Chery A21 2005 Service Manual
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Chery A21 2005 Service Manual

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Table of Contents

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A21-2005
START AND CHARGE SYSTEM
Storage
Baterry
Terminal
ACC
Position
L0CK
ACC
0N
START
Generator
Starter
CIRCUIT DIAGRAM
AM1
IG2
AM2
ST2
Ignition Switch
Starter Relay
NO.03/01
To
instrument
16#

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Summary of Contents for Chery A21 2005

  • Page 1 A21-2005 NO.03/01 CIRCUIT DIAGRAM START AND CHARGE SYSTEM Terminal Position L0CK START Ignition Switch Starter Relay Storage Baterry Generator Starter instrument...
  • Page 2 A21-2005 NO.03/02 CIRCUIT DIAGRAM ABS SYSTEM ABS Control Left Right Left Right Rear Rear Front Front Wheel Wheel Wheel Wheel Sensor Sensor Sensor Sensor...
  • Page 3 A21-2005 NO.03/03 CIRCUIT DIAGRAM AIR CONDITIONING SYSTEM Blower A/C P ressure S witch Governor Resistor A/C Control Inner Temperature Sunlight Sensor Sensor Outer Temperature Sensor Water T emperature S ensor Cycling Motor Mode Damper Motor Incorporated Damper Motor...
  • Page 4 A21-2005 NO.03/04 CIRCUIT DIAGRAM AUDIO SYSTEM A ntenna Left Rear Speaker Left Front Speaker Left Front Door Speaker Right Front Speaker Right Front Door Front ISU PP3/3 Speaker Right Rear Speaker Steering Wheel Shortcut Key...
  • Page 5 A21-2005 NO.03/05 CIRCUIT DIAGRAM AIR BAG SYSTEM Driver Airbag Front Passenger Side Airbag Left Front Pretensioner Right Front Pretensioner Seat Belt Seat Belt Left Impact Sensor Right Impact Sensor Front Passenger Driver Side Airbag Side Airbag To ISU PE2/16 To D iagnostic C onnector 7# Front Passenger Airbag Lock Switch To Instrument 17#...
  • Page 6 A21-2005 NO.03/06 CIRCUIT DIAGRAM INSTRUMENT SYSTEM Instrument Terminal Resistor...
  • Page 7 To Antitheft Control A4 To Antitheft Control A1 To Front ISU PE2/22 To ABS6 Brake Switch Vortex Control Valve EMS Relay Exhaust Timing Solenoid Valve Intake Timing Solenoid Valve Nozzle 2 To Instrument 27# Nozzle 4 Nozzle 3 Nozzle 1 P ower S teering Switch Carbon Canister Solenoid Valve Clutch Switch...
  • Page 8 Left Rear Regulator Motor R ear W indshield G lass Heater resistor Regulator Switch of Right Rear Door Regulator Motor of Right Rear Door Regulator Switch of Left Rear Door Left Backup Lamp Left T urn Light Left Position Lamp License Lamp High Mounted Stop Lamp Right Position Lamp...
  • Page 9 To Sunroof Module 4# Key Signal Switch Front Fog Lamp Nignt Lamp Adjusting Switch Right Front T urn S ignal Lamp Right Side Turn S ignal Lamp Left Front Position Lamp To D ouble Switch 6# Left Front Turn Signal Lamp Right Front Position Lamp Left Side T urn S ignal Lamp Regulator Motor of Right Front Door...
  • Page 10 A21 ENGINE PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 11 CHAPTER I ENGINE PARAMETER AND SPECIAL TOOL I. TECHNICAL DATA DESCRIPTION ENGINE FEATURE Engine model SQR481H Four cylinders, water-cooled, in-line double overhead Engine type camshaft, 16 valves, controllable burning rate (CBR) and variable valve timing (VVT) Cylinder diameter (mm) Piston stroke 77.5 Displacement 1.597...
  • Page 12 II. SPECIAL TOOL: Camshaft Timing Tool Crankshaft Timing Tool Flywheel Tool Guide Sleeve Of Crankshaft Oil Seal Guide Sleeve Of Camshaft Oil Seal Hydraulic Hoist PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 13 III. ENGINE NUMBER POSITION Position of Engine Cylinder Block Number Engine Oil Dipstick CHAPTER II ENGINE ACCESSORIES SECTION I ENGINE TIMING CALIBRATION 1. Dismantle dynamo belt Use wrench to clamp the tension pulley bolt, screw it counterclockwise and dismantle the generator bolt.
  • Page 14 2. Dismantle the right engine mounting bracket Use small crane to hoist the engine, dismantle the bolts of right suspension and lift down the right mounting bracket. 3. Dismantle crankshaft pulley Shift the car into the 5th gear, step on the brake, and dismantle the fixed bolt of crankshaft pulley.
  • Page 15 4. Dismantle timing belt Exhaust Camshaft Pulley Air Intake Loosen the central fixed bolt of tension Camshaft pulley of timing belt, dismantle the timing Pulley belt. Meanwhile, loosen the hollow stay bolts connecting the air intake and exhaust Idler camshaft pulleys and the camshafts. Timing Belt Coolant Pump Belt...
  • Page 16 Gear Missing Abnormal Wearing Belt Core Desquamation Even if no outer damage is confirmed, you should also replace the belt when any of the following conditions occurs. (1) If the water in the coolant pump is leaked and more water should be filled continuously. (2) If the belt is spotted with much oil stains, and the rubber may be damaged due to expansion, you should replace the belt.
  • Page 17 PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 18 7. Crankshaft phase alignment Screw off the bulkhead of cylinder block, screw the crankshaft tool into it, rotate the crankshaft until crankshaft tool completely clamps the crankshaft. At this time, the crankshaft cannot rotate clockwise and counterclockwise. Crankshaft Tool 8. Mount and strain the timing belt Mount the timing belt in the position shown in the figure, use allen wrench to rotate the tension pulley in order to strain the belt,...
  • Page 19 SECTION II LIFTING AND INSTALLATION OF ENGINE 1. When the ignition switch is shut off, you can pull out the battery earth cable, loosen the fastening screw,and dismantle the battery. 2. Loosen the condenser drainpipe, screw off the expanded pot lid, and discharge all the anti-freezing solution.
  • Page 20 5. Remove the (f) the harness plug of CBR solenoid valve. 6. Dismantle (g) the earth cable bolt of cylinder head, remove (h) the wire harness plug of starter coil, (i) wire harness plugs of four oil injectors, (j) knock sensor plug, (k) wire harness plug of throttle valve controller.
  • Page 21 9. Dismantle (p) transmission gearshift cable and (q) hydraulic pipe of clutch. 10. Use crane to hoist the engine hanger from the top, and dismantle the two hexagonal flange bolts front suspension bracket. 11. Dismantle the hexagonal flange bolts of girder under the car body.
  • Page 22 13. Dismantle the coolant reservoir and cleaning the reservoir. 14. Loosen the three hexagonal flange bolts of engine's right bracket. 15. Loosen three bolts right suspension cushion, and dismantle the right suspension cushion assembly and bracket. 16. Dismantle the hexagonal flange bolts of left suspension cushion in order to ensure no connection between the engine and car body.
  • Page 23 SECTION III ENGINE ACCESSORIES 1 Replacement of Dynamo belt 1.1 Needed tools and auxiliary materials 13 #open end wrench and new dynamo belt 1.2 Process of removal As the figure illustrated, rotate the13#open end wrench counterclockwise and recede the tension pulley. At the same time, the belt tension shall disappear, so you can dismantle the belt.
  • Page 24 Dismantle dynamo belt (Process of removal is shown in the “replacement of dynamo belt”). Use 13# sleeve to dismantle the bolt (I) connecting the generator and bracket. 2.3 Installation steps: The Installation steps is opposite to Process of removal. Use allen wrench to dismantle the bolt (II) connecting generator and bracket, and then take out the generator.
  • Page 25 Lift down the wire harness plug. Dismantle the dynamo belt. （ The removal methods are detailed in the “replacement of dynamo belt”. Dismantle the intake manifold. Detailed sequences are shown in “the removal of intake manifold ”. Loosen the bolt (I) connecting the A/C compressor and fixed bracket.
  • Page 26 Carefully handle the bracket and A/C compressor, and dismantle them. 3.3 Installation steps Installation steps is opposite to Process of removal. 4 Replacement of Power Steering Pump 4.1 Needed tools and auxiliary materials 17#open wrench,ratchet wheel,ratchet rod, power steering oil. 4.2 Process of removal Pull out the harness plugs of power steering switch: use17#open end wrench...
  • Page 27 4.3 Installation steps The installing steps are reverse to those for removal. 5 Replacement of Idler 5.1 Needed tools and auxiliary materials Ratchet wheel wrench, 13# ,15# sleeves 5.2 Process of removal Dismantle the dynamo belt. Detailed sequences are shown in the “removal of dynamo belt”.
  • Page 28 6.3 Installation steps The installing steps are reverse to those for removal. 7 Replacement of Air cleaner Core 7.1 Needed tools Right-angled screwdriver. 7.2 Process of removal Undo the clips around the air cleaner case. Uplift the filter case and take out the filter paper.
  • Page 29 Use 10# sleeve to dismantle the fixed bolts of ignition coil. 8.3 Installation steps Installation steps is opposite to Process of removal. 9 Replacement of High Voltage Cable 9.1 Process of removal Remove one end of the high voltage cable from the ignition coil. Pull out the connection end of high voltage cable and sparking plug, and dismantle the high voltage cable.
  • Page 30 10 Replacement of Sparking Plug 10.1 Needed tools Carry-on wrenches 10.2 Process of removal Pull out the connection end of high voltage cable and sparking plug. Use carry-on wrenches to screw off the sparking plug. Torque: 10.3 Installation steps The installing steps are reverse to those for removal.
  • Page 31 12 Replacement of Starter 12.1 Needed tools and auxiliary materials A set of open end wrenches and a set of sleeve wrenches. 12.2 Removal Dismantle the conductor of engine oil dipstick. Loosen the bolts connecting the engine oil dipstick with cylinder block and intake manifold.
  • Page 32 CHAPTER III ENGINE BLOCK SECTION I ENGINE CYLINDER HEAD 1. Structure Diagram 1. Pad-Intake Manifold 2. Intake Manifold Assembly 3. Hexagonal Flange Bolt 4. Throttle Valve Assembly 5. Gasket-Throttle Body Assembly 6. Oil Injector Assembly 7. Fuel Delivery Pipe Assembly 8.
  • Page 33 1. Intake Valve 12. Front Camshaft Oil Seal 2. Valve Oil Seal 13. Exhaust Camshaft Assembly 3. Spring Seat 14. Rocker Assembly 4. Valve Spring 15. Hydraulic Tappet Assembly 5. Spring Retainer 16. Stud Bolt (9 Bars) 6. Keeper 17. Cylinder Head Gasket 7.
  • Page 34 2. Maintenance Replace intake manifold, CBR control valve plate, delivery pipe, oil injector 2.1.1 Needed tools and auxiliary materials Ratchet wheel, ratchet rod, 10# sleeve and crosshead screwdriver 2.1.2 Process of removal Put the ignition key at the OFF position. Loosen the oil injector plug.
  • Page 35 2.1.3 Installation steps The installing steps are reverse to those for removal. Note: Pay more attention to the position of seal ring. There is a slot at the arrow pointing position. 2.2 Replace camshaft, bearing bushing, valve and valve oil seal 2.2.1 Needed tools and auxiliary materials Special tool for valve oil seal, engine lubricant, a set of sleeve tools and one...
  • Page 36 Use torque wrench to remove the air intake and exhaust camshaft pulleys. Dismantle the back cover of timing belt. Dismantle the air intake and exhaust camshaft bearing caps in turn, and place them well in order. Note: The second, third, fourth and fifth camshaft bearing caps are marked with I1, I2, I3, I4 (E1, E2, E3, E4), which stands for the corresponding bearing cap of 1, 2, 3, 4...
  • Page 37 2.2.3 Check 1) Check the valve spring. Use caliper rule to check the free length of valve spring and the length specified in special pressure. Standard Limit Value(mm) value(mm) Free length 47.7 Length of 620N Replace with the new valve spring if the measured value exceeds the limit value.
  • Page 38 4) Check the diameter of value stem a: Use micrometer caliper to measure the diameter of valve stem. Measuring Point Valve Guide Outer Diameter Inner Diameter Of Of Valve Stem Valve Guide Use inner micrometer guage to measure the inner diameter of valve guide. Measuring Point Calculate the difference of measured value and the clearance.
  • Page 39 Standard Limit value value ￠5.98±0.008 Outer diameter of valve stem EX ￠5.96±0.008 (mm) ￠5.4±0.1 Inner diameter of valve guide ￠5.4±0.1 (mm) Clearance 0.02 (mm) 0.04 Thickness of 0.3±0.15 value top 0.3±0.15 （mm） 2.2.3 Installation The installing steps are reverse to those for removal.
  • Page 40 SECTION II INTRODUCTION TO NEW ENGINE TECHNOLOGIES——CBR& VVT 1. CBR PROFILE CBR principle and structure By controlling the organization modes of air flow (eddy flow and turbulent flow), CBR (Controlled Bum Rate) can improve the burn rate, reduce displacement, and boost the economical efficiency of fuel.
  • Page 41 2.VVT PROFILE VVT Principle VVTi is the abbreviation of variable valve timing with intelligent. During the operation of engine, the valve opening time is called as valve timing. When the engine operates at different rotation speeds, we need different valve timings to provide the optimal valve closing control, so that the power and combustion efficiency can achieve the best effect.
  • Page 42 1. Camshaft Phaser Assembly 5. Engine ECU 2. Control Valve-Camshaft Phaser Assembly 6. Crankshaft Position Sensor 3. Oil Pump Assembly 7. Camshaft Position Sensor 4. Engine Piston 8. Camshaft SECTION III SHORT ENGINE I. STRUCTURE DIAGRAM PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 43 1. Piston 12. Oil Pump 2. Connecting Rod Upper Bearing 13. Bolt 3. Timing Hole Plug 14. Gasket 4. Connecting Rod Lower Bearing 15. Crankshaft Timing belt pulley 5. Pad 16. Gasket 6. Bolt (M) 17. Bolt 7. Oil Filter 18.
  • Page 44 23. Crankshaft Main Bearing Bolt 26. O-Type Ring 24. Frame Bolt 27. Crankshaft 25. Frame 28. Cylinder Block PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 45 II. MAINTENANCE 1. Replacement of Oil Pan 1.1 Needed tools and auxiliary materials 10# open end wrench, 10#, 15#, 17# sleeves, ratchet wheel, ratchet rod, Le Tai 5901 Glue and engine oil. Replacement Process of 1.2.1 Process of removal Loosen the oil discharge bolt of oil pan to discharge the engine oil.
  • Page 46 Use 15# sleeve wrench to dismantle the bolts connecting the oil return pipe of PVC valve and oil pan Use rubber pestle to knock the edge of oil pan, and dismantle the oil pan. Note: more attention safety precaution, since the oil pan may fall down during the knocking process.
  • Page 47 clockwise. Fasten the bolt up to specified torque from the central part to both sides clockwise. （As the figure illustrated）. Torque: 15±3NM Fill engine oil up to specified volume. 2 Replacement of Oil Strainer 2.1 Needed tools and auxiliary materials 10#open end wrench, 10#, 15#, 17# sleeves, ratchet wheel, ratchet rod Le Tai 5901 Glue,engine oil.
  • Page 48 3 Replacement of Piston, Piston Ring, Piston Pin and Connecting Rod Bearing 3.1 Needed tools and auxiliary materials 10#open end wrench, 10#,15#,17# sleeves, ratchet wheel , ratchet rod, Le Tai 5901 Glue,engine oil, torque wrench, special piston mounting tools, feeler gauge, clearance gauge, micrometer caliper 3.2 Process of replacement...
  • Page 49 Use wood stem to uplift the connecting rod and piston slightly, and then dismantle the piston and connecting rod assembly. Take down the piston ring. Take down the retainer ring of piston pin, and pull out the piston pin. Note: Since the tension force of retainer ring is very strong, you should do the removal work carefully in order to avoid hurting person.
  • Page 50 Check the clearance between piston ring and ring slot. Use piston ring to clean up the carbon deposit in the ring slot. Use feeler gauge to measure the clearance between the piston ring and ring slot. Standard Wearing limit value(mm) (mm) First 0.04--0.08...
  • Page 51 b. Use feeler gauge to measure the orifice. Standard value Limit (mm) (mm) First 0.2-0.4 ring Second 0.4-0.6 ring 0.2-0.9 ring Check the piston pin and the diameter of piston pin Use micrometer caliper to measure the outer edges of the part shown in the following figure, and select the maximum value as the diameter size of piston pin.
  • Page 52 Standard size Wearing limit Clearance between piston pin and piston pin hole 0.002-0.013 Check the connecting rod journal and the connecting rod bearing. Check the diameter of connecting rod journal. Use micrometer caliper to measure the connecting rod journal. Rotate the crankshaft for 90°, and carry out measurement.
  • Page 53 Loosen the connecting rod bolt, dismantle the bearing cap; and use the measuring rule on the clearance gauge packaging bag to measure the width of the widest portion of the flattened clearance gauge, and get the clearance value. Plastic Gauge Wearing Standard value limit...
  • Page 54 Check the cylinder block Check whether there is scuffing or piston scraping on the cylinder wall. If the defect exits, please dissection 12 mm cylinder or and set with bushing or replace it. Center Use cylinder gauge to measure the inner Bottom diameter and cylindericity.
  • Page 55 Mount the connecting rod upper bearing and connecting rod together. Note: The bearing notch should be in alignment with the notch on the connecting rod. Apply engine lubricant onto the engine cylinder, use special tools to clamp the piston ring, and use wood handle to slightly knock on the piston head so as to mount the piston connecting rod assembly.
  • Page 56 Check the axial clearance of connecting rod Use micrometer caliper or feeler gauge to measure the axial clearance. Standard Limit value value（mm） (mm) Clearance 0.15 0.50 Mount oil strainer. Mount oil pan. 10) Mount cylinder. 11) Mount timing belt. 4.Replacement of Front crankshaft oil seal 4.1 Needed tools and auxiliary materials Ratchet wheel, ratchet rod, 13#, 15#, 17#, 22# sleeves, 13#open end wrench, allen...
  • Page 57 Use slot-head screwdriver to pry out the old oil seal Note: Be careful when dismantling the oil seal, and avoid scuffing the oil seal seat ring. 4.2.2 Installation Clean up the dirt and stain on the oil seal seat ring, and apply a layer of lubricant onto the seat ring.
  • Page 58 5 Replacement of Oil Pump 5.1 Needed tools and auxiliary materials A set of big sleeve tools, a set of small sleeve tools, and a set of open end wrenches 5.2 Process of replacement 5.2.1 Process of removal Dismantle the timing belt( detailed methods are shown in the “removal of engine timing belt”).
  • Page 59 Lift down the engine assembly from the car( detailed methods are shown in the “lifting and installation of engine assembly”. Dismantle he clutch pressure plate. Dismantle the flywheel. Firstly use special tool to clamp the flywheel, and then use sleeve wrench to dismantle the fixed bolts.
  • Page 60 7 Replacement of Crankshaft and Thrust Washer 7.1 Needed tools and auxiliary materials A set of open end wrenches, a set of sleeve tools, one small crane, Le Tai glue, engine oil, feeler gauge and micrometer guage. 7.2 Process of removal Lift down the engine (detailed methods are shown in the “lifting and installation of engine”).
  • Page 61 7.3 Check Check the oil clearance of crankshaft main journal. Clean the journal and bearing bushing. Plastic Gauge Installation of crankshaft Cut the plastic gauge to make it have the same length with that of the bearing, and then put it onto the crankshaft journal to make it parallel with the central line of shaft.
  • Page 62 7.4 Installation Clean up the short engine, and apply engine lubricant. Install the crankshaft correctly, and mount the thrust washer in proper position. Latch on the cylinder block frame, and fasten the crankshaft fixed bolts. The fastening sequence is illustrated in the figure.
  • Page 63 Chery Service Manual for A520 Body Dimension and Accessories CHAPTER EIGHT WINDSHIELD I. DISASSEMBLING FRONT WINDSHIELD 1. Remove the wiper arm and the lower trim panel of the windshield; Figure 147 2. Pull the piano wire through the body and the glass and tie both ends of the piano wire with wood block or similar;...
  • Page 64 Chery Service Manual for A520 Body Dimension and Accessories INSTALLING FRONT WIND SHIELD 1. Cut away the rough parts on the body Bonding Agent with a knife and clean the cut surface of the bonding agent with a rag soaked with washer fluid;...
  • Page 65 Chery Service Manual for A520 Body Dimension and Accessories 4. Replacing clamping piece necessary; ① Remove the stopper with a knife ② Remove the old clamping piece ③ Replace with a new clamping piece Figure 153 5. Position the glass;...
  • Page 66 Chery Service Manual for A520 Body Dimension and Accessories 7. Install the water resistance piece; Install the water resistance piece using double face adhesive tape as shown in the 7mm (0.28 inch) figure Note: Do not touch the glass surface after cleaning;...
  • Page 67 Chery Service Manual for A520 Body Dimension and Accessories 10. Mixing the bonding agent; Note: Make sure that the moulding be installed within the application period of the bonding agent, and the bonding agent should be mixed within 5 minutes.
  • Page 68 Chery Service Manual for A520 Body Dimension and Accessories Note: ① To install the glass, align the reference marks on the glass and the body and then lightly press the glass into from the edge. ② Apply the bonding agent on the edges of the glass with a scraper.
  • Page 69 Chery Service Manual for A520 Body Dimension and Accessories II. DISASSEMBLING INSTALLING REAR WINDSHIELD 1. Lay down the seat back and remove the coat track; Figure 165 2. Remove the lower moulding Cut off the double face adhesive tape at both ends of the moulding with a scraper as shown in the figure;...
  • Page 70 Chery Service Manual for A520 Body Dimension and Accessories ③ Pull the piano wire along the bonding agent to cut it off. Tip: Do not let the piano wire spoil the two stoppers. ④ Remove the glass, and then remove the...
  • Page 71 Chery Service Manual for A520 Body Dimension and Accessories 3. Clean the glass removed ① Clear the bonding agent adhered to the glass with a scraper ② Remove the stopper with a knife ③ Clean the glass with washer fluid...
  • Page 72 Chery Service Manual for A520 Body Dimension and Accessories 6. Apply a layer of primer M on the contact Primer M surface of the body with a brush Primer M Note: Let the primer dry for more than 3 minutes. Do not apply the primer on the bonding agent.
  • Page 73 Chery Service Manual for A520 Body Dimension and Accessories 9. Applying the bonding agent: Cut off the tip of the pot, fill the bonding agent into the pot, place the pot into the sealant gun, and then apply the bonding agent on the glass as shown in the figure;...
  • Page 74 Chery Service Manual for A520 Body Dimension and Accessories PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 75 Chery Service Manual for A520 Body Dimension and Accessories CHAPTER FIVE DISASSEMBLING AND INSTALLATING THE SUN ROOF 1. STRUCTURAL DIAGRAM 1）Sun roof frame 2）Windshield frame 3）Sun roof central bracket 4）Sun roof back bracket 5）Rear roof frame 6）Car lining 7）Sun roof track 8）Sun roof module...
  • Page 76 Chery Service Manual for A520 Body Dimension and Accessories 2. NECESSARY TOOLS Cross screwdriver, internal spline wrench, ratchet gear and ratchet rod 3. REPLACING THE SUN ROOF GLASS 3.1 Disassembling the sun roof glass Turn on the power switch to lift up the sun roof in full tilt.
  • Page 77 Chery Service Manual for A520 Body Dimension and Accessories 3.2 Installing the sun roof glass Turn on the power switch to operate the sliding mechanism without glass to the full open position, and then place the glass in the middle of the support bar of the sliding mechanism.
  • Page 78 Chery Service Manual for A520 Body Dimension and Accessories Reinforce slightly with four bolts. And then pull the glass forward lightly to reinforce other bolts slightly from the middle one by one. Turn on the power switch to operate the sun roof to the full close position.
  • Page 79 Chery Service Manual for A520 Body Dimension and Accessories 4. REPLACING THE SUN VISOR 4.1 Disassembling the sun visor Remove roof. (See disassembling methods Body Accessories for detailed disassembling procedures.) Remove the locating clip as shown in the figure. (Each at left and right) 3) Draw out the sun visor backwards.
  • Page 80 Chery Service Manual for A520 Body Dimension and Accessories Disconnect the power supply control line and the connecting wire between the motor and the sun roof control unit (SCU), and then cut off the band fixing the motor harness. Remove the fixing bolts of the sun roof motor to detach the sun roof motor.
  • Page 81 Chery Service Manual for A520 Body Dimension and Accessories (SCU). Remove the connecting screws that attach the module to the roof to detach the sun roof module. 6.2 Installing the sun roof control module The installing steps are reverse to those for removal.
  • Page 82 Chery Service Manual for A520 Body Dimension and Accessories the roof hole is too big or the height of the glasses and their relative positions glass is incorrect PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 83 Chery Service Manual for A520 Body Dimension and Accessories 8. TROUBLESHOOTING WHEN THE SUN ROOF IS OUT OF CONTROL 1) The sun roof module could not control the sun roof’s status a) The full open function key fails to work, or pressing the power switch (One Touch) could not run the unit.
  • Page 84 Chery Service Manual for A520 Body Dimension and Accessories 9.3 The sun roof produces abnormal sounds: Definition: Whenever the sun roof produces abnormal sounds when running. Analyze and detect: Check the sun roof for misalignment produced by the manual assembly...
  • Page 85 Chery Service Manual for A520 Body Dimension and Accessories CHAPTER FOUR: DISASSEMBLING THE INTERIOR TRIM 1. Remove the A-pillar trim panel; Assembly requirement: the metal clips of the pillar trim panel should be installed in place without any looseness. The trim panel should be in good fitting with the roof and the weather strip.
  • Page 86 Chery Service Manual for A520 Body Dimension and Accessories Remove the cover, and then unscrew the fastening screws of the seat belt; Figure 96 Remove the lower trim panel for B pillar; Figure 97 Remove the fixing bolts for the seat belt;...
  • Page 87 Chery Service Manual for A520 Body Dimension and Accessories bolts of the front row seats seat belts and make sure that the latch of the seat belts could be operated easily and the tightening torque for the fixing nuts is 50±5 N•m.
  • Page 88 Chery Service Manual for A520 Body Dimension and Accessories 8. Remove the two bolts and slider track; Figure 102 9. Remove the weather strip; Figure 103 10. The inner harness connector on the left rear door as shown; Figure 104 PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 89 Chery Service Manual for A520 Body Dimension and Accessories 11. From here outwards to pull out the harness; Figure 105 12. Remove C pillar trim panel; Figure 106 13. Remove the weather strip from the left rear door; Figure 107 PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 90 Chery Service Manual for A520 Body Dimension and Accessories 14. Disassembling passenger grab handle: lift the trim cover and unscrew the two set screws to detach the handle: Figure 108 15. Disassembling the sun visor: unscrew the fastening bolts; Assembly requirement: The tightening force...
  • Page 91 Chery Service Manual for A520 Body Dimension and Accessories 17. Pry out the vanity mirror to replace the bulb in the right sun visor with a flat head screwdriver; Figure 111 18. Pry out the lamp house, remove the screws, pull out the harness, and then detach the indoor front ceiling light;...
  • Page 92 Chery Service Manual for A520 Body Dimension and Accessories 20. Pry out the lamp house to replace the bulb; Figure 114 21. Pry out the snap clip to detach the roof; Assembly requirements: The front end height of the roof should not interfere with the installation of the front windscreen.
  • Page 93 CHERY A520 SERVICE MANUAL CHASSIS CHAPTER I BRAKE SYSTEM SECTION I BRAKE SYSTEM PARAMETER 1) Check brake disc: The friction surface of brake disc should be flat and has no apparent grooves; otherwise, brake disc should be replaced. 2) Check the thickness of brake disc: Use caliber rule to check the thickness of brake disc.
  • Page 94 CHERY A520 SERVICE MANUAL CHASSIS SECTION II DISASSEMBLY AND ASSEMBLY OF REAR BRAKE Needed tools: ratchet, ratchet rod, 8#, 13#, 15# and 20# sleeves, 13#, 14#, 17#, 30# box end wrenches, vice clamp, torque spanner and flat-tip screwdriver. 2.1 Disassembly sequence: Screw off the tire clamp nut and dismount the tire.
  • Page 95 CHERY A520 SERVICE MANUAL CHASSIS Use 30# box end wrench to screw off the clamp nut of the wheel hub bearing unit. Torque: 78±5N.m Use 8# socket wrench to screw a M8 bolt into the bolthole illustrated in the figure, and pack out the brake disc.
  • Page 96 CHERY A520 SERVICE MANUAL CHASSIS Use vice clamp to rotate the locating pin of handbrake shoe, and take out the hold-down spring seat (each for brake leading shoe and brake trailing shoe). Dismount return spring handbrake control cable of handbrake shoe, and take down the handbrake shoe.
  • Page 97 CHERY A520 SERVICE MANUAL CHASSIS Take out the guide pin. Note: When taking out the guide pin, you should avoid damaging the dust cover. If the dust cover is damaged, you should replace it immediately; otherwise, the piston alignment return shall not occur, leading to accidents.
  • Page 98 CHERY A520 SERVICE MANUAL CHASSIS the one who is under the guidance of professional personnel can dismount brake caliper piston. 2.4 Assembly of rear brake caliper Assemble the rear brake caliper according to the reverse sequence of disassembly. SECTION DISASSEMBLY...
  • Page 99 CHERY A520 SERVICE MANUAL CHASSIS Use torque wrench and 17# sleeve to loosen bolts connecting brake assembly and steering knuckle. Torque: 85±5N.m Use box end wrench to loosen the bolts connecting the brake hose and brake caliper. (If only friction disc needs to be replaced during maintenance, there is no need to dismantle the brake pipeline).
  • Page 100 CHERY A520 SERVICE MANUAL CHASSIS Use cross-head screwdriver to screw off the fastening screw of brake disc, and lift down the brake disc. Check the thickness of brake disc, and replace the brake disc if its thickness is less than the specified minimum thickness.
  • Page 101 CHERY A520 SERVICE MANUAL CHASSIS 10) Disassemble the connectors of the ABS wheel-speed sensor unit and wire harness, and take out the ABS wheel-speed sensor unit. 3.3 Assembly of front wheel brake assembly sequence opposite disassembly sequence. 3.4 disassembly of front-wheel brake caliper Remove the thickness monitoring harness of friction wafer from the bracket.
  • Page 102 CHERY A520 SERVICE MANUAL CHASSIS Uplift the fixing bracket of brake caliper, and take out the brake lining. Check the thickness of friction wafer, and replace it if it cannot meet the requirement. Note: When replacing friction wafer, please replace it in pair.
  • Page 103 CHERY A520 SERVICE MANUAL CHASSIS Use ratchet wrench and 10#, 13# sleeves to loosen the fastening bolts connecting bracket and floor plate, and dismount the bracket. Remove the brake cable from the cable connection. Uplift the backseats and uncover the carpet.
  • Page 104 CHERY A520 SERVICE MANUAL CHASSIS Dismount the rear tire, and dismantle the rear brake assembly as the figure illustrated (Disassembly sequence is detailed in the “Dismounting of rear wheel brake assembly". Use vice clamp to dismount the return spring under the drum brake, and remove the push rod as illustrated in the figure.
  • Page 105 CHERY A520 SERVICE MANUAL CHASSIS 4.2 Assembly sequence: Assemble the handbrake control cable according to the reverse sequence of disassembly. Note: After replacing brake shoe handbrake control cable, you need to regulate parking brake: ² Loosen the parking brake handle.
  • Page 106 CHERY A520 SERVICE MANUAL CHASSIS SECTION REPLACEMENT HANDBRAKE HANDLE Needed tools: ratchet wrench,10# sleeve, vice clamp, cross-head screwdriver, and slot-head screwdriver. 5.1 Disassembly sequence: Use screwdriver to pry out the edges of central armrest box, and dismount the central armrest box.
  • Page 107 CHERY A520 SERVICE MANUAL CHASSIS SECTION REPLACEMENT BRAKE MASTER CYLINDER Needed tools: clamp pliers, 10#, 12# open end wrenches, 13# sleeve and ratchet wrench. 6.1 Disassembly sequence: 1) Pull out the plug of oil level sensor. 2) Use sucker to pump out the brake oil.
  • Page 108 CHERY A520 SERVICE MANUAL CHASSIS Dismount fluid reservoir Remark: Push the fluid reservoir upwards in order to remove it from the master cylinder and remove the O-shape seal ring from the groove of fluid reservoir. Check whether the fluid reservoir is cracked or deformed, and replace it if necessary.
  • Page 109 CHERY A520 SERVICE MANUAL CHASSIS Dismount the brake light switch plug and remove the brake light switch. Use vice clamp to dismount the pin connecting the vacuum booster pump to the brake pedal, and remove the connecting pin. Dismount the four fixed bolts of the...
  • Page 110 CHERY A520 SERVICE MANUAL CHASSIS Loosen adjusting bolt to regulate the brake pedal to standard height. 7.2 Assembly sequence: The assembly sequence is opposite to disassembly sequence. PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 111 CHERY A520 SERVICE MANUAL CHASSIS SECTION VIII ABS SYSTEM MAINTENANCE Needed tools: Chery-specific diagnostic tester, 10#, 13# open end wrenches, ratchet wrench and 10# sleeve 8.1 Precautions prior to maintenance When the ignition switch is at the ignition position, you should not disassemble and assemble the electric components and harness connectors of the system in order to prevent the electronically controlled units (ECU) from being damaged.
  • Page 112 ABS. 8.2 Schematic diagram of abs control Chery S11 EBC440V System Schem atic ABS O nly System INSTRUM ENT CLUSTER ABS Warning...
  • Page 113 CHERY A520 SERVICE MANUAL CHASSIS 8.3 Disassembly and assembly sequence Dismount the ABS module plug. Push the white clip shown in the figure towards the arrow direction, and the ABS module plug shall recede. Use 10#, 12# open end wrenches to dismount the nuts connecting ABS assembly and pipelines.
  • Page 114 CHERY A520 SERVICE MANUAL CHASSIS Section IX Brake Fluid Filling and Air Discharge Needed tools: diagnosis instrument and 10# open end wrench If air enters into the brake system in the case of brake component repairing or replacement, you should implement the complete air discharge process. Before the brake is air-discharged, the front and rear air-discharge cylinder piston must return to the highest position.
  • Page 115 CHERY A520 SERVICE MANUAL CHASSIS 9.2 Air discharge sequence of brake system is: Left back right front right back left front. If the ABS system connects with failure diagnosis instrument, you can access the fluid filling and air release program, and discharge the air from the ABS system according to the steps prompted by the system.
  • Page 116 CHERY A520 SERVICE MANUAL CHASSIS CHAPTER III FOUR-WHEEL ALIGNMENT CHECK & ADJUSTMENT SECTION I BASIC CHECK ADJUSTMENT WORK PRIOR CHECK I. PREPARATION WORK PRIOR TO ADJUSTMENT Check tire pressure and adjust it to specified pressure Standard inflation pressure of cold tire (Kpa)
  • Page 117 CHERY A520 SERVICE MANUAL CHASSIS If the car height cannot meet the standard, you should check whether there is damage or deformation front rear suspensions. Check the wheel bearing clearance, and replace front wheel bearings when necessary. Check the status of rims and tires.
  • Page 118 CHERY A520 SERVICE MANUAL CHASSIS Tire wearing (1) Check the depth of left tire tread. As the right figure illustrated: Standard tire: not less than 1.6mm. Snow tire: 50% tire tread. f the pointed wearing phenomena Wearing Indicating Wearing Indicating occur, the tire should be replaced.
  • Page 119 CHERY A520 SERVICE MANUAL CHASSIS Precautions on tire and rim (1) Disqualified tire and rim should not be used. (2) Aluminum alloy rim is easily scored, therefore, soft cloth shall be used to clean up the rim, and steel brush shall be prohibited.
  • Page 120 CHERY A520 SERVICE MANUAL CHASSIS 6. Tire pressure Use barometer to check the pressure of all tires (including spare tires), and regulate the pressure if necessary. Inflate the tire strictly in accordance with the specified pressure standard, and ensure the tire pressure not more than 10% rated air pressure during the process of inflation.
  • Page 121 CHERY A520 SERVICE MANUAL CHASSIS Aluminum-alloy rim: 3mm 9. Tire rotation In order to prolong the operating life of tire and determine the tire wearing, tire rotation should be carried out when every 6000km is reached. Note: * The best tire must be selected for front wheel.
  • Page 122 CHERY A520 SERVICE MANUAL CHASSIS 11. Wheel disassembly Disassembly sequence: (1) Dismount the fastening bolt of wheel; PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 123 CHERY A520 SERVICE MANUAL CHASSIS (2) Unbolt the wheel. Assembly process (1) When installing the wheel and tire assembly, you should fasten the wheel bolts onto the wheel hub by using your hands, and then take special tools to fasten it tightly according to the diagonal process, with the tightening torque of 110±10 Nm.
  • Page 124 CHERY A520 SERVICE MANUAL CHASSIS SECTION II FRONT WHEEL ALIGNMENT Kingpin caster 50′±30′ angle Front wheel ±10′ camber angle Front wheel 5′47＂±5′(or 1mm) toe-in Kingpin 35′±30′ inclination angle I. CHECK AND REGULATE THE FRONT-WHEEL KINGPIN CASTER ANGLE, FRONT-WHEEL CAMBER ANGLE,...
  • Page 125 CHERY A520 SERVICE MANUAL CHASSIS (2) Loosen the locknut of right steering tie rod and rubber sleeve clamp, and screw down the toe-in adjusting lever to regulate the length as per requirements until it reaches the specified numerical value. (3) Fasten the locknuts, reinstall the rubber...
  • Page 126 CHERY A520 SERVICE MANUAL CHASSIS 2. Check the front wheel steering angle Maximum rotating angle of outer wheel After replacing tie rod joints or regulate Maximum rotating angle of toe-in, you should check the steering angle. If the front wheel steering angle doesn't...
  • Page 127 CHERY A520 SERVICE MANUAL CHASSIS enhance the steering force, but can improve the stability of straight driving. 4. Camber angle Under normal circumstances, there is no need to regulate the camber angle of the installed independent suspensions and wheel steering knuckle. If the wheel camber angle...
  • Page 128 CHERY A520 SERVICE MANUAL CHASSIS SECTION III REAR WHEEL ALIGNMENT CHECK ADJUSTED REAR-WHEEL CAMBER ANGLE, AND REAR-WHEEL TOE-IN VALUES: Criteria: Rear wheel alignment should meet the requirements as follows: Rear wheel toe-in 17′20＂±5′(or 3mm) Rear wheel camber 40′±10′ angle II. REAR WHEEL TOE-IN AND REAR...
  • Page 129 CHERY A520 SERVICE MANUAL CHASSIS Rear-wheel camber angle adjustment (1) As the figure illustrated, loosen the adjusting bolt 16 and adjusting nut 4 of the upper control arm, and prevent the nut from shedding out of the slot. Adjusting Nut 4...
  • Page 130 CHERY A520 SERVICE MANUAL CHASSIS SECTION IV TROUBLESHOOTING MANUAL Problem Possible Reason Countermeasures Excessive tire wearing Shown in the following items. or asymmetric wearing Improper tire pressure Adjust Early tire wearing Improper wheel alignment parameters Adjust Improper tire pressure Adjust...
  • Page 131 CHERY A520 SERVICE MANUAL CHASSIS Deficient tire pressure Adjust Failure of steering system Check Heavy steering wheel Failure of suspension system Check Improper wheel alignment parameters Check Deficient tire pressure Adjust Failure of steering system Check Bad alignment return Failure of suspension system...
  • Page 132 CHERY A520 SERVICE MANUAL CHASSIS CHAPTER IV SUSPENSION DRIVE AND AXLE SECTION I FRONT SUSPENSION STRUCTURE FEATURE Adopt McPherson independent suspension,accompanying with stabilizer bar, coil spring, double acting telescopic shock absorber. McPherson suspension structure: In McPherson suspension, the coil spring combines with...
  • Page 133 CHERY A520 SERVICE MANUAL CHASSIS I. DISASSEMBLY AND ASSEMBLY OF FRONT VIBRATION DAMPER Disassembly sequence: (Take the right vibration damper for example) Use jack to uplift the car, dismount the two bolts connecting the vibration damper and steering knuckle. Bolt mounting torque: 110±5Nm.
  • Page 134 CHERY A520 SERVICE MANUAL CHASSIS Dismount the bolts connecting the control arm and stabilizer bar. Mounting torque: 50±3Nm (The left and right sides are the same.) Dismount the bolts connecting the control arm and vehicle body. Bolt mounting torque: 180±15 Nm (The left and right sides are the same).
  • Page 135 CHERY A520 SERVICE MANUAL CHASSIS III. DISASSEMBLY AND ASSEMBLY OF STEERING KNUCKLE Disassembly sequence: (Take the right steering knuckle for example. The left and right steering knuckles have the same disassembly process.) 1. Dismount tire Mounting torque: 110±10Nm Dismount the plug of wheel speed sensor and plug of the brake-disk thickness alarm.
  • Page 136 CHERY A520 SERVICE MANUAL CHASSIS Dismount the bolts connecting the steering knuckle and the lower control arm. Mounting torque: 110±5Nm Dismount the two bolts connecting the steering knuckle and vibration damper. Mounting torque: 110±5Nm Assembly sequence: Assemble the steering knuckle in the reverse sequence of disassembly.
  • Page 137 CHERY A520 SERVICE MANUAL CHASSIS ismount the bolts connecting the side member and vehicle body. Mounting torque: 100-120 Nm Dismount the bolts connecting the side member and engine, and can remove the engine suspension bolts shown in the figure for easy disassembly.
  • Page 138 CHERY A520 SERVICE MANUAL CHASSIS Uplift the car, and dismount the fastening nuts of under-frame and vehicle body.(the left and right sides are the same) Mounting torque: 180±15Nm. Dismount the bolts connecting the under-frame and control arm (the left and right sides are the same).
  • Page 139 CHERY A520 SERVICE MANUAL CHASSIS Dismount the bolts connecting the under-frame and vehicle body (the left and right sides are the same). Mounting torque: 80--90 Nm Dismount the four bolts connecting the suspensions and under-frame. But for easy disassembly and assembly, we...
  • Page 140 CHERY A520 SERVICE MANUAL CHASSIS VI. MOUNTING OF THE FRONT STABILIZER BAR ASSEMBLY Serial Name of Spare Quantity Parts Stabilizer bar Extension bolt Rubber pad Metal sleeve Clamp Bolt Rubber support Put the rubber support sheath 8 onto the stabilizer bar1, install the clip 6 onto the...
  • Page 141 CHERY A520 SERVICE MANUAL CHASSIS VII. ASSEMBLY OF FRONT AXLE AND FRONT SUSPENSION 24 Nut 17 Front Sliding Pole 22 Engine Side Member 16 Bolt 1 Nut 2 2 Nut 20 Under-frame 8 Nut 3 Bolt 7 Rubber Cushion 14 Nut...
  • Page 142 CHERY A520 SERVICE MANUAL CHASSIS —— Use bolt 23 to connect the control arm assembly19 and under-frame 20 up to the specified fastening torque (bolt 23:180±15Nm). The left and right sides are the same. —— Use bolt 14 and installation clamp of stabilizer bar 13 to fix the stabilizer bar assembly 21 onto the rubber sleeve 12 up to specified fastening torque of 25±2 Nm.
  • Page 143 CHERY A520 SERVICE MANUAL CHASSIS SECTION II REAR SUSPENSION STRUCTURE FEATURE Adopt longitudinal trailing arm suspension, three-linkage rod, cylindrical coil spring, double-acting telescopic vibration damper. One end of longitudinal rear trailing arm connects with vehicle body through rubber hinge. This rubber hinge has different longitudinal rigidity. One end of the three horizontal oscillating arms connects with rear trailing arm by use of rubber bushing, while the other end connects with vehicle body through rubber bushing.
  • Page 144 CHERY A520 SERVICE MANUAL CHASSIS Exploded View of Rear Trailing Arm Assembly Bolt Left Rear Trailing Arm Rear Upper Control Arm Assembly Guide Bar Assembly Gasket Bolt Rear Lower Control Arm Assembly Assembling Bolt PDF created with pdfFactory Pro trial version...
  • Page 145 CHERY A520 SERVICE MANUAL CHASSIS I. DISASSEMBLY AND ASSEMBLY OF REAR VIBRATION DAMPER Disassembly sequence: Open the trunk lid; dismount the side enclosure to expose the bolts connecting rear strut assembly and vehicle body. Dismount the two connecting bolts. Mounting torque: 50±10 Nm.
  • Page 146 CHERY A520 SERVICE MANUAL CHASSIS II. CHECK VIBRATION DAMPER: Check Vibration Damper ① Check the vibration damper to see whether there is oil leakage. If oil leakage exists, you should replace the vibration damper. Check the damping force of vibration damper to see if it qualifies.
  • Page 147 CHERY A520 SERVICE MANUAL CHASSIS II. DISASSEMBLY AND ASSEMBLY OF REAR UPPER CONTROL ARM Disassembly sequence: Dismount the bolts connecting the upper control arm and vehicle body. Mounting torque: 100~120Nm. Dismount the bolts connecting the upper control arm and rear trailing arm.
  • Page 148 CHERY A520 SERVICE MANUAL CHASSIS III. DISASSEMBLY AND ASSEMBLY OF REAR LOWER CONTROL ARM Disassembly sequence: Dismount the bolts connecting the control arm and vehicle body. Mounting torque: 100~120Nm Dismount the bolts connecting the control arm and rear vibration damper.
  • Page 149 CHERY A520 SERVICE MANUAL CHASSIS IV. DISASSEMBLY AND ASSEMBLY GUIDE BAR Disassembly sequence: Dismount the four fastening bolts of wheel. Mounting torque:110±10Nm Take down the tire. Dismount the bolts connecting guide bar and rear trailing arm assembly. Mounting torque: 90～100Nm.
  • Page 150 CHERY A520 SERVICE MANUAL CHASSIS V. ASSEMBLY OF REAR AXLE AND SUSPENSION SYSTEM 8 Nut 1 Bolt 2 Trailing Arm 23 Bolt 3 Upper Control Arm 4 Nut 22 Nut 5 Gasket 6 Gasket 9 Rear Sliding Pole 7 Nut...
  • Page 151 CHERY A520 SERVICE MANUAL CHASSIS N ⋅ . Do not left and right sides are the same, and the fastening torque is 100～120 fasten the bolt at this time. —— Use bolt 10 and nut 11 to fix the rear strut 9 and rear lower control arm17( fix them at the position as the arrow illustrated).
  • Page 152 Chery Service Manual for A520 Body Dimension and Accessories CHAPTER NINE BODY DIMENSION Dimension of the beam: Unit: mm PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 153 Chery Service Manual for A520 Body Dimension and Accessories Assembly dimension of the body Side view PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 154 Chery Service Manual for A520 Body Dimension and Accessories The clearance between the front fender and the headlamp at B1-B1: 1.5 ± 1 Headlamp Front Fender The clearance between the front fender and the front bumper at B2-B2: Front Fender...
  • Page 155 Chery Service Manual for A520 Body Dimension and Accessories The clearance between the front fender and the front bumper at B3-B3: Front Fender Front Bumper The allowable installation deviation between the front fender and the front bumper at F1: Front Fender...
  • Page 156 Chery Service Manual for A520 Body Dimension and Accessories The clearance between the front fender and the side panel at B4-B4: 3.2 ± 0.5 Side Panel Front Fender The clearance between the front fender and the front door at B5-B5: 4.5 ± 1...
  • Page 157 Chery Service Manual for A520 Body Dimension and Accessories The clearance between the side panel and the front door frame at B7-B7: 4.5 Side Panel Front Door Frame The clearance between the front door frame and the rear door frame at B8-B8: 4.5 ± 1...
  • Page 158 Chery Service Manual for A520 Body Dimension and Accessories The clearance between the front door and the rear door at B9-B9: 4.5 ± 1 Side Panel Front Door Rear Door The clearance between the rear door frame and the side panel at B10-B10: 4.5...
  • Page 159 Chery Service Manual for A520 Body Dimension and Accessories The clearance between the rear trim panel of the rear door and the side panel at B12-B12: 4 Rear Door Frame Side Panel Rear Trim Panel of the Rear Door The clearance between the rear door and the side panel at B13-B13: 4.5...
  • Page 160 Chery Service Manual for A520 Body Dimension and Accessories The clearance between the rear door and the side panel at B14-B14: 4.5 ± 1 Rear Door Side Panel The clearance between the fuel filler opening cover and the side panel at B15-B15: 3 ± 1...
  • Page 161 Chery Service Manual for A520 Body Dimension and Accessories The clearance between the rear bumper and the side panel at B16-B16: 0 ± 1 Side Panel Rear Bumper The clearance between the rear bumper and the side panel at B17-B17: 0±0.5...
  • Page 162 Chery Service Manual for A520 Body Dimension and Accessories The clearance between the side panel and the tail light at B19-B19: 1 ± 0.5 Tail Light Side Panel The clearance between the side panel and the tail light at B20-B20: 1±0.5...
  • Page 163 Chery Service Manual for A520 Body Dimension and Accessories The clearance between the front fender and the fender apron at B22-B22:2.5 ± 1 Front Fender Fender Apron The clearance between the front door and the fender apron at B23-B23: 6.3 ± 1...
  • Page 164 Chery Service Manual for A520 Body Dimension and Accessories The clearance between the rear door and the fender apron at B24-B24: 6.4 ± 1 Rear Door Side Panel Fender Apron The clearance between the fender apron and the side panel at B25-B25: 3±1...
  • Page 165 Chery Service Manual for A520 Body Dimension and Accessories The allowable installation deviation between the rear bumper and the side panel (on rear fender) at F2: Side Panel (on Rear Fender) Rear Bumper PDF created with pdfFactory Pro trial version...
  • Page 166 Chery Service Manual for A520 Body Dimension and Accessories Top view PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 167 Chery Service Manual for A520 Body Dimension and Accessories The clearance between the headlamp and the engine hood at A1-A1: 3 ± 1 Parallelism Headlamp Engine Hood The clearance between the front fender and the engine hood at A2-A2: 4 ± 1...
  • Page 168 Chery Service Manual for A520 Body Dimension and Accessories The clearance between the tail light and the luggage compartment cover at A4-A4: 4 ± 1 Tail Light 0.5 ± 1 (From f to g) From g to h and descend from 0.5 ± 1 to 0 ± 1...
  • Page 169 Chery Service Manual for A520 Body Dimension and Accessories Rear view The clearance between the rear bumper and the luggage compartment cover at C1-C1: 8.2 Luggage Rear Bumper PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 170 Chery Service Manual for A520 Body Dimension and Accessories The clearance between the rear bumper and the luggage compartment cover at C2-C2: 4 Luggage Rear Bumper The clearance between the tail light and the luggage compartment cover at C3-C3: 4 ± 1...
  • Page 171 Chery Service Manual for A520 Body Dimension and Accessories The clearance between the tail light and the luggage compartment cover at C4-C4: 4 ± 1 0 ± 0.5 (From h to i ) Tail Light Luggage The clearance between the rear bumper and the tail light at C5-C5: 3±1...
  • Page 172 Chery Service Manual for A520 Body Dimension and Accessories The allowable installation deviation between the rear bumper and the luggage compartment cover at F5: Luggage Compartment Tail Light Rear Bumper Front view PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 173 Chery Service Manual for A520 Body Dimension and Accessories The clearance between the engine hood and the air inlet grille at D1-D1 is 4.5 ± 1, while the clearance between the front bumper and the air inlet grille is 1 ± 0.5...
  • Page 174 Chery Service Manual for A520 Body Dimension and Accessories The clearance between the front bumper and the air inlet grille at D2-D2: 1.5 ± 1 Air Inlet Grille Front Bumper The clearance between the front bumper and the air inlet grille at D3-D3: 1.5 ± 0.5...
  • Page 175 Chery Service Manual for A520 Body Dimension and Accessories The clearance between the headlamp and the front bumper at D5-D5: 4 ± 1 Headlamp Front Bumper The clearance between the front fog light and the front bumper at D6-D6: Front Fog Light...
  • Page 176 Chery Service Manual for A520 Body Dimension and Accessories Dimension of the engine compartment: Mark Name Diameter Mark Name Diameter Support hole for the Mounting hole for the right mounting bracket body of cowl panel of the engine Mounting hole for the...
  • Page 177 Chery Service Manual for A520 Body Dimension and Accessories Dimension of the windshield: Joint Place of Rear Windshield Cross Beam and Side Panel (on Rear Fender) Joint Place of Top Cover and Side Panel (on Rear Fender) Joint Place of Top Cover and Side Panel...
  • Page 178 Chery Service Manual for A520 Body Dimension and Accessories Opening dimension of all the parts: Dimension of the body, left-right Note: Symbols in uppercase English letter indicates the left of the body while lowercase English letter indicates the right of the body. (View from the...
  • Page 179 Chery Service Manual for A520 Body Dimension and Accessories the front door guide rail of the side panel Upper corner point Rear upper corner of the front door point of the rear door guide rail of the guide rail of the side...

  • Page 180: Table Of Contents

    Chery Service Manual for A520 Body Dimension and Accessories SQR7161A2H/SQR7201A2F BODY DIMENSION & ACCESSORIES TABLE OF CONTENTS CHAPTER ONE: FRONT ACCESSORIES CHAPTER TWO: TRUNK LID CHAPTER THREE: DOOR CHAPTER FOUR: INTERIOR TRIM CHAPTER FIVE: SUN ROOF CHAPTER SIX: INSTRUMENT PANEL...

  • Page 181: Chery Service Manual For A520

    Chery Service Manual for A520 Body Dimension and Accessories APPEARANCE VIEW: Figure 1 1. Engine Hood 2. Windscreen Wiper Arm 3. Front Windscreen 4. Tail Light Assembly 5. Air Inlet Grille Assembly 6. Front Bumper Assembly 7. Left Front Headlamp Assembly 8.

  • Page 182: Body Dimension & Accessories

    Chery Service Manual for A520 Body Dimension and Accessories CHAPTER ONE FRONT ACCESSORIES DISASSEMBLING ENGINE HOOD 1. Pry out the snap clips (7 total) with a screwdriver, and dismount the heat shield; Figure 2 2. Loosen the washing hose, and then keep prying the spray nozzle clip to take out the spray nozzle from outside;...
  • Page 183 Chery Service Manual for A520 Body Dimension and Accessories II. DISASSEMBLING FRONT BUMPER Remove the fastening screws on the air inlet grille to dismount the air inlet grille; Figure 5 Remove the upper fastening bolts on the front bumper; Figure 6...
  • Page 184 Chery Service Manual for A520 Body Dimension and Accessories 4. Remove screws with club screwdriver, and pull out the lower fog light connecting plug to remove the front bumper. Figure 8 III. DISASSEMBLING HEADLAMP: To remove the headlamp, remove the four bolts and pull out the connecting harness;...
  • Page 185 Chery Service Manual for A520 Body Dimension and Accessories Pull out the harness to back out the high beam bulb counter-clockwise; Figure 11 Pull out the harness, open the circlip, and then back out the lower beam bulb counter-clockwise; Figure 12 5.
  • Page 186 Chery Service Manual for A520 Body Dimension and Accessories 6. Back turn light bulb counter-clockwise; Figure 14 IV. DISASSEMBLING WIPER WASHING SYSTEM: Remove the lower trim panel of the front windscreen; Figure 15 To remove the wiper motor, unplug the...
  • Page 187 Chery Service Manual for A520 Body Dimension and Accessories 3. To remove the wiper arm, remove the bolts; Figure 17 4. Remove the lower trim panel of the front windscreen; Figure 18 5. To remove the wiper link, remove the bolts.
  • Page 188 Chery Service Manual for A520 Body Dimension and Accessories 6. Remove the bolts as shown; Figure 20 Then, remove the two bolts as shown to remove the washer fluid pot; Figure 21 8. Remove the washer pump. Figure 22 PDF created with pdfFactory Pro trial version...
  • Page 189 Chery Service Manual for A520 Body Dimension and Accessories V. DISASSEMBLING THE FENDER: 1. Remove the fastening bolts; Figure 23 2. Remove the screws on the fender apron; Figure 24 3. Move the trim panel, and remove the fastening bolts on the fender;...
  • Page 190 Chery Service Manual for A520 Body Dimension and Accessories Figure 26 4. Remove the bolts connecting the body from inside. (You can remove the tire when the operation space is too narrow). Figure 27 DISASSEMBLING THE ENGINE HOOD CONTROL CABLE: 1.
  • Page 191 Chery Service Manual for A520 Body Dimension and Accessories hood lock is 14±2N·m. PDF created with pdfFactory Pro trial version www.pdffactory.com...

  • Page 192: Chapter Two Trunk Lid

    Chery Service Manual for A520 Body Dimension and Accessories CHAPTER TWO TRUNK LID I. DISASSEMBLING THE LUGGAGE COMPARTMENT DOOR 1. Pry out the license plate light with a flat head screwdriver; Figure 29 2. To pull out the harness from inside the luggage compartment, unplug the harness plug;...
  • Page 193 Chery Service Manual for A520 Body Dimension and Accessories 4. To remove the luggage compartment lock, remove the bolts with a wrench; Assembly requirements: Adjust the luggage compartment lock to make sure that the left and right clearance between the luggage compartment cover and the rear side enclosure is uniform 5±0.5 mm.
  • Page 194 Chery Service Manual for A520 Body Dimension and Accessories II. DISASSEMBLING THE TAIL LIGHT ASSEMBLY 1. Remove the luggage compartment wheel house trim assembly and the floor mat; Assembly requirements: The contact part of the carpet circumference and the luggage...
  • Page 195 Chery Service Manual for A520 Body Dimension and Accessories III. DISASSEMBLING REAR BUMPER Remove the three fastening screws to remove the rear cover of the trim panel; Figure 38 Remove rear bump fastening screws and bolts to remove the rear cover of the trim panel;...
  • Page 196 Chery Service Manual for A520 Body Dimension and Accessories Remove the harness connector of the reversing radar to remove the rear bump. Figure 41 IV. DISASSEMBLING THE WEATHER STRIP OF THE REAR LUGGAGE COMPARTMENT: Disassemble the weather strip of the rear luggage compartment as shown in the right figure.
  • Page 197 Chery Service Manual for A520 Body Dimension and Accessories PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 198 Chery Service Manual for A520 Body Dimension and Accessories CHAPTER SEVEN DISASSEMBLING AND INSTALLING THE EVAPORATOR 1. Appearance view of A21 evaporator 2. Necessary tools for disassembling Cross screwdriver, vice, flat screwdriver, 8# socket, ratchet gear and ratchet rod. 3. Disassembling...
  • Page 199 Chery Service Manual for A520 Body Dimension and Accessories 3) Pull out the blower. 3.1.2 Installation The installing steps are reverse to those for removal. 3.2 Replacing the heater water tank 3.2.1 Disassembling the heater water tank 1) Remove the bolts and clips as shown in the figure.
  • Page 200 Chery Service Manual for A520 Body Dimension and Accessories 3.3 Replacing the evaporator core assembly 3.3.1 Disassembling the evaporator core assembly Remove the fastening bolts for the expansion valve and the evaporator core assembly with an Allen wrench. Remove the three screws at the joint...
  • Page 201 Chery Service Manual for A520 Body Dimension and Accessories 4) Remove the screws as shown in the figure. Remove the fastening screws on the trunk lid of the evaporator core assembly to detach the trunk lid, and then take out the evaporator core assembly.
  • Page 202 Chery Service Manual for A520 Body Dimension and Accessories Remove the connecting screws that attach the speed regulating resistor module to the evaporator housing, and then pull out the speed regulating resistor module. 3.4.2 Installing the speed regulating resistor of the blower fan The installing steps are reverse to those for removal.
  • Page 203 Chery Service Manual for A520 Body Dimension and Accessories 3.6 Replacing the mode damper servo motor 3.6.1 Disassembling procedures Remove the pull rod connecting with the motor and remove the fastening screws connecting the motor with the bracket (3). 3.6.2 Installation procedures The installing steps are reverse to those for removal.
  • Page 204 Chery Service Manual for A520 Body Dimension and Accessories 3.8 Replacing the indoor temperature sensor 3.8.1 Disassembling procedures Disconnect the plug in unit of the sensor harness, remove the connecting screw that attach the hose to the housing and remove the hose, replace it.

  • Page 205: Chapter Six Instrument Panel

    Chery Service Manual for A520 Body Dimension and Accessories CHAPTER SIX INSTRUMENT PANEL 1. Horn Switch 2. Combination Instrument 3. Vent of Air Conditioning 4. Air Bag for Front Passenger Side 5. Steering Wheel Assembly 6. Air Bag Assembly 7. Ashtray 8.
  • Page 206 Chery Service Manual for A520 Body Dimension and Accessories 1. Remove the instrument mask; Figure 117 Remove the bolts as shown to remove the instrument; Note: Clearing method for the instrument maintenance indicator lamp ① Turn off the ignition switch;...
  • Page 207 Chery Service Manual for A520 Body Dimension and Accessories 4. Unscrew the fastening screw to remove the steering switch. Remove the wiper switch with the same method; Figure 120 5. Unscrew the fastening bolts with internal spline to remove the air bag assembly;...
  • Page 208 Chery Service Manual for A520 Body Dimension and Accessories 7. Remove right blanking cover assembly; Figure 123 8. Remove the left lower trim panel assembly of the instrument panel; Figure 124 9. Remove the glove box assembly; Figure 125 PDF created with pdfFactory Pro trial version...
  • Page 209 Chery Service Manual for A520 Body Dimension and Accessories 10. Remove the trim strip; Figure 126 11. Unscrew the fixing bolts; Figure 127 12. Remove the bezel of the central control panel; Figure 128 PDF created with pdfFactory Pro trial version...
  • Page 210 Chery Service Manual for A520 Body Dimension and Accessories 13. Remove the fastening bolts, take out the CD player, and then pull out the harness; Figure 129 14. Remove the fastening screw, take out the air conditioner control panel, and then pull out the harness;...
  • Page 211 Chery Service Manual for A520 Body Dimension and Accessories 16. Remove the fastening screws and bolts as shown; Figure 132 Figure 133 Figure 134 PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 212 Chery Service Manual for A520 Body Dimension and Accessories 17. Remove the bolts as shown to remove the instrument panel; Figure 135 18. Unscrew the fastening bolts as shown; Figure 136 19. Remove the fixing bolts at two sides to remove the beam;...
  • Page 213 Chery Service Manual for A520 Body Dimension and Accessories 20. Remove the front ISU module as shown; Figure 138 21. Let out the refrigerant, remove the fastening bolts on the expansion valve with an internal hexagonal socket to remove the expansion valve. Remove the two clamps with pliers to remove the water pipe.
  • Page 214 Chery Service Manual for A520 Body Dimension and Accessories 23. Detach the evaporator assembly after removes the fastening bolts and the ground wire; Figure 141 Figure 142 Figure 143 PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 215 Chery Service Manual for A520 Body Dimension and Accessories Figure 144 24. Detach the evaporator assembly after removes the fastening bolts and the Ground Wire ground wire; Figure 145 25. Remove the engine compartment shock pad. Figure 146 PDF created with pdfFactory Pro trial version...
  • Page 216 Chery Service Manual for A520 Body Dimension and Accessories CHAPTER THREE DOOR DISASSEMBLING LEFT FRONT DOOR Remove the trim strip from the left front door; Figure 44 Remove the outside weather strip from the left front door; Figure 45 Remove the set screw. Pull out the...
  • Page 217 Chery Service Manual for A520 Body Dimension and Accessories 4. Unscrew the set screw on inside door handle to detach the bezel for the inside door handle; Figure 47 5. Remove the screws and take out the arm rest cover. Pry out the window regulator switch and pull out the harness;...
  • Page 218 Chery Service Manual for A520 Body Dimension and Accessories Figure 50 7. Remove the protective film from the left front door; Figure 51 8. Remove the set screw of inside door handle to loosen the inside control cable and the inner retention cable;...
  • Page 219 Chery Service Manual for A520 Body Dimension and Accessories 9. Disassemble the set screws, pull out the harness, and then detach the speaker; Figure 53 10. Unscrew the fixing bolts from the trim panel bracket and then dismount it; Figure 54 11.
  • Page 220 Chery Service Manual for A520 Body Dimension and Accessories 12. Unscrew the seven fixing nuts on the inner door panel; Figure 56 13. Take window regulator assembly; Assembly requirements: M, the torque of the fixing bolt or nut should be 7±1 N· m. Make...
  • Page 221 Chery Service Manual for A520 Body Dimension and Accessories 15. Take out the rear guide rail of the glass from inside the door; Figure 59 16. Unscrew the fastening bolts from the lock with an internal spline wrench; Figure 60 17.
  • Page 222 Chery Service Manual for A520 Body Dimension and Accessories 18. The latch mechanism is as shown in the figure: A: Locking cable B: Opening out control cable C: Link the opening out push rod D: Link the latch pull rod Figure 62 19.
  • Page 223 Chery Service Manual for A520 Body Dimension and Accessories 21. Take out the door handle; A: Latch pull rod B: Opening out push rod C: Latch (could be replaced directly on the vehicle) Figure 65 22. Remove the door check;...
  • Page 224 Chery Service Manual for A520 Body Dimension and Accessories 24. Remove the glass run; Figure 68 25. The inner harness of the door could be taken out from outside; Figure 69 II. DISASSEMBLING THE REAR DOOR See left front door for considerations during disassembling the parts 1.
  • Page 225 Chery Service Manual for A520 Body Dimension and Accessories 2. Unscrew the screws to detach the inner and outer trim panels of the triangle glass; Figure 71 3. Unscrew the screw to detach the bezel for the inside door handle;...
  • Page 226 Chery Service Manual for A520 Body Dimension and Accessories 5. Pry out the window regulator switch to pull out the harness; Figure 74 6. The door trim panel could be removed; Figure 75 7. Remove the protective film from the left rear door;...
  • Page 227 Chery Service Manual for A520 Body Dimension and Accessories 8. Unscrew the fastening screw for the inside door handle to detach the handle; Figure 77 9. Remove the fixing bolts from the trim panel bracket; Figure 78 10. Lower the glass to a proper position,...
  • Page 228 Chery Service Manual for A520 Body Dimension and Accessories 11. Remove the fastening screws for the glass guide rail; Figure 80 12. Remove the top screws to detach the glass rear guide rail and the triangle glass; Figure 81 13. Remove the top fastening bolts from the window regulator;...
  • Page 229 Chery Service Manual for A520 Body Dimension and Accessories 14. Remove the lower bolts from the window regulator; Figure 83 15. Remove the lock fastening screws with an internal spline socket; Figure 84 16. Loosen the opening out pull rod from the door handle, pull out the harness, and then detach the lock;...
  • Page 230 Chery Service Manual for A520 Body Dimension and Accessories 17. Remove the door handle bolt 1; Figure 86 18. Remove the door handle bolt 2 to take out the handle; Figure 87 18. Remove the door check; Figure 88 PDF created with pdfFactory Pro trial version...
  • Page 231 Chery Service Manual for A520 Body Dimension and Accessories 19. Remove the weather strip from the door opening; Figure 89 20. Pull out the inner harness of the door from outside; Figure 90 PDF created with pdfFactory Pro trial version...
  • Page 232 Chery Service Manual for A520 Body Dimension and Accessories ADJUSTING THE DOOR I. ADJUSTING THE FRONT DOOR Adjust the front door in front, back and vertical directions: Unscrew the body hinge bolts to adjust the door with special tools for maintenance.
  • Page 233 CHERY A520 SERVICE MANUAL CHASSIS Steering pump ring CHAPTER II STEERING SYSTEM SECTION I INSTRUCTION AND Pressure plate OPERATION Thrust plate I. SAFETY REGULATIONS ON POWER Flow control valve STEERING SYSTEM Rotor If the risk of electrical short circuit exists in...
  • Page 234 CHERY A520 SERVICE MANUAL CHASSIS 3. The gear of pinion mesh with that of the Multi-functional driving handle controls gear rack. components as follows: - Headlight high beam 4. This shall make the gear rack move. - Windscreen wiper and washer...
  • Page 235 CHERY A520 SERVICE MANUAL CHASSIS SECTION II SPECIFICATIONS OF ASSEMBLY TORQUE Tightening Number Of Affiliated Assemblies Torque Vehicles Bracket And Low Right Bracket Of Secure Steering 25±3 Column 25±3 Connection Universal Connector And Steering gear 10±1 Secure steering sleeve bracket 10±1...
  • Page 236 CHERY A520 SERVICE MANUAL CHASSIS SECTION DISASSEMBLY ASSEMBLY OF STEERING SYSTEM DISASSEMBLY OF STEERING GEAR DISASSEMBLY: DISASSEMBLE UNIVERSAL CONNECTOR OF STEERING SHAFT 1. Loosen the fastening bolts of universal connector. II. DISMOUNT SUBFRAME ASSEMBLY 1. Discharge the power steering system (Refer to steering system fluid) 2.
  • Page 237 CHERY A520 SERVICE MANUAL CHASSIS 5. Loosen the fixed bolts at the both ends of left and right lower links. 6. Loosen the ball bolts on the left and right lower links. 7. Loosen the fixed bolts of subframe. 8. Lossen the fixed bolts of subframe.
  • Page 238 CHERY A520 SERVICE MANUAL CHASSIS 9. Loosen the fixed bolts of transmission’s rear mountings. 10. Dismount the frame assembly. III. DISMOUNT THE STEERING GEAR ASSEMBLY FROM THE SUBFRAME. 1. Dismount the fuel pipes of steering gear. Loosen the fixed bolts of pipe clamp.
  • Page 239 CHERY A520 SERVICE MANUAL CHASSIS Loosen the fixed bolts of pipelines on steering gear. Dismount high-pressure oil pipe and oil return pipe. 2. Dismount stabilizer bar. Loosen the extension bolts connecting the stabilizer bar to the lower link. Note: Before...
  • Page 240 CHERY A520 SERVICE MANUAL CHASSIS 4. Dismount thermal shield. 5. Remove the fixed bolts of steering gear. Remove the steering mechanism assembly. Assembly: The installing steps are reverse to those for removal PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 241 CHERY A520 SERVICE MANUAL CHASSIS SECTION IV MAINTENANCE MANUAL LIQUID FILLING LIQUID FILLING Type: ATF-Ⅲ Filling volume:1L First of all, fill steering fluid to the Max position when the engine stops operating. Start up the engine and fill steering fluid to the middle position between Max and Min.
  • Page 242 CHERY A520 SERVICE MANUAL CHASSIS 5. Ensure all old power steering fluid to be cleaned out from the power steering system. 6. Turn the ignition switch to the OFF (shut off) position. 7. If power steering fluid is polluted, the power steering system should be flushed out.
  • Page 243 CHERY A520 SERVICE MANUAL CHASSIS Inspection Method for Power Steering Oil On the power steering system, you should Variation of Liquid Level: Within 5mm take advantage of the engine power to drive the power steering oil to rotate, so that the pressure of power steering oil can generate steering driving force.
  • Page 244 CHERY A520 SERVICE MANUAL CHASSIS Inspection on Static Steering Force 1. Park the vehicle on the flat pavement, and rotate the steering wheel to the right ahead. Start up the engine and regulate engine’s rotation rate 1000±100r/min. Note: After checking the rotation rate of the engine, you must have it return to the standard idle speed.
  • Page 245 CHERY A520 SERVICE MANUAL CHASSIS function, but steering force must be boosted. 4. Since the power steering oil also serves as the lubricant of the system, therefore you are not allowed to drive your car when the liquid level is very low or there is no hydraulic oil in the liquid reservoir;...
  • Page 246 CHERY A520 SERVICE MANUAL CHASSIS SECTION V REGULAR TROUBLESHOOTING OF POWER STEERING SYSTEM Atmosphere Trouble Reason Troubleshooting Method 1. The tire pressure of steering 1. Inflate the tire to normalized wheel is very low. value. 2. All connecting linkages and 2.
  • Page 247 CHERY A520 SERVICE MANUAL CHASSIS 3. The power steering mechanism 3. Discharge the air from the is air-filled. power steering mechanism. 4. Hydraulic oil emulsion or 4. Replace hydraulic oil thickening Abrasion damage 5. Replace the redirector gear redirector gear PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 249 1． …………………………………………………………………………………………………………… ……… Vehicle Ele ctric Equipment Distributing Figure 2． …………………………………………………………… …………………………… ……………………………………………… Figure Rea ding Description ………………………………… ……………………………………… …………………………………………………………………………… 3． Connector Note 4． ……………………………………………………………………………………………… ……… Position of Front Engine Compartment Electric Equipment 5． ………………………………… ……………………………………… ……………………………………… ……… Position of Four Doors Electric Equipment ……...

  • Page 250: 2． Figure Rea Ding Description

    Figu re reading descript ion 2 Distribution of Various Earth points and Main Modules ． 1．Instruction of Main Circuit Symbols Wi rin g jo in t Gro und Connector H eater M otor Oxy gen Senso r Spir al Cable Spea ker E le ct rom agne tic co il S w i tc h co nt ro l...
  • Page 251 Figu re reading descript ion 2 Distribution of Various Earth points and Main Modules ． 1．Instruction of Main Circuit Symbols Wi rin g jo in t Gro und Connector H eater M otor Oxy gen Senso r Spir al Cable Spea ker E le ct rom agne tic co il S w i tc h co nt ro l...
  • Page 252 6 . Groun d points on the v ehicle ( actual 4. Number o f main c ircuit bo ard ACC1 ACC2 l ines sha ll prevail). with in relay box ILLUM ： 30 From the battery 1st. Negative of the battery 7th pin. Near 5．Fuse Numb er ：...
  • Page 253 Engine control unit pin description Connector Note Connect point Connect point ECU plug-in unit Oxygen se nsor heat ing Inle t temperature Ignition co il 2 Ignition co il to groun d Non- Persiste nt power Oxygen se nsor heat ing Non- Persiste nt power...
  • Page 254 ABS plug-in unit Front Groun d and F ront Right Front G round and Roof Harness Plug-I n Unit Door Harness Plug-In 45 46 — Front G round/ Fron t Right Door Front Ground/R oof 16 17 Front G round and Re ar Ground Harness Plug-In U nit Instrument and Front Ground Harness Plug-In Unit —...

  • Page 255: Position Of Front Engine Compartment Electric Equipment

    P osition of front engine com partme nt electric equ ipment Wiper Mot or A/C high/low pressure switch Ig nition coil Fuel injector High pressu re wire Knock sensor Cam sha ft p osi ti on se nso r （Only for 2.0L engine） Coolant temperatur e sensor Position of wiper motor Air flow m eter...

  • Page 256: Position Of Four Doors Electric Equipment

    Posi tion of Four D oors Electric Equipm ent F/L door wind ow regul ator assemb ly R/L door win dow reg ulator as sembly F/R door win dow reg ulator as sembly Fron t left do or Front right do or Rear left do or Rear right doo r Fro nt left do or lock...

  • Page 257: Position Of Instrument Electric Equipment

    Position of instrument electric equipment Key hole illuminat ion lamp Mirror for m ake up F ront passen ger side airb ag Co mbination instrument Horn switc h Re ar window heating Warn ing lamp switch Front fo g lamp R ear fog lamp Switch A ssem bly...

  • Page 258: Position Of Trunk Electric Equipment

    Posi tion of trunk electric equipment High- mounted brake lamp Rear left lamp Re ar right l am p Turn Light Back up L ight Bra ke Lamp/Si de Light Bulbs:12V 21W /5W Rear Fog Light Bulb s:12V 21W Re ar Repro ducer Tail Lamp Assembly Re ar ISU...

  • Page 259: Starting And Charging System

    Starting and Charging System Ignition switch： 1．Circuit diagram 1. 1# and 6# pin of ignition switch is the power of battery 30. 2. When the ignition switch is at the ACC position, the 1#、3# pin of ignition switch is connected, and ACC1 and ACC2 relay both get electricity. The contact point close, 30th live ACC1 wire-87# pin of ACC1 relay-30# pin of ACC1 relay-ACC1 wire get electricity;...
  • Page 260 2．Equipment position figure of starting and charging circuit 3．Starting and Charging System Circuit analy se Ign ition switch relay Starter rela y Starter motor 30A fuse Sb2 start charg ing circui t is shown as figure 8-1. The charging system is a system charging t he batter y with the output el ectricity o f the AC generator .
  • Page 261 ECU System Circuit ACC1 ACC1 ACC2 ACC2 ILLUM ILL UM FB15 7.5A This Fuse W ire is This Fuse Wire is FB16 FB31 FB32 FB20 Within the Within the Fuse Box J10# Fuse Box K10# Positive Fu se Box Positive Fuse Box Fuse Box K Fuse Box K Plug-In Unit...
  • Page 262 Engine management system is mainly composed of sensor、electronic control unit（ECU） and actuator three parts. It controls the basic air intake volume、fuel inject volume and ignition advance angle when then engine is running. The A5 automobile apply the ME7.9.7 electric control system, the constitution is shown as figure 9-2： Air int ake press ure temp erature s ensor Fuel distribution Spark plug...
  • Page 263 CODE. For example: the flashing of P0203 is : flash 10 times continuously-intermission-flash 2 ◆ Engine ECU times continuously-intermission-flash 10 times continuously-intermission-flash 3 times continuously. ECU receives and deals with the engine state signal s which is inputted by each sensor, （...
  • Page 264 （2）Electric throttle and accelarate pedal position sensor The crankshaft position sensor is to supply engine speed、 crankshaft rotating angle and TDC signal to ECU. I t is used to control the engine ignition and fuel eject timing. The driver offer the engine real time torque requirement to ECU with the help of accelerate pedal, ECU send the impulse signal to the electric throttle according to the information it gained.Therefore, the motor in the electric throttle run and the throttle open to the required angle.
  • Page 265 （5）Knock sensor （7）Oxygen s ensor The oxygen s ensor is used to detect th e content of oxygen in th e exhaust,the The knock sensor supply engine knock information to ECU, and control the knock. transmits a signal to ECU, a ccording to the in formation ECU wi ll make t he fuel closed loop control so that the eng ine can w ork in th e best C ondition, and mak e the CO, HC, N Ox comp ound tran sformed and depurated mo stly by the three-w ay catalytic converter .
  • Page 266 Fault descriptio n: Badnes s idle speed, badness acceleration, badness tail gas, over fuel （10）Clutch pedal switch consume et c. Fault analysis： Moist ure enterin g inside of s ensor, then the temper ature is ch anged and t he pin is br oken; The 1st pin of clutch pedal swit ch is connec tted the sensor i s poisoned（...
  • Page 267 Actuator ◆ （2）Fuel injector ECU sends electric impulse to the coil of injec tor and forms the magnetic field （1）Ignition coil power.Wh en the power incre ases enough to overcome the combined force o f release spring The ign ition coil transfor ms the low pressu re DC of battery to the hig h pressure pressure 、needle v alve grav ity and fri ction, the needle va lve begin to rise and the fuel inject procedure start.
  • Page 268 （ ）Fuel pump relay （4）A/C rela y The battery supplies power to electr ic fuel pum p through fuel pump relay, the relay The A/C switch open, blower switch open , the A/C pressure is normal, the can only p ut through the electric fuel pum p circuit when startin g or the engine is run ning. evaporator temperature sensor detects the correct data, the A/C requir ement signal is When the engine stop running a ccidently, the fuel pu mp will also stop automatically.
  • Page 269 （6）Canister purge valve （5）Cooling fan control module Canister purge valv e controls the volume of cleaning air flow from c harcoal ECU Controls the running of fan according to the engin e coolan t temperature canister to air int ake main pipe. Th e adsorb ing capab ility of carbon canister is l imited, and A/C requirement signa l, it contr ols the re lay of fan system if conditio ns are met.

  • Page 270: Abs System

    ABS System ABS brake down parts A CC 1 ACC 2 Brake lamp switch Brake pedal ABS control unit Hydraulic pressure ABS hydraulic pressure unit with pump electromotor low pressure reservior ILLUM Execute parts Control unit Sensor To The Brake Switch, ECU21#, Front ISU PE2 22# El ec tr oma gnetic v alv e...

  • Page 271: Airbag System

    Airbag System circuit analysis: AC C1 ACC 1 ACC2 T he circuit of airbag is shown as figure 11-1. AC C2 When there is serious frontal crash, to avoid the driver or front ILLUM ILLU M passenger bumping onto the steering wheel or instrument panel, there will be an airbag expand on the steering wheel and instrument panel so as to protect the driver and front passenger.

  • Page 272: Auto A/C System

    A uto A/C System AC C1 ACC2 1 LLUM T Wiper To Instrument F b13 External motor 2# 30 A 10 A Temperature Sensor Instrument /Air Fr ont Gr oun d/F ron t To Wiper Conditioner /14 En gin eCom pa rt ment /D Switch 9# T FRONT T FRONT...
  • Page 273 Auto A/C System Circuit Analyse： control the blower, when the coolant temperature is too low, the system will start the preheat control. That's to say when the coolant temperature is too low and it is in warming working condition , to prevent the cool wind from blowing out, if the coolant temperature is lower than the The Auto A/C is shown as figure12-1.

  • Page 274: Manual A/C System

    Manual A/C System Manual A/C System Circu it Analyse： ACC1 ACC2 The manual A/ C is shown as figure13-1. When the ignition switch is at the position of ON, the ACC1 and the 15th line get electricity. IL LU M The 15th line supplies power to the A20 pin of A/C controller .

  • Page 275: Front Isu System

    Front ISU System ACC1 ACC1 ACC2 ACC2 ILLUM ILLUM FB22 7.5A Inst rume nt/ Front Ins trument 11 Ground/ A2 FB30 W L/W W L/W W L/W (2)31 (3)58b High Beam Low Be am Rel ay Relay To Fron t E ngi ne Compartment Fus e Box G1 3 L1 2...
  • Page 276 A5 has two veh icle body compute r, one is front IS U shown as fig ure 14-2 electricity. （ W hen the ignition p ower is of f, open one door, the inner il lumination lamp wi ll light on the other is rear ISU .
  • Page 277 4．Headlamp circuit 3．Turn lamp and hazard warning light circuit （1）Turn lamp and dangerous warning lamp circuit （1）High Beam Circuit As shown in figure 14-4, the 30th power line supply power to the E pin of front ISU via fuse High Be am Contr ol Circuit： Fb29 and then fuse FB25, and output from the C20 pin of front ISU to suppply power to F/R turn The vo ltage of 30 th line→fu se FB22→h igh beam r elay coil→the A19 pi n of front I SU, lamp and right side turn lamp;...
  • Page 278 ACC1 ACC2 ILLUM FB22 7.5A To Ins trum ent 11 Right low beam High Beam Relay Low Beam Relay FB25 FB27 FB26 FB14 L 12 F/R Low beam Ins tru me nt / Fro nt I nstrum en t / Gr oun d/ 9 Fr ont G ro und /9 Left high beam...
  • Page 279 5．Night lamp adjusting circuit ACC1 T he n i g ht l am p a djus t i n g c ir cu it i s show n as fi gur e 14- ACC2 6 , t he br i g ht nes s ad j ustme nt of t he da r k l ight ( n i ght l am p ) i s ILLUM c o ntro ll e d by t he k nob a t t h e l ef t l o w e r par t o f i ns t rum ent.
  • Page 280 The CA N data bus designed by the BOSCH c ompany is applied b y Chery A5, sh own as fig ure 14-8. This enables the data communication of eac h compute r, and for ms the on-board network syst em. The in strument is con nectted to the engine EMS、A BS、front ISU computer by C AN line and...

  • Page 281: Rear Isu System

    Rear ISU System ACC1 ACC1 ACC2 ACC2 ILLUM ILLUM FB31 To front 7.5A To front ISU A29 ISU A30 Trunk Lid LockMotor Regulator Switch Regulator Switch Re ar Wind sh ield Conta ct Swi tch Contact Switch of Rear Right Door of Rear Left Door G lass Hea te r R ea r Lef t...
  • Page 282 （1）Reverse warning control unit （1）Rear ISU （2）Reverse warning R/L sensor （3）Reverse warning m id sensor The parts that controlled by the rear ISU have the following functions: （4）Reverse warning R/R sensor ①Rear window galvanothermy wire time control （5）Rear ISU computer ②Rear trunk lock motor （6）Reverse switch ③Rear trunk illuminat ion lamp...
  • Page 283 （3）Brake lamp a nd rev ersing lamp circuit The 30th wi re suppl ies power to the C1 pin of rear ISU via fuse Fb31, th e rear ISU gets el ectricity. The B1 pin of rear ISU is connect ted to th e left bra ke lamp、h igh-mou nted bra ke lamp and righ t brake la mp;...

  • Page 284: Instrument System

    Instrument System Circuit Analysis： ACC1 ACC1 ACC2 ACC2 The A5 aut omobile c ombination instrum ent contains serie s of instr uments ILLUM and met ers that show the vehicle status、all k inds of warning lamp that supervise ILLUM the vehi cle to pre vent abno rmal performance and inform the driv er and indicator FB22 lamps th at show the driver how each part wor ks and al so illume the instr uments To Air Bag...

  • Page 285: Wiper System

    Wiper System ACC1 ACC2 ILLUM Wip e r Mo tor b u ild in P lac e FB12 W iper System Circu it Analysis: The wi per system ciruit is s hown as fi gure 17-1 . W ip e r Mo to r P la ce W ip e r Mo to r The ACC2 power supply w ire supplies power to the C19 of front ISU、the 3r d、7th、8th pin of w iper switch via fuse F B12.

  • Page 286: Power Re Ar View Mirror System

    Powe r Rea r View Mirr or Sys tem Power Rear View Mirror System Circuit analyse： The power rear view mirror is shown as figure 18-1. When the ignition switch is set to the ACC1 ACC2 position of ON or ST, the voltage of the battery gets to the 15th wire→7.5A fuse Fb2→7th pin of power rear view mirror switch, the power rear view mirror get voltage.

  • Page 287: Power Window Of Front Door & Pow Er Door Lock System

    Power Window of Fr ont Door & P ower D oor Lock System AC C1 ACC2 ILLU M Re ar Righ t Rea r Le ft Fro nt R igh t F ron t Le ft Doo r D oor Do or D oor Lo ck M ot or...

  • Page 288: Electric Seat System

    Electric Seat System Power W indow of Front Do or & P ower Door L ock Cir cuit analyse： ACC1 The circuit analysis of fron t door window lifter and four doors lock. ACC2 Please re fer to fig ure 19- 1. I LLUM 1．p ower w indow The power window system c ircuit is composed of power wi ndow main...
  • Page 289 Electric Seat System C ircuit Analys is： The driver seat of A5 is elec tric adjust able seat. It has four adjusting m otor and adjust （3）Up wards an d downw ards of s eat rear part control switc h. The adj usting mot or is perma nent magnet motor. I t realizes t he the circ umvolve When press the UP button of t he seat's r ear part, battery voltage that r eaches the from frontisp iece to inv erse with t he differen t electrifi ed directio n of each m otor .

  • Page 290: Seat Heater System

    S eat Heater Sys tem S eat Heater System Circuit Analysis： ACC1 ACC2 （1）Front lef t seat he ater I LLUM ◆Control circ uit When press the front left seat heating switch, the voltage of ACC2 wire→ 15 A Fb6 fu se→2nd p in of front left sea t heating switch→contact point of f ront left seat heating switch→...

  • Page 291: Audio System

    Audio System Cir cuit Analysis : The circui t of the acoustics is shown as f igure 22-1 . The aco ustic syste m possess the fuctio ns of tape play、radio listenin g 、broad cast frequency memory、sound control、front/rea r/left /righ t reprod ucer volum e and so on.
  • Page 292 Audio System Cir cuit Analysis : The circui t of the acoustics is shown as f igure 22-1 . The aco ustic syste m possess the fuctio ns of tape play、radio listenin g 、broad cast frequency memory、sound control、front/rea r/left /righ t reprod ucer volum e and so on.

  • Page 293: Sun Roof & Cigarette Lighter System

    Sun roof & Cigarette Lighter System Circuit Analysis： ACC1 AC C2 1. The voltage of the 30 th wire supply to the 1st pin ILLUM of sun roof system via fuse F b17; The voltage of the 30th wire supply to the 4th pin of s un roof s ystem via fuse FB24 FB17 FB24 and then k ey switch signal, the 4th p in of the sun roof is...

  • Page 294: Circuit Of The Front Engine Compartment Fuse Box

    Circuit of the Front Engine Compartment Fuse Box FB29 B attery FB22 FB23 SB 4 FB21 FB19 FB24 3 0A 6 0A High Lo w AC C AC C I GNITION beam be am RELAY relay RELAY REL AY re lay FB26 FB2 4 F B4...
  • Page 295 Front Engine Compartment Fuse Box Relay Box Po wer of instru ment 、 fron t ISU and combin ation switch illumin ation the 15th wire EC U15 pin power Ignition relay Po wer Power rear of air view Fuse Starter mirro r main Reserve...
  • Page 296 voltage of batter y→FuseFB29→fu se FB19→the E10 pin of Ci rcuit of the Front Circuit of the Front Engine Compartme nt Fuse Box Circuit Engine Compart ment Fuse Box→s upply po wer to TC U。 Analyse ： 7． Voltag e of battery→Fuse FB29→fuse SB6→the C1 p in of Circ uit of the Front E ngine Co mpartment Fuse Box→supply power to ignition lighter 1．...
  • Page 297 ② Fu se FB3→ the L10 pin of Circuit of the F ront En gine Co mpartme nt Fuse ② fuse FB9→ the K17 pin of Circuit of the Front Eng ine Compartment Fuse B ox→Inst rument/ ISU/DL C。 Box→Re ar Oxygen Sensor Warmer。 ③F Fb1→the K7 p in of Circuit of the Front Engine C ompartment Fus e Box→...
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  • Page 324 CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM CONTENT 1. NOTICE TO THE EFI SYSTEM SERVICE ..................3 1.1. GENERAL SERVICE ...........................3 1.2. NOTICE DURING THE SERVICE.....................3 1.3. SERVICE TOOLS .........................4 1.4. EXPLANATIONS OF THE ABBREVIATION IN THE MANUAL.........6 2. ME7.9.7 SYSTEM INTRODUCTION....................6 2.1.
  • Page 325 CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM 8. Regular starts but idle speed is not steady after the engine heating........60 9. Regular starts but idle speed is not steady or dying out when there is partial loading..61 10. Regular starts with high idle speed..................62 11.

  • Page 326: Notice To The Efi System Service

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM EFI SERVICE MANUAL A21 car is equipped with ME7.9.7 EFI system which developed by UAES. This manual will introduce the general service and the operational principle and character of sensor elements of EFI system in detail. At last there will be some diagnostic method and flow for the typical problems.

  • Page 327: Service Tools

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM decrease its life. And do not exchange anode and cathode of the pump. ● Carry out jump spark inspection at necessary time when inspect the ignition system, and the time to inspect must be short. Do not open the throttle valve to prevent a lot of...
  • Page 328 CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM Tool name: Digital multimeter Function: Inspect the character parameter of voltage, current, resistance. Tool name: Fuel pressure gauge Function: Inspect the pressure in fuel system, judge the status of fuel pump and fuel pressure regulator.

  • Page 329: Explanations Of The Abbreviation In The Manual

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM 1.4. EXPLANATIONS OF THE ABBREVIATION IN THE MANUAL DG Speed Sensor DVE Electronic Throttle Valve DR Fuel Pressure Regulator FPM Accelerator Pedal ECU Electronic Control Unit (Computer) EKP Fuel Pump EMS Engine Management System...
  • Page 330 CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM Engine electronic control system schematic of ME7.9.7 chart 2.2 Phase Sensor Ignition Coil Canister Control Valve Fuel Distribution Pipe Assembly Phase Sensor Air intake temperature sensor Oxygen Sensor Front Catalytic Converter Knock Sensor Temperature Sensor...

  • Page 331: Control Signal: Me7.9.7 System Input/Output Signal

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM ME7.9.7 engine management system is an electronic gasoline control system, and it can provide lots of control characters about operator and vehicle or equipment. The system adopts a combination method of open loop and closed loop (feed back) control to provide all kinds of control signal to engine.

  • Page 332: Introduction Of System Malfunction Diagnosis Function

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM Cooling fan relay 2.3. INTRODUCTION OF SYSTEM MALFUNCTION DIAGNOSIS FUNCTION 2.3.1. MALFUNCTION INFORMATION RECORD The ECU monitors sensor, actuator, related circuit, malfunction indicator and accumulator voltage etc., and EUC itself continuously. At the same time the ECU inspect the reliability test on sensor signal output, actuator driving signal and internal signal (e.g.: closed loop...

  • Page 333: 3, Diagnosis Meter Connection

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM ★ Output winking code that is P-CODE value after the K cable contact with the ground more than 2.5 seconds. For example: the winking mode of P0203 is: wink 10 times continuously – intermission – wink 2 times continuously – intermission - wink 10 times continuously –...
  • Page 334 CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM l Idle speed control l Knock control l Provide sensor power: 5V/100mA l Closed loop control l Control carbon canister solenoid valve l Air conditioner switch l engine malfunction indicator l Fuel fix quantity modification...
  • Page 335 CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM Accelerator position sensor Sensor 1 Brake switch Upstream oxygen sensor Speed signal Knock sensor A Medium switch Knock sensor B Power 1 Brake light CAN communication Non persistent power Electronic throttle valve Accelerating sensor...
  • Page 336 CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM l Malfunction phenomena: idle speed not stable, accelerating not good, can not start, idle speed is too high, exhaust gas exceed standard, difficult to start, air conditioner failure, injector control failure, engine dies out etc..

  • Page 337: Coolant Temperature Sensor

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM 3.2 COOLANT TEMPERATURE SENSOR 1)exterior drawing and pin This sensor has two exchangeable pins. 2)Purpose: The sensor provide the coolant temperature signal to ECU for ignition timing and modifying fuel injection of starting, idle speed and normal working.

  • Page 338: Knock Sensor

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM (Disassemble joint)leave digital multimeter at ohm shift and contact the No.1 and No. 2 pin of the sensor by its two meter ℃ pens. When it is 20 Rated the resistance is 2.5kΩ±5%. The other temperature can get reference from above chart.

  • Page 339: Oxygen Sensor

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM l Malfunction phenomenon: badness accelerating. l Normal malfunction reason: all kinds of liquid such as oil, coolant, braking liquid and water contact with sensor for a long time and erode the sensor. l Simple measuring method: (disassemble the joint) put digital multimeter at ohm shift, and contact the No.1, No.

  • Page 340: Speed Sensor (Crankcase Positioning Sensor)

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM tube inside. The working of oxygen sensor is carried out by transferring the concentration difference of the oxygen ion outside of ceramic tube to voltage (100mv—900mv)signal and output. 5)Working voltage:12—14V 6)Malfunction and diagnosis method...
  • Page 341 CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM Service notice: l For the inductive engine speed sensor, it is permitted to take out from its pack before it is assembled to the auto or testing device right away. l Inductive engine speed sensor is assembled by press in method but not hammer tapping.

  • Page 342: Phase Sensor (Cam Shaft Positioning Sensor)

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM 3 sensor connectors. The rated resistance is 860Ω±10% When it is 20℃ 3.6 PHASE SENSOR (CAM SHAFT POSITIONING SENSOR) 1)Exterior drawing and pin This sensor has three pins: No. 1 grounding, No. 2 for signal output and No. 3 connecting to power anode.

  • Page 343: Electric Fuel Pump

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM 3.7 ELECTRIC FUEL PUMP 1)Exterior drawing and pin The electric fuel pump has two pins connecting to pump relay. There are “+”and “-” showing anode and cathode on the pump housing near to pins.

  • Page 344: Electromagnetic Injector

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM different flow according to the requirement of engine, but with the same exterior looking. The pump which can be assembled to perhaps is not the fittest. For service the replaced electric fuel pump must has the same part number as the original pump;...

  • Page 345: Air Flow Sensor

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM conquer Return spring pressure, needle valve gravity and friction force, the needle valve begin to rise up and start the injection process. The pressure of return spring makes needle valve close again when the injection impulse is stopped.

  • Page 346: Double Spark Ignition Coil

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM make the heat exchange different of the heat diaphragm of both sides. This will make the temperature of two sensing element measuring point inside of the flowmeter Changes differently and appears difference in temperature. And the difference of the temperature will increase with the increase of the airflow.
  • Page 347 CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM anode. 2)Installation position: on the engine 3)Purpose: Ignition coil transfers the low voltage of primary winding to high voltage of secondary winding, and produce spark by spark plug discharging then burning the combustible gas inside of the cylinder.

  • Page 348: Carbon Canister Solenoid Valve

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM 3.11 CARBON CANISTER SOLENOID VALVE 1)Exterior drawing and pin definition Canister control valve only has two pins; one is connect to No.87 pin of main relay output end; and another pin connected to No. 5 pin of ECU.

  • Page 349: Fuel Pressure Regulator

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM joint) leave digital multimeter to ohm shift, two meter pen connect to the pins of canister valve, it is 26±4 Ω when it is 20 . ℃ 3.12 FUEL PRESSURE REGULATOR 1)Exterior drawing 2)Installation position: Fuel bracket assembly 3)Purpose: Adjust the pressure inside of fuel pipe, keep the System pressure around 350Kpa.

  • Page 350: Electronic Throttle Valve And Accelerator

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM causticity liquid to wash it; 3, avoid it from distorting by outside force. Simple measurement method: connect fuel pressure gauge at fuel intake pipe, start the engine and make the engine running at idle speed;...

  • Page 351: Fan Control

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM requirement of the engine working conditions according to the impulse signal frequency and width of impulse. 3.14 FAN CONTROL ECU control the fan according to water temperature of the engine and the requirement signal and control the fan system delay at the fit conditions.

  • Page 352: Air Conditioner Control

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM Short circuits from low-speed relay line to ground Open circuits of low-speed relay line Engine coolant temperature sensor failure Engine intake air temperature sensor failure 3.15 AIR CONDITIONER CONTROL 1)Working principle Switch on the air conditioner and blower; air...

  • Page 353: Me7 System Test And Repair According To Tdc

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM Blower circuit malfunction (fuse is burnt, relay circuit is open circuit or short circuit) Irregular pressure of air conditioner (much higher of the high voltage or the much lower of the low voltage) Malfunction of evaporator temperature sensor...
  • Page 354 CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM Much lower voltage of the air intake P0107 P0340 Phase sensor signal failure pressure sensor Much higher voltage of the air intake Much lower voltage of the phase P0108 P0342 pressure sensor sensor Indicated temperature is much lower of...

  • Page 355: Diagnosis Flow When There Is Different Dtc

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM unreasonable failure 4.2 DIAGNOSIS FLOW WHEN THERE IS DIFFERENT DTC P0107 Much lower voltage of the air intake pressure sensor Operating steps Result Follow up steps Connect the diagnostic tester and commutator, put the Next step ignition switch to “ON”...
  • Page 356 CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM DTC P0112 Circuit voltage is much lower of the throttle position sensor Operating steps Result Follow up steps Connect the diagnostic tester and commutator, put the Next step ignition switch to “ON” Observe “air intake temperature” item in data flow, if it is To step No.
  • Page 357 CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM Repair or Check if it is short circuit to ground between ECU pin replace No. 17, No. 40 and sensor connector No.1, No.2 cable Next step Start the engine at idle speed. Observe the value changes Diagnosis help of diagnostic tester “air intake temperature”, the value...
  • Page 358 CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM at that time). ℃ Notice: if the value always is - 40 there is perhaps open circuit failure in the circuit. Take off the joint of coolant temperature sensor on Next step the cable, check the resistance values using multimeter between the sensor connector No.
  • Page 359 CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM DTC: P0123 Circuit voltage is much higher of the throttle position sensor Operating steps Result Follow up steps Connect the diagnostic tester and commutator, put Next step the ignition switch to “ON” Observe “throttle valve absolute opening” item in...
  • Page 360 CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM Operating steps Result Follow up steps Connect the diagnostic tester and commutator, put the Next step ignition switch to “ON”. Start the engine and leave it at idle speed until its Diagnosis help coolant reaches to the normal value. Observe the value changes of “oxygen sensor voltage”...
  • Page 361 CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM connectors C (white) and D (white) using multimeter, Change sensor and observe if it is 2-5Ω when it is 20℃. Check the fuse inside of oxygen sensor heating circuit Change fuse and observe if it is blow.
  • Page 362 CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM DTC: P0172 Closed loop air fuel ratio control self adapting exceeds it minimum limit (Notice: below diagnosis flow is fit for when air intake pressure sensor failure, canister control valve failure and oxygen sensor failure are not appeared at the same time; if there are failures existing at the same time please deal with other failures at first and then do as below.)
  • Page 363 CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM and observe if it is around 3.7V. Diagnosis help Check if there is open circuit or short circuit to ground Repair or replace between 1 cylinder injector joint pin No.2 and the cable ECU pin No.27.
  • Page 364 CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM between 3 cylinder injector joint pin No.2 and the cable ECU pin No.7. Diagnosis help DTC: P0204 The 4 cylinder injector circuit failure Operating steps Result Follow up steps Connect the diagnostic tester and commutator, put the Next step ignition switch to “ON”...
  • Page 365 CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM Operating steps Result Follow up steps Connect the diagnostic tester and commutator, put the Next step ignition switch to “OFF” Take off the knock sensor joint from the cable; check Next step the resistance value by multimeter between knock sensor connector No.1and No.2 and observe if it is...
  • Page 366 CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM DTC: P0340 Phase sensor signal failure Operating steps Result Follow up steps Connect the diagnostic tester and commutator, put the Next step ignition switch to “ON” Take off the phase sensor joint from the cable; check the To step No.4...
  • Page 367 CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM DTC: P0343 Much higher voltage of the phase sensor Operating steps Result Follow up steps Connect the diagnostic tester and commutator, put the Next step ignition switch to “ON” Take off the phase sensor joint from the cable; check To step No.4...
  • Page 368 CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM DTC: P0444 Much lower voltage of canister control valve drive grade control circuit Operating steps Result Follow up steps Connect the diagnostic tester and commutator, put the Next step ignition switch to “ON” Take off the canister control valve joint from the cable;...
  • Page 369 CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM DTC: P0480 Air conditioner condenser cooling fan relay control circuit failure Follow up Operating steps Result steps Connect the diagnostic tester and commutator, put the Next step ignition switch to “OFF” Take off the air conditioner condenser cooling fan relay;...
  • Page 370 CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM DTC: P0506 Rotating speed of idle speed is lower than target idle speed Operating steps Result Follow up steps Connect the diagnostic tester and commutator, put the Next step ignition switch to “OFF”. Next step...
  • Page 371 CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM DTC: P0508 Idle speed regulator control circuit voltage is too low Operating steps Result Follow up steps Connect the diagnostic tester and commutator, put the Next step ignition switch to “ON”. Take off the idle regulator joint and Check the resistance...
  • Page 372 CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM Check if there is open circuit or short circuit to ground Repair or between the circuits of ECU pin No.44, No.45, No.63 and replace cable main relay pin No.87. Next step Next step Start the engine and check if the entire generator recharging Replace voltage is around 9-16V at the different engine speed.
  • Page 373 CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM DTC: P0601 ECU testing code failure Operating steps Result Follow up steps Connect the diagnostic tester and commutator, put the Next step ignition switch to “ON”. Next step Clean up the DTC and check the failure once again if it System if is a steady failure.
  • Page 374 CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM DTC: P0646 Much lower voltage of air conditioner compressor relay control circuit Operating steps Result Follow up steps Connect the diagnostic tester and commutator, put the Next step ignition switch to “OFF”. Take off air conditioner compressor relay; put ignition To step No.4...

  • Page 375: Typical Failure And Its Diagnosis Flow

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM DTC: P1651 Trouble light control circuit failure Follow up Operating steps Result steps Connect the diagnostic tester and commutator, put the Next step ignition switch to “ON”. Carry out action test to engine trouble light by using Next step diagnostic meter “actuator action test”...

  • Page 376: Typical Failure Diagnosis Flow

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM 2 Confirm that the failure exists before the customer complaints; 3 Inspect the engine according to the above steps and find nothing wrong; 4 During the service please do not ignore the influence from vehicle maintenance, cylinder pressure, mechanical ignition timing and fuel conditions;...

  • Page 377: The Engine Can Draw Rotating But Can Not Start Successfully When It Is Started

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM 2. The engine can draw rotating but can not start successfully when it is started. General failure component: 1) no fuel in fuel tank; 2) fuel pump; 3) speed sensor; 4) ignition coil; 5) engine mechanical part.

  • Page 378: It Is Hard To Start The Heating Car

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM 3. It is hard to start the heating car. General failure component: 1) water inside of fuel; 2) fuel pump; 3) coolant temperature sensor; 4) fuel pressure regulator vacuum pipe; 5) ignition coil. General diagnostic flow...

  • Page 379: It's Hard To Start The Cold Car

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM 4. It’s hard to start the cold car. General failure component: 1), water in the fuel; 2), fuel pump; 3), coolant temperature sensor; 4), injector; 5), ignition coil; 6), throttle valve and idle speed by pass port; 7), engine mechanical part.

  • Page 380: Normal Engine Speed But Hard To Start At Any Time

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM 5. Normal engine speed but hard to start at any time. General failure component: 1), water in fuel; 2), fuel pump; 3), coolant temperature sensor; 4), injector; 5), ignition coil; 6), throttle valve and idle speed by pass port; 7), air intake port;...

  • Page 381: Regular Starts But The Idle Speed Is Not Steady At Any Time

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM 6. Regular starts but the idle speed is not steady at any time. General failure component: 1), water in fuel; 2), injector; 3), spark plug; 4), throttle valve and idle speed by pass port; 5), air intake port; 6), idle speed regulator; 7), ignition timing;...

  • Page 382: Regular Starts But The Idle Speed Is Not Steady During Engine Heating

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM 7. Regular starts but the idle speed is not steady during engine heating. General failure component: 1), water in fuel; 2), coolant temperature sensor; 3), spark plug; 4), throttle valve and idle speed by pass port; 5), air intake port; 6), idle speed regulator;...

  • Page 383: Regular Starts But Idle Speed Is Not Steady After The Engine Heating

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM 8. Regular starts but idle speed is not steady after the engine heating. General failure component: 1), water in fuel; 2), coolant temperature sensor; 3), spark plug; 4),throttle valve and idle by pass port; 5), air intake port; 6), idle speed regulator;...

  • Page 384: Regular Starts But Idle Speed Is Not Steady Or Dying Out When There Is Partial Loading

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM 9. Regular starts but idle speed is not steady or dying out when there is partial loading. General failure component: 1) air conditioner system; 2) idle speed regulator; 3) injector. General diagnosis flow: Operating steps...

  • Page 385: Regular Starts With High Idle Speed

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM 10. Regular starts with high idle speed. General failure component: 1) throttle valve and idle speed by pass port; 2) vacuum pipe; 3) idle speed regulator; 4) coolant temperature sensor; 5) ignition timing. General diagnosis flow:...

  • Page 386: Low Engine Speed Or Dying Out Exists When It Is Accelerated

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM 11. Low engine speed or dying out exists when it is accelerated. General failure component: 1) water in fuel; 2) air intake pressure sensor and throttle position sensor; 3) spark plug; 4) throttle valve and idle speed by pass port; 5) air intake port;...

  • Page 387: React Slowly When It Is Accelerated

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM 12. React slowly when it is accelerated. General failure component: 1) water in fuel; 2) air intake pressure sensor and throttle position sensor; 3) spark plug; 4) throttle valve and idle speed by pass port; 5) air intake port;...

  • Page 388: The Performance Is Poor When It Is Accelerated

    CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM 13. The performance is poor when it is accelerated. General failure component:1) water in fuel; 2) air intake pressure sensor and throttle position sensor; 3) spark plug; 4) ignition coil; 5) throttle valve and idle speed by pass port;...
  • Page 389 CHERY·A21 SERVICE MANUAL ENGINE EFI SYSTEM Next step Repair or Check the exhaust pipe if the air exhausting is smooth replace exhaust pipe Diagnosis Connect EFI system adaptor, turn on the ignition switch; help check the power supply of pin No.12, 13, 44, 45 and No.63 Repair if it is in right conditions;...
  • Page 390 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE MECHANISM OF 2.0NA ENGINE CONTENT CHAPTER 1 ENGINE PARAMETER AND SPECIAL MAINTENANCE TOOLS ..2 SECTION 1 TECHNOLOGY DATA INSTRUCTION ..........2 SECTION 2 SPECIAL TOOLS................... 5 SECTION 3 ENGINE NUMBER POSITION ............. 6 SECTION 4 COLLATING METHOD OF ENGINE TIMING........

  • Page 391: Chapter 1 Engine Parameter And Special Maintenance Tools

    CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE CHAPTER 1 ENGINE PARAMETER AND SPECIAL MAINTENANCE TOOLS SECTION 1 TECHNOLOGY DATA INSTRUCTION ENGINE CHARACTER Engine Model SQR481H 4-Cylinder, Water Cooled, In-line Double Overhead Camshaft, 16 Valve, Engine Type Controllable Burning Rate, Variable Valve Timing Cylinder Diameter（mm）...
  • Page 392 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE TECHNOLOGY DATA INSTRUCTION Item Standard Value Intake cam 37.15 Cam Height Exhaust cam 37.05 − Intake cam − Camshaft Diameter Camshaft − Exhaust cam − Intake cam 0.15--0.20 Axial clearance of Camshaft Exhaust cam 0.15--0.20...
  • Page 393 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE Outer Diameter Pressure Height 16±0.3 Protruding Part of Valve Stem 47.5 Piston Piston Skirt Diameter 83.46±0.009 Ring 0.04--0.08 Side Clearance Ring 0.01--0.025 Ring 0.2--0.4 End Play Ring 0.4--0.6 Piston Ring Ring Height...

  • Page 394: Section 2 Special Tools

    CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE SECTION 2 SPECIAL TOOLS Camshaft Timing Tool Crankshaft Timing Tool Flywheel Tool Guide Sleeve of Crankshaft Oil Seal Guide Sleeve of Camshaft Oil Seal Hydraulic Hoist PDF created with pdfFactory Pro trial version...

  • Page 395: Section 3 Engine Number Position

    CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE Fuel Pressure Gauge Cylinder Pressure Gauge: when measure the cylinder pressure, firstly remove the spark plug, screw the pipe end of instrument instead of it, and operate the engine by starter, then take the maximum value in cylinder pressure gauge as cylinder pressure.

  • Page 396: Section 4 Collating Method Of Engine Timing

    CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE SECTION 4 COLLATING METHOD OF ENGINE TIMING 1. Remove the upper cover of engine timing belt. 2. Remove the lower cover of engine timing belt. 3. Loosen the central bolt of timing belt tension pulley and remove the timing belt.
  • Page 397 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE 5. Loosen the bolt of valve cover and remove the valve cover. 6. Rotate the camshaft in order to clip the camshaft tool into the slot at the end of Camshaft Tool camshaft.

  • Page 398: Chapter 2 Engine Body

    CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE 9. Mount the timing belt and rotate tension pulley with Allen wrench in order to tension the belt and make the finger of tensioner point to the middle of U slot opening. Fasten the bolt of tension pulley,...
  • Page 399 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE II. MAINTENANCE 1. Replace upper and lower covers of timing belt 1.1 Needed tools and auxiliary materials Allen wrench, 10#, 13# sleeve, ratchet wheel and ratchet rod. 1.2 Removal Loosen the five bolts on the upper cover with Allen wrench.
  • Page 400 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE Remove the 5 bolts on the lower cover of timing belt with 10# sleeve, ratchet wheel and ratchet rod. Remove the lower cover. Inspection Observe the timing cover and the timing belt.
  • Page 401 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE timing belt” for details). Loosen the central bolt of tension pulley and remove the timing belt. 2.3 Inspection Check the timing belt carefully; replace the parts if any following situation occurs. (1) Chap of back-side rubber (2) Chap of dedendum, chap of separated cord fabric.
  • Page 402 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE 2.4 Installation The installing steps are reverse to those for removal. Note: Do engine timing. 3. Replace idler wheel, tensioner and contact belt pulley 3.1 Needed tools and auxiliary materials Allen wrench, 10#, 13# and 15# sleeve, ratchet wheel and ratchet rod.

  • Page 403: Section 2 Cylinder Head

    CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE SECTION 2 CYLINDER HEAD I. STRUCTURAL DIAGRAM 1. Gasket—Intake Manifold 5. Gasket—Throttle Valve Body Assembly 2. Intake Manifold Assembly 6. Oil injector Assembly 3. Hexagonal Flange Bolt 7. Fuel Distribution Pipe Assembly 4.
  • Page 404 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE 1. Intake Valve 12. Front Camshaft Oil Seal 2. Valve Oil Seal 13. Exhaust Camshaft Assembly 3. Valve Spring Seat 14. Rocker Arm Assembly 4. Valve Spring 15. Hydraulic Tappet Assembly 5. Valve Spring Retainer 16.
  • Page 405 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE II. MAINTENANCE Replace intake manifold, delivery pipe and oil injector 2.1.1 Needed tools and auxiliary materials Ratchet wheel, ratchet rod, 10# sleeve and crosshead screwdriver 2.1.2 Process of removal Put the ignition key at the OFF position.
  • Page 406 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE 2.1.3 Installation steps The installing steps are reverse to those for removal. 2.2 Replace camshaft, bearing bushings, valve and valve oil seal. 2.2.1 Needed tools and auxiliary materials Special tools for valve oil seal, engine...
  • Page 407 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE Dismantle the belt pulley of air intake and exhaust camshafts with torque wrench. Remove the back cover of timing belt. Dismantle the bearing caps of air intake and exhaust camshaft respectively and put them down in the sequence.
  • Page 408 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE See the following picture for removal sequence of intake and exhaust camshaft-bearing caps: 8) Take out the camshaft and the hydraulic tappet. 9) Remove the valve spring with special tools. (Picture is unavailable) 10) Remove the used valve oil seal with special tools.
  • Page 409 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE 2) Check camshaft Measure camshaft diameter with micrometer caliper. Standard Value Limit Value （mm） (mm) -0.040 ￠24 Diameter -0.053 Replace with the new camshaft if the measured value exceeds the limit value.
  • Page 410 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE Use internal micrometer guage to measure the internal diameter of valve guide and the measuring point is a Measuring Point quartering point of guide. Calculate the difference of measured value and the clearance.
  • Page 411 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE Examine the protruding capacity of Top of Valve Stem valve stem. And Examine the protruding high of valve stem with vernier caliper.（See picture） Protruding High of Valve Stem Standard Value （ mm）...
  • Page 412 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE Revise it if the planeness exceeds, and replace when it exceeds the limit value. The permitted maximum abrading thickness between cylinder block and cylinder head is: 2.2.3 Installation The installing steps are reverse to those for removal.
  • Page 413 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE 1. Pad—Thermostat Seat 2. Thermostat Seat 3. Hexagonal Flange Bolt 4. Thermostat Assembly 5. Hexagonal Flange Bolt 6. Cover—Thermostat Seat 2.3.2 Needed tools and auxiliary materials Hatch clamp,10# sleeve, ratchet wheel and wrench 2.3.3 Removal...

  • Page 414: Section 3 Short Engine

    CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE SECTION III SHORT ENGINE I. STRUCTURE DIAGRAM 1. Piston 12. Oil Pump 2. Connecting Rod Upper Bearing 13. Bolt 3. Timing Hole Plug 14. Gasket 4. Connecting Rod Lower Bearing 15. Crankshaft Timing belt pulley 5.
  • Page 415 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE 23. Crankshaft Main Bearing Bolt 26. O-Type Ring 24. Frame Bolt 27. Crankshaft 25. Frame 28. Cylinder Block PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 416 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE II. MAINTENANCE 1. Replace oil pan 1.1 Needed tools and auxiliary materials 10# open end wrench, 10#, 15# and 17# sleeve, ratchet wheel and ratchet rod, Le Tai 5901 Glue, engine oil 1.2 Process of Replacement...
  • Page 417 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE Remove the connecting bolt between the oil return pipe of PVC valve and the oil pan with 15# sleeve wrench. Tap the edge of oil pan with rubber pestle, and then remove the oil pan.
  • Page 418 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE 2 Replace the engine oil strainer 2.1 Needed tools and auxiliary materials 10# open end wrench, 10#, 15#, 17# sleeve, ratchet wheel and ratchet rod, Le Tai 5901 Glue, engine oil 2.2 Process of replacement 2.2.1 Process of removal...
  • Page 419 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE 3 Replace the piston, piston ring, piston pin and connecting rod bearing 3.1 Needed tools and auxiliary materials 10# open end wrench, 10#, 15#, 17# sleeve, ratchet wheel and ratchet rod, Le Tai 5901...
  • Page 420 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE Uplift the connecting rod and the piston with a wooden stem and then remove the connecting rod and piston assembly. Remove the piston ring. Remove the retainer ring of piston pin and draw out the piston pin.
  • Page 421 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE Examine the clearance between piston ring and ring groove. Clean up the accumulated carbon in the ring groove with piston ring. Examine the clearance between piston ring and ring groove with feeler gauge.
  • Page 422 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE Inspect the diameter of piston pin and piston pin hole. As the following picture, measure the piston position around with micrometer caliper. take the maximum value as the diameter of piston pin.
  • Page 423 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE Inspect the connecting rod journal and connecting rod bearing Examine the diameter of connecting rod journal. Measure the axle diameter of connecting rod with micrometer caliper. Rotate the crankshaft 90° and measure it again.
  • Page 424 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE Loosen the connecting rod bolt, remove the cap, and measure the maximum width of pressed clearance gauge with the ruler on its package to get the clearance value. Standard Abrasion Value Limit Clearance 0.016—0.051...
  • Page 425 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE Inspect cylinder Inspect if the cylinder wall is scratched or scored. If there are cylinder scoring and scratching you need to hone cylinder wall, replace cylinder liner or replace 12 mm cylinder block.
  • Page 426 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE Mount the upper bearing of connecting rod and the connecting rod together. Note: the gap on bushing should be orderly with that of connecting rod. Spread the engine transmission oil in the...
  • Page 427 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE Mount the lower bearing of connecting rod and the connecting rod cap together. Then spread engine transmission oil. Note: the gap on bushing should be orderly with that of connecting rod. Close the connecting rod cap and screw down the bolt.
  • Page 428 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE Engage the gear to 5th, then press the brake with toes, Dismantle connecting bolt of timing belt pulley and crankshaft with torque wrench. Remove the timing belt. Torque:130±10,then screw 65°±5° Pry out the old oil seal with right-angled screwdriver carefully.
  • Page 429 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE 5.2 Process of Replacement 5.2.1 Process of Removal Dismantle the timing belt (See “removal of timing belt” for details). Engage the gear to 5th, then press the brake with toes, and remove the timing belt pulley.
  • Page 430 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE 6.2 Installation Clean the oil seal seat ring. Clean the oil seal seat ring with clean oiled gauze. Spread the oil at the lip of crankshaft front oil seal. Enclose the guide sleeve of crankshaft oil seal, special tool, with that oil seal.
  • Page 431 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE Dismantle the accessories, such as dynamo, compressor, power steering pump and bracket. （See the “replacement of engine accessory” for details） Dismantle the engine cylinder head assembly. （ See the “replacement of cylinder head” for details）...
  • Page 432 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE Mount the main bearing cap carefully and screw down the bolt with specified torque. e): Dismantle main bearing carefully. Measure the width at the most bread part of pressed plastic line with ruler on plastic clearance gauge package, then get clearance value.
  • Page 433 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE Inspect the crankshaft axial clearance Mount the crankshaft and measure its radical clearance with micrometer guage. Standard Value Clearance 0.076—0.265 Replace the new thrust washer if the measured value exceeds the limit value.
  • Page 434 CHERY A21 SERVICE MANUAL MECHANISM OF 2.0NALC ENGINE mount the water pipe and insert electric connector. 8 Replace coolant pump 8.1 Needed tools and auxiliary materials A box sleeve wrench, a set of open end wrench, allen wrench, coolant 8.2 Removal Remove the engine timing belt.（see...
  • Page 435 CHERY A520 SERVICE MANUAL QR519 TRANSMISSION QR519 TRANSMISSION SERVICE MANUAL PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 436 CHERY A520 SERVICE MANUAL QR519 TRANSMISSION CONTENTS I OUTSIDE VIEW AND FUNCTIONAL DIAGRAM OF ASSEMBLY ......3 II FUNCTIONAL DIAGRAM OF ASSEMBLY..............5 III TRANSMISSION SERIAL NUMBER ................. 6 IV TECHNICAL PARAMETERS ..................6 V TIGHTENING TORQUE FOR ASSEMBLY ..............7 VI DISASSEMBLY PROCEDURE &...

  • Page 437: I Outside View And Functional Diagram Of Assembly

    CHERY A520 SERVICE MANUAL QR519 TRANSMISSION I OUTSIDE VIEW AND FUNCTIONAL DIAGRAM OF ASSEMBLY Gear Shift Mechanism Quick Coupler Assembly Rear Cover For Release Assembly Bearing Clutch Housing Transmission Housing Assembly Assembly PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 438 CHERY A520 SERVICE MANUAL QR519 TRANSMISSION Lifting Eye Blanking Cover Blanking Cover Drain Plug For Odometer Differential Oil Seal PDF created with pdfFactory Pro trial version www.pdffactory.com...

  • Page 439: Functional Diagram Of Assembly

    CHERY A520 SERVICE MANUAL QR519 TRANSMISSION II FUNCTIONAL DIAGRAM OF ASSEMBLY 0. Synchronizer Ring -Reverse Synchronizer 15. 1st Driven Gear 1. 5th Synchronizer 16. 1st Synchronizer Ring 2. 5th Synchronizer Ring 17. Axle Shaft 3. 5th Driving Gear 18. Side Gear 4.

  • Page 440: Transmission Serial Number

    CHERY A520 SERVICE MANUAL QR519 TRANSMISSION III TRANSMISSION SERIAL NUMBER The transmission serial number is inscribed on the transmission nameplate close to the gear shift mechanism on top of the transmission, i.e. the third row of data on the nameplate (as shown in the right-hand figure).

  • Page 441: Tightening Torque For Assembly

    CHERY A520 SERVICE MANUAL QR519 TRANSMISSION V TIGHTENING TORQUE FOR ASSEMBLY Torque for Name assembly (N·M) 93.2 – 104.9 Differential bolt M10X1.25 29.4 – 49 Drain plug assembly M18X1.5-6h 29.4 – 49 Oil-limiting plug M18X1.5-6h 6.9 – 9.8 Bolt for oil retainer & oil-receiving trough assembly M6 X12 6.9 –...

  • Page 442: Disassembly Procedure & Notice

    CHERY A520 SERVICE MANUAL QR519 TRANSMISSION VI DISASSEMBLY PROCEDURE & NOTICE DISASSEMBLY TRANSMISSION ASSEMBLY 1. Place the transmission on the workbench, screw off the oil drain plug and then rotate the transmission to drain the transmission oil as possible as you can;...
  • Page 443 CHERY A520 SERVICE MANUAL QR519 TRANSMISSION 4. Release joint assembly as shown in the figure; Air Exhaust Switch Figure 4 5. Disassemble the release bearing bolts and remove the release bearing; Figure 5 6. Screw off the rear cover bolts and remove the rear cover;...
  • Page 444 CHERY A520 SERVICE MANUAL QR519 TRANSMISSION 7. Directly take out the reverse synchronizer Reverse ring; Synchronizer Ring Figure 7 8. Engage some forward gear, and then remove the elastic lock pin by using a punch before moving down the 5th shift fork and gear.
  • Page 445 CHERY A520 SERVICE MANUAL QR519 TRANSMISSION 10. Remove the elastic lock pin with the punch; engage the reverse gear and take out the 5th-reverse shift fork; Figure 10 11. Remove the 5th synchronizer along with the 5th driving and driven gears;...
  • Page 446 CHERY A520 SERVICE MANUAL QR519 TRANSMISSION 13. Screw off the bearing retainer bolts with a hexagonal socket wrench and remove the bearing retainer; Figure 13 14. Take out the adjusting washer for rear output shaft bearing by using a caliper;...
  • Page 447 CHERY A520 SERVICE MANUAL QR519 TRANSMISSION 16. Screw off the gearshift mechanism housing bolts; Figure 16 17. Screw off the shifting finger locating base; Figure 17 18. Remove the backup lamp switch; now, you can directly pull the control mechanism assembly transmission housing;...
  • Page 448 CHERY A520 SERVICE MANUAL QR519 TRANSMISSION 19. Screw out the three fixing bolts as shown in Figure 19 (1. The 5th/reverse shift fork locating base; 2. The 3rd/4th shift fork locating base; 3. The 1st/2nd shift fork locating base). Note: the bolt to the 1st/2nd shift fork locating base is relatively long;...
  • Page 449 CHERY A520 SERVICE MANUAL QR519 TRANSMISSION 22. Screw off the clutch housing bolts; Figure 22 23. Manually lift up the transmission housing suspend transmission assembly and then use the copper bar to hit the input and output shafts; and remove the transmission housing as well as the 5th collar;...
  • Page 450 CHERY A520 SERVICE MANUAL QR519 TRANSMISSION 25. Screw out the reverse shift fork mechanism assembly bolts and remove the reverse shift fork; Figure 25 26. Remove the split baffle ring with a caliper; Figure 26 27. Take hold of the input shaft assembly,...
  • Page 451 CHERY A520 SERVICE MANUAL QR519 TRANSMISSION VII EXPLODED VIEW INPUT SHAFT ASSEMBLY Figure 28 1. Input shaft assembly 10. Steel wire spring for 3rd-4th synchronizer 2. Front input shaft bearing 11. Guide block for 3rd-4th synchronizer 3. Input shaft 12. Gear sleeve for 3rd-4th synchronizer 4.
  • Page 452 CHERY A520 SERVICE MANUAL QR519 TRANSMISSION DISASSEMBLY: If a special tool is available, you can directly use it to disassemble the input shaft assembly. Otherwise, use the detacher to carefully pull out the 4th-collar, 4th driving gear, 4th gear needle roller bearing, 3rd-4th synchronizer assembly and 3rd driving gear in sequence.
  • Page 453 CHERY A520 SERVICE MANUAL QR519 TRANSMISSION Check the gear sleeve and gear hub of the 3rd-4th synchronizer: ① Assemble the gear sleeve and gear hub together and check whether they can slide smoothly or whether they are locked up (as shown in Figure 30).
  • Page 454 CHERY A520 SERVICE MANUAL QR519 TRANSMISSION OUTPUT SHAFT ASSEMBLY Figure 33 11. Spring – 1st-2nd Synchronizer 1. Output Shaft Assembly 12. Gear Hub – 1st-2nd Synchronizer 2. Front Bearing Inner Race for Output Shaft 13. Ball – 1st-2nd Synchronizer Guide Block 3.
  • Page 455 CHERY A520 SERVICE MANUAL QR519 TRANSMISSION DISASSEMBLY: (1) Use a puller to pull out the rear output shaft bearing and the 4th driven gear; (2) Take out the 3rd-4th driven collar; (3) Successively take out the 3rd driven gear, driven...
  • Page 456 CHERY A520 SERVICE MANUAL QR519 TRANSMISSION necessary to change them. For the specified limit values, refer to the table in Page 15. Note: if it is necessary to change the outer synchronizer ring, inner synchronizer ring or synchronizer cone ring, you shall use a new complete set of these components for substitution.
  • Page 457 CHERY A520 SERVICE MANUAL QR519 TRANSMISSION IDLER GEAR ASSEMBLY Figure 36 1. Reverse Idler Gear 2. Bushing – Reverse Idler Gear 3. Idler Gear Assembly 4. Idler Gear Gasket 5. Idler Gear Shaft PDF created with pdfFactory Pro trial version...
  • Page 458 CHERY A520 SERVICE MANUAL QR519 TRANSMISSION REVERSE SHIFT FORK MECHANISM ASSEMBLY Figure 37 1. Housing for Reverse Locating Base 2. Spring for Reverse Locating Base 3. Ball for Reverse Locating Base 4. Reverse Shift Arm Bracket 5. Reverse Shift Arm 6.
  • Page 459 CHERY A520 SERVICE MANUAL QR519 TRANSMISSION 1ST/2ND SHIFT FORK ASSAMBLY Figure 38 1. 1st-2nd Shift Fork 2. 1st-2nd Fork Shaft 3. Spring Pin 4. 1st-2nd Shift Fork Assembly PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 460 CHERY A520 SERVICE MANUAL QR519 TRANSMISSION 3RD, 4TH, 5TH & REVERSE FORK SHAFT COMPONENTS Figure 39 1. 3rd-4th Fork Shaft 2. 3rd-4th Fork Bracket 3. Spring Pin 4. 3rd-4th Shift Fork 5. Split Baffle Ring 6. Reverse Pin 7. Interlock Pin 8.
  • Page 461 CHERY A520 SERVICE MANUAL QR519 TRANSMISSION GEAR SELECTION & SHIFT MECHANISM ASSEMBLY Figure 40 PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 462 CHERY A520 SERVICE MANUAL QR519 TRANSMISSION 22. Boot –Gear Selection & Shift Shaft 1. Gear Selection & Shift Shaft 23. Oil Seal –Gear Selection & Shift Shaft 2. 1st-2nd Return Spring 3. Top Base For 1st-2nd Return Spring 24. Air Duct Cap 4.
  • Page 463 CHERY A520 SERVICE MANUAL QR519 TRANSMISSION NOTICE FOR INSTALLATION: Press in the linear bearing so that the side of its model number inscribed is on the side of controller housing. Smear the transmission oil onto the oil seal lip. Transmission oil:...
  • Page 464 CHERY A520 SERVICE MANUAL QR519 TRANSMISSION DIFFERENTIAL ASSEMBLY Figure 43 1. Differential Housing 2. Final Drive Driven Gear 3. Front/Rear Differential Bearing 4. Spherical Washer –Planetary Gear 5. Planetary Gear Shaft 6. Adjusting Washer – Side Gear 7. Fixing Pin – Planetary Gear 8.
  • Page 465 CHERY A520 SERVICE MANUAL QR519 TRANSMISSION NOTICE FOR INSTALLATION: Installation of the adjusting washers, side gears, spherical washers, planetary gears and the planetary gear shaft: (1) Assemble adjusting washers respectively on the backs of the side gears and put the side gears in place within the differential.
  • Page 466 CHERY A520 SERVICE MANUAL QR519 TRANSMISSION FIXING THE LOCK PIN Differential Fixing pin Install the fixing pin to the place as shown in Housing Planet gear shaft Figure 43. Figure 47 PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 467 CHERY A520 SERVICE MANUAL QR519 TRANSMISSION CLUTCH HOUSING ASSEMBLY Figure 48 1. Clutch Housing 6. Oil Seal – Differential 2. Collar 161410 7. Magnet 3. Oil Drain Channel 8. Front Output Shaft Bearing Outer Ring 4. Fixing Pin 9. Oil Seal – Input Shaft 5.
  • Page 468 CHERY A520 SERVICE MANUAL QR519 TRANSMISSION TRANSMISSION HOUSING ASSEMBLY Figure 49 PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 469 CHERY A520 SERVICE MANUAL QR519 TRANSMISSION 1. Transmission Housing 2. Differential Bearing Outer Ring 3. Washer – Oil-Limiting/Drain Plug 4. Drain Plug 5. Oil Seal – Differential 6. Fixing Pin – Rear Cover 7. Collar 8. Oil-Limiting Plug 9. Fixing Pin – Gearshift Housing 10.
  • Page 470 CHERY A520 SERVICE MANUAL QR519 TRANSMISSION REAR COVER ASSEMBLY Figure 51 Rear Cover 2. Oil Drain Tube for Input Shaft 3. Reverse Synchronizer Cone 4. Screw – Reverse Synchronizer Cone 5. Rear Cover Assembly PDF created with pdfFactory Pro trial version...

  • Page 471: Transmission Assembly & Notice

    CHERY A520 SERVICE MANUAL QR519 TRANSMISSION VIII TRANSMISSION ASSEMBLY & NOTICE The transmission assembly procedure is reverse to its disassembly procedure, and the followings need attention: 1. It is necessary to use Mobilux EP2 (sealant) for the rear cover assembly, clutch housing assembly and gearshift mechanism assembly.

  • Page 472: Use/Operation Method & Notice

    CHERY A520 SERVICE MANUAL QR519 TRANSMISSION X USE/OPERATION METHOD & NOTICE 1. Employ the Double-Clutching method for upshifting and downshifting. When you shift gear, please depress the clutch pedal to the bottom and rapidly control the gearshift lever after the transmission is free from torque force of the engine.

  • Page 473: Common Faults & Troubleshooting

    CHERY A520 SERVICE MANUAL QR519 TRANSMISSION XI COMMON FAULTS & TROUBLESHOOTING Fault Possible cause Troubleshooting Damaged input or/and output shaft Replace the bearing bearing(s) Gear tooth faces damaged due to knocking, burr or pit corrosion existing, or poor Repair or replace the gear Excessive contact between them.

  • Page 474: List Of Wearing Parts

    CHERY A520 SERVICE MANUAL QR519 TRANSMISSION XII LIST OF WEARING PARTS Number Name Quantity Needle roller bearing for 1st/2nd gears Needle roller bearing for 3rd/4th/5th gears Front input shaft bearing Rear input shaft bearing Front output shaft cone bearing Rear output shaft cone bearing...
  • Page 475 1-2004 No.02/01 CIRCUIT DIAGRAM READING INSTRUCTION 1. NO. of relay circuit: 30 ： Coming from storage battery 15 ： Controling by ignition switch ACC ： Ignition switch radio set 31 ： Ground 58b ： Luminous regulating line 2. This circuit diagram is suitable to configuration of A21 1.6 and 2.0. Considering the time limit, it is liable to mistakes or omissions.

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