of the second main bearing cap (see from the front) which is for installing the carrier of oil collector.
Page 140 Usage, repair and maintenance specification of CAC gasoline engine 【13】. Engine oiling system: 1). The description of the oiling system: Through oil collector (2), the rotary oil pump(1) which is installed in the front end of crankshaft draws oil from oil pan (3) and pressurizes. The pressure oil comes into the full flow type oil filter through the assistant oil passage (4) on the left of cylinder body (viewed from the front).
Page 141 Usage, repair and maintenance specification of CAC gasoline engine 2) The removal and installation of oil pan： removal： ——Loosen drain plug and drain oil ——Loosen eighteen M6×20 bolts ——Take out the sealing gasket of oil pan ——Check if the left and right reinforced plates are still clipped on the back face of oil pan flange face Fig.
Page 142 Usage, repair and maintenance specification of CAC gasoline engine The removal and installation of oil collector assembly removal： ——Loosen locknut of oil collector assembly and take out the nut and flat washer ——Loosen carrier bolts and take out the bolts。 ——Loosen flange face bolt of oil collector (two ) and take out the two bolts with spring washers Fig.
Page 143 Usage, repair and maintenance specification of CAC gasoline engine 4. The removal and installation of oil pump with oil seal assembly removal： ——Loosen six M6×30 hexagonal flange surface bolts. Remove the bolts (as the figure indicates ) ——Remove oil pump with oil seal assembly Fig.
Page 144 Usage, repair and maintenance specification of CAC gasoline engine ——Check the clearance between outer rotor of oil pump and case bore of oil pump. The clearance between outer rotor of oil pump and case bore of oil pump should be 0.06—0.19mm. Fig.
Page 145 CAC Gasoline Engine Maintenance And Servicing Manual ANHUI CHERY AUTOMOBILE CO., LTD CAC478/480 GASOLINE ENGINE Instruction Book on Using and Maintenance PDF 文件使用 "pdfFactory Pro" 试用版本创建 www.fineprint.com.cn...
Page 146: Int Ro Duct Io N
CAC Gasoline Engine Maintenance And Servicing Manual Catalogue Int ro duct io n…… …………………………… ……………… ……………………………1 Engine configuration view and sectional view……………………………………………3 Main engine technical indexes and operation parameters………………………………11 Engine structural features………………………………………………………………13 Engine service……………………………………………………………………………15 Engine removal and assembly procedure………………………………………………17 [1]、Positioning no.1 cylinder top dead center (compression) …………………………17 [2]、Upper and lower timing gear cover assemblies removal and installation………18 [3]、Crankshaft pulley removal and installation………………………………………18...
Page 147 CAC Gasoline Engine Maintenance And Servicing Manual Foreword CAC478、 CAC480 series vehicle gasoline engines , which are the products introduced from Ford ( Britain) corporation CVH production line, are made by Anhwei chelly automobile Corp. Products are made up of carburetor type, single-point electric control fuel injection type and electric control fuel injection type , which may meet the requirements for different performance and emission.
Page 148: Engine Configuration View And Sectional View
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Page 149: Genera
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Page 150: Operation Theory
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Page 153: Crankshaft, Crankshaft Thrust Washer, Bearing Bushing And Main Bearing Capremoval And I N S T A L L A T I O
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Page 154 CAC Gasoline Engine Maintenance And Servicing Manual Carburetor engine exploded view PDF 文件使用 "pdfFactory Pro" 试用版本创建 www.fineprint.com.cn...
Page 155 CAC Gasoline Engine Maintenance And Servicing Manual 1、 temperature regulator seat assembly 11、camshaft thrust plate temperature regulator seat 12、camshaft timing gear 2、 distribulator 13、timing belt 3、 camshaft assembly 14、upper\ lower timing gear cap assembly 4、 fuel pump assembly 15、water pump assembly 5、...
Page 156: Main Engine Technical Indexes And Operation Parameters
CAC Gasoline Engine Maintenance And Servicing Manual Main engine technical indexes and operation parameters CAC478C CAC480C CAC480M ← ← Type Line,4-cyl, four strokes, water-cooling ← Cylinder bore diameter(mm) 77.24 79.94 ← Stroke(mm) 74.30 79.52 ← Total displacement(L) 1.392 1.596 Compression ratio 9.5∶1 9.75∶1 9.75∶1...
Page 157 CAC Gasoline Engine Maintenance And Servicing Manual Application parameters： Lubricant(With temperature at - 10℃ or more) SAE10W/30—50( grade SF) Gasoline 93#(SH0041) Common unleaded Gasoline Engine oil pressure Idling 100kPa 2000r/min(80℃) 280kPa Engine oil capacity (L) 3.86(New oil filter) Oil pump pressure regulator starts to open(pressure) kPa 440±20 Engine oil filter by-pass valve starts to open (pressure) kPa 78—118...
Page 158: Engine Structural Features
CAC Gasoline Engine Maintenance And Servicing Manual Engine structural features 1.Cylinder block：Made from gray cast iron. Without bibcock. Without cylinder liner.5 main bearing seats. Main Intermediate bearing anti-thrust. Main bearing caps are retained by spigot. Main bearing bolts of 12.9 grade. 2.Cylinder head：Made from aluminum alloy.
Page 159 CAC Gasoline Engine Maintenance And Servicing Manual 19.Intake manifold：Made from Aluminum alloy. With mixture warm upped by water jacket. Electric heated intake manifold is optional. 20.Exhaust manifold：Made from ductalloy or black cast iron. 21.Oil pan：Stamping ，Low carbon steel. Oil pool is in the front of cylinder block. 22.Oil pump：Rotor type.
Page 160: Engine Service
CAC Gasoline Engine Maintenance And Servicing Manual Engine maintenance： —— Check lubricant level Daily maintenance —— Check coolant level —— Check bolt for loosing —— Check for leaking (oil, water, air) —— Replace engine oil and oil filter Per8000km —— Clean air filter，check air intake tube for cracking ——...
Page 161 CAC Gasoline Engine Maintenance And Servicing Manual CAC478、480Contents and intervals for Constant maintenance ×1000km ☆ ☆ ☆ ☆ ☆ ☆ Replace engine oil ☆ ☆ ☆ ☆ ☆ ☆ Replace oil filter ☆ ☆ ☆ ☆ ☆ ☆ Clean air filter core ☆...
Page 162: Engine Removal And Assembly Procedure
CAC Gasoline Engine Maintenance And Servicing Manual Engine removal and assembly procedure 【1】、Positioning no.1 cylinder top dead center (compression) ——Remove two M6×55 flange-shaped bolts, remove upper timing gear cover. ——Install a wrench on crankshaft pulley bolt, rotate crankshaft Clockwise (viewed from the direction of pulley) until the TDC notch on crankshaft pulley aligns with the TDC mark (0) on timing gear cover.
Page 163: Upper And Lower Timing Gear Cover Assemblies Removal And Installation
CAC Gasoline Engine Maintenance And Servicing Manual 【2】、Upper and lower timing gear cover assemblies removal and installation upper timing gear cover assembly Removal： ——Loosen and remove 2 bolts for upper timing gear cover assembly. ——Remove upper timing gear cover and seal assembly.
Page 164: Valve Cover And Seal Gasket Removal And Installation
CAC Gasoline Engine Maintenance And Servicing Manual Installation： ——Clean pulley and crankshaft journal， remove the oil in pulley groove . ——Install pulley on crankshaft journal, aligning keyway with semicircular key. ——Slip cushion block onto bolts and finger screw ——Block flywheel ring gear with screwdriver, preventing crankshaft from turning.
Page 165: Timing Belt Removal, Installation And Adjustment
CAC Gasoline Engine Maintenance And Servicing Manual Installation： ——Clean cylinder head and valve cover contacting surface. ——Push the wedge of valve cover seal gasket into appropriate valve cover groove, integrating valve cover with seal gasket. ——Install valve cover and seal gasket assembly on cylinder head.
Page 166 CAC Gasoline Engine Maintenance And Servicing Manual Note：With belt removed， don't turn gear excessively，or piston head and valve may be damaged for contacting. ——If belt need to be reused ，check for improper wear ,delaminate crack (particularly at the foot of teeth) or dirt. If lightly suspected, replace it.
Page 167 CAC Gasoline Engine Maintenance And Servicing Manual 【6】、Tension pulley, crankshaft gear and camshaft gear removal, check and installation 1. Tension pulley Timing gear Removal： ——Rotate crankshaft to no.1 cylinder compression TDC. ——Remove belt. cushion ——Loosen 2 tension pulley mounting bolts， push tension pulley aside to release belt tension with a large screwdriver.
Page 168: Tension Pulley, Crankshaft Gear And Camshaft Gear Removal, Check And Installation22 [7]、Camshaft Oil Seal Removal And Installation
CAC Gasoline Engine Maintenance And Servicing Manual Installation： ——Check gear tooth for wear, pitting or scratch. ——Install camshaft semicircular key，protrusion should be 1.64—2.11mm. ——Install camshaft gear on camshaft with new bolt though cushion block，new bolt should be pre-pasted and tightened to 52—60Nm.——Check whether crankshaft is positioned at compression TDC.
Page 169: Valve Mechanism And Cylinder Head Removal, Check And Installation
CAC Gasoline Engine Maintenance And Servicing Manual 【8】、Valve mechanism and cylinder head removal, check and installation 1.Valve mechanism for 478 and 480 engine： Rocker arm-8 Rock arm nut-8 .tightening torque 25-29n.m Rocker arm seat-8 Rocker arm seat washer-8 Valve locking piece-16 hydraulic lifting rod-8 clearance with...
Page 170 CAC Gasoline Engine Maintenance And Servicing Manual 2.Cylinder cover bolts removal and cylinder head assembly installation Cylinder head bolts removal： ——Rotate camshaft until keyway is rightly upside. ——Loosen cylinder cover bolts in order as specified in diagram. ——Note：Cylinder cover bolts must be replaced after removed and are not permitted to reuse.
Page 171 CAC Gasoline Engine Maintenance And Servicing Manual ——Install new cylinder head bolts and washers into bolt holes, screw in by hand. ——Tighten cylinder head bolts in four steps in the order Fig.24 as diagram specified. Step 1：Tighten to 20—40Nm Step 2：Tighten to 40—60Nm Step 3：Rotate 90°...
Page 172 CAC Gasoline Engine Maintenance And Servicing Manual Installation： ——Check rocker arm contact surface for abnormal wear， replace rocker arm if necessary. ——Pull rocker arm support washers onto rocker arm double end studs. ——Lubricate rocker arms and rocker arm supports with engine oil.
Page 173 CAC Gasoline Engine Maintenance And Servicing Manual Hydraulic lifting rod installation： ——Hydraulic lifting rod size： Cylinder head Lifting rod Grade lifting rod hole clearance outside diameter diameter Φ22.200—Φ22.212 Φ22.25±0.015 Standard 0.023—0.065 Fig.31 Φ22.454—Φ22.466 Φ22.50±0.015 0.023—0.065 ——Apply hyperbolical gear lubricant or engine oil on lifting rod, lifting rod outside diameter and lifting rod ends, install lifting rods in original order into the holes in the cylinder head.
Page 174 CAC Gasoline Engine Maintenance And Servicing Manual ——Camshaft journal and cylinder head cam bearing hole size： (1) Standard size Cylinder head Camshaft Camshaft journal bearing hole journal number diameter diameter 44.74—44.76 44.783—44.808 44.99—45.01 45.033—45.058 45.24—45.26 45.283—45.308 45.49—45.51 45.533—45.558 Fig.35 45.74—45.76 45.783—45.808 (2).
Page 175 CAC Gasoline Engine Maintenance And Servicing Manual 5.Valve, valve spring, valve oil seal, spring seat assembly removal and installation： Removal： Using special tools for valve compression, take out valve locking pieces, don't compress spring excessively, compress spring enough to slip locking pieces out of its stroke, or valve stem may be bent.
Page 176 CAC Gasoline Engine Maintenance And Servicing Manual ——Measure valve spring free length and spring force: Compression (mm) Spring load (N) Spring free length =37.084 =27.7 892.7 =47.2 =27.0 Fig.42 Fig.42 ——Grinding the valve and the valve seat with the valve conical angle(Intake valve and exhaust valve): 44°30′—...
Page 177 CAC Gasoline Engine Maintenance And Servicing Manual 6.the sizes for intake valve, intake valve seat, exhaust valve seat and valve guide ―the size of intake valve seat and cylinder head valve seat hole ― Diameter of the Diameter. of intake press fit cylinder head Fig.46...
Page 178: Piston And Connecting Rod Assembly Removal And Installation
CAC Gasoline Engine Maintenance And Servicing Manual 【9】: Removal and installation of the piston and rod assembly. Removal: ——Remove the crankshaft to the bottom dead center of the cylinder. Check and make sure that there is a cylinder mark on the connecting rod and its cap.
Page 179 CAC Gasoline Engine Maintenance And Servicing Manual position 19mm to the bottom skirt. unit：mm 488 dia. of 478 dia. of piston 480E *dia. of piston skirt skirt(mm) piston skirt (mm) (mm) 77.19—77.20 79.91—79.92 79.915—79.925 77.20—77.21 79.92—79.93 79.925—89.935 factory group 77.21—77.22 79.93—79.94 79.935—79.945 77.22—77.23...
Page 180 CAC Gasoline Engine Maintenance And Servicing Manual ——Measure the crosshead end bore of the connecting rodФ20.589 +0.02 PDF 文件使用 "pdfFactory Pro" 试用版本创建 www.fineprint.com.cn...
Page 181: Flywheel Assembly And Rear Oil Seal Bracket Assembly Removal And Installation
CAC Gasoline Engine Maintenance And Servicing Manual ——Check and make sure that the oil injection hole of the connecting rod large end is not blocked. The outside diameter is φ1mm. Installation: ——Need not to divide into groups for the piston weight, piston pin holes and the accessory piston skirt.
Page 182 CAC Gasoline Engine Maintenance And Servicing Manual Installation of the piston and rod assembly： Apply engine oil on piston, piston ring and cylinder bore. Stagger 120°among the first compression ring, the second ring and oil ring cotter, then install piston rod into cylinder bore. push the piston an rod assembly by hammer into the cylinder bore.
Page 183 CAC Gasoline Engine Maintenance And Servicing Manual 2). The removal and installation of carrier assembly of the real oil seal: Removal： ——Remove 4 bolts (as arrow indicates). ——Take out carrier assembly of the real oil seal ——Remove carrier sealing gasket of the real oil seal Fig.58 ——Use chisel or screwdriver to pry the real oil seal from the carrier of the real seal oil.
Page 184 CAC Gasoline Engine Maintenance And Servicing Manual ——Tighten four M6 bolts to 8.0 —11.0Nm。 ——Remove the plastic piece. Sealing plate M6 bolt×20（4） Tighten torque 8~11Nm Fig.62 【11】. Removal and installation crankshaft, crankshaft thrust washer, halves and main bearing cap Removal： Fig.
Page 185 CAC Gasoline Engine Maintenance And Servicing Manual carefully. Arrange them according to the sequence. Read the bearing clearance according to the proportion stated in the cover of plastic clearance gauge. Check the bearing clearance from the third main bearing and extending to the two sides.
Page 186: Oil Baffle Assembly Removal And Installation
CAC Gasoline Engine Maintenance And Servicing Manual —the size of crankshaft thrust, thrust washer and cylinder block thrust： unit：mm The size of size The thickness of level cylinder body crankshaft thrust thrust washer thrust standard 24±0.03 28.825—28.875 2.326±0.025 oversize 24±0.03 29.205—29.255 2.516±0.025 0.38...
Page 187: Engine Oiling System
CAC Gasoline Engine Maintenance And Servicing Manual ——Nine main bearing bolts are hex head flange side bolts, and one is stud. For horizontal engine, the stud is mounted in the left threaded hole of the second main bearing cap (see from the front) which is for installing the carrier of oil collector.
Page 188 CAC Gasoline Engine Maintenance And Servicing Manual 【13】. Engine oiling system: 1). The description of the oiling system: Through oil collector (2), the rotary oil pump(1) which is installed in the front end of crankshaft draws oil from oil pan (3) and pressurizes.
Page 189 CAC Gasoline Engine Maintenance And Servicing Manual 2) The removal and installation of oil pan： removal： ——Loosen drain plug and drain oil ——Loosen eighteen M6×20 bolts ——Take out the sealing gasket of oil pan ——Check if the left and right reinforced plates are still clipped on the back face of oil pan flange face Fig.
Page 190 CAC Gasoline Engine Maintenance And Servicing Manual The removal and installation of oil collector assembly removal： ——Loosen locknut of oil collector assembly and take out the nut and flat washer ——Loosen carrier bolts and take out the bolts。 ——Loosen flange face bolt of oil collector (two ) and take out the two bolts with spring washers Fig.
Page 191 CAC Gasoline Engine Maintenance And Servicing Manual 4. The removal and installation of oil pump with oil seal assembly removal： ——Loosen six M6×30 hexagonal flange surface bolts. Remove the bolts (as the figure indicates ) ——Remove oil pump with oil seal assembly Fig.
Page 192 CAC Gasoline Engine Maintenance And Servicing Manual ——Check the clearance between outer rotor of oil pump and case bore of oil pump. The clearance between outer rotor of oil pump and case bore of oil pump should be 0.06—0.19mm. Fig. 83 ——Check the radial clearance between inner rotor and outer rotor of oil pump.
Page 193 CAC Gasoline Engine Maintenance And Servicing Manual ——If relief valve spring is not to specification, it must be replaced. Installation： ——Install the outer and inner rotor into the oil pump house Fig. 87 ensuring the installation mark of outer and inner rotor upward. ——Install oil pump cover on oil pump.
Page 194: Engine Cooling System
CAC Gasoline Engine Maintenance And Servicing Manual ——Remove the thin plastic protective tape Fig. 91 tightening torque 18.0-25.0Nm removal and installation of oil filter and oil pressure sensor. Removal： ——Remove the oil filter. rotate oil filter counterclockwise during removal. ——Remove the oil pressure sensor Installation：...
Page 195 CAC Gasoline Engine Maintenance And Servicing Manual 【14】 Engine cooling system 1) Description for cooling system warm wind heat The cooling system is of pressure system. It expansion pressure exchanger tank includes water pump driven by timing belt, hose hose crosscurrent radiator, expansion tank, pressure hose hose...
Page 196 CAC Gasoline Engine Maintenance And Servicing Manual Grade Ⅱ≤91℃ wide opening temperature 89°－102° Operating voltage 12V PDF 文件使用 "pdfFactory Pro" 试用版本创建 www.fineprint.com.cn...
Page 197 CAC Gasoline Engine Maintenance And Servicing Manual ——Coolant draining ： (1) remove pressure cap of expansion water tank (2) connect a container under the radiator. Remove the outlet hose of radiator or open the drain plug of radiator. ——Cleaning cooling system： (1) drain the coolant and then close the drain plug of radiator or install the outlet hose of radiator (2) add clean water into the max water level of expansion tank and install the pressure cap (3) start engine and keep idling., warm engine to normal working temperature and stop engine cooling...
Page 198: Engine Air Intake And Exhaust System
CAC Gasoline Engine Maintenance And Servicing Manual 2) The removal and installation of water pump assembly ——The structure of water pump assembly 1—water pump case 2—water pump impeller 3—water pump gear 4—water pump bearing 5—water pump seal (ceramics—black lead) Fig. 94 Removal：...
Page 199 CAC Gasoline Engine Maintenance And Servicing Manual 3) The removal and installation of thermostat seat with thermostat assembly ——Loosen three M6×40 bolts and remove them ——Remove thermostat seat with thermostat assembly ——Pry out spring clip by chisel or screwdriver Fig.96 ——Take out the thermostat Fig.
Page 200 CAC Gasoline Engine Maintenance And Servicing Manual thermostat Spring clip Sealing gasket Sealing gasket Overflow pipe Drainage pipe Sealing gasket Small recircula- ting pipe Temperature seat assembly Plug screw Tighten torque Fig.100 Assembly: ——Clip the thermostat seat, and put the rubber seal ring into the thermostat hole. ——Install the thermostat(with spring outward) ——Install spring clip, ensure that the clip is clipped in the thermostat seat groove.
Page 201 CAC Gasoline Engine Maintenance And Servicing Manual guide cover Intake hose carburetor Air filter exhaust manifold Intake preheat hose intake manifold engine front sound absorber back sound absorber Exhaust hose Fig. 101 intake and exhaust system arrangement of carburetor engine ——The air filter is equipped with a intake air temperature controller.
Page 202 CAC Gasoline Engine Maintenance And Servicing Manual ——The air filter is equipped with a intake air temperature controller. When the temperature is low, the hot air intake valve controlled by the temperature controller will open and the hot air, flowing by the exhaust manifold, will be directed into the air filter from the intake preheating hose to supply more hot air and facilitate the fuel atomization during cold winter.
Page 203: Engine Crankcase Ventilation System
CAC Gasoline Engine Maintenance And Servicing Manual The intake manifold ‘s air may be preheated by the electrical heater as well as by coolant. As the coolant’s temperature is lower than 60°, the electronic heater will be energized to facilitate the cold starting. The electrical heater’s energizing or deenergizing is controlled by the intake preheating switch and relay.
Page 204 CAC Gasoline Engine Maintenance And Servicing Manual 4. The removal and assembly for the exhaust manifold, heat insulation cover and rear lifting lug: Removal: －Loose and remove the M12×25 allen screw, and remove the rear lug . －Loose and remove two M8×12 screw and remove the heat insulation cover .
Page 205 CAC Gasoline Engine Maintenance And Servicing Manual 【16】 Positive Crankcase Ventilation（PCV）system of engine. 1. Description for PCV system of the Carburetor engine: PCV system is a closed system. The leaking air of piston from the Crankcase goes to the Connection cylinder head cover through the PCV hose.
Page 206 CAC Gasoline Engine Maintenance And Servicing Manual 2.2 PCV valve’s function: under the low speed condition, the vacuum of intake manifold is very high, which keep the valve closed, and only a small opening exists to allow the gas pass through. Therefore it won’t change the mixture rate.
Page 207: Engine Fuel Supply System
CAC Gasoline Engine Maintenance And Servicing Manual ——Remove the studs of same length . Assembly: ——submerge the push rod into the engine oil or pour engine oil into the rod’s hole of the cylinder head and install the push rod into the hole. The gap between push rod and hole is 0.035-0.055mm.
Page 208 CAC Gasoline Engine Maintenance And Servicing Manual ——Adjustment of Peirburg 2E3 carburetor: CO adjustment Idle overdrive Idle speed adjustment: screw cut-off valve Rotating the screw inward will increase idle speed. Rotating the screw outward will decrease idle speed. CO adjustment: Cone valve Rotating the CO screw inward will enrich the mixture .
Page 209 CAC Gasoline Engine Maintenance And Servicing Manual 【18】 Engine electrical system. The electrical system includes battery, alternator, starter, breakerless distributor, ignition controller, spark plug, high-power ignition coil, high pressure assembly, water temperature sensor, oil pressure switch, electric fan, thermo switch, and idle speed solenoid valve of carburetor. 1.
Page 210 CAC Gasoline Engine Maintenance And Servicing Manual The JFZ1913—4 alternator for independent assembly. Fig. 121 The JFZ18D13 ZB alternator for independent assembly. Fig. 122 alternator bracket for independent assembly. Fig. 123 Starter. Rated output: 0.95kW Speed range: 1000-1800r/min Voltage: Type: QDY1258 SD6RA78 ——the flywheel gear ring for vehicle and the one for...
Page 211 CAC Gasoline Engine Maintenance And Servicing Manual ——The left chart is QDY1258 ——When checking starter, you should clean carbon brush. Its surface should not have dust and calibrator, and the brush can move freely in the carbon brush carrier. Change them if the brush and carrier are damaged severely.
Page 212: Carburetor Engine Malfunction , Cause And Correction
CAC Gasoline Engine Maintenance And Servicing Manual PDF 文件使用 "pdfFactory Pro" 试用版本创建 www.fineprint.com.cn...
Page 213 CAC Gasoline Engine Maintenance And Servicing Manual ——Loosen and remove two M6× 20 bolts. ——Remove the distributor. ——remove the distributor’s “O “seal. Assembly: Fig. 129 distributor assembly ——Insure that the engine is set correctly with No.1 Cylinder at TDC. TDC mark tongue ——install new “O”...
Page 214 CAC Gasoline Engine Maintenance And Servicing Manual 7. Ignition coil assembly. type Ignition coil assembly Fig. 132 Connector wiring harness assembly. ng assembly PDF 文件使用 "pdfFactory Pro" 试用版本创建 www.fineprint.com.cn...
Page 215 CAC Gasoline Engine Maintenance And Servicing Manual Carburetor engine faults ,causes and corrections 1.engine does not run during starting: Cause correction (1). Battery wires are loose or corroded reconnect or replace the wires . (2). Battery is discharged or damaged recharge or replace the battery .
Page 216 CAC Gasoline Engine Maintenance And Servicing Manual 4. difficult to start for engine when temperature is high: Cause correction (1). Air filter is dirty or blocked clean air filter core or replace case (2). low cylinder compression pressure sent to service spot for check and service (3).
Page 217 CAC Gasoline Engine Maintenance And Servicing Manual (8). Timing belt tightening incorrectly adjust timing belt tension (9). Idle mixture too rich or lean adjust carburetor idle mixture adjustment screw 8. engine Stalls during idling: Cause Correction (1). Low idle speed adjust idle speed (2).fuel outlet port or transition port for Idle speed blocked...
Page 218 CAC Gasoline Engine Maintenance And Servicing Manual 10. Engine accelerates hesitately Cause Correction (1). Intake manifold or connecting hose vacuum leaking service and check (2). Fuel filter clogged replace fuel filter (3). Fuel pump damaged. Or low fuel outlet pressure replace fuel pump (4).
Page 219: Cac480Mengine Single-Point Electric Control Injection System
CAC Gasoline Engine Maintenance And Servicing Manual 13. Carburetor backfire. Cause Correction (1). Engine ignited too late check adjust distributor adjust ‘teeth’ belt tension and (2). Incorrect Timing belt assembling or inadequate belt tension tension pulley (3). Carburetor fuel level too low or check and adjust float chamber mixture too lean needle valve...
Page 220 CAC Gasoline Engine Maintenance And Servicing Manual 16. Engine noise. (1). Preigniton or knocking occursduring accelerating or under heavy load Cause Correction check ‘teeth’ belt tension, tension a. Incorrect ignition timing pulley or distributor b. Incorrect fuel grade fuel correct grade c.
Page 221 CAC Gasoline Engine Maintenance And Servicing Manual (8). Air exists in cooling system bleeding the air (9). Too lean mixture adjust carburetor 18. Engine is too cold Cause Correction (1). themostat damaged replace thermostat (2). Water temperature sensor damaged replace water temperature sensor 19.
Page 222 CAC Gasoline Engine Maintenance And Servicing Manual Fig. 134 single port injection system 1. fuel tank 2. fuel pump fuel filter 4. check valve 5. fuel pressure regulator fuel injector 7. air filter 8. fuel vapor connecting pipe 9.engine idle speed actuator 10.
Page 223 CAC Gasoline Engine Maintenance And Servicing Manual advance is calculated by a basic chart(pressure, revolution) and trimmed by engine load, water temperature, and air temperature. In addition, it may perform dynamic ignition advance to stabilize idle speed. Engine idle speed actuator adjusts the by-pass pipe opening to keep idle value constant . And engine idle actuator is consisted of linear stepper motor.
Page 224 CAC Gasoline Engine Maintenance And Servicing Manual Fuel vapor recirculate solenoid Engine idle actuator Fuel pump Oil injector High pressure ignition coil Absolute pressure sensor TDC/RPM sensor Throttle valve position sensor PDF 文件使用 "pdfFactory Pro" 试用版本创建 www.fineprint.com.cn...
Page 225 CAC Gasoline Engine Maintenance And Servicing Manual Water temperature sensor Intake temperature sensor A/C signal λ sensor Fig. 135 The control-illustration for single Port Injection System According toλsensor signal, ECU will automatically revise C0 parameter(close loop). When λsensor fails, ECU may work under open loop. 2.
Page 226 CAC Gasoline Engine Maintenance And Servicing Manual The following accessories and engine air filter are installed on the upper body of throttle valve. ·fuel system pipe and fuel return pipe ·fuel pressure regulator ·bottom-supplying fuel injector IWM ·intake air temperature sensor. ——Fuel pressure regulator As engine is running, fuel pump supplies fuel (fuel supply volume of pump is about 80L/h) through filter and pipe to fuel pressure regulator(chart 137).
Page 227 CAC Gasoline Engine Maintenance And Servicing Manual IWM523 fuel injector applied in the system is of the shortened type of the first generation. It is entirely made of stainless steel and superior in the function. The advantage may be embodied when the commercial fuel containing corrosive material is applied.
Page 228 CAC Gasoline Engine Maintenance And Servicing Manual Connecting chart water Fig.139 temperature sensor and principle 2.2 Lower body(air system)—description and function of accessories Excepted that connecting throttle valve to accelerator pedal by a lever, the following parts should be installed on the lower body. ·throttle valve position sensor ·stepper motor ·hot water loop near the throttle valve and idle air by-pass...
Page 229 CAC Gasoline Engine Maintenance And Servicing Manual holes in the bracket for installing the potentiometer on throttle valve. · there is spline on the shaft. the spine provides data about throttle position. The data is used to confirm idle operation condition(accelerator pedal released), full load(accelerator pedal depressed) and accelerating or decelerating conditions.
Page 230 CAC Gasoline Engine Maintenance And Servicing Manual feature by-pass channel idle actuator parameter throttle spiral resistance valve operation temperature throttle valve leak by-pass valve air control. Fig. 141 Idle step motor and air by-pass valve If stepper motor needs to be replaced, remove the positive connector first and replace actuator. Then turn ignition key to position 1(accessory position), ECU will readjust actuator position(to limit switch) and adjust for steps according to engine water temperature so as to adjust idle speed with valve linear (axial direction)movements(forward or backward).
Page 231 CAC Gasoline Engine Maintenance And Servicing Manual 3.2 fuel filter Fuel filter (see drawing 143) is connected between fuel pump and the fuel intake port of the throttle valve body. It comprises an aluminum case and a bracket with a stainless steel in it. for the high sensitivity of fuel injector and the the existence of external impurities being in the fuel system, it is necessary to use the high-efficiency paper filter core.
Page 232 CAC Gasoline Engine Maintenance And Servicing Manual timing： Rotate the engine pulley(2) to keep cylinder 1 and cylinder 4 at TDC, i.e. the mark on the pulley (2) and the mark (3 and 4) on the timing wheel cover of engine must be matched (see figure. 145). see from the front end, rotation direction top dead center position crankshaft...
Page 233 CAC Gasoline Engine Maintenance And Servicing Manual 3-way connector ( figure. 147) a. supply 5V voltage b. negative pole signal c. positive pole signal Fig. 147 absolute pressure sensor When engine is shut down, the sensitive membrane will bent according to the value of atmospheric pressure (mmHg). After the ignition switch is switched on, the actual atmospheric pressure may be obtained by this method.
Page 234 CAC Gasoline Engine Maintenance And Servicing Manual When ECU microprocessor identifies the signals of two tooth-missed signals , it will begin to count tooth. cylinder 1 or cylinder 4 TDC comes after 20 teeth are counted .cylinder 2 or cylinder 3 TDC comes after 50 teeth are counted (determine by pair).
Page 235 CAC Gasoline Engine Maintenance And Servicing Manual 6 zirconiumλ sensor is designed to detect the oxygen in exhaust emission In endothermal engine, the combustion is produced by the reaction of hydrogen and oxygen and then emits heat. Fuel is composed of hydrocarbons. It includes carbon atom and hydrogen atom which are combined together by different modes (paraffin, olefine, aromatics).
Page 236 CAC Gasoline Engine Maintenance And Servicing Manual to check all sensors and actuators, injection system ECU has a complete high-efficiency self-diagnosis system. When failure occurs, the warning light will turn on. Warning：Before checking exhaust emission orλsensor, check： 1. The warning light should go out, or use CHECK—UP1 diagnosis instrument to determine the failure and adjust it for correct operation.
Page 237 CAC Gasoline Engine Maintenance And Servicing Manual Catalytic converter may damp the three contaminations in the exhaust: unburned hydrocarbon (HC), carbon monoxide(CO) and nitrogen oxide (NO two kinds of complicated chemical reactions exist in the catalytic converter: the oxidation of carbon monoxide and hydrocarbon changing into carbon dioxide and water;...
Page 238 CAC Gasoline Engine Maintenance And Servicing Manual Ignition switch Fig. 154 principle drawing of anti-fuel vaporization system 1. fuel tank 2. Two-way check valve 3. fuel Injection pressure system 4.multi-function valve 6. charcoal canister 7. fuel vapor recirculation solenoid 8.throttle valve body After long time since engine stopped, the temperature in the fuel tank will rise (Since the vehicle doesn’t move, the dynamic ventilation is not enough.) and the pressure in the fuel tank will rise.
Page 239 CAC Gasoline Engine Maintenance And Servicing Manual If the pressure in the fuel tank (1) rises beyond the specified value, two-way check valve (2) will open reducing the pressure in the fuel tank. If necessary, the valve may open reversely to vent inward when the fuel tank is vacuumed. —When the fuel level is at middle or low , when it exceeds a specified pressure, the multi-function valve (4) will permit the fuel vapor to reach the charcoal canister (6) and be absorbed by the activated carbon granule.
Page 240: Wir Ing Diagram
CAC Gasoline Engine Maintenance And Servicing Manual Fig.156 1.fuel tank 2.fuel pump (submerged in fuel tank) 3. Filter screen prefilter (installed in the inlet of fuel pump) 4.fuel filter 5.fuel delivery pipe 6.fuel injector(installed in the throttle valve) 7.pressure regulator 8.fuel return pipe 9.fuel recirculation check valve (stop backflowing ) 10.fuel cut-off switch...
Page 241 CAC Gasoline Engine Maintenance And Servicing Manual Relay of system power supply Fig.157 1. battery 8.5A ECU fuse 3.1# ignition coil (cylinder 1、4) 9.dual relays (A—ECU，B—fuel pump) 3.λsensor 11.fuel pump 4.fuel injector 12. fuel vapor recirculation solenoid 5.2# ignition coil (cylinder 2、3) 13.ECU 6.ignition switch 14.main ground wire of engine...
Page 242: Syst Em Service
CAC Gasoline Engine Maintenance And Servicing Manual Fig. 158 PDF 文件使用 "pdfFactory Pro" 试用版本创建 www.fineprint.com.cn...
Page 243 CAC Gasoline Engine Maintenance And Servicing Manual 1.injection/ignition system ECU 17.injection system warning light (on the instrument panel) 2.battery 20.fuel cut-off switch 3.ignition switch 21.A/C control unit 4.25A system fuse 22.A/C compressor relay 5.5A ECU fuse 23.A/C compressor 6.dual relays 26.engine idling actuator 7.revolution counter 27.throttle valve position sensor...
Page 244 CAC Gasoline Engine Maintenance And Servicing Manual 27.without connection line 28.speed sensor positive input 29.λsensor positive input 30.throttle valve potentiometer signal input 31.intake air temperature sensor signal input 32.absolute pressure sensor signal input 33.without connection line 34.main ground wire of engine 35.ignition switch +12V power supply input A/C I/O may only be supplied to the vehicle equipped with A/C and the ECU of the corresponding engine, i.e.
Page 245 CAC Gasoline Engine Maintenance And Servicing Manual system fuse ECU fuse dual relays ignition coil of cylinder 2,3 ignition coil of cylinder 1, 4 fuel vapor solenoid sensor sensor fuel injector step motor throttle valve position sensor intake gas temperature sensor absolute pressure sensor water temperature sensor tacho/top dead center sensor...
Page 246 CAC Gasoline Engine Maintenance And Servicing Manual the installation position in engine single point injection/ ignition system Fig. 161 1.injection/ignition ECU2 diagnosis passage 12.λsensor 3.speed/ TDC sensor 13.fuel pressure regulator 4.engine flywheel 14.fuel injector 5.ignition coil with dual high-pressure connector 15.dual relays (for ECU and fuel pump) 7.throttle valve position sensor 16.25A injection/ ignition system fuse...
Page 247: Malfunction, Cause And Correction
CAC Gasoline Engine Maintenance And Servicing Manual ——engine idling speed actuator doesn’t work ——shorted fuel injector +12V circuit ——opened or shorted ignition coil circuit also, monitor the following failure： ——with engine cycling start or engine working, signal wheel is not synchronous. ——opened or shorted λsensor circuit ——opened fuel pump circuit Fig.
Page 248 CAC Gasoline Engine Maintenance And Servicing Manual Removal and reinstallation for fuel pump： Fuel pump is installed inside the fuel tank. Removal procedure is as following: —— switch off the power supply —— remove quick release fuel Outlet pipe and fuel return pipe Remove and reinstall filter ——...
Page 249 CAC Gasoline Engine Maintenance And Servicing Manual tightening torque 0.5—0.6Nm at ambient temperature, The resistance indicated by digital multimeter should be 2.5—4.5Ω. Note: Even though little lead exists in the fuel, the sensor may fail soon. the function inspection is specified every 45,000km and 90,000km.
Page 250 CAC Gasoline Engine Maintenance And Servicing Manual 5.malfaction, cause and correction Malfuction cause Correction Fuel pump. fuel check for operation by CHECK—UP1 injector IVM523 Tachometer Check wring, sensor resistance and installation of the sensor. Vehicle cannot start senser. Dual relays Check for function, connector connection and blown fuse.
Page 251 CAC Gasoline Engine Maintenance And Servicing Manual PDF 文件使用 "pdfFactory Pro" 试用版本创建 www.fineprint.com.cn...
Page 252 Maintenance Manual for Chery·Windcloud Marelli EFI System Installation: to be installed on pressurizer. Chapter One: Operating Principle for Troubleshooting: mainly check if there is Marelli Control Execute short circuit or open circuit on the Components connection between 4 lines on senosr and ECU.
Page 253 Maintenance Manual for Chery·Windcloud Marelli EFI System Troubleshooting: mainly check if there is 2. Throttle Position Sensor short circuit or open circuit on the connection between 3 lines on senosr and Purpose: this sensor is designed to provide ECU. ECU with information of throttle angle. As...
Page 254 Maintenance Manual for Chery·Windcloud Marelli EFI System 3. Coolant Temperature Sensor TF-W Purpose: this sensor is designed to provide coolant temperature information. To provide engine ECU with water temperature signal used for control of ignition timing and fuel injection pulse width in startup, idle speed and normal operation.
Page 255 Maintenance Manual for Chery·Windcloud Marelli EFI System between them. 4. Knock Sensor KS Purpose: this sensor is designed to provide ECU with engine knocking information so as to carry out knocking control. When engine detects a knocking signal, ECU Knocking block 2.
Page 256 Maintenance Manual for Chery·Windcloud Marelli EFI System Troubleshooting: mainly check if the plug 5. Oxygen Sensor connection of several wires on the sensor is Purpose: this sensor is designed to provide in good condition, and if there is short the information that if there is surplus circuit or open circuit.
Page 257 Maintenance Manual for Chery·Windcloud Marelli EFI System 6. Electronic Control Unit (ECU) Purpose: ECU is the core of electronic engine control system. Sensors sent various signals to ECU for electric control, and then ECU controls operations of fuel injector and ignition coil, etc. after internal calculation, thus controlling working of engine.
Page 258 Maintenance Manual for Chery·Windcloud Marelli EFI System ECU Pin Definition: Connected to Connected to Not in use Air conditioning compressor relay control Not in use Not in use Not in use Not in use Engine speed signal Oxygen sensor ground...
Page 259 Maintenance Manual for Chery·Windcloud Marelli EFI System 7. Electric Fuel Pump Purpose: to carry fuel from fuel tank to engine fuel injection system at a certain pressure and flow rate (different in systems). Composition and principle: electric fuel pump is coaxially installed with pump motor Electric fuel pump in the same casing.
Page 260 Maintenance Manual for Chery·Windcloud Marelli EFI System Working pressure: 350 kPa 8. Electromagnetic Injector Injector resistance: 13.8 -15.2± 10% Working temperature: -30°C - +110°C Purpose: according to ECU instruction, injector ejects fuel within the stipulated time, by which means providing engine with fuel and atomizing it.
Page 261 Maintenance Manual for Chery·Windcloud Marelli EFI System Coil resistance: (1-4, 2-3) 53ohm at 23 ±5 ℃ 9. Idle Speed Actuator Stepper Motor Min. stroke ensured by pusher: 8.9 mm (around 214 steps) Functions: there is also a bypath air passage provided by idle speed actuator with stepper motor.
Page 262 Maintenance Manual for Chery·Windcloud Marelli EFI System 10. Ignition Coil Function: ignition coil transforms low voltage of primary winding into high voltage of secondary winding, spark is generated through discharge of spark plug to ignite fuel and air mixture in cylinder.
Page 263 Maintenance Manual for Chery·Windcloud Marelli EFI System 11. Carbon Canister Control Valve Purpose: to be used for the control of purge flow rate of carbon canister. Carbon canister control valve is controlled by ECU in accordance with engine load via the duration and frequency of electric impulse (i.e.
Page 264 Maintenance Manual for Chery·Windcloud Marelli EFI System 12. Assembly of Steely Fuel Distributing Pipe Purpose: to store and distribute fuel to provide fuel injection system with a fairly stable pressure environment, to achieve counterbalance of supply pressure and fuel feed of each cylinder as well as smooth engine operation.
Page 265 Maintenance Manual for Chery·Windcloud Marelli EFI System 13. Rotational Speed Sensor Purpose: rotational speed sensor provides engine ECU with rotating speed, rotating angle and reference signals for control of engine cylinder detection and ignition; rotational speed sensor of induction type...
Page 266 Maintenance Manual for Chery·Windcloud Marelli EFI System Chapter Two: Basic Principle for EFI System Failure Diagnosis (1). Failure Information Record Electronic control unit constantly monitors sensors, actuators, relevant circuits, fault indicating lamp and accumulator voltage, etc. and even electronic control unit itself, and...
Page 267 Maintenance Manual for Chery·Windcloud Marelli EFI System repair at maintenance station so as to avoid the embarrassment of breaking down on highway or outdoors. Once failure is identified disappeared, the use of normal data will be restored. (6). Failure Alarm Some vehicles equipped with MARELLI system have fault indicating lamps.
Page 268 Maintenance Manual for Chery·Windcloud Marelli EFI System Failure: too low circuit voltage of intake pressure sensor Step Operation Result Solution Connect scanner and commutator, and then turn Go to next step ignition switch to “ON”. Check Intake Pressure in data stream to see if it is...
Page 269 Maintenance Manual for Chery·Windcloud Marelli EFI System wire harness and check the resistance value between Pin 1 and Pin 2 with a multimeter to see if it corresponds with temperature (refer Replace sensor corresponding chapter of this manual for details, around 2.5K ohm at normal temperature).
Page 270 Maintenance Manual for Chery·Windcloud Marelli EFI System Failure: too high circuit voltage of throttle position sensor Step Operation Result Solution Connect scanner and commutator, and then turn Go to next step ignition switch to “ON”. Check Throttle Absolute Opening in data stream to Go to next step see if it is 4%-10% (depends on specific car model).
Page 271 Maintenance Manual for Chery·Windcloud Marelli EFI System C. Check spark plug to see if clearance is proper; D. Check high voltage wire to see if resistance is Diagnosis too high; Instruction E. Check intake conduit to see if it is worn out, etc.
Page 272 Maintenance Manual for Chery·Windcloud Marelli EFI System Unplug oxygen sensor connector from wire harness, Go to next step check voltage between (corresponding to white wire of oxygen sensor) and Pin D (corresponding to white wire of oxygen sensor, two thick wires on ECU wire harness) of the...
Page 273 Maintenance Manual for Chery·Windcloud Marelli EFI System A. Check intake system for severe air leakage; B. Check injectors for blockage; C. Check spark plug to see if clearance is proper; Repair as per D. Check sub live wire to see if resistance is too diagnosis high;...
Page 274 Maintenance Manual for Chery·Windcloud Marelli EFI System Repair Check the connection between Pin 1 of Cylinder 1 replace wire injector connector and main relay to see if open or harness short circuit to ground occurs. Go to next step Check the resistance between Pin 1 and Pin 2 of...
Page 275 Maintenance Manual for Chery·Windcloud Marelli EFI System Failure: injector circuit error in Cylinder 3 Step Operation Result Solution Connect scanner and commutator, and then turn Go to next step ignition switch to “ON”. Unplug Cylinder 3 injector connector from wire...
Page 276 Maintenance Manual for Chery·Windcloud Marelli EFI System injector connector and cathode of power supply Go to next step with a multimeter to see if it is around 3.7V. Repair Check the connection between Pin 2 of Cylinder 4 replace wire...
Page 277 Maintenance Manual for Chery·Windcloud Marelli EFI System of knock sensor connector and Pin 70 of ECU to see Go to next step if open, short circuit to power/ground occurs. Replace knock sensor as per specification, trial run Diagnosis the engine at a speed higher than 2200RPM.
Page 278 Maintenance Manual for Chery·Windcloud Marelli EFI System Failure: driver stage control circuit error of carbon canister control valve Step Operation Result Solution Connect scanner and commutator, and then turn Go to next step ignition switch to “ON”. Unplug carbon canister control valve connector...
Page 279 Maintenance Manual for Chery·Windcloud Marelli EFI System Check the resistance between Pin 1 and Pin 2 of Replace carbon canister control valve with a multimeter to control valve see if it is between 17.5-23.5Ω at 20℃. Diagnosis Check the voltage between Pin 2 of carbon canister...
Page 280 Maintenance Manual for Chery·Windcloud Marelli EFI System ignition switch to “OFF”. Go to next step Carry Check throttle regulating screw, throttle cable and necessary working conditions of throttle to see if they are inspection, normal. repair maintenance Go to next step...
Page 281 Maintenance Manual for Chery·Windcloud Marelli EFI System Failure: too low control circuit voltage of idle speed regulator Step Operation Result Solution Connect scanner and commutator, and then turn Go to next step ignition switch to “ON”. Unplug idle speed regulator connector, check...
Page 282 Maintenance Manual for Chery·Windcloud Marelli EFI System Diagnosis Instruction Failure: improper system voltage signal Step Operation Result Solution Connect scanner and commutator, and then turn Go to next step ignition switch to “OFF”. Go to next step Check battery voltage with a multimeter to see if it Replace is around 12V.
Page 283 Maintenance Manual for Chery·Windcloud Marelli EFI System Repair replace wire harness Failure: too high system votage Step Operation Result Solution Connect scanner and commutator, and then turn Go to next step ignition switch to “OFF”. Go to next step Check battery voltage with a multimeter to see if it Replace is around 12V.
Page 284 Maintenance Manual for Chery·Windcloud Marelli EFI System Step Operation Result Solution Connect scanner and commutator, and then turn Go to next step ignition switch to “OFF”. Unplug air conditioner compressor relay, turn Go to Step 4 ignition switch to “ON”, check voltages between...
Page 285 Maintenance Manual for Chery·Windcloud Marelli EFI System Failure: too high control circuit voltage of air conditioner compressor relay Step Operation Result Solution Connect scanner and commutator, and then turn Go to next step ignition switch to “OFF”. Unplug air conditioner compressor relay, turn Go to Step 4 ignition switch to “ON”, check voltages between...
Page 286 Maintenance Manual for Chery·Windcloud Marelli EFI System 6. Diagnostic Steps for Various Engine Failures Preliminary inspection shall be carried out before proceeding with diagnostic steps for any engine failure: (1). Make sure ECU and fault indicating lamp are working normally.
Page 287 Maintenance Manual for Chery·Windcloud Marelli EFI System 1). Engine dose not rotate or rotates slowly when starting Step Operation Result Solution Check the voltage between two terminals of Go to next step accumulator with a multimeter to see if it is around Repair or replace 10-12.5V.
Page 288 Maintenance Manual for Chery·Windcloud Marelli EFI System 2). Engine rotates but fails to start when starting Step Operation Result Solution Turn ignition switch to “ON”, and check with scanner Eliminate failure to see if there is any failure information recorded.
Page 289 Maintenance Manual for Chery·Windcloud Marelli EFI System again to restart fuel pump. Check to see if fuel Go to Step 16 pressure is established. Turn on fuel gauge valve, clamp the fuel return pipe Replace fuel with fuel return interceptor to stop fuel returning.
Page 290 Maintenance Manual for Chery·Windcloud Marelli EFI System 3). Vehicle warm starting is difficult Step Operation Result Solution Set ignition switch in “ON”. Check with scanner Eliminate failure to see if there is failure information record. displayed Go to next step Connect fuel pressure gauge valve.
Page 291 Maintenance Manual for Chery·Windcloud Marelli EFI System 4). Rotating speed is normal, but starting is difficult all along Step Operation Result Solution Set ignition switch in “ON”. Check with scanner Eliminate failure to see if there is failure information record.
Page 292 Maintenance Manual for Chery·Windcloud Marelli EFI System Make engine run at idle speed, and check to see Go to next step if ignition advance angle is normal after coolant Replace ECU temperature reaches normal value. Check if cylinder compression pressure of Go to next step engine is normal.
Page 293 Maintenance Manual for Chery·Windcloud Marelli EFI System 5). Vehicle cold starting is difficult Step Operation Result Solution Set ignition switch in “ON”. Check with scanner Eliminate failure to see if there is failure information record. displayed Go to next step...
Page 294 Maintenance Manual for Chery·Windcloud Marelli EFI System Check if fuel pressure is lower than 350kPa Go to next step Go to step 16 Shut down fuel gauge valve. Switch on ignition Go to next step switch again to make fuel pump work once more, Go to step 15 and check if fuel pressure is established.
Page 295 Maintenance Manual for Chery·Windcloud Marelli EFI System 6). Instable idle speed occurs anytime Set ignition switch in “ON”. Check with scanner Eliminate failure to see if there is failure information record. displayed Go to next step Check if idle speed actuator of idle speed stepper...
Page 296 Maintenance Manual for Chery·Windcloud Marelli EFI System with fuel return interceptor to ensure no fuel Repair/ replace return, and check if fuel pressure is formed injector or fuel pipe rapidly. Check if leakage or clogging occurs in fuel inlet Repair or replace pipe.
Page 297 Maintenance Manual for Chery·Windcloud Marelli EFI System 7). Idle speed is instable during warming-up Set ignition switch in “ON”. Check with scanner Eliminate failure to see if there is failure information record. displayed Go to next step Check if air filter is smooth.
Page 298 Maintenance Manual for Chery·Windcloud Marelli EFI System 8). Idle speed is instable after the completion of warming-up Set ignition switch in “ON”. Check with scanner Eliminate failure to see if there is failure information record. displayed Go to next step...
Page 299 Maintenance Manual for Chery·Windcloud Marelli EFI System Replace fuel pressure regulator Make engine run at idle speed, and check to see Go to next step if ignition advance angle is normal after coolant Replace ECU temperature reaches normal value. Pull out coolant temperature sensor to see if...
Page 300 Maintenance Manual for Chery·Windcloud Marelli EFI System 9). Idle speed unsteadiness or flameout when using load (air conditioner, etc.) Set ignition switch in “ON”. Check with scanner Eliminate failure to see if there is failure information record. displayed Go to next step...
Page 301 Maintenance Manual for Chery·Windcloud Marelli EFI System 10). Periodical unsteadiness (ECU shall have self-learning again after power cutoff) Set ignition switch in “ON”. Check with scanner Eliminate failure to see if there is failure information record. displayed Go to next step Check if air filter is smooth.
Page 302 Maintenance Manual for Chery·Windcloud Marelli EFI System 11). Excessive idle speed (ECU shall have self-learning again after power cutoff) Set ignition switch in “ON”. Check with scanner Eliminate failure to see if there is failure information record. displayed Go to next step...
Page 303 Maintenance Manual for Chery·Windcloud Marelli EFI System 12). Low rotating speed or engine flameout during acceleration Set ignition switch in “ON”. Check with scanner Eliminate failure to see if there is failure information record. displayed Go to next step Check if air filter is smooth.
Page 304 Maintenance Manual for Chery·Windcloud Marelli EFI System Replace fuel pressure regulator ignition switch “ON”. Connect Go to next step commutator between ECU and wire harness to check the voltages of output signal terminal, Repair or replace ground terminal and 76#, 60# pins (served as wire harness 4.5-5V sensor power) of ECU throttle position...
Page 305 Maintenance Manual for Chery·Windcloud Marelli EFI System 13). Slow response when accelerating Set ignition switch in “ON”. Check with scanner Eliminate failure to see if there is failure information record. displayed Go to next step Shut down the engine and check if air filter is Go to next step smooth.
Page 306 Maintenance Manual for Chery·Windcloud Marelli EFI System 14). Poor performance and disability occur during acceleration Check if there exists failure of clutch slipping, Repair low tire pressure, braking drag, incorrect tire Go to next step size, four-wheel alignment error and etc.
Page 307 Maintenance Manual for Chery·Windcloud Marelli EFI System with fuel return interceptor to ensure no fuel Repair/ replace return, and check if fuel pressure is formed injector or fuel pipe rapidly. Check if leakage or clogging occurs in fuel inlet Repair or replace fuel...
Page 308 Maintenance Manual for Chery·Windcloud Marelli EFI System 8. System Maintenance Safety Precautions 1). Diagnostic maintenance safety precautions for EFI system (1). Controller dismounting requirement   C ontroller shall be dismounted before electric welding or stoving varnish;   W hen dismounting controller, ignition switch shall be pulled to OFF so as to avoid damage;...
Page 309 Maintenance Manual for Chery·Windcloud Marelli EFI System Caution: the ECU plug of A-series engine is liable to have problem of interior looseness, in case such problem occurs while line, sensors and control unit are all normal, ECU wire harness shall be replaced or ECU plug shall be disposed of.
Page 310 Maintenance Manual for Chery·Windcloud MOTOROLA EFI System Chapter One: Operating Principle for EFI Control and Execute Components Intake Pressure Intake Temperature Sensor MOTOROLA system adopts measurement method of velocity and density to measure the air capacity entering engine so as to control fuel injection pulse width further accurately control engine power output.
Page 311 Maintenance Manual for Chery·Windcloud MOTOROLA EFI System 2. Throttle Position Sensor MOTOROLA sensor Purpose: designed to provide ECU with information of throttle angle and angle rate. As per such information，ECU could obtain engine load information and operating mode information (for instance: start-up, idle speed, reverse, part...
Page 312 Maintenance Manual for Chery·Windcloud MOTOROLA EFI System 3. Coolant Temperature Sensor TF-W Purpose: this sensor is designed to provide coolant temperature information. To provide engine ECU with water temperature signal used for control of ignition timing and fuel injection pulse width in startup, idle speed and normal operation.
Page 313 Maintenance Manual for Chery·Windcloud MOTOROLA EFI System 4. Knock Sensor KS Purpose: this sensor is designed to provide ECU with engine knocking information so as to 1. Knocking block carry out knocking control. 2. Casing 3. Piezoelectric ceramics 4. Contactor 5.
Page 314 Maintenance Manual for Chery·Windcloud MOTOROLA EFI System a specified time. 5. Oxygen Sensor Purpose: this sensor is designed to provide the information that if there is surplus oxygen after full combustion of fuel, which is injected into engine cylinder in the intake air. ECU, when...
Page 315 Maintenance Manual for Chery·Windcloud MOTOROLA EFI System 6. Electronic Control Unit (ECU) Purpose: With microprocessor as core composition, ECU has a sensor signal input interface, also, it is an electric control engine control center for actuator drive circuit, which receives and...
Page 316 Maintenance Manual for Chery·Windcloud MOTOROLA EFI System 3. ECU Pins Definition: Radiator fan Ignition coil 1 Ignition coil 2 Ground Rotation Fuel conditioning speed pump pressure output control switch Injector 1 Injector 3 Compressor relay Condensor Ground relay Idle stepper...
Page 317 Maintenance Manual for Chery·Windcloud M OTOROLA EFI System 7. Electric Fuel Pump Purpose: to carry fuel from fuel tank to engine at a certain pressure and flow rate (different in systems). Composition and principle: electric fuel pump is coaxially installed with pump motor in the same casing.
Page 318 Maintenance Manual for Chery·Windcloud MOTOROLA EFI System 8. Electromagnetic Injector Purpose: according to ECU instruction, injector ejects fuel within the stipulated time, by which means providing engine wtih fuel and atomising it. Composition and principle: ECU sends out electric impulse to injector coil, forming magnetic field force.
Page 319 Maintenance Manual for Chery·Windcloud MOTOROLA EFI System 9. Idle Speed Actuator Stepper Motor Functions: there is a bypath air passage in throttle valve casing, and engine speed can be controlled by bypath airflow, while bypath airflow is controlled by stepper motor, which is located in bypath air passage.
Page 320 Maintenance Manual for Chery·Windcloud MOTOROLA EFI System 10. Ignition Coil Function: ignition coil transforms low voltage of primary winding into high voltage of secondary winding, spark is generated through discharge of spark plug to ignite fuel and air mixture in cylinder.
Page 321 Maintenance Manual for Chery·Windcloud MOTOROLA EFI System 11. Assembly of Steely Fuel Distributing Pipe Purpose: to store and distribute fuel from fuel pump and control system fuel pressure through fuel pressure regulator to provide fuel injection system with a fairly stable...
Page 322 Maintenance Manual for Chery·Windcloud MOTOROLA EFI System Crankshaft Position Sensor (Rotational Speed Sensor) Purpose: crankshaft position sensor is designed to provide ECU with signals of engine speed, rotation angle and top dead center to be used in engine ignition, fuel injection and timing system.
Page 323 Maintenance Manual for Chery·Windcloud MOTOROLA EFI System Chapter Two: Basic Principle for EFI System Failure Diagnosis (1). Failure Information Record Electronic control unit constantly monitors sensors, actuators, relevant circuits, fault indicating lamp and accumulator voltage, etc. and even electronic control unit itself, and...
Page 324 Maintenance Manual for Chery·Windcloud MOTOROLA EFI System failure mark being set on some important parts such as ECU, manifold absolute pressure sensor, throttle position sensor, coolant temperature sensor, knock sensor, oxygen sensor, phase sensor, injector and two driver stages of idle speed actuator stepper motor, ECU will alarm by lighting up fault indicating lamp until the said failure mark restores.
Page 325 Maintenance Manual for Chery·Windcloud MOTOROLA EFI System element breakdown (for example: sensor, actuator or ECU); may be wire having open circuit or short circuit to ground or accumulator anode; and may be even mechanical failure. Failure is an internal error, its external exhibition is various symptoms. If a symptom is found,...
Page 326 Maintenance Manual for Chery·Windcloud MOTOROLA EFI System Engine Failure Code Table Code Error source Type Error description Countermeasure to be adopted error Flash code Intake pressure sensor Lit Excessive intake pressure Replaced with throttle position 2311 signal Intake pressure sensor...
Page 327 Maintenance Manual for Chery·Windcloud MOTOROLA EFI System sensor Crankshaft position First Lit First tooth error Resynchronization 2431 sensor Crankshaft position Miss Lit Missing tooth error Resynchronization 4431 sensor Idle speed stepper motor Short Stepper motor short circuit Nil 2122 Fuel pump...
Page 328 Maintenance Manual for Chery·Windcloud MOTOROLA EFI System 3．Failure and Troubleshooting of EFI (1). Engine fails to start or has difficulty in starting Cause of failure Troubleshooting Injector failure Use scanner to test if injector works in good order Check crankshaft rotating speed, clearance between head of position...
Page 329 Maintenance Manual for Chery·Windcloud MOTOROLA EFI System （3）Unsteady engine idle speed Cause of failure Troubleshooting Air leakage occurs Fasten throttle valve casing setscrew alfunction of idle speed Repair or replace throttle valve casing control valve Throttle position sensor Check throttle opening and check if working parameter of...
Page 330 Maintenance Manual for Chery·Windcloud MOTOROLA EFI System EFI Maintenance Precautions: 4.1 Fuel Unleaded premium gasoline (in conformity with SH0041 standard, lead≤ 0.005g/L) for vehicles shall be used with RON no less than 90 or above 90, otherwise, damage may occur on engine management system and three-way catalytic converter and affect emission.
Page 331 Maintenance Manual for Chery·Windcloud MOTOROLA EFI System Users are not allowed to adjust throttle valve adjusting screw on throttle body. The position of such screw has been accurately adjusted in final assembly. Improper adjustment may cause high idling speed, engine closing down or affect idle speed stability, emission and economical efficiency of fuel consumption.
Page 332 Index FORWORD ···································································································································· 1、Automatic transmission (A/T) assembly description ·································································· 1.1、4HP14 A/T assembly explode view ························································································· 1.2、Transmission Power transfer schematic ··················································································· 1.3、Adjusting automatic transmission clearance ············································································ 1.3.1、Adjusting shift shaft clearance ···························································································· 1.3.2、Adjusting output gear clearance ··························································································· 1.3.2.1、Adjusting main rear output gear clearance ·········································································...
Page 333 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD FOREWORD This manual covers 4HP14 automatic transmission (A/T) repairing methods, detailed A/T removing & assembling procedures and information on determining if a transmission needs repairing upon problems. In addition, we recommend as followings: 1、Throttle cable, gasket, O ring, shim and other vulnerable parts must be replaced after removing.
Page 334 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD 1、4HP14 A/T assembly discription 1.1、 4HP14 A/T assembly explode view...
Page 335 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD 1.2、 4HP14 A/T power transfer schematic...
Page 336 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD 1.3、A/T clearence adjustment 1.3.1 Shift shaft clearence adjustment Install shift shaft clearence adjuster 5P 95 000 287 on housing surface, ensuring no clearence between lock cam and shift cam.
Page 337 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD 1.3.2、Rear output gear clearence adjustment 1.3.2.1、Main sub output gear clearence adjustment Hold driven shaft and output shaft with mounting bracket 5P 96 000 288 and 5P 95 000 289.
Page 338 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD Tighten sub rear output gear mounting bolt to 10 Nm with torque wrench. Only after both gears installed correctly can the parking plunger be removed easily. Turn gear with an appropriate bolt repeatly (as shown on fig.).
Page 339 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Making marks on bolts and gears as shown on figure. Turn screw 12 mm counterclockwise from marking position. Using appropriate tool tamp mounting bolt flange edge to distortion.
Page 340 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD 1.3.3.2、Driven shaft clearence adjustment Assembling requirements: Install 1.75 mm thickness gasket and sub rear output gear, and tighten bolt by hand. To maintain the clearance, select the thickest washer in alternative dimensions.
Page 341 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Set the indicator to zero. 1.Turn the screw until the needle moves. 2.Turn the gear till needle to zero position. Loosen transmisson lower mount carrier 5P 95 000...
Page 342 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD Turn the gear to determine indicator reading. Reading X For example, X=0.46mm Washer thickness S is calculated by following formula: S = 1.75mm (Xmm – 0.06mm) S = Required washer thickness 1.75 = Maximun washer thickness provided in table.
Page 343 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD 1.3.3、Clutch A clearance (snap ring thickness) adjustment Install 2.2mm thickness snap ring. Use measuring unit with dial indicator. Put the indicator right on, pointer must be at zero position.
Page 344 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD 1.3.4、Central seat clearance (washer thickness) Install adjusting washer (2.0mm thickness) and flanged thrust washer. Install clutch, brake, oil pump and other middle units. And retain with bolts. Tighten torque is 10Nm.
Page 345 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD When measuring, the indicator must be positively placed and the pointer is set to zero positon. As shown on fig., pull up the handle; read out the measured result. Clearance should be within 0.1mm~0.3mm.
Page 346 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD 1.3.5、Differential Pretension Install adjustor 5P 95 000 286 and tighten to 7Nm, pressing bearing and outer race. As shown on fig., turn the housing clockwise, tighten to 7Nm and repeat the above procedures.
Page 347 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD As shown on fig., distance B is the height from lug in speedmeter drive gear housing to housing top. For example Distance B = 8.65mmm Pretension washer thickness is within 0.1mm to 0.15mm.
Page 348 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD 1.3.6、Brake band C pretension Apply lubricant on locating rod of brake band, Adjusting bolt tighten torque is 10Nm. Tool: 6# socket spanner NOTE: While tightening the brake band, place the locating rod to proper installation position.
Page 349 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD 1.3.7、Adjusting throttle cable Pull the throttle cable to the most length, Measure as shown on figure. And the measuring value cannot be more than 39mm; otherwise, it will affect the kick down function.
Page 350 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD 1.4、Special tools Figure Code and Application A/Tp operating bracket of 5 x 46 000 244 Torque converter driver/installer 5 x 56 000 090 Bearing inner race remover Rolle x 48 500.
Page 351 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Figure Code and Application Removing and installing socket Rolle x 1000 1 Removing and installing socket 5 x 46 000 232 (used for inner racer of roller bearing on driven shaft and 1st gear one-way overrunning clutch snap ring.
Page 352 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD Figure Code and Application Piston C assembling tool 5 x 46 000 295 Diaphragm spring compression device 5 x 46 167. Clutch B drum hook 5 x 46 000 095...
Page 353 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Figure C ode and Application 5×46 000 146 Clutch diaphragm spring compression device B 5 x 46 000 146. Diaphragm spring compression device 5 x 46 000 148 Output shaft roller bearing remover 5 x 46 000 296.
Page 354 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD Figure Code and Application one-way overrun clutch snap ring remover 5 x 46 000 243. Output shaft gear and differential bearing inner race remover 5 x 46 000 297.
Page 355 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD 序号 Figure Code and Application Bearing outer race puller Puller 21/7. Bearing outer race puller 22/2. Shift shaft oil seal installing tool 5 x 46 000 187. -23-...
Page 356 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD Figure Code and Application Dowel pin drift of shift shaft 5×46 000 119 Oil sealing installing socket 5×46 000 161 Driven shaft bearing inner race compression tool 5×46 000 182...
Page 357 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Figure Code and Application Oil pump sealing installing tool 5 x 46 000 299. Output shaft, output gear and differential bearing inner race compression tool 5 x 46 000 300.
Page 358 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD Figure Code and Application Differential oil sealing assembling tool 5×46 000 111 Speedmeter drive gear case oil sealing intalling socket 5×46 000 180 Pawl spring adjuster 5P 89 001 995.
Page 359 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Figure Code and Application Shift shaft clearence adjuster 5P 95 001 287. Input shaft mounting carrier 5P 95 000 288. Output shaft mounting carrier 5P 95 000 289.
Page 360 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD Figure Code and Application Shaft shaft position adjuster 5P 95 001 285. Output gear clearence test tool 5P 01 001 518. Middle seat clearence test tool 5P 01 001 415.
Page 361 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Figure Code and Application Differential adjuster 5P 95 000 286 -29-...
Page 362 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD Name Tool Torque (Nm) Hex bolt (lug) SW=13mm Locking bolt M14 (housing) SW=6mm Locking bolt M10 (housing) SW=5mm Back light switch (housing) SW=27mm Mounting bolt (bearing) Torx bix 45...
Page 363 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD 1.6、Transmission general check The following points must be checked: Correct oil level Checking fluid level when engine idle. Checking fluid level after fluid temperature rises to 80ºC. Fluid level must be between Max. and Min. mark.
Page 364 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD 2、A/T internal disassembling 2.1、Assembly removing Support transmission assembly with 5 x 46 000 244 braket and drain oil. Remove converter carrier. Remove torque converter with special tool 5 x 56 000 090.
Page 365 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Remove 10 valve plate mounting bolts with 10 big size bolt head. Tool: 27# quincunx socket spanner. Turn over transmission by 90 degree, remove 17 mounting bolts on the converter housing.
Page 366 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD Remove differential and drive gear of the speedmeter. Remove central seat, oil pump and brake C assembly. Tool: 27# quincunx socket spanner. NOTE: During disassembling, hold transmission firmly.
Page 367 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Loosen C-type brake band. Remove clutch A, clutch B and 2nd gear one-way overrunning clutch as an assembly. Separate clutch A, clutch B and one-way overrunning clutch. Slightly remove the tensioned brake band, USE CARE not to bend brake band.
Page 368 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD Remove clutch E and input shaft. Remove center shaft, clutch E support and thrust bearing together. Remove sun gear shaft, clutch A support and thrust bearing as an assembly.
Page 369 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Remove sun gear drive drum and thrust bearing. Remove the sun gear. As shown on fig., remove planetery mechanism -37-...
Page 370 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD Install locator 5P 95 000 289 on output shaft top, and fix it on the transmission housing. Install locator on the driven shaft and fix it on the housing with bolts.
Page 371 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD As shown on figure, apply stop shift, using appropriate tool, loosen rear sub output gear mounting bolt. After removing main rear and sub rear output gear with appropriate tool, new transmission rear output gear can be removed by hand.
Page 372 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD If necessary, using special tool 5 x 46 000 297 and 2 cotter spanners, remove rolling bearing inner race in direction shown figure. Turn over transmission by 180o, remove 2 holding units.
Page 373 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Remove output gear and rear gear ring as an assembly. Remove slice gear C (refers to sub gear without wheel). Release parking position; remove governor cover and governor assembly.
Page 374 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD Turn over the transmission by 90 , remove protect plate. Using removing/installing socket 5 x 46 000 155 remove groove nut. Remove 1st gear one-way overrunning clutch. -42-...
Page 375 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD 2.2、Removing brake C. Install an installer 5 x 46 000 295 with screw mechanism, push brake band hydraulic cylinder head inwards. Remove snap ring with 2 screwdrivers. Take off brake band hydraulic cylinder cap and brake band piston C’.
Page 376 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD Screw adjuster bolt out after loosening locking nut. Pull out brake band locator rod. 2.3、Removing brake band D Turn over transmission by 90 As shown on figure, remover cotter snap ring with 2 screwdrivers.
Page 377 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Remove complete brake D assembly and diaphragm spring. Insert air gun into oil inlet and remove piston D using HP gas. 2.4 、 Removing central seat, brake C...
Page 378 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD Insert air gun into oil inlet hole, removing piston C using HP gas. Remove snap ring with screwdriver. Remove central seat snap ring. First step: loosen pump body connecting bolts.
Page 379 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Second step, pull out snap ring of the center seat with 2 hooks. Loosen connecting bolt, separate central seat from pump body. Only plastic hammer can be used to remove.
Page 380 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD 2.5、 Removing clutch B and 2 one-way overrun clutch Remove cotter snap ring and clutch B assembly. Press pressure plate with special tool 5 x 46 000 146, then remove snap ring and thrust washer.
Page 381 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Insert the air gun into oil inlet hole; remove pistion B using HP gas. One-way overrun clutch can not be further disassembled. 2.6、Removing clutch A Using appropriate snap ring plier, remove snap ring.
Page 382 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD Remove the snap ring, clutch A assembly and diaphragm spring in order. Using special tool 5 x 46 000 167 press piston with flow guiding flange, then remove snap ring with appropriate tool.
Page 383 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Knock piston gently, and remove piston A and the diaphragm spring. 2.7、Removing clutch E Take out thrust washer. Remove cotter snap ring and clutch E assembly. -51-...
Page 384 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD Remove diaphragm spring with the special tool 5 ×46 000 148, and then take off retainer. Remove shim spring. Insert air gun, and remove piston E using HP gas.
Page 385 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Remove rolling bearing using special tool 5×46 000 296. Remove cotter snap ring, place whole one-way overrun clutch into remover/installer 5×46 000 232. Remove cotter snap ring with installing sleeve 5×46 000 243 and a screwdriver.
Page 386 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD As shown on figure, one-way overrun clutch can be thoroughly disassembled: Clutch inner ring, outer gear ring and free wheel. 2.9、Removing governor and speedometer Loosen four mounting bolts and separate the governor case from the hub sleeve.
Page 387 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD 2、Remove piston 2 Press down spring with screwdriver, remove locking piece, spring and piston 2. After removing, components are as shown in figure. There are only two pistons.
Page 388 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD Revolve two planetary gears to appropriate position, and then take them out. For new type structure, remove two differential side shafts, and then take out two side gears.
Page 389 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Remove hex bolts in the speed meter drive gear case . Tool: 13# sleeve Loosen mounting bolts in the speedometer sensing rotor and carrier. Take out the speedometer sensing rotor and carrier, and then remove the sealing ring with appropriate tool.
Page 390 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD Drift housing sealing ring using appropriate drift. The bearing outer race may be removed with the sleeve. Remove the differential taper rolling bearing outer race in same method.
Page 391 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Loosen mounting bolts and remove the mounting carrier. Take out two dowel pins on throttle cam, throttle cam, and return spring. Loosen two mounting bolts and remove pawl spring.
Page 392 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD Removing parking plunger, brake plate, spring, and lock cam. Take out the brake rotor dowel pin. With appropriate drift, remove elastic pin and then remove shift shaft. -60-...
Page 393 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Remove shift cam and adjusting gasket. Remove dowel pin using appropriate drift. Take out pawl and retracting spring. Removing bolts and sealing ring. Remove bearing outer race with special tool Puller 21/7 和...
Page 394 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD Remove driven shaft bearing and outer race with same method. Remove differential and shift shaft sealing ring. Loosen back light switch. Tool: 27# socket -62-...
Page 395 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Remove all locking bolt, and clean housing. -63-...
Page 396 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD 3、Assembling 3.1、Assembling transmission housing and parking system. If necessary, install lug 01 250, and fix with hex bolts. Tool: 13# socket Torque: 23Nm When assembling bolts, use new sealing washer.
Page 397 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Part number Name Dimensions Torque (Nm) 01022 Locking bolt M14×1.5 — 01020 Sealing ring A14×18 01270 Locking bolt M10×1 — 01260 Sealing ring A10×14 Installing back light switch 01 112 with use new sealing washer 01 116.
Page 398 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD Preheat to 70℃, and press bearing outer race 09 090 and 09 040 into the housing. Install driven bearing outer race properly, and adjust its position in the housing. Otherwise the mounting bolt can not be aligned with threaded holes.
Page 399 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Press differential oil sealing 09 130 into location with installing sleeve 5×46 000 299. Install shift shaft oil sealing 06 010 with special spindle drift 5×46 000 187.
Page 400 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD Insert brake rotor dowel pin 06 100 and adjusting piece 5P 89 001 995. Install pawl spring dowel pin 06 040, and then install the pawl spring. Keep pawl spring close to the adjusting piece, and then fix with two bolts 06 050.
Page 401 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Connect locking cam 24 020 and brake rotor 06 110 with the lock spring 24 010. Locking cam must be installed on brake rotor. Install the whole mechanism on the dowel pin, and connect the brake rotor and lock cam with spring.
Page 402 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD NOTE: The washer thickness should be adjusted as procedures in section 1.4.1 in page 5/1. The adjusting washer is installed between the cam and the housing. Therefore brake rotor must be removed, and pull shift shaft out enough as necessary.
Page 403 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Install pawl 24 040 on dowel pin, and then install dowel pin to stop. Connect return spring and the pawl, and push the spring outward. Install the parking plunger 24 030.
Page 404 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD 3.2、Installing band brake C’ Install O-ring 31 340 on groove on brake band plunger 31 330 end. Oil O ring before installing. -72-...
Page 405 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Insert plunger into the housing, with O-ring end facing outward for sealing. Install adjusting blot 31 350, washer 31 360, and adjusting nut 31 370, and screw bolt into housing half or so.
Page 406 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD Place spring 31 430 on piston. After oiling O-ring, mount whole piston into the housing. Place 2 O rings 31 470 on brake fluid hydraulic cylinder cap and apply oil or Vaseline, and then install cylinder cap.
Page 407 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD After bending brake band with pressure, install it into housing, and adjust position between the brake band and two plungers. -75-...
Page 408 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD 3.3、Assembling brake D and 1 one-way overrun clutch Install O-rings 17 020 and 17 030 in piston 17. 010, and apply lubricant. Build piston into the housing with flange part upward.
Page 409 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Install diaphragm spring 17 040and thrust washer 17 090. Install one-way overrun clutch 17 130 into the clutch outer gear ring, USE CARE to right tooth match, and push clutch downwards to stop.
Page 410 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD Install clutch hub 17 180 half or so, and then turn clockwise to location. Place clutch on special tool 5×46 000 232, and install snap ring 17 100 with installing drift pin 5 ×46 000 243.
Page 411 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Install safety ring 17 190 (tooth type of thin steel ring) and grooved nut 17 200, and tighten grooved nut with socket spanner 5×46 000 155. Torque：50Nm As shown on figure, using appropriate drift, tamp tooth ring into groove on grooved nut, enhancing locking.
Page 412 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD 3.4、Assembling governor driven shaft Insert piston 33 040 into the governor case 33 030，and fix with lock sheet 33 050. -80-...
Page 413 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Insert piston 33 070 and spring 33 070, and fix with lock sheet 33 090. Governor units are shown on right figure. The piston may not be divided into three sections.
Page 414 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD Fix the centrifugal block 33 098 with bolts. Install two snap rings 33 020, and let them interlocked. Install O-ring 33 022 into the governor hub. Tool: 27 # inner socket spanner Torque: 10Nm Install the governor shroud 33 110.
Page 415 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Press bearing inner race 09 080 into driven shaft 5×46 000 070 with special tool 5×46 000 182. Install one end of the driven shaft into the governor.
Page 416 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD 3.5、Assembling planetary mechanism and rear output gear Install drive wheel drum 17 170 into 2nd gear one-way overrun clutch outer race. -84-...
Page 417 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Press rolling bearing inner race 14 050 into output shaft 14 010 with installing socket 5× 46 000 300. onnect output shaft with front gear ring 32 040, and fix with snap ring 32 050.
Page 418 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD Install a mounting carrier 5P 95 000 289. Then turn housing by 180°. Press bearing inner race 14 050 onto rear main output gear 09 010 using installing socket 5×...
Page 419 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD As shown on right figure, install washer 09 022 and sub rear output rear onto driven shaft. Tighten bolt 09 030. NOTE: The whole output gear mechanism needs adjusting by procedures in section 1.4.2 in page...
Page 420 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD Install washer 14 020, thrust bearing 14 030 and thrust washer14 040. Install snap ring 32 020 into groove of planetary carrier, and suddenly press both ends of the snap ring for self-locking.
Page 421 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Install the sun gear 32 030 in the planetary mechanism. Install drive wheel drum 30 310 and make it engaged with the sun gear. Install washer 02 190, thrust bearing 02 180 and thrust washer 02 170 onto drive wheel drum.
Page 422 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD Install sun gear shaft 02 160, and inspect its engagement condition. If the installation is right, drive drum shall turn towards the sun gear. Install thrust washer 30 170, thrust bearing 30...
Page 423 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD 3.6、Installing input shaft and clutch E assembly After applying lubricant or petrolatum to O ring, install it into piston E 30 050. -91-...
Page 424 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD Press piston E into the cylinder body of engine input shaft 30 010. Install two U washers 30 080 on the top of the piston with installing tool 5×46 000 148, and fix with snap ring 30 090.
Page 425 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Install retainer ring 30 120 on the top of clutch assembly. If the group numbers of the clutch inner friction plate and sheet steel is changed, the outer diameter of the retainer ring shall be changed accordingly.
Page 426 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD 3.7、Assembling clutch A assembly Install 2 O-ring 02 068 and on piston and apply lubricant to piston. -94-...
Page 427 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Install piston A into cylinder A02 050. Install diaphragm spring 02 090 with its convex surface upwards. Install O-ring 02 096 into piston 02 092, and lubricate O-ring.
Page 428 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD Assembling the whole clutch E assembly. Install diaphragm spring 02 142 first, and then install outer teeth sheet steel 02 120 and friction plate 02 130 alternately. Install retainer ring 02 140, and fix with snap ring 01 150.
Page 429 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Install worm assembly, and install snap ring 02 022 with a snap ring pliers. NOTE: The worm must be fixed with the snap ring, otherwise there may exists axial clearance.
Page 430 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD 3.8、Assembling clutch B and 2nd gear one-way overrun clutch. After applying lubricant to O-ring, install O-ring 31 220 into clutch drum B 31 140. -98-...
Page 431 The manual of 4HP14 A/T removing & installing CHERY AUTOMOBILE CO., LTD Install lubricated O-ring 31 230 into piston B 31 210. Install piston B into the clutch drum and install one pressure ring on the piston. Install diaphragm spring 31 290 with special tool and install thrust washer 31 302 and retainer ring 31 300.
Page 432 The manual of 4HP14 A/T removing and installing CHERY AUTOMOBILE CO., LTD Install clutch B into the clutch drum. Install retainer ring 21 250, and then install friction plate 31 260 and outer teeth sheet steel 31 250 alternately. Install retainer ring 31 270 and snap ring 31 280 onto assembly top.
Page 433 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Index 4HP14 Automatic Transmission Technical Parameter Transmission Technical Parameter Fluid pressure Fluid capacity Automatic transmission shift control element working principle Automatic transmission bolt tightening torque 4HP14 Automatic transmission special tool Special tool list...
Page 434 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 4HP14 Automatic transmission fault diagnosis Fault analysis when the control handle is at Position P Fault analysis when the control handle is at Position R Fault analysis when the control handle is at Position N...
Page 435 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Clutch E Housing Main back output gear Parking mechanism Control valve plate assembly Clutch A and brake D control valve plate Bottom valve plate Main valve plate Transmission assembly Brief introduction of automatic transmission structure and working...
Page 436 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 4HP14 Automatic transmission technical parameters. Transmission Technical Parameter Design ability Input torque 100-270N.m Converter maximum gain coefficient 1.9-2.5 Converter diameter 260mm Gear ratio Gear 1 2.412 Gear 2 1.369 Gear 3 (maximum) 1.000...
Page 437 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Automatic transmission shift actuator’s working principle Control handle position Parki Neutr Back ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ Drive clutch ○ Clutch gear clutch ○ ○ ○...
Page 438 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Automatic transmission bolt tightening torque Item Lb-Ft Lb-In Brake band adjusting bolt Brake band lock nut Bolt connecting the converter case with the housing Bolt connecting the converter case with the engine...
Page 439 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 4HP14 Automatic transmission special tool Special tool KA-000-088 (KA-0888) J-28467-B Differential Engine hanger adjuster J2936-1 KA-002-111 (KA-111) Bearing inner Bearing assembler racer remover KA-000-155 (KA-155) KA-001-023 Grooved nut remover (KA-232) Bolt remover...
Page 440 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual KA-000-287 KA-000-300 (KA300) (KA287) Bearing assembler Locator KA-000-288 (KA-288) KA-001-483 (KA 483) Driven shaft Gap detector locator KA-000-298 KA-001-655 (KA 655) (KA298) Main back output gear Bearing inner gap detector racer remover...
Page 441 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual DIAGRAM 1...
Page 442 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual DIAGRAM 2...
Page 443 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual DIAGRAM 3...
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Page 450 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual DIAGRAM 10...
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Page 462 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual DIAGRAM 22...
Page 463 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual DIAGRAM 23...
Page 464 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 4HP14 Automati c transmission assem sketch 4HP14 Automatic transmission appearance vie 1. Differential out 2. Side cover 3. Oil 4. Neutral start switc 5. Shift shaft 6. Air vent 7. Air throttle cable 8.
Page 465 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 4HP14 Automatic tran smission assem bly exploded vie 1. Torque converter 2. Intermediate seat and brake C assembly . Brake D 3. Output shaft ain output gear 4. Differential iaphragm spring 5.
Page 466 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 4HP14 Automatic transm ission fault diagnosis Fault diagnosis Auto matic transmission initial inspection Fault description Actions Engine idle abnormal Z Adjust the idle speed The transmission has abnormal noise when Fill in transmission oil...
Page 467 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual When necessary, replace the transmission assembly Brake D is damaged. No Replace brake D. braking on Position 1 and When necessary, replace the transmission ck gear assembly. The governor is stuck.
Page 468 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual It is impossible to shift f rom 1 Dirty governor Clean governor valve coupler to 2 gear and 2 to 1 gear or gearshift valve is stuck. Replace 1 gearshift valve on the control valve plate’s bottom valve to 2 gear.
Page 469 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual The main oil circuit does not have normal oil Replace the valve plate assembly. pressure. The en gine has a too high RPM when downshift The tim e control valve and d ownshift valve don’t...
Page 470 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Oil leaking fault Oil pressure inspection procedure Oil pressure test. Oil pressure test procedure: Remove the plug for the main oil circuit’s side compression hole on the transmission hou sing and connect the oil gauge.
Page 471 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Fault diagnosis: Fault description Possible causes Too low RPM when at position D and R The engine does not have enough power. The one-way clutch of the converter’s guide roller slips.
Page 472 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual mon oil leaking Fault description Fault diagnosis Actions torque converter leaks ousing’s sealing gasket. Replace the gasket. at its housing. Cracks on the converter’s welding seam. Replace the torque converter eaks at the contact The connecting bolt is loose.
Page 473 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Oil changing isassembly procedure: Lift the vehicle Place an oil box under the transmission to collect the oil. Loosen the oil drain plug to drain the oil inside the transmission. Loosen the oil pan’s connecting bolt and take off the oil pan and gasket.
Page 474 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Housing gap sealing Locate the oil leaking position; Use the detergent to clean the oil leaking position and then blow dry ote: The epoxy resin grouting agent will hurt skin and eyes. Please operate as instructed by ckaging label provided by the manufacturer.
Page 475 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Gear shift cable adjustment djustment procedure: The adjustment of gearshift cable important compliance of the position of the shift lever with that of the gear shifter arm. Pull the shift lever to...
Page 476 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Air throttle cable removal and assembly isassembly procedure: Remove the battery; Remove the cable ends from the air throttle’s swing arm; 3 Lift the v ehicle; 4. Remove the oil pa n and gasket.
Page 477 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Assembly procedure: Install the air throttle cable; 2.Install the air throttle cable on the air throttle’s swing arm; Lift the vehicle; Rotate the cam by certain degree and install the cable;...
Page 478 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Air throttle cable adjustment Ad ustment procedure: Adjust the gap between the idle positioning block adjusting turnbuckl Permissible gap: 0~1mm Check the distance between t idle po sitioning block and the adjusting turnbuckle when WO Distance scope: 39.0~40.0mm...
Page 479 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Assembly procedure: Put the return spring on the cam; Install the cam and fix with the pawl spring; The tightening torque for the pawl spring’s positioning bolt: 10Nm 3.Install the air throttle cable;...
Page 480 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 3.Loosen the connecting bolt between the neutral start switch and the case; Remove the neutral start switch; ssembly procedure: Install the neutral start switch and fix it on the case with the connecting nut;...
Page 481 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual control mechanism’s ectromagnectic interlock isassembly procedure: Remove battery’s negative terminal; Remove the central control panel; 3. Remove the electromagnetic interlock’s electric terminal; Remove the electromagnetic interlock. ssembly procedure: Install the electromagnetic interlock and fix it with a bolt;...
Page 482 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 5.Loosen the fixing nut between the oil feed pipe and the oil pan. Remove the oil feed pipe. ssembly procedure: 1.Install the oil feed pi pe and fix it with a fixing nut.
Page 483 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Vehicle speed sensor isassembly procedure: Remove the battery’s negative terminal; 2. Lift the vehicle; 3. Remove the vehicle spe sensor’s terminal; Remove the dowel pin on vehicle speed sensor and remove the vehicle speed sensor.
Page 484 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Assembly procedure: Install O-ring on the vehicle speed sensor; Install the vehicle speed sensor and fix it with the dowel pin. Install the terminal on the vehicle speed sensor; 3. 4.Lower the vehicle 5.Connect the batter...
Page 485 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Oil pan and gasket isassembly procedure: Lift the vehicle Drain off the hydraulic fluid inside the transmission. ote: Do not damage the contact surface between the oil pan and case when removing the oil n.
Page 486 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Side cover and gasket isassembly procedure: Lift the vehicle; . Remove the left front el and its drum; 3. Drain off the fluid in transmission; 4. Loosen the side cover’s connecting bolts;...
Page 487 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 4. Take out the odometer’s drive gear. ssembly procedure: Install the odometer’s drive gear; 2. Install the odometer’s drive gear case and fix it with the connect ing bolt; ghtening torque: 43Nm Put on the vehicle speed sensor’s terminal;...
Page 488 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Drive shaft oil sealing isassembly procedure: Lift the vehicle; Remove the two front wheels; Take off the drive shaft on the autom atic transmission. Remove the right drive shaft’s o il sealing;...
Page 489 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 2. Right drive shaft’s oil sealing; Put on left and right drive shafts; Install two front wheels; .Lower the vehicle. Oil cooling pipe isassembly procedure: Remove the battery; Place a oil box under the vehicle to collect the oil;...
Page 490 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 5. Loosen the terminals between the cooling pipe and the cooler. Loosen the terminals between the cooling pipe and the transmission. Remove the cooling pipe and the cooling guide pipe. ssembly procedure: Install the cooling pipe and the cooling guide pipe.
Page 491 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 3. Install the cooling guide pipe and fix it on the cooler with nuts; Tightening torque: 22Nm Install the clip connecting the cooling guide pipe and the case; The clip’s tightening torque:...
Page 492 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual t back suspension. Tool: J-28467-B engine hanger Disassembly procedure 1. Remove the battery; Remove the coolant tank; Remove the coolant tank’s top cover; engine hanger J-28467-B lift engine;...
Page 493 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 5. R emove the bolt connecting the left suspension and the cushion. emove bolt nnecting the left back suspension ansmission. emove left suspension. ssembly procedure: Install the upper left suspension; Install...
Page 494 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 3. Install the bolt connecting the left suspension and the cushion. 4. Remove the engine h anger; 5.Install the cooler’s back cover; Install the coolant tank; The tightening torque on the coolant tank’s...
Page 495 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Front suspension Disassembly procedure: 1. Remove battery’s negative terminal; 2. Remove the cooling fan ’s electric terminal; 3. Remove the cooling fan; 4. Remove the bolt co nnecting the front suspension and the front cross-member;...
Page 496 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 6. Install the engine hanger and lift the engine; Remove the transmission suspension; Lift the vehicle; Drain off the fluid; . Remove vehicle speed sensor’s terminal; Lower the v ehicle; . Remove cooling pipe;...
Page 497 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual . Lower the vehicle; . Loosen the bolt connecting the upper part of the converter case and the engine; Lift the vehicle; 23. Support one jack under the transmission. Loosen the bolt connecting th lower part of the converter case and the engine;...
Page 498 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Remove the jack and lower the vehicle; Install the bolt connecting the upper part of the converter with the engine; Tightening torque: 75Nm Lift the vehicle; Install the bolt connecting the...
Page 499 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Interior disassembly of the tomatic transmission. ecial tools: 26941 bearing outer racer mover A-001-023 non-standard bolt mover A-001-154 grooved remover A-000-288 driven shaft lo cator isassembly procedure: Remove transmission assembly from the whole vehicle;...
Page 500 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 8. Turn the transmission by 90 degree and face the converter case upwards; Loosen the bolt connecting the converter case with the housing. 10.Take off the converter case and its gasket. Take off the odometer’s drive gear;...
Page 501 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 12. Loosen the bolt connecting the middle seat with the housing. .Take out the middle seat, oil pump and brake C; .Take out the adjusting washer and thrust washer.
Page 502 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 15.Loosen the lock nut. Rotate the adjusting bolt counterclockwise. Loosen the brake band C’; 16.R emove th e clutch A, clutch B and 2 gear one-way overrun clutch assembly; .You will see that the clutch A is...
Page 503 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 18.Take out brake C’. Please don’t bend the brake band arbitrarily. .Take out the input shaft and clutch E assembly. .Take out the middle shaft, clutch E rack and thrust bearing.
Page 504 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 21. Take out the sun gear shaft and rack washer thrust bearing. . Take out the drive drum and thrust bearing. . Take out the sun gear.
Page 505 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 24. Take out the planetary gear mechanism needle bearing. . Fix the driven shaft with the special tool of KA-000-288. . Turn the transmission by 90 degree to the direction as shown by the figure;...
Page 506 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 29. Pry the output gear lock bolt’s flange edge to flat; .Loosen the main back output gear’s lock bolt with the special tool of KA-001-023.0 .Take off the lock bolt and main...
Page 507 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 32.Loosen the auxiliary back output gear’s lock bolt with the special tool of KA-001-023. .Take off the lock bolt and auxiliary back output gear; .Take out the output shaft, spokeless gear and gear ring;...
Page 508 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 35. Remove the driven shaft’s locator of KA-288; . Take off the driven shaft; . Loosen the parking position. Take governor’s shroud and the governor itself. 38.P ry the space washer for 1 gear one-way overrun clutch’s...
Page 509 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 39. Loosen 1 gear one-way overrun clutch’s grooved nut with the special tool of KA-000-155. .Take off the grooved nut and 1 gear one-way overrun gear’s outer racer. .Take off 1 gear one-way overrun gear.
Page 510 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 42. Turn the transmission by 90 degree, as shown by the figure; . Remove brake D’s snap ring; .Take off the brake D assembly and diaphragm spring; 45.U se high-pressure gas to remove the...
Page 511 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual .Remove the lock bolt on the driven shaft bearing’s outer racer; .Use the dedicated tool of J29369-1 to remove the driven shaft bearing’s outer racer. .Apply the same method in removing the main back output gear roller bearing’s...
Page 512 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual ervice of major parts on the tomatic transmission rake band C’ ssembly procedure: Remove transmission assembly from the whole vehicle; Remove brake C’ from the transmission; Remove the snap ring on the hydraulic cylinder head of brake C’.
Page 513 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 6.Separate piston C’, piston rod and two disk washers; Remove O-ring on the piston; 8. Lo osen the pretension adjusting nut for the brake band;...
Page 514 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 9. Take out the carrier rod on the brake band C’; . Remove the O-ring on carrier rod of brake band C’. ssembly procedure: Put an O-ring on brake band C’.
Page 515 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 2.Plu g in the carrier rod of brake band C’. Install the adjusting bolt, washer and adjusting nut. adjusting bolt is screwed in by half. ote: Two disk washers have assembled so that the sunk...
Page 516 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 5.Put a spring on the piston push rod. plug piston C’ assembly into the housing; Install the hydraulic cylinder head; Install the snap ring; Install the brake band C’; 9. Install...
Page 517 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Middle seat, brake C and oil mp assembly ecial tool: KA-000-914 aphragm spring lock unit isassembly procedure: 1. Remove automatic transmission assembly from the whole vehicle; Remove the middle seat, brake C ’...
Page 518 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 6.Take out the diaphragm spring, compression ring and retaining ring; Plug the air gun into the oil feed hole and remove piston C with high pressure air. . Take out plug C;...
Page 519 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 9. Remove the positioning snap ring on the middle ring and the middle ring itself. If necessary, O-ring on the middle ring could be removed; 10.Loosen bolt connecting the middle seat with the oil pump;...
Page 520 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual .Spring, hydraulic valve spindle and valve cap on the middle seat; .Take out the annulus gear and pinion of the oil pump; embly procedure: 1.In stall the oil pump’s annulus gear and pinion. Face the side...
Page 521 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 2. Install the spring, hydraulic valve spindle and valve cap; Install the middle seat. Please pay attention that the inner hole on the middle seat should be aligned with the spring;...
Page 522 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 5.Install the middle ring and fix it with a snap ring. 6.Install piston C. Install diaphragm spring, compression ring and retaining...
Page 523 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Use the special tool of KA-000-914 diaphragm spring compressor to press down the diaphragm spring and install the fixing snap ring; 9.Install brake C assem bly; Install the positioning snap ring on brake C assembly;...
Page 524 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Clutch gear e-way overrun clutch ecial tool: KA-000-914 aphragm spring compressor isassembly procedure: 1. Remove tran smission assembly from the whole vehicle. Remove clutch A, clutch B and 2 gear one-way overrun clutch from the transmission.
Page 525 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 6.Take out the adjusting washer and snap ring; 7. Remove KA-000-914 of diaphragm spring compressor; Take out the diaphragm spring and snap ring; Plug the air gun into the oil feed hole and remove piston B...
Page 526 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual .Take out piston B. Replace O-ring if necessary. .Replace O-ring on clutch B drum, if necessary. ssembly procedure: Install piston B;...
Page 527 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 2.Install diaphragm spring and compression ring; 3.Use special tool KA-000-914 (diaphra gm spring compressor) to press down the compression ring; 4. Install the snap ring adjusting washer;...
Page 528 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Install clutch B assembly; Install clutch B assembly’ positioning snap ring; Assemble clutch A, clutch B and 2 gear one-way overrun clutch into an ent ity; Install clutch A, clutch B and...
Page 529 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual lutch A ecial tool: KA-000-913 aphragm spring compressor sassembly procedure: Remove automatic transmission assembly from the vehicle. Remove clutch A from the automatic transmission. Remove the snap r ing on clutch A’s worm shaft;...
Page 530 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Press down piston A and remove the snap ring; Introduce in compressed air from the oil feed hole remove piston A assembly; Knock lightly piston assembly on the worktable to diaphragm spring;...
Page 531 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 9.Replace O-ring on the booster piston, if necessary. 10.Replace O-ring on piston A. ssembly procedure: 1.Install diaphragm spring on the booster piston.
Page 532 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 2.Install piston A on the booster piston. Install the booster piston into clutch A drum. 4. Use the special tool of KA-000-913 (diaphragm spring compressor) to press down the booster piston and...
Page 533 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Install clutch A assembly; Install clutch assembly’s positioning snap ring; Check the gap between clutch A assembly. As shown in the figure, put the dial indicator on top of clutch A drum.
Page 534 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 10. Install the worm shaft; Install the s nap ring on clutch A’s worm shaft; 12. Install clutch A assembly into the transmission; Install assembled transmission into the vehicle; lutch E...
Page 535 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 4. Remove the snap ring and clutch E assembly; special tool KA-001-715-04 bearin remover to press down piston 6. Take out the retaining ring and diaphragm spring; 7. In troduce in compressed air fro...
Page 536 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 8. Take out piston E; Replace O-ring on piston E, if necessary; Assembly procedure: 1. Put the piston E on the input shaft; 2. Press down piston E; Install the retaining ring...
Page 537 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 4. Install clutch E assembly and snap ring; 5. Put the adjusting washer on input shaft: 6. Install th e clutch E assembly on the transmission: 7.Install the assembled transmission assembly on the vehicle.
Page 538 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 5. Remove the tapered roller bearing from the output shaft with special tool KA-000-060 (bearing remover); Remove the retaining ring and snap ring; Remove gear one-way overrun clutch’s inner racer;...
Page 539 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 8. Remove the snap ring on 1 gear one-way overrun clutch’s inner racer; Separate the clutch drum from the clutch’s inner racer. ssembly procedure: Install the one-way overrun clutch drum onto the clutch’s...
Page 540 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 4. Press the clutch’s outer racer on the one-way overrun clutch drum; 5. Install the snap ring and retaining ring with the special t ool of KA-000-232 (bearing remover); Press fit the tapered roller...
Page 541 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual transmission assembly from the vehicle; Remove the driven shaft and governor from the automatic transmission assembly; Take off the governor’s shield; 4. L oosen the connecting bolt on the governor take governor’s cas...
Page 542 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 2. Install the spring and two adjusting valve spindles on the governor’s case. Then fix them with lock pieces; Install the centrifugal bock on the governor’s drum and fix it with a bolt: tightening torque: 10Nm.
Page 543 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Install the governor’s shroud; Install the driven shaft and governor assembly; Install the assembled governor on the vehicle. ousing ecial tool: KA-002-111 bearing ter racer assembler KA-002-298 bearing ter racer remover...
Page 544 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual ssembly procedure: Install the outer racer of the differential’s tapered roller bearing with KA-002-298 (bear ing outer racer remover and assembler); Install the odometer’s drive gear case; Install the outer racer of the input shaft’s tapered roller bearing with...
Page 545 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual transmission from the vehicle. 2. Remove the differential from the transmission; 3. Remove th e dowel pin on the planetary gear shaft; 4. Remove the planetary g ear shaft; 5. Take out the planetary gear;...
Page 546 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual .Remove the tapered roller bearing from differential with KA-001-060; Remove the outer racer of the differential bearing housing; embly procedure: 1.In stall the out er racer of the differential bearing housing;...
Page 547 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Install the differential’s tapered roller bearing with KA-000-300 (bearing assembler); Install the side shaft gear and planetary gear. After installation, the central lines of two side shaft gears must be aligned. Otherwise, it impossible to install the side shaft;...
Page 548 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Install the dowel pin of planetary gear shaft; Install the differential into the housing; Install assembled transmission on the vehicle. ain back output gear ecial tool: A-000-060 bearing remover A-000-300 bearing assembler...
Page 549 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual rking mechanism Special tool: A-000-187 oil sealing remover A-000-287 oil sealing assembler isassembly proc edure: Remove automatic transmission assembly from the vehicle; Remove the oil pan from the automatic transmission; Remove the control valve plate assembly;...
Page 550 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 8. Ta ke out shift shaft, shift cam, adjusting washer and brake disk’s pintle; Pry the sunk part at the flange of the lock nut on the main back output gear to flat;...
Page 551 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 11. Take off the oil guide groove; Press out the dowel pintle the parking pawl. Take out the pawl and return spring; . Remove the shift shaft’s -ring.
Page 552 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Assembly procedure: Install the shift shaft’s O-ring. Push in the dowel pintle on the parking pawl about half of its length. Put on the return spring and parking pawl. 3. P ush the dowel pintle to its osition.
Page 553 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 4. Push in the shift shaft by half of its length. Put on the s hift shaft cam. Then push the shift shaft to s position; Install the pawl spring and fix it with a bolt: Tightening torque: 10Nm.
Page 554 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 7. Engage the shift cam with the parking cam closely. Use the special tool of KA-000-287 (locator) to fix the parking cam; Check the gap between the shift cam and house. Deduct the reading by 0.10mm to get the...
Page 555 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual . Engage the parking cam with the shift cam correctly; 12. Install the parking carrier rod; Install the plastic oil guide groove;...
Page 556 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual . Install the main back output gear and fix it with the fixing bolt. Knock the bolt’s flange into the sunk pit on the gear; . Adjust the output shaft’s gap;...
Page 557 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 5. Loosen the connecting bolt on th bottom v alve plate. Take off the bottom valve plate; Remove the bottom cover. Remove the top baffle from the middle valve plate.
Page 558 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Take out the valve ball an small tab at lower side of the middle valve plate; Turn over the middle valve plate; . Remove the control valve plate for clutch A and brake D.
Page 559 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 12. Take off the oil circuit board together with the top baffle from the middle valve plate. Turn over the oil circuit board and top baffle. Put them on the worktable.
Page 560 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Take off the throttle metal tab, lock pin and valve ball from the oil circuit board; ssembly procedure: ote: Ensure that each throttle etal tab is installed to its correct sition.
Page 561 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Install the vent valve ball, lock piece and throttle metal tab on top side of the main valve plate; Turn over the top baffle and oil circuit board together and put them on the main valve plate;...
Page 562 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Turn over the main valve plate; Install the shift valve ball and throttle metal tab on bottom side of the main valve plate; Install the bottom baffle; . Install the bottom valve cover and fix it with bolts;...
Page 563 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual . Install the bottom valve board and fix it with a bolt; tightening torque: 8Nm 12. I nstall oil feed filter screen and gasket; 13. Install oil feed filter screen and fix it with bolts;...
Page 564 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Clutch A and brake D automatic trol valve plate Disassembly procedure: Remove utomatic transmission assembly from the vehicle; Remove the control va lve plate assembly from the transmission; 3. Remove clutch A and brake D’s...
Page 565 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Take out brake D control valve spindle and spring; Take out clutch A control valve spindle and spring; Assembly procedure: 1. Install clutch A control valve spindle and spring;...
Page 566 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Brake D control valve spindle and spring; Install clutch A and brake D control valve plate’s side compression plate; tightening torque: 8Nm Install the pressure regulator and spring;...
Page 567 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 5. Install shift valve; Install clutch A and brake D control valve board on the main valve board; Install the valve plate assembly on the transmission; Install transmission assembly on the vehicle.
Page 568 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Take out 2 gear lock valve and spring; Take out the control valve and limit spring; Take out the position 3 slide valve and spring;...
Page 569 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Take out 4 downshift valve and spring; . Loosen the fixing bolt on the bottom valve plate’s inner side compression plate to take off bottom valve plate’s compression plate and gasket;...
Page 570 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Take out 1 shift valv ssembly procedure: 1. Install 1 shift valve; Install 2 –3 –4 upshift valve and spring;...
Page 571 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Bottom valve plate’s inner side compression plate and gasket. Fix them with bolts; Tightening torque: 8Nm Install 4 downshift valve and spring; 5. Install position 3 slide valve and spring;...
Page 572 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Install the control valve and limit spring; Install 2 gear lock valve and spring; 8. Install 1 –2 shift slide valve and spring;...
Page 573 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Install bottom v alve plate’s outer side compression plate and fix it with bolts; Tightening torque: 8Nm . Assemble the control valve plate assembly; . Install the valve plate assembly on the automatic transmission;...
Page 574 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 6. T ake out 2 –3 shift valv 7. T ake out the delay v alve and interior and exterior springs; Take out brake C’ brak e valve and its interior and exterior...
Page 575 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Take out clu tch E’s slide valve and its interior and exterior springs; 10. Take out main oil circuit’s pressure regulator and its interior and exterior springs; . Loosen the connecting bolt on the main valve plate’s control...
Page 576 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual . Take out 4 –3 shift slide valve and spring; . Take out 3 –4 shift slide valve and spring; . Take out 4 kickdown valve and its spring;...
Page 577 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual . Take out the pressure regulator and its spring; . Take out 1 gear and back gear lock valve and spring; Take out 1 –2 –3 shift control valve and its spring;...
Page 578 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Take out 3 –4 shift slide valve and its spring; ssembly procedure: Install 3 shift slide valve and its spring; Install 1 –2 –3 shift control valve and its spring; Install 2 –3...
Page 579 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Install 1 gear and back gear’s lock valve and its spring; Install the pressure regulator and its spring; Install 4 –3 kickdown valve and its spring...
Page 580 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 7. Install 3 shift slide valve and its spring; Install 4 –3 shift slide valve and its spring; Install the main valve plate’s control valve compression plate and fix it with bolts; The...
Page 581 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual . Install the main oil circuit’s pressure regulator interior and exterior springs; . Install clutch E’s control valve and its interior and exterior springs; . Install the brake valve on brake C’ and its interior and...
Page 582 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 13. Install the delay valve and its interior and exterior springs; . Install 2 shift valve; 15. Install 3 shift valve;...
Page 583 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual . Install shuttle valve’s compression plate and fix it with bolts: bolts’ tightening torque: 8Nm 17. Assemble valve late assembly; . Install the valve plate assembly on the transmission; . Install...
Page 584 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 3. Use the transmission fluid to lubricate piston D; 4. Install piston D; Turn over the transmission by 180 degree and face the side of driven shaft upwards; ote: Preheat the transmission ℃...
Page 585 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 9. Install the protection ring and grooved nut. Lock the grooved nut: grooved nut’s tightening to rque: 50Nm; Bend the protection ring’s square teeth and lock it on the grooved nut;...
Page 586 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Install the positioning snap ring on brake D assembly; 14. Turn over the transmission by 90 degree, as shown by the figure: Install the governor and its protection shroud; . Install the driven shaft;...
Page 587 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 17. Fix the driven shaft with the special tool of KA-000-288. . Pull the shift gear to the parking position; . Adjust the position of brake D assembly;...
Page 588 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 20. Install the clutch D’s drive drum onto the clutch’s outer racer and install the output shaft and gear ring mechanism onto the case; . Install the auxiliary back output gear and one 1.75mm thick gasket.
Page 589 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 27. Tu rn the bolt clockwise by mm. Then knock the bolt’s ange into deformed sha pes so that it sinks into the sunk pit on the gear; Tighten the auxiliary back output gear with a tightening torque of 150Nm.
Page 590 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual . Turn the gear to reset the gauge index to zero; 32. R emove th e driven shaft’s fixing device KA-000-288; . Turn adjusting bolt clockwise by 270 degree. Then turn the gear until the gauge index is calibrated.
Page 591 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual . Install planetary gear mechanism; . Install the sun gear into the planetary gear mechanism; . Install the drive drum so that the inner racer engages with the sun gear;...
Page 592 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 43. Install thrust washer, thrust bearing and thin disk washer into the drive drum; . Install the sun gear shaft: ote: Correct installation of the sun ar: The drive drum could only tate towards the sun gear at one rection.
Page 593 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 46. Put the washer and thrust bearing on top of the middle shaft; 47. I nstall the input shaft and tate it conti nuously when assembling. Engage it with clutch E case and sun gear shaft rack that are integrated with the input shaft.
Page 594 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 49. Install clutch A and clutch B assembly into the transmission; 50. Install the brake band C’; 51. Install the positioning ring on top of washer of 2 gear one-way overrun clutch;...
Page 595 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Put the adjusting washer and thrust washer onto the input shaft; . Install the oil pump assembly and fix it with bolts; The torque on the bolt connecting the middle seat with the pump body: 10N .
Page 596 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 55. Install the dial indicator and reset it to zero; . The gap should be between 0.1mm to 0.3mm. Otherwise, select the washer with different depth and adjust the gap into permissible scope;...
Page 597 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Rotate drive drum clockwise when installing the bearing; Verify the torque again: 60. Measure the distance from the bearing’s outer racer to the case plane with a depth gauge; 61. Measure with a depth gauge...
Page 598 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 62. In accordance with the measurements, install one or two washers between the differential and the odometer drive gear case. Adopt the combination of different depths in order to get the most approximate value.
Page 599 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 66. Turn over the transmis sion by 90 degree, as shown by the figure; 67. Install the control valve plate assembly to ensure that the manual valve is installed to the correct position.
Page 600 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Brief introduction of automatic transmission’s structur e and working principle Brief introduction of the automat ic transmission 4HP14 is an automatic transmission with tr ansversely-laid front drive and four gearshifts. The transmission is comprised of an oil pump, torque converter with a torque shock absorber, four gear planetary gear mechanism and control system.
Page 601 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual The engine’s motion brings along the rotation of case and impeller on the torque converter. The hydraulic fluid in the impeller dashes from the outside edge of impeller blade to the worm gear under the centrifugal force to bring along the worm gear’s rotation.
Page 602 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Control element one-way overrun clutch is comprised of an outer racer, inner racer with a roller and one-way overrun clutch between them. The one-way overrun clutch could only transfer the torque along the rotation direction and rotates freely at another direction.
Page 603 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 2. Position 1 1 gear’s power transfer route Brake D is also engaged. The planetary rack is locked by brake D. The engine’s brake is realized by its idle rotation resistance.
Page 604 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Hydraulic control system The hydraulic control system controls under following conditions: 1. The control handle’s position or main oil circuit’s pressure; 2. Accelerator pedal’s position or throttle oil pressure; 3. Vehicle speed or regulator oil pressure;...
Page 605 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual 6. Throttle pressure regulator The throttle pressure regulator is a relief valve and adjusts the oil pressure in the throttle oil circuit when the throttle valve is at different positions. Idle position The accelerator pedal is in free condition.
Page 606 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual scope of 1 gear. The lock valve also prevents the manual downshift from 2 to 1 gear when it is beyond the scope of 1 gear by controlling the pressure in brake C’s oil circuit.
Page 607 CHERY AUTOMOBILE CO., LTD Automatic Transmission Fault Diagnosis Manual Centrifugal governor The centrifugal governor is installed on and rotates along with the driven shaft. The governor is used to produce the oil pressure on the governor to provide an oil pressure varying with the vehicle speed for the control system.
Page 608 Content Part 1 Motorola Multi-port electric fuel injection motor system 1、system description…………………………………………………………1 2、operation…………………………………………………………………2 3、fuel injection system using and servicing…………………………………10 4、fuel injection system fault and repairing…………………………………12 5、ECU circuit……………………………………………………………17 6、engine circuit………………………………………………………………18 7、electric injection theory diagram……………………………………………19 8、ECU pin definition…………………………………………………………21 Part 2 M&M Multi-port electric injection engine systems 1、system description…………………………………………………………23 2、operation……………………………………………………………………23 3、fuel injection system control strategy………………………………………24...
Page 609 Preface MOT and M&M multi-port motors are applied in CHERY cars, and the detailed matching and establishment rules are as follows Electric Motor model Gear Ex factory No. injection type type “SQR480EB*EB×× SQR480EB ×××××” “SQR480EC*EC×× SQR480EC ×××××” “SQR480ED*ED×× M&M SQR480ED ×××××”...
Page 610 1 Motorola Multi-port electric injection motor system FOREWARD Either MOT or M & M multi-port fuel injection system is installed on Chery sedan with following differences: Engine Transmission Factory Number SQR480EB*EB××××××× 480EB SQR480EC*EC××××××× 480EC M&M SQR480ED*ED××××××× 480ED Note: MOT and M & M are two different systems, and understand which...
Page 611 Part MOT multi-port electric fuel injection engine system...
Page 612 SQR480EC electric fuel injection system System description Electric fuel injection system is a complete functions system and mainly consists of fuel system, air system and electric control system. It also includes ignition control and exhaust control functions etc. Fuel system Fuel passes through fuel tank built-in oil pump to fuel filter, and is pressed to oil rail after filtering, then sprayed into cylinder via fuel injector, and then returns to fuel tank through fuel pressure adjuster, which can maintain constant fuel pressure.
Page 613 II. Operation SQR480EC electric fuel injection system controls ignition, fuel injection, idle ect. upon engine speed signal, air intake pressure, throttle position signal, air temperature signal, oxygen sensor signal and coolant temperature signal. The system utilize an advanced control strategy, and selected components and a complete set of strict production process, and is an electric fuel injection system featuring intelligence and stability, meets the strict technological demands of car manufacturer with the exhaust meeting the Euro II standard.
Page 614 ●Measuring Method a ohmmeter method Measure resistance with an ohmmeter, and determine if water temperature sensor operates upon measured engine coolant temperature and below diagram. Remove coolant temperature sensor, immerse into water and heat water. The sensor has different resistance at corresponding temperature.
Page 615 When temperature is 800℃, impedance 25.0+/-10% When temperature is -40℃, heater 12.2+/-10% impedance is...
Page 616 ●Detecting Method: a、voltage signal method Before testing oxygen sensor, engine must be under normal operation temperature. 【Note】Only digital voltmeter can be used to test oxygen sensor, otherwise oxygen sensor will be damaged. ● During testing, the insulation may be pricked. Before testing, digital voltmeter leads must be connected to oxygen sensor ground lead and signal lead.
Page 617 ⑷ signal corresponding to 2 mis-teeth. Speed sensor determines firing and fuel injection time by monitoring the teeth on the flying wheel, engine speed and crankshaft position signal. ● Testing method a ohmmeter method: the coil resistance is 515Ω, b oscilloscope method: Use oscilloscope to monitor pulse waveform, and a voltage pulse will generate when a tooth pass by.
Page 618 Remove TPS connector. Depress throttle slowly and monitor resistance. Measuring resistance at wide open throttle (WOT), resistance is 5KΩ±20% at WOT. Verify resistance change smoothly when throttle closed.
Page 619 b voltmeter method: Remove sensor connector, turn ignition on, measure 5V reference voltage at sensor connection. Connect a voltmeter between Pin B22 and ground. If 5V reference voltage is not sufficient, check ECU voltage at this wire. If ECU voltage is normal but not sufficient at sensor, repair 5V reference voltage wire.
Page 620 2.2.4 Fuel pump Fuel is pumped to fuel hose by fuel pump and then supplied to fuel injector. Fuel pressure in fuel pipe is maintained at 3.942±0.049Bar. Testing Method Listening： Once ignition is turned to ON position and engine still off, fuel pump running sound can be heard for 1 second and then stops.
Page 621 Electronic Specification ITEM CONDITION IDEL GOAL Coil resistance Temp: 27 48±2.4Ω Coil induction 1kHz sine wave input 38±6mH Steps ●Testing method a Ohmmeter Method Remove step motor connector, measure resistance between 1A~1B and 2A~2B. Remove ECU connector, measure resistance between A71~A8 and A5~A6. b Hand Sensing Method When ignition switch is turned on, short-time vibration should be felt.
Page 622 3820.2 3537.5 4102.9 2509.3 2346.2 2672.4 2051.3 1928.2 2174.4 1686.0 1584.9 1787.1 1157.1 1088.8 1225.4 810.0 763.0 857.0 577.6 548.7 606.5 419.1 395.6 442.6 309.0 292.0 326.0 231.4 218.7 244.1 175.7 166.2 185.2 135.2 127.0 143.3 105.4 98.6 112.2 83.1 77.3 88.9 ●Testing method:...
Page 623 3.1 fuel and purge system using and servicing 3.1.1 Fuel grade used in Chery engine must be higher than 93#RON, and leaded gasoline or fuel grade lower than 93#RON CAN NOT be used. Leaded oil could do harm to the 3-way catalyst, resulting in the loss of oxidization and reduction function to harmful materials in exhaust.
Page 624 3.1.7 After cool starting, the engine is in fast idle. With water temperature increasing, engine speed decrease. After engine warming up (water temperature above 85 ℃), engine speed stabilize at 950±50r/min. 3.1.8 Wrap pipe connector with plastic cloth when servicing fuel pipe, preventing fuel splash.
Page 625 III. SQR480EC EI system faults and trouble shooting 4.1 CAN NOT START ENGINE Check ignition system Power check 1 battery problem 2 fuse voltage check Check ignition switch 3 check starter relay 4 check starter 5check connecting harness Repair replace defective components Check...
Page 626 4.2 Hard to start Check fault Determine fault source upon fault codes codes Check if air intake system 1 Hose connection vacuum leakage or intake 2 throttle valve body air intake valve dirt valve 3 PCV hose check if ignition system fault Remove fuel injector...
Page 627 4.3 Rough Idle Check fault code determine fault source upon fault code 1 Hose connection Check air intake system 2 throttle valve body air intake vacuum leakage, air intake valve valve dirt 3 intake manifold mounting Check air filter core Wash or replace Check ignition system fault 1 check if wire power leakage...
Page 628 Check fuel injector Check fuel injector, injector dirt, and repair or replace as necessary. Check coolant temperature Check coolant temperature sensor and connector, repair or sensor replace as necessary Check intake Check intake air temperature temperature pressure pressure sensor sensor Check oxygen sensor Check oxygen...
Page 629 Check fuel Check pressure regulator, pressure and fuel pressurea, repair or replace as necessary. Check fuel fuel injector, repair or injector replace as necessary. 4.5 Low idle speed If engine idle speed is low referring to each actuator and sensor mentioned above, check following components: Engine coolant temperature sensor fault: check engine coolant temperature sensor and wire, repair or replace as necessary.
Page 630 4.6 engines often stalls Check step motor fault 1 repair or replace step motor 1 check mount screw 2 check step motor wire 2 short time vibration 3 replace or turn idle motor should be felt when mount screw ignition switch turned Check throttle position Throttle position sensor and its sensor...
Page 631 Ignition system fault check Fuel circuit pressure, fuel injector, and fuel pump check Engine compression pressure check...
Page 632 Multi-port fuel injection -ECU wiring harness...
Page 633 Engine Theory Diagram...
Page 634 Brake light Brak Electric control gear heoryt diagram Igniti Ignition Powe Ignition Fuse Power Battery Negative Ignition Sensor Shiel Rotational Rotationa High/low Compress Oxygen Throttle Throttle Absolute intake Water Water Igni Igni Ignit fuel fuel injector 1 fuel fuel injector 2 fuel injector fuel injector 3 fuel...
Page 635 Groun Rotational speed signal tachomet vehicle speed signal input Cooling fan relay Cool ing fan relay Cooling fan relay 2 Cooling fan relay 2 Knock input High Compression knock sensor diagnose input ·This diagram is used for SQR480EB and SQR480EC engine ·The italic parts means functions under development.
Page 636 Socket A ECU Pin Function Input/Output (I/O) Cylinder 3fuel Injector Output Control not used not used not used not used not used not used Step Motor-2A Output Step Motor -2B Output Step Motor -1B Output Step Motor -1A Output Cylinder 1 fuel Injector Output Control Cylinder2 fuel...
Page 637 ECU Pin Function Input/Output (I/O) Oxygen Sensor Input not used not used not used not used P/N gear Signal Input P gear Signal Input Rotational Speed Sensor Input Rotational Speed Sensor Input Vehicle Speed Input Fuel Pump Output Water Temperature Input Sensor Signal A/C Demand Signal...
Page 638 Part II M&M MULTI-PORT ELECTRIC INJECTION ENGINE SYSTEM...
Page 639 Operation And Maintenance Instruction For SQE480ED Engine Sequential Multi-port Fuel Injection System 1. Description SQR480Ed electric injection utilize M&M sequential multi-port fuel injection system which is of λSpeed Density Type ( engine speed, air density, air/fuel mixture control) and can control sequential fuel injection and distributor less ignition. The system consists of 4 essential parts.
Page 640 correct air/fuel ratio by controling injected fuel quantity. Fuel is directly sprayed into intake manifold beside the intake valve under pressure of 3.5bar. The fuel injector of each cylinder takes correspondingly phase control upon sequence of air intake and open time of intake valve. Injection terminal is stored in ECU MAP Diagram and will change with engine speed and intake manifold pressure.
Page 641 strategy works. When throttle is not closed and warm engine speed is less than 1400rpm, it will recover fuel supply. 6. Full load When engine is under full load, ECU will prolong basic injection time to obtain the maximum output power and guarantee 3 way catalyst converter temperature is within specification.
Page 642 Pressure regulator Fig.2 Supply System 1. fuel pipe 2. fuel return pipe 3.fuel tank 4.fuel filter 5.fuel pump 6.fuel injector 7. (1) Fuel pump Fuel pump is located in the fuel tank with a mesh filter on pump inlet. The rotor is driven by motor whose power is supplied by relay.
Page 643 direction, loosen fuel pipe. * Hold seat collar firmly, pull fuel pipe off as arrow direction. (5) Fuel rail Fuel rail is used for distributing fuel into fuel injector and fixing fuel injector. (6) Fuel injector This system uses top fuel supply single hole fuel injector. Fuel injection pressure is 3.5bar， output fuel is continuously atomized and in cone angle (15°angle from fuel injector axes )。...
Page 644 (1) Throttle valve body Throttle valve body calculate air intake volume upon throttle pedal depressing status. Auxiliary air intake volume is regulated by step motor when engine idles. To avoid condensation and freezing under some conditions, throttle valve regulator bar is against anti-stuck screw preventing throttle from full closed.
Page 645 3. Control system (1) ECU ECU is located in the cabin of engine, connected to wiring harness via 80-pin interface. ECU is used for handling signals from various sensors and controlling actuators to obtain optimum operating conditions.. Comparing to the previous mode, it has added many functions. But due to using of many customized circuits of special functions, it has powerful integration, compact structure, and small size.
Page 646 load and accelerating/decelerating operating conditions, and carry out fuel injection volume control corresponding with throttle opening. Throttle position sensor includes a potentiometer, and the moving parts is operated by throttle shaft. During operation, ECU supply 5V voltage to sensor and measured parameter is variable of throttle opening from minimum to maximum.
Page 647 Oxygen sensor is used for detecting the content of oxygen in exhaust, which is a major component for ensuring actual air/fuel ratio of engine to approaching theoretical air/fuel ratio. Oxygen sensor is mounted on the exhaust front pipe, before 3-way catalyst converter. Oxygen sensor mainly consists of a ceramics shell made of zirconium oxidize，...
Page 648 Voltage Rich Lean excessive air coefficient Fig 9 Oxygen Sensor and Performance Character Chart ceramics body 2. Protecting tube 3.outer metal shell of sensor 4. heating resistor a. signal positive(+) , exposed to air b. signal negative(-) exposed to exhaust gas Oxygen sensor operation theory: when temperature is over 300℃，zirconia can separate ox ion from of oxygen in the exhaust gas passing through oxygen sensor.
Page 649 4. Ignition system Ignition system is a grouped electronic control ignition system (1—4 cylinders in one group, 2—3 cylinders in the other group). The ignition system is integrated with fuel injection system, which is an electronic system with a built-in power supply module, and canprovide with all kinds of optimal ignition value Upon input instaneous physical parameters related with engine operating condition, all kinds of optimal ignition values can be wrote into program via a managing circuit.
Page 650 advanced identification and correction strategy such as enrich air/fuel mixture shall be adapted to reduce ignition advance angle. Operational theory: Knock sensor consist of piezoelectric non-resonant quartz and converts electric signal into mechanical energy in form vibrations. The sensor is connected to engine ECU through a shielded wire.
Page 651 coolant temperature reaches specified value (about 65℃). When engine warming up, ECU will send a square wave signal to carbon canister. Carbon canister on and off is regulated by cycle ratio of signal itself. Therefore ECU may control fuel vapor quantity input to intake manifold, preventing mixture richness making an abrupt change.
Page 652 When throttle is at idle position, engine speed less than 1500 rpm, intake manifold pressure lower than a preset value and air/fuel mixture richness self-adapt, carbon canister solenoid keep closed to ensure an more optimum engine performance. (3) Fuel tank ventilation safety valve it has the following functionsThe valve is installed on filter cover and has following functions upon pressure inside fuel tank: 1.
Page 653 structure of anti-theft ECU is as shown in fig 14.
Page 654 Fig 14 Anti-theft ECU Anti-theft ECU pin definition 8-pin connector 3-pin connector Antenna Not used positive warning indicator not used Antenna +30(12V) negative ground Not used to ECU serial surface Not used +15 (ignition switch positive) Warning indicator Warning indicator on instruments panel is controlled by anti-theft ECU, indicating user state information.
Page 655 start. During engine starting, if throttle is at wide open position, injected fuel will reduce a lot, which providing a method of cleaning fuel from fuel spilling engine and need not remove and wash spark plug. It may take a long time to start engine during first starting (new car or after repairing fuel system) because fuel pipe need to be charged with appropriate fuel pressure.
Page 656 perform unwarranted repairing. When ignition is on, DO NOT remove any electrical devices to avoid electric components being damaged by inductive electromotive force generated in circuit. 6. Electric fuel injection system faults and repairing 1. Basic knowledge for electric control fuel injection system repairing The electric control fuel injection system is a complicated system.
Page 657 Problem causes Actions check if fuel injector operating condition Fuel injector fault normal using scan tester. Using feeler gauge, check clearance Crankshaft speed and position sensor crankshaft speed and position sensor head fault and signal wheel tooth top. Check sensor circuit.
Page 658 (3) Unstable idle speed Problem Causes Actions Air leakage Fasten throttle valve body mounting screw. Failed idle control valve Repair or replace the throttle valve body Failed throttle position Check throttle opening. Check if throttle position sensor sensor operating parameter within specification. throttle Check if throttle cable installed correctly.
Page 659 Wiring diagram...
Page 660 Key words 1.ECU anti-theft device 13.coolant temperature sensor 2.knock sensor 14.coolant temperature meter 3.ignition coil 15.coolant overheat indicator 4. fuel pump 16.idle step motor 5.fuel injector 17.Top Dead Center/speed sensor 6.oxygen sensor 18.A/C 7.carbon canister solenoid 19.Fan relay (first stage speed) 8.ignition switch 20.Fan relay(second stage speed) 9.System failure warning indicator...
Page 661 Appendix 2：Electrical Components Specification Part ： Electrical Internal expanded view Specification： fuel injector Code：IWP116 Fuel injector shape, single hole Operating temperature：-30℃～+110℃ Nominal resistance： 13.8～15.2Ω10%(at 20℃) Connector voltage：12V fuel injection pressure：3.5bar Part ： Throttle Internal expanded view Specification： valve position Effective electric power angle：90°±2 sensor Mechanical angle：105°±4°...
Page 662 A11-2002 CIRCUIT MANUAL ET VEHICLE CIRCUIT MANUAL （2002 VERSION） Note: The differences between ET VEHICLE CIRCUIT MANUAL and previous part are in pages No. 1, 2, 14, 15 and an added page No.23 Automatic Transmission Gear. PDF 文件使用 "pdfFactory Pro" 试用版本创建 www.fineprint.com.cn...
Page 663 A11-2002 CIRCUIT MANUAL CONTENT ························ ——Battery, Alternator, Automatic Transmission Start System, Ignition Switch, Back Light ——MPI Electronic Injection (EJ) (MOTOROLA) ························································································ ································································································ ——A/C Unit, Control Head, Cooling System ——A/C Switch, Interior Circulate Solenoid, High & Low Pressure Switch·················································· · ——Oil Pressure Switch, Coolant Temperature Sensor, Manual Brake Indicator Switch, Odometer Sensor ·······························································································································...
Page 664 A11-2002 CIRCUIT MANUAL BATTERY，ALTERNATOR，A/T START SYSTEM，IGNITION SWITCH，BACK LIGHT B=White N=Black R=Red M=Brown V=Green A=Blue H=Grey Z=Purple G=Yellow A Battery T2 Back Light Switch B Starter Motor M1 Left Back Light C Alternator M2 Right Back Light C1 Voltage Regulator (1) Ground, on ground carrier beside central electrical box D Ignition Switch (2) Body ground, near battery J207 A/T Start Relay...
Page 665: Mpi Electronic Injection (Ej)(Motorola)
A11-2002 CIRCUIT MANUAL MPI ELECTRONIC INJECTION (EJ)(Motorola) B=White N=Black R=Red M=Brown V=Green A=Blue H=Grey Z=Purple G=Yellow J=Orange F=Pink J Power Relay P35 ECU Fuse P36 Power Fuse M Idle Step Motor KS Knock Sensor TW Crankshaft Position Sensor IC Ignition Coil Q Spark Plug IJ 1-4 Fuel Injector QS Oxygen Sensor...
Page 666 A11-2002 CIRCUIT MANUAL PDF 文件使用 "pdfFactory Pro" 试用版本创建 www.fineprint.com.cn...
Page 667: A/C Unit, Control Head, Cooling System
A11-2002 CIRCUIT MANUAL A/C UNIT, CONTROL HEAD, COOLING SYSTEM B=White N=Black R=Red M=Brown V=Green A=Blue H=Grey Z=Purple Y=Yellow A+ battery positive J69 Cooling fan high-speed relay E9 blower switch J70 Cooling fan low speed relay F18 thermo switch J5 A/C blower relay (in electrical box) N23 blower in-line speed J6 Rear Window preheat relay Regulator resistance...
Page 668 A11-2002 CIRCUIT MANUAL A/C UNIT SWITCH, INTERIOR CIRCULATION SOLENOID, HIGH & LOW PRESSURE SWITCH B=White N=Black R=Red M=Brown V=Green A=Blue H=Grey Z=Purple G=Yellow E35 A/C unit switch F23 High pressure switch E36 Interior circulation switch F73 Low pressure switch K84 A/C operating illumination light (7)(8) Main circuit ground N63 Interior circulation solenoid TK 5 holes connector...
Page 669 A11-2002 CIRCUIT MANUAL OIL PRESSURE SWITCH, COOLANT TEMPERATURE SENSOR, MANUAL BRAKE INDICATOR SWITCH, ODOMETER SENSOR B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW G2 Coolant temperature gauge sensor (9) ground, on engine cylinder F22 Oil pressure switch (low pressure) (10) ground connection, in headlight wiring harness F9 Manual brake indicator switch TQ1 10 holes connector...
Page 670: Radio And 6 Speakers
A11-2002 CIRCUIT MANUAL RADIO AND 6 SPEAKERS B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW radio R1 antenna R2 front left speaker T8 8 holes connector R3 front right speaker T1 single hole connector R4 right rear speaker R5 left rear speaker R6 left front speaker R7 right front speaker PDF 文件使用...
Page 671: Instrument Panel (Ip) And Mfa
A11-2002 CIRCUIT MANUAL INSTRUMENT PANEL (I/P) AND MFA B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW F10 multi way converter J119 multi function display K6 engine self-check indicator F15 voltage stabilizer K1 ABS warning indicator K7 oil pressure warning light G20 fuel sensor K2 left turn indicator K8 engine overheat warning light...
Page 672 A11-2002 CIRCUIT MANUAL FRONT FOG LIGHT, CIGAR LIGHTER, A/C PANEL INDICATOR B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW L16 A/C Control Panel Indicator L28 Cigar Lighter Illumination Light L22 Left Front Fog Light Cigar Lighter （11）Ground, In headlight wiring harness L23 Right Front Fog Light F66 Coolant Level Switch PDF 文件使用...
Page 673: Rear Window Heating System, Dual Tone Horn, Compressor Magnetic
A11-2002 CIRCUIT MANUAL REAR WINDOW HEATING SYSTEM, DUAL TONE HORN, A/C COMPRESSOR MAGENETIC CLUTCH B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW J1 Idle Up Relay (in electrical box) J3 dual tone Horn J39 Rear Window Heating Switch Illumination Light K10 Rear Window Heating Indicator E15 Rear Window Heater Switch H1(2) dual tone Horn...
Page 674: Wiper, Horn Button, Washer
A11-2002 CIRCUIT MANUAL WIPER, HORN BUTTON, WASHER B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW E22 wiper switch horn button J31 intermittent wiper relay fuse 15A wiper motor V5 washer PDF 文件使用 "pdfFactory Pro" 试用版本创建 www.fineprint.com.cn...
Page 675: Headlight, Front Position Light, Light Relay
A11-2002 CIRCUIT MANUAL HEADLIGHT, FRONT POSITION LIGHT, LIGHT RELAY B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW A+ Battery Positive J55 Light Relay L1 Left High Beam Headlight S27 Right High Beam Headlight Fuse 10A L2 Left Low Beam Headlight S28 Left Low Beam Headlight Fuse 10A L3 Right Low Beam Headlight S29 Left Position Light Fuse 10A...
Page 676: Turn Light, Parking Light Switch, Emergency Warning
A11-2002 CIRCUIT MANUAL TURN LIGHT, PARKING LIGHT SWITCH, EMERGENCY WARNING RELAY B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW E2 Turn Light Switch E3 Emergency Warning Light Switch E4 Dimmer and Turn Light Switch E19 Parking Light Switch J2 Emergency Warning Light Relay K6 Emergency Warning Light S17 Fuse 10A PDF 文件使用...
Page 677: Taillight, Side Light, Brake
A11-2002 CIRCUIT MANUAL TAILLIGHT, SIDELIGHT, BRAKELIGHT B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW F18 brake light switch M9 left brake light T3 3 holes connector L15 left taillight M10 right brake light T1 single hole connector L20 right taillight M501 right side turn light (14) Ground in rear light M2 rear right position light...
Page 678: Light Switch, Gear Position Illumination Light
A11-2002 CIRCUIT MANUAL LIGHT SWITCH, GEAR POSITION ILLUMINATION LIGHT B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW E1 Light Switch E20 Panel indicator / instruments illumination light variable resistance L9 Panel illumination light M Gear spotlight S3 Fuse 10A PDF 文件使用...
Page 679: Rear Fog Lamp
A11-2002 CIRCUIT MANUAL REAR FOG LAMP B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW E23 Front Fog Lamp Switch T3 3 Holes Connector J4 Fog Lamp Relay (in electrical box) T3a 3 Holes Connector K17 Rear Fog Lamp Indicator T2 2 Holes Connector L1 Rear Fog Lamp T1 Single Hole Connector...
Page 680: Adjustment
A11-2002 CIRCUIT MANUAL HEADLIGHT ADJUSTMENT Light Adjust Illumination Light B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW E102 Headlight Height Adjustment Switch (16) Ground, Located Beside Central Electrical Box L54 Light Adjustment Illumination Light (15) Ground, at headlight V48 Left Front Headlight Adjustment Motor T1 Single Hole Connector V49 Right Front Headlight Adjustment Motor PDF 文件使用...
Page 681: Lamp, Door Touch Switch
A11-2002 CIRCUIT MANUAL INTERIOR FRONT AND REAR LIGHT, LUGGAGE COMPARTMENT LIGHT, SUN VISOR LIGHT, LICENSE PLATE LAMP, DOOR TOUCH SWITCH B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW F2 Left Front Door Touch Switch TAa 2 Holes Connector, on left side of luggage compartment F3 Right Front Door Touch Switch W1 Interior Rear Ceiling Lamp F5 Luggage Compartment Illumination Light Switch...
Page 682: Central Locking
A11-2002 CIRCUIT MANUAL CENTRAL LOCKING B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW C Central Locking Control Unit ( in left front door) TB2 4 Holes Connector (right B pillar side) V28 Right Front Door Lock Control Motor TK1 12 Holes Connector (left A pillar Side) V29 Left Rear Door Lock Control Motor TK2 12 Holes Connector (right A pillar Side) V30 Right Rear Door Lock Control Motor...
Page 683: Mirror
A11-2002 CIRCUIT MANUAL POWER MIRROR B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREN Z=PURPLE G=YELLOW F77 Mirror Switch Z4 Left Mirror Defogger X1 Left Adjust Z5 Right Mirror Defogger X2 Right Adjust TK1 12 Holes Connector (left A pillar side ) Y1 Up Adjust TK2 12 Holes Connector (right A pillar side) Y2 Down Adjust...
Page 684: Abs
A11-2002 CIRCUIT MANUAL B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW J104 ABS Controller G47 Left Front Wheel RPM Sensor Battery S33 ABS Solenoid Valve Power Fuse ABS Solenoid S34 ABS Hydraulic Pump Power Fuse ABS Hydraulic Pump TK Diagnosis Connector Right Rear Wheel RPM Sensor (18) Ground point, at ground carrier on central electrical box Right Front Wheel RPM Sensor...
Page 685: Power Window Glass Lifter Control Unit
A11-2002 CIRCUIT MANUAL POWER GLASS LIFTER CONTROL UNIT B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW Window Glass Lifter Module (19) Beside Central Electrical Box Left Front Window Lifter Switch 12 Holes Connector (Left B Pillar Side) Right Front Window Lifter Switch 12 Holes Connector (Right B Pillar Side) Left Front Window Lifter Motor Right Front Window Lifter Motor...
Page 686: Power Window Glass Lifter Control Switch
A11-2002 CIRCUIT MANUAL POWER GLASS LIFTER CONTROL SWITCH B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW Rear Window Glass Lifter Lock –Out Switch Left Rear Window Glass Lifter Motor Left Rear Dorr Upper Window Lifter Switch Right Rear Window Glass Lifter Motor Right Rear Dorr Upper Window Lifter Switch 4 Holes Connector Glass (Left B Pillar Side) Left Rear Window Glass Lifter Switch...
Page 687: Automatic Transmission (A/T) Gear
A11-2002 CIRCUIT MANUAL AUTOMATIC TRANSMISSION GEAR B=WHITE N=BLACK R=RED M=BROWN V=GREEN A=BLUE H=GREY Z=PURPLE G=YELLOW K Gear Selector Switch H Gear Selector Box PDF 文件使用 "pdfFactory Pro" 试用版本创建 www.fineprint.com.cn...
Page 688 SQR 7160 series sedan utilizes the worldwide latest generation MK20-I/E model ABS (Anti-Block System). Among China’s similar class sedans, Chery sedan is the earliest one that utilizes MK20-I/E ABS system and the sole one in China who take ABS system as standard equipment. ABS system has following main characteristics: * 4 channel composite structure in design;...
Page 689 Chery SQR7160 series sedan ABS system－fault diagnostic and repairing CONTENT 1. Fault Diagnostic Flow Chart ········································································································································ 2. Fault Diagnostic Precaution ········································································································································· 3. Scan Tool Operating Method and Function Introduction ······························································································ 3.1Operating Method ··············································································································································· 3.2 Brief Introduction On Function Code ·················································································································...
Page 690 16.1 Dry HCU…………………………………………………………………………...(29) 16.2 Oil Carried HECU………………………………………………………………….(29) Attachment I ABS FAQ………………………………………………………………… (31) Attachment II Precautions on using ABS (32) ································································································...
Page 691 Chery SQR7160 series sedan ABS system－fault diagnostic and repairing nostic Chart...
Page 692: Fault Diagnostic Flow Chart
Chery SQR7160 series sedan ABS system－fault diagnostic and repairing 1. Faut Diagnostic Flow Chart Beginning Ignition off, connect scan tool. Turn ignition to ON position Enter 03 (electronic brake) at ADDRESS Is there communication? go to FAULT W/O CODEDIAGNOSTIC CHART...
Page 693: Fault Diagnostic Precaution
Chery SQR7160 series sedan ABS system－fault diagnostic and repairing 2. Fault Diagnostic Precaution ABS is an electronic hydraulic controlled system and below condition is normal when ABS is under normal operating condition. Condition Explanation After engine on, bumping similar sound may occurs from System self-check sound engine compartment sometime.
Page 694: Scan Tool Operating Method And Function Introduction
Chery SQR7160 series sedan ABS system－fault diagnostic and repairing 3. Scan Tool, Operating Method and Function Introduction 3.1 Operating Method * Ignition off, connect scan tool to diagnostic connector, then turn ignition on. * Enter 03, then press Q key，ABS will be in operation condition.
Page 695 Chery SQR7160 series sedan ABS system－fault diagnostic and repairing 4. Intermittent Fault Repair Precaution In electronic controlled system, instantaneous contact problem at circuit or signal input & output area may occur, causing intermittment fault or fault code set during ECU self-check. If symptom continuously exists, determine defective part referring to FAULT W/CODE DIAGNOSTIC CHART.
Page 696: Checking Abs Warning Light
Chery SQR7160 series sedan ABS system－fault diagnostic and repairing 5. MK20-I/E SYSTEM 5.1 Checking ABS warning light Check if ABS warning light is as following: Ⅰ.When ignition turned ON, ABS goes on for about 1.7 senconds，then goes off。 Ⅱ. If ABS warning light is not as specified, a problem is indicated and the fault code must be retrived.
Page 697 Chery SQR7160 series sedan ABS system－fault diagnostic and repairing 6. Hydraulic Controlled Unit Diagnostic 6.1 Hydraulic controlled unit can be diagnosed using scan tool. Follow below procedures after entering 03. Resullt Under Normal Step Action Taken Data Displayed Condition Hydraulish ABS Pumpe V64...
Page 698: Quick Fault Repairing Index
Chery SQR7160 series sedan ABS system－fault diagnostic and repairing 7. Quick Fault Repairing Index 7.1 Fault w/code check chart index Code Fault description Diagnosing object Check chart No. Page No. 65535 Electronic controlled unit Defective P.29 01276 ABS Hydraulic pump Inoperative motor P.12...
Page 699: Abs Ecu Socket
Chery SQR7160 series sedan ABS system－fault diagnostic and repairing 8. ABS ECU SOCKET...
Page 700: Electric Circuit
Chery SQR7160 series sedan ABS system－fault diagnostic and repairing 9. ELECTRICAL CIRCUIT MK20-I/EABS，EDS And ASR Electrical Circuit Valve coil(EDS) Only for ABS Pin 8,9,21,25:4.8mm width Other pins:1.5mm width...
Page 701: Fault With Code Diagnostic Chart
Chery SQR7160 series sedan ABS system－fault diagnostic and repairing 10. FAULT W/CODE DIAGNOSTIC CHART Code 01276 Possible causes ［Note］After vehicle speed is over 20 KM/H, code will be set when ABS ● short to power or ground ● loose engine wiring hareness ECU detect motor operate incorrectly.
Page 702 Chery SQR7160 series sedan ABS system－fault diagnostic and repairing Code 00283，00285，00290，00287 Possible causes ● Sensor not installed ● Short in sensor coil or harness ［Note］ When no open circuit detected, code will be set if no signal output short. after vehicle over 20km/h.
Page 703 Chery SQR7160 series sedan ABS system－fault diagnostic and repairing Code 00283，00285，00290，00287 Possible causes ● sensor coil harness intermittent ［Note］When vehicle speed is over 20km/h，code will be set if sensor signal poor contact or short. ●big or small air gap between sensor is not within the gap specification.
Page 704 Chery SQR7160 series sedan ABS system－fault diagnostic and repairing Code 00283，00285，00290，00287 Possible causes ●Sensor connector or coil open ［Note］Code will be set when sensor has recognizable open or short ●Sensor coil short ●Sensor connector or harness short problem. ［Method］ Poor sensor connection, coil or wiring harness short, defective to ground or power ●Defective ABS ECU sensor signal...
Page 705 Chery SQR7160 series sedan ABS system－fault diagnostic and repairing Code 01044 Possible causes ［Note］ When ECU software programming code is not consistent with ABS ●Pin connection error in ABS harness. ●ABS ECU programming error. harness pin, code will be set.
Page 706 Chery SQR7160 series sedan ABS system－fault diagnostic and repairing Code 00668 Possible causes ● Blown ABS system fuse ● High or low battery voltage ［Note］ ● defective ABS electrical harness When no voltage or high voltage at terminal 30, code is set。...
Page 707 Chery SQR7160 series sedan ABS system－fault diagnostic and repairing Code 01130 Possible causes ● high frequency electromagnetic ［Note］When ABS is interrupted by high frequency electromagnetic wave wave interference or micro prcrosser recognized an incrorrect input speed signal, code is set.
Page 708: Fault Without Code Diagnostic Chart
Chery SQR7160 series sedan ABS system－fault diagnostic and repairing 11. FAULT W/O CODE DIAGNOSTIC CHART Ignition On (Engine off), ABS warning light is not on Possible causes ● blown fuse ［Note］ ● burned ABS warning light blub ● open voltage circuit ABS warning light not on maybe caused by open warning light voltage ●damaged ABS warning light control...
Page 709 Chery SQR7160 series sedan ABS system－fault diagnostic and repairing Engine, ABS warning light does not go off Possible causes ［Note］ ●defective warning light control unit ●open ABS warning light control unit. Possible causes: ● defective ABS ECU. defective ABS warning light control unit or open ABS warning light ciucuit.
Page 710 Chery SQR7160 series sedan ABS system－fault diagnostic and repairing Abnormal ABS Opearation Possible Causes: ●Sensor not correctly installed ●Sensor wiring harness has problem ●damaged sensor ●damaged gear ring ［Note］This problem has a close relation with driving and road surface ●foreign material on sensor ●damaged wheel bearing...
Page 711 Chery SQR7160 series sedan ABS system－fault diagnostic and repairing Sensor installed correctly? Reinstall sensor. Not normal Not normal Check sensor output voltage Check each sensor Replace Normal Normal Not normal Replace Check each sensor gear ring Perform HCU DIAGNOSTIC using scan tool...
Page 712 Chery SQR7160 series sedan ABS system－fault diagnostic and repairing Long Brake Pedal Travel Possible Causes ●brake fluid leakage ［Note］Visually inspect if there is an external leakage or mechanical ●normally closed valve leakage problem. Check if there is air in system by bleeding method. Check if ●there is air in system...
Page 713 Chery SQR7160 series sedan ABS system－fault diagnostic and repairing Depressing Brake Pedel Need Strong Force Possible Causes ［Note］ Check booster and brake pedal travel using conventional methods. ●booster problem Normally open valve problem can be checked by hydraulic unit diagnostic ●normally open valve problem...
Page 714 Chery SQR7160 series sedan ABS system－fault diagnostic and repairing No Diagnostic Code Output (No communication with scan tool) Possible Causes ● blown fuse ●broken diagnostic cable and loose ［［Note］When no communication with scan tool, it may be caused by open connector ABS ECU power and diagnostic circuit.
Page 715: Abs System Check
＞12.2 LR Wheel Speed Sensor Output Voltage mV/Hz ＞12.2 RR Wheel Speed Sensor Output Voltag 22-23 mV/Hz High Peak Voltage ≦2 Sensor Output Voltage Ratio Low Peak Voltage 0.0-1.0 Example：12-14(Chery) SQR7160 Ω Model Identification For more, see ABS electrical Circuit.
Page 716 Chery SQR7160 series sedan ABS system－fault diagnostic and repairing Check item Key Igition Position Action Standard Memo Note: Vacuum must be applied to vacuum booster when performing follwing checks. When LF wheel can not Depress Normally closed spin, pedal does not...
Page 717: Abs Operation Check
Chery SQR7160 series sedan ABS system－fault diagnostic and repairing 13.ABS Operating Check 13.1 Checking wheel speed sensor output voltage 1. Check if air gap between wheel speed sensor and gear ring is within specification. Front wheel gap specification：see front wheel speed sensor installing illustration.
Page 718: Removing And Installing
Chery SQR7160 series sedan ABS system－fault diagnostic and repairing 14. REMOVING AND INSTALLING 14.1 Spare parts supply method * HECU (DRY) * HCU and ECU disassembly (OIL CARRIED HCU) 14.2 Removing and Installing Precaution * Before repairing, locate problem source using scan tool.
Page 719: Replacing Ecu
Chery SQR7160 series sedan ABS system－fault diagnostic and repairing * Remove and mark brake fluid pipe (1-4 ) to each wheel cylinder. Plug ports immediately. * Remove screw cap holding HECU on the carrier. * Remove HECU assembly from ca rrier.
Page 720: Ecu Programming
Chery SQR7160 series sedan ABS system－fault diagnostic and repairing and 15+3Nm(M12×１). * Fill new brake fluid to fluid reservoir until fluid level reaches MAX, and bleeding as specified method. * Turn ignition to ON position, ABS warning light should go on 1.7 second and then off.
Page 721 Chery SQR7160 series sedan ABS system－fault diagnostic and repairing 16. Filling brake fluid and bleeding 16.1 Oil Carried HCU If spare part is an oile carried HCU, after replacing, fill and bleed HCU using conventional brake system methods. 16.2 Dry HECU If spare HECU is a dry one, after replacing, HECU second circuit must be bleeded after filling and bleeding as per conventional brake system.
Page 722 Chery SQR7160 series sedan ABS system－fault diagnostic and repairing From previous page. Depress brake pedal and keep depressed, hydraulic pump operates and pedal kick back. Loosen brake pedal, and loosen left and right front brake caliper bleed screw, press key.
Page 723 Chery SQR7160 series sedan ABS system－fault diagnostic and repairing Attachment I ABS FAQ ●What is ABS? ABS is abbreviation of Anti-Lock System. ABS ensures to maintain good braking stability and cornering while keeping optimum braking distance on various road surfarces.
Page 724 Chery SQR7160 series sedan ABS system－fault diagnostic and repairing Attachment II Precautions on ABS 4 MUST ITEMS 1、Depress brake pedal and keep pedal depressed firmly to obtain enough and consecutive braking force for ABS operating effectively. 2、 To keep enough braking distance, when driving on a good road surface, at least 3 seconds braking time must be left for front vehicle and a longer braking time must be left when driving on a bad road surface.
Page 725 Maintenance Manual for Chery·Windcloud M7.9.7 EFI System grounding between sensor wire harnesses. Chapter One: Operating Principle for EFI Control and Execute Components 1. Intake Pressure and Intake Air Temperature Sensor Purpose: detects manifold absolute pressure 0.1~0.2bar from and intake air temperature, provides engine with load information.
Page 726 Maintenance Manual for Chery·Windcloud M7.9.7 EFI System 2. Throttle Position Sensor Purpose: this sensor is designed to provide ECU with information of throttle angle. As per such information, ECU obtains engine load information and operating mode information (for instance: start-up, idle...
Page 727 Maintenance Manual for Chery·Windcloud M7.9.7 EFI System 3. Coolant Temperature Sensor TF-W Purpose: this sensor is designed to provide coolant temperature information. To provide engine ECU with water temperature signal used for control of ignition timing and fuel injection pulse width in startup, idle speed and normal operation.
Page 728 Maintenance Manual for Chery·Windcloud M7.9.7 EFI System 4. Knock Sensor KS Purpose: this sensor is designed to provide ECU with engine knocking information so 1. Knocking block as to carry out knocking control. 2. Casing 3. Piezoelectric ceramics 4. Contactor 5.
Page 729 Maintenance Manual for Chery·Windcloud M7.9.7 EFI System liable to result in sensor failure. 5. Oxygen Sensor Purpose: this sensor is designed to provide the information that if there is surplus oxygen after full combustion of fuel, which is injected into engine cylinder in the intake air.
Page 730 Maintenance Manual for Chery·Windcloud M7.9.7 EFI System 6. Electronic Control Unit (ECU) Purpose: ECU is the core of electronic engine control system. Sensors sent various signals to ECU for electric control, and then ECU controls operations of fuel injector and ignition coil, etc. after internal calculation, thus controling working of engine.
Page 731 Maintenance Manual for Chery·Windcloud M7.9.7 EFI System 3. ECU Pin Definition: Connected to Type Connected to Type Oxygen sensor heating Output Air conditioning temperature Input sensor Ignition coil 2 Output Ignition ground Ground 44 Non-continuous power Input Non-continuous power Input...
Page 732 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System 7. Electric Fuel Pump Purpose: to carry fuel from fuel tank to engine at a certain pressure and flow rate (different in systems). Composition and principle: electric fuel pump is coaxially installed with pump motor in the same casing.
Page 733 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System 8. Electromagnetic Injector Purpose: according to ECU instruction, injector ejects fuel within the stipulated time, by which means providing engine wtih fuel and atomising it. Composition and principle: ECU sends out...
Page 734 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System 9. Idle Speed Actuator Stepper Motor Functions: there is also a bypath air passage provided by idle speed actuator with stepper motor. When throttle is shut, air enters engine through this bypath air passage. ECU...
Page 735 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System 10. Ignition Coil ZSK-ROV Function: ignition coil transforms low voltage of primary winding into high voltage of secondary winding, spark is generated through discharge of spark plug to ignite fuel and air mixture in cylinder.
Page 736 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System 11. Carbon Canister Control Valve Purpose: to be used for the control of purge flow rate of carbon canister. Carbon canister control valve is controlled by ECU in accordance with engine load via the duration and frequency of electric impulse (i.e.
Page 737 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System 12. Assembly of Steely Fuel Distributing Pipe Purpose: to store and distribute fuel to provide fuel injection system with a fairly stable pressure environment, to achieve counterbalance of supply pressure and fuel feed of each cylinder as well as smooth engine operation.
Page 738 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System Chapter Two: Basic Principle for EFI System Failure Diagnosis (1). Failure Information Record Electronic control unit constantly monitors sensors, actuators, relevant circuits, fault indicating lamp and accumulator voltage, etc. and even electronic control unit itself, and...
Page 739 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System or outdoors. Once failure is identified disappeared, the use of normal data will be restored. (6). Failure Alarm Some vehicles equipped with M7.9.7 system have fault indicating lamps. In case failure...
Page 740 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System memory will be removed automatically.   U se scanner to remove failure information record by selecting the command of “Clear failure memory”.   Unplug ECU connection or pull out accumulator wires, and clear failure information record in external RAM.
Page 741 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System Failure code: P0107 too low circuit voltage of intake pressure sensor Step Operation Result Solution Connect scanner and commutator, and then turn Go to next step ignition switch to “ON”. Check Intake Pressure in data stream to see if it is...
Page 742 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System wire harness and check the resistance value between Pin 1 and Pin 2 with a multimeter to see if it Replace sensor corresponds with temperature (refer corresponding chapter of this manual for details).
Page 743 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System Failure code: P0123 too high circuit voltage of throttle position sensor Step Operation Result Solution Connect scanner and commutator, and then turn Go to next step ignition switch to “ON”. Check Throttle Absolute Opening in data stream to Go to next step see if it is 4%-10% (depends on specific car model).
Page 744 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System A. Check intake system for severe air leakage; Repair as per B. Check injectors for blockage; diagnosis C. Check spark plug to see if clearance is proper; D. Check high voltage wire to see if resistance is Diagnosis too high;...
Page 745 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System oxygen sensor) of sensor connector, Pin 18 of ECU and Pin B (corresponding to black wire of oxygen Diagnosis sensor) of sensor connector to see if open circuit Instruction occurs. Failure code: P0135 heating circuit error of upstream oxygen sensor...
Page 746 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System Go to next step Connect a fuel pressure gauge to fuel inlet pipe of Check fuel system and observe fuel pressure under all repair fuel working conditions to see if it is around 350kPa.
Page 747 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System A. Check injector for leakage; Repair as per B. Check exhaust pipe for leakage; diagnosis C. Check ignition timing to see if it is proper; Diagnosis D. Check intake conduit to see if it is worn out;...
Page 748 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System Go to next step Check the resistance between Pin 1 and Pin 2 of Go to next step Cylinder 2 injector with a multimeter to see if it is Replace around 11-16Ω at 20℃.
Page 749 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System Unplug Cylinder 4 injector connector from wire Go to Step 4 harness, check the voltage between Pin 1 of the connector and cathode of power supply with a Go to next step multimeter to see if it is around 12V.
Page 750 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System Failure code: P0325 circuit error of knock sensor Step Operation Result Solution Connect scanner and commutator, and then turn Go to next step ignition switch to “OFF”. Unplug knock sensor connector from wire harness,...
Page 751 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System Unplug engine speed sensor connector from wire Go to next step harness, check the resistance between Pin 2 and Pin 3 of engine speed sensor with a multimeter to see if Replace sensor it is around 770-950Ω...
Page 752 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System Connect scanner and commutator, and then turn Go to next step ignition switch to “ON”. Unplug carbon canister control valve connector Go to Step 4 from wire harness, check the voltage between Pin 1...
Page 753 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System Repair Check the connection between Pin 2 of carbon replace wire canister control valve connector and Pin 46 of ECU harness to see if short circuit to ground occurs. Diagnosis Instruction...
Page 754 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System condenser, turn ignition switch to ON. Check the voltage between power supply terminals of relay Go to next step (i.e. Pin 30 and 85 of relay) and cathode of power supply to see if it is around 12V.
Page 755 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System Failure code: P0500 improper speed signal Step Operation Result Solution Connect scanner and commutator, and then turn Go to next step ignition switch to “OFF”. For models equipped with ABS, please check ABS Repair ABS to see if failure code occurs.
Page 756 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System Failure code: P0507 higher idling speed than target value Step Operation Result Solution Connect scanner and commutator, and then turn Go to next step ignition switch to “OFF”. Go to next step...
Page 757 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System Connect scanner and commutator, and then turn Go to next step ignition switch to “ON”. Unplug idle speed regulator connector, check Go to next step respectively the resistances between Pin A and Pin...
Page 758 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System Diagnosis Instruction Check ground point of engine wire harness to see if Repair it is normal. replace wire harness Failure code: P0562 too low system voltage Step Operation Result Solution Connect scanner and commutator, and then turn Go to next step ignition switch to “OFF”.
Page 759 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System Failure code: P0601 non-programmed check code error of ECU Step Operation Result Solution Connect scanner and commutator, and then turn Go to next step ignition switch to “ON”. Clear failure code, recheck the failure to see if it is a Go to next step constant failure.
Page 760 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System Failure code: P0646 too low control circuit voltage of air conditioner compressor relay Step Operation Result Solution Connect scanner and commutator, and then turn Go to next step ignition switch to “OFF”.
Page 761 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System Step Operation Result Solution Repair Check the connection between Pin 86 of relay replace wire (control terminal of air conditioner compressor harness relay) and Pin 70 of ECU to see if short circuit Diagnosis occurs.
Page 762 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System 6. Diagnostic Steps for Various Engine Failures Preliminary inspection shall be carried out before proceeding with diagnostic steps for any engine failure: (1). Make sure ECU and fault indicating lamp are working normally (models without fault indicating lamp directly go to next step).
Page 763 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System 1). Engine dose not rotate or rotates slowly when starting Step Operation Result Solution Check the voltage between two terminals of Go to next step accumulator with a multimeter to see if it is around Repair or replace 10-12.5V.
Page 764 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System 2). Engine rotates but fails to start when starting Step Operation Result Solution Turn ignition switch to “ON”, and check with scanner Eliminate failure to see if there is any failure information recorded.
Page 765 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System with fuel return interceptor to stop fuel returning. Repair or replace Check to see if fuel pressure occurs quickly. injector or fuel pipe Check fuel inlet pipe to see if leakage or blockage Repair or replace occurs.
Page 766 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System 3). Vehicle warm starting is difficult Step Operation Result Solution Set ignition switch in “ON”. Check with scanner Eliminate failure to see if there is failure information record. displayed Go to next step Connect fuel pressure gauge valve.
Page 767 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System 4). Rotating speed is normal, but starting is difficult all along Step Operation Result Solution Set ignition switch in “ON”. Check with scanner Eliminate failure to see if there is failure information record.
Page 768 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System if ignition advance angle is normal after coolant Adjust ignition temperature reaches normal value. advance angle Check if cylinder compression pressure of Go to next step engine is normal. Troubleshooting Check if intake manifold absolute pressure and Repair or replace intake air temperature sensor is blocked up.
Page 769 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System 5). Vehicle cold starting is difficult Step Operation Result Solution Set ignition switch in “ON”. Check with scanner Eliminate failure to see if there is failure information record. displayed Go to next step...
Page 770 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System Check if fuel pressure is lower than 350kPa Go to next step Go to step 16 Shut down fuel gauge valve. Switch on ignition Go to next step switch again to make fuel pump work once more, Go to step 15 and check if fuel pressure is established.
Page 771 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System 6). Instable idle speed occurs anytime Set ignition switch in “ON”. Check with scanner Eliminate failure to see if there is failure information record. displayed Go to next step Check if EWD3 idle speed actuator or idle speed Repair or replace actuator of idle speed stepper motor is stuck.
Page 772 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System with fuel return interceptor to ensure no fuel Repair/ replace return, and check if fuel pressure is formed injector or fuel pipe rapidly. Check if leakage or clogging occurs in fuel inlet Repair or replace pipe.
Page 773 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System 7). Idle speed is instable during warming-up Set ignition switch in “ON”. Check with scanner Eliminate failure to see if there is failure information record. displayed Go to next step Check if air filter is smooth.
Page 774 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System 8). Idle speed is instable after the completion of warming-up Set ignition switch in “ON”. Check with scanner Eliminate failure to see if there is failure information record. displayed Go to next step...
Page 775 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System Check if fuel return pipe is blocked up or bent. Repair or replace fuel return pipe Replace fuel pressure regulator Make engine run at idle speed, and check to see Go to next step...
Page 776 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System 9). Idle speed unsteadiness or flameout when using load (air conditioner, etc.) Set ignition switch in “ON”. Check with scanner Eliminate failure to see if there is failure information record. displayed...
Page 777 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System 10). Periodical unsteadiness (ECU shall have self-learning again after power cutoff) Set ignition switch in “ON”. Check with scanner Eliminate failure to see if there is failure information record. displayed Go to next step Check if air filter is smooth.
Page 778 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System 11). Excessive idle speed (ECU shall have self-learning again after power cutoff) Set ignition switch in “ON”. Check with scanner Eliminate failure to see if there is failure information record. displayed...
Page 779 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System 12). Low rotating speed or engine flameout during acceleration Set ignition switch in “ON”. Check with scanner Eliminate failure to see if there is failure information record. displayed Go to next step Check if air filter is smooth.
Page 780 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System ignition switch “ON”. Connect Go to next step commutator between ECU and wire harness to check the voltages of output signal terminal, Repair or replace ground terminal and 32#, 33# pins (served as wire harness 4.5-5V sensor power) of ECU throttle position...
Page 781 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System 13). Slow response when accelerating Set ignition switch in “ON”. Check with scanner Eliminate failure to see if there is failure information record. displayed Go to next step Shut down the engine and check if air filter is Go to next step smooth.
Page 782 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System 14). Poor performance and disability occur during acceleration Check if there exists failure of clutch slipping, Repair low tire pressure, braking drag, incorrect tire Go to next step size, four-wheel alignment error and etc.
Page 783 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System with fuel return interceptor to ensure no fuel Repair/ replace return, and check if fuel pressure is formed injector or fuel pipe rapidly. Check if leakage or clogging occurs in fuel inlet...
Page 784 Maintenance Manual for Chery · Windcloud M7.9.7 EFI System 8. System Maintenance Safety Precautions 1). Diagnostic maintenance safety precautions for EFI system (1). Controller dismounting requirement   C ontroller shall be dismounted before electric welding or stoving varnish;   W hen dismounting controller, ignition switch shall be pulled to OFF so as to avoid damage;...

Chery A11 2003 Repair Manual

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