Page 1 Chery QQ Service Manual Mechanical Part of SQR 472Engine SQR 472 Engine （Service Manual for Mechanical Part） After-sales Department of Chery Automobile Sales Co., Ltd.
Page 2 Chery QQ Service Manual Mechanical Part of SQR 472Engine CONTENTS Chapter 1 Reading Instruction ............................2 1) Reading method of Maintenance Instruction......................2 2) Meaning of Marks and Abbreviations ........................3 3) Special Maintenance Tool............................4 Chapter 2 Disassembly, Assembly and Maintenance....................6 1) Timing Belt................................6 1.
Page 3 Chery QQ Service Manual Mechanical Part of SQR 472Engine Chapter 3 Table of Main Fit Clearance for SQR472 Engine ..................55 Chapter 4 Table of Measurement Parameters of SQR472 Engine ................59 Chapter 5 Table of Main Fitting Torque for SQR472 Engine ..................61 Chapter 6 Positions on SQR472 Engine to be Lubricated ..................62...
Page 4: Chapter 1 Reading Instruction
Chery QQ Service Manual Mechanical Part of SQR 472Engine Chapter 1. Reading Instruction 1) Reading Method of Maintenance Instruction １.1 Auxiliary Materials If it is required in the operation instruction to prepare the auxiliary materials such as special tools, tools, measuring instruments and grease in advance, you should list all auxiliary materials required in a table before carrying out each operation.
Page 5: Meaning Of Marks And Abbreviations
Chery QQ Service Manual Mechanical Part of SQR 472Engine 1 .4 Definitions Refers to allowed value during inspection, maintenance and adjustment. Standard value Refers to the maximum or minimum value that should not be exceeded during Limit inspection, maintenance and adjustment...
Page 6: Special Maintenance Tool
Chery QQ Service Manual Mechanical Part of SQR 472Engine 3) Special Maintenance Tools: Outside view Name or symbol Purpose Engine disassembly and inspection auxiliary Mount on the engine service device stand Disassembly and assembly Engine service stand of engine Disassembly of camshaft...
Page 7 Chery QQ Service Manual Mechanical Part of SQR 472Engine Outside view Name or symbol Purpose Disassembly and assembly Piston pin puller of piston pin Embeded combination oil seal and helical Installation of oil seal gear puller Disassembly and assembly Crankshaft pulley holding tool...
Page 8: Chapter 2 Disassembly, Assembly And Maintenance
Chery QQ Service Manual Mechanical Part of SQR 472Engine Chapter 2. Disassembly, Assembly and Maintenance Disassemble or assemble the engine with roll over stand. Disassemble or assemble the engine parts on the roll over stand. 1) Timing Belt 1. Structure Diagram ①...
Page 9: Disassembly
Chery QQ Service Manual Mechanical Part of SQR 472Engine 2. Disassembly 2.1 Remove the water pump pulley as the view showing. It will be better of disassembling with special tool. Torque: 25±1.5 N.m 2.2 Disassembly of Timing Belt Cover Torque: 6±1N.m 2.3 Disassembly of torsional damper...
Page 10 Chery QQ Service Manual Mechanical Part of SQR 472Engine Disassembly of tension pulley 2.5.1 Compress the top dead center at the first cylinder Timing Mark Clockwise piston. After disassembly of timing cover, pull the bolt and clockwise rotate the timing gear with wrench.
Page 11 Chery QQ Service Manual Mechanical Part of SQR 472Engine 2.8 Inspect the timing belt carefully, and replace new components under any of the following circumstances or when the mileage is up to the conditions of replacement: 2.8.1 Chap of back-side rubber 2.8.2 Chap of dedendum, chap of separated cord fabric.
Page 12: Installation
Chery QQ Service Manual Mechanical Part of SQR 472Engine Check the timing belt back plate for any deformation. Standard size of crankshaft timing gear Width 28.6mm 3. Installation 3.1 Assembly of crankshaft timing pulley. Timing Mark 3.2 Installation of timing (at the top dead center of the first cylinder piston) 3.2.1 Put the camshaft timing gear on the front end of the...
Page 13 Chery QQ Service Manual Mechanical Part of SQR 472Engine 3.3.2 Rotate the crankshaft along the rotating direction of the engine for 2 rounds so that the timing mark on the timing gear of camshaft and crankshaft is matched respectively, and then tighten the crankshaft belt pulley bolts.
Page 14 Chery QQ Service Manual Mechanical Part of SQR 472Engine 3.5.2 With flywheel 3.5.2.1 Prevent the gear from rotating with special tool. 3.5.2.2 Then screw down the bolt of torsional damper. 3.6 Assembly of timing cover. Mount the sealing strips at the positions as indicated in the right figure.
Page 15: Camshaft
Chery QQ Service Manual Mechanical Part of SQR 472Engine 2) Camshaft 1. Structure Diagram (1) Cylinder head chamber cover assembly (2) Cylinder head cover gasket (3) Camshaft timing belt (4) Camshaft cover ※: Components which may (5) Blanking cover not be reused (6) Camshaft bearing cap Unit: N·m(kg·cm)
Page 16 Chery QQ Service Manual Mechanical Part of SQR 472Engine 2. Disassembly 2.1 ① Cylinder head chamber cover assembly; ② Disassembly sequence cylinder head chamber cover; 2.2 Remove the camshaft timing gear with special tool. Notice: ·The special tool should be made as indicated in the right figure.
Page 17 Chery QQ Service Manual Mechanical Part of SQR 472Engine 2.3.2 Position the main sub gear on intake camshaft with bolts, as can be seen from the right picture. Fixing Bolt Notice: In order to eliminate the radial force of the...
Page 18 Chery QQ Service Manual Mechanical Part of SQR 472Engine 2.7.1 Measure the camshaft with micrometer caliper. If it is below to the specified limit, replace with a new one. Camshaft journal Unit: mm Type Item ZL, RL GL, GS, ZS φ23.0...
Page 19 Chery QQ Service Manual Mechanical Part of SQR 472Engine 3.2 Under the circumstance that special tools are not available: 3.2.1 Screw the M6 bolts into the camshaft driven gear at the position indicated in the right figure. Insert a Bolt...
Page 20 Chery QQ Service Manual Mechanical Part of SQR 472Engine 3.6 Assembly of camshaft cove Spread sealant on the position (slot) of camshaft cover as Glue Spread Line can be seen from the right picture. 3.6.1 Assembly of Camshaft Cover Tighten the bolts in the order as indicated in the right figure and with the specified torque.
Page 21 Chery QQ Service Manual Mechanical Part of SQR 472Engine 3.9 Installation of cylinder head cover 3.9.1 The old cushion of the timing belt cover which contacts the cylinder head cover should be removed completely. 3.9.2 Put the new cushion into the gloove of the timing belt cover accurately.
Page 22 Chery QQ Service Manual Mechanical Part of SQR 472Engine clearance once again: Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4 — — — — If the clearance exceeds the standard value, adjust it by replacing the adjustment gasket. Notice: The position at which the measurement result exceeds the standard value as well as the measurement result should be recorded.
Page 23: Structure Diagram
Chery QQ Service Manual Mechanical Part of SQR 472Engine micrometer caliper. 4.4.3.3 Select the gasket on the basis of the standard value of valve tappet ① Intake valve Select gasket thickness = Unload thickness + (Measured valve clearance -0.25mm) ② Exhaust valve Select gasket thickness = Unload thickness + (Measured valve clearance -0.25mm)
Page 24: Cylinder Head
Chery QQ Service Manual Mechanical Part of SQR 472Engine Spark plug 20±1Nm Cylinder Head Weather Strip I Cylinder cushion Adjustment gasket Valve tappet Valve spring retainer Valve spring seat Valve Spring 10 Intake valve 11 Exhaust valve ※ 12 Valve oil seal...
Page 25 Chery QQ Service Manual Mechanical Part of SQR 472Engine of the assembly of cylinder head, slowly tighten these bolts in the order as indicated in the right figure for several times untill ther are tightened properly. Notice: Remove the cylinder head bolts with a torque socket wrench in the contrary order.
Page 26 Chery QQ Service Manual Mechanical Part of SQR 472Engine 3.2.2 Measure the free state of the spring. Standard value: 37mm 3.3 Inspection of valve 3.3.1 Check if it is deformed or abrades. Inspection of valve Unit: mm Limit: Item Standard value 0.10...
Page 27 Chery QQ Service Manual Mechanical Part of SQR 472Engine 3.3.3 Replacement of valve guide. 3.3.3.1 Heat the cylinder head with hot water to 80-100 ℃. 3.3.3.2 Take out the valve guide from one side of combustion chamber with special tool, as can be seen from the right picture.
Page 28 Chery QQ Service Manual Mechanical Part of SQR 472Engine 3.3.4.2 Repair of valve seat insert Notice: The repair of valve seat is always conducted in the course of the inspection of valve’s fitting position. The surface repaired should be free from any breakage. Take it out slowly after the inspection.
Page 29 Chery QQ Service Manual Mechanical Part of SQR 472Engine 3.4.3 Installation 3.4.3.1 Assembly of valve spring washer and valve oil Auxilary Tool of Valve Spring Assembly seal 3.4.3.1.1 Clamp the special auxiliary tool on the top of Valve valve stem and spread oil around the auxiliary tool and the Valve Oil Seal inner of new valve oil seal.
Page 30 Chery QQ Service Manual Mechanical Part of SQR 472Engine assembly Spread 3.4.4.1 Spread a little oil on the flange side of bolt and Position threaded part 3.4.4.2 Tighten the cylinder bolts in the order indicated in the right figure for 3 times till the torque reaches the specified value.
Page 31: Structure Diagram
Chery QQ Service Manual Mechanical Part of SQR 472Engine 4) Water Pump 1. Structure Diagram Components which may not be reused ① O-ring (nonreusable) ② Water pump body ③ Dust seal 2. Disassembly 2.1.○ 1 Disassembly O-ring Notice: The O-ring is nonreusable.
Page 32 Chery QQ Service Manual Mechanical Part of SQR 472Engine 5) Oil Pump 1. Structure Diagram Components which may not be reused ① Torq ue for oil pan bolt: 8±2 N.m ② Oil collector ③ Oil collector spacer (nonreusable) ④ Oil pump ⑤...
Page 33: Cleanup
Chery QQ Service Manual Mechanical Part of SQR 472Engine 2.2 Remove the engine oil drainer, engine oil collector gasket Notice: The oil collector gasket is nonreusable. 2.3 Remove the engine oil pump assembly and the engine oil pump gasket. 2.4 Remove the rear oil seal bracket.
Page 34: Disassembly And Assembly Of Engine Oil Pump
Chery QQ Service Manual Mechanical Part of SQR 472Engine 4 Disassembly and Assembly of Engine Oil Pump 4.1 Structure Diagram ① Seal Ring ② Engine Oil Pump Cover Sheet ③ Engine Oil Pump Inner Rotor ④ Engine Oil Pump Outer Rotor ⑤...
Page 35 Chery QQ Service Manual Mechanical Part of SQR 472Engine 4.2.4 Remove the cotter pin Notice: The cotter pin is nonreusable. Notice: When removing the cotter pin, be careful not to let the spring or the spring seat spring out or fall off abruptly.
Page 36 Chery QQ Service Manual Mechanical Part of SQR 472Engine 4.3.1.3 Measure the clearance between the rotor and pump body. Standard value: 0.10-0.181mm Limit: 0.25 mm 4.3.2 Inspect the oil pressure relief valve 4.3.2.1 No abrasion or scrape shall be found on the oil pressure relief valve.
Page 37 Chery QQ Service Manual Mechanical Part of SQR 472Engine 4.4.3 When the outer gear or inner gear is put into the engine oil pump, its mark should be seen. Mark 4.4.4 The new weather strip should be fixed in the groove of oil pump cover.
Page 38 Chery QQ Service Manual Mechanical Part of SQR 472Engine 5.2 Disassembly 5.2.1 Remove the rear crankshaft oil seal with a screwdriver. Notice: The rear oil seal of the crankshaft is nonreusable. 5.3 Inspection Inspect the oil seal for damage and the abrasion at its lip.
Page 39 Chery QQ Service Manual Mechanical Part of SQR 472Engine engine oil drainer Torque: 6±1N.m Assembly of the oil pan 6.4.1 Clean up the joint surface between the oil pan with the cylinder. 6.4.2 Spread sealant, then assemble it. Grease: Loctite 5699 Notice: ·The sealing line should be unbroken with its...
Page 40 Chery QQ Service Manual Mechanical Part of SQR 472Engine 6) Crank Connecting Rod Mechanism 1 Structure Diagram Components which may not be reused ① Connecting rod cover ② Connecting rod bushing ③ Piston connecting rod assembly ④ Main bearing cap ⑤...
Page 41 Chery QQ Service Manual Mechanical Part of SQR 472Engine 2 Disassemble of Crank Connecting Rod Mechanism 2.1 Inspect the axial momentum of the connecting rod 2.1.1 Measure the axial clearance with a dial gauge or feeler gauge. Standard value: 0.15-0.25mm Limit: 1.2mm...
Page 42 Chery QQ Service Manual Mechanical Part of SQR 472Engine 2.2.5 If it is beyond the limit, replace the bearing bushing. Notice: Replacing the bearing bushing with the product of the same manufacturer’s brand. The thickness of the connecting rod bushing which meets the requirements of Connecting Rod clearance = diameter of big end hold –...
Page 43 Chery QQ Service Manual Mechanical Part of SQR 472Engine Inspect the crankshaft for its radial clearance. 2.4.1 Remove the crankshaft bearing cap by softly tapping with a resin hammer. 2.4.2 Clean the inside and surface of the bearing bushing, the inside and surface of the bearing cap, the cylinder wall and journal.
Page 44 Chery QQ Service Manual Mechanical Part of SQR 472Engine 2.5 Disassembly and assembly of the piston and connecting rod assembly 2.5.1 Remove the first ring, second ring and the oil ring with a pair of piston ring moving pliers. Notice: Don’t get the piston and piston ring of each cylinder confused.
Page 45: Routine Inspection
Chery QQ Service Manual Mechanical Part of SQR 472Engine 4 Routine Inspection 4.1 Cylinder Body 4.1.1 Inspect the top surface of cylinder body for its flatness (1) Measure at the six points shown in the right figure with a ruler and a feeler gauge.
Page 46 Chery QQ Service Manual Mechanical Part of SQR 472Engine 4.2.4 Measure the diameter of the piston 4.2.4.1 Measure at about 11 mm to the bottom of the piston, along the direction vertical to the piston pin. φ Standard value: 4.2.5 Inspect the clearance between the piston ring and the ring gloove 4.2.5.1...
Page 47 Chery QQ Service Manual Mechanical Part of SQR 472Engine 4.2.7 Inspect the clearance between the piston and cylinder wall Measurement position of piston 4.2.7.1 Measure the inner diameter of the cylinder and Outer Diameter the outer diameter of the piston at the positions as indicated in the right figure.
Page 48 Chery QQ Service Manual Mechanical Part of SQR 472Engine 5.1.1 Assemble the piston, connecting rod and the Mark Forward piston pin with special tool following the instructions below: 5.1.1.1 Spread engine oil over the pin hole of the connecting rod, assemble according to the group mark and direction mark of piston and connecting rod.
Page 49 Chery QQ Service Manual Mechanical Part of SQR 472Engine Resemble crankshaft main bearing cap, Thrust Plate crankshaft, crankshaft bearing bushing and the crankshaft axial thrust plate, pay attention to the following: 5.3.1 Assembling the bearing bushing, its raised thrust block should fit into the locating groove in the cylinder body.
Page 50 Chery QQ Service Manual Mechanical Part of SQR 472Engine 5.4 Assemble the piston and connecting rod assembly, connecting rod bearing bushing and the connecting rod bearing cap, pay attention to the following: 5.4.1 The opening of compression ring and the opening of oil ring should be in the specified direction.
Page 51 Chery QQ Service Manual Mechanical Part of SQR 472Engine Chapter 3. Table of Main Fit Clearance for SQR472 Engine SQR472 Clearance between Cylinder Hole and Piston Skirt (Piston to Cylinder Clearance) Name of Component Size and Tolerance Clearance or Value of...
Page 52 Chery QQ Service Manual Mechanical Part of SQR 472Engine Piston Pin φ18 Fit Clearance between Connecting Rod Body Hole and Bolt Bar Name of Component Size and Tolerance Clearance or Value of Remark Interferenc The hole should be processed along Connecting rod body hole φ8.08 H...
Page 53 Chery QQ Service Manual Mechanical Part of SQR 472Engine of φ28H Remarks: In the above tables, the capital letter and suffix following the sizes (For example, H ) mean the process precision, which are unconcerned with the maintenance and may be ignored in the course of maintenance.
Page 54 Chery QQ Service Manual Mechanical Part of SQR 472Engine Chapter 5. Table of Main Fitting Torque for SQR472 EngineSQR472 Name Specification Quantity Fixing Torque (Nm) Remark Main bearing cap bolt M10X1.25 70±3.5 Connecting rod cover bolt M8X1 40±2 Oil pump bolt M8X1 20±1.5...
Page 55 Chery QQ Service Manual Mechanical Part of SQR 472Engine Spread glue Intake/exhaust stud 10±1 Intake pipe nut 25±1.5 Ignition coil bracket assembly bolt 20±1.5 Front lifting lug bolt 20±1.5 Exhaust pipe nut 25±1.5 Exhaust pipe thermal shroud bolt 6±1 Bolt on crankshaft pulley & torsional damper M12X1.25...
Page 56 Chery QQ Service Manual Mechanical Part of SQR 472Engine Chapter 6. Positions on SQR472 Engine to be Lubricated Type of lubricating oil: Engine lubricating oil Designation of lubricating oil: SAE10W/30-50(SF Class) Position to be lubricated Remark Joint surface of connectong rod bolt head...
Page 57 Chery QQ Service Manual Mechanical Part of SQR 472Engine Chapter 7. Positions on SQR472 Engine to be Spread with Sealant SQR472 Position to be spread with Form and amount of Type of sealant Remark sealant sealant (reference) ф(3~4)mm Joingt surface of oil pan Loctite 5699 ф(3~4)mm...
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Page 126 • Chery QQ Service Manual Transmission System Content Chapter 1 Clutch Section 1 Summarization Section 2 Fault Diagnosis Section 3 Maintenance on Car Section 4 Disassembling Section 5 Recommended Regulations of torque Section 6 Repair Materials Needed Transaxle Chapter 2...
Page 127 • Chery QQ Service Manual Transmission System Explanation 1,This manual book is applicable to the usage and maintenance of the gearboxes of model DABS10-4 and DABS10-8 manufactured by our factory. 2,The DABS10-4,DABS10-8 front-wheel-drive transaxles, with fine functions, advanced structures, made with high precise, compared with the current local products, it is in the leading position.
Page 128 • Chery QQ Service Manual Transmission System Chapter 1 The Clutch Section 1 Summarization The clutch used in this car is dry type, a diaphragm spring disc spring, often press type clutch. The clutch disc assembly is consist of six pieces of absorber springs, and is fixed on the input axle of the transmission through splined hub.
Page 129 • Chery QQ Service Manual Transmission System Section 2 Fault Diagnosis Fault Reasons Solution Phenomenon The free journey (free moving clearance) of Adjust the pedal free play the clutch pedal is unavailable. The clutch disc has been frayed or has greasy...
Page 130 Chery QQ Service Manual Transmission System Section 3 Maintenance on car .Maintenance (1) The Clutch Pedal Height According to the following regulations, use pedal bracket adjusting bolt to adjust the clutch pedal height. It is normal if the height of clutch pedal is higher 8mm(0.3in)than the height of brake pedal..
Page 131 Chery QQ Service Manual Transmission System The cable is abraded badly. The cable is abraded The cable is bended or knotted. The boot is broken. The top is frayed. Fixing the clutch cable. Fixing: Before fixing cable, lubricants must be laid on the cable top and the connector.
Page 132 Chery QQ Service Manual Transmission System 1.Fix the flywheel with special tool, take apart the bolt of the pressure plate assembly, Pressure plate assembly and clutch disc assembly. 1. Pressure plate assembly 2. Bolt 3. Special tool (flywheel fixing bracket) Disassembling Pressure plate assembly.
Page 133 Chery QQ Service Manual Transmission System input shaft bearing The Standard Value Maintenance Disassemble the input shaft Measure depressed depth 1. 5mm 0.5mm of rivet 0.06in 0.02in Pressure plate assembly: 1.Check if the diaphragm spring has been frayed abnormally or damaged.
Page 134 Chery QQ Service Manual Transmission System 4.Apply a thin layer of lubricant on the input shaft , install the transaxle with engine. Attention: 1. Input shaft A: Baste When installing the transmission input shaft in the clutch disc assembly, turn the crankshaft via flywheel till the Splined hub joggles.
Page 135 Chery QQ Service Manual Transmission System 5.Hang the return spring, spread lubricant on the side and the arm of the release fork, install the bearing. Spread lubricant on the splined hub, install the spacer NO.2 and seal . Fix the release fork cover.
Page 136 Chery QQ Service Manual Transmission System Section 6 Necessary Maintenance Materials Material The SUZUKI Use the part product of the recommendation The SUZUKI high Pulling cable catch class lubricates the fat A connecting pin. The lithium lubricates the (99000-25010) Release fork spacer and seal.
Page 137 Chery QQ Service Manual Transmission System Chapter 2 Transaxle Section 1 DABS10-4 Transaxle I. A gearbox technique brief introduction of section 1 DABS10-4, DABS10-8 Transaxle Main Functions And Technical Data A type Machine gear type The gear number Gearshift Compare speed compare 3.416...
Page 138 Chery QQ Service Manual Transmission System Fig.1-1 Transaxle 1- Input shaft 2- 5th Synchronizer assembly 3- 5th gear 4- 4th gear 5- Synchronizer assembly 6- 3rd gear 7- Transaxle case 8- Reverse gear shaft 9- Reverse gear 10-Clutch case 11- Output shaft...
Page 139 Chery QQ Service Manual Transmission System Fig.1-2 Transaxle drive system 1-Input shaft 2- Oil seal 3- Input shaft bearing 4- 3 rd gear 5-3rd, 4th needle roller bearing 6- Synchronizer ring 7- Snap ring 8- Synchronizer assembly 9- Synchronizer insert...
Page 140 Chery QQ Service Manual Transmission System III , Shift and select lever shaft control system Fig.1-3 1- Reverse shift fork 2- Reverse shift fork assembly 3-Reverse, 5th shaft 4-Reverse, 5th shift fork shaft 5- 3rd, 4th shift fork shaft 6-1st, 2nd shift fork shaft...
Page 141 Chery QQ Service Manual Transmission System The turning of the shift lever drives the shift and select lever shaft move up and down, and the select lever shaft also moves up and down, this is for select shaft. The forward and backward movement of shift lever drives the shift and select lever shaft...
Page 142 Chery QQ Service Manual Transmission System prevent reverse. fig.1-6 2. It is allowed to shift from 5th to the middle position, but is not allowed to shift to reverse. However, when the shift and select lever shaft moves to neutral of 3rd, 4th, the shift restrict bolt cam cannot effect as the Figure 16.
Page 143 Chery QQ Service Manual Transmission System fig.1-8 5.Fault Diagnosis Condition Cause Measure The shift fork shaft has been Replace frayed. Replace The shift fork and synchronizer ring have been frayed Replace Joggle is in The spring has been destroyed. version...
Page 144 Chery QQ Service Manual Transmission System Section2 Transaxle Maintenance on Car I. Exchange of Oil Fig.2-1 1.Before checking and changing the transaxle gear oil, be sure the engine has stopped and the vehicle stops on a plane surface. 2.Lift the vehicle, check the oil level and if there is any leakage.
Page 145 Chery QQ Service Manual Transmission System 1-The end of Tie rod 2- Steering 3- Lock cap 4- Cotter pin 5-Special tool Fig.2-2 4.Remove the two brackets. 5.Remove Ball joint bolt and disjoin the Suspension arm from the steering. 1- Steering...
Page 146 Chery QQ Service Manual Transmission System 7. Remove the used differential oil seal , fix the new oil seal. 1- Differential oil seal 2- Special tool Fig.2-5 8.Check if the surface of the oil seal is smooth and spread some lubricant on it.
Page 147 Chery QQ Service Manual Transmission System 1- Speedometer sensor 2- O-ring 3- Speed meter driven gear Fig.2-7 5.Use the clamp to fix the plane part of the driven gear box, use professional tools bearing disassembly tool and puller slide hammer to remove the oil seal.
Page 148 Chery QQ Service Manual Transmission System Slotted spring pin 1,Driven gear 3,Driven gear box 4,Special tool 5, Special tool 6,O –seal ring 7,Gear box snap ring 8, Oil seal 9,Special tool Fig.2-8 -45- Chery Automobile Co., Ltd...
Page 149 • Chery QQ Service Manual Transmission System 6. Check if the oil level is right. Disassembly: 1. Disconnect the cathode of the battery. 2. Disconnect the speed sensor connect. 3. Remove the speed sensor 1-SPEED SENSOR 2- O--ring 3-Speedometer driven gear Fig.2-10...
Page 150 • Chery QQ Service Manual Transmission System Shift and select lever shaft control system 1.Shift handle assembly 2.Shift mechanism assembly 3.Shift cable assembly 4.Bolt 5.Bracket 6.Nut 7.Clip 8.Washer 9.Cotter pin 10.Bolt Chery Automobile Co., Ltd...
Page 151 • Chery QQ Service Manual Transmission System 1.Strengthen pole 2. Nut 3. Control shift lever retainer 4. Control shift lever retainer bolt 6.NO.1 exhaust pipe 5. Shift and select lever shaft 7. Shift lever 8. Shift and select lever shaft bolt and nut Disassembly: On the lift.
Page 152 • Chery QQ Service Manual Transmission System Installation 1 According to the reverse demounting order, install the shift lever , if necessary, replace the used parts. Notice: After installation, please check if the shift lever works smoothly. Shift lever vertical 0-0.2mm(0-0.007in)
Page 153 • Chery QQ Service Manual Transmission System Section 3 Disassembly and installation of the transaxle I Dismantle transaxle Under the engine lid. Disconnect the battery ground; remove the battery and the bracket. Screw the clutch cable nut off, Remove the connector from the cable and dismantle the cable from the bracket.
Page 154 • Chery QQ Service Manual Transmission System Screw off the shift and select lever shaft bolt and nut, remove the control from the shift shaft. Screw off the strengthen pole nut, remove the strengthen pole and gasket. Disconnect the exhaust pipe.
Page 155 • Chery QQ Service Manual Transmission System ·When lifting the transaxle, push drive shaft right universal coupling into differential. ·Push the drive shaft universal coupling to the right position, and joggle the Drive shaft and Differential. Caution: Spread lubricant on the shift and select lever shaft spacer, do not spread lubricant on the strengthen pole spacer.
Page 156 • Chery QQ Service Manual Transmission System Caution: Do not distort the left side case. Remove the 5th shift fork bolt and guide ball. Hammer the slotted spring pin out. Notice: It is much easier to magnetize the guide ball.
Page 157 • Chery QQ Service Manual Transmission System 1,Gear disassembly tool 2, 5th shift fork 3,Synchronizer hub sleeve Section 4 Maintenance of the transaxle I, Disassemble 5th gear 1 Loosen 8 bolt , remove the rear gear box. 2 Remove the snap ring thrust gasket.
Page 158 • Chery QQ Service Manual Transmission System It is much easier to magnetize the placement. 4 Remove the snap ring. and slotted spring pin. 1- 5th Shift fork bolt 2- Slotted spring pin 3- Snap ring 4- Special tool Fig.3-2 5 Remove the 5th Shift fork,5th synchronizer assembly, synchronizer ring.
Page 159 • Chery QQ Service Manual Transmission System 1- 5th gear 2- 5th driven gear 4- Special tool Fig.3-4 7 The output shaft nut Use chisel to loosen the welded part of the nut. 1- 5th lock nut 2-Nut 3- Chisel Fig.3-5...
Page 160 • Chery QQ Service Manual Transmission System 1- Shift and select lever shaft 2- Shift and select lever shaft fork 3- Bolt Fig.3-7 3 Remove the 3 shift fork shaft bolt and gasket, take out the spring and ball. 4 Loosen the 4 bolt on the case, take out the clip,stationary rings and case.
Page 161 • Chery QQ Service Manual Transmission System 1-Transmission case 2- Clutch housing 3- Transmission case bolt 4- Reverse idler gear shaft bolt Fig.3-10 10 Use screwdriver separate clutch housing and transmission case. Caution: Do not insert the tools into the joint of the two crust, otherwise the joint can be damaged.
Page 162 • Chery QQ Service Manual Transmission System 13 Remove the reverse idler gear shaft and gasket, take away the reverse idler gear shaft. 14 Remove the reserve,5th shift fork shaft assembly. 1-Reverse ,5th shift fork shaft assembly Reverse idler gear...
Page 163 Chery QQ Service Manual Transmission System 1- Clutch housing assembly 2- 1st 2nd shift fork shaft assembly 3- 3rd 4th shift fork shaft assembly 4- Output shaft assembly 5-Input shaft assembly Fig.3-14 3 Clutch case assembly 1. Remove the differential assembly from the clutch case.
Page 164 Chery QQ Service Manual Transmission System Notice: If the input shaft bearing still remains in the clutch case, use special tool to pull out the bearing. 1- Input shaft oil seal 2- Output shaft bearing outer 3- Special tool Fig.3-17 5.
Page 165 Chery QQ Service Manual Transmission System Input shaft assembly Disassemble: 1. Use bearing puller to remove the input shaft right bearing. Fig.3-20 2. Use special tools to clip the 4th gear, pull it out with the 5th gear spacer, left bearing.
Page 166 Chery QQ Service Manual Transmission System 1- Snap ring 2- Synchronizer ring Fig.3-22 5.Remove the synchronizer assembly and 3rd gear. 6.Remove the 3rd gear needle roller bearing . 1- Input shaft 2- Synchronizer 3- Synchronizer 4- 3rd gear Fig.3-23 7. Disassemble the Synchronizer assembly.
Page 167 Chery QQ Service Manual Transmission System 3.Blow oil pipeline. 1- Input shaft Oil pipeline Fig.3-25 4. Assemble the synchronizer assembly, insert 3 synchronizer insert, and then install the spring according to the Fig. 1- Snap ring 3-Hub 4- Hub sleeve outer race 5-3rd gear Fig.3-26...
Page 168 Chery QQ Service Manual Transmission System 1- Right bearing 2- Input shaft 3- Special tool Fig.3-27 6. Install the 3rd gear needle roller bearing lubricate needle roller bearing install 3rd gear and synchronizer ring 7. Use hammer and special tool to install synchronizer assembly.
Page 169 Chery QQ Service Manual Transmission System 1- Snap ring 2-Needle roller bearing 3- Synchronizer ring 4- 4th gear 5-Input shaft Fig.3-29 9. Use special tool and hammer to press the left bearing. 10 . Use special tool to press the 5th gear spacer.
Page 170 Chery QQ Service Manual Transmission System 1- Special tool 3-4th driven gear Fig.3-31 Caution: In order to avoid breaking the 4th driven gear, do not clip the gear head. 2.Clip the 2nd driven gear, pull out the driven gear, 3rd driven gear with the Spacer together.
Page 171 Chery QQ Service Manual Transmission System 1- Hub sleeve outer race 2- Snap ring 3- Special tool Fig.3-33 5. Remove the synchronizer assembly, 1st Synchronizer ring. 6. Remove the 1st driven gear and needle roller bearing. 1, Output shaft 2, Hub sleeve outer race...
Page 172 Chery QQ Service Manual Transmission System 1- Gear 2- Synchronizer ring Fig.3-35 Standard 1.0~1.4mm Clearance a Use limit 0.5mm 3. In order to keep lubricate smoothly, blow the oil away, be sure there is not any backup in the oil way.
Page 173 Chery QQ Service Manual Transmission System 1- Snap ring 3- Hub 4- Hub sleeve outer race Notice: Synchronizer insert is not on the right direction. Snap ring and synchronizer insert and synchronizer assembly, 5th synchronizer assembly compare is big. 5.Install the output shaft bearing.
Page 174 Chery QQ Service Manual Transmission System 7. Hammer the synchronizer assembly. Notice: Use special tool support right output shaft avoid bearing holding race destroy When installing the synchronizer assembly, keep the synchronizer insert and the synchronizer insert on the synchronizer assembly face to face.
Page 175 Chery QQ Service Manual Transmission System 1-3rd, 4th spacer 2-3rd driven gear 3- 2nd driven gear 4- Special tool 5- Special tool Fig.3-42 10. Use the same special tools to install the 4th driven gear. 11. Use hammer or special tools to install the left bearing.
Page 176 Chery QQ Service Manual Transmission System Fig.3-44 Shift and select lever shaft assembly Shift and select lever shaft 2- Gasket 3- Slotted spring pin 4- Select lever shaft 5- Slotted spring pin 6- Spring 7- Shift cam spring 8- Shift cam...
Page 177 Chery QQ Service Manual Transmission System 1-1st.2nd Shift fork shaft 2-1st .2nd Shift head 3-1st .2nd Shift fork 1st , 2nd Shift fork shaft assembly 1-3rd, 4th Shift fork shaft 2-3rd, 4th Shift head 3-3rd, 4th Shift fork 3rd, 4th Shift fork shaft assembly.
Page 178 Chery QQ Service Manual Transmission System 1- Shift fork 2- Hub sleeve Fig.3-47 1.Use feeler gauge to check the clearance between shift fork and hub sleeve, if the clearance exceeds 1.0mm, please replace the parts. Notice: Check the contact position of shift fork and hub sleeve carefully to determine if replace the parts.
Page 179 Chery QQ Service Manual Transmission System 1.Remove the slotted spring pin and disassemble every part. 2.Clean every part thoroughly and determine if some parts need to be replaced. 3.Install all the parts according to the figure and the installing order.
Page 180 Chery QQ Service Manual Transmission System 1- Bearing puller 2- Special tool 3- Bearing 4-Speedometer gear Fig.3-50 3. Remove the left-side bearing . 1- Bearing puller 2- Special tool 3-Left bearing Fig.3-51 4. Clip the differential case, remove the 8 nut, 8 Differential bolt and 4 lock nut.
Page 181 Chery QQ Service Manual Transmission System Adjustment and Re-installation: After disassembling, check if there is any distortion and make a record. Replace the attainted parts, clean all the new parts and install. 1, Installation side gear measure the clearance of side gear. Install the side gear.
Page 182 Chery QQ Service Manual Transmission System Notice: Spread lubricant on the contact surface of side gear adjust gasket, pinion gear, pinion gear and pinion gear shaft, side gear and differential case. 3, Dive in the slotted spring pin, till the end of pin enter into the differential case thoroughly.
Page 183 Chery QQ Service Manual Transmission System II: Installation 1 Clutch case assembly 1, Use hammer and special tools to install the input shaft oil seal keep the oil seal spring side upward and spread lubricant on the oil seal. 2, Use hammer and special tools .
Page 184 Chery QQ Service Manual Transmission System 2-Oil seal boot 3-Differential right oil seal 4-Shift lever bolt 5-Special tool A Blow hole (downward) Fig.3-59 6, Install the shift head on the shift lever. Torque 31.5 35.5 N·m 1-Shift head 2-Shift lever 3-Bolt Fig.3-60...
Page 185 Chery QQ Service Manual Transmission System 2, Use hammer and special tools to install the near side oil seal, keep the oil seal surface equal with the case surface and spread lubricant on the oil seal. 1-Differential left oil seal 2-Special tool Fig.3-62...
Page 186 Chery QQ Service Manual Transmission System 2, Spread lubricant on the “O” ring and gear, install the speedometer driven gear assembly and then screw down the torque. Torque 8 12 N·m 1-Clutch case 2-Speedometer driven gear assembly 3-Bolt Fig.3-65 Notice: When installing speedometer driven gear, turn the differential ring driven gear lightly to joggle the gear.
Page 187 Chery QQ Service Manual Transmission System Distance a The distance a is 5mm reverse shift fork end and reverse idle gear clearance is 1mm 5, Install the reserve, 5 shift fork shaft assembly. 1-Reserve, 5th Shift fork shaft assembly 2-Clutch...
Page 188 Chery QQ Service Manual Transmission System 1-Transmissan case 2-Clutch case 3-Transmission bolt 4-Reverse idle gear shaft bolt Fig3-69 11, Check-up shift fork shaft point spring worn. Point spring free length Standard Use Limit Reserve, 5th spring Red 33.8 32.7 Spring Green 33.6...
Page 189 Chery QQ Service Manual Transmission System 1-Input shaft 2-Left bearing outer race 3-Special tool Fig.3-71 2, First put a adjust gasket on the bearing outer race and a ruler on the adjust gasket, use the press ruler to measure the clearance “a”(between case surface and the ruler) Clearance a (adjust gasket) 0.08—0.12mm...
Page 190 Chery QQ Service Manual Transmission System 4, Install the bearing cover, insert the end of the bearing cover into the groove of the reserve, 5th guide shaft .Spread whorl glue on the bolt. Notice: Turn the output shaft, to check if it turns smoothly.
Page 191 Chery QQ Service Manual Transmission System 5 Shift guide case assembly 1. In case of disassembly or installing screw torque bolt check-up blow hole straightway Torque : 8 12N·m 2. Clean case and transmission surface 1-Reserve, 5 Interlock bolt 2-Shift guide case A Blow hole Fig.3-81...
Page 192 Chery QQ Service Manual Transmission System 1-Shift select shaft 2-Interlock 3-Shift lever fork 4- Bolt 5-Shaft restrict bolt 3-83 7. Clean the contacting interface and spread sealed adhesive evenly. Sealed adhesive seal glue HZ1213Q/320222 YAP02-92 8. Install the transmission case assembly, clip and hanger assembly, Screw down the 4 bolt Torque 8 12N·m...
Page 193 Chery QQ Service Manual Transmission System 1-Bolt 2-Transmission cover board Fig.3-85 6 Clutch release shaft system Round Fig.3-86 Clutch release shaft 1-Spacer1 2-Release shaft assembly 3-Release spring 4-Spacer 5-Bolt 6-Nut 7-Clip Disassemble: 1, Disassemble the clip ,loosen the bolt, remove the clutch 2, Turn the release shaft, take out the release bearing.
Page 194 Chery QQ Service Manual Transmission System 4, Use hammer to knock the spacer 2. 5, Remove the release shaft and return spring . Clutch release shaft Check if the release shaft and slotted spring pin have been declined and broken.
Page 195 Chery QQ Service Manual Transmission System 5, Use hammer or special tools to punch 3 small holes. 1-Releaseshaft 2-Oil seal Plug Fig.3-93 6, Hang the return spring. 7, Spread lubricant inside the release bearing and on the release shaft, install the release bearing.
Page 196 Chery QQ Service Manual Transmission System 1-Bolt 2-Clutch fork Punch Fig.3-95 Chapter 3 Torque Stated Torque N·m Position Drain plug 18—23 Shift lever bolt 32—36 Shift head bolt 31.5—35.5 Speedometer case bolt 8—12 Shift lever point bolt 10—16 Reverse Shift fork bolt 18—28...
Page 197 Chery QQ Service Manual Transmission System Chapter 4 Maintenance Materials Needed Materials Specifications Oil seal Bearing Lithium 2# lubricant Clutch release bearing Lubricant Clutch Release shaft Needle roller bearing Lubricant Gear Clutch case and transmission case surface Seal glue Transmission case and gear case...
Page 198: Special Tools
Chery QQ Service Manual Transmission System Chapter 5 Special Tools Dial indicator Snap ring pliers Dial indicator bracket Bearing install tool Bearing install tool Bearing install tool Slotted spring pin Bearing disassembly Bearing install tool disassembly tool tool -96- Chery Automobile Co., Ltd...
Page 199 Chery QQ Service Manual Transmission System Bearing tool Bearing install tool Oil seal install tool Bearing outer race install Slotted spring pin Bearing install tool tool disassembly tool Bearing install tool Bearing disassembly Spacer disassembly tool tool -97- Chery Automobile Co., Ltd...
Page 200 Chery QQ Service Manual Transmission System Bearing install tool Spacer disassembly tool Spacer disassembly tool Handle Puller slide hammer Puller 5th gear lock tool E-ring install tool -98- Chery Automobile Co., Ltd...
Page 201 Chery QQ Service Manual Transmission System Chapter 6 Propeller Shaft Universal joint This propeller shaft is available for the vehicles with manual transaxles. Summarization The front wheel driven shaft adopts universal joint and the differential. 1. Wheel universal joint (right) 2.
Page 202 Chery QQ Service Manual Transmission System 1 Let out the transaxles oil. 2 Remove the driven shaft universal joint to make the snap ring. Break away from the differential universal joint splined hub. Driven shaft universal joint left Remove the joint from the Suspension arm.
Page 203 Chery QQ Service Manual Transmission System Caution: When disassembling the propeller shaft assembly, Be sure to prevent the rough touch and collision. 2. Disassembling the right shaft. On the ground: Loosen the rivet and remove the propeller shaft nut and gasket .
Page 204 Chery QQ Service Manual Transmission System Loosen the central bearing seat bolt, remove the output shaft from differential side gear. 3. Disassemble the propeller shaft. Remove the differential universal joint boot hoop. Boot hoop Move the boot to the middle position and take out the shaft from the bell-mouthed.
Page 205 Chery QQ Service Manual Transmission System 3 Scrape off the lubricant and remove the holding snap ring with special tool (A). Boot hoop 4 Draw out the holding and boot. Holding Notice: The end of wheel universal joint Installation Installation of propeller shaft.
Page 206 Chery QQ Service Manual Transmission System 1.Boot 2.Boot hoop 4 Install the holding . Caution: When installing the holding, keep the small diameter towards the shaft end. 5 Use special tool (A) to install the snap ring. 1.Snap ring -104-...
Page 207 Chery QQ Service Manual Transmission System 6 Spread 30-40 g of SUZUKI high class grease H on the surface of the holding. 7 . Put the holding into the bell-mouthed, and then put the snap ring in the snap ring slot.
Page 208 Chery QQ Service Manual Transmission System 9. Fix the boot on the bell-mouthed. Adjust the measure (A) and (B) to accord with the fig. Below. Left drive shaft lubricate Differential side Wheel side lubricate Right drive shaft lubricate 2 install output shaft and bearing race.
Page 209 Chery QQ Service Manual Transmission System 1.Right seal L b i t 1.Snap ring 2.Output shaft Installation Install the propeller shaft assembly according to the reverse order, clean the front wheel bearing oil seal and spread lubricant. First install the end of wheel universal joint on the steering and then install the universal joint on the end of differential.
Page 210 Chery QQ Service Manual Transmission System Recommended Value of torque Torque Screw down parts N·m kg·m 1b-ft Manual Drain plug 25-30 2.5-3.0 18.5-21.5 transaxles Automatic 18-23 1.8-2.3 13.5-16.5 transaxles Manual Oil level, refill plug 36-54 3.6-5.4 26.5-39.0 transaxles Ball joint bolt and nut 50-70 5.0-7.0...
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Page 218 Chery QQ Service Manual Chassis System Warning: Do not fill in the liquid excessively, which may result in the overflow of the braking liquid to the engine or other parts of the front cabin during the operation of the braking system.
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Page 222 Chery QQ Service Manual Chassis System Brake pedal parts 1.Pedal pad;2.Brake pedal;3.Gasket;4.Pedal return spring;5.Bolt;6.Nut;7.Pedestal. Chery Automobile Co., Ltd...
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Page 228 Chery QQ Service Manual Chassis System Exhaust operation ( II ) Chery Automobile Co., Ltd...
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Page 231 Chery QQ Service Manual Chassis System Threetimes Goodg Chery Automobile Co., Ltd...
Page 232 Chery QQ Service Manual Chassis System Holding Three times Holding Chery Automobile Co., Ltd...
Page 233 Chery QQ Service Manual Chassis System Operate on the clean desk without mineral oil. Chery Automobile Co., Ltd...
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Page 237 Chery QQ Service Manual Chassis System 1. Brake caliper 2. Locating bolt 3. Brake disc Chery Automobile Co., Ltd...
Page 238 Chery QQ Service Manual Chassis System Piston protector 1. screw 2. soft pipe 3. washer Chery Automobile Co., Ltd...
Page 239 Chery QQ Service Manual Chassis System Caliper casing Caliper bracket Bolt protector Caliper casing Caliper bracket Chery Automobile Co., Ltd...
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Page 248 Chery QQ Service Manual Chassis System Start Tester linkage Key switch to ON Open tester switch, ,select QQseries Select MK20-I/E type ABS system Select Versatile OBD-16 diagnosis socket Whether able to communicating Non- check table repair Hap malfunction Lasting malfunction...
Page 249 Chery QQ Service Manual Chassis System Chery Automobile Co., Ltd...
Page 250 Chery QQ Service Manual Chassis System Want clear DTC ? [Yes] Delete key on engine off Chery Automobile Co., Ltd...
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Page 252 Chery QQ Service Manual Chassis System Faulty appears again? Chery Automobile Co., Ltd...
Page 253 Chery QQ Service Manual Chassis System Abnormal Abnormal Replace Normal Abnormal Replace Normal Abnormal Fix or replace Abnormal Normal Replace Replace Fix or replace Chery Automobile Co., Ltd...
Page 254 Chery QQ Service Manual Chassis System Fix connecter · · Chery Automobile Co., Ltd...
Page 255 Chery QQ Service Manual Chassis System · · · · · · · Chery Automobile Co., Ltd...
Page 256 Chery QQ Service Manual Chassis System · · · · Abnormal Abnormal Abnormal Chery Automobile Co., Ltd...
Page 257 Chery QQ Service Manual Chassis System · · · · · · · · · · · Chery Automobile Co., Ltd...
Page 258 Chery QQ Service Manual Chassis System Replace ABS ECU Chery Automobile Co., Ltd...
Page 259 Chery QQ Service Manual Chassis System · · · · · Check any leakage Check disc Replace disc Check manual brake Check exhaust Check valve leakage · · Check valve Abnormal Replace HECU Check booster and pedal travel Chery Automobile Co., Ltd...
Page 260 Chery QQ Service Manual Chassis System · · · · Can tester communicate with Fix tester and try other MK20 ABS ECU again Check ABS fuse Replace Norma Any display on tester Check source wire, ground wire, replace connector Check terminal is conducted...
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Page 263 Chery QQ Service Manual Chassis System A.Front piston; B.Rear piston 1.Right front wheel;2.Left rear wheel 3.Right rear wheel;4.Left front wheel Chery Automobile Co., Ltd...
Page 264 Chery QQ Service Manual Chassis System To stop switch Battery side 60Afuses Chery Automobile Co., Ltd...
Page 265 Chery QQ Service Manual Chassis System Connect diagnosis instrument and diagnosis socket OBD-16] Selection [Versatile OBD-16]diagnosis socket _ _ _ _ _ 01901 quit End coding and Chery Automobile Co., Ltd...
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Page 268 Chery QQ Service Manual Chassis System Chapter two Tests and Adjustments of Four-Wheel Positioning Section One: Basic Tests and Checks Preparations prior to adjustments I. Checks prior to adjustments 1 Checks on tire air pressure 2 Checks on car body 1 Check the tire air pressure, and adjust to the specified pressure.
Page 269 Chery QQ Service Manual Chassis System 2 Tire tears and wears Check the depth of the remaining tire textures. The depth of the remaining tire textures (as shown in the Figure) Standard tires: 1.6mm min. Snow ground tires: 50 % tire textures...
Page 270 Chery QQ Service Manual Chassis System 4 Points of attention for the rim sections and tires 1 Do not use the under-standard rim sections or tires; 2 The aluminum alloy rims are easy to be damaged by scraps. Please use soft cloth when doing the cleaning.
Page 271: Inspection
Chery QQ Service Manual Chassis System 8 Rim sections and tires non-circularity 1 Lift the car and support it securely; 2 Place the probe of the dial gauge on the rim section and measure the extent of non-circularity for each turning of a circle.
Page 272 Chery QQ Service Manual Chassis System 11 Installation When making the assembly of the outboa wheels and tires, first fix the wheel screws onto block the hubs manually and tighten them slightly. Then use special tools to tighten the screws in...
Page 273 Chery QQ Service Manual Chassis System 1 Check to see if there is any oil leakage; 2 Check to see if there are any tears and wears of the assembly sheaths; 3 Check the resistance of the absorbers. Make proper replacement if any incompliance is detected.
Page 274 Chery QQ Service Manual Chassis System Attention: Before testing and checking the wheel positioning, the car should be first adjusted to the specified height. If the car height does not meet the specification, check the front and rear suspension systems of the car to see if there are any damages or deformations.
Page 275 Chery QQ Service Manual Chassis System III. Check and adjust the front wheel main pin backward tilting angle, main pin interior falling-in angle, wheel camber angle as well as the wheel toe-in and steering angle Specifications: The requirements for the front wheel positioning are as follows: Main pin backward tilting angle 3°.15...
Page 276 Chery QQ Service Manual Chassis System alignment can be made by way of adjusting the connecting screw nuts for the independent suspension system and the knuckles. (1) First check (visually) to see if there are any damages on the driving system parts and components before doing the alignment.
Page 277 Chery QQ Service Manual Chassis System IV. The toe-in and camber angle of the rear wheels cannot be adjusted. Check the camber angle and toe-in of the rear wheels. If they fail to be in the specified limits, check to see if there are any deformed parts. Replace the defective parts.
Page 278 Chery QQ Service Manual Chassis System Excessive bias of tire and rim section Replacement Loose wheel screw nuts or axle heads Tightening Vibration Imbalance of tires Adjustment and down of Broken or damaged engine suspension Replacement steering wheel rubber Broken or damaged gear box supporting...
Page 279: Specifications
Chery QQ Service Manual Chassis System Chapter Three Suspension System Section One Specifications Tautness for Various Fasteners Torque Part No. Description Quantity Installation position (N·m) Q150B1010 Connecting bolts Braking tube and clamp 13-17 Rear absorber and rear shaft M12×1.25, Q151B1255 Bolts...
Page 280 Chery QQ Service Manual Chassis System Section Two Front Suspension Frame Maintenance of the front suspension frame I. Configuration Diagram of Front Suspension Frame Dampener; 2 Joining bolt; 3 Spiral spring; 4 Thrust bearing; 5 Spring upper stand washer; 6 Spring lower stand washer;...
Page 281 Chery QQ Service Manual Chassis System II. Removal and installation of the front balanced beam and the rubber sleeves for the balanced beam Removal 1 Loosen the two fastening screw nuts of the supporting frame and car body. There is one supporting frame on either side.
Page 282 Chery QQ Service Manual Chassis System Steps for installation: 1.Do the installation by referring supporting frame. to the dismounting steps. Remove the two fastening bolts for the 2.Points of attention: absorber and car frame. In the screw tightening process, the fastening...
Page 283 Chery QQ Service Manual Chassis System Steps for installation: body as shown in the figure to discharge the air 1.Do the installation by referring to the inside. dismounting steps. 2.Points of attention: . In the screw tightening process, the fastening...
Page 284 Chery QQ Service Manual Chassis System Removal 1. Loosen the spring compressor and place the jaws between the spring tops and bottoms (as shown the arrow). 2. Press the spring till it is separated from the upper and lower spring stands.
Page 285 Chery QQ Service Manual Chassis System Steps of installation: 1. Install the new absorber in the installation fixture. 2. If the used spring needs to be replaced, loosen the spring and then take the used spring out from the spring compressor.
Page 286 Chery QQ Service Manual Chassis System 2 Remove the balanced beam and rubber sleeve 9. Install the separation sheath bearing and the positioning device. assembly. 10. Make use of new nuts for tightening against Attention: When removing the balanced beam, looseness.
Page 287 Chery QQ Service Manual Chassis System Section Three Rear Suspension Frame Rear Suspension service I . Rear Suspension parts 1. 7. 12. 15. 21. Screw nuts; 2. Horizontal stabilizing bar; 3. 9. 11. 17. Bolts; 4. Lower supporting stand; 5. Spiral spring; 6. Spacing block; 8. Dampener; 10. Rear bridge; 13.16. Spiral washer; 14. Left and right swinging arm;...
Page 288 Chery QQ Service Manual Chassis System II. Dampener In the screw tightening process, the fastening Removal bolts controlled by torque + corner tightening submission limits should be replaced after each 1 Lift up the car and remove the bolts joining action of loosening.
Page 289 Chery QQ Service Manual Chassis System Remove the bolts fastening the vertical Removal and installation of the swinging arm and the car body. horizontal 4 Remove the rear swinging arm. Steps of installation: stabilizing rod and rear bridge 1. Do the installation by referring to the steps of dismounting.
Page 290 Chery QQ Service Manual Chassis System 2) Remove the joining bolt for the horizontal Steps of installation: stabilizingrod and t he rear bridge. 1. Do the installation by referring to the steps of dismounting. 2. Points of attention: In the screw tightening process, the fastening...
Page 291 Chery QQ Service Manual Chassis System Chapter 4 Steering System Torque specifications Application Specifications Steering box installation nut 70-80Nm Tie rod and rack fixture nut 63-77Nm Tie rod end plane and steering knuckle fixture nut 32-38Nm Power steering pump installation bolt...
Page 292 Chery QQ Service Manual Chassis System Manipulate part overhaul Steering wheel and steering column decompose view 1. Steering universal coupling shaft and universal coupling 2 3. Bolts 4. Steering core shaft assembly 5. Bolts 6. Jump ring 7. Washer 8. Spring 9.Steering column...
Page 293 Chery QQ Service Manual Chassis System Steering wheel free-play inspection In the assembled mode, check the free-play of the steering wheel while the car is driving in straight line. The free play of the steering wheel in the circumferential direction should be no larger than 0~30mm.
Page 294 Chery QQ Service Manual Chassis System Inspection 1 The steering shaft and universal coupling: check to see if the steering shaft is bent, or if the spine is damaged; check to see if there are any cracks on the universal coupling, or if the free play is too large.
Page 295 Chery QQ Service Manual Chassis System II Removal of power steering gear 4. Turn steering pivot left into gap of wheel, assembly pull the lever into engine compartment. (I)Removal Disassembly procedure 1. Put steering wheel forward and lock steering, remove steering shaft.
Page 296 Chery QQ Service Manual Chassis System Fixture Fixture Install pivot on front surround with Screw steering gimbal assembly with 70-80Nm. 22.5-27.5Nm. Insert two ends of lever and screw with steering node. Description and operation ( Use new nuts) with 32-38Nm.
Page 297 Chery QQ Service Manual Chassis System Problem Measure Demand adjust Lock core Ignition switch Lock core sets not correct If need to replace part, refer “ The ignition switch lock core replacing” If need to replace part, refer “ The ignition switch lock Lock core damage core replacing”...
Page 298 Chery QQ Service Manual Chassis System Service guide Replace ignition switch core Removal 1. Remove plastic cover 2. Insert needle into lock hole and pull out the core from lock seat. Steps of installation 1. Push the moving block to the direction shown in the figure.
Page 299 Chery QQ Service Manual Chassis System 3. Loosen the safety bolts. Drill holes on safety bolts with electric screwdriver to pull out the bolts. 4. Remove steering column. Points of attention Don’t turn ignition switch in LOCK position. 5. Remove up steering shaft and lower steering guide bearing from pillar.
Page 300 Chery QQ Service Manual Chassis System bag components. Fixture Screw shaft flange bolts to 22.5-27.5Nm. Screw gear flange bolts to 22.5-27.5 Nm. Screw steering wheel and shaft bolts to 27-33Nm. 10. Check forwards position for steering mechanics. Description and operation...
Page 301: Power Steering System
Chery QQ Service Manual Chassis System Power steering system Exterior identify Power steering box (16) Nut (1) Steering tie rod (17) Cover cap socket unit (18) Lock nut (2) Fixed ring (19) Dust cap (3) Dust cap (20) Circlet (4) Lock...
Page 302 Chery QQ Service Manual Chassis System Power steering service schematic diagram Steering oil pump Steering oil tank Steering oil pipe Power steering gear Chery Automobile Co., Ltd...
Page 303 Chery QQ Service Manual Chassis System Steering system fizzy noise Step Measure Identification: Fizzy noise is heard during Engine running or steering wheel turning If the fizzy noise becomes loud When TO step 2 System perfect comparing with other normal vehicle?
Page 304 Chery QQ Service Manual Chassis System Power steering box diagnosis Points of attention: Fizzy noise Don’t turn steering to the end and keep on. It Some noise will be heard during steering in will damage pump. fixed place under conventional condition.
Page 305 Chery QQ Service Manual Chassis System Power steering pump replace Points of attention Residual fluid will flow out into the container. Disassembly procedure Steps of installation 1. Remove transmission belt and loosen adjust 1. Put the tank into support and screw bolts.
Page 306 Chery QQ Service Manual Chassis System Rinse power steering system Attention: Use suitable steering fluid when filling or replacing fluid, otherwise it will damage hose and seal. 1. Lift vehicle to run wheel freely. 2. Suck out fluid from tank.
Page 307 Chery QQ Service Manual Chassis System 6. Push lower end of node to side of steering pivot to disconnect up end with steering pillar. 4. Remove bolts on pivot. 7. Remove steering node assembly. 8. Remove steering assembly. 5. Loosen two bolts on steering node.
Page 308 Chery QQ Service Manual Chapter 1 Start System Section 1 Summary Start circuit Start circuit is composed of battery, start motor, ignition switch and relational circuit. The connection of these parts is shown in the following figure. This chapter only refers to start motor.
Page 309 Chery QQ Service Manual 1.Drive cap protective cover 2.Drive shaft sleeve 3.Drive 4. Armature snap ring 5.Pinion stop ring 6.Overspeed clutch assembly 7.Start pinion fork 8.Magnet switch protective cover 9.Magnet switch 10.Retain coil 11.Suction coil 12.Rectifier end cover 13.Brush press spring 14.Brush bracket assembly...
Page 310 Chery QQ Service Manual Section 2 Fault Diagnoses The description of start system fault: 1. Starter motor dose not run (or run slowly) 2. Start motor can run but can not start the engine 3. Abnormal noise 4. Fault state Battery connection post (include engine side earth wire link) and starter motor connection post is tightened or not.
Page 311 Chery QQ Service Manual 5.Brush joint not well or wear and tear Repair or replace 6.Brush spring die down Replace 7.Rectifier damage Replace 8.Excitation coil connect earth not well Repair 9.Armature layer short circuit Replace 10. The running of crankshaft is not flexible...
Page 312 Chery QQ Service Manual Tighten torque (a):18~28N.m(1.8--2.8kg—m.13.5—20.01b—ft) Magnet switch assembly Disassembly 1. Loose the nut from the magnet switch then disconnect wire. 2. Take two nuts away, draw up the rear part of the magnet switch in order to separate the inner side hook and fork, then remove magnet switch.
Page 313 Chery QQ Service Manual 1.start motor bracket 2.brush 3.brush bracket 4. Use long-nose pliers to pull out the brush, then remove brush holder 1.armature 2.snap ring 3.drive end cover 5. Remove starter bracket 6. Use spring snap ring pliers and screwdriver to remove armature snap ring, then pull the pinion stop ring and overspeed clutch out.
Page 314 Chery QQ Service Manual Assembly 1. Check each part according to the method described in section “inspect and repair”, if necessary, please replace or repair it. 2. Daub lubricating grease according 1.armature to the figure before install the 2.overspeed clutch 3.pinion stop ring...
Page 315 Chery QQ Service Manual 5. Daub lubricating grease on inside of the end cover, install rectifier end cover. 6. Install end cover sealing gasket and braking spring, then install armature retainer firmly, Daub lubricating grease on the 40% space before install the rear cover.
Page 316 Chery QQ Service Manual Section 4 Check and Repair Armature Check whether the rectifier is dirty or damaged. If need repair, repair it by sand paper or on the lathe. Earthing It should be insulated between the rectifier plate and armature iron core, check it by ohmmeter.
Page 317 Chery QQ Service Manual Surface of the rectifier Use 100# emery cloth to trim and clean the surface of the rectifier, and check the deepness of the mica. If necessary, trim the deepness. Deepness A of rectifier mica piece 1.insulating mica 2.rectifier plate...
Page 318 Chery QQ Service Manual Magnet switch protective cover and plunger Check whether magnet switch protective cover is damaged and whether plunger is worn or damaged, replace if necessary. Magnet switch Push plunger then loose hand, plunger should return to original position rapidly. Replace if necessary.
Page 319 Chery QQ Service Manual Battery Performance test Caution: Each test should be finished in 3 seconds in order to avoid damaging coil. Attraction test Connect test wire according to the figure. Check Remove the wire whether the pinion (overspeed clutch) bounce out. If don’t bounce out, please replace magnet switch.
Page 320 Chery QQ Service Manual Starter technical data Voltage Output power 0.8 KW Start time 30 s Rotation direction See from pinion side clockwise Brush length 0.650in Number of teeth of start pinion Characteristic Condition Ensure Empty load Below 55A above 5000 r/m 9.5V...
Page 321: General Information
Chery QQ Service Manual Charging System Chapter 2 Charging System Section 1 Battery . General Information In the electric system, the battery has three functions. First of all, it is the energy source of starting engine and the car; Secondly, it acts as the voltage regulator of electric appliance system;...
Page 322 Chery QQ Service Manual Charging System Carrier and holding-down clamp Before the battery is installed, the carrier and holding-down device should be cleaned. And they should be prevented from corrosion. The carrier should maintain a good status. Ensure that no other materials are on the carrier before the battery is installed.
Page 323 Chery QQ Service Manual Charging System With assistant battery Caution: Avoid pushing or pulling the car to start, which may cause the damage of exhaust gas purification system and/or other parts. When the jumper cable is applied, carefully handle the assistant battery and the discharged battery.
Page 324 Chery QQ Service Manual Charging System discharged battery. 4. Start the engine of the car preparing to jump-start, and switch off other electrical equipments. And then start the engine of the car with low-battery battery. 5. The step of disconnecting jumper cable must be exactly contrary to that of connecting.
Page 325 Chery QQ Service Manual Charging System 3. With the polar protective circuits, some chargers won’t charge until the lead is appropriately connected to the terminal post of the battery. The fully discharged battery has not enough voltage to activate the whole circuit. Even though the lead is correctly connected, the battery can’t accept charging current.
Page 326 Chery QQ Service Manual Charging System Section 2: Generator . General Information The main charging coefficient is just the charging coefficient of the regulator of integrated circuit. The electric connection of its internal elements is shown in the following figure.
Page 327 Chery QQ Service Manual Charging System The characteristics of the generator are that a solid-state regulator is installed in it, and all the elements of the regulator are packed in a sealed case. The regulator, together with the brush carrier assembly, is installed in the slip ring and frame. The given voltage of generator can’t be modified.
Page 328 Chery QQ Service Manual Charging System and restrains the radio noise. . Trouble Shooting In order to avoid the damage to generator the following items should be observed: Attention: Never mix up the polarity of IG terminal post and L terminal post.
Page 329 Chery QQ Service Manual Charging System Fault indicator comes on Symptom Possible Reasons Measures ●The fuse snaps. Check the fuse. While ignition switch ●Something wrong with indicator Check cluster switched on and the engine is lamp in the cluster gauge.
Page 330 Chery QQ Service Manual Charging System Voltmeter Be connected between terminal post B of generator and the earthing. Ammeter Be connected between terminal post B of generator and the positive terminal of battery. 6. Measure the voltage and current under each of the following circumstance.
Page 331 Chery QQ Service Manual Charging System Note: Take into consideration that the voltage varies with the temperature of the regulator case. Before this test, the discharged batte ry must be fully charged. Note: When the engine runs, never remove the terminal post of the battery, otherwise, the electronic parts may be damaged.
Page 332 Chery QQ Service Manual Charging System than 20A, repair or replace the generator. Overcharged battery 1. Please see section “Battery” for ensuring the status of the battery. 2. The excessively effusion of electrolyte is the obvious indication of being overcharged. Then remove the generator to repair, and check the exciting coil winding for ground connection or short circuit.
Page 333 Chery QQ Service Manual Charging System 5. Remove the bolt of engine cover (downside), and then remove the cover; 6. Remove the construction bolt to take out the belt from the downside. 7. Install them in the step contrary to that of removal, and adjust the driving belt to the specified output tightness.
Page 334 Chery QQ Service Manual Charging System 4. Loosen the belt pulley nut with clamp and remove the belt pulley. Note: When the clamp is used, a piece of clean cotton cloth should be laid between rotor and clamp to avoid the damage to rotor.
Page 335 Chery QQ Service Manual Charging System 12. Remove 4 bolts and baffle and push out the bearing on the driving end. 13. If necessary, loosen stud bolts and pull out the stator. Note: Heating the frame on the driving end may facilitate disassembling stator.
Page 336 Chery QQ Service Manual Charging System Tightening torque of belt pulley nut: 95 130N.m Check and Adjustment Rotor ground The slip ring and rotor core should be conductively closed, which should be checked by means of ohmmeter. Open circuit Connect the ohmmeter probe to the slip ring to check whether the exciting coil is current-carrying and its electric resistance value.
Page 337 Chery QQ Service Manual Charging System exchange the places of the two probes. Only one should be conductive, the other should be infinite. Otherwise, replace the rectifier assembly. Note: Never use a 500V megohmmeter to test the rectifier, because it may damage the diode of the rectifier.
Page 338 Chery QQ Service Manual Charging System 10A25 -30 to 90 Tolerable ambient temperature -22 to 194 Polarity Minus ground Rotation direction Clockwise, seeing from belt pulley - 31 -...
Page 339 2. Air bag Chery S11 equip air bag at the driver and copilot position. Improper maintenance will cause the incidental inflation of airbag and serious consequential accidents. So you should regard the warning content on SRS equipment before maintenance.
Page 340 Chery QQ Service Manual Section 1 Car Body Electric Equipment Common Fault Clearance The cause analysis of car body electric equipment common fault can see in table 1. Table 1 Car body electric equipment fault clearance Fault system Fault symptom or phenomenon...
Page 341 Chery QQ Service Manual Fuse Only one small lamp light Harness Bulb Small lamp fuse Small lamp dose not work Headlight switch (headlight is normal) Harness Small lamp bulb Harness Rear combination light dose not Bulb light Headlight switch Headlight switch...
Page 342 Chery QQ Service Manual Only one rear foglight dose not Bulb light Harness Hazard alarm light switch Turning and hazard alarm light Flasher don’t light Fuse Harness Bulb Flash frequency is abnormal Flasher Harness Hazard alarm light fuse Hazard alarm light dose not light...
Page 343 Chery QQ Service Manual Bulb One lamp dose not light Harness Braking light fuse Braking light switch Braking light dose not light Bulb Braking light Harness equipment Braking light switch Braking light always light Harness Bulb One lamp dose not light...
Page 344 Chery QQ Service Manual Wiper switch Syringe dose not work, rear wiper Rear wiper motor dose not work Harness Syringe tube and nozzle Syringe motor No cleaning solution sprayed Wiper switch Syringe fuse Harness Wiper contact car body when wiper...
Page 345 Chery QQ Service Manual Engine ECU Engine fault warning lamp dose not Instrument circuitry template light Harness Fuel fluid level warning switch Fuel fluid level warning lamp dose Instrument circuitry template not light Bulb Harness Bulb Oil pressure warning lamp dose not...
Page 346 Chery QQ Service Manual Instrument circuitry template Front foglight indicator lamp dose Bulb not light Harness Window control switch Electric window equipment dose Guard against theft computer not work (all) (electric door lock Harness dose not work) Power supply fuse of controller...
Page 347 Chery QQ Service Manual Section 2 Lamplight System Operation Guide Please abide by relating Highway Code when use lighting facilities below. 1. Small lamp, headlight switch OFF – close vehicle outside lamp gear - lighten parking lamp/sidelights, illuminating lamp of instrument and switch, license plate lamp.
Page 348 Chery QQ Service Manual lever is pushed towards dashboard and upper beam indicator light will light up simultaneously. Headlight low beam will be lit up when control lever is pulled back to original position. 3. Headlight glitter switch If you want headlight glitter when you drive, you can pull control lever towards steering wheel to the change point, then control lever may be released.
Page 349 Chery QQ Service Manual With the headlight switch on, turn on the front foglight switch, front foglight can operate but rear foglight can not. With the headlight switch on, turn on the rear foglight switch, rear foglight can operate with front foglight simultaneously.
Page 350 Chery QQ Service Manual Change driveway signal light Pull the handle upwards or downwards to change point and hold on, corresponding turning light will flash. At the same time, the turn signal indicator light of corresponding direction on the instrument panel will flash simultaneously.
Page 351 Chery QQ Service Manual 7. Interior ceiling light switch OFF position Interior ceiling light will not illuminate. ON position Interior ceiling light will remain on. Middle position (door position) Interior ceiling light will illuminate when vehicle door is opened. Interior ceiling light will still illuminate in 8 seconds after close the door in order to help passenger seating safely.
Page 352 Explanation of lighting system Chery S11series passenger car entire vehicle lighting fitting includes illumination equipment and light signal equipment. It is used to guarantee the car’s normal running and safe driving at night or in the fog. It includes: headlight (lower beam and upper...
Page 353 Chery QQ Service Manual Installation: a. Install head light in corresponding position, ensure the bolt fixing hole and the headlight cross member welding nut are concentric; b. Locate the headlight by three M6 bolts with the torque 1.6 2.0 N·m. Drop the...
Page 354 Chery QQ Service Manual 4. Removal and installation of front turn signal lamp emoval: Raise the vehicle and then remove from the bottom of the vehicle i f possible. Loose two screws the take out the turn signal lamp Remove the harness connector, then take down the turn signal lamp from th...
Page 355 Chery QQ Service Manual Put the bolt with expand nut into the lo cation hole on the car body, then fix the lighting fitting with tapping screw; Connect lamp seat harness, install the c arpet. Close the luggage compartment lid.
Page 356 Chery QQ Service Manual Insert base line of the lamp into sheet-metal hole, screw hole on the lamp and screw hole on the sheet-metal is c oncentric, then tighten tapping screw. insert two bolts of license plate into sheet-metal hole, install the nut and tapping screw, adjust install position then tighten nut and tapping screw;...
Page 357 Chery QQ Service Manual Installation: Connect the harness connector; put the lamp into top install hole in correct position and direction, tighten the tap ping screw by screwdriver, then press the shade of ceiling light in by your hands. . Removal and installation of high-mounted stop lamp...
Page 358 Chapter 4 Inspection and Repair of BCM Computer Control System .General BCM is abbreviation of Body Control Module of Chery Automobile, which is also named antitheft computer control unit. It is a device designed to facilitate the driver and passengers to use some electric devices in the vehicle and simple maintenance.
Page 359 Chery QQ Service Manual BCM Computer Control System integration of the antitheft device, power windows and central door lock module. The system is installed on the left side of the evaporator that is at the lower center of the central console. When the switch on the remote control device is pressed down, the central door lock system will enter a security mode with glass window automatically closed to avoid raining, wind or theft in case the user forgets to lock the windows.
Page 360 Chery QQ Service Manual BCM Computer Control System The central door lock prevails when these two operations are in conflicts and the glass elevator stops. When the central door lock completes the glass elevator resumes the previous task. Remote antitheft function The remote controller has two keys;...
Page 361 Chery QQ Service Manual BCM Computer Control System will automatically work to close the glass windows one by one if the glass window is not closed. Code setting mode Turn on the ignition switch IGN ON/OFF for two times within 7 second and push IGN at ON position.
Page 362 Chery QQ Service Manual BCM Computer Control System Note: Only the battery with regulated voltage (+3V) is available. Put in a proper manner according to positive and negative marks. 2. Check BCM computer Terminal check of BCM computer is tabulated as below.
Page 363 Chery QQ Service Manual BCM Computer Control System Grounding Signal for elevation of left rear power window Signal for decline of left rear power window Antitheft indication signal to left turn indicator Elevation signal to left front power window switch...
Page 364 Chery QQ Service Manual BCM Computer Control System 3 Inspection and repair of BCM computer (antitheft computer) circuit Connect the plug on to BCM computer (antitheft computer). As shown in the figure above, check each circuit terminal, with the result as tabulated below.
Page 365 Chery QQ Service Manual BCM Computer Control System Central control lock “ON” Power supply A12-Grounding voltage Central control lock “OFF” Conducting Antitheft works Power supply voltage A13-Grounding Antitheft fails Nonconducting Ignition switch “ON”, power window switch Conducting “UP” A14-Grounding Ignition switch “ON”, power window switch Power supply “DOWN”...
Page 366 Chery QQ Service Manual BCM Computer Control System Ignition switch “ON”, power window switch Conducting “UP” A23-Grounding Ignition switch “ON”, power window switch Power supply “DOWN” voltage Antitheft works Power supply A25-Grounding voltage Antitheft fails Nonconducting Ignition switch “ON”, power window switch Conducting “UP”...
Page 367 6). For central door lock control of antitheft computer, refer to of “Central Door Lock Maintenance”. 4. Division and match of QQ remote controls QQ remote controls features two brands and three modules. I) 9CG, two modules 1) Module 1...
Page 368 Chery QQ Service Manual BCM Computer Control System (Electrical parts and relay are set on the same side in the module. It has a small lock of remote control with projected mark, a red seal circle, and two batteries. ) 2) Module 2 (Electrical parts and relay are set on different sides in the module.
Page 369 Chery QQ Service Manual BCM Computer Control System antitheft indicator will flash once. This indicates this remote control has entered into the system. Note: The first remote control is set into the system After Step 3). Following that, press any key of the second remote control to set it into the system. Many service stations only operate one remote control hereto.
Page 370 Chery QQ Service Manual BCM Computer Control System Chapter 5 Operation and Maintenance of Audio System I. Audio system functions and operations (illustrated just by using Baoling Electronic Tuning Radio (ETR) and please refer to the supplied specifications for other radios).
Page 371 Chery QQ Service Manual BCM Computer Control System (2) Mode selection (MODE) Press (3) key repeatedly and you will be able to select the function modes in the following order: VOL→BAS→TRE→BL→ FA→VOL. In each mode, press “+” or “-” to adjust electrical frequency for each mode.
Page 372 Chery QQ Service Manual BCM Computer Control System (6) Save key (1-6) Radio Save key (1-6) can save more than 30 radio stations (18 FM stations and 12 AM stations). When users need to save radio stations, they can do so by pressing “ ” or “ ”...
Page 373 Chery QQ Service Manual BCM Computer Control System (1) The turn-on operation is the same as in the radio mode. (2) Insert gently a cassette with the open side on the right into the compartment. When the display shows TAPE and “◄” or “►”, the device is in normal play status.
Page 374 Chery QQ Service Manual BCM Computer Control System setting mode 6 MUTE 7 Volume 8 Power switch 9 Display 10 BAND SCAN: Radio frequency scanning/CD player song scanning ◄ ►: High-end and low-end scanning (playing) Previous/next song (CD cassette) Automatic music scan system 11 AST: automatic saving system 12.
Page 375 Chery QQ Service Manual BCM Computer Control System 3. Audio circuit diagram - 96 -...
Page 376 Chery QQ Service Manual BCM Computer Control System IV. Disassembly and assembly of the Audio system 1. Disassembly and assembly of the Audio system Disassembly: Turn off the power and ignition switch, and remove wires connected with the battery. Remove the outer shield of the radio.
Page 377 Chery QQ Service Manual BCM Computer Control System Assembly: Reverse to the disassembly process. 3. Disassembly and assembly of the antenna Disassembly: Remove the top light (refer to Disassembly of Top Light). Loosen the bolts. Remove the plug connected to signal reception lines to remove the antenna.
Page 378 .The structure and maintenance of wiper and wash equipment The structure of wiper and wash equipment Wiper and washer equipment of Chery S11 consist of fuse, combination wiper switch with intermittent position, windshield wiper relay and motor, rear wiper motor, wiper abutment, connecting rod assembly, locating lever, wiper rubber strip, water injection pump, reservoir and nozzle etc.
Page 379 Chery QQ Service Manual BCM Computer Control System Structure of the wiper 1- wiper arm 2- wiper rubber strip 3- protective cover abutment 4 5 7- nuts 6- swing link 8- 9- journal 10- motor 11- crankshaft The circuit system for the wiper and wash equipment is shown in the figure. If the...
Page 380 Chery QQ Service Manual BCM Computer Control System switch is in its “third” position, the wiper operates in the fast mode. When the wiper switch is turned in the direction of instrument panel to the last position, the rear wiper operates in its slow mode and the water injection pump injects water at mean time.
Page 381 Chery QQ Service Manual BCM Computer Control System Circuit diagram of the wiper and wash equipment - 102 -...
Page 382 Chery QQ Service Manual BCM Computer Control System Inspection and Repair of wiper and wash equipment 1 Removal of Wiping rubber Strip Hold the two steel straps on the sealed side of wiping rubber strip with slip-joint pliers, remove them from the upper clamp and draw the rubber strip together with the steel straps from the other clamps of wiper blade.
Page 383 Chery QQ Service Manual BCM Computer Control System Installation of the wiper abutment 4 Inspection of conduction of wiper switch and washer switch As shown in the figure, if the performance of conduction does not conform to the states shown in the figure, the wiper switch and the washer switch must be replaced.
Page 384 Chery QQ Service Manual BCM Computer Control System Figure Inspection of wiper and washer switches 5 Inspection of the operation of the front washer As shown in the figure, the terminals 8 and 5 are respectively connected to the positive and negative pole (anode and cathode) of the secondary cell, and the positive and negative probes of a voltmeter are respectively connected to the terminals 7 and 5.
Page 385 Chery QQ Service Manual BCM Computer Control System Figure Inspection of the performance of the front wiper motor 7 Trouble-shooting of the wiper and wash equipment Typical troubleshooting can be seen in the table Trouble-shooting chart of wiper and washing equipment...
Page 386 . Inspection and Repair of Horns Only one horn is used in Chery S11, it is installed to the inside of front left bumper beam, the current through the horn relay contacts is supplied by F4(10A)
Page 387 Chery QQ Service Manual BCM Computer Control System Horn button wiring broken or loose contact Repair or replace thereof The sound of horn is Insufficient charge of secondary cell Recharge or change the cell Horn defective Replace Interference between horn and direction...
Page 388 Chery QQ Service Manual BCM Computer Control System Switch ON 2 Inspection of defroster wiring While cleaning the window, wipe with soft cloth along the line, don’t damage the defroster wiring. Don’t use cleaning agent or cleaning device, otherwise the surface will be damaged.
Page 389 Chery QQ Service Manual BCM Computer Control System Connect the positive probe of the Voltage meter to positive terminal of the defroster, negative probe to the earth end. Press the positive probe on the hot wire and move it to the negative terminal.
Page 390 Chery QQ Service Manual BCM Computer Control System the function power windows timer After the start-up switch shut off, the power windows are operable within 30 seconds. If the doors are opened or closed in the period, the power windows can be operated within another 30 seconds.
Page 391 Chery QQ Service Manual BCM Computer Control System Stop condition of the door windows: it is the same as that of power windows. In the stepping mode, once another switch is turned on, the operation (of lowering switch in raising operation/lowering switch/raising switch in raising operation) stops.
Page 392 Chery QQ Service Manual BCM Computer Control System switch switch position Connection to the instrument conductance Switch on the 13-12 driver side 3-12 DOWN 14-12 Switch on the 5-12 3-12 5-3 by-driver 3-12 side(window DOWN 6-12 3-12 unlocked) Switch on the...
Page 393 Chery QQ Service Manual BCM Computer Control System switch position connection to the conductance instrument Front driver side secure 12-11 switch 3-12 On the door interior panel of the drive side, an rear window secure switch button is provided. Push the button, the power windows switches of the by-driver side and the both rear door windows are deactivated.
Page 394 Chery QQ Service Manual BCM Computer Control System negative pole of the secondary cell, and check if the motor rotates clockwise as shown in the figure; connect the terminals reversely, check if the motor rotates anticlockwise. If the result is not as mentioned, replace the front left power window motor.
Page 395 Chery QQ Service Manual BCM Computer Control System connecting wire defective repair or replace None of the power windows connecting wire defective repair or replace wire works power window motor repair or replace power window switch repair or replace theftproof computer...
Page 396 Chery QQ Service Manual BCM Computer Control System secure button down. Door lock The front doors can be locked and unlocked from outside with the key and can be locked from inside with the door handle. Before leaving the car, push down the locking rod down and close the door to lock it.
Page 397 Chery QQ Service Manual BCM Computer Control System side of the lower evaporation box. It gets power supply from the secondary cell, and receives opening and closing signal from the door lock device of the front left door to control the direction of the central door lock device. The BCM computer (theftproof computer) is in charge of controlling the central door lock and power window.
Page 398: Internal Rearview Mirror
Chery QQ Service Manual BCM Computer Control System Pages 107-108 show the circuit diagram of power supply of the power window .The structure, Inspection and Repair of the power rearview mirror 1. Internal rearview mirror External appearance of the assembly...
Page 399 Chery QQ Service Manual BCM Computer Control System (1) Explosive view (2)Usage/operation guide and warning Usage/operation guide According to the different driver’s visual, adjust the mirror angular of the assembly Turn the handle to adjust the mirror angular in the up and down direction to prevent dazzle.
Page 400 Chery QQ Service Manual BCM Computer Control System The rearview mirror of Chery S11 is electric controlled. If the driver turns the turning switch on, turning light of the rearview mirror gives turning signal in the corresponding direction. Turn the adjust button in the car to adjust the angular of the mirror in upward, downward, leftward or rightward direction.
Page 401 Chery QQ Service Manual BCM Computer Control System Technical parameter Parameter Criterion reflectivity of the mirror ≥40% Left R1200 R2000 curvature of the mirror surface Right R1200 upward/downward, leftward/rightward ≥7° turning angle of the rearview mirror folding angle inward of left rearview Max 65°...
Page 402: Inspection Of Power Rearview Mirror
Chery QQ Service Manual BCM Computer Control System Electric circuit diagram of power rearview mirror 3. Inspection of power rearview mirror Power rearview mirror can only be operated in one direction For example, the power rearview mirror can only turn left or turn up, defective switch can be...
Page 403 Chery QQ Service Manual BCM Computer Control System determined, replacement should be made. If motor or wiring is defective, power rearview mirror can not be operated in both directions; if the wiring is broken, no current flows through the motor, so the power rearview mirror cannot turn in any direction.
Page 404: Fuse And Relay
Chery QQ Service Manual BCM Computer Control System between the wiring and the car body. If only the switch is replaced without eliminating the short cut, the switch will still be cut off. Therefore, under such circumstances, remove the power rearview mirror wiring connector instead of replacing the switch, check which wire among the yellow, green, blue, grey and black-red wires is short with car body.
Page 405 Chery QQ Service Manual BCM Computer Control System Fuse and relay of the engine chamber - 126 -...
Page 406 Chery QQ Service Manual Inspection and Repair of BCM Computer Control System -127-...
Page 407 Chery QQ Service Manual Chapter7 Air-conditioning Section 1 General I. Major parts of the air-conditioning and refrigerant flow chart. Chery Automobile Co.,Ltd...
Page 408 Chery QQ Service Manual II. Function descriptions of each part ompressor 1. C The compressor serves to compress the refrigerant that is evaporated as gaseous one in evaporator, so the compressed gaseous refrigerant is fed by force into condensator in which it is changed to liquid form, heat resulted from vaporization of liquid refrigerant can be reused.
Page 409 Chery QQ Service Manual compressor does not run. . It is recommended to use high power electric magnetic clutches. Diagram for the clutch fitted on the compressor 3. Condensator A condensator serves to change the high temperature and high pressure refrigerant in gaseity to liquid one by taking away the heat of the refrigerant in gaseity by force.
Page 410 Chery QQ Service Manual 5. High-low pressure protection switch The high-low pressure protection switch is used for control. When there is abnormal pressure variation occurring in circular refrigerant, the switch will cut off the circuit of the electric magnetic clutch and the condensator’s fan to stop the compressor.
Page 411 Chery QQ Service Manual III. Function of each control element 1.Relay (condensator’ fan/electric magnetic clutch) The relay is used to control condensator fan motor and electric magnetic clutch respectively. As far as the air conditioning (compressor) is running, the condensator fan will work continuously.
Page 412 Chery QQ Service Manual below 196kpa (2.0 kg/cm2,28.4psi)….off over 226kpa (2.3kg/cm2,32.7psi)…on Engine cooling water temperature Over 110(230 )…off Below 103(230 )…on When starting engine makes the engine start…off Evaporator temperature: When the air conditioner’s switch on Over 2.5(36.5 )…off Below 4.0(39.2 )…on...
Page 413 Chery QQ Service Manual Chery Automobile Co.,Ltd...
Page 414: Principle Of Operation
Chery QQ Service Manual principle of operation: When startup a car, the ignition cell (+)12V will supply power to ECU, duty relay and the main relay coil respectively, the duty relay closes and ECU makes the main relay close after receiving the ignition signal.
Page 415 Chery QQ Service Manual The ECU makes the low speed relay operating after receiving the A/C switch closed signal, then the fan begins to work. When the water temperature is higher than certain degree, ECU will make the fan‘s high speed relay operating automatically, then the high speed fan works.
Page 416 Chery QQ Service Manual eyes and skin. If it occurs, wash with cooled water. Warning: (a) Do not wipe your eyes or skin. (b) Clean the oil on your skin properly (c) Go to hospital for professional treatment at once 4.
Page 417 Chery QQ Service Manual Section 3 Items of Tools and Devices Maintenance kit for air conditioner Spare valve for discharging refrigerant Refrigerant charge meter green Refrigerant charge hose blue Refrigerant charge hose orange Refrigerant charge hose Disconnecting valve charge hoses...
Page 418 Chery QQ Service Manual and vacuum. The vacuum range is 0-5X10 pa(0-760mmHg), the pressure scale starts from 0 and range is over 4.2X10 pa(approximate 4.2kgf/cm ). The high-pressure meter scale starts from 0 and range is over 21.1X10 pa(approximate 21.1kgf/cm These two meters are fitted on the same seat, each end of which has a manual valve and under which there are three path joint.
Page 419 Chery QQ Service Manual Secion 5 Operating Method of the Recovery Device for Refrigerant I. Recovery refrigerant from the refrigerating device When refrigerant is discharged from the refrigerating device at following cases, a recovery device should be used to recovery refrigerant: Before changing parts on refrigerant pipe.
Page 420 Chery QQ Service Manual II. Operating method for recovery device 1. The manifold pressure meter set is installed on the spare valve. Refrigerant is recovered from the refrigerating device. (1) The middle hose is connected to recovery device. (2) To operate recovery device.
Page 421 Chery QQ Service Manual II. Preparation for parts of air conditioner Parts should be put according to the installation order after the package box for parts is open. At the same time, you must make sure that no part is missed or bad. When installing air conditioner, you must protect the fenders and seats with supplementary mats.
Page 422 Chery QQ Service Manual Section 7 Recovery, Evacuation and Charge I. Recovery of refrigerant Refrigerant recovery unit must be used when the refrigerant for air conditioning is discharged. Directly discharging refrigerant into atmosphere will bring harmful effects on environment. Note: when using recovery unit, you must follow the operating instruction of the device.
Page 423 Chery QQ Service Manual observed. If reading becomes greater, it indicates there is leakage. So the system must be repaired before evacuation operation continues. If the reading keeps unchanged, it indicates there is no leakage. You can continue evacuation. 6 the total evacuation time should be over 15 mins.
Page 424 Chery QQ Service Manual The refrigerant should be stored at cool and dark places. Do not put it at places of high temperature, such as the place directly under sunshine or close to fire or in the car (including trunk).
Page 425 Chery QQ Service Manual of the refrigerant tank is used, replacement should be done according to method as described in the following. unscrew the plate nut return the hole forming pin back and remove the charge valve of the refrigerant tank.
Page 426 Chery QQ Service Manual your eyes and skin. 5 fit the maintenance valve cover. Section 8 Trouble-shooting I. Trouble-shooting Chart Fault Possible reasons Action Electric magnetic clutch operating fault a.fuse blowout or relay fault Replace the fuse and check if short circuit occurs b.electric magnetic clutch fault...
Page 427 Chery QQ Service Manual Improperly wiring in the circuit Check the expansion valve Over damp system Repair if necessary evacuate and charge the system Condensator is blocked Check the condensator Drive belt trackslip Check or replace the drive Compressor fault...
Page 428 Chery QQ Service Manual Possible position Diagnosis and Result Reason Phenomenon of the fault measurement power source is fuse Without air conditioner out of condition voltage 12V condition relay power source conditioner No. 30, 87 pin Relay is out of...
Page 429 Chery QQ Service Manual work resistance of air Measuring Resistance is short Without speed governing blower is out of resistance is over circuit signal condition 0Ω Switch Measuring switch Switch is out of Without control signal blower is out of...
Page 430 Chery QQ Service Manual Section 9 Maintenance On-board Note: you should comply with the following rules when maintaining air conditioning system. 1. Wiring 1 remove the accumulator’s negative wire to avoid short circuit. 2 the lead connector should be plugged fixedly.
Page 431 Chery QQ Service Manual should be dropped on the seat surface of the connecting nut and the O-shape of seal ring. 4 when the joint is screwed or unscrewed, two wrenches should be used, one is for tightening, the other for supporting.
Page 432 Chery QQ Service Manual determined and make-up the same amout of oil. Warning: if refrigerant HFC-134a R-134a splashes into eyes, you should go to hospital for treatment quickly. It is not permissible to wipe your hurted eyes, but to wash them with a large amount of clean cold water to make the temperature of your hurted parts rise to the freezing point.
Page 433 Chery QQ Service Manual High pressure side 1.37-1.57 14-16kg/cm Water vapor exists in the refrigeration system. Symptom discontinuous cold air to no cold air. Fault symptom of Possible reasons Fault diagonosis Troubleshooting refrigeration action system When running, pressure The vapor entering Drier 1 replace the stock Chery Automobile Co.,Ltd...
Page 434 Chery QQ Service Manual at low pressure side refrigeration oversaturation solution drier sometimes is normal, system ices in the ↓ evacuate but sometimes vacuum. spraying hole of Water vapor ices at repeatly to eliminate the expansion valve the spraying hole of...
Page 435 Chery QQ Service Manual found and repaired, then air in systemis evacuated. 4. Refrigerant circulation is out of condition Symptom insufficient cold air Fault symptom of Possible reasons Fault diagonosis Troubleshooting refrigeration system action Low pressure at both low Refrigerant can not...
Page 436 Chery QQ Service Manual Fault symptom of Possible reasons Fault diagonosis Troubleshooting action refrigeration system pressure side Refrigerant can not Refrigerant check the thermal indicates vacuum and flow because the water doesn’t circulate sensitive pipe, expansion high pressure side vapor or dirt block the...
Page 437 Chery QQ Service Manual Fault symptom Possible reasons Fault diagonosis Troubleshooting action of refrigeration system High pressure at both Good performance Excessive refrigerant in 1 clean the condensator the low and high cannot be played circulation check the working pressure sides even...
Page 438 Chery QQ Service Manual High pressure at both enters Air exists in the 1 check if the compressor high refrigeration refrigeration system polluted pressure sides system ↓ insufficient. Low pressure pipe is Inadequate vacuum evacuate air in the system and charge new touched refrigerant.
Page 439: Refrigeration System
Chery QQ Service Manual Fault symptom Possible reasons Fault diagonosis Troubleshooting of refrigeration action system Too high pressure at Leakage exists in Ompression Repair or replace the low pressure the compressor condition ↓ compressor. side Air valve leaks air or gets...
Page 440 Chery QQ Service Manual 2 whether leakage exists at joints of condensator. 3 whether the radiator rib of the condensator is damaged. If the radiator rib is blocked you should wash it with water and dry it with compressed air.
Page 441 Chery QQ Service Manual 2 evacuate and charge the system in accordance with the above methods. 3. Evaporator thermantidote Remove 1 remove the negative wire of the accumulator. 2 prohibit the air bag system function. 3 when regrigerant is recovered with recovery and regenerative unit , you must follow the operating instruction of the device.
Page 442 Chery QQ Service Manual 2 check whether cracks or scratches exists at joints of the inlet and outlet. If necessary, please repair it. 4. Expansion valve Check before removal 1 connect the manifold pressure meter to the service valve. 2 make the engine run in a speed of 1000r/min and turn on the air conditioner.
Page 443 Chery QQ Service Manual See “remove and disassemble” in the evaporator section for details. Installation 1 install the thermistor in the order contrary to removing it. 2 evacuate and charge the system according to the above described methods. 6. Refrigeration pipe Check 1 check whether the hoses and the metal tubes leak air with leakage detector.
Page 444 Chery QQ Service Manual Switch ● ● ● ● ● ● If the air conditioner switch does not conduct, please replace it. 2 high-low pressure protection switch This car is equiped with the high-low pressure protection switch check 1 check whether switches conduct at normal temperature of about 25...
Page 445 Chery QQ Service Manual 1 remove the negative wire of the accumulator. 2 remove the relay connector and then remove the relay. wiring as shown in the diagram. Check whether the pins conducting. If not, please replace the relay. Compression system Parts of the compressor must be free from dirt and foreign substance when the compressor is being maintained.
Page 446 Chery QQ Service Manual condition No rotating item replace locked Oil or air leakage Seal replace condition Light maintenance can be done onboard and the refrigerant needn’t be discharged, while the refrigerant must be discharged in overhaul. There are three main types of the compressor faults air leakage, noise and underpressure.
Page 447 Chery QQ Service Manual follow the operating instruction of the device. The lost oil in compressor must be measured and make-up the same amount of oil. remove the electric magnetic clutch lead from the wiring bundle of air conditioner. 5 remove the intaking hose and discharging hose from the compressor.
Page 448 Chery QQ Service Manual Chapter 8 Air Bag System Maintenance and use of air bag Diagnose Inspection of SRS diagnostic system When the SRS is powered on, airbag SDM will turn on warning light and start a self-checking, during which the warning light will flash for 6 seconds with a frequency of 1Hz. Any fault detected by SDM will activate airbag warning light, and the fault will be stored to SDM memory.
Page 449 Chery QQ Service Manual Maintenance and Service of SRS System Warning: In case engine is stopped and fuse is taken off, the SDM will provides sufficient voltage for 1 minute to activate airbag. If airbag is still connected, do not start maintenance operation within one minute after power supply to SDM is switched off.
Page 450 Chery QQ Service Manual Connecting Airbag 1. Insert airbag fuse into fuse box 2. Turn ignition switch to on position, airbag indicator light will be turned on for 6 seconds and then goes out. If the indicator light does not work in accordance with the foregoing, please refer to “Check with SRS Diagnostic System”...
Page 451 Chery QQ Service Manual Checking Airbag Parts after Inactivation in Accident The airbag must be checked after any collision accident, whether it is activated or not. Steering post must be measured for dimensions. Check dashboard and steering post cover for crack and other damages.
Page 452 Chery QQ Service Manual 3. Tighten fastening bolts with torque of 8-12Nm. 4. Connect SDM wire harness connector; 5. Push connector fuse lock in position; 6. Fix the left and right decorating plates of dashboard central control panel; 7. Power on SRS. Please refer to “Connecting Airbag” part of this manual.
Page 453 Chery QQ Service Manual case of insufficient spreading room and cause personal injuries or vehicle damages. 1. Connect horn and airbag wire harness connector to airbag socket; 2. Install airbag module; 3. Fix airbag module screws 4. Tighten airbag screws with a tightening torque of 13-17Nm;...
Page 454 Chery QQ Service Manual Four nuts: M6 Tighten torque: 10N.m Two bolts: Torx-T50 Tighten torque: 15N.m Disassembling Procedure Warning: In case engine is stopped and fuse is taken off, the SDM will provides sufficient voltage for 1 minute to activate airbag. If airbag is still connected, do not start maintenance operation within one minute after power supply to SDM is switched off.
Page 455 Chery QQ Service Manual Always activate an airbag before it is scrapped. If the whole vehicle is disposed of and disassembled, the airbag may be triggered inside the vehicle. Disposal of Activated Airbag Warning: Please take following precautions to avoid activation of airbag inside vehicle and consequential injuries.
Page 456 Chery QQ Service Manual Activated Airbag”. Activating Airbag (outside vehicle) For vehicles within warranty period, before activating airbag, please contact regional maintenance manager for approval or other specifications. Please activate the airbag under following circumstances: Vehicle is to be disassembled. Please refer to “Spreading Airbag” part of this manual;...
Page 457 Chery QQ Service Manual consequential injuries. Remove all movable or loose parts within spreading coverage of airbag before activating airbag. Activate and spread the airbag with doors closed and side windows open. Spread the airbag only in the reserved spreading area. All necessary maintenance staff must stay at least 10 meters away from the vehicle in the front.
Page 458 Chery QQ Service Manual Air bag computer Spire cable Under the shift handle Driver’s Passenger’s Beside the air bag air bag module - 170 -...
Page 459 Chery QQ Service Manual Chapter 9 Engine Hood and Luggage Compartment Removal of the engine hood 1.Loosen four fixed bolts and lift the engine hood. 2. Unclench the engine hood rod. 3. Loosen two fixed bolts to take out the upper lock.
Page 460 Chery QQ Service Manual 4. Loosen two fixed bolts to take out the lower lock. 5. Loosen the engine hood cable. 6. Adjust left and right engine hood bolts to ensure normal gap. - 224 –Chery Automobile Co.,Ltd...
Page 461 Chery QQ Service Manual Remove the engine hood hinge 1.Remove the fender (refer to “Remove Fender”) 2.Loosen four fixed bolts both left and right to take out the engine hood hinge. Replace the engine hood support 1.Take the support out of engine hood Screw out bolts, and get the support out of engine hood.
Page 462 Chery QQ Service Manual Torque: 22 Newton-meter (225 kg-cm, 16 pound-foot) Adjust the engine hood Loosen the hinge bolts, and adjust the engine hood in forward, backward and vertical directions. Torque: 11.5 Newton-meter (115 kg-cm, 8.3 pound-feet) Install the hood lock control assembly 1.Apply grease on the lock before parts installation.
Page 463 Chery QQ Service Manual Remove the Luggage Compartment 1. Loosen 5 bolts on the left lining board and take them out. 2. Disconnect the trunk cable set and loosen wiper pipe. 3. Hold the trunk and unfasten 4 fixed bolts on the hinge.
Page 464 Chery QQ Service Manual 4. Remove hydraulic rod and take out luggage compartment assembly. Remove the lock assembly(mechanical) 1.Detach the connectors. 2.Unfasten 2 fixed bolts and take out the lock. Remove the lock assembly(electric) 1. Detach the connectors. - 228 –Chery Automobile Co.,Ltd...
Page 465 Chery QQ Service Manual 2. Unfasten 3 fixed bolts to take out the lock, and disconnect the motor wire. Remove the electric switch (1) Unfasten fixed bolts of the trunk. (2) Detach the connecting rod on the lock switch of trunk.
Page 466 Chery QQ Service Manual (3) Unfasten 2 fixed bolts on the trunk lock. (4) Take out the lock assembly. Adjust the trunk door 1. Adjust the trunk door (1)Loosen bolts, and adjust the door in forward/backward, and left/right directions. (2)Increase or decrease the amount of washers between hinge and trunk door to adjust the front end in upward or downward directions.
Page 467 Chery QQ Service Manual (3)Be careful of sputtering iron scrap when drilling the hole. (4)Air in the cylinder is colorless, smell-less, and nontoxic (5)Deal with the support carefully. Do not drop paint or oil on it. (6)When the support fully extrudes, do not turn the piston rod or cylinder.
Page 468 Chery QQ Service Manual Chapter 10 Door Disassembly of front door Removal of inner door panel of front door Remove set bolt on the fixed handle base plate with cross screwdriver. Remove bolts of fixed handle with cross screwdriver. Remove 4 set bolts of inner door panel.
Page 469 Chery QQ Service Manual Sway the door inner door panel from top to bottom by hand, take out the inner door panel upwards. From the rear of inner door panel, separate the connecting rod of fixed handle, then take out the fixed handle.
Page 470 Chery QQ Service Manual Take out inner door panel. Removal of Front door Horn Remove the inner door panel; “removal interior decorative panel” for reference. Remove 4 set bolts of the horn. Remove the horn plug, take the horn out.
Page 471 Chery QQ Service Manual Removal of front door switch Remove set bolts of front door switch with Cross screwdriver. Take the door switch assembly out. Removal front door locks institution Remove 2 set bolts on the lock buckle with cross screwdriver.
Page 472 Chery QQ Service Manual Take door check strap out. Remove front door set bolts Adjustment of front door Adjust front door frontward, backwards and vertically Loosen the hinge bolts of body side with special tools and adjust the door. Adjust the front door along left/right and vertical direction.
Page 473 Chery QQ Service Manual Remove 2 set bolts of door glass guide rail. Separate door inner panel Assembly. Remove set bolts on upper part of door glass guide; Take out the door inner panel and glass guide rail. Loosen 2 set bolts of window winder and glass bracket.
Page 474 Chery QQ Service Manual panel. Fix the guide, block and 2 nuts after adjustment. Lift glass again and check to see if the installation is good or not. Removal of window winder Take out the door inner panel. Loosen 2 set bolts of the window winder and...
Page 475 Chery QQ Service Manual Chapter 11 Seat and Belt Removal of front seat Remove 4 set bolts of front seat Take out the seat assembly Removal of rear seat 1. Removal of rear left seat cushion Loosen 4 set bolts, lift left rear seat cushion frontward and upward.
Page 476 Chery QQ Service Manual Removal of backrest Draw back the buckle on rear seat, move seat cushion frontward from the rear. Draw back the left/right bolts, move the backrest frontward. Loosen 3 set bolts, take out backrest of rear Seat assembly.
Page 477 Chery QQ Service Manual Dismantlement of backrest lock Loosen outer cover of the seat. Loosen 2 set bolts, take out rear back lock. Removal of safety belt of rear seat Draw back the buckle, move the seat pad frontward; Loosen set bolt of the safety belt handspike, take out the bolts.
Page 478 Chery QQ Service Manual Chapter 12 Interior accessories Removal of vehicle roof panel Pull out inner panel of A pillar on the left side. Loosen bolts on the sun shading panel with screwdriver. - 242 -...
Page 479 Chery QQ Service Manual Loosen 3 handles on the roof panel. Open the 8 latch hooks with flat screwdriver. From top to bottom, pull out the roof panel assembly. Removal of radio Loosen 2 set bolts of the radio. Take out the radio, disconnect the plug.
Page 480 Chery QQ Service Manual Removal of A/C panel Loosen 4 set screws. Open fixed clip (make the mark) and loosen the cable on air outlet. Loosen plug, pull out the A/C panel Removal of back light switch Open the switch with a small Screwdriver.
Page 481 Chery QQ Service Manual Removal of antenna Remove set bolts of antenna. Remove the launching wire of the antenna. The installation sequence is in the reverse direction of the dismantle sequence. - 245 -...
Page 482 Chery QQ Service Manual Chapter 13 Outside Accessories Removal of rearview mirror Remove plastic protective Cover of the rearview mirror. Remove 2 set screws of the outside rearview mirror. Remove 3 set screws of rearview mirror plastic parts. - 246 -...
Page 483 Chery QQ Service Manual Loosen the harness connector of the mirror from the door inner panel; take out the rearview mirror assembly. Removal of headlamp Remove front bumper (see dismantlement of front bumper for reference) 2 Loosen 3 set bolts, take out the head lamp.
Page 484 Chery QQ Service Manual Removal of high-mount stop lamp Loosen 2 set screws, pull out lamp cover downwards Loosen 3 set screws, take out the high-mounted stop lamp. Removal of number plate lamp/protective panel assembly Loosen 4 set screws of the license plate lamp with screw driver to take them off.
Page 485 Chery QQ Service Manual Loosen 2 set screws on the protective panel, and then take off the screws. Removal of fuel tank lid Loosen set bolt of fuel tank lid; remove the fuel tank lid. The installation sequence is just the reverse of dismantlement sequence...
Page 486 15 front pillar ornament (16) sun shading board and holder 17 small illuminating light 18 middle sun shading boards 19 interior rear-view mirror 20 front roof lining 21 windshield wiper arms 22 sealing strips for windshield - 258 – Chery Automobile Co.,Ltd...
Page 487 Drag the wire along all sides of windshield to cut off bonding agent to remove windshield Attention Bonding agent should be kept on car body as much as possible when cutting windshield joint - 259 – Chery Automobile Co.,Ltd...
Page 488 2 Clean windshield with cleaning liquid Attention Do not touch windshield after cleaning 4. Replace clamps if necessary 1 Remove stops with knife 2 Take down used clamps 3 Put new clamps on - 260 – Chery Automobile Co.,Ltd...
Page 489 M bonding agent Attention 1 Wait for base coating layer to dry over 3 minutes 2 No coating on bonding agent 3 Never reserve unsealed base paint M for later use - 261 – Chery Automobile Co.,Ltd...
Page 490 1 Cut off the Note of tubular pot and fill bonding agent in the pot 2 Put the pot into sealing glue gun 10mm (0.39in) 3 Apply bonding agent on windshield as showed in the drawing - 262 – Chery Automobile Co.,Ltd...
Page 491 1 Water leakage test shall be conducted after hardening period (2) Block up water leaking places with sealant 14.Install upper inlaid strips on windshield Put upper inlaid strips on car body and pat the strips by hand to tighten - 263 – Chery Automobile Co.,Ltd...
Page 492 Torque 43 N.m 32 lbf/in rear seat cushions front seats Torque 37 N/m 375 kgf/cm 27 lbf/in windshield sealing strips for windshield windshield wiper arms - 264 – Chery Automobile Co.,Ltd...
Page 493 Lead piano wire out between car body and glass Bind up two wire ends with wood blocks or similar objects Note Do not let piano wire damage two stops Remove the glass 6. Remove rear window inlaid strips - 265 – Chery Automobile Co.,Ltd...
Page 494 Remove block stop by knife Block stop 4. Clean removed glass Remove the bonding agent stuck on glass with scraper Remove block stop by knife Clean glass with cleaning liquid Attention Do not touch glass after cleaning - 266 – Chery Automobile Co.,Ltd...
Page 495 Coat a layer of base paint G with brush or sponge on glass periphery and joint surface Clear base paint with a clean rag before drying Attention Leave base paint layer dry for 3 minutes at least No coating on bonding agent - 267 – Chery Automobile Co.,Ltd...
Page 496 Remove excess or spilled bonding agent with scraper Fasten glass until bonding agent hardened 11. Water leakage checking and maintenance Water leakage test shall be conducted after curing time Block up water leaking places with sealant - 268 – Chery Automobile Co.,Ltd...
Page 497 Torque 18 N.m 185 kgf/cm 13 lbf/in bolts on the lower end of rear seat belt Torque 43 N.m 440 kgf/cm 32 lbf/in rear seat cushions When installing, the sequence is the reverse procedure of removal - 269 – Chery Automobile Co.,Ltd...
Page 498 Loosen four set bolts on wiper motor and take down the motor Remove blade Loosen seven set bolts and take down blade Remove rear window wiper assembly - 270 – Chery Automobile Co.,Ltd...
Page 499 1 Remove front bumper See the chapter on removal of front bumper 2 Loosen three set bolts and take down jet washer Loosen cable plug and move out and upward to get out front and rear jet - 271 – Chery Automobile Co.,Ltd...
Page 500 Chery QQ Service Manual washer motors Remove nozzle Pull out the nozzle upwards to take apart with the tube When assembling, the sequence is the reverse procedure of removal. - 272 – Chery Automobile Co.,Ltd...
Page 501 Check if there is vertical separation front rim Front rim between sealing strip and roof sheet Front rim: 0±1.0 mm 0±0.039 in Rear rim 0±1.0 mm 0±0.039 in - 273 – Chery Automobile Co.,Ltd...
Page 502 Loosen the fixing nuts on sun-roof and shift sun-roof bracket forward and backward to adjust As showed in the drawing Make link rod slide forward and backward to align two marks Slide by hand bracket to front terminal - 274 – Chery Automobile Co.,Ltd...
Page 503 5. Clearance adjustment clearance between left side and right side Loosen fixing nuts to readjust sun-roof to correct position When assembling, the sequence is the reverse procedure of removal. - 275 – Chery Automobile Co.,Ltd...
Page 504 1. Remove baffle plates 1 Loosen three fixing screws 2 Loosen fixing screws and remove fasteners with unfastening tool 2. Remove splashers front-left and right Loosen three fixinging screws on splasher 2 Detach three fasteners with - 276 – Chery Automobile Co.,Ltd...
Page 505 3. Remove front grid Loosen two fixing screws and remove grid 4. Remove front bumper 1 Loosen four fixing screws on inner left and right sides - 277 – Chery Automobile Co.,Ltd...
Page 506 5. Remove front fog light Loosen two screws and remove front fog light 6. Remove front turn signal light Loosen fixing screws and remove front turn signal light - 278 – Chery Automobile Co.,Ltd...
Page 507 Chery QQ Service Manual 7. Remove the grid cover on front bumper Loosen four screws on upper and lower sides Press down protecting fasteners and get grid cover out - 279 – Chery Automobile Co.,Ltd...
Page 508 Loosen four fixing nuts on left and right and take down inner bumper Remove rear bumper Loosen two fixing screws on left and right ( in boot ) Loosen two cross recess head screws in tail part - 280 – Chery Automobile Co.,Ltd...
Page 509 Loosen two set bolts on lower side and tremove rear bumper Remove the small bulb on rear bumper Loosen fixing screws and take down the small bulb When assembling, the sequence is the reverse procedure of removel. - 281 – Chery Automobile Co.,Ltd...
Page 510 69 lbf-in seat-belt retractor assembly body lower inner front seat-belt power seat regulator manual seat regulator body rear seat-belt lower end of outer back seat-belt body inner back seat-belt body - 282 – Chery Automobile Co.,Ltd...
Page 511 Chery QQ Service Manual - 283 – Chery Automobile Co.,Ltd...
Page 512 Chapter 18 Explanation of S11 Entire Vehicle Circuitry and Pins Chery S11 car electrical system adopt centric circuitry board mode, it means that the most part of relays and fuses are installed in the engine compartment relay box front side, main line connect each electric apparatus front back of the engine compartment relay box.
Page 513 Chery QQ Service Manual Section 1 Harness in engine compartment 1. The distribution of engine compartment harness: - 285 - PDF created with pdfFactory Pro trial version www.pdffactory.com...
Page 514 Chery QQ Service Manual Section 2 Engine harness 1. The distribution of engine harness: - 286 - PDF created with pdfFactory Pro trial version www.pdffactory.com...
Page 515 Chery QQ Service Manual - 287 - PDF created with pdfFactory Pro trial version www.pdffactory.com...
Page 516 Chery QQ Service Manual - 288 - PDF created with pdfFactory Pro trial version www.pdffactory.com...
Page 517 Chery QQ Service Manual Section 3 Instrument Wire Harness Arrangement of Instrument Wire Harness - 307 –Chery Automobile Co.,Ltd...
Page 518 Chery QQ Service Manual - 308 –Chery Automobile Co.,Ltd...
Page 519 Chery QQ Service Manual Section 4 Interior Wire Harness 1 Arrangement of Interior Wire Harness - 309 –Chery Automobile Co.,Ltd...
Page 520 Chery QQ Service Manual Body System Chapter 2 Service of Car Body Sheet Metal Work 2.1 Overview of maintenance for four doors and two lids Car body mainly consists of various kinds of framework parts, panels and other parts, technology of making door is the most complicated technology which touch upon parts stamping,...
Page 521 Chery QQ Service Manual Body System 2.1.2 Technological process of door maintenance: Generally speaking, basic method of four doors and two lids maintenance is the same as technology of common sheet metal work maintenance; the following procedures are introduced as follows: (1) Initial check Measure the relative position and dimension between gaps for door and other car body unit.
Page 522 Chery QQ Service Manual Body System (5) Detect after disassemble. Generally speaking, it includes measurement for geometric dimensions between sheet metal parts of all kinds, inspect concrete location of damage, make clear the type of damage, analyze cause of damage, determine maintenance plan.
Page 523 Chery QQ Service Manual Body System 2.2 Basic method of door maintenance In view of above-mentioned damage type, main methods of doors and lids maintenance include sinking trim, flame straightening, weld, repair by embedding 2.2.1 Trimming the rough and uneven surface...
Page 524 Chery QQ Service Manual Body System 2)Not knocking the beam pad with hammer. This method means put the beam pad under the lowest place of the hollowness, knock the nearby place with hammer. Generally speaking, while trimming the hollowness with hammer and beam pad ,the protruding side shall be knocked by the hammer, the other side shall be gasket ,you can make rough shaping with wooden hammer then make fine trimming with iron hammer.(see figure 7).In the case of...
Page 525 Chery QQ Service Manual Body System (1) Heating position and flame energy. Effectiveness of flame straightening is up to heating position and flame energy, different heating position result in different straightening effectiveness. The maximum and longest deformation position shall be selected to be the heating position, that is to say the outside of deformation.
Page 526 Chery QQ Service Manual Body System (3) Cooling contraction mode You can choose appropriate cooling mode according to stretchable degree of sheet metal after evacuation from flame, different cooling mode result in different shrinkage. 1) Natural cooling contraction. That means natural cooling in the air, which is applicable to deformation place with smaller shrinkage.
Page 527 Chery QQ Service Manual Body System to take the small weld nugget as positioned weld according to interspaces of 30mm-50mm, carry out welding in order after knocking ,make the surface to be flattened. In the case of welded seam which needs high intensity, it is better for you to adopt two sided welding mothod.
Page 528 Chery QQ Service Manual Body System less than 20% of the plate thickness; As to whether or not strength of weld nugget is strong enough, you can make use of shovel and hammer to carry out negate damaging test. You can knock in between two weld nuggets with shovel,to see whether or not it will be sealing off, you can knock it with hammer for the recovery.
Page 529 Chery QQ Service Manual Body System 2.4.3 Tighten the M8×22 combination bolts in proper order by hand, then hold the front end of wrench by left hand shown as the illustration, hold the handle by right hand, operate vertically, make the door hinge and hull structure body tightened.
Page 530 Chery QQ Service Manual Body System 2.5.2 Dimension of vehicle body 2.5.2.1 Side view - 19- Chery Automobile Co., Ltd...
Page 531 Chery QQ Service Manual Body System In the illustration: point a to point b, point d to point c, alignment is transitive evenly from 0 to 1,point e to point f, point h to point g, the clearance is transitive evenly from 4 to 4.5.other The...
Page 532 Chery QQ Service Manual Body System C-C The cross section, request of clearance and plane - 21- Chery Automobile Co., Ltd...
Page 533 Chery QQ Service Manual Body System MA The cross section enlarging figure, request of plane is 0±1 MB The cross section enlarging figure, request of plane is 0±1 - 22- Chery Automobile Co., Ltd...
Page 534 Chery QQ Service Manual Body System D-D The cross section, request of clearance and plane E-E The cross section, request of clearance and plane - 23- Chery Automobile Co., Ltd...
Page 535 Chery QQ Service Manual Body System F-F The cross section, request of clearance and plane G-G The cross section, request or clearance and alignment - 24- Chery Automobile Co., Ltd...
Page 536 Chery QQ Service Manual Body System H-H The cross section, request of clearance and plane J-J The cross section, request of clearance and plane - 25- Chery Automobile Co., Ltd...
Page 537 Chery QQ Service Manual Body System K-K The cross section, request of clearance and plane L-L The cross section, request of clearance and plane - 26- Chery Automobile Co., Ltd...
Page 538 Chery QQ Service Manual Body System 2.5.2.2 Front view figure - 27- Chery Automobile Co., Ltd...
Page 539 Chery QQ Service Manual Body System In the figure: From point m to point n, clearance is transitive evenly from 3.6 to 5.8,from point j to point k, the clearance is transitive evenly from 5.8 to 3.6. - 28- Chery Automobile Co., Ltd...
Page 540 Chery QQ Service Manual Body System M-M The cross section, request of clearance and plane MC The cross section enlarging figure, request of plane 0±1 - 29- Chery Automobile Co., Ltd...
Page 541 Chery QQ Service Manual Body System MD The cross section enlarging figure, request of plane is 0±1 ME The cross section enlarging figure, request of plane is 0±1 - 30- Chery Automobile Co., Ltd...
Page 542 Chery QQ Service Manual Body System MF The cross section enlarging figure, request of plane is 0±1 N-N The cross section, request of clearance and plane - 31- Chery Automobile Co., Ltd...
Page 543 Chery QQ Service Manual Body System P-P The cross section, request of clearance and plane Q-Q The cross section, request of clearance and plane - 32- Chery Automobile Co., Ltd...
Page 544 Chery QQ Service Manual Body System 2.5.2.3 Rear view figure - 33- Chery Automobile Co., Ltd...
Page 545 Chery QQ Service Manual Body System R-R The cross section, request of clearance and plane S-S The cross section, request of clearance and plane - 34- Chery Automobile Co., Ltd...
Page 546 Chery QQ Service Manual Body System T-T The cross section, request of clearance and plane U-U The cross section, request of clearance and plane - 35- Chery Automobile Co., Ltd...
Page 547 Chery QQ Service Manual Body System V-V The cross section, request of clearance and plane W-W The cross section, request of clearance and plane - 36- Chery Automobile Co., Ltd...
Page 548 Chery QQ Service Manual Body System 2.5.2.4 Dimension of engine room - 37- Chery Automobile Co., Ltd...
Page 549 Chery QQ Service Manual Body System 2.5.2.5 Distance dimension between two points of every part Control dimension Remark 1326.7±1.5 Front windshield diagonal 908.8±1 Front windshield YO position distance 345.7±1 Center distance between front shock absorber and front wheel housing outside panel front end port 622.2±1...
Page 550 Chery QQ Service Manual Body System Dimension of vehicle body , Left/Right Remark: Capital letter English alphabet symbol shows right side of vehicle body , small letter shows left side of vehicle body (See from rear part of vehicle) 1323...
Page 551 Chery QQ Service Manual Body System 2.5.2.6 Crossbeam size - 40- Chery Automobile Co., Ltd...
Page 552 Chery QQ Service Manual Body System 2.5.2.7 Reference point --- symmetry Symmetrical reference points Symmetrical reference points refer to the two corresponding points which are located symmetrically on the centerline with same length, width and height; you can make use of the symmetrical reference points to carry out high-speed check-up, so as to make sure that the damage degree of bottom configuration parts of the vehicle body.
Page 553 All dimensions can be measured from the following aspects: ● Length to the zero line (1) ● Height to the datum line (2) ● Width to the centre line (3) All dimensions are symmetrical if there are no other regulations. - 46- Chery Automobile Co., Ltd...
Page 554 CHERY SQR7080 EZ Drive TRANSMISSION SERVICE MANUAL PDF created with pdfFactory Pro trial version www.pdffactory.com...
Page 555 PDF created with pdfFactory Pro trial version www.pdffactory.com...
Page 556 CHERY SQR7080 EZ Drive SERVICE MANUAL TABLE OF CONTENTS CHARACTERISTICS OF THE CLUTCH....................1 DRIVE RATIOS OF THE MECHANICAL TRANSMISSION ..............2 PARTS RELATED TO MECHANICAL TRANSMISSION ................. 3 BRIEF INTRODUCTION TO MECHANICAL TRANSMISSION ............. 4 SUGGESTIONS ABOUT MECHANICAL TRANSMISSION ..............5 SCHEMATIC DIAGRAM OF MECHANICAL TRANSMISSION .............
Page 557 PDF created with pdfFactory Pro trial version www.pdffactory.com...
Page 558 CHERY SQR7080 EZ Drive SERVICE MANUAL CHARACTERISTICS OF THE CLUTCH Vehicle Transmission model Engine Mechanism Brake disc model model 26 – gear wheel BL: blue C06 0 JH1 003 E = 7.6mm B: white JH2 002 D = 181.5mm N: black...
Page 559 CHERY SQR7080 EZ Drive SERVICE MANUAL DRIVE RATIOS OF THE TRANSMISSION Transmission Vehicle Cylinder Speed The 1st The 4th The 5th Reverse model model torque torque gear gear gear gear gear gear C06 6 15/56 21/19 11/37 22/41 28/37 30/29...
Page 560 CHERY SQR7080 EZ Drive SERVICE MANUAL PARTS RELATED TO MECHANICAL TRANSMISSION Name Related part MOLYKOTE 33 (moderate) Control shaft's half-moon parts REF: 77 01 028 179 FRENBLOC glue Fixing bolt for brake ring Frequently Changed Parts Removed parts to be substituted:...
Page 561 CHERY SQR7080 EZ Drive SERVICE MANUAL BRIEF INTRODUCTION TO MECHANICAL TRANSMISSION Automated mechanical transmission is a manual mechanical transmission equipped with an electronically controlled hydraulic unit, in which an embedded computer controls both operating of the clutch and changing of the drive ratio. Thus, there is no need to provide a clutch pedal and speed control is implemented through an electronic contact lever, and the accelerator and brake pedals are electronically connected to the engine through the embedded engine computer.
Page 562 CHERY SQR7080 EZ Drive SERVICE MANUAL SUGGESTIONS ABOUT MECHANICAL TRANSMISSION Important: Automated mechanical transmission During any maintenance or repair of the electronically controlled hydraulic unit, it is a must to use detergent and compressed air for cleaning. Do not let the hydraulic pipeline open; do not use any high-pressure cleaner for cleaning.
Page 563 CHERY SQR7080 EZ Drive SERVICE MANUAL SCHEMATIC DIAGRAM OF MECHANICAL TRANSMISSION Throttle Front-door contact Engine computer Transmission mechanism for gear position selection and speed change Transmission computer Transmission mechanism of the clutch Gearshift handle 10. Power supply pack Position sensor for accelerator & brake pedals (load sensor) 11.
Page 564 CHERY SQR7080 EZ Drive SERVICE MANUAL MECHANICAL TRANSMISSION PERFORMANCE The electronically controlled hydraulic system mounted on the transmission is comprised of two transmission mechanisms: à Transmission mechanism for gear position selection and speed change à Transmission mechanism for clutch and hydraulic unit The entire hydraulic system is connected with transmission and engine computers.
Page 565 CHERY SQR7080 EZ Drive SERVICE MANUAL MECHANICAL TRANSMISSION – ELECTRONICALLY CONTROLLED HYDRAULIC UNIT Tightening torque (unit: DAN.M) M8 bolt for electric pump set M10 bolt for electric pump set Nut for drive mechanism module Pin for drive mechanism module High-press pipeline coupler...
Page 566 CHERY SQR7080 EZ Drive SERVICE MANUAL Unscrew the six fixing bolts and remove the Place the control shaft onto the drive mechanism hydraulic unit. module and lock it. Replace the two half-moon parts: Screwdriver impression and shaft pin should be aligned respectively with the marks.
Page 567 CHERY SQR7080 EZ Drive SERVICE MANUAL MECHANICAL TRANSMISSION – ELECTRONICALLY CONTROLLED HYDRAULIC UNIT Remove the handle of this hydraulic unit. Fix the hydraulic unit to the transmission by Oil filling into oil tank tightening the fixing bolts. The mark shown on the oil tank is the lowest standard.
Page 568 CHERY SQR7080 EZ Drive SERVICE MANUAL MECHANICAL TRANSMISSION – ENERGY STORAGE Tightening torque (unit: DAN.M): Energy storage Lifting ring fixing Operation: Energy storage is used to ensure that the pump runs intermittently. Its full inflation can guarantee three speed loads of clutch engagement/disengagement.
Page 569 CHERY SQR7080 EZ Drive SERVICE MANUAL MECHANICAL TRANSMISSION – ELECTRIC PUMP SET Tightening torque (unit: DAN.M) M8 bolt for electric pump set M10 bolt for electric pump set High-press pipeline coupler Energy storage Remarks: Before maintaining the entire automated mechanical transmission, use a special repair tool to remove the energy storage.
Page 570 CHERY SQR7080 EZ Drive SERVICE MANUAL MECHANICAL TRANSMISSION – PUMP Tightening torque (unit: DAN.M) M8 bolt for electric pump set M10 bolt for electric pump set High-press pipeline coupler Energy storage M6 bolt for electric pump Remarks: Before maintaining the entire automated mechanical transmission, use a special repair tool to remove the energy storage (refer to the section of “ENERGY...
Page 571 CHERY SQR7080 EZ Drive SERVICE MANUAL Notice: When you change the electric pump set, it is inevitable to change its relay. The relay is probably damaged due to frequent ignition, and therefore if so, you shall replace the relay so as to avoid damaging the new electric pump set.
Page 572 CHERY SQR7080 EZ Drive SERVICE MANUAL MECHANICAL TRANSMISSION – OIL TANK Tightening torque (unit: DAN.M) Energy storage High-pressure pipeline coupler Lifting ring fixing nut Remarks: Before maintaining the entire automated mechanical transmission, use a special repair tool to remove the energy storage (refer to the section of “ENERGY...
Page 573 CHERY SQR7080 EZ Drive SERVICE MANUAL MECHANICAL TRANSMISSION – CLUTCH MODULE Tightening torque (unit: DAN.M) Energy storage High-pressure pipeline coupler Lifting ring fixing nut M8 bolt for electric pump set M10 bolt for electric pump set M6 bolt for electric pump...
Page 574 CHERY SQR7080 EZ Drive SERVICE MANUAL Remount: Remounting: Spring Notice: Remount the sleeve on condition that the Piston washer shall have a correct mounting compression spring is mounted in the correct direction due to its unusual lip shape. direction so as to damage the piston washer.
Page 575 CHERY SQR7080 EZ Drive SERVICE MANUAL Fix the potentiometer Carry out the following steps according to the opposite sequence. Tighten the potentiometer into the clutch module through the compression spring. Fill the ELF RENAULT MATIC D3 SYN DEXRON oil to the degree that the oil level is 32 to 38 mm higher than the lowest mark line.
Page 576 CHERY SQR7080 EZ Drive SERVICE MANUAL MECHANICAL TRANSMISSION – DRIVE MECHANISM MODULE Instruction of part and component: 1. Electromagnetic valve for clutch 2. Electromagnetic valve for gear engagement 3. Electromagnetic valve for gear position selection 4. Engagement position sensor 5. Gear position sensor 6.
Page 577 CHERY SQR7080 EZ Drive SERVICE MANUAL – Supporting board for fasteners (A) Remove the transmission support from the vehicle body. Remove: – Mounting bracket for lifting ring (B) – Energy storage Lower the transmission as possible as you can and take off the control shaft cover.
Page 578 CHERY SQR7080 EZ Drive SERVICE MANUAL Put two half-moon parts and circlip into the control shaft groove. Fix the hydraulic unit onto the transmission by It is easy to carry out the following assembly screwing its fixing bolts. procedure, which is opposite to the disassembly Hold the control shaft with a screwdriver so as to procedure.
Page 579 CHERY SQR7080 EZ Drive SERVICE MANUAL MECHANICAL TRANSMISSION – ELECTROMAGNETIC VALVE Tightening torque (unit: DAN.M) Energy storage High-pressure pipeline coupler Lifting ring fixing nut Electromagnetic valve bolt Remarks: Disconnect the related connections for electromagnetic valves. Before maintaining the entire automated...
Page 580 CHERY SQR7080 EZ Drive SERVICE MANUAL Electromagnetic valve 2: Lower the transmission as possible as you can. Removal: Disconnect related connections It is necessary to lower the transmission to remove electromagnetic valves. the clutch electromagnetic valve 2. Remove the electromagnetic valve 2 (D).
Page 581 CHERY SQR7080 EZ Drive SERVICE MANUAL MECHANICAL TRANSMISSION – ENGAGEMENT POSITION SENSOR Tightening torque (unit: DAN.M) Power on position sensor bolt Disconnect the engagement position connector (A) Drive mechanism module nut Remove the engagement position sensor (A) Lifting ring fixing nut...
Page 582 CHERY SQR7080 EZ Drive SERVICE MANUAL MECHANICAL TRANSMISSION – GEAR POSITION SELECTION SENSOR Tightening torque (unit: DAN.M) Power on position sensor bolt Disconnect the gear position selection connector (B) Electromagnetic valve Remove the gear position selection sensor (B) Lifting ring fixing nut...
Page 583 CHERY SQR7080 EZ Drive SERVICE MANUAL MECHANICAL TRANSMISSION – CLUTCH POSITION SENSOR Tightening torque (unit: DAN.M) Clutch position sensor bolt Remounting: M8 bolt for electric pump set Carry out the following remounting procedure that M10 bolt for electric pump set is opposite to the removal procedure.
Page 584 CHERY SQR7080 EZ Drive SERVICE MANUAL MECHANICAL TRANSMISSION – PRESSURE SENSOR Tightening torque (unit: DAN.M) Position sensor bolt Remounting: Drive mechanism module nut Carry out the following remounting procedure that Lifting ring fixing nut is opposite to the removal procedure.
Page 585 CHERY SQR7080 EZ Drive SERVICE MANUAL MECHANICAL TRANSMISSION – CLUTCH SPEED SENSOR After replacing the transmission's clutch speed sensor, it is necessary to start the vehicle so as to recover the fault light to the condition of being not illuminated due to being free from fault and delete all the memories of the computer.
Page 586 CHERY SQR7080 EZ Drive SERVICE MANUAL Line distribution: 52-line connector: 1 – power supply module 1 2 – power supply module 2 3 – gear position selection electromagnetic valve 4 26 <--- high drive ratio information 27 ---+ battery 28 ---+ after ignition 29 - à...
Page 587 CHERY SQR7080 EZ Drive SERVICE MANUAL MECHANICAL TRANSMISSION – RELAY Position: There are two relays that can be activated by the system: Start-up relay (A) near the buzzer under the instrument board (B). Pump relay on the interconnection box within the engine compartment.
Page 588 CHERY SQR7080 EZ Drive SERVICE MANUAL MECHANICAL TRANSMISSION – FUSE Position: The system employs three fuses for power supply: 3A fuse (A) on the ignition switch's positive pole (+), located on the fuse side panel of driver compartment, connected to the main shaft 28 of the transmission computer connector.
Page 589 CHERY SQR7080 EZ Drive SERVICE MANUAL MECHANICAL TRANSMISSION – WIRE HARNESS The wire harness is integrated with the hydraulic unit and bundles eleven connectors for different components. Five main electromagnetic valves are placed together on one sleeve and the plate is fixed onto the hydraulic block.
Page 590 CHERY SQR7080 EZ Drive SERVICE MANUAL MECHANICAL TRANSMISSION – GEARSHIFT LEVER Method of application: For control lever type gearshift, there is only one stable position. Any operation of the gearshift lever from this position will produce a pulse, which is also called “signal”.
Page 591 CHERY SQR7080 EZ Drive SERVICE MANUAL Removal: Disconnect the battery. Remove: – Gearshift lever base frame dust boot – Transmission base Disconnect electric connection of the gearshift lever. Take out the following two electric wires of the gearshift lever's electric connector: Undo the circlip that surrounds the gearshift lever Line 8 –...
Page 592 CHERY SQR7080 EZ Drive SERVICE MANUAL MECHANICAL TRANSMISSION – SPECIAL REQUIREMENTS ON REPLACEMENT OF SYSTEM AND COMPONENTS KIT hydraulic unit/computer/transmission/reprogramming Ignition Re-initialization after all experiments (attempts) are carried out: RZ002 “attempt” Title: control of VP008 “Gear position selection & gear engagement attempt”...
Page 593 CHERY SQR7080 EZ Drive SERVICE MANUAL Title: control of RZ003 “Important Attempts” Place the gearshift lever to the neutral position Start the engine Wait for ten seconds (used in important clutch experiments) and provide no speed. If the check result is OK, ET062 “Important experiments finished” will be shown. Otherwise, repeat the procedure (C).
Page 594 CHERY SQR7080 EZ Drive SERVICE MANUAL Title: control of AC011 “Hydraulic unit overflow port screw plug” Wait until the program comes to an end Turn off the engine Wait for one minute Ignition (if any fault occurs, the buzzer will be started) If the check result is OK, ET061 “Region Qualified”...
Page 595 CHERY SQR7080 EZ Drive SERVICE MANUAL CONTROL OF MACHINE PARTS – MAIN CYLINDER Tightening torque (unit: DAN.M) M10×100 Reassembly: Main cylinder bolt Check on the length of the pushrod. Servo brake bolt Size: X = 22.3MM It can be adjusted by using the measuring rod (P) Removal: according to its particular model.
Page 596 CHERY SQR7080 EZ Drive SERVICE MANUAL Remarks: the vehicle is equipped with the master cylinder that is integrated with the servo brake. The servo brake sealing is directly associated with the master cylinder. It is necessary to substitute a new washer (A) when in repair.
Page 597 CHERY SQR7080 EZ Drive SERVICE MANUAL CONTROL OF MACHINE PARTS – SERVO BRAKE Indispensable special tools ELE 1294-01 Glass cleaning tool MOT. 1453 Engine bracket 2* TAV. 1233-01 Seat frame tool Tightening torque (unit: DAN.M) M10×100 Main cylinder bolt Servo brake bolt...
Page 598 CHERY SQR7080 EZ Drive SERVICE MANUAL It can be adjusted by using the measuring rod according to its particular model. Size: X = 22.3mm It can be adjusted by using the measuring rod (P) according to its particular model. –...
Page 599 CHERY SQR7080 EZ Drive SERVICE MANUAL CONTROL OF MACHINE PARTS – AIR FILTER & SERVO BRAKE CHECK VALVE Replace the check valve Change of air filter This operation can be carried out in the vehicle. Disassembly: Disconnect the servo relief inlet pipe.
Page 600 S11 Brake System...
Page 601 S11 Brake System Introduction Right brake lamp ABS warning lamp Left brake lamp ABS master ABS control module cylinder Vacuum booster Brake lamp switch Left rear wheel speed sensor ABS electronic Brake switch control module ABS hydraulic ABS wheel speed sensor control unit...
Page 602 Composition of Ordinary Brake System Parking brake control lever Brake booster Brake pedal Disc brake Proportioning valve Brake master cylinder Parking brake cable Disc brake...
Page 603: Brake Booster
Brake Booster 1. Usually, the brake booster can increase the braking force two to four times. 2. Brake booster's performance varies with the actual atmospheric pressure, vacuum degree and its active area. The bigger its active area is, the stronger its boosting force is.
Page 604 Brake Booster not in Braking Vacuum Variable-pressure chamber - chamber A Constant-pressure chamber Cylinder sleeve - chamber B Relationship between F and F To brake wheel cylinder pushes the Valve piston to the right. Brake master cylinder Spring Piston...
Page 605 Brake Booster in Braking Vacuum Relationship between F and F < F pushes the piston to the right Valve Hydraulic pressure Brake master cylinder...
Page 606 Brake Booster Structure Constant-pressure chamber Diaphragm Power piston Vacuum Check valve Reaction disc Valve body Valve control lever Brake master Air filter cylinder Booster housing Push rod sealing member Booster housing Variable-pressure chamber Booster sealing member housing Diaphragm spring...
Page 607 1. Brake Booster not in Braking Piston Vacuum valve (opened) Passage A Control valve Control valve spring Constant pressure Opened vacuum Valve body chamber valve & control valve A is connected with B Air valve (closed) Valve control lever Passage B Air filter element Air valve return spring Variable pressure chamber...
Page 608 2. Brake Booster in Braking Piston Control valve Constant Closed vacuum pressure valve & control chamber valve Booster A is not connected push rod with B Air valve B is connected (opened) with C Air filter element Reaction disc Passage B Variable pressure chamber When not in braking...
Page 609 3. Brake Booster in the Retained Position Piston Vacuum valve (closed) Control valve Closed vacuum valve & control Control valve spring valve Constant pressure chamber A is not connected with B or C Stop Air valve (closed) Valve control lever Variable pressure chamber When in the retained position (brake force)
Page 610 4. Brake Booster in the Released Position Piston Vacuum valve (opened) Passage A Control valve Opened vacuum valve & control valve A is connected Air valve (closed) with B and C Valve control lever Passage B Air valve return spring Variable pressure chamber When in the released position (brake)
Page 611 Purpose of Brake Master Cylinder Brake master cylinder Brake pedal Front/rear brakes Drum brake...
Page 612 Brake Master Cylinder Structure Reservoir Liquid lever sensor RF/LR brake cylinders RR/LF brake cylinders Second piston Rubber piston cup Primary piston Tandem brake master cylinder...
Page 613 1. Brake Master Cylinder not in Braking Compensating port Secondary return spring Inlet port Primary return spring Piston cup is located between inlet port and compensating port Primary piston cup Stopper bolt Secondary piston cup When not in braking...
Page 614 2. Brake Master Cylinder in Braking Compensating port 进油孔 Piston cup Inlet port Both inlet port compensating port are closed with the oil pressure increased Primary piston Secondary piston When in braking...
Page 615 3. Brake Master Cylinder when Released (1) Orifice Inlet port The orifice in the piston is opened and the brake fluid flows back Piston cup to the piston-cup side When brake pedal is released (1)
Page 616 4. Brake Master Cylinder when Released (2) Compensating port compensating port allows surplus fluid to flow back to the reservoir When brake pedal is released (2)
Page 617 5. Rear-end Leakage In contact Secondary piston Primary piston Rear-end leakage...
Page 618 6. Front-end Leakage Piston contacts cylinder wall Secondary piston Primary piston Front-end leakage...
Page 619: Proportioning Valve
Proportioning Valve Proportioning valve...
Page 620 Importance of Proportioning Valve 1. Loads on front and rear wheels are different The front wheels of the vehicle bear more of the vehicle weight than its rear wheels. In addition, its center of gravity will move forward when in braking, resulting in increased load on front wheels and reduced load on rear wheels.
Page 621 Requirements on Rear-wheel Brake Force Bifurcation point Pressure in brake master cylinder...
Page 622 Proportioning Valve RF wheel LF wheel RF wheel RR wheel...
Page 623 Working Principle of Proportioning Valve — When the Pressure is zero Proportioning valve Piston Control valve Spring Rear...
Page 624 Working Principle of Proportioning Valve — When the Pressure is Low Piston Small area Large area Piston Spring...
Page 625 Working Principle of Proportioning Valve — When the Pressure is high <F When the pressure is higher than some point, the difference between chambers A and B will overcome the spring's elastic force to make the piston move until the port C is closed.
Page 626 1.When the Braking Pressure is Low Cylinder cup From brake master cylinder Piston To rear-wheel brake wheel cylinders Spring...
Page 627 2.When the Braking Pressure is High In contact Piston...
Page 628 3.When the Brake Pedal is Released Cylinder cup When the brake pedal is released, the pressure drop in the left chamber will cause the Piston piston to move to the left. Spring...
Page 629: Disc Brake
Disc Brake Fixed caliper Motion Floating caliper Piston Brake lining Brake disc Rotor disc Friction disc thickness sensor Floating-caliper type...
Page 630 Front-wheel Brake...
Page 631 Rear-wheel Brake...
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Chery QQ Service Manual

Chapter 1 Reading Instruction

Chapter 2 Disassembly, Assembly and Maintenance

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