Chery T21 2014 Service Manual
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Chery T21 2014 Service Manual

Chery T21 2014 Service Manual

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Table of Contents

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CHERY T21
Service Manual
2014
FOREWORD
This manual contains on-vehicle diagnosis
and service procedures for Chery T21.
It is very important to read and be familiar
with this manual thoroughly for proper repair
and maintenance. This manual should be
kept in a handy place for quick and easy
reference.
The contents in this manual, including all
illustrations and specifications, are current at
the time of printing. Any modifications
involving with repair and maintenance occur,
relevant information supplementary to this
volume will be made available at Chery
dealers.
Chery Automobile Co., Ltd. reserves all
rights. Specifications and contents in this
manual are subject to change without
notification, and Chery Automobile Co., Ltd.
takes no legal obligations and
responsibilities.
All rights reserved. Any unit or individual
shall not reproduce or copy this manual in
any form or by any means, or transmit it on
the network by any form for any purpose
without written permission of Chery
Automobile Co., Ltd.
This manual only applies to the models
listed below:
T21 2.0L MT
T21 2.0L CVT
CAUTION:
This manual is only for specialized
technicians. If non-specialized or uncertified
individuals privately perform repairs or
maintenance only referring to this manual or
without proper equipment and tools, it may
damage the customer's vehicle and hurt you
and other persons nearby.
In order to prevent dangerous operation and
damage to the vehicle, be sure to follow the
instructions shown below:
- The contents in this manual must be read
thoroughly. Have a good understanding of
all the contents written in the
PRECAUTION of "INTRODUCTION"
section.
- Before performing the repair procedures,
be sure to wear safety equipment properly
to avoid personal injury.
- When performing the repair procedures,
be sure to use specified and
recommended tools to prevent damage to
the customer's vehicle. Be sure to confirm
the safety of technicians before operating
to avoid personal injury.
- If a part needs to be replaced, use Chery
genuine part with the same part number.
Do not use any inferior quality part.
- Observe the "WARNING" and
"CAUTION" in this manual carefully in
order to reduce the risk of personal injury
and vehicle damage due to improper
operation during service and
maintenance.
All Rights Reserved © 2014
Chery Automobile Co., Ltd.
01

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Summary of Contents for Chery T21 2014

  • Page 1 Chery Automobile Co., Ltd. reserves all - If a part needs to be replaced, use Chery rights. Specifications and contents in this genuine part with the same part number. manual are subject to change without Do not use any inferior quality part.

  • Page 3: Table Of Contents

    FOREWORD INTRODUCTION PREPARATION SERVICE SPECIFICATIONS MAINTENANCE SQR484F ENGINE MANAGEMENT SYSTEM SQR484F ENGINE MECHANICAL SQR484F FUEL SUPPLY SYSTEM SQR484F EMISSION CONTROL SYSTEM SQR484F INTAKE SYSTEM SQR484F EXHAUST SYSTEM SQR484F COOLING SYSTEM SQR484F LUBRICATION SYSTEM SQR484F IGNITION SYSTEM SQR484F STARTING SYSTEM SQR484F CHARGING SYSTEM QR525MHE TRANSMISSION QR019CHB CVT CLUTCH...
  • Page 5 STEERING COLUMN HYDRAULIC ASSIST STEERING ELECTRONIC POWER STEERING AIR CONDITIONING SUPPLEMENTAL RESTRAINT SYSTEM SEAT BELT ENGINE IMMOBILIZER LIGHTING SYSTEM WIPER AND WASHER DOOR LOCK INSTRUMENT CLUSTER AUDIO SYSTEM REVERSING RADAR SYSTEM HORN OTHER SYSTEM WINDSHIELD/WINDOW GLASS REAR VIEW MIRROR INSTRUMENT PANEL SEAT ENGINE HOOD/DOOR EXTERIOR...

  • Page 7: Introduction

    02-11 How to Read Circuit Diagram 02-22 Symbols 02-14 Circuit Diagram Index 02-26 CIRCUIT DIAGNOSIS  ABBREVIATION TABLE 02-28 INFORMATION 02-15 Abbreviation Table 02-28 How to Use Tester 02-15 ECM Control System  Troubleshooting 02-15 02– Chery Automobile Co., Ltd.
  • Page 8 02– Chery Automobile Co., Ltd.
  • Page 9  Problem symptoms table Malfunction locations can be determined quickly by troubleshooting in accordance with the symptom type. 4. Specifications This manual categorizes specifications as below:  Torque specifications  Clearance specifications  Capacity specifications 02– Chery Automobile Co., Ltd.
  • Page 10 02 - INTRODUCTION Preparation 1. Preparation for vehicle service RT21020010 02– Chery Automobile Co., Ltd.
  • Page 11  For non-reusable parts such as gaskets, O-rings, and self-locking Removed Parts nuts, replace them with new ones as instructed in this manual.  Retain removed parts for customer inspection, if requested. 02– Chery Automobile Co., Ltd.
  • Page 12  Follow the safety procedures described in the instruction manual.  Keep vehicle stable when using a lifter to prevent vehicle from tilting during operation. Stabilize the vehicle by adjusting the length of lifter arm and vehicle position. Lifter Center Front RT21020020 02– Chery Automobile Co., Ltd.

  • Page 13: Service Operation

     The reference values of fasteners and torque specifications in this service manual use metric unit.  Recycling all the fasteners (nuts, bolts, etc.) during maintenance and service operation is important for assembly. If it's impossible to recycle fasteners, be sure to use other fasteners with the same specifications. 02– Chery Automobile Co., Ltd.
  • Page 14 If following parts need to be replaced, replace them with new ones. Oil Seal Cotter Pin  Oil seal  Gasket  O-ring Gasket Nylon Nut  Lock washer  Cotter pin Lock Washer  Nylon nut O-ring RT21020050 02– Chery Automobile Co., Ltd.
  • Page 15 For elastic clamp, push tabs in the direction of arrow as shown in the illustration after installation to widen the tabs slightly. Clamp Track RT21020070 13.Vise When using vise, install protective plates on the jaws of vise to prevent parts from being damaged. RT21020080 02– Chery Automobile Co., Ltd.
  • Page 16  Exhaust gas may cause injury and death. There is odorless, colorless Carbon Oxide (CO) in the exhaust gas. People will faint and get poisoned after inhaling it.  Cool the exhaust pipe with a fan.  Keep the area around vehicle clean and tidy.  Monitor the engine coolant thermometer. 02– Chery Automobile Co., Ltd.

  • Page 17: Vehicle Information

    Descriptor Section (VDS) and Vehicle Indicator Section (VIS), with a total of 17-digit characters. The detailed descriptions are as follows: RT21020110 □ ○ : represents a letter or a number (letters I, O and Q cannot be used); : represents a number. 02– Chery Automobile Co., Ltd.
  • Page 18 "E" represents 2014.  The eleventh digit of VIN represents assembly plant code. "C" represents Chery Automobile Co., Ltd Dalian Branch.  The last six digits of VIN represent production sequence number. The number means the real production serial number of this model.
  • Page 19 The transmission number (for MT model) is stamped on the transmission case. QR525MHE XXXXXXXXX RT21020140 The transmission number (for CVT model) is stamped on the transmission case, close to the transmission oil dipstick. QR019CHA XXXXXXXXX RT21020150 02– Chery Automobile Co., Ltd.

  • Page 20: Symbols

    23 - Cruise Indicator 24 - Transmission Malfunction Warning Light 25 - Parking Brake Indicator 26 - Hazard Flasher Warning light 27 - Horn 28 - Cigarette Lighter 29 - Hood Open 30 - Windshield Washer 02– Chery Automobile Co., Ltd.

  • Page 21: Circuit Diagnosis Information

    This model uses ECM control system. Most malfunction inspection procedures only involve in checking the circuits of ECM control system one by one. An adequate understanding of the system and a basic knowledge of electricity are enough to perform effective troubleshooting, accurate diagnosis and necessary repairs. 02– Chery Automobile Co., Ltd.

  • Page 22: Diagnosis And Troubleshooting

    Repair circuit and replace component as necessary. Operate system in all modes. Confirm that system can operate normally in all conditions. Confirm that you have not inadvertently created new malfunctions during your diagnosis or repair steps. 02– Chery Automobile Co., Ltd.

  • Page 23: Circuit Simulation Test

    Sensors and relays. Slightly vibrate the sensors and relays that you want to check in the system. The sensors or relays that are loose or poorly installed may be found through this test. 02– Chery Automobile Co., Ltd.
  • Page 24 Malfunction may occur only during high humidity or in rainy or snowy weather. In this case, malfunction may occur due to water entering electrical parts. Leakage can be checked by spraying water to vehicle (similar to car wash). RT21020180 02– Chery Automobile Co., Ltd.

  • Page 25: Precautions For Control Module And  Electrical Components Inspection

    If connector is installed by tightening bolt, loosen mounting bolt and then disconnect the connector by hand.  When connecting components: Make sure that terminals are not bent or damaged, and then connect it correctly before installing connector. 02– Chery Automobile Co., Ltd.
  • Page 26  Check that fuse wire is connected. Good Blown RT21020220  If fuse wire is blown, confirm that there is no short in the circuit.  A fuse with the same rated amperage must be used for replacing. 02– Chery Automobile Co., Ltd.

  • Page 27: How To Check Connector

    When securing the wire harness of male terminal, try to insert the male terminal into female terminal. Move connector and check if male terminal can be inserted easily. HINT: If male terminal can be inserted into female terminal easily, replace the female terminal. 02– Chery Automobile Co., Ltd.

  • Page 28: Circuit Information

    2. Option splices Option splice is indicated by diamonds (solid line), and marked with pin number inside. AUTO TRANSMISSION MANUAL TRANSMISSION CONTROL CONTROL UNIT UNIT E-106 E-106 E-106 E-106 E-106 E-106 SENSOR SENSOR E-106 E-106 RT21020260 02– Chery Automobile Co., Ltd.
  • Page 29 D9 D10 D11 D12 E-049 I-001 [22] I-004 1 2 3 4 5 6 7 8 4 5 6 1 2 3 9 10 11 12 13 14 15 16 I-009 I-003 I-013 E-011 ET21020000 02– Chery Automobile Co., Ltd.
  • Page 30 The number "2" and "3" inside male connector indicates the terminal number. "----" indicates different terminals come from the same junction connectors. Motor This symbol indicates a motor. Component Name It indicates the name of component. 02– Chery Automobile Co., Ltd.
  • Page 31 It indicates the cross section of connector and description of the [21] Connector View terminal number. The letter "W" indicates the color of connector. The color codes are [22] Connector Color the same as above. 02– Chery Automobile Co., Ltd.
  • Page 32 SQR484F Charging System QR525MHE Transmission QR019CHA Transmission Clutch Drive Shaft Differential Axle Suspension Tire and Wheel Brake Control System Brake Parking Brake Steering Column Hydraulic Assist Steering Electronic Assist Steering Air Conditioning Supplemental Restraints System Seat Belt 02– Chery Automobile Co., Ltd.
  • Page 33 Engine Immobilizer Lighting System Wiper and Washer Door Lock Instrument Cluster Audio System Reversing Radar System Horn Other System Windshield/Window Glass Rear View Mirror Instrument Panel Seat Engine Hood/Door Exterior Interior Body Dimensions Wire Harness 02– Chery Automobile Co., Ltd.
  • Page 34 Rear Left Wheel Speed Sensor Rear Right Wheel Speed Sensor Ground Heated Oxygen Sensor Idle Air Control Intake Temperature Ignition Ignition Control Immobilizer Control Module Injector Input Shaft Speed Sensor ISS Sensor Knock Sensor Manifold Absolute Pressure 02– Chery Automobile Co., Ltd.
  • Page 35 Oil Pressure Switch Output Shaft Speed Sensor OSS Sensor Positive Crankcase Ventilation Valve PCV Valve Power Supply Supplemental Restraints System Throttle Position Sensor Transmission Control Module Turbine Speed Sensor Vehicle Identification Number Vehicle Speed Sensor 02– Chery Automobile Co., Ltd.
  • Page 36 - MEMO - 02– Chery Automobile Co., Ltd.
  • Page 37 DIFFERENTIAL 03-25 Tool 03-44 Tools 03-25 HORN 03-45 AXLE 03-26 Tool 03-45 Tools 03-26 WINDSHIELD/WINDOW GLASS 03-46 SUSPENSION 03-28 Tools 03-46 Tools 03-28 REAR VIEW MIRROR 03-47 BRAKE CONTROL SYSTEM 03-29 Tool 03-47 Tools 03-29 03– Chery Automobile Co., Ltd.
  • Page 38 INSTRUMENT PANEL 03-48 Tool 03-50 Tools 03-48 EXTERIOR 03-51 SEAT 03-49 Tool 03-51 Tool 03-49 INTERIOR 03-52 ENGINE HOOD/DOOR 03-50 Tool 03-52 03– Chery Automobile Co., Ltd.
  • Page 39 03 - PREPARATION SQR484F ENGINE MANAGEMENT SYSTEM PREPARATION Tools Special Tool X-431 3G Diagnostic Tester RCH0000001 General Tools Fuel Injector Cleaning Analyzer RCH0000062 Ignition Timing Light RCH0000016 Digital Multimeter RCH0000002 03– Chery Automobile Co., Ltd.
  • Page 40 03 - PREPARATION Cylinder Pressure Gauge RCH0000044 Fuel Pressure Gauge RCH0000048 Oscilloscope RCH0000061 03– Chery Automobile Co., Ltd.
  • Page 41 03 - PREPARATION SQR484F ENGINE MECHANICAL Tools Special Tools Crankshaft Front Oil Seal Guide Tool RCH0000049 Crankshaft Front Oil Seal Installer RCH0000067 Camshaft Oil Seal Installer RCH0000017 Valve Spring Compression Adapter RCH0000050 Valve Spring Compressor RCH0000028 03– Chery Automobile Co., Ltd.
  • Page 42 03 - PREPARATION Crankshaft Rear Oil Seal Installer RCH0000031 Valve Oil Seal Installer RCH0000034 Valve Oil Seal Guide Sleeve RCH0000035 Clutch Pressure Plate Installer RCH0000018 Valve Oil Seal Remover RCH0000037 03– Chery Automobile Co., Ltd.

  • Page 43: Preparation

    03 - PREPARATION Valve Cotter Installer RCH0000029 Flywheel Holding Tool RCH0000040 Oil Filter Remover RCH0000054 Camshaft Timing Tool RCH0000033 Crankshaft Timing Tool RCH0000027 03– Chery Automobile Co., Ltd.
  • Page 44 03 - PREPARATION General Tools Piston Installer RCH0000039 Dial Indicator and Magnetic Holder RCH0000023 Outer Diameter Micrometer 0.01mm 75mm RCH0000064 Vernier Caliper RCH0000019 Precision Ruler RCH0000063 03– Chery Automobile Co., Ltd.
  • Page 45 03 - PREPARATION Feeler Gauge RCH0000060 Cylinder Gauge RCH0000065 Caliper Gauge RCH0000069 Digital Multimeter RCH0000002 Flexional Magnetic Rod RCH0000042 03– Chery Automobile Co., Ltd.
  • Page 46 03 - PREPARATION Engine Hoist RCH0000043 Engine Equalizer RCH0000026 Transmission Carrier RCH0000005 Fuel Pressure Gauge RCH0000048 Cylinder Pressure Gauge RCH0000044 03– Chery Automobile Co., Ltd.
  • Page 47 03 - PREPARATION Engine Service Platform RCH0000057 03– Chery Automobile Co., Ltd.

  • Page 48: Sqr484F Fuel Supply System

    03 - PREPARATION SQR484F FUEL SUPPLY SYSTEM Tools Special Tool Fuel Tank Pressure Cap Remover RCH0000004 General Tools Digital Multimeter RCH0000002 Fuel Pressure Gauge RCH0000048 Transmission Carrier RCH0000005 03– Chery Automobile Co., Ltd.

  • Page 49: Sqr484F Emission Control System

    03 - PREPARATION SQR484F EMISSION CONTROL SYSTEM Tool General Tool Digital Multimeter RCH0000002 03– Chery Automobile Co., Ltd.

  • Page 50: Sqr484F Intake System

    03 - PREPARATION SQR484F INTAKE SYSTEM Tools Special Tool X-431 3G Diagnostic Tester RCH0000001 General Tools Digital Multimeter RCH0000002 Precision Ruler RCH0000063 Feeler Gauge RCH0000060 03– Chery Automobile Co., Ltd.

  • Page 51: Sqr484F Exhaust System

    03 - PREPARATION SQR484F EXHAUST SYSTEM Tools General Tools Precision Ruler RCH0000063 Feeler Gauge RCH0000060 03– Chery Automobile Co., Ltd.

  • Page 52: Sqr484F Cooling System

    03 - PREPARATION SQR484F COOLING SYSTEM Tools General Tools Digital Multimeter RCH0000002 Cooling System Pressure Tester RCH0000055 Freezing Point Tester RCH0000007 03– Chery Automobile Co., Ltd.

  • Page 53: Sqr484F Lubrication System

    03 - PREPARATION SQR484F LUBRICATION SYSTEM Tools Special Tools Oil Pan Remover and Scraper RCH0000056 Oil Filter Remover RCH0000054 General Tool Oil Pressure Tester RCH0000006 03– Chery Automobile Co., Ltd.

  • Page 54: Sqr484F Ignition System

    03 - PREPARATION SQR484F IGNITION SYSTEM Tool General Tool Digital Multimeter RCH0000002 03– Chery Automobile Co., Ltd.

  • Page 55: Sqr484F Starting System

    03 - PREPARATION SQR484F STARTING SYSTEM Tools Special Tool X-431 3G Diagnostic Tester RCH0000001 General Tool Digital Multimeter RCH0000002 03– Chery Automobile Co., Ltd.

  • Page 56: Sqr484F Charging System

    03 - PREPARATION SQR484F CHARGING SYSTEM Tool General Tool Digital Multimeter RCH0000002 03– Chery Automobile Co., Ltd.

  • Page 57: Qr525Mhe Transmission

    03 - PREPARATION QR525MHE TRANSMISSION Tools Special Tools Input Shaft Oil Seal Installer RCH0000008 Differential Oil Seal Installer RCH0000009 Installer Joint RCH0000010 Bearing Remover RCH0000011 Punch RCH0000015 03– Chery Automobile Co., Ltd.
  • Page 58 03 - PREPARATION Puller RCH0000059 General Tools Transmission Carrier RCH0000005 Engine Equalizer RCH0000026 Hydraulic Press RCH0000012 03– Chery Automobile Co., Ltd.

  • Page 59: Qr019Chb Cvt

    03 - PREPARATION QR019CHB CVT Tools Special Tools Puller RCH0000059 Differential Oil Seal Installer RCH0000009 General Tools Engine Equalizer RCH0000026 Transmission Carrier RCH0000005 03– Chery Automobile Co., Ltd.

  • Page 60: Clutch

    03 - PREPARATION CLUTCH Tools Special Tool Clutch Pressure Plate Installer RCH0000018 General Tools Vernier Caliper RCH0000019 Digital Multimeter RCH0000002 03– Chery Automobile Co., Ltd.

  • Page 61: Differential

    03 - PREPARATION DIFFERENTIAL Tools Special Tools Bearing Remover RCH0000011 Punch RCH0000015 General Tools Hydraulic Press RCH0000012 Dial Indicator and Magnetic Holder RCH0000023 03– Chery Automobile Co., Ltd.

  • Page 62: Axle

    03 - PREPARATION AXLE Tools Special Tool Ball Pin Separator RCH0000024 General Tools Dial Indicator and Magnetic Holder RCH0000023 Transmission Carrier RCH0000005 Hydraulic Press RCH0000012 03– Chery Automobile Co., Ltd.
  • Page 63 03 - PREPARATION Bearing Remover RCH0000011 Engine Equalizer RCH0000026 03– Chery Automobile Co., Ltd.

  • Page 64: Suspension

    03 - PREPARATION SUSPENSION Tools Special Tool Spring Compressor RCH0000021 General Tools Transmission Carrier RCH0000005 Engine Equalizer RCH0000026 03– Chery Automobile Co., Ltd.

  • Page 65: Brake Control System

    03 - PREPARATION BRAKE CONTROL SYSTEM Tools Special Tool X-431 3G Diagnostic Tester RCH0000001 General Tool Digital Multimeter RCH0000002 03– Chery Automobile Co., Ltd.

  • Page 66: Brake

    03 - PREPARATION BRAKE Tools Special Tool Brake Caliper Piston Pressing Tool RCH0000053 General Tools Dial Indicator and Magnetic Holder RCH0000023 Vernier Caliper RCH0000019 Digital Multimeter RCH0000002 03– Chery Automobile Co., Ltd.

  • Page 67: Parking Brake

    03 - PREPARATION PARKING BRAKE PREPARATION Tools General Tools Digital Multimeter RCH0000002 Vernier Caliper RCH0000019 03– Chery Automobile Co., Ltd.
  • Page 68 03 - PREPARATION STEERING COLUMN Tools Special Tool Steering Wheel Remover RCH0000014 General Tool Electric Drill RCH0000013 03– Chery Automobile Co., Ltd.
  • Page 69 03 - PREPARATION HYDRAULIC ASSIST STEERING Tool Special Tool Ball Pin Separator RCH0000024 03– Chery Automobile Co., Ltd.
  • Page 70 03 - PREPARATION ELECTRONIC POWER STEERING Tools Special Tools Ball Pin Separator RCH0000024 X-431 3G Diagnostic Tester RCH0000001 General Tool Digital Multimeter RCH0000002 03– Chery Automobile Co., Ltd.
  • Page 71 03 - PREPARATION AIR CONDITIONING Tools General Tools Refrigerant Recycling Machine RCH0000046 Digital Multimeter RCH0000002 03– Chery Automobile Co., Ltd.
  • Page 72 03 - PREPARATION SUPPLEMENTAL RESTRAINT SYSTEM Tools Special Tool X-431 3G Diagnostic Tester RCH0000001 General Tool Digital Multimeter RCH0000002 03– Chery Automobile Co., Ltd.
  • Page 73 03 - PREPARATION SEAT BELT Tool General Tool Digital Multimeter RCH0000002 03– Chery Automobile Co., Ltd.
  • Page 74 03 - PREPARATION ENGINE IMMOBILIZER Tools Special Tool X-431 3G Diagnostic Tester RCH0000001 General Tool Digital Multimeter RCH0000002 03– Chery Automobile Co., Ltd.
  • Page 75 03 - PREPARATION LIGHTING SYSTEM Tools Special Tool X-431 3G Diagnostic Tester RCH0000001 General Tool Digital Multimeter RCH0000002 03– Chery Automobile Co., Ltd.
  • Page 76 03 - PREPARATION WIPER AND WASHER Tool General Tool Digital Multimeter RCH0000002 03– Chery Automobile Co., Ltd.
  • Page 77 03 - PREPARATION DOOR LOCK Tools Special Tool X-431 3G Diagnostic Tester RCH0000001 General Tool Digital Multimeter RCH0000002 03– Chery Automobile Co., Ltd.
  • Page 78 03 - PREPARATION INSTRUMENT CLUSTER Tools Special Tool X-431 3G Diagnostic Tester RCH0000001 General Tool Digital Multimeter RCH0000002 03– Chery Automobile Co., Ltd.
  • Page 79 03 - PREPARATION AUDIO SYSTEM Tool General Tool Digital Multimeter RCH0000002 03– Chery Automobile Co., Ltd.
  • Page 80 03 - PREPARATION REVERSING RADAR SYSTEM Tool General Tool Digital Multimeter RCH0000002 03– Chery Automobile Co., Ltd.
  • Page 81 03 - PREPARATION HORN Tool General Tool Digital Multimeter RCH0000002 03– Chery Automobile Co., Ltd.
  • Page 82 03 - PREPARATION WINDSHIELD/WINDOW GLASS Tools Special Tool Interior Crow Plate RCH0000025 General Tool Digital Multimeter RCH0000002 03– Chery Automobile Co., Ltd.
  • Page 83 03 - PREPARATION REAR VIEW MIRROR Tool General Tool Digital Multimeter RCH0000002 03– Chery Automobile Co., Ltd.
  • Page 84 03 - PREPARATION INSTRUMENT PANEL Tools Special Tools Steering Wheel Remover RCH0000014 Interior Crow Plate RCH0000025 03– Chery Automobile Co., Ltd.
  • Page 85 03 - PREPARATION SEAT Tool General Tool Digital Multimeter RCH0000002 03– Chery Automobile Co., Ltd.
  • Page 86 03 - PREPARATION ENGINE HOOD/DOOR Tool General Tool Interior Crow Plate RCH0000025 03– Chery Automobile Co., Ltd.
  • Page 87 03 - PREPARATION EXTERIOR Tool General Tool Interior Crow Plate RCH0000025 03– Chery Automobile Co., Ltd.
  • Page 88 03 - PREPARATION INTERIOR Tool General Tool Interior Crow Plate RCH0000025 03– Chery Automobile Co., Ltd.

  • Page 89: Service Specifications

    04-49 DRIVE SHAFT 04-26 Specifications 04-49 Specifications 04-26 REVERSING RADAR SYSTEM 04-50 DIFFERENTIAL 04-27 Specification 04-50 Specifications 04-27 HORN 04-51 AXLE 04-28 Specification 04-51 Specifications 04-28 WINDSHIELD/WINDOW GLASS 04-52 SUSPENSION 04-30 Specifications 04-52 Specifications 04-30 04– Chery Automobile Co., Ltd.
  • Page 90 REAR VIEW MIRROR 04-53 ENGINE HOOD/DOOR 04-57 Specifications 04-53 Specifications 04-57 INSTRUMENT PANEL 04-54 EXTERIOR 04-59 Specifications 04-54 Specifications 04-59 SEAT 04-56 INTERIOR 04-61 Specifications 04-56 Specifications 04-61 04– Chery Automobile Co., Ltd.
  • Page 91 20 ± 5 Engine Speed Sensor Fixing Bolt 8 ± 2 Camshaft Position Sensor Fixing Bolt 8 ± 0.5 VVT Control Valve Fixing Bolt 8 ± 2 Engine Control Module Bracket Fixing Nut 7 ± 1 04– Chery Automobile Co., Ltd.
  • Page 92 3.9 ± 0.5 Crankshaft Rotation Direction Counterclockwise (viewed from cross section of engine flywheel) Starting Type Electrical starting Cooling Type Forced circulation type antifreeze cooling Lubrication Type Compound type (pressure, splash lubrication) Fuel Pressure (bar) 04– Chery Automobile Co., Ltd.
  • Page 93 Exhaust Cam Intake Cam 0.15 - 0.20 Camshaft Axial Clearance (mm) Exhaust Cam 0.15 - 0.20 Lower Surface Flatness (mm) 0.04 Cylinder Head Overall Height (mm) 139.83 ± 0.335 Surface Grinding Limit Grinding is not permitted 04– Chery Automobile Co., Ltd.
  • Page 94 Oil Ring +0.06 First Ring +0.05 +0.04 Piston Ring Groove Height (mm) Second Ring +0.02 +0.05 Oil Ring +0.01 21 Diameter (mm) -0.006 Piston Pin Length (mm) -0.5 +0.010 21 Piston Pin Hole Diameter (mm) +0.006 04– Chery Automobile Co., Ltd.
  • Page 95 Intake Camshaft Phaser Assembly Fixing Bolt 120 ± 5 1st step: 130 ± 10 Crankshaft Timing Pulley Fixing Bolt 2nd step: 65° ± 5° 1st step: 35 ± 5 Flywheel Fixing Bolt 2nd step: 45° ± 5° 04– Chery Automobile Co., Ltd.
  • Page 96 90 ± 5 Assembly and Body (for MT Model) Fixing Nut Between Left Mounting Bracket and 80 ± 6 Transmission Case (for MT Model) Left Mounting Cushion Assembly Locking Nut (for 80 ± 6 CVT Model) 04– Chery Automobile Co., Ltd.
  • Page 97 1st step: 25 ± 3 Connecting Rod Bearing Cap Fixing Bolt 2nd step: 90° ± 5° Crankshaft Frame Fixing Bolt 20 + 3 1st step: 45 ± 5 Main Bearing Cap Fixing Bolt 2nd step: 180° ± 10° 04– Chery Automobile Co., Ltd.
  • Page 98 Valve Guide or Guide Bottom Hole (Cylinder Head) SM10W-40 Camshaft Oil Seal Lip and Camshaft Journal SM10W-40 Oil Filter Gasket Surface SM10W-40 All engine lubricants should be 5W-40 (for winter)/10W-40 (for summer) SM grade or higher. 04– Chery Automobile Co., Ltd.
  • Page 99 Coolant Temperature Sensor Loctite 243 Oil Pressure Sensor Loctite 577 Camshaft Variable Valve Timing Control Valve Loctite 243 Oil Deflector Bolt Loctite 243 Oil Pump Mounting Bolt Loctite 5910 Timing Gear Rear Cover Fixing Screw Loctite 243 04– Chery Automobile Co., Ltd.
  • Page 100 Worm Clamp 3.5 ± 0.5 Fuel Pressure Specifications SQR484F Pressure (kPa) Fuel Pressure on Fuel Rail - Key (ON) Fuel Pressure on Fuel Rail - Engine Idling Fuel Pressure on Fuel Rail - Key (LOCK) 04– Chery Automobile Co., Ltd.
  • Page 101 Fixing Bolt Coupling Bolt Between Activated Charcoal Canister 7 ± 1 Assembly and Body Exhaust Manifold Heat Insulator Fixing Bolt 23 ± 2 Upstream Oxygen Sensor 40 - 60 Downstream Oxygen Sensor 40 - 60 04– Chery Automobile Co., Ltd.
  • Page 102 Oil Dipstick Fixing Bolt 8 ± 3 Engine Wire Harness Fixing Bolt 8 ± 3 Intake Manifold Assembly Fixing Nut 8 ± 3 Electronic Accelerator Pedal Fixing Bolt 10 ± 2 Worm Clamp 5 ± 0.5 04– Chery Automobile Co., Ltd.
  • Page 103 Coupling Spring Bolt Between Center Pipe Assembly 50 ± 5 and Muffler Assembly Muffler Assembly Left Hanger Block III Assembly 50 ± 5 Fixing Bolt Muffler Assembly Right Hanger Block III Assembly 50 ± 5 Fixing Bolt 04– Chery Automobile Co., Ltd.
  • Page 104 Timing Belt Idler Pulley Fixing Bolt 40 + 5 Water Pump Assembly Fixing Bolt 8 + 3 Coolant Capacity Item Capacity (L) Cooling System Coolant Concentration G11 Additive Soft Water Coolant Freezing Point Item Freezing Point Value (°C) Coolant 04– Chery Automobile Co., Ltd.
  • Page 105 04 - SERVICE SPECIFICATIONS Cooling System Test Pressure Item System Pressure (bar) Cooling System (Test Pressure) 1.3 ± 0.2 04– Chery Automobile Co., Ltd.
  • Page 106 8 + 3 Oil Strainer Bracket Fixing Bolt 17 - 23 Oil Strainer Bracket Fixing Nut 17 - 23 Coupling Bolt Between Oil Strainer and Oil Pump 17 - 23 Oil Pump Fixing Bolt 8 - 11 04– Chery Automobile Co., Ltd.
  • Page 107 Specifications Torque Specifications Description Torque (N·m) Spark Plug 30 ± 3 Ignition Coil Fixing Bolt 8 + 3 Spark Plug Specifications Engine Type SQR484F Spark Plug Type FR7DTC Spark Plug Gap (mm) 0.8 - 0.9 04– Chery Automobile Co., Ltd.
  • Page 108 04 - SERVICE SPECIFICATIONS SQR484F STARTING SYSTEM Specifications Torque Specifications Description Torque (N·m) Starter Power Cable Nut 13 ± 1 Starter Fixing Bolt 35 ± 5 ignition Starting Switch Fixing Screw 13 ± 2 04– Chery Automobile Co., Ltd.
  • Page 109 Battery Tray Bracket Fixing Bolt 20 ± 2 Alternator Output Cable Fixing Nut 18 - 22 Alternator Fixing Bolt 20 + 5 Battery Specification Engine Type Battery Type Specification SQR484F 6-QW-70QR 12 V, 70 Ah, CCA (SAE) 560 A 04– Chery Automobile Co., Ltd.
  • Page 110 Transmission Upper Coupling Bolt 60 ± 5 Engine Side Coupling Bolt 60 ± 5 Transmission Gear Ratio Table Gear Ratio Type QR525MHE Gear Gear Gear Ratio 3.583 2.053 1.379 1.03 0.821 Reverse 3.417 Final Drive 4.313 Speedometer 0.806 04– Chery Automobile Co., Ltd.
  • Page 111 Parameter Model QR019CHB Type Central Distance (mm) Maximum Input Torque (N·m) Final Drive Ratio 5.141 Pulley Speed Ratio Scope 0.44 - 2.39 Solenoid Quantity Gear Shift Positions P, R, N, D, L, M (manual mode) 04– Chery Automobile Co., Ltd.
  • Page 112 04 - SERVICE SPECIFICATIONS Item Parameter Fluid Type SP - III Transmission Fluid Capacity (L) 8.0 ± 0.2 04– Chery Automobile Co., Ltd.
  • Page 113 16 ± 2 Clutch Release Cylinder Fixing Bolt 22 ± 2 Clutch Pressure Plate 25 ± 2 Clutch Driven Disc Specifications Measurement Item Specification (mm) Clutch Driven Disc Standard Thickness 7.6 ± 0.2 Minimum Rivet Depth 04– Chery Automobile Co., Ltd.
  • Page 114 Drive Shaft Fixing Nut 300 ± 20 Coupling Nut Between Steering Knuckle and Control 180 ± 10 Arm Ball Pin Coupling Bolt Between Front Left Wheel Speed 10 ± 1 Sensor and Front Left Steering Knuckle Assembly 04– Chery Automobile Co., Ltd.
  • Page 115 04 - SERVICE SPECIFICATIONS DIFFERENTIAL Specifications Torque Specification Description Torque (N·m) Final Drive Driven Gear Bolt 111 - 118 Clearance Specification Description Acceptable Range (mm) Clearance Between Differential Case and Planetary 0.025 - 0.150 Gear 04– Chery Automobile Co., Ltd.
  • Page 116 Sub Frame Welding Assembly Coupling Bolt Between Front Sub Frame Welding 120 ± 10 Assembly and Steering Gear Assembly Coupling Bolt Between Upper Part of Front Sub 180 ± 10 Frame Welding Assembly and Body 04– Chery Automobile Co., Ltd.
  • Page 117 Swing Arm Assembly and Rear Sub Frame 120 ± 10 Assembly Coupling Bolt Between Rear Sub Frame Assembly 120 ± 10 and Body Coupling Nut Between Rear Sub Frame Assembly 120 ± 10 and Body 04– Chery Automobile Co., Ltd.
  • Page 118 Assembly and Front Sub Frame Welding Assembly Coupling Bolt Between Lower Part of Rear Shock 45 ± 5 Absorber Assembly and Rear Trailing Arm Assembly Coupling Nut Between Upper Part of Rear Shock 45 ± 5 Absorber Assembly and Body 04– Chery Automobile Co., Ltd.
  • Page 119 Coupling Nut Between Rear Stabilizer Link Assembly 45 ± 5 and Rear Stabilizer Bar Assembly Rear Brake Line Fixing Plug 16 ± 2 Coupling Bolt Between Rear Stabilizer Bar Assembly 25 ± 3 and Body 04– Chery Automobile Co., Ltd.
  • Page 120 04 - SERVICE SPECIFICATIONS Description Torque (N·m) Steering Tie Rod Locking Nut 55 ± 5 Steering Wheel Locking Nut 35 ± 5 04– Chery Automobile Co., Ltd.
  • Page 121 Tire Type Description Parameter Tire Type 225/65 R17 102H Rim Type Description Parameter Rim Type 17 × 7J Tire Pressure Specifications of Cold Tire Description Pressure (kPa) Front Tire (Unloaded) Rear Tire (Unloaded) Spare Tire 04– Chery Automobile Co., Ltd.
  • Page 122 ABS Control Module Assembly Mounting Bracket 23 ± 2 Fixing Nut ABS Control Module Assembly Bottom Mounting Nut 8 ± 2 Front Wheel Speed Sensor Fixing Bolt 10 ± 1 Rear Wheel Speed Sensor Fixing Bolt 10 ± 1 04– Chery Automobile Co., Ltd.
  • Page 123 Rear Brake Caliper Bleeder Plug 9 - 11 Locating Bolt Between Rear Brake Caliper Fixing 25 ± 3 Bracket and Rear Brake Cylinder Assembly Coupling Plug Between Rear Brake Hose Assembly 16 ± 2 and Brake Pipe 04– Chery Automobile Co., Ltd.
  • Page 124 Minimum Thickness Description Maximum Runout (mm) (mm) (mm) Front Brake Disc 0.06 Front Brake Lining Rear DIH (Drum-in-hat) Standard Thickness Minimum Thickness Description Maximum Runout (mm) (mm) (mm) Rear Brake Disc 0.06 Rear Brake Lining 04– Chery Automobile Co., Ltd.
  • Page 125 23 ± 2 Bracket and Rear Brake Bottom Board Assembly Rear DIH (Drum-in-hat) Description Standard Thickness (mm) Minimum Thickness (mm) Rear Brake Shoe Lining Description Standard Inner Diameter (mm) Maximum Inner Diameter (mm) Rear Brake Disc 04– Chery Automobile Co., Ltd.
  • Page 126 Steering Boot Fixing Nut 10 ± 1 Coupling Bolt Between Electronic Power Steering Column and Intermediate Shaft Data Specifications Description Standard Value Steering Wheel Free Play (Rotation Angle) ≤ 15° Steering Wheel Centering/Returnability (Rotation > 70° Angle) 04– Chery Automobile Co., Ltd.
  • Page 127 Locking Nut Between Ball Pin Assembly and 45 ± 5 Steering Knuckle Assembly Mounting Bolt Between Steering Gear Assembly and 120 ± 10 Front Sub Frame Welding Assembly Steering Tie Rod Adjustment Nut 55 ± 5 04– Chery Automobile Co., Ltd.
  • Page 128 Torque Specifications Description Torque (N·m) Ball Pin Locking Nut 35 ± 3 Coupling Bolt between Steering Gear Input Shaft and Steering Column with Intermediate Shaft 60 ± 5 Assembly Steering Gear Fixing Bolt 120 ± 10 04– Chery Automobile Co., Ltd.
  • Page 129 Fixing Nut Between A/C High Pressure Line II and 7 ± 1 Condenser Assembly Coupling Bolt Between Rear Mounting Cushion 70 ± 5 Assembly and Rear Mounting Bracket Coupling Nut Between Rear Mounting Cushion 70 ± 5 Assembly and Rear Mounting Bracket 04– Chery Automobile Co., Ltd.
  • Page 130 600 ± 10 Refrigerant Oil Charging Specifications Description Charging Capacity (ml) It is necessary to pour out 50 ml of refrigerant oil Compressor Assembly Replacement from the new compressor assembly Condenser Replacement Evaporator Replacement A/C Line Replacement 04– Chery Automobile Co., Ltd.
  • Page 131 SUPPLEMENTAL RESTRAINT SYSTEM Specifications Torque Specifications Description Torque (N·m) Coupling Bolt Between Front Passenger Airbag and 10 ± 1 Instrument Panel Crossmember Assembly Coupling Nut Between SRS Control Module 10 ± 1 Assembly and Body 04– Chery Automobile Co., Ltd.
  • Page 132 Rear Seat Belt Buckle Assembly Fixing Bolt 50 ± 5 Rear Center Seat Belt Buckle Assembly Fixing Bolt 50 ± 5 Rear Right Seat Belt Buckle Assembly Fixing Bolt 50 ± 5 Front Seat Belt Buckle Fixing Nut 50 ± 5 04– Chery Automobile Co., Ltd.
  • Page 133 Rear Dome Light Assembly Fixing Screw 1.5 ± 0.5 Rear Fog Light & Reflector Assembly Fixing Screw 1.5 ± 0.5 High Mounted Stop Light Fixing Nut 3.5 ± 0.5 Back-up Light Switch 20 ± 2 04– Chery Automobile Co., Ltd.
  • Page 134 Guide Pipe Assembly Fixing Bolt 7 ± 1 Washer Fluid Reservoir Assembly Fixing Bolt 7 ± 1 Brake Fluid Reservoir Assembly Fixing Nut 9 ± 1 Rain Gutter Rail Reinforcement Assembly Fixing Bolt 10 ± 1 04– Chery Automobile Co., Ltd.
  • Page 135 Back Door Lock Striker Assembly Fixing Screw 10 ± 1 Auxiliary Fascia Console Rear Cover Plate 1.5 ± 0.5 Assembly Fixing Screw Front Door Outside Handle Fixing Screw Wireless Key Upper Cover Fixing Screw 0.4 ± 0.1 04– Chery Automobile Co., Ltd.
  • Page 136 04 - SERVICE SPECIFICATIONS NSTRUMENT CLUSTER Specification Torque Specification Description Torque (N·m) Instrument Cluster Fixing Screw 1.5 ± 0.5 04– Chery Automobile Co., Ltd.
  • Page 137 No Disc DVD Control Panel Fixing Screw 2 ± 0.5 Wire Harness Fixing Screw 0.7 ± 0.2 Steering Wheel Quick Button Trim Cover Fixing 0.7 ± 0.2 Screw Steering Wheel Quick Button Fixing Screw 0.7 ± 0.2 04– Chery Automobile Co., Ltd.
  • Page 138 04 - SERVICE SPECIFICATIONS REVERSING RADAR SYSTEM Specification Torque Specification Description Torque (N·m) Fixing Bolt Between Reversing Radar Control 5 ± 1 Module Assembly and Body 04– Chery Automobile Co., Ltd.
  • Page 139 04 - SERVICE SPECIFICATIONS HORN Specification Torque Specification Description Torque (N·m) Horn Fixing Bolt 16 ± 2 04– Chery Automobile Co., Ltd.
  • Page 140 Rear Door Glass Assembly Fixing Bolt 9 ± 1 Front Door Power Glass Regulator Assembly Fixing 9 ± 1 Bolt Rear Door Power Glass Regulator Assembly Fixing 9 ± 1 Bolt A/C Control Panel Fixing Screw 2 ± 0.5 04– Chery Automobile Co., Ltd.
  • Page 141 04 - SERVICE SPECIFICATIONS REAR VIEW MIRROR Specifications Torque Specifications Description Torque (N·m) Outside Rear View Mirror Assembly Fixing Bolt 6 ± 1 Inside Rear View Mirror Assembly Fixing Screw 1.5 ± 0.5 04– Chery Automobile Co., Ltd.
  • Page 142 Steering Column Assembly Fixing Bolt 25 ± 3 Blower Fixing Bolt 4 ± 1 Ground Wire Fixing Nut 15 ± 2 Instrument Panel Crossmember Assembly Fixing 25 ± 3 Bolt Instrument Panel Crossmember Assembly Fixing 7 ± 1 04– Chery Automobile Co., Ltd.
  • Page 143 04 - SERVICE SPECIFICATIONS Description Torque (N·m) Instrument Panel Crossmember Assembly Fixing 7 ± 1 Screw Instrument Panel Crossmember Bracket Assembly 25 ± 3 Fixing Bolt 04– Chery Automobile Co., Ltd.
  • Page 144 Seatback Assembly Rear Seat Folder Mechanism Assembly Outer Cover 4.8 ± 0.5 Fixing Screw Rear Seat Reclining Adjuster Inner Cover Fixing 4.8 ± 0.5 Screw Rear Seat Bracket Assembly Fixing Bolt 48 ± 4.8 04– Chery Automobile Co., Ltd.
  • Page 145 Fixing Bolt Between Rear Door Hinge Assembly and 70 ± 3 Body Rear Door Lock Striker Assembly Fixing Screw 10 ± 1 Back Door Grip Assembly Fixing Screw 7 ± 1 Back Door Lower Protector Assembly Fixing Screw 1.5 ± 0.5 04– Chery Automobile Co., Ltd.
  • Page 146 Back Door Upper Trim Board Assembly Fixing Screw 3 ± 1 Back Door Upper Trim Board Assembly Fixing Nut 5 ± 1 Back Door Opener Switch Assembly Fixing Bolt 10 ± 1 Back Door Air Spring Assembly Ball Pin 10 ± 1 04– Chery Automobile Co., Ltd.
  • Page 147 Rear Wheel House Protector Assembly Fixing Screw 3 ± 1 Front Windshield Lower Garnish Assembly Fixing 3 ± 1 Screw Roof Rack Assembly Fixing Bolt 9 ± 1 Rear Spoiler Assembly Fixing Nut 5 ± 1 04– Chery Automobile Co., Ltd.
  • Page 148 Rear Fog Light Fixing Screw 1.5 ± 0.5 Back Door Upper Trim Board Assembly Fixing Screw 3 ± 1 Back Door Upper Trim Board Assembly Fixing Nut 5 ± 1 Camera Fixing Screw 6 ± 0.5 04– Chery Automobile Co., Ltd.
  • Page 149 Interior Rear Dome Light Assembly Fixing Screw 1.5 ± 0.5 High Pitched Speaker Fixing Screw 3 ± 0.5 Fuel Tank Opening Bracket Assembly Fixing Bolt 10 ± 1 Ground Wire Harness Fixing Nut 15 ± 2 04– Chery Automobile Co., Ltd.
  • Page 150 - MEMO - 04– Chery Automobile Co., Ltd.

  • Page 151: Maintenance

    Engine Compartment Inspection 05-10 Maintenance Schedule Table 05-3 Brake System Inspection 05-10 REPLACEMENT INSTRUCTION 05-6 Power Steering System Inspection 05-11 ADJUSTMENT ITEM 05-7 Chassis Inspection 05-12 Final Inspection 05-13 INSPECTION ITEMS 05-8 Off-vehicle Inspection 05-8 05– Chery Automobile Co., Ltd.
  • Page 152 05– Chery Automobile Co., Ltd.
  • Page 153 Maintenance Schedule Table The maintenance schedule table lists the vehicle maintenance items required to be performed. Please take your vehicle to a Chery authorized service station for maintenance service according to the mileage specified in the maintenance schedule table. Maintenance Schedule Table (Note: I = Inspect, adjust and replace as necessary; R = Replace; C = Clean; ...
  • Page 154 3. It is recommended to replace the brake fluid every 2 years or every 40000 km (whichever comes first). 4. It is recommended to check the power steering fluid every 10000 km and replace every 2 years or every 30000 km (whichever comes first). 05– Chery Automobile Co., Ltd.
  • Page 155 9. It is recommended to check the air filter every 5000 km. Clean or replace the filer element if necessary. 10.It is recommended to replace the timing belt every 40000 km. 11. The battery is maintenance-free. CAUTION  Depending on different surrounding environment and road conditions, the replacing intervals may be shortened. 05– Chery Automobile Co., Ltd.
  • Page 156 17-14 Automatic Transmission Fluid (ATF) Replacement 18-110 Power Steering Fluid Replacement 29-7 Coolant Replacement 12-13 Brake Fluid Replacement 26-13 Electronic Throttle Replacement 10-20 Electronic Throttle Cleaning 10-22 Spark Plug Replacement 14-12 A/C Element Replacement 31-72 05– Chery Automobile Co., Ltd.
  • Page 157 05 - MAINTENANCE ADJUSTMENT ITEM Adjustment Item See page Front Combination Light Adjustment 35-70 05– Chery Automobile Co., Ltd.
  • Page 158 2. Check the wheel and tire (spare tire included) (See page 24-5). 3. Rotate tires. a. Chery recommends you to rotate tires every 10000 km. However, the best suitable time for tire rotation differs depending on driver's driving habits and road conditions. Tire rotation method (See page 24-11).
  • Page 159 8. Check the sun visor. a. Check that sun visors are securely installed and move freely. 9. Check the seat. a. Check the front seat assembly (See page 46-22). b. Check the rear seat assembly (See page 46-34). 05– Chery Automobile Co., Ltd.
  • Page 160 26-12). c. Check if brake fluid level is between "MAX" and "MIN" lines. d. If brake fluid level drops to the "MIN" line or below, add brake fluid and check brake system for leakage. RT21260050 05– Chery Automobile Co., Ltd.
  • Page 161 RT21290030 4. Check the ball pin assembly (equipped with hydraulic assist steering) (See page 29-19). 5. Check the ball pin assembly (equipped with electronic assist steering) (See page 30-22). 05– Chery Automobile Co., Ltd.
  • Page 162 7. Check the rear stabilizer bar assembly (See page 23-44). 8. Check the rear stabilizer link assembly (See page 23-45). 9. Check the exhaust pipe. a. Visually check the pipes, hanger blocks and connections for corrosion, leakage or damage. 05– Chery Automobile Co., Ltd.
  • Page 163  Rear seatbacks lock securely after folding down. 5. Be sure to deliver a clean vehicle. Focus on the following items:  Steering wheel  Shift lever knob  All switch knobs  Door handles  Seat 05– Chery Automobile Co., Ltd.
  • Page 164 - MEMO - 05– Chery Automobile Co., Ltd.

  • Page 165: Sqr484F Engine Management System

    06-160 P0131-00 06-69 P0605-00 06-160 P0132-00 06-69 P1619-00 06-162 P0133-00 06-69 P0531-00 06-164 P0134-00 06-69 U0101-87 06-169 P2195-00 06-69 U0129-87 06-172 P2196-00 06-69 U0140-87 06-175 P0136-00 06-75 U0155-87 06-178 P0137-00 06-75 U0164-87 06-182 P0138-00 06-75 06– Chery Automobile Co., Ltd.
  • Page 166 Engine Control Module (ECM) 06-256 Removal & Installation -  Description 06-256 Upstream Oxygen Sensor 06-247 Operation 06-256 Removal & Installation -  Removal 06-256 Downstream Oxygen Sensor 06-247 Installation 06-257 Camshaft Position Sensor 06-248 Description 06-248 06– Chery Automobile Co., Ltd.
  • Page 167 Once detecting and confirming a fault, it will store trouble code and recall "Limp Home" function. When detecting that fault has been eliminated, it will return to use normal value. Basic Components of Engine Management System RT21060010 06– Chery Automobile Co., Ltd.
  • Page 168  System voltage protection When system voltage becomes extremely high due to charging system malfunction, engine management system will activate the protection program to limit engine speed, thus avoiding damage to ECM and battery. 06– Chery Automobile Co., Ltd.
  • Page 169 10.Never remove battery cable when engine is running. 11. The positive, negative battery cables and ECM must be removed before performing welding on vehicle. 12.Do not puncture wire outer coat to detect electric signals input and output by components. 06– Chery Automobile Co., Ltd.
  • Page 170 VVT Control Valve Fixing Bolt 8 ± 2 Engine Control Module Bracket Fixing Nut 7 ± 1 Tools Special Tool X-431 3G Diagnostic Tester RCH0000001 General Tools Fuel Injector Cleaning Analyzer RCH0000062 Ignition Timing Light RCH0000016 06– Chery Automobile Co., Ltd.
  • Page 171 06 - SQR484F ENGINE MANAGEMENT SYSTEM Digital Multimeter RCH0000002 Cylinder Pressure Gauge RCH0000044 Fuel Pressure Gauge RCH0000048 Oscilloscope RCH0000061 06– Chery Automobile Co., Ltd.
  • Page 172 Oxygen Sensor Ground Upstream Oxygen Sensor Camshaft Position Sensor 2 (Exhaust) Throttle 5 V Power Supply Ground Air Flow Meter Ground 5 V Power Supply Throttle Ground Throttle Actuator (-) ECU Ground 4 ECU Ground 3 06– Chery Automobile Co., Ltd.
  • Page 173 Brake Light Switch A/C Compressor Relay Coil (CVT) Starter Relay Coil (MT) Electronic Accelerator Pedal Sensor 2 Ground A/C Switch Electronic Accelerator Pedal Sensor 2 ECU Ground 2 5 V Power Supply ECU Ground 1 06– Chery Automobile Co., Ltd.
  • Page 174 17 18 19 20 21 22 23 24 25 26 27 28 29 30 13 14 15 16 17 18 19 20 21 22 9 10 11 12 13 14 9 10 E-035 E-033 ET21060010 06– Chery Automobile Co., Ltd.
  • Page 175 25 26 27 28 29 30 31 32 33 34 E-007 13 14 15 16 17 18 19 20 21 22 9 10 1 2 3 4 5 1 2 3 4 E-017 E-035 E-024 E-004 E-018 ET21060020 06– Chery Automobile Co., Ltd.
  • Page 176 C7 C8 C9 C10 25 26 27 28 29 30 31 32 33 34 13 14 15 16 17 18 19 20 21 22 E-023 E-007 9 10 E-035 E-006 E-008 E-010 E-011 E-012 E-013 ET21060030 06– Chery Automobile Co., Ltd.
  • Page 177 9 10 11 12 13 14 15 19 20 21 22 B-038 E-070 B3 B4 B5 C1 C2 C3 C4 C5 B7 B8 B9 B10 C7 C8 C9 C10 E-059 E-046 E-002 E-073 E-023 ET21060040 06– Chery Automobile Co., Ltd.
  • Page 178 17 18 19 20 21 22 23 24 25 26 27 28 29 30 14 15 16 17 18 19 20 21 22 23 24 9 10 11 12 13 14 I-007 87 30 87 30 ET21060050 06– Chery Automobile Co., Ltd.
  • Page 179 17 18 19 20 21 22 23 24 25 26 27 28 29 30 13 14 15 16 17 18 19 20 21 22 9 10 11 12 13 14 9 10 E-035 E-033 ET21060060 06– Chery Automobile Co., Ltd.
  • Page 180 17 18 19 20 21 22 23 24 25 26 27 28 29 30 13 14 15 16 17 18 19 20 21 22 9 10 11 12 13 14 9 10 E-035 E-033 ET21060070 06– Chery Automobile Co., Ltd.
  • Page 181 17 18 19 20 21 22 23 24 25 26 27 28 29 30 13 14 15 16 17 18 19 20 21 22 9 10 11 12 13 14 9 10 E-035 E-033 ET21060080 06– Chery Automobile Co., Ltd.
  • Page 182 6. If several wire harnesses are crimped into one ground terminal, check if they are installed correctly. Make sure all wire harnesses are clean, securely fastened and well contacted without crimping any excessive insulation coat. 06– Chery Automobile Co., Ltd.
  • Page 183 Manifold Abs. Pressure or Bar. Pressure Range/Performance P0107-00 Manifold Abs. Pressure or Bar. Pressure Low Input P0108-00 Manifold Abs. Pressure or Bar. Pressure High Input P0112-00 Intake Air Temp. Circ. Low Input P0113-00 Intake Air Temp. Circ. High Input 06– Chery Automobile Co., Ltd.
  • Page 184 P0458-00 Evaporative Emission System Purge Control Valve Circuit Low P0459-00 Evaporative Emission System Purge Control Valve Circuit High P0480-00 Cooling Fan 1 Control Circuit P0481-00 Cooling Fan 2 Control Circuit P0501-00 Vehicle Speed Sensor Range/Performance 06– Chery Automobile Co., Ltd.
  • Page 185 P1270-00 ECU Defective Secret Key and Security P1271-00 Immo Wrong Security Code Received Security P1272-00 Electronic Control Module Incorrect Coding P1273-00 MIL Call-up Circ. Open/Short to B+ IMMO P1274-00 MIL Call-up Circ./Transm. Contr. Module Range/Performance 06– Chery Automobile Co., Ltd.
  • Page 186 Mass or Volume Air Flow Circ. Low Input P0103-00 Mass or Volume Air Flow Circ. High Input P0531-00 A/C Refrigerant Pressure Sensor "A" Circuit Range/Performance P1568-00 DV-E Cause of Failure: Spring Check U0001-00 High Speed CAN Defective 06– Chery Automobile Co., Ltd.
  • Page 187 36 37 38 39 40 41 42 43 44 45 46 17 18 19 20 21 22 23 24 25 26 27 28 29 30 9 10 11 12 13 14 A3 A4 A5 A7 A8 A9 A10 E-076 E-033 ET21065000 06– Chery Automobile Co., Ltd.
  • Page 188 17 18 19 20 21 22 23 24 25 26 27 28 29 30 13 14 15 16 17 18 19 20 21 22 9 10 11 12 13 14 9 10 E-035 E-033 ET21065001 06– Chery Automobile Co., Ltd.
  • Page 189 4 5 6 7 8 9 10 11 12 13 14 E-033 RT21065001 Check ECM fuse a. Unplug ECM fuse EF19 (10A) from engine compartment fuse and relay box. b. Check resistance of fuse. Standard resistance: less than 1 Ω Replace ECM fuse 06– Chery Automobile Co., Ltd.
  • Page 190 Connection Condition Main relay terminals 85 and 87 (engine compartment fuse Always 11 to 14 V and relay box side) - Body ground Repair or replace wire harness or connector (main relay - battery) RT21060030 06– Chery Automobile Co., Ltd.
  • Page 191 4 5 6 7 8 9 10 11 12 13 14 E-033 (15, 16) or E-076 (A6) - Body No continuity ground E-033 E-033 (15, 16) or E-076 (A6) - Battery No continuity RT21065003 positive 06– Chery Automobile Co., Ltd.
  • Page 192 4 5 6 7 8 9 10 11 12 13 14 E-033 RT21065005 Check ECM fuse a. Unplug ECM fuse EF17 (10A) from engine compartment fuse and relay box. b. Check resistance of fuse. Standard resistance: less than 1 Ω Replace ECM fuse 06– Chery Automobile Co., Ltd.
  • Page 193 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Repair or replace wire harness or 1 2 3 4 5 6 7 8 9 10 11 12 13 14 connector E-033 RT21065007 06– Chery Automobile Co., Ltd.
  • Page 194 06 - SQR484F ENGINE MANAGEMENT SYSTEM Check ignition switch assembly (See page 15-67) Replace ignition switch assembly Repair or replace engine compartment fuse and relay box or wire harness (engine compartment fuse and relay box - ignition switch) 06– Chery Automobile Co., Ltd.
  • Page 195 P0030-00 O2 Sensor Heater Contr. Circ. (Bank1 (1) Sensor 1) P0031-00 O2 Sensor Heater Contr. Circ. (Bank1 (1) Sensor 1) Low P0032-00 O2 Sensor Heater Contr. Circ. (Bank1 (1) Sensor 1) High P0053-00 O2 Sensor Heater Resistance (Bank1 (1) Sensor 1) 06– Chery Automobile Co., Ltd.
  • Page 196 17 18 19 20 21 22 23 24 25 26 27 28 29 30 13 14 15 16 17 18 19 20 21 22 9 10 11 12 13 14 9 10 E-035 E-033 ET21065002 06– Chery Automobile Co., Ltd.
  • Page 197  When performing circuit diagnosis and test, always refer to the circuit diagram for specific circuit and component information. Diagnosis Procedure Check ECM ground point a. Turn ignition switch to LOCK. b. Check ECM grounds E-026 and E-028 (See page 06-18). Repair or replace ground wire harness or ground point 06– Chery Automobile Co., Ltd.
  • Page 198 Check voltage between terminal 4 of upstream oxygen sensor connector E-084 and body ground. Multimeter Specified Condition Connection Condition E-084 (4) - Body Ignition switch ON 11 to 14 V ground E-084 Go to step 5 RT21065008 06– Chery Automobile Co., Ltd.
  • Page 199 E-076 (A7) - Body Always No continuity ground E-084 (4) or E-076 (A7) - Always No continuity Battery positive Replace fuse, main relay, wire harness or connector (upstream oxygen sensor - engine compartment fuse and relay box) 06– Chery Automobile Co., Ltd.
  • Page 200 Terminal D Terminal A - Terminal B Terminal A - RT21090140 Terminal C Terminal A - Always No continuity Terminal D Terminal B - Terminal C Terminal B - Terminal D Replace upstream oxygen sensor 06– Chery Automobile Co., Ltd.
  • Page 201 Refer to "DTC Confirmation Procedure". c. Check if DTC P0030-00, P0031-00, P0032-00 or P0053-00 still exists. Replace ECM System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 202 P0036-00 O2 Sensor Heater Contr. Circ. (Bank1 (1) Sensor 2) P0037-00 O2 Sensor Heater Contr. Circ. (Bank1 (1) Sensor 2) Low P0038-00 O2 Sensor Heater Contr. Circ. (Bank1 (1) Sensor 2) High P0054-00 O2 Sensor Heater Resistance (Bank1 (1) Sensor 2) 06– Chery Automobile Co., Ltd.
  • Page 203 33 34 35 36 37 38 39 40 41 42 43 44 45 46 E-033 17 18 19 20 21 22 23 24 25 26 27 28 29 30 E-043 9 10 11 12 13 14 ET21065003 06– Chery Automobile Co., Ltd.
  • Page 204  When performing circuit diagnosis and test, always refer to the circuit diagram for specific circuit and component information. Diagnosis Procedure Check ECM ground point a. Turn ignition switch to LOCK. b. Check ECM grounds E-026 and E-028 (See page 06-18). Repair or replace ground wire harness or ground point 06– Chery Automobile Co., Ltd.
  • Page 205 Check voltage between terminal 4 of downstream oxygen sensor connector E-043 and body ground. Multimeter Specified Condition Connection Condition E-043 (4) - Body Ignition switch ON 11 to 14 V ground E-043 Go to step 5 RT21065011 06– Chery Automobile Co., Ltd.
  • Page 206 E-076 (A7) - Body Always No continuity ground E-043 (4) or E-076 (A7) - Always No continuity Battery positive Replace fuse, main relay, wire harness or connector (downstream oxygen sensor - engine compartment fuse and relay box) 06– Chery Automobile Co., Ltd.
  • Page 207 Terminal D Terminal A - Terminal B Terminal A - RT21090140 Terminal C Terminal A - Always No continuity Terminal D Terminal B - Terminal C Terminal B - Terminal D Replace downstream oxygen sensor 06– Chery Automobile Co., Ltd.
  • Page 208 Refer to "DTC Confirmation Procedure". c. Check if DTC P0036-00, P0037-00, P0038-00 or P0054-00 still exists. Replace ECM System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 209 06 - SQR484F ENGINE MANAGEMENT SYSTEM P0101-00 Mass or Volume Air Flow Circ. Range/Performance P0102-00 Mass or Volume Air Flow Circ. Low Input P0103-00 Mass or Volume Air Flow Circ. High Input 06– Chery Automobile Co., Ltd.
  • Page 210 E-033 17 18 19 20 21 22 23 24 25 26 27 28 29 30 13 14 15 16 17 18 19 20 21 22 9 10 11 12 13 14 9 10 E-035 ET21065004 06– Chery Automobile Co., Ltd.
  • Page 211  When performing circuit diagnosis and test, always refer to the circuit diagram for specific circuit and component information. Diagnosis Procedure Check ECM ground point a. Turn ignition switch to LOCK. b. Check ECM grounds E-026 and E-028 (See page 06-18). Repair or replace ground wire harness or ground point 06– Chery Automobile Co., Ltd.
  • Page 212 1 2 3 4 5 1.3 V (value Idle changes with E-017 model) E-017 (5) - Body Instantaneous ground voltage is about Rapidly depress 4 V (value accelerator pedal changes with model) RT21060060 Go to step 8 06– Chery Automobile Co., Ltd.
  • Page 213 13 14 15 16 17 18 19 20 21 22 9 10 Multimeter Specified Condition Connection Condition E-017 (4) or E-035 RT21065015 E-035 (45) - Body Always No continuity ground E-017 (4) or E-035 (45) - Always No continuity Battery positive 06– Chery Automobile Co., Ltd.
  • Page 214 E-017 (5) or E-035 (27) - Body Always No continuity ground E-035 RT21065017 E-017 (5) or E-035 (27) - Always No continuity Battery positive Repair or replace wire harness or connector (air flow meter - ECM) 06– Chery Automobile Co., Ltd.
  • Page 215 Refer to "DTC Confirmation Procedure". c. Check if DTC P0101-00, P0102-00 or P0103-00 still exists. Replace ECM System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 216 E-033 17 18 19 20 21 22 23 24 25 26 27 28 29 30 13 14 15 16 17 18 19 20 21 22 9 10 11 12 13 14 9 10 E-035 ET21065004 06– Chery Automobile Co., Ltd.
  • Page 217  When performing circuit diagnosis and test, always refer to the circuit diagram for specific circuit and component information. Diagnosis Procedure Check ECM ground point a. Turn ignition switch to LOCK. b. Check ECM grounds E-026 and E-028 (See page 06-18). Repair or replace ground wire harness or ground point 06– Chery Automobile Co., Ltd.
  • Page 218 1 2 3 4 5 1.6 V (value changes with E-017 E-017 (1) - Body Engine running model); signal ground after warming up voltage does not change when increasing speed. Go to step 7 RT21060070 06– Chery Automobile Co., Ltd.
  • Page 219 Condition E-017 (1) or E-035 RT21065019 E-035 (38) - Body Always No continuity ground E-017 (1) or E-035 (38) - Always No continuity Battery positive Replace wire harness or connector (air flow meter - ECM) 06– Chery Automobile Co., Ltd.
  • Page 220 Refer to "DTC Confirmation Procedure". c. Check if DTC P0112-00 or P0113-00 still exists. Replace ECM System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 221 37 38 39 40 41 42 43 44 45 46 25 26 27 28 29 30 31 32 33 34 E-021 13 14 15 16 17 18 19 20 21 22 9 10 E-007 E-035 ET21065005 06– Chery Automobile Co., Ltd.
  • Page 222  When performing circuit diagnosis and test, always refer to the circuit diagram for specific circuit and component information. Diagnosis Procedure Check ECM ground point a. Turn ignition switch to LOCK. b. Check ECM grounds E-026 and E-028 (See page 06-18). Repair or replace ground wire harness or ground point 06– Chery Automobile Co., Ltd.
  • Page 223 Turn ignition switch to ON. b. Check voltage between engine coolant temperature sensor terminal and body ground. Multimeter Specified Condition Connection Condition E-021 (2) - Body Ignition switch ON ground E-021 Go to step 5 RT21065021 06– Chery Automobile Co., Ltd.
  • Page 224 E-035 RT21065022 E-021 (2) or E-035 (37) - Body Always No continuity ground E-021 (2) or E-035 (37) - Always No continuity Battery positive Replace wire harness or connector (engine coolant temperature sensor - ECM) 06– Chery Automobile Co., Ltd.
  • Page 225 Check resistance of engine coolant temperature sensor. Multimeter Specified Condition Connection Resistance is 2.5 kΩ ± 5% (20°C), 300 - 400 Ω in boiled water (value 1 - 2 changes with boiled water temperature) RT21060100 Replace engine coolant temperature sensor 06– Chery Automobile Co., Ltd.
  • Page 226 Refer to "DTC Confirmation Procedure". c. Check if DTC P0116-00, P0117-00 or P0118-00 still exists. Replace ECM System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 227 37 38 39 40 41 42 43 44 45 46 4 5 6 25 26 27 28 29 30 31 32 33 34 E-009 13 14 15 16 17 18 19 20 21 22 9 10 E-007 E-035 ET21065006 06– Chery Automobile Co., Ltd.
  • Page 228  When performing circuit diagnosis and test, always refer to the circuit diagram for specific circuit and component information. Diagnosis Procedure Check ECM ground point a. Turn ignition switch to LOCK. b. Check ECM grounds E-026 and E-028 (See page 06-18). Repair or replace ground wire harness or ground point 06– Chery Automobile Co., Ltd.
  • Page 229 2 4.22 Accelerator pedal depressed 4.29 additive correction of the mixture adaptation 0.00 Voltage PWG potentiometer 1 0.77 Voltage PWG potentiometer 2 0.38 Go to step 8 Doubled PWG potentiometer-2 voltage 0.75 RT21060120 06– Chery Automobile Co., Ltd.
  • Page 230 Multimeter Specified Condition Connection Condition E-009 (3) or E-035 RT21065025 E-035 (43) - Body ground Always No continuity E-009 (3) or E-035 (43) - Battery positive Replace wire harness or connector (electronic throttle - ECM) 06– Chery Automobile Co., Ltd.
  • Page 231 E-035 (13) - Battery positive Always No continuity E-009 (2) or E-035 (22) - Body ground E-009 (2) or E-035 (22) - Battery positive Repair or replace wire harness or connector (electronic throttle - ECM) 06– Chery Automobile Co., Ltd.
  • Page 232 Refer to "DTC Confirmation Procedure". c. Check if DTC P0121-00, P0122-00 or P0123-00 still exists. Replace ECM System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 233 P0133-00 O2 Sensor Circ., Bank1-Sensor1 Slow Response P0134-00 O2 Sensor Circ., Bank1-Sensor1 No Activity Detected P2195-00 O2 Sensor Signal Stuck Lean; Bank 1 Sensor 1 P2196-00 O2 Sensor Signal Stuck Rich; Bank 1 Sensor 1 06– Chery Automobile Co., Ltd.
  • Page 234 17 18 19 20 21 22 23 24 25 26 27 28 29 30 13 14 15 16 17 18 19 20 21 22 9 10 11 12 13 14 9 10 E-035 E-033 ET21065002 06– Chery Automobile Co., Ltd.
  • Page 235  If DTC is not detected, the malfunction indicated by the DTC is intermittent (See page 06-18). CAUTION  When performing circuit diagnosis and test, always refer to the circuit diagram for specific circuit and component information. 06– Chery Automobile Co., Ltd.
  • Page 236 Using multimeter, measure voltage between terminals 2 and 1 of connector E-084. Multimeter Specified Condition Connection Condition Fluctuates fast between 0.1 and E-084 E-084 (2) - E-084 0.9 V (when Engine running operating temperature is 350°C) Go to step 7 RT21060130 06– Chery Automobile Co., Ltd.
  • Page 237 (16) 37 38 39 40 41 42 43 44 45 46 25 26 27 28 29 30 31 32 33 34 13 14 15 16 17 18 19 20 21 22 9 10 E-035 RT21065028 06– Chery Automobile Co., Ltd.
  • Page 238 Check if DTC P0130-00, P0131-00, P0132-00, P0133-00, P0134-00, P2195-00 or P2196-00 still exists. Replace ECM System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 239 P0138-00 O2 Sensor Circ., Bank1-Sensor2 High Voltage P0140-00 O2 Sensor Circ., Bank1-Sensor2 No Activity Detected P2270-00 O2 Sensor Signal Stuck Lean; Bank 1 Sensor 2 P2271-00 O2 Sensor Signal Stuck Rich; Bank 1 Sensor 2 06– Chery Automobile Co., Ltd.
  • Page 240 33 34 35 36 37 38 39 40 41 42 43 44 45 46 E-033 17 18 19 20 21 22 23 24 25 26 27 28 29 30 E-043 9 10 11 12 13 14 ET21065003 06– Chery Automobile Co., Ltd.
  • Page 241  If DTC is not detected, the malfunction indicated by the DTC is intermittent (See page 06-18). CAUTION  When performing circuit diagnosis and test, always refer to the circuit diagram for specific circuit and component information. 06– Chery Automobile Co., Ltd.
  • Page 242 (calc.load value) acc. To SAE J1979 23.83 Engine running Air mass flow kg/h at about 0.45 V output voltage oxygen sensor downstream catalyst 0.46 relative air charge 17.25 Go to step 7 RT21060140 06– Chery Automobile Co., Ltd.
  • Page 243 36 37 38 39 40 41 42 43 44 45 46 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 E-033 RT21065030 06– Chery Automobile Co., Ltd.
  • Page 244 Check if DTC P0136-00, P0137-00, P0138-00, P0140-00, P2270-00 or P2271-00 still exists. Replace ECM System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 245 E-033 13 14 15 16 17 18 19 20 21 22 17 18 19 20 21 22 23 24 25 26 27 28 29 30 9 10 9 10 11 12 13 14 E-035 ET21065007 06– Chery Automobile Co., Ltd.
  • Page 246 (See page 06-18). Repair or replace ground wire harness or ground point Check injector connector of cylinder 1 a. Disconnect injector connector E-010 of cylinder 1. b. Check injector connector. Repair or replace connector RT21060150 06– Chery Automobile Co., Ltd.
  • Page 247 Check for Open E-010 Multimeter Specified Condition Connection Condition E-010 (1) - E-023 Always Continuity C1 C2 C3 C4 C5 (C3) C7 C8 C9 C10 E-023 RT21065032 06– Chery Automobile Co., Ltd.
  • Page 248 E-010 (2) or E-035 (4) - Body E-035 ground RT21065033 Always No continuity E-010 (2) or E- 035 (4) - Battery positive Repair or replace wire harness or connector (injector of cylinder 1 - ECM) 06– Chery Automobile Co., Ltd.
  • Page 249 Refer to "DTC Confirmation Procedure". c. Check if DTC P0201-00 still exists. Replace ECM System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 250 E-033 13 14 15 16 17 18 19 20 21 22 17 18 19 20 21 22 23 24 25 26 27 28 29 30 9 10 9 10 11 12 13 14 E-035 ET21065008 06– Chery Automobile Co., Ltd.
  • Page 251 (See page 06-18). Repair or replace ground wire harness or ground point Check injector connector of cylinder 4 a. Disconnect injector connector E-013 of cylinder 4. b. Check injector connector. Repair or replace connector RT21060160 06– Chery Automobile Co., Ltd.
  • Page 252 Check for Open E-013 Multimeter Specified Condition Connection Condition E-013 (1) - E-023 Always Continuity C1 C2 C3 C4 C5 (C3) C7 C8 C9 C10 E-023 RT21065035 06– Chery Automobile Co., Ltd.
  • Page 253 Condition E-013 (2) or E-035 (10) - Body E-035 ground RT21065036 Always No continuity E-013 (2) or E-035 (10) - Battery positive Repair or replace wire harness or connector (injector of cylinder 4 - ECM) 06– Chery Automobile Co., Ltd.
  • Page 254 Refer to "DTC Confirmation Procedure". c. Check if DTC P0271-00 still exists. Replace ECM System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 255 06 - SQR484F ENGINE MANAGEMENT SYSTEM SQR484F ENGINE MANAGEMENT SYSTEM P1106-00 Throttle Pos. Contr. Malfunction P1110-00 Throttle Actuator Electrical Malfunction (MT only) Idle Speed Control Throttle Position Mechanical P1111-00 Malfunction P1568-00 DV-E Cause of Failure: Spring Check P0606-00 ECM/PCM Processor 06– Chery Automobile Co., Ltd.
  • Page 256 37 38 39 40 41 42 43 44 45 46 4 5 6 25 26 27 28 29 30 31 32 33 34 E-009 13 14 15 16 17 18 19 20 21 22 9 10 E-007 E-035 ET21065006 06– Chery Automobile Co., Ltd.
  • Page 257 Diagnosis Procedure Check ECM ground point a. Turn ignition switch to LOCK. b. Check ECM grounds E-026 and E-028 (See page 06-18). Repair or replace ground wire harness or ground point Check electronic throttle connector 06– Chery Automobile Co., Ltd.
  • Page 258 Accelerator pedal Voltage PWG potentiometer 1 0.77 4.29 depressed Voltage PWG potentiometer 2 0.38 Doubled PWG potentiometer-2 voltage 0.75 Accelerator pedal 4.22 released Throttle position sensor 2 Accelerator pedal RT21060180 0.71 depressed Go to step 7 06– Chery Automobile Co., Ltd.
  • Page 259 E-009 (1) - Always No continuity Battery positive E-035 (11) or E-009 (4) - Body Always No continuity ground E-035 (11) or E-009 (4) - Always No continuity Battery positive Repair or replace related wire harness 06– Chery Automobile Co., Ltd.
  • Page 260 No continuity E-009 (2, 5, 3, 6) - Body ground E-035 (22, 14, 43, 13) or Always No continuity E-009 (2, 5, 3, 6) - Battery positive Replace wire harness or connector (electronic throttle - ECM) 06– Chery Automobile Co., Ltd.
  • Page 261 Check if DTC P1106-00, P1110-00, P1111-00, P1568-00 or P0606-00 still exists. Replace ECM System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 262 06 - SQR484F ENGINE MANAGEMENT SYSTEM P0300-00 Random/Multiple Cylinder Misfire Detected P0301-00 Cyl.1 Misfire Detected P0302-00 Cyl.2 Misfire Detected P0303-00 Cyl.3 Misfire Detected P0304-00 Cyl.4 Misfire Detected 06– Chery Automobile Co., Ltd.
  • Page 263 E-033 13 14 15 16 17 18 19 20 21 22 17 18 19 20 21 22 23 24 25 26 27 28 29 30 9 10 9 10 11 12 13 14 E-035 ET21065009 06– Chery Automobile Co., Ltd.
  • Page 264  When performing circuit diagnosis and test, always refer to the circuit diagram for specific circuit and component information. Diagnosis Procedure Check ECM ground point a. Turn ignition switch to LOCK. b. Check ECM grounds E-026 and E-028 (See page 06-18). Repair or replace ground wire harness or ground point 06– Chery Automobile Co., Ltd.
  • Page 265 Connect ignition coil connector. b. Connect spark plug and ignition coil, and ground spark plug housing. c. Start and run the engine for no more than 2 seconds, and check if spark is generated. Go to step 6 06– Chery Automobile Co., Ltd.
  • Page 266 Check resistance of secondary winding of ignition coil. Multimeter Specification Condition Connection (kΩ) Normal Post 1 - Post 4 9.5 - 12.1 temperature Normal Post 2 - Post 3 9.5 - 12.1 temperature RT21140080 Replace ignition coil 06– Chery Automobile Co., Ltd.
  • Page 267 Check for Short C7 C8 C9 C10 Multimeter Specified E-023 Condition Connection Condition RT21065040 E-018 (3) or E-023 (C4) - Body Always No continuity ground E-018 (3) or E-023 (C4) - Always No continuity Battery positive 06– Chery Automobile Co., Ltd.
  • Page 268 (ignition coil - ECM) Check for DTCs a. Use X-431 3G diagnostic tester to read the ECM DTC. b. Refer to "DTC Confirmation Procedure". c. Check if DTC P0300-00, P0301-00, P0302-00, P0303-00 or P0304-00 still exists. 06– Chery Automobile Co., Ltd.
  • Page 269 06 - SQR484F ENGINE MANAGEMENT SYSTEM Replace ECM System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 270 13 14 15 16 17 18 19 20 21 22 17 18 19 20 21 22 23 24 25 26 27 28 29 30 9 10 9 10 11 12 13 14 E-035 E-033 38 34 E-007 E-016 1 2 3 ET21065010 06– Chery Automobile Co., Ltd.
  • Page 271  When performing circuit diagnosis and test, always refer to the circuit diagram for specific circuit and component information. Diagnosis Procedure Check ECM ground point a. Turn ignition switch to LOCK. b. Check ECM grounds E-026 and E-028 (See page 06-18). Repair or replace ground wire harness or ground point 06– Chery Automobile Co., Ltd.
  • Page 272 Remove engine speed sensor. b. Check and clean engine speed sensor and installation area, and check for damage, foreign matter or excessive movement, etc. that cause signal incorrectness. Clean or replace engine speed sensor 06– Chery Automobile Co., Ltd.
  • Page 273 E-016 (1) or E-035 (32) - Body ground E-016 (1) or E-035 (32) - Battery positive Always No continuity E-016 (2) or E-035 (33) - Body ground E-016 (2) or E-035 (33) - Battery positive 06– Chery Automobile Co., Ltd.
  • Page 274 Refer to "DTC Confirmation Procedure". c. Check if DTC P0322-00 still exists. Replace ECM System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 275 06 - SQR484F ENGINE MANAGEMENT SYSTEM P0327-00 Knock Sensor 1 Circ. Low Input P0328-00 Knock Sensor 1 Circ. High Input 06– Chery Automobile Co., Ltd.
  • Page 276 13 14 15 16 17 18 19 20 21 22 17 18 19 20 21 22 23 24 25 26 27 28 29 30 9 10 9 10 11 12 13 14 E-035 E-033 38 34 E-007 1 2 3 E-005 ET21065011 06– Chery Automobile Co., Ltd.
  • Page 277 Check ECM grounds E-026 and E-028 (See page 06-18). Repair or replace ground wire harness or ground point Check knock sensor connector a. Disconnect knock sensor connector E-005. b. Check knock sensor connector. Repair or replace connector RT21060330 06– Chery Automobile Co., Ltd.
  • Page 278 E-035 (26) or E-005 (1) - Battery RT21065043 No continuity positive E-035 (25) or E-005 (2) - Body ground No continuity E-035 (25) or E-005 (2) - Battery No continuity positive Replace wire harness or connector (knock sensor - ECM) 06– Chery Automobile Co., Ltd.
  • Page 279 Refer to "DTC Confirmation Procedure". c. Check if DTC P0327-00 or P0328-00 still exists. Replace ECM System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 280 17 18 19 20 21 22 23 24 25 26 27 28 29 30 13 14 15 16 17 18 19 20 21 22 9 10 11 12 13 14 9 10 E-035 E-033 ET21065012 06– Chery Automobile Co., Ltd.
  • Page 281  When performing circuit diagnosis and test, always refer to the circuit diagram for specific circuit and component information. Diagnosis Procedure Check ECM ground point a. Turn ignition switch to LOCK. b. Check ECM grounds E-026 and E-028 (See page 06-18). Repair or replace ground wire harness or ground point 06– Chery Automobile Co., Ltd.
  • Page 282 Go to step 10 Check camshaft position sensor connector a. Turn ignition switch to LOCK. b. Disconnect camshaft position sensor connectors E-020 and E-015. c. Check camshaft position sensor connector. Repair or replace camshaft position sensor connector 06– Chery Automobile Co., Ltd.
  • Page 283 (3) or E-035 (34) - Always No continuity Body ground E-020 (3), E-015 (3) or E-035 (34) - Always No continuity Battery positive Repair or replace wire harness or connector (camshaft position sensor - ECM) 06– Chery Automobile Co., Ltd.
  • Page 284 E-035 (41) - Battery positive E-020 (1), E-015 (1) or E-035 (31) - Body ground E-020 (1), E-015 (1) or E-035 (31) - Battery positive Replace wire harness or connector (camshaft position sensor - ECM) 06– Chery Automobile Co., Ltd.
  • Page 285 Refer to "DTC Confirmation Procedure". c. Check if DTC P0341-00 or P0346-00 still exists. Replace ECM System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 286 Turn ignition switch to ON. Start the engine and warm it up to normal operating temperature, and then select Read Code. Display (DTC Output) Proceed to DTC P0420-00 DTC P0420-00 and other DTCs Go to DTC chart, and perform troubleshooting for other DTCs first 06– Chery Automobile Co., Ltd.
  • Page 287 Turn ignition switch to ON and start the engine. b. Check exhaust system for leakage. Repair or replace related exhaust system components Check downstream oxygen sensor Replace downstream oxygen sensor Replace three-way catalytic converter, and go to step 5 06– Chery Automobile Co., Ltd.
  • Page 288 Refer to "DTC Confirmation Procedure". c. Check if DTC P0420-00 still exists. Replace ECM System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 289 06 - SQR484F ENGINE MANAGEMENT SYSTEM SQR484F ENGINE MANAGEMENT SYSTEM Evaporative Emiss. System Purge Control Valve Circ. P0444-00 Open Evaporative Emission System Purge Control Valve P0458-00 Circuit Low Evaporative Emission System Purge Control Valve P0459-00 Circuit High 06– Chery Automobile Co., Ltd.
  • Page 290 E-033 13 14 15 16 17 18 19 20 21 22 17 18 19 20 21 22 23 24 25 26 27 28 29 30 9 10 9 10 11 12 13 14 E-035 ET21065013 06– Chery Automobile Co., Ltd.
  • Page 291  When performing circuit diagnosis and test, always refer to the circuit diagram for specific circuit and component information. Diagnosis Procedure Check ECM ground point a. Turn ignition switch to LOCK. b. Check ECM grounds E-026 and E-028 (See page 06-18). Repair or replace ground wire harness or ground point 06– Chery Automobile Co., Ltd.
  • Page 292 Measure voltage between canister solenoid valve connector terminal and body ground. Multimeter Specified Condition Connection Condition E-024 (1) - Body Ignition switch ON 11 to 14 V ground E-024 Go to step 5 RT21065047 06– Chery Automobile Co., Ltd.
  • Page 293 E-023 (C9) - Always No continuity Body ground E-024 (1) or E-023 (C9) - Always No continuity Battery positive Repair or replace wire harness or connector (canister solenoid valve - engine compartment fuse and relay box) 06– Chery Automobile Co., Ltd.
  • Page 294 RT21090050 Replace canister solenoid valve Check for DTCs a. Use X-431 3G diagnostic tester to read the ECM DTC. b. Refer to "DTC Confirmation Procedure". c. Check if DTC P0444-00, P0458-00 or P0459-00 still exists. 06– Chery Automobile Co., Ltd.
  • Page 295 06 - SQR484F ENGINE MANAGEMENT SYSTEM Replace ECM System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 296 06 - SQR484F ENGINE MANAGEMENT SYSTEM P0480-00 Cooling Fan 1 Control Circuit P0481-00 Cooling Fan 2 Control Circuit P0691-00 Cooling Fan 1 Control Circuit Low 06– Chery Automobile Co., Ltd.
  • Page 297 E-033 13 14 15 16 17 18 19 20 21 22 17 18 19 20 21 22 23 24 25 26 27 28 29 30 9 10 9 10 11 12 13 14 E-035 ET21065014 06– Chery Automobile Co., Ltd.
  • Page 298  When performing circuit diagnosis and test, always refer to the circuit diagram for specific circuit and component information. Diagnosis Procedure Check ECM ground point a. Turn ignition switch to LOCK. b. Check ECM grounds E-026 and E-028 (See page 06-18). Repair or replace ground wire harness or ground point 06– Chery Automobile Co., Ltd.
  • Page 299 Check if fuse is normal. c. Check cooling fan relay. Multimeter Specified Condition Connection 30 - 87 No continuity Continuity 30 - 87 (when battery voltage is applied between terminals 85 and 86) Replace fuse or relay RT21060250 06– Chery Automobile Co., Ltd.
  • Page 300 4 5 6 7 8 9 10 11 12 13 14 Specified Multimeter Connection Condition E-033 (56) or E-046 (2) - Body ground No continuity E-033 RT21065050 E-033 (56) or E-046 (2) - No continuity Battery positive 06– Chery Automobile Co., Ltd.
  • Page 301 Refer to "DTC Confirmation Procedure". c. Check if DTC P0480-00, P0481-00 or P0691-00 still exists. Replace ECM System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 302 06 - SQR484F ENGINE MANAGEMENT SYSTEM P0560-00 System Voltage Malfunction P0562-00 System Voltage Low Voltage P0563-00 System Voltage High Voltage 06– Chery Automobile Co., Ltd.
  • Page 303 13 14 15 16 17 18 19 20 21 22 17 18 19 20 21 22 23 24 25 26 27 28 29 30 9 10 9 10 11 12 13 14 E-035 E-033 A3 A4 A5 E-076 A7 A8 A9 A10 E-069 ET21065015 06– Chery Automobile Co., Ltd.
  • Page 304  When performing circuit diagnosis and test, always refer to the circuit diagram for specific circuit and component information. Diagnosis Procedure Check battery a. Check if battery voltage is normal. Recharge or replace battery Check battery terminals a. Check if battery terminals are loose or corroded. Tighten or replace battery terminals 06– Chery Automobile Co., Ltd.
  • Page 305 36 37 38 39 40 41 42 43 44 45 46 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 E-033 RT21065052 06– Chery Automobile Co., Ltd.
  • Page 306 E-033 (20) or E-076 (A2) - No continuity RT21065053 Battery positive Repair or replace wire harness or connector Repair or replace engine compartment fuse and relay box or wire harness (engine compartment fuse and relay box - battery) 06– Chery Automobile Co., Ltd.
  • Page 307 Unplug fuse EF17 (10 A) from engine compartment fuse and relay box. b. Check resistance of fuse EF17. Standard resistance: less than 1 Ω Replace fuse Check wire harness and connector (ECM - engine compartment fuse and relay box) 06– Chery Automobile Co., Ltd.
  • Page 308 Refer to "DTC Confirmation Procedure". c. Check if DTC P0560-00, P0562-00 or P0563-00 still exists. Replace ECM System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 309 06 - SQR484F ENGINE MANAGEMENT SYSTEM P0627-00 Fuel Pump "A" Control Circuit/Open P0628-00 Fuel Pump "A" Control Circuit Low P0629-00 Fuel Pump "A" Control Circuit High 06– Chery Automobile Co., Ltd.
  • Page 310 E-033 13 14 15 16 17 18 19 20 21 22 17 18 19 20 21 22 23 24 25 26 27 28 29 30 9 10 9 10 11 12 13 14 E-035 ET21065016 06– Chery Automobile Co., Ltd.
  • Page 311  When performing circuit diagnosis and test, always refer to the circuit diagram for specific circuit and component information. Diagnosis Procedure Check ECM ground point a. Turn ignition switch to LOCK. b. Check ECM grounds E-026 and E-028 (See page 06-18). Repair or replace ground wire harness or ground point 06– Chery Automobile Co., Ltd.
  • Page 312 E-033 (41) or E-069 (F7) - No continuity Body ground E-033 RT21065056 E-033 (41) or E-069 (F7) - No continuity Battery positive Repair or replace wire harness or connector (engine compartment fuse and relay box - ECM) 06– Chery Automobile Co., Ltd.
  • Page 313 Refer to "DTC Confirmation Procedure". c. Check if DTC P0627-00, P0628-00 or P0629-00 still exists. Replace ECM System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 314 06 - SQR484F ENGINE MANAGEMENT SYSTEM P0645-00 A/C Clutch Relay Circuit P0646-00 A/C Clutch Relay Control Circuit Low P0647-00 A/C Clutch Relay Control Circuit High 06– Chery Automobile Co., Ltd.
  • Page 315 E-033 13 14 15 16 17 18 19 20 21 22 17 18 19 20 21 22 23 24 25 26 27 28 29 30 9 10 9 10 11 12 13 14 E-035 ET21065017 06– Chery Automobile Co., Ltd.
  • Page 316  When performing circuit diagnosis and test, always refer to the circuit diagram for specific circuit and component information. Diagnosis Procedure Check ECM ground point a. Turn ignition switch to LOCK. b. Check ECM grounds E-026 and E-028 (See page 06-18). Repair or replace ground wire harness or ground point 06– Chery Automobile Co., Ltd.
  • Page 317 20 21 22 23 24 25 26 27 28 29 30 or E-033 (58) Always Continuity 1 2 3 4 5 6 7 8 9 10 11 12 13 14 (CVT) - E-069 (F1) E-033 RT21065057 06– Chery Automobile Co., Ltd.
  • Page 318 Refer to "DTC Confirmation Procedure". c. Check if DTC P0645-00, P0646-00 or P0647-00 still exists. Replace ECM System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 319 13 14 15 16 17 18 19 20 21 22 17 18 19 20 21 22 23 24 25 26 27 28 29 30 9 10 9 10 11 12 13 14 E-035 E-033 A3 A4 A5 E-076 A7 A8 A9 A10 E-069 ET21065015 06– Chery Automobile Co., Ltd.
  • Page 320  When performing circuit diagnosis and test, always refer to the circuit diagram for specific circuit and component information. Diagnosis Procedure Check ECM ground point a. Turn ignition switch to LOCK. b. Check ECM grounds E-026 and E-028 (See page 06-18). Repair or replace ground wire harness or ground point 06– Chery Automobile Co., Ltd.
  • Page 321 Connection Condition Main relay terminals 87 and 85 (engine compartment fuse Always 11 to 14 V and relay box side) - Body ground Repair or replace wire harness or connector (main relay - battery) RT21060030 06– Chery Automobile Co., Ltd.
  • Page 322 Repair or replace wire harness or connector Check for DTCs a. Use X-431 3G diagnostic tester to read the ECM DTC. b. Refer to "DTC Confirmation Procedure". c. Check if DTC P0688-00 still exists. Replace ECM 06– Chery Automobile Co., Ltd.
  • Page 323 06 - SQR484F ENGINE MANAGEMENT SYSTEM System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 324 Check ECM grounds E-026 and E-028 (See page 06-18). Repair or replace ground wire harness or ground point Check ECM connector a. Disconnect ECM connector E-033 and E-035. b. Check if connector is normal. Repair or replace connector 06– Chery Automobile Co., Ltd.
  • Page 325 06 - SQR484F ENGINE MANAGEMENT SYSTEM Replace ECM 06– Chery Automobile Co., Ltd.
  • Page 326 Check ECM grounds E-026 and E-028 (See page 06-18). Repair or replace ground wire harness or ground point Check ECM connector a. Disconnect ECM connector E-033 and E-035. b. Check if connector is normal. Repair or replace connector 06– Chery Automobile Co., Ltd.
  • Page 327 Refer to "DTC Confirmation Procedure". c. Check if DTC P1619-00 still exists. Replace ECM System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 328 13 14 15 16 17 18 19 20 21 22 17 18 19 20 21 22 23 24 25 26 27 28 29 30 9 10 9 10 11 12 13 14 E-035 E-033 3 2 1 E-041 ET21065018 06– Chery Automobile Co., Ltd.
  • Page 329 Turn ignition switch to LOCK. b. Check ECM grounds E-026 and E-028 (See page 06-18). Repair or replace ground wire harness or ground point Check A/C pressure sensor connector a. Disconnect A/C pressure sensor connector E-041. RT21060290 06– Chery Automobile Co., Ltd.
  • Page 330 4 5 6 7 8 9 10 11 12 13 14 Multimeter Specified Condition Connection Condition E-041 (3) or E-033 (19) - Body Always No continuity E-033 RT21065061 ground E-041 (3) or E-033 (19) - Always No continuity Battery positive 06– Chery Automobile Co., Ltd.
  • Page 331 (A/C pressure sensor - ECM) Replace A/C pressure sensor, and check for DTCs a. Use X-431 3G diagnostic tester to read the ECM DTC. b. Refer to "DTC Confirmation Procedure". c. Check if DTC P0531-00 still exists. Replace ECM 06– Chery Automobile Co., Ltd.
  • Page 332 06 - SQR484F ENGINE MANAGEMENT SYSTEM System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 333 43 44 45 46 47 48 49 50 51 52 53 54 55 56 E-030 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 ET21065019 06– Chery Automobile Co., Ltd.
  • Page 334 Repair or replace ground wire harness or ground point Check ECM connector and TCM connector a. Disconnect ECM connector E-033. b. Disconnect TCU connector E-030. c. Check if connectors are normal. Repair or replace connector 06– Chery Automobile Co., Ltd.
  • Page 335 Refer to "DTC Confirmation Procedure". c. Check if DTC U0101-87 still exists. Replace TCU System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 336 12 11 10 9 8 7 6 5 4 3 2 24 23 22 21 20 19 18 17 16 15 14 37 36 35 34 33 32 31 30 29 28 27 26 E-085 ET21065020 06– Chery Automobile Co., Ltd.
  • Page 337 Repair or replace ground wire harness or ground point Check ECM connector and ABS connector a. Disconnect ECM connector E-033. b. Disconnect ABS connector E-085. c. Check if connectors are normal. Repair or replace connector 06– Chery Automobile Co., Ltd.
  • Page 338 Refer to "DTC Confirmation Procedure". c. Check if DTC U0129-87 still exists. Replace ABS control module System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 339 20 21 22 23 24 25 26 27 28 29 30 9 10 9 10 11 12 13 14 E-035 E-033 1 2 3 4 5 6 7 8 9 10 14 15 I-005 E-027 ET21065021 06– Chery Automobile Co., Ltd.
  • Page 340 Repair or replace ground wire harness or ground point Check ECM connector and BCM connector a. Disconnect ECM connector E-033. b. Disconnect BCM connector I-005. c. Check if connectors are normal. Repair or replace connectors 06– Chery Automobile Co., Ltd.
  • Page 341 Refer to "DTC Confirmation Procedure". c. Check if DTC U0140-87 still exists. Replace BCM System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 342 20 21 22 23 24 25 26 27 28 29 30 9 10 9 10 11 12 13 14 E-035 E-033 1 2 3 4 5 6 7 8 9 10 14 15 I-015 I-005 E-027 ET21065022 06– Chery Automobile Co., Ltd.
  • Page 343 Check ECM connector, instrument cluster connector and BCM connector a. Disconnect ECM connector E-033. b. Disconnect instrument cluster connector I-015. c. Disconnect BCM connector I-005. d. Check if connectors are normal. Repair or replace connectors 06– Chery Automobile Co., Ltd.
  • Page 344 E-033 (1) or I-005 (A15) - Battery No continuity positive RT21065065 E-033 E-033 (17) or I-005 (A14) - Body No continuity ground E-033 (17) or I-005 (A14) - Battery No continuity positive Repair or replace CAN line 06– Chery Automobile Co., Ltd.
  • Page 345 Refer to "DTC Confirmation Procedure". c. Check if DTC U0155-87 still exists. Check or replace BCM and ICM System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 346 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 ET21065023 06– Chery Automobile Co., Ltd.
  • Page 347 Check ECM connector, A/C control panel connector and BCM connector a. Disconnect ECM connector E-033. b. Disconnect A/C control panel connector K-012. c. Disconnect BCM connector I-005. d. Check if connectors are normal. Repair or replace connectors 06– Chery Automobile Co., Ltd.
  • Page 348 E-033 (1) or I-005 (A15) - Battery No continuity positive RT21065065 E-033 E-033 (17) or I-005 (A14) - Body No continuity ground E-033 (17) or I-005 (A14) - Battery No continuity positive Repair or replace CAN line 06– Chery Automobile Co., Ltd.
  • Page 349 Check if DTC U0164-87 still exists. Check or replace BCM and A/C control panel System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 350 20 21 22 23 24 25 26 27 28 29 30 9 10 9 10 11 12 13 14 E-035 E-033 1 2 3 4 5 6 7 8 9 10 14 15 I-018 E-027 ET21065024 06– Chery Automobile Co., Ltd.
  • Page 351 Repair or replace ground wire harness or ground point Check ECM connector and engine immobilizer module connector a. Disconnect ECM connector E-033. b. Disconnect engine immobilizer module connector I-018. c. Check if connectors are normal. Repair or replace connectors 06– Chery Automobile Co., Ltd.
  • Page 352 Refer to "DTC Confirmation Procedure". c. Check if DTC U0167-87 still exists. Replace engine immobilizer module System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 353  When performing circuit diagnosis and test, always refer to the circuit diagram for specific circuit and component information. Diagnosis Procedure Check ECM ground point a. Turn ignition switch to LOCK. b. Check ECM grounds E-026 and E-028 (See page 06-18). Repair or replace ground wire harness or ground point 06– Chery Automobile Co., Ltd.
  • Page 354 Check intake/exhaust VVT control valves. Specified Multimeter Connection Condition Terminal 1 - Terminal 2 8 Ω d. When battery voltage is applied between terminals 1 and 2, control valve should move quickly. RT21060211 Replace intake/exhaust VVT control valve 06– Chery Automobile Co., Ltd.
  • Page 355 Refer to "DTC Confirmation Procedure". c. Check if DTC P000A-00 or P000B-00 still exists. Replace ECM System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 356 E-033 13 14 15 16 17 18 19 20 21 22 17 18 19 20 21 22 23 24 25 26 27 28 29 30 9 10 9 10 11 12 13 14 E-035 ET21065025 06– Chery Automobile Co., Ltd.
  • Page 357 Turn ignition switch to LOCK. b. Check ECM grounds E-026 and E-028 (See page 06-18). Repair or replace ground wire harness or ground point Check VVT control valve connector a. Disconnect intake VVT control valve connector E-006. RT21070520 06– Chery Automobile Co., Ltd.
  • Page 358 Check voltage between connector terminals and body ground. Multimeter Specified Condition Connection Condition E-006 (1) - Body ground Ignition switch ON 11 to 14 V E-006 E-008 (1) - Body E-008 ground Go to step 5 RT21065070 06– Chery Automobile Co., Ltd.
  • Page 359 Always No continuity Body ground E-006 (1), E-008 (1) or E-023 (C3) - Always No continuity Battery positive Repair or replace wire harness or connector (VVT control valve - engine compartment fuse and relay box) 06– Chery Automobile Co., Ltd.
  • Page 360 Check intake/exhaust VVT control valves. Specified Multimeter Connection Condition Terminal 1 - Terminal 2 8 Ω c. When battery voltage is applied between terminals 1 and 2, control valve should move quickly. RT21060211 Replace intake/exhaust VVT control valve 06– Chery Automobile Co., Ltd.
  • Page 361 Refer to "DTC Confirmation Procedure". c. Check if DTC P0010-00 or P0013-00 still exists. Replace ECM System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 362  When performing circuit diagnosis and test, always refer to the circuit diagram for specific circuit and component information. Diagnosis Procedure Check ECM ground point a. Turn ignition switch to LOCK. b. Check ECM grounds E-026 and E-028 (See page 06-18). Repair or replace ground wire harness or ground point 06– Chery Automobile Co., Ltd.
  • Page 363 Refer to "DTC Confirmation Procedure". c. Check if DTC P0012-00 or P0015-00 still exists. Replace ECM System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 364 17 18 19 20 21 22 23 24 25 26 27 28 29 30 13 14 15 16 17 18 19 20 21 22 9 10 11 12 13 14 9 10 E-035 E-033 ET21065026 06– Chery Automobile Co., Ltd.
  • Page 365  When performing circuit diagnosis and test, always refer to the circuit diagram for specific circuit and component information. Diagnosis Procedure Check ECM ground point a. Turn ignition switch to LOCK. b. Check ECM grounds E-026 and E-028 (See page 06-18). Repair or replace ground wire harness or ground point 06– Chery Automobile Co., Ltd.
  • Page 366 Go to step 8 Check camshaft position sensor connector a. Disconnect intake camshaft position sensor connector E-020 (1). b. Disconnect exhaust camshaft position sensor connector E-015 (2). c. Check camshaft position sensor connectors. Repair or replace connector RT21060351 06– Chery Automobile Co., Ltd.
  • Page 367 (3) or E-035 (34) - Always No continuity Body ground E-020 (3), E-015 (3) or E-035 (34) - Always No continuity Battery positive Repair or replace wire harness or connector (camshaft position sensor - ECM) 06– Chery Automobile Co., Ltd.
  • Page 368 E-035 (41) - Battery positive E-020 (1), E-015 (1) or E-035 (31) - Body ground E-020 (1), E-015 (1) or E-035 (31) - Battery positive Replace wire harness or connector (camshaft position sensor - ECM) 06– Chery Automobile Co., Ltd.
  • Page 369 Go to step 15 Check engine speed sensor connector a. Turn ignition switch to LOCK. b. Disconnect engine speed sensor connector E-016. c. Check engine speed sensor connector. Repair or replace engine speed sensor connector 06– Chery Automobile Co., Ltd.
  • Page 370 37 38 39 40 41 42 43 44 45 46 E-016 (2) - E-035 25 26 27 28 29 30 31 32 33 34 (33) 13 14 15 16 17 18 19 20 21 22 9 10 E-035 RT21065042 06– Chery Automobile Co., Ltd.
  • Page 371 Rotate crankshaft, and check crankshaft and flywheel gear ring for damage, foreign matter, etc. that cause signal incorrectness. Clear off debris and clean flywheel gear ring. Replace flywheel if necessary (See page 07-42) Check engine timing a. Check for timing deviation. Correct engine timing 06– Chery Automobile Co., Ltd.
  • Page 372 Refer to "DTC Confirmation Procedure". c. Check if DTC P0016-00 or P0018-00 still exists. Replace ECM System is operating normally. Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has been repaired. 06– Chery Automobile Co., Ltd.
  • Page 373 Engine cranks normally but cannot start Engine speed sensor 06-214 successfully while starting Ignition coil Engine mechanical Water in fuel Fuel pump Difficult to start with hot engine Coolant temperature sensor 06-216 Fuel pressure regulator Ignition coil 06– Chery Automobile Co., Ltd.
  • Page 374 Engine starts normally, but idles roughly 06-225 during warming up Throttle Intake pipe Engine mechanical Water in fuel Coolant temperature sensor Spark plug Engine starts normally, but idles roughly 06-227 after warming up Throttle body Intake pipe Engine mechanical 06– Chery Automobile Co., Ltd.
  • Page 375 Ignition timing Exhaust pipe Water in fuel Air flow meter and throttle position sensor Spark plug Ignition coil Lack of power and poor performance when Throttle 06-239 accelerating Intake pipe Injector Ignition timing Exhaust pipe 06– Chery Automobile Co., Ltd.
  • Page 376 Replace lubricant with appropriate number Check engine internal mechanical resistance a. Check if engine internal mechanical resistance is too strong, causing starter motor not to run or run slowly. Check and repair engine internal resistance 06– Chery Automobile Co., Ltd.
  • Page 377 06 - SQR484F ENGINE MANAGEMENT SYSTEM Go to Diagnostic Help 06– Chery Automobile Co., Ltd.
  • Page 378 OK: Spark is generated. Check and repair ignition system Check pressure of cylinder a. Measure compression of misfiring cylinder (See page 07-20). Check engine to confirm cause of low compression 06– Chery Automobile Co., Ltd.
  • Page 379 36 37 38 39 40 41 42 43 44 45 46 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 E-033 RT21065069 Go to Diagnostic Help 06– Chery Automobile Co., Ltd.
  • Page 380 Check and repair ignition system Disconnect coolant temperature sensor connector, start engine and observe if engine starts successfully at this time Check and repair wire harness or replace sensor Check fuel pressure regulator Replace fuel pressure regulator 06– Chery Automobile Co., Ltd.
  • Page 381 36 37 38 39 40 41 42 43 44 45 46 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 E-033 RT21065069 Go to Diagnostic Help 06– Chery Automobile Co., Ltd.
  • Page 382 Disconnect coolant temperature sensor connector, start engine and observe if engine starts successfully at this time Check and repair wire harness or replace sensor Depress accelerator pedal slightly, and observe if it is easy to start Clean throttle 06– Chery Automobile Co., Ltd.
  • Page 383 36 37 38 39 40 41 42 43 44 45 46 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 E-033 RT21065069 Go to Diagnostic Help 06– Chery Automobile Co., Ltd.
  • Page 384 Check spark a. Remove ignition coil and spark plug of one cylinder, and ground spark plug housing. Start the engine, and check if spark is generated. OK: Spark is generated. Check and repair ignition system 06– Chery Automobile Co., Ltd.
  • Page 385 (See page 07-20). Check engine to confirm cause of low compression Check engine ignition sequence and ignition timing a. Check if engine ignition sequence and ignition timing are as specified. Check and repair ignition timing 06– Chery Automobile Co., Ltd.
  • Page 386 36 37 38 39 40 41 42 43 44 45 46 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 E-033 RT21065069 Go to Diagnostic Help 06– Chery Automobile Co., Ltd.
  • Page 387 Replace spark plug Check throttle for carbon deposits Clean throttle Check injector for leakage or blockage Clean or replace injector Check fuel condition a. Observe if trouble occurs just after fuel is filled. Replace fuel 06– Chery Automobile Co., Ltd.
  • Page 388 36 37 38 39 40 41 42 43 44 45 46 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 E-033 RT21065069 Go to Diagnostic Help 06– Chery Automobile Co., Ltd.
  • Page 389 Check and repair wire harness or replace sensor Check injector for leakage or blockage Clean or replace injector Check fuel condition a. Observe if trouble occurs just after fuel is filled. Replace fuel 06– Chery Automobile Co., Ltd.
  • Page 390 36 37 38 39 40 41 42 43 44 45 46 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 E-033 RT21065069 Go to Diagnostic Help 06– Chery Automobile Co., Ltd.
  • Page 391 Check and repair wire harness or replace sensor Check injector for leakage or blockage Clean or replace injector Check fuel condition a. Observe if trouble occurs just after fuel is filled. Replace fuel 06– Chery Automobile Co., Ltd.
  • Page 392 36 37 38 39 40 41 42 43 44 45 46 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 E-033 RT21065069 Go to Diagnostic Help 06– Chery Automobile Co., Ltd.
  • Page 393 HIGH-level signal with A/C ON Check and repair A/C system Check if A/C system pressure, compressor magnetic clutch and A/C compressor pump are normal Check and repair A/C system Check injector for leakage or blockage Clean or replace injector 06– Chery Automobile Co., Ltd.
  • Page 394 36 37 38 39 40 41 42 43 44 45 46 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 E-033 RT21065069 Go to Diagnostic Help 06– Chery Automobile Co., Ltd.
  • Page 395 Disconnect coolant temperature sensor connector, start engine and observe if engine idles normally at this time Check and repair wire harness or replace sensor Check engine ignition timing a. Check if engine ignition timing is as specified. Check and repair ignition timing 06– Chery Automobile Co., Ltd.
  • Page 396 36 37 38 39 40 41 42 43 44 45 46 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 E-033 RT21065069 Go to Diagnostic Help 06– Chery Automobile Co., Ltd.
  • Page 397 Check spark plug of each cylinder, and observe if the type and gap are as specified. Replace spark plug Check throttle for carbon deposits Clean throttle Check air flow meter and throttle position sensor and wire harness Check and repair wire harness or replace sensor 06– Chery Automobile Co., Ltd.
  • Page 398 Check if engine ignition sequence and ignition timing are as specified. Check and repair ignition timing Check exhaust system a. Check exhaust system for leakage or blockage. Repair or replace related exhaust system components 06– Chery Automobile Co., Ltd.
  • Page 399 36 37 38 39 40 41 42 43 44 45 46 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 E-033 RT21065069 Go to Diagnostic Help 06– Chery Automobile Co., Ltd.
  • Page 400 Check spark plug of each cylinder, and observe if the type and gap are as specified. Replace spark plug Check throttle for carbon deposits Clean throttle Check air flow meter and throttle position sensor and wire harness Check and repair wire harness or replace sensor 06– Chery Automobile Co., Ltd.
  • Page 401 Check if engine ignition sequence and ignition timing are as specified. Check and repair ignition timing Check exhaust system a. Check exhaust system for leakage or blockage. Repair or replace related exhaust system components 06– Chery Automobile Co., Ltd.
  • Page 402 36 37 38 39 40 41 42 43 44 45 46 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 E-033 RT21065069 Go to Diagnostic Help 06– Chery Automobile Co., Ltd.
  • Page 403 Check spark plug of each cylinder, and observe if the type and gap are as specified. Replace spark plug Check spark a. Remove ignition coil and spark plug of one cylinder, and ground spark plug housing. Start the engine, and check if spark is generated. OK: Spark is generated. 06– Chery Automobile Co., Ltd.
  • Page 404 Check if engine ignition sequence and ignition timing are as specified. Check and repair ignition timing Check exhaust system a. Check exhaust system for leakage or blockage. Repair or replace related exhaust system components 06– Chery Automobile Co., Ltd.
  • Page 405 36 37 38 39 40 41 42 43 44 45 46 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 E-033 RT21065069 Go to Diagnostic Help 06– Chery Automobile Co., Ltd.
  • Page 406 Disconnect intake VVT control valve connector. RT21070520 b. Remove intake VVT control valve fixing bolt and intake VVT control valve. (Tightening torque: 8 ± 2 N·m) RT21060310 Installation Installation is in the reverse order of removal. 06– Chery Automobile Co., Ltd.
  • Page 407 5. Remove coolant temperature sensor. a. Disconnect coolant temperature sensor connector and remove coolant temperature sensor. (Tightening torque: 11 - 16 N·m) RT21060320 WARNING  Remove the coolant temperature sensor when engine cools down to avoid scalding injury. 06– Chery Automobile Co., Ltd.
  • Page 408 Installation is in the reverse order of removal. CAUTION  Perform sealing with anaerobic seal gum.  Confirm that the sensor is tightened fully during installation.  After installing engine coolant temperature sensor, add coolant and check coolant level. 06– Chery Automobile Co., Ltd.
  • Page 409 Disconnect knock sensor connector, and move away the knock sensor cable from bracket. RT21060330 b. Remove intake manifold assembly (See page 10-24). c. Remove knock sensor fixing bolt and knock sensor. (Tightening torque: 20 ± 5 N·m) RT21060340 06– Chery Automobile Co., Ltd.
  • Page 410  DO NOT apply lubricant, grease or seal gum when installing knock sensor. Keep engine block clean and dry, and never allow any foreign matter (such as oil) on the installation area of knock sensor.  Never tap knock sensor when installing it. 06– Chery Automobile Co., Ltd.
  • Page 411 Engine Control Module (ECM) calculates the efficiency of catalytic converter. Removal & Installation - Upstream Oxygen Sensor (See page 09-13) Removal & Installation - Downstream Oxygen Sensor (See page 09-15) 06– Chery Automobile Co., Ltd.
  • Page 412 Remove intake camshaft position sensor and exhaust camshaft position sensor. Installation Installation is in the reverse order of removal. CAUTION  The sensor should be pressed into mounting hole. Never use tools (such as a hammer) to strike the sensor into mounting hole forcibly. 06– Chery Automobile Co., Ltd.
  • Page 413 Remove engine speed sensor fixing bolt and engine speed sensor. (Tightening torque: 8 ± 2 N·m) RT21060370 Installation Installation is in the reverse order of removal. CAUTION  Press in the engine speed sensor rather than tap when installing it. 06– Chery Automobile Co., Ltd.
  • Page 414 IH must increase to keep hot-wire resistance and temperature difference of air sucked invariant and at a fixed value. Therefore, hot-wire current IH is function of air mass flow. Removal & Installation (See page 10-13) 06– Chery Automobile Co., Ltd.
  • Page 415 Engine Control Module (ECM) signal. If Engine Control Module (ECM) cuts off the control signal to primary winding circuit, it will stop charging and a high voltage will be induced in the secondary winding. Removal & Installation (See page 14-10) 06– Chery Automobile Co., Ltd.
  • Page 416 When engine stops running because of an accident, the fuel pump stops running automatically. The maximum pressure at electric fuel pump outlet is adjusted by pressure regulator to keep the whole fuel system pressure at 400 kPa. Removal & Installation (See page 08-14) 06– Chery Automobile Co., Ltd.
  • Page 417 The pressure of return spring forces the needle to close again when injection pulse stops. Removal & Installation (See page 08-26) 06– Chery Automobile Co., Ltd.
  • Page 418 (NLP) determined in a mechanical way when a malfunction occurs. The electronic throttle assembly consists of four parts: drive module, train module, executive module and feedback module, and all components are integrated into the same throttle valve housing. Removal & Installation (See page 10-20) 06– Chery Automobile Co., Ltd.
  • Page 419 Engine Control Module (ECM) and pressure difference between canister inlet and outlet. When there is no electric pulse, the canister solenoid valve closes. Removal & Installation (See page 09-7) 06– Chery Automobile Co., Ltd.
  • Page 420 For MT model, disconnect 2 ECM connectors (1). For CVT model, disconnect 2 ECM connector (1) and TCU connector (2). RT21060390 c. Remove ECM bracket fixing nuts (arrow). (Tightening torque: 7 ± 1 N·m) RT21060400 06– Chery Automobile Co., Ltd.
  • Page 421 Installation is in the reverse order of removal. CAUTION  Pay attention to static electricity protection when installing.  Take care to protect connector pins.  To prevent water droplets from accumulating on connector joint, face it down. 06– Chery Automobile Co., Ltd.
  • Page 422 - MEMO - 06– Chery Automobile Co., Ltd.

  • Page 423: Sqr484F Engine Mechanical

    Crankshaft Front Oil Seal 07-39 Disassembly 07-80 Removal 07-39 Inspection 07-86 Installation 07-40 Selection of Bearing Shell 07-93 Flywheel 07-42 Selection of Connecting Rod  Removal 07-42 Bearing Shell 07-94 Inspection 07-42 Assembly 07-94 Installation 07-43 07– Chery Automobile Co., Ltd.
  • Page 424 07– Chery Automobile Co., Ltd.
  • Page 425 Electrical control Ignition Sequence 1 - 3 - 4 - 2 Idle Speed (r/min) 750 ± 50 Rated Power (kW) Rated Power Speed (r/min) 5750 Max. Torque (N·m) Max. Torque Speed (r/min) 4300 - 4500 07– Chery Automobile Co., Ltd.
  • Page 426 With atmospheric temperature at -25°C, engine can start smoothly within 30 seconds without taking special measures. Starting test shows that Starting Performance staring can be performed 3 times consecutively. If it fails to start once, perform starting again after 2 minutes. 07– Chery Automobile Co., Ltd.
  • Page 427 Side Clearance (mm) Second Ring 0.025 - 0.070 First Ring 0.2 - 0.4 End Gap (mm) Piston Ring Second Ring 0.4 - 0.6 -0.01 First Ring -0.05 -0.006 Height (mm) Second Ring -0.050 Oil Ring 07– Chery Automobile Co., Ltd.
  • Page 428 Cylindricity (mm) 0.01 Upper Surface Flatness (mm) 0.04 Surface Grinding Limit Grinding is not permitted Connecting Rod Big End Radial Clearance (mm) 0.021 - 0.056 Connecting Rod Big End Axial Clearance (mm) 0.15 - 0.40 07– Chery Automobile Co., Ltd.
  • Page 429 Locking Nut for Through Bolt Between Rear Mounting Bracket and Rear Mounting Cushion 70 ± 5 Assembly (for MT Model) Coupling Bolt Between Rear Mounting Bracket and 55 ± 5 Transmission Case (for MT Model) 07– Chery Automobile Co., Ltd.
  • Page 430 Assembly Bracket and Engine Block Coupling Nut Between Shift Cable and Shift Arm (for 18 ± 2 CVT Model) Coupling Plug Between Pipe II Assembly and Clutch 16 ± 2 Release Cylinder Bracket II Fixing Bolt 15 ± 2 07– Chery Automobile Co., Ltd.
  • Page 431 1st step: 25 ± 3 Connecting Rod Bearing Cap Fixing Bolt 2nd step: 90° ± 5° Crankshaft Frame Fixing Bolt 20 + 3 1st step: 45 ± 5 Main Bearing Cap Fixing Bolt 2nd step: 180° ± 10° 07– Chery Automobile Co., Ltd.
  • Page 432 Valve Guide or Guide Bottom Hole (Cylinder Head) SM10W-40 Camshaft Oil Seal Lip and Camshaft Journal SM10W-40 Oil Filter Gasket Surface SM10W-40 All engine lubricants should be 5W-40 (for winter)/10W-40 (for summer) SM grade or higher. 07– Chery Automobile Co., Ltd.
  • Page 433 Coolant Temperature Sensor Loctite 243 Oil Pressure Sensor Loctite 577 Camshaft Variable Valve Timing Control Valve Loctite 243 Oil Deflector Bolt Loctite 243 Oil Pump Mounting Bolt Loctite 5910 Timing Gear Rear Cover Fixing Screw Loctite 243 07– Chery Automobile Co., Ltd.
  • Page 434 07 - SQR484F ENGINE MECHANICAL Tools Special Tools Crankshaft Front Oil Seal Guide Tool RCH0000049 Crankshaft Front Oil Seal Installer RCH0000067 Camshaft Oil Seal Installer RCH0000017 Valve Spring Compression Adapter RCH0000050 Valve Spring Compressor RCH0000028 07– Chery Automobile Co., Ltd.
  • Page 435 07 - SQR484F ENGINE MECHANICAL Crankshaft Rear Oil Seal Installer RCH0000031 Valve Oil Seal Installer RCH0000034 Valve Oil Seal Guide Sleeve RCH0000035 Clutch Pressure Plate Installer RCH0000018 Valve Oil Seal Remover RCH0000037 07– Chery Automobile Co., Ltd.
  • Page 436 07 - SQR484F ENGINE MECHANICAL Valve Cotter Installer RCH0000029 Flywheel Holding Tool RCH0000040 Oil Filter Remover RCH0000054 Camshaft Timing Tool RCH0000033 Crankshaft Timing Tool RCH0000027 07– Chery Automobile Co., Ltd.
  • Page 437 07 - SQR484F ENGINE MECHANICAL General Tools Piston Installer RCH0000039 Dial Indicator and Magnetic Holder RCH0000023 Outer Diameter Micrometer 0.01mm 75mm RCH0000064 Vernier Caliper RCH0000019 Precision Ruler RCH0000063 07– Chery Automobile Co., Ltd.
  • Page 438 07 - SQR484F ENGINE MECHANICAL Feeler Gauge RCH0000060 Cylinder Gauge RCH0000065 Caliper Gauge RCH0000069 Digital Multimeter RCH0000002 Flexional Magnetic Rod RCH0000042 07– Chery Automobile Co., Ltd.
  • Page 439 07 - SQR484F ENGINE MECHANICAL Engine Hoist RCH0000043 Engine Equalizer RCH0000026 Transmission Carrier RCH0000005 Fuel System Pressure Tester RCH0000048 Cylinder Pressure Gauge RCH0000044 07– Chery Automobile Co., Ltd.
  • Page 440 07 - SQR484F ENGINE MECHANICAL Engine Service Platform RCH0000057 07– Chery Automobile Co., Ltd.
  • Page 441 Flywheel or clutch (loose) 07-42 Piston ring (worn, scratched or damaged) 07-84 Piston ring groove (fouled) 07-87 Oil loss or spark plug blockage Valve oil seal (worn or damaged) 07-57 Valve (excessive clearance between valve 07-60 and guide) 07– Chery Automobile Co., Ltd.
  • Page 442  Loosen the high-voltage cables (1) in order, pull them upward from spark plug holes, and move them to one side. RT21140110 CAUTION  Be careful not to damage high-voltage cables when pulling them upward. 07– Chery Automobile Co., Ltd.
  • Page 443 If pressure remains low, the valve may be stuck or not properly installed or there is air leakage from cylinder head gasket. i. Install the spark plug (See page 14-12). j. Connect all fuel injector connectors (See page 08-26). k. Install the high-voltage cables. 07– Chery Automobile Co., Ltd.
  • Page 444 Engine stall Low fuel economy  Possible indications of cylinder head gasket leakage between cylinder and adjacent water jacket are as follows: Engine overheat Coolant loss Excessive steam (white smoke) emitted from exhaust system Coolant foaming 07– Chery Automobile Co., Ltd.
  • Page 445 2 - Upper Idler Pulley 3 - A/C Compressor 4 - Lower Idler Pulley 5 - Accessory Drive Belt 6 - Power Steering Pump Pulley 7 - Crankshaft Pulley 8 - Accessory Drive Belt Tensioner 07– Chery Automobile Co., Ltd.
  • Page 446  After installing the accessory drive belt, check that it fits properly in the ribbed grooves. Check that the belt has not slipped out of grooves on the bottom of the crankshaft pulley by hand. Right Wrong Wrong RT21070030 07– Chery Automobile Co., Ltd.
  • Page 447 5 ~ 6 mm 100 N Check that the displacement of belt should be within  5 - 6 mm. If the displacement is too large or too small, adjust or repair. RT21070040 07– Chery Automobile Co., Ltd.
  • Page 448  After installation, turn crankshaft with a wrench to run accessory drive belt several circles, and check if crankshaft turns smoothly and belt runs well. If it does not turn smoothly, reinstall the accessory drive belt.  Make sure to install accessory drive belt in place, and not interfere with other components. 07– Chery Automobile Co., Ltd.
  • Page 449  After installation, turn crankshaft with a wrench to run accessory drive belt several circles, and check if crankshaft turns smoothly and belt runs well. If it does not turn smoothly, reinstall the accessory drive belt.  Make sure to install accessory drive belt in place, and not interfere with other components. 07– Chery Automobile Co., Ltd.
  • Page 450 15 - Camshaft Timing Pulley Fixing Bolt Washer 16 - Timing Belt Front Cover Lower Body 17 - Timing Belt Front Cover Lower Body Gasket 18 - Water Pump Assembly 19 - Water Pump Assembly Gasket 20 - Semi-circle Key 07– Chery Automobile Co., Ltd.
  • Page 451 (Tightening torque: 40 + 5 N·m) d. Loosen and remove 6 fixing bolts (arrow) from timing belt front cover lower body, and remove the timing belt front cover lower body (2). (Tightening torque: 7 N·m) RT21070100 07– Chery Automobile Co., Ltd.
  • Page 452 RT21070130 CAUTION  This operation needs patience, and exercise extreme care not to damage the crankshaft.  When crankshaft is stuck completely, pistons in 4 cylinders of engine are at the same level. 07– Chery Automobile Co., Ltd.
  • Page 453 Belt worn: as shown in the illustration (6). d. Belt teeth missing and damaged: as shown in the illustration (4) and (6). RT21070150 CAUTION  Check timing belt carefully before installation. If any of above conditions occurs, replace the timing belt. 07– Chery Automobile Co., Ltd.
  • Page 454 (1) with a torque wrench in the direction of arrow as shown in the illustration.  (Tightening torque: 120 ± 5 N·m) RT21070171 CAUTION  Loosen exhaust camshaft phaser assembly without removing it. 07– Chery Automobile Co., Ltd.
  • Page 455 (3) and timing belt idler pulley (4) are at outside of tooth. RT21070190 4. Install the timing belt tensioner. a. Install the fixing bolt to timing belt tensioner by hand, and do not tighten the fixing bolt of timing belt tensioner. 07– Chery Automobile Co., Ltd.
  • Page 456 7. Tighten the exhaust camshaft phaser assembly (1) fixing bolt. (Tightening torque: 120 ± 5 N·m) RT21070221 8. Remove the camshaft locking special tool. 9. Remove the crankshaft timing tool, and install the plug. (Tightening torque: 40 + 5 N·m) 07– Chery Automobile Co., Ltd.
  • Page 457 Tighten the exhaust/intake camshaft phaser assembly fixing bolt. f. Remove the camshaft locking special tool. g. Remove the crankshaft timing tool. 11. Tighten the intake/exhaust phaser covers. (Tightening torque: 30 N·m) 12.Other installation procedures are in the reverse order of removal. 07– Chery Automobile Co., Ltd.
  • Page 458 (1) with a torque wrench in the direction of arrow as shown in the illustration, and remove the exhaust camshaft phaser assembly.  (Tightening torque: 120 ± 5 N·m) RT21070171 07– Chery Automobile Co., Ltd.
  • Page 459 Using a flat tip screwdriver wrapped with tape, pry out the exhaust camshaft oil seal (1) and intake camshaft oil seal (2) carefully. RT21070230 CAUTION  Be careful not to damage the oil seal retainer and surface of camshaft when removing camshaft oil seal. 07– Chery Automobile Co., Ltd.
  • Page 460  Procedures listed below are for intake camshaft oil seal. a. Using a special tool (camshaft oil seal installer) (1), install the intake camshaft oil seal (2) to intake camshaft (3). RT21070240 2. Other installation procedures are in the reverse order of removal. 07– Chery Automobile Co., Ltd.
  • Page 461 (3), lining (4) and semi-circle key (5) in order. RT21070260 CAUTION  Semi-circle key is small, so it is easy to be ignored. During installation, pay thorough attention not to forget to install. 07– Chery Automobile Co., Ltd.
  • Page 462 5. Using a brass bar, install the semi-circle key (5) in place. HINT: Protrusion height of semi-circle key should be 2.2 - 2.3 6. Install the crankshaft timing pulley (3), washer (2) and bolt (1) in order. RT21070260 07– Chery Automobile Co., Ltd.
  • Page 463 7. Tighten the crankshaft timing pulley fixing bolt (arrow). (Tightening torque: 1st step: tighten to 130 ± 10 N·m; 2nd step: retighten by 65° ± 5°) RT21070250 8. Other installation procedures are in the reverse order of removal. 07– Chery Automobile Co., Ltd.
  • Page 464 2. Check if starter drive gear ring is worn. If excessively worn, replace the flywheel. 3. Check contact surface of clutch lining. If the contact surface is damaged or excessively worn, replace the flywheel with a new one. 07– Chery Automobile Co., Ltd.
  • Page 465 3. Install the flywheel fixing bolts (arrow), and then hold the flywheel securely with the flywheel holding tool (1). Tighten the flywheel fixing bolts. (Tightening torque: 1st step: tighten to 35 ± 5 N·m; 2nd step: retighten by 45° ± 5°) RT21070290 07– Chery Automobile Co., Ltd.
  • Page 466 (1). RT21070300 CAUTION  Be careful not to damage surrounding parts and oil seal retainer when removing oil seal.  Be careful not to damage oil pan gasket when removing rear oil seal bracket. 07– Chery Automobile Co., Ltd.
  • Page 467 (2) with the part number side facing outward. HINT: Apply a coat of engine oil to the rear oil seal lip or crankshaft rear oil seal journal. RT21070301 3. Other installation procedures are in the reverse order of removal. 07– Chery Automobile Co., Ltd.
  • Page 468 (Tightening torque: 8 ± 0.5 N·m) h. Remove the fixing bolt (3) from exhaust camshaft position sensor and remove the exhaust camshaft position sensor (4) from cylinder head cover.  (Tightening torque: 8 ± 0.5 N·m) RT21070330 07– Chery Automobile Co., Ltd.
  • Page 469 Avoid gasket falling out from groove during installation. RT21070360 4. Apply seal gum to connecting part of camshaft 1st bearing cap and cylinder head cover in the oval areas as shown in the illustration. RT21070370 07– Chery Automobile Co., Ltd.
  • Page 470 First screw the bolts in order until they press against the cylinder head and fit closely with cylinder head, then tighten them again to the specified torque in order. RT21070380 6. Other Installation procedures are in the reverse order of removal. 07– Chery Automobile Co., Ltd.
  • Page 471 07 - SQR484F ENGINE MECHANICAL Camshaft Description ×4 ×8 ×8 ×4 ×4 ×4 ×4 RT21070390 07– Chery Automobile Co., Ltd.
  • Page 472 (1) with a torque wrench in the direction of arrow as shown in the illustration, and remove the exhaust phaser cover. (Tightening torque: 30 N·m) RT21070170 07– Chery Automobile Co., Ltd.
  • Page 473 (Tightening torque: 120 ± 5 N·m) RT21070181 11. Remove the timing belt rear cover. a. Remove the timing belt idler pulley fixing bolt (arrow) and remove the timing belt idler pulley.  (Tightening torque: 40 + 5 N·m) RT21070400 07– Chery Automobile Co., Ltd.
  • Page 474 Remove the intake camshaft oil seal and exhaust camshaft oil seal separately. 13. Remove the rocker arm and hydraulic lifter. a. Remove the rocker arm with hydraulic lifter assembly (1) in the direction of arrow as shown in the illustration. RT21070440 07– Chery Automobile Co., Ltd.
  • Page 475 Turn the dial of dial indicator to reset it to zero.  Push camshaft forward and backward gently (do not rotate camshaft) and read the value from dial indicator. RT21070480 07– Chery Automobile Co., Ltd.
  • Page 476 4. Tighten the camshaft bearing cap fixing bolts in the order shown in the illustration. RT21070500 5. Install the camshaft oil seals (See page 07-38). 6. Other installation procedures are in the reverse order of removal. 07– Chery Automobile Co., Ltd.
  • Page 477 6 - Valve Guide 7 - Cylinder Head Fixing Bolt 8 - Cylinder Head Fixing Bolt Washer 9 - Cylinder Head 10 - Stud 11 - Cylinder Gasket 12 - Exhaust Valve 13 - Intake Valve 07– Chery Automobile Co., Ltd.
  • Page 478 19.Remove the cylinder head cover (See page 07-46). 20.Remove the exhaust camshaft phaser assembly (See page 07-50). 21.Remove the intake camshaft phaser assembly (See page 07-51). 22.Remove the timing belt rear cover (See page 07-51). 07– Chery Automobile Co., Ltd.
  • Page 479 2. Remove the rocker arm and hydraulic lifter (See page 07-52). 3. Using a special tool (valve spring compressor) (1), compress the valve spring and remove the valve cotter (2) with a flexional magnetic rod. RT21070550 07– Chery Automobile Co., Ltd.
  • Page 480 Cylinder head flatness must be within 0.04 mm. Specification Measurement Item (mm) Cylinder Head Flatness 0.04 If cylinder head flatness is not within the specified RT21070580 range, repair or replace cylinder head. 07– Chery Automobile Co., Ltd.
  • Page 481 Check valve height. Using a micrometer, measure valve height. Specification Measurement Item (mm) Total Height Intake Valve Height 107.998 Exhaust Valve Height 106.318 If height is less than specified value, replace the valve. RT21070584 07– Chery Automobile Co., Ltd.
  • Page 482 Specification Measurement Item (mm) Clearance Between Intake Valve and 0.012 - 0.043 Guide Clearance Between Exhaust Valve 0.032 - 0.063 and Guide If clearance is not within the specified range, replace valve or valve guide. 07– Chery Automobile Co., Ltd.
  • Page 483 Install the valve oil seal (4) to the valve oil seal guide sleeve. RT21070589 c. Tap the valve oil seal installer lightly with a rubber hammer to install the valve oil seal in place. 07– Chery Automobile Co., Ltd.
  • Page 484 6. Using a valve spring compressor, compress the valve spring and install the valve cotter (3) in place. RT21070591 7. Tap valve cotter lightly with a rubber hammer to make sure the cotter is installed in place after assembly. 07– Chery Automobile Co., Ltd.
  • Page 485  Check cylinder head fixing bolts before installation. If they are damaged, replace immediately.  Be sure to tighten cylinder head bolts by following the operating procedures above strictly to achieve the technology standard for vehicle usage. 2. Other installation procedures are in the reverse order of removal. 07– Chery Automobile Co., Ltd.
  • Page 486 5. Remove the engine rear mounting bracket (for MT model). a. Remove 3 coupling bolts (arrow) between rear mounting bracket and transmission case. (Tightening torque: 55 ± 5 N·m) RT21070620 b. Remove the engine rear mounting bracket from transmission case. 07– Chery Automobile Co., Ltd.
  • Page 487 Remove 3 coupling bolts (arrow) between rear mounting bracket and transmission case. (Tightening torque: 80 ± 6 N·m) RT21070623 b. Remove the engine rear mounting bracket from transmission case. 8. Installation is in the reverse order of removal. 07– Chery Automobile Co., Ltd.
  • Page 488 Remove 2 coupling bolts (arrow) between front mounting bracket and transmission case. (Tightening torque: 55 ± 5 N·m) RT21070650 b. Remove the engine front mounting bracket from transmission case. 7. Installation is in the reverse order of removal. 07– Chery Automobile Co., Ltd.
  • Page 489 8. Remove the engine left mounting bracket (for MT model). a. Remove 3 fixing nuts (arrow) between left mounting bracket and transmission case. (Tightening torque: 80 ± 6 N·m) RT21070670 b. Remove the left mounting bracket. 07– Chery Automobile Co., Ltd.
  • Page 490 3. Remove the engine trim cover assembly (See page 10-10). 4. Remove the engine lower right protector assembly (See page 48-29). 5. Use an engine equalizer to hang the engine. 6. Remove the engine right mounting cushion assembly. 07– Chery Automobile Co., Ltd.
  • Page 491 Remove 3 fixing bolts (arrow) from right mounting cushion assembly. (Tightening torque: 55 ± 5 N·m) RT21070691 b. Remove the engine right mounting bracket assembly. 8. Installation is in the reverse order of removal. 07– Chery Automobile Co., Ltd.
  • Page 492 (2) on right side between precatalytic converter assembly bracket and cylinder block (Tightening torque for coupling bolt on left side:  23 ± 2 N·m; Tightening torque for coupling bolt on right side: 50 ± 5 N·m). RT21110100 07– Chery Automobile Co., Ltd.
  • Page 493 RT21070711 26.Disconnect the connection between vacuum pipe and vacuum booster. a. Move the vacuum pipe away from vacuum booster in the direction of arrow as shown in the illustration. RT21070720 07– Chery Automobile Co., Ltd.
  • Page 494 30.Move away the gear select and shift cable (for MT model). a. Remove the cotter pins (arrow) connecting gear select and shift cable and transmission gear shift control mechanism. RT21070750 07– Chery Automobile Co., Ltd.
  • Page 495 32.Disconnect the connection of clutch hydraulic line (for MT model). a. Loosen the coupling plug (arrow) and disconnect the connection between clutch release cylinder pipe II assembly and clutch release cylinder. (Tightening torque: 16 ± 2 N·m) RT21070770 07– Chery Automobile Co., Ltd.
  • Page 496 (for MT model). (Tightening torque: 15 ± 2 N·m) RT21070790 b. Remove the transmission ground wire fixing bolt (arrow) and move away the transmission ground wire (for CVT model). (Tightening torque: 15 ± 2 N·m) RT21070791 07– Chery Automobile Co., Ltd.
  • Page 497 (1). RT21070800 b. Remove the battery wire harness ground wire fixing bolt (arrow) and move away the battery wire harness ground wire. RT21070810 07– Chery Automobile Co., Ltd.
  • Page 498 40.Remove the engine front mounting assembly (See page 07-66). 41.Remove the engine equalizer and use an engine hoist to hang the lifting eyes on both sides of the engine. 42.Remove the engine left mounting cushion assembly (See page 07-67). 07– Chery Automobile Co., Ltd.
  • Page 499 45.Hang the engine with transmission out of engine compartment. 46.Remove the engine wire harness and battery wire harness from engine. 47.Separate the engine and the transmission. 48.Install the engine on the engine service platform. Installation Installation is in the reverse order of removal. 07– Chery Automobile Co., Ltd.
  • Page 500 RT21070860 1 - Cylinder Head Gasket 2 - Cylinder Block 3 - Crankshaft Main Bearing Upper Shell 4 - Thrust Washer 5 - Crankshaft 6 - Crankshaft Main Bearing Lower Shell 7 - Crankshaft Frame 07– Chery Automobile Co., Ltd.
  • Page 501 6 - Connecting Rod Bearing Cap 7 - Connecting Rod Fixing Bolt 8 - First Compression Ring 9 - Second Compression Ring 10 - Upper Rail 11 - Oil Ring Expander 12 - Lower Rail 07– Chery Automobile Co., Ltd.
  • Page 502 14.Remove the small circulation metal tube. a. Remove the small circulation metal tube fixing bolt (2). (Tightening torque: 20 ± 5 N·m) RT21070890 b. Remove the small circulation metal tube from engine. 07– Chery Automobile Co., Ltd.
  • Page 503 (Tightening torque: 40 + 5 N·m) b. Remove the oil cooler bracket with oil pressure switch assembly (1). c. Remove the intake manifold lower bracket fixing bolt (2) and remove the intake manifold lower bracket (3). RT21070920 07– Chery Automobile Co., Ltd.
  • Page 504 (See page 12-31). 25.Remove the crankshaft timing pulley. a. Loosen the crankshaft timing pulley fixing bolt (arrow). (Tightening torque: 1st step: tighten to 130 ± 10 N·m; 2nd step: retighten for 30° ± 5°) RT21070250 07– Chery Automobile Co., Ltd.
  • Page 505 Remove the connecting rod bearing cap fixing bolts (arrow), and remove the connecting rod bearing cap. (Tightening torque: 1st step: tighten to 25 ± 3 N·m; 2nd step: retighten for 90° ± 5°) RT21070950 07– Chery Automobile Co., Ltd.
  • Page 506 Piston pin is semi-floating and cannot be assembled by general process after removal, so it is not allowable to be removed in service. If there are abnormal noises caused by improper piston pin clearance, replace the piston connecting rod assembly. 07– Chery Automobile Co., Ltd.
  • Page 507  Take care when removing crankshaft, as it is heavy. If necessary, ask other operators to assist.  Take particular care when removing crankshaft. Avoid scratching the contact surface of crankshaft and bearing shell. 39.Remove the crankshaft thrust washer. a. Remove the crankshaft thrust washers (arrow) from cylinder block. RT21071010 07– Chery Automobile Co., Ltd.
  • Page 508 Cylindricity in axial direction = (maximum bore diameter measured at A, B and C in axial direction - minimum bore diameter measured at A, B and C in axial direction)/2 Compare the maximum value measured at the 2 directions with the standard cylinder cylindricity. Roundness calculation method 07– Chery Automobile Co., Ltd.
  • Page 509 12 mm RT21071040 4. Check piston. a. Using a scraper, remove the carbon deposits on the top of piston. RT21071050 b. Using a piston ring, remove the carbon deposits in the piston ring groove. RT21071060 07– Chery Automobile Co., Ltd.
  • Page 510 Measurement Item (mm) First Ring 0.04 - 0.08 Piston Ring Side Clearance Second Ring 0.025 - 0.070 RT21071090 If piston ring side clearance is not within the specified range, replace the piston connecting rod assembly. 07– Chery Automobile Co., Ltd.
  • Page 511 The cylindricity is the half of the difference between maximum and minimum values among the four values. Cylindricity = (maximum diameter - minimum diameter)/2 Measurement Item Specification (mm) Cylindricity 0.007 Crankshaft Main Journal Roundness 0.04 07– Chery Automobile Co., Ltd.
  • Page 512 Push the crankshaft forward and backward and read the value from the dial indicator. Specification Measurement Item (mm) RT21071140 Crankshaft Axial Clearance 0.070 - 0.265 If crankshaft axial clearance is not within the specified range, replace the thrust washer as a set. 07– Chery Automobile Co., Ltd.
  • Page 513 RT21071170 c. Install the connecting rod bearing caps, and tighten the connecting rod bearing cap fixing bolts to  20 + 5 N·m. CAUTION  DO NOT turn the crankshaft during installation. 07– Chery Automobile Co., Ltd.
  • Page 514 RT21071190 Specification Measurement Item (mm) Connecting Rod Big End Axial 0.15 - 0.40 Clearance If the axial clearance of connecting rod big end is not within the specified range, replace the piston connecting rod assembly. 07– Chery Automobile Co., Ltd.
  • Page 515 Apply a coat of engine oil to the inner surface of main bearing shell before installation. The back side of bearing shell should be clean without any oil or foreign matter during assembly. 07– Chery Automobile Co., Ltd.
  • Page 516 The back side of bearing shell should be clean without any oil or foreign matter during assembly. Assembly 1. Install the crankshaft main bearing shell. CAUTION  Apply a coat of engine oil to the inner surface of main bearing shell before installation. 07– Chery Automobile Co., Ltd.
  • Page 517 (1) face outward while the other side without groove is jointed with the cylinder block inside wall. RT21071010 3. Install the crankshaft. a. Apply seal gum to the installation surface of frame before installation. RT21071210 07– Chery Automobile Co., Ltd.
  • Page 518 Expander compression rings staggered by 120° from the upper rail opening. The piston ring should rotate in the ring Upper Rail groove freely without any stuck condition. RT21071230 07– Chery Automobile Co., Ltd.
  • Page 519 Apply a coat of engine oil to the piston surface and cylinder inside wall. c. As shown in the illustration, install the piston connecting rod assembly to the cylinder with the piston installer (1). RT21071260 07– Chery Automobile Co., Ltd.
  • Page 520 2nd step: retighten for 90° ± 5°) RT21070950 CAUTION  Apply a small amount of engine lubricant to the connecting rod, connecting rod bearing cap and thread joint surface. 8. Other assembly is in the reverse order of disassembly. 07– Chery Automobile Co., Ltd.
  • Page 521 Installation 08-25 Fuel System Pressure Release 08-10 Fuel Rail Injector Assembly 08-26 Fuel Supply System Pressure Test 08-11 Removal 08-26 ON-VEHICLE SERVICE 08-12 Inspection 08-27 Fuel Filter Assembly 08-12 Installation 08-27 Removal 08-12 Installation 08-13 08– Chery Automobile Co., Ltd.
  • Page 522 08– Chery Automobile Co., Ltd.
  • Page 523 08 - SQR484F FUEL SUPPLY SYSTEM GENERAL INFORMATION SQR484F FUEL SUPPLY SYSTEM Description ×3 ×5 RT21080010 08– Chery Automobile Co., Ltd.
  • Page 524 Worm Clamp 3.5 ± 0.5 Fuel Pressure Specifications SQR484F Pressure (kPa) Fuel Pressure on Fuel Rail - Key (ON) Fuel Pressure on Fuel Rail - Engine Idling Fuel Pressure on Fuel Rail - Key (LOCK) 08– Chery Automobile Co., Ltd.
  • Page 525 08 - SQR484F FUEL SUPPLY SYSTEM Tools Special Tool Fuel Tank Pressure Cap Remover RCH0000004 General Tools Digital Multimeter RCH0000002 Fuel System Pressure Tester RCH0000048 Transmission Carrier RCH0000005 08– Chery Automobile Co., Ltd.
  • Page 526 When fuel supply system pressure is high, diaphragm spring in the regulator is jacked up by pressure, then valve opens and fuel flows out from the regulator. When pressure reaches normal value, the regulator shuts off and fuel stops flowing out. Finally, system pressure reaches a steady state. 08– Chery Automobile Co., Ltd.
  • Page 527 17 18 19 20 21 22 23 24 25 26 27 28 29 30 9 10 11 12 13 14 9 10 E-070 11 12 13 14 15 19 20 21 22 I-006 I-015 ET21080010 08– Chery Automobile Co., Ltd.
  • Page 528 37 38 39 40 41 42 43 44 45 46 25 26 27 28 29 30 31 32 33 34 13 14 15 16 17 18 19 20 21 22 9 10 E-007 E-035 E-010 E-011 E-012 E-013 ET21080020 08– Chery Automobile Co., Ltd.
  • Page 529 Injector is clogged and leaks Poor fuel quality Excessive foreign matter in fuel tank Fuel supply system line (broken) Fuel injector (short in coil) 08-26 Injector does not work Electric fuel pump assembly (damaged) 08-14 Wire harness 08– Chery Automobile Co., Ltd.
  • Page 530 2. Start and run engine until it stalls. 3. Restart engine until it does not run. 4. Turn ignition switch to LOCK. 5. Disconnect the negative battery cable. 6. Insert the electric fuel pump assembly relay into the original place. 08– Chery Automobile Co., Ltd.
  • Page 531 If measured pressure value is too high, it indicates that injector may be clogged or electric fuel pump assembly pressure modulating valve may be malfunctioning. Replace injector (See page 08-26) or electric fuel pump assembly (See page 08-14) if necessary. 08– Chery Automobile Co., Ltd.
  • Page 532 1. Release fuel pressure in fuel supply system (See page 08-10). 2. Turn off all the electrical equipment and ignition switch. 3. Disconnect the negative battery cable. 4. Raise the vehicle to a proper height. 08– Chery Automobile Co., Ltd.
  • Page 533 Be careful not to damage the joint. If the clip is damaged, replace it.  Turn ignition switch ON (without starting engine) to apply fuel pressure to fuel supply system, and then check connections for leakage. 08– Chery Automobile Co., Ltd.
  • Page 534 Multimeter Connection Specification Battery positive (+) - Terminal 3 Fuel pump RT21080062 operates Battery negative (-) - Terminal 4 If electric fuel pump assembly does not operate, replace it. 08– Chery Automobile Co., Ltd.
  • Page 535  Operation staff should wear protective glasses and rubber gloves and avoid inhaling much fuel gas.  Only use parts approved by Chery Automobile Co., Ltd. to replace electric fuel pump assembly.  As electric fuel pump assembly radiates through fuel, low fuel level in fuel tank will directly shorten the service life of electric fuel pump assembly.
  • Page 536 (Tightening torque: 75 ± 5 N·m) RT21080090 f. Pull up the electric fuel pump assembly from fuel tank and disconnect the fuel level sensor connector (arrow). RT21080100 08– Chery Automobile Co., Ltd.
  • Page 537 Be careful not to damage the joint. If the clip is damaged, replace it.  Turn ignition switch ON (without starting engine) to apply fuel pressure to fuel supply system, and then check connections for leakage. 08– Chery Automobile Co., Ltd.
  • Page 538 Remove the fuel tank cap assembly (1) from fuel filler door hinge assembly. c. Remove the fuel filler door outer cover plate (2) from fuel filler door hinge assembly in the direction of arrow as shown in the illustration. RT21080120 08– Chery Automobile Co., Ltd.
  • Page 539 (Tightening torque: 22 ± 2 N·m) CAUTION  Cover the joint with a plastic bag after disconnecting fuel breather hose and fuel filler hose, in order to prevent foreign matter from entering fuel tank and fuel from evaporating or leaking. 08– Chery Automobile Co., Ltd.
  • Page 540 08 - SQR484F FUEL SUPPLY SYSTEM d. Remove 3 fixing screws (arrow) from filler tube assembly. (Tightening torque: 7 ± 1 N·m) RT21080170 e. Remove the filler tube assembly. Installation Installation is in the reverse order of removal. 08– Chery Automobile Co., Ltd.
  • Page 541 3. Disconnect the negative battery cable. 4. Open the fuel filler door, rotate the fuel tank cap assembly in the direction of arrow as shown in the illustration and discharge fuel vapor in fuel tank. RT21080110 08– Chery Automobile Co., Ltd.
  • Page 542 RT21080180 CAUTION  Cover the joint with a plastic bag after disconnecting fuel breather hose and fuel filler hose, in order to prevent foreign matter from entering fuel tank and fuel from evaporating or leaking. 08– Chery Automobile Co., Ltd.
  • Page 543 Remove 4 fixing bolts (arrow) from fuel tank fixing strips and remove the fuel tank fixing strips. (Tightening torque: 25 ± 3 N·m) RT21080220 i. Slowly lower the transmission carrier to remove the fuel tank. 08– Chery Automobile Co., Ltd.
  • Page 544 (2). When vehicle body bumps or overturns, fuel vapor valve will automatically lock to prevent fuel overflow. 2. Fuel Breather Pipe Function of fuel breather pipe: When filling fuel tank through fuel filler, fuel vapor will get out of fuel tank through fuel breather pipe (3). 08– Chery Automobile Co., Ltd.
  • Page 545 Be careful not to damage the joint. If the clip is damaged, replace it.  Turn ignition switch ON (without starting engine) to apply fuel pressure to fuel supply system, and then check connections for leakage. 08– Chery Automobile Co., Ltd.
  • Page 546 4. Remove the engine trim cover assembly (See page 10-10). 5. Remove the fuel rail injector assembly. a. Disconnect the connectors (arrow) of 4 injectors separately. RT21080260 b. Move away the engine wire harness clips from fuel rail. 08– Chery Automobile Co., Ltd.
  • Page 547 Installation is in the reverse order of removal. CAUTION  Install a new seal to the injector sealing surface.  Before installing the injector, apply clean grease or gasoline to the O-ring sealing surface for easy installation, preventing damage to the O-ring. 08– Chery Automobile Co., Ltd.
  • Page 548 - MEMO - 08– Chery Automobile Co., Ltd.
  • Page 549 Fuel Tank Cap Assembly Inspection 09-6 Inspection 09-14 ON-VEHICLE SERVICE 09-7 Installation 09-14 Activated Charcoal Canister Solenoid  Downstream Oxygen Sensor 09-15 Valve and Bracket 09-7 Removal 09-15 Removal 09-7 Inspection 09-15 Inspection 09-8 Installation 09-15 Installation 09-8 09– Chery Automobile Co., Ltd.
  • Page 550 09– Chery Automobile Co., Ltd.
  • Page 551 When engine stops operating, the fuel vapor and fresh air will be stored in the activated charcoal canister assembly. When canister solenoid valve opens, the fuel vapor will enter intake manifold to burn. 09– Chery Automobile Co., Ltd.
  • Page 552 Coupling Bolt Between Activated Charcoal Canister 7 ± 1 Assembly and Body Exhaust Manifold Heat Insulator Fixing Bolt 23 ± 2 Upstream Oxygen Sensor 40 - 60 Downstream Oxygen Sensor 40 - 60 Tool General Tool Digital Multimeter RCH0000002 09– Chery Automobile Co., Ltd.
  • Page 553 17 18 19 20 21 22 23 24 25 26 27 28 29 30 13 14 15 16 17 18 19 20 21 22 9 10 11 12 13 14 9 10 E-035 E-033 ET21090010 09– Chery Automobile Co., Ltd.
  • Page 554 A. If result is not as specified, replace canister. RT21090020 Fuel Tank Cap Assembly Inspection 1. Visually check that fuel tank cap assembly is not deformed or damaged. 2. If result is not as specified, replace fuel tank cap assembly. 09– Chery Automobile Co., Ltd.
  • Page 555 5. Remove the activated charcoal canister solenoid valve bracket. a. Remove 2 fixing bolts (arrow) from the activated charcoal canister solenoid valve bracket, and remove the activated charcoal canister solenoid valve bracket. (Tightening torque: 7 ± 1 N·m) RT21090040 09– Chery Automobile Co., Ltd.
  • Page 556 Measure resistance between 2 pins of canister solenoid with a digital multimeter. Multimeter Measurement Specification (Ω) Connection Temperature Terminal 1 - 20°C 26 ± 4 Terminal 2 RT21090050 Installation Installation is in the reverse order of removal. 09– Chery Automobile Co., Ltd.
  • Page 557 Loosen the elastic clamp (1), remove the charcoal canister breather pipe from activated charcoal canister assembly. RT21090070 CAUTION  Positioning distance from hose end to elastic clamp is 3 - 5 mm. 09– Chery Automobile Co., Ltd.
  • Page 558 ENVIRONMENTAL PROTECTION  Unneeded activated charcoal canister assembly should be handled by the specialized department according to local laws and regulations. Never discard it at will. Installation Installation is in the reverse order of removal. 09– Chery Automobile Co., Ltd.
  • Page 559  DO NOT suck air through valve. Petroleum substances inside the valve are hazardous to your health. b. Blow air into intake manifold side, and check that air flows difficultly. If result is not as specified, replace PCV valve. 3. Remove the clean hose from PCV valve. 09– Chery Automobile Co., Ltd.
  • Page 560 Installation is in the reverse order of removal. CAUTION  Press PCV valve rubber boot into T-joint, then press in the PCV valve.  End surface of PCV valve larger diameter is flush with end surface of PCV valve rubber boot. 09– Chery Automobile Co., Ltd.
  • Page 561 Remove 4 fixing bolts (arrow) from exhaust manifold heat insulator, and remove the exhaust manifold heat insulator. (Tightening torque: 23 ± 2 N·m) RT21110020 c. Remove the upstream oxygen sensor (arrow) from precatalytic converter assembly. (Tightening torque: 40 - 60 N·m) RT21090130 09– Chery Automobile Co., Ltd.
  • Page 562 Pin A - Pin D Always No continuity RT21090140 Pin B - Pin C Pin B - Pin D If result is not as specified, replace upstream oxygen sensor. Installation Installation is in the reverse order of removal. 09– Chery Automobile Co., Ltd.
  • Page 563 Pin A - Pin D Always No continuity RT21090140 Pin B - Pin C Pin B - Pin D If result is not as specified, replace downstream oxygen sensor. Installation Installation is in the reverse order of removal. 09– Chery Automobile Co., Ltd.
  • Page 564 - MEMO - 09– Chery Automobile Co., Ltd.
  • Page 565 Intake Manifold Assembly 10-24 Hot Wire Air Flow Meter 10-13 Removal 10-24 Removal 10-13 Inspection 10-26 Installation 10-13 Installation 10-26 Air Filter Element 10-14 Electronic Accelerator Pedal 10-27 Removal 10-14 Removal 10-27 Installation 10-15 Installation 10-27 10– Chery Automobile Co., Ltd.
  • Page 566 10– Chery Automobile Co., Ltd.
  • Page 567 9 - Worm Clamp 10 - Front Intake Hose 11 - Electronic Throttle Assembly 12 - Electronic Throttle Assembly Gasket 13 - Intake Manifold Assembly 14 - Intake Manifold Gasket 15 - Intake Manifold Assembly Lower Bracket 10– Chery Automobile Co., Ltd.
  • Page 568 Engine Wire Harness Fixing Bolt 8 ± 3 Intake Manifold Assembly Fixing Nut 8 ± 3 Electronic Accelerator Pedal Fixing Bolt 10 ± 2 Worm Clamp 5 ± 0.5 Tools Special Tool X-431 3G Diagnostic Tester RCH0000001 10– Chery Automobile Co., Ltd.
  • Page 569 10 - SQR484F INTAKE SYSTEM General Tools Digital Multimeter RCH0000002 Precision Ruler RCH0000063 Feeler Gauge RCH0000060 10– Chery Automobile Co., Ltd.
  • Page 570 17 18 19 20 21 22 23 24 25 26 27 28 29 30 13 14 15 16 17 18 19 20 21 22 9 10 11 12 13 14 9 10 E-035 E-033 ET21100010 10– Chery Automobile Co., Ltd.
  • Page 571 37 38 39 40 41 42 43 44 45 46 E-021 25 26 27 28 29 30 31 32 33 34 E-016 13 14 15 16 17 18 19 20 21 22 9 10 E-007 E-020 E-015 E-035 ET21100020 10– Chery Automobile Co., Ltd.
  • Page 572 17 18 19 20 21 22 23 24 25 26 27 28 29 30 13 14 15 16 17 18 19 20 21 22 9 10 11 12 13 14 9 10 E-035 E-033 ET21100030 10– Chery Automobile Co., Ltd.
  • Page 573 Intake manifold assembly (broken, leaked) 10-24 Intake system leaks Electronic throttle assembly 10-20 Crankcase vent tube Intake line or component connection Air filter element (damaged, blocked) 10-17 Intake system blocked Engine trim cover assembly (blocked) 10-10 Intake line (blocked) 10– Chery Automobile Co., Ltd.
  • Page 574 Loosen the worm clamp (arrow) and disconnect the connection between front intake hose and engine trim cover assembly.  (Tightening torque: 5 ± 0.5 N·m) RT21100030 c. Remove the engine trim cover assembly from the bracket. RT21100040 10– Chery Automobile Co., Ltd.
  • Page 575 Remove the exhaust manifold heat insulator. b. Remove 2 fixing bolts (arrow) from the trim cover rear right bracket, and remove the trim cover rear right bracket. (Tightening torque: 7 ± 1 N·m) RT21100070 10– Chery Automobile Co., Ltd.
  • Page 576 Remove 2 fixing bolts (arrow) from the trim cover rear left bracket, and remove the trim cover rear left bracket. (Tightening torque: 7 ± 1 N·m) RT21100080 Installation Installation is in the reverse order of removal. 10– Chery Automobile Co., Ltd.
  • Page 577 Remove 2 fixing bolts (arrow) from the hot wire air flow meter.  (Tightening torque: 4.5 ± 0.5 N·m) RT21100081 c. Remove the hot wire air flow meter. Installation Installation is in the reverse order of removal. 10– Chery Automobile Co., Ltd.
  • Page 578 III assembly (2) from the pipe clamp on the air filter upper housing. RT21100100 d. Remove 2 coupling screws (arrow) between air filter upper housing and lower housing.  (Tightening torque: 1.3 ± 0.2 N·m) RT21100110 e. Remove the air filter upper housing. 10– Chery Automobile Co., Ltd.
  • Page 579 3. Other installation procedures are in the reverse order of removal. ENVIRONMENTAL PROTECTION  Unneeded air filter element should be handled by the specialized department according to local laws and regulations. Never discard it at will. 10– Chery Automobile Co., Ltd.
  • Page 580 Remove 2 fixing bolts (arrow) from the air induction pipe assembly.  (Tightening torque: 7 ± 1 N·m) RT21100130 b. Remove the air induction pipe assembly from the air filter assembly. Installation Installation is in the reverse order of removal. 10– Chery Automobile Co., Ltd.
  • Page 581 Disconnect the hot wire air flow meter connector (1). RT21100090 c. Move the inlet pipe II assembly (1) and canister solenoid valve inlet pipe (2) from the bracket on air filter upper housing. RT21100100 10– Chery Automobile Co., Ltd.
  • Page 582 5. Remove the hot wire air flow meter. a. Remove 2 fixing bolts (arrow) from the hot wire air flow meter.  (Tightening torque: 4.5 ± 0.5 N·m) RT21100160 b. Remove the hot wire air flow meter from the air filter assembly. 10– Chery Automobile Co., Ltd.
  • Page 583 Remove 3 fixing bolts (arrow) from the air filter assembly bracket.  (Tightening torque: 7 ± 1 N·m) RT21100170 c. Remove the air filter assembly bracket. Installation Installation is in the reverse order of removal. 10– Chery Automobile Co., Ltd.
  • Page 584  Try to prevent body paint surface from being scratched during removal and installation. 1. Turn off all the electrical equipment and ignition switch. 2. Disconnect the negative battery cable. 3. Remove the engine trim cover assembly (See page 10-10). 4. Remove the electronic throttle assembly. 10– Chery Automobile Co., Ltd.
  • Page 585  Wasted coolant should be handled by the specialized department according to local laws and regulations. Never discard it at will. e. Remove 4 fixing bolts (arrow) from the electronic throttle assembly.  (Tightening torque: 8 + 3 N·m) RT21100200 f. Remove the electronic throttle assembly and its gasket. 10– Chery Automobile Co., Ltd.
  • Page 586 1. Thin stick: used to support throttle valve plate for cleaning the carbon deposited on contact wall between valve plate and throttle. Please use plastic, wooden or bamboo thin stick. Do not use metal thin stick, avoiding scratching or deforming the valve plate. 2. Clean cloth or paper towel 10– Chery Automobile Co., Ltd.
  • Page 587  Clean fitting surface of electronic throttle assembly.  Perform throttle self-learning procedures after installation (See page 06-19). After self-learning completed, start vehicle and observe if it operates properly.  Check and add engine coolant. 10– Chery Automobile Co., Ltd.
  • Page 588 Loosen the elastic clamp (2) and disconnect the connection between canister solenoid valve outlet hose and intake manifold assembly. d. Remove the intake manifold bracket fixing bolt (arrow).  (Tightening torque: 18 ± 2 N·m) RT21100240 10– Chery Automobile Co., Ltd.
  • Page 589 (for MT model). 9. Disconnect the coupling joint (arrow) between line assembly and intake manifold assembly, and remove the line assembly (1) from the intake manifold assembly. RT21100280 10– Chery Automobile Co., Ltd.
  • Page 590 0.04 mm, replace the cylinder head. RT21100290 Installation Installation is in the reverse order of removal. CAUTION  Clean the inner wall of intake manifold assembly and the fitting surface.  Replace intake manifold gasket. 10– Chery Automobile Co., Ltd.
  • Page 591 Disconnect the electronic accelerator pedal connector (1). b. Remove 3 fixing bolts (arrow) from the electronic accelerator pedal. (Tightening torque: 10 ± 2 N·m) RT21100300 c. Remove the electronic accelerator pedal. Installation Installation is in the reverse order of removal. 10– Chery Automobile Co., Ltd.
  • Page 592 - MEMO - 10– Chery Automobile Co., Ltd.
  • Page 593 Center Pipe Assembly 11-15 Exhaust System Gas Leakage  Removal 11-15 Inspection 11-6 Installation 11-16 ON-VEHICLE SERVICE 11-7 Muffler Assembly 11-17 Exhaust Manifold Assembly 11-7 Removal 11-17 Removal 11-7 Installation 11-19 Inspection 11-8 Installation 11-9 11– Chery Automobile Co., Ltd.
  • Page 594 11– Chery Automobile Co., Ltd.
  • Page 595 11 - SQR484F EXHAUST SYSTEM GENERAL INFORMATION SQR484F EXHAUST SYSTEM Description ×4 ×4 ×3 RT21110010 11– Chery Automobile Co., Ltd.
  • Page 596 Coupling Spring Bolt Between Center Pipe Assembly 50 ± 5 and Muffler Assembly Muffler Assembly Left Hanger Block III Assembly 50 ± 5 Fixing Bolt Muffler Assembly Right Hanger Block III Assembly 50 ± 5 Fixing Bolt 11– Chery Automobile Co., Ltd.
  • Page 597 11 - SQR484F EXHAUST SYSTEM Tools General Tools Precision Ruler RCH0000063 Feeler Gauge RCH0000060 11– Chery Automobile Co., Ltd.
  • Page 598 The judging standard is that engine does not shudder and no "poof" sound can be heard at the joints. 11– Chery Automobile Co., Ltd.
  • Page 599 5. Remove the exhaust manifold assembly. a. Remove 4 coupling nuts (arrow), disconnect the connection between exhaust manifold assembly and precatalytic converter assembly, and take off the gasket in the connecting part. (Tightening torque: 50 ± 5 N·m) RT21110030 11– Chery Automobile Co., Ltd.
  • Page 600 If warpage on the surface is greater than 0.04 mm, replace RT21110060 3. Check that there are no scratches and roughness on exhaust manifold gasket. Otherwise, replace it. RT21110070 11– Chery Automobile Co., Ltd.
  • Page 601 11 - SQR484F EXHAUST SYSTEM Installation Installation is in the reverse order of removal. CAUTION  When installation is completed, check that there is no exhaust gas leakage between exhaust manifold assembly and cylinder head, precatalytic converter assembly. 11– Chery Automobile Co., Ltd.
  • Page 602 Take off and disconnect the upstream oxygen sensor connector (arrow) from the bracket. RT21090110 b. Remove 4 fixing bolts (arrow) from the exhaust manifold heat insulator, and remove the exhaust manifold heat insulator. (Tightening torque: 23 ± 2 N·m) RT21110020 11– Chery Automobile Co., Ltd.
  • Page 603 Remove 2 left coupling bolts (1) and right coupling bolt (2) between precatalytic converter assembly bracket and cylinder block. (Tightening torque for left coupling bolt: 23 ± 2 N·m) (Tightening torque for right coupling bolt: 50 ± 5 N·m) RT21110100 11– Chery Automobile Co., Ltd.
  • Page 604  Check for exhaust gas leaks. If gas leaks, tighten defective area to prevent leaking. Replace damaged parts as necessary.  Check that there is no exhaust gas leakage in upstream oxygen sensor connection.  Check that there is no exhaust gas leakage in downstream oxygen sensor connection. 11– Chery Automobile Co., Ltd.
  • Page 605 Remove 2 coupling nuts (arrow), disconnect the connection between main catalytic converter assembly and center pipe assembly, and take off the gasket in the connecting part. (Tightening torque: 50 ± 5 N·m) RT21110140 c. Remove the main catalytic converter assembly. 11– Chery Automobile Co., Ltd.
  • Page 606  If there are any cracks or leakage in main catalytic converter assembly, replace as necessary.  Keep sufficient distance between main catalytic converter assembly and body during installation.  Check for exhaust gas leaks. If gas leaks, tighten defective area to prevent leaking. Replace damaged parts as necessary. 11– Chery Automobile Co., Ltd.
  • Page 607 RT21110140 b. Remove 2 spring bolts (arrow), disconnect the connection between center pipe assembly and muffler assembly, and take off the sphere flange grommet in the connecting part. (Tightening torque: 50 ± 5 N·m) RT21110150 11– Chery Automobile Co., Ltd.
  • Page 608 Make sure that clearance between exhaust system components and muffler heat insulator I or vehicle underbody is more than 25 mm.  Check for exhaust gas leaks. If gas leaks, tighten defective area to prevent leaking. Replace damaged parts as necessary. 11– Chery Automobile Co., Ltd.
  • Page 609 RT21110150 b. Detach the diamond shaped hanger block (1) between left side of muffler assembly and body hook. c. Detach the hanger block III (2) between left side of muffler assembly and body hook. RT21110170 11– Chery Automobile Co., Ltd.
  • Page 610 Remove 4 clamping pieces (1) from the muffler assembly heat insulator I, and remove the muffler assembly heat insulator I. b. Remove 4 clamping pieces (2) from the muffler assembly heat insulator II, and remove the muffler assembly heat insulator II. RT21110210 11– Chery Automobile Co., Ltd.
  • Page 611  During installation, make sure that clearance between tailpipe of muffler pipe and bumper on the rear body is more than 30 mm.  Check for exhaust gas leaks. If gas leaks, tighten defective area to prevent leaking. Replace damaged parts as necessary. 11– Chery Automobile Co., Ltd.
  • Page 612 - MEMO - 11– Chery Automobile Co., Ltd.
  • Page 613 Radiator Assembly 12-29 Coolant Adding 12-14 Removal 12-29 Tank Upper Crossmember Assembly 12-16 Installation 12-30 Removal 12-16 Water Pump Assembly 12-31 Installation 12-17 Removal 12-31 Expansion Tank 12-18 Inspection 12-32 Removal 12-18 Installation 12-32 Installation 12-18 12– Chery Automobile Co., Ltd.
  • Page 614 12– Chery Automobile Co., Ltd.
  • Page 615 12 - SQR484F COOLING SYSTEM GENERAL INFORMATION SQR484F COOLING SYSTEM Description ×2 ×4 ×4 ×2 ×6 ×4 ×4 RT21120010 12– Chery Automobile Co., Ltd.
  • Page 616 Also, the engine cooling system provides heat to the heater core in the cabin to improve driving comfort. 12– Chery Automobile Co., Ltd.
  • Page 617 Item Capacity (L) Cooling System Coolant Concentration G11 Additive Soft Water Coolant Freezing Point Item Freezing Point Value (°C) Coolant Cooling System Test Pressure Item Test Pressure (bar) Cooling System (Test Pressure) 1.3 ± 0.2 12– Chery Automobile Co., Ltd.
  • Page 618 12 - SQR484F COOLING SYSTEM Tools General Tools Digital Multimeter RCH0000002 Cooling System Pressure Tester RCH0000055 Freezing Point Tester RCH0000007 12– Chery Automobile Co., Ltd.
  • Page 619 12 - SQR484F COOLING SYSTEM Cooling System Operation Flowchart RT21120020 12– Chery Automobile Co., Ltd.
  • Page 620 When coolant temperature is higher than 102°C, the cooling fan starts to operate at high speed; f. When coolant temperature is below 99°C, the cooling fan stops at high speed; g. When coolant temperature is below 93°C, the cooling fan stops at low speed. 12– Chery Automobile Co., Ltd.
  • Page 621 17 18 19 20 21 22 23 24 25 26 27 28 29 30 13 14 15 16 17 18 19 20 21 22 9 10 11 12 13 14 9 10 E-035 E-033 ET21120010 12– Chery Automobile Co., Ltd.
  • Page 622 Unable to reach normal engine Cooling fan assembly (constantly 12-26 temperature operating) Thermostat 12-19 Fan controller 12-25 Cooling fan assembly 12-26 Cooling fan does not operate or abnormal air speed Wire harness ECM (Engine Control Module) failure 06-256 12– Chery Automobile Co., Ltd.
  • Page 623 (expansion tank cap opening) and tighten it slowly. RT21120040 CAUTION  Make sure there is no leakage in the connecting part of coolant system pressure tester, in order to avoid pressure leakage during test. 12– Chery Automobile Co., Ltd.
  • Page 624 If the freezing point is beyond the specified value, replace the coolant. HINT: Scale 1 is used to measure the freezing point value of propylene glycol coolant, and scale 2 is used to measure the battery electrolyte concentration. 12– Chery Automobile Co., Ltd.
  • Page 625 6. After the coolant stops flowing, retighten the radiator drain cock plug. CAUTION  Tighten the drain cock plug to prevent leakage. ENVIRONMENTAL PROTECTION  Wasted coolant should be handled by the specialized department according to local laws and regulations. Never discard it at will. 12– Chery Automobile Co., Ltd.
  • Page 626 12 - SQR484F COOLING SYSTEM Coolant Adding Only use coolant that meets Chery specifications. Coolant Capacity Item Capacity (L) Cooling System Coolant Concentration G11 Additive Soft Water WARNING  If it is necessary to add coolant when engine is hot, loosen expansion tank cap slightly first to release internal pressure and loosen the cap completely after waiting for a while, and then add coolant.
  • Page 627 "MAX" and "MIN" lines. If the coolant level is below the "MIN" line, repeat all above procedures. If the coolant level is above the "MAX" line, drain the coolant until the level is between "MAX" and "MIN" lines. 12– Chery Automobile Co., Ltd.
  • Page 628 RT21120031 b. Disconnect the connector (arrow) from engine compartment contact switch, and remove the engine compartment contact switch. RT21120032 12– Chery Automobile Co., Ltd.
  • Page 629 RT21120034 f. Remove 4 fixing bolts (arrow) from tank upper crossmember assembly. (Tightening torque: 7 ± 1 N·m) RT21120035 g. Remove the tank upper crossmember assembly. Installation Installation is in the reverse order of removal. 12– Chery Automobile Co., Ltd.
  • Page 630 (Tightening torque: 7 ± 1 N·m) e. Remove the expansion tank from expansion tank bracket. Installation Installation is in the reverse order of removal. CAUTION  Check that coolant has been added to the specified level after installation. 12– Chery Automobile Co., Ltd.
  • Page 631 (Tightening torque: 7 ± 1 N·m) RT21090040 7. Remove the thermostat housing. a. Loosen the elastic clamp (arrow) and disconnect the connection between engine outlet hose thermostat housing. RT21120090 12– Chery Automobile Co., Ltd.
  • Page 632 If the result is not as specified, adjust the thermostat grommet to the specified position or replace the thermostat with a new one. RT21120120 2. Check the opening temperature and maximum lift of thermostat. HINT: Valve opening temperature is engraved in the thermostat. RT21120130 12– Chery Automobile Co., Ltd.
  • Page 633  As shown in the illustration, align the protrusion (1) of thermostat grommet and groove (2) of thermostat seat during installation.  Check that coolant has been added to the specified level after installation. RT21120150 12– Chery Automobile Co., Ltd.
  • Page 634 Remove the fixing bolt (1) from engine ground wire, and disconnect the engine wire harness. (Tightening torque: 7 ± 1 N·m) f. Remove the fixing bolt (2) from engine speed sensor bracket. (Tightening torque: 7 ± 1 N·m) RT21120170 12– Chery Automobile Co., Ltd.
  • Page 635 Remove 4 fixing bolts (arrow) from thermostat seat. (Tightening torque: 8 + 3 N·m) RT21120190 i. Remove the thermostat seat and thermostat seat gasket. 9. Remove the coolant temperature sensor (arrow) from the thermostat seat. (Tightening torque: 11 - 16 N·m) RT21120200 12– Chery Automobile Co., Ltd.
  • Page 636 Installation is in the reverse order of removal. CAUTION  Check that coolant has been added to the specified level after installation.  Replace thermostat seat gasket with a new one during installation, and the removed gasket cannot be reused. 12– Chery Automobile Co., Ltd.
  • Page 637 RT21120210 b. Remove 2 fixing bolts (arrow) from fan controller. (Tightening torque: 7 ± 1.5 N·m) RT21120220 c. Remove the fan controller from cooling fan assembly. Installation Installation is in the reverse order of removal. 12– Chery Automobile Co., Ltd.
  • Page 638 6. Remove the water tank upper crossmember trim board (See page 48-10). 7. Remove the engine hood lock assembly (See page 37-39). 8. Remove the tank upper crossmember assembly (See page 12-16). 9. Remove the cooling fan assembly. 12– Chery Automobile Co., Ltd.
  • Page 639 10.Remove the fan controller. a. Disconnect the fan controller connector (1). b. Remove 2 fixing bolts (arrow) from the fan controller, and remove the fan controller from the cooling fan assembly. (Tightening torque: 7 ± 1.5 N·m) RT21120260 12– Chery Automobile Co., Ltd.
  • Page 640 12 - SQR484F COOLING SYSTEM Installation Installation is in the reverse order of removal. CAUTION  Check that the coolant has been added to the specified level after installation. 12– Chery Automobile Co., Ltd.
  • Page 641 9. Drain the coolant (See page 12-13). 10.Remove the cooling fan assembly (See page 12-26). 11. Remove the radiator assembly. a. Loosen the elastic clamp (arrow) and disconnect the connection between engine outlet hose and radiator assembly. RT21120270 12– Chery Automobile Co., Ltd.
  • Page 642 Loosen the elastic clamp (2) and disconnect the connection between engine inlet pipe and radiator assembly. RT21120280 d. Remove the radiator. Installation Installation is in the reverse order of removal. 12– Chery Automobile Co., Ltd.
  • Page 643 Remove the fixing bolt (arrow) from timing belt idler pulley, and remove the timing belt idler pulley. (Tightening torque: 40 + 5 N·m) RT21120290 b. Remove 6 fixing bolts (arrow) from water pump assembly. (Tightening torque: 8 + 3 N·m) RT21120300 12– Chery Automobile Co., Ltd.
  • Page 644  If water pump is damaged, replace rather than attempt to repair it.  Check that coolant has been added to the specified level after installation.  Perform cooling system pressure test after adding coolant. check for leakage in the cooling system. 12– Chery Automobile Co., Ltd.
  • Page 645 Engine Oil Replacement 13-11 Installation 13-23 Engine Oil Draining 13-11 Oil Pump Assembly 13-24 Engine Oil Adding 13-12 Removal 13-24 Oil Filter 13-13 Installation 13-25 Removal 13-13 Installation 13-14 Oil Dipstick Tube 13-15 Removal 13-15 Installation 13-15 13– Chery Automobile Co., Ltd.
  • Page 646 13– Chery Automobile Co., Ltd.
  • Page 647 13 - SQR484F LUBRICATION SYSTEM GENERAL INFORMATION SQR484F LUBRICATION SYSTEM Description ×4 ×4 ×7 ×2 ×18 ×6 RT21130010 13– Chery Automobile Co., Ltd.
  • Page 648  Wear protective clothing and gloves.  Wash your skin thoroughly with soap and water, or use waterless hand cleaner to remove any used engine oil.  Never use gasoline, thinners or solvents. 13– Chery Automobile Co., Ltd.
  • Page 649 8 + 3 Oil Strainer Bracket Fixing Bolt 17 - 23 Oil Strainer Bracket Fixing Nut 17 - 23 Coupling Bolt Between Oil Strainer and Oil Pump 17 - 23 Oil Pump Fixing Bolt 8 - 11 13– Chery Automobile Co., Ltd.
  • Page 650 13 - SQR484F LUBRICATION SYSTEM Tools Special Tools Oil Pan Remover and Scraper RCH0000056 Oil Filter Remover RCH0000054 General Tool Oil Pressure Tester RCH0000006 13– Chery Automobile Co., Ltd.
  • Page 651 11 - Crankshaft Description 1. Solid arrow: indicates the flow of high-pressure lubricant. 2. Hollow arrow: indicates the flow of low-pressure lubricant. 3. Dark area: indicates the high-pressure lubricant. 4. Bright area: indicates the low-pressure lubricant. 13– Chery Automobile Co., Ltd.
  • Page 652 07-78 oil pan, which will cause oil dilution) Line (blocked) Engine oil (high oil viscosity, excessive oil After cranking , clunking sound from engine filling capacity) is heard Cylinder block (oil passage blocked) 07-78 13– Chery Automobile Co., Ltd.
  • Page 653 If oil level is below the "MIN" mark, it is necessary to add engine oil. RT21130040 CAUTION  When adding engine oil, the oil level should not be above the "MAX" mark. 13– Chery Automobile Co., Ltd.
  • Page 654 Apply a small amount of seal gum to the threads when installing the oil pressure switch. 6. Connect the oil pressure switch connector and check the engine oil for leakage. 7. Install the engine lower right protector assembly. 13– Chery Automobile Co., Ltd.
  • Page 655  Apply a certain pushing force to drain plug while loosening the plug by hand, and have the drain plug attached to the thread tightly to prevent oil from overflowing in advance. Move away the hand quickly to prevent burn by the oil with a certain temperature. 13– Chery Automobile Co., Ltd.
  • Page 656 Never discard it at will. 5. Wipe off the drain plug and tighten it. (Tightening torque: 35 ± 3 N·m) Engine Oil Adding Only use engine oil that meets Chery specifications Engine Type SQR484F Oil Capacity (L) 4 ± 0.5...
  • Page 657 Using the oil filter remover (1), remove the oil filter (2). (Tightening torque: 25 ± 3 N·m) RT21130090 ENVIRONMENTAL PROTECTION  The removed oil filter should be handled by specialized department according to local laws and regulations. Never discard it at will. 13– Chery Automobile Co., Ltd.
  • Page 658  Slightly rotate oil filter in place by hand, and tighten oil filter until grommet contacts with oil filter bracket base.  Using a special tool to tighten oil filter. (Tightening torque: 25 ± 3 N·m) 13– Chery Automobile Co., Ltd.
  • Page 659 Installation is in the reverse order of removal. CAUTION  Check oil dipstick tube grommet when installing, if damaged, replace with a new one.  Apply a coat of engine oil to oil dipstick tube grommet when installing. 13– Chery Automobile Co., Ltd.
  • Page 660  Before inspecting oil pressure switch, please make sure that oil level is proper and coolant temperature is up to above 90°C, and that oil filter is used within 5000 km and electrical fan stops operating. 1. Use an oil pressure tester as shown in the illustration. RT21130100 13– Chery Automobile Co., Ltd.
  • Page 661 2. Apply a small amount of seal gum to the threads when installing the oil pressure switch as shown in the illustration. Width of a: 3 mm RT21130120 3. Other installation procedures are in the reverse order of removal. 13– Chery Automobile Co., Ltd.
  • Page 662  After disconnecting oil cooler outlet hose and oil cooler inlet hose, cover the hoses with wooden corks or equivalent to prevent coolant in hoses from flowing out. d. Remove the oil filter joint (1) and oil cooler assembly (2) in order. RT21130140 13– Chery Automobile Co., Ltd.
  • Page 663 Installation Installation is in the reverse order of removal. CAUTION  Clean installation surface of oil cooler assembly.  Replace fuel filter.  Add engine oil to specified level.  Check and add engine coolant. 13– Chery Automobile Co., Ltd.
  • Page 664 (1) (for CVT model). (Tightening torque: 50 ± 5 N·m) RT21130150 b. Remove coupling bolts (arrow) between transmission assembly and oil pan (for MT model). (Tightening torque: 50 ± 5 N·m) RT21130160 13– Chery Automobile Co., Ltd.
  • Page 665 6. Remove the residual seal gum on oil pan with oil pan remover and scraper (1). RT21130180 CAUTION  After removing seal gum with oil pan scraper, clean the cylinder block installation surface, thread hole and oil pan with appropriate cleaner. 13– Chery Automobile Co., Ltd.
  • Page 666 (Tightening torque: 15 + 3 N·m) 10 14 25 RT21130170 3. Other installation procedures are in the reverse order of removal. 13– Chery Automobile Co., Ltd.
  • Page 667 1. Clean the oil strainer mesh. 2. Replace the grommet.  Oil strainer grommet (1)  Oil pump and oil pan connecting pipe grommet (2)  Oil filter and oil pan connecting pipe grommet (3) RT21130210 13– Chery Automobile Co., Ltd.
  • Page 668 8. Remove the oil pump assembly. a. Remove 4 fixing bolts (arrow) from the oil pump assembly. (Tightening torque: 17 - 23 N·m) RT21130220 b. Using a proper tool (1), pry out the oil pump assembly (2). RT21130230 13– Chery Automobile Co., Ltd.
  • Page 669  Apply a proper amount of seal gum to the bolt mounting planes (arrow) before installing the oil pump assembly fixing bolts. RT21130260 13– Chery Automobile Co., Ltd.
  • Page 670 - MEMO - 13– Chery Automobile Co., Ltd.
  • Page 671 Tool 14-4 Inspection 14-11 Circuit Diagram 14-5 Installation 14-11 DIAGNOSIS & TESTING 14-6 Spark Plug 14-12 Problem Symptoms Table 14-6 Removal 14-12 Service Precautions 14-7 Inspection 14-13 ON-VEHICLE SERVICE 14-8 Installation 14-13 High-voltage Cable 14-8 14– Chery Automobile Co., Ltd.
  • Page 672 14– Chery Automobile Co., Ltd.
  • Page 673 14 - SQR484F IGNITION SYSTEM GENERAL INFORMATION SQR484F IGNITION SYSTEM Description ×4 RT21140010 14– Chery Automobile Co., Ltd.
  • Page 674 Spark Plug 30 ± 3 Ignition Coil Fixing Bolt 8 + 3 Spark Plug Specifications Engine Type SQR484F Spark Plug Type FR7DTC Spark Plug Gap (mm) 0.8 - 0.9 Tool General Tool Digital Multimeter RCH0000002 14– Chery Automobile Co., Ltd.
  • Page 675 17 18 19 20 21 22 23 24 25 26 27 28 29 30 13 14 15 16 17 18 19 20 21 22 9 10 11 12 13 14 9 10 E-035 E-033 ET21140010 14– Chery Automobile Co., Ltd.
  • Page 676 Engine speed sensor 06-249 Intake VVT control valve 06-242 Engine hesitation, power drop, unstable performance Exhaust VVT control valve 06-242 Camshaft position sensor 06-248 06-256 Spark plug 14-12 Rough, unstable idling or stall Ignition coil 14-10 06-256 14– Chery Automobile Co., Ltd.
  • Page 677 9. Confirm that the following vacuum hoses are connected securely without any leakage: a. Canister solenoid valve; b. Charcoal canister; c. PCV valve; d. Warm damper vacuum system; e. Brake booster. 10.Check the fuel pump hose and wire connection to make sure they are connected securely. 14– Chery Automobile Co., Ltd.
  • Page 678 Loosen the high-voltage cables (1) in order and pull them upward to remove them from the spark plug holes. RT21140030 d. Remove the high-voltage cable. CAUTION  Be careful not to damage the high-voltage cables when pulling them upward. 14– Chery Automobile Co., Ltd.
  • Page 679 Cable Installation Installation is in the reverse order of removal. CAUTION  Install cylinder 1 to 4 high-voltage cables to spark plug hole and ignition coil in accordance with the marks on high-voltage cables. 14– Chery Automobile Co., Ltd.
  • Page 680 Disconnect the high-voltage cables (arrow) for each cylinder, and put them aside. RT21140050 c. Loosen and remove 4 fixing bolts (arrow) from the ignition coil assembly. (Tightening torque: 8 + 3 N·m) RT21140060 d. Remove the ignition coil. 14– Chery Automobile Co., Ltd.
  • Page 681 Installation is in the reverse order of removal. CAUTION  Make sure the connection between ignition coil and ignition coil high-voltage post, spark plug is reliable during installation, or it may cause the high-voltage leakage, resulting in poor ignition. 14– Chery Automobile Co., Ltd.
  • Page 682  Be careful not to damage the high-voltage cables when pulling them upward. 5. Remove the spark plug. a. Using a special spark plug socket wrench (1), loosen the spark plug (2). b. Remove the spark plug (2). RT21140090 14– Chery Automobile Co., Ltd.
  • Page 683 1. Install 4 spark plugs respectively into the cylinder head mounting holes for pre-tightening, and then retighten the spark plugs with a torque wrench.  (Tightening torque: 30 ± 3 N·m) 2. Other procedures are in the reverse order of removal. 14– Chery Automobile Co., Ltd.
  • Page 684 - MEMO - 14– Chery Automobile Co., Ltd.
  • Page 685 Diagnostic Trouble Code (DTC) Chart 15-22 Removal 15-69 B1500-13 15-23 Inspection 15-70 B1501-13 15-23 Installation 15-70 B1516-19 15-23 Passive Entry & Passive Start (PEPS) B1517-23 15-23 Controller (w/ PEPS System) 15-71 B1502-13 15-30 Removal 15-71 B1503-13 15-30 Installation 15-71 15– Chery Automobile Co., Ltd.
  • Page 686 15– Chery Automobile Co., Ltd.
  • Page 687 1 - Ignition Starting Switch 2 - Fuse and Relay Box 3 - Battery 4 - Starter Starting system, equipped in the vehicle without Passive Entry & Passive Start (PEPS) system, consists of battery, ignition switch and starter, etc. 15– Chery Automobile Co., Ltd.
  • Page 688 15 - SQR484F STARTING SYSTEM w/ PEPS System RT21150020 1 - Engine Switch 2 - Passive Entry & Passive Start (PEPS) Controller 3 - Fuse and Relay Box 4 - Battery 5 - Starter 15– Chery Automobile Co., Ltd.
  • Page 689 Passive Entry & Passive Start (PEPS) system has the following functions:  Keyless entry function;  Compatible general remote function;  One-button keyless start function;  Back door smart open function;  Engine immobilizer function. 15– Chery Automobile Co., Ltd.
  • Page 690 3. DC motor: it converts electrical energy from battery into electromagnetic moment. 15– Chery Automobile Co., Ltd.
  • Page 691 Torque (N·m) Starter Power Cable Nut 13 ± 1 Starter Fixing Bolt 35 ± 5 Ignition Starting Switch Fixing Screw 13 ± 2 Tools Special Tool X-431 3G Diagnostic Tester RCH0000001 General Tool Digital Multimeter RCH0000002 15– Chery Automobile Co., Ltd.
  • Page 692 33 34 35 36 37 38 39 40 41 42 43 44 45 46 17 18 19 20 21 22 23 24 25 26 27 28 29 30 9 10 11 12 13 14 E-033 ET21150010 15– Chery Automobile Co., Ltd.
  • Page 693 CONTROL E-014 PEPS (J1) I-029 E-022 E-067 E-069 J108 J107 J106 J105 J104 J103 J102 J101 9 10 11 12 13 14 J116 J115 J114 J113 J112 J111 J110 J109 E-014 I-029 E-071 E-050 ET21150020 15– Chery Automobile Co., Ltd.
  • Page 694 J107 J106 J105 J104 J103 J102 J101 J208 J207 J206 J205 J204 J203 J202 J201 J116 J115 J114 J113 J112 J111 J110 J109 J216 J215 J214 J213 J212 J211 J210 J209 I-017 I-029 I-030 ET21140020 15– Chery Automobile Co., Ltd.
  • Page 695 9 10 11 12 13 14 E-073 E-065 E-074 B7 B8 B9 B10 E-067 E-071 J108 J107 J106 J105 J104 J103 J102 J101 J116 J115 J114 J113 J112 J111 J110 J109 I-029 I-013 E-069 ET21140030 15– Chery Automobile Co., Ltd.
  • Page 696 J114 J113 J112 J111 J110 J109 J216 J215 J214 J213 J212 J211 J210 J209 J308 J307 J306 J305 I-035 B-056 I-029 I-030 2 3 4 B-012 T-006 9 10 14 15 I-034 IMMOBILIZER COIL ET21140040 15– Chery Automobile Co., Ltd.
  • Page 697 18 17 16 15 14 13 12 11 10 I-035 I-006 F-003 H-004 7 10 13 16 7 10 13 16 B-040 B-061 8 11 14 17 8 11 14 17 9 12 15 18 9 12 15 18 ET21140050 15– Chery Automobile Co., Ltd.
  • Page 698 Passive Entry & Passive Start (PEPS) 15-71 controller Wire harness or connector Battery (weak battery, internal fault) 16-7 Starter runs weakly Starter 15-64 Starter (incorrect installation, internal fault) 15-64 Starter is racing Flywheel ring gear (gear teeth broken) 07-42 15– Chery Automobile Co., Ltd.
  • Page 699 Specified Condition 30 - 87 10 kΩ or more Below 1 Ω (when battery voltage is applied to 30 - 87 terminals 85 and 86) If result is not as specified, replace the starter relay. 15– Chery Automobile Co., Ltd.
  • Page 700 8. Generally, perform maintainable service for starter when servicing the vehicle. Also, the maintenance interval can be shortened or extended properly depending on actual conditions. 9. Remove the negative battery cable before removing the starter. 15– Chery Automobile Co., Ltd.
  • Page 701 Record DTCs, and clear DTCs NEXT Verify and duplicate problem: simulate problem occurring condition, and read DTCs again For current DTC, go to step 8 occurs No  For history DTC, go to step 9 15– Chery Automobile Co., Ltd.
  • Page 702 Troubleshoot according to Diagnostic Trouble Code (DTC) chart, then go to step 10 NEXT Troubleshoot according to Problem Symptoms Table, then go to step 10 NEXT Confirm problem is repaired, and perform repair completion inspection NEXT 15– Chery Automobile Co., Ltd.
  • Page 703  If multiple trouble codes were set, refer to the circuit diagrams to look for any common ground circuit or power supply circuit applied to the DTC.  Refer to Technical Bulletin that is applied to the malfunction. 15– Chery Automobile Co., Ltd.
  • Page 704 J102 IG1 Relay Drive (High) J110 Starter Relay Inspection J103 ACC Relay Drive (High) J111 Ignition Signal J104 IG2 Relay Drive (High) J112 J105 CAN-L J113 Starter Relay (High) J106 CAN-H J114 Gear Position Signal 15– Chery Automobile Co., Ltd.
  • Page 705 (Low Frequency Antenna) Negative Front Left Door Handle Sensor (Low Front Right Door Handle Sensor J303 J307 Frequency Antenna) Positive (Low Frequency Antenna) Positive Back Door Low Frequency Antenna Back Door Low Frequency Antenna J304 J308 Negative Positive 15– Chery Automobile Co., Ltd.
  • Page 706 Lost Communication with EMS Missing Message U0101-87 Lost Communication with TCM Missing Message U0129-87 Lost Communication with BSM Missing Message U0140-87 Lost Communication with BCM Missing Message U0329-87 Lost Communication with ESCL Missing Message U1300-55 Software Configuration Error Not Configured 15– Chery Automobile Co., Ltd.
  • Page 707 15 - SQR484F STARTING SYSTEM B1500-13 Driver Door Outside LF Antenna Circuit Open B1501-13 Passenger Door Outside LF Antenna Circuit Open B1516-19 HSU Overload B1517-23 HSU Switch Continuously Pressed Failure 15– Chery Automobile Co., Ltd.
  • Page 708 7 10 13 16 7 10 13 16 B-040 8 11 14 17 B-061 8 11 14 17 9 12 15 18 9 12 15 18 J304 J303 J302 J301 J308 J307 J306 J305 B-056 F-003 H-004 ET21140060 15– Chery Automobile Co., Ltd.
  • Page 709 Check if wire harnesses are worn, pierced, pinched or partially broken. h. Look for broken, bent, protruded or corroded terminals. i. Check that the related connector pins are in good condition. Repair or replace related wire harness and connector 15– Chery Automobile Co., Ltd.
  • Page 710 Check for Short 9 12 15 18 Multimeter Specified B-061 Condition Connection Condition B-056 (J307) or B -061 (18) - Body Always No continuity RT21150230 ground B-056 (J306) or B-061 (10) - Body Always No continuity ground 15– Chery Automobile Co., Ltd.
  • Page 711 F-003 (2) - Always No continuity Battery positive F-007 (9) or F-003 (1) - Battery Always No continuity positive Repair or replace front left door wire harness and connector Check front right door wire harness and connector 15– Chery Automobile Co., Ltd.
  • Page 712 Remove the front right door handle sensor (built-in low frequency antenna). c. Replace front left/right door handle sensors (built-in low frequency antenna) with new ones. d. Connect X-431 3G diagnostic tester to Data Link Connector (DLC) again to check if any DTC is detected. 15– Chery Automobile Co., Ltd.
  • Page 713 15 - SQR484F STARTING SYSTEM Repair or replace PEPS controller System operates normally 15– Chery Automobile Co., Ltd.
  • Page 714 15 - SQR484F STARTING SYSTEM B1502-13 Front Internal LF Antenna Circuit Open B1503-13 Middle Internal LF Antenna Circuit Open B1504-13 Rear Internal LF Antenna Circuit Open 15– Chery Automobile Co., Ltd.
  • Page 715 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 I-035 I-006 J208 J207 J206 J205 J204 J203 J202 J201 J216 J215 J214 J213 J212 J211 J210 J209 I-043 B-024 B-035 I-030 ET21140070 15– Chery Automobile Co., Ltd.
  • Page 716 Check if wire harnesses are worn, pierced, pinched or partially broken. g. Look for broken, bent, protruded or corroded terminals. h. Check that the related connector pins are in good condition. Repair or replace related wire harness and connector 15– Chery Automobile Co., Ltd.
  • Page 717 18 17 16 15 14 13 12 11 10 Multimeter Specified Condition I-035 Connection Condition I-030 (J208) or I-035 (13) - Body Always No continuity RT21150260 ground I-030 (J207) or I-035 (14) - Body Always No continuity ground 15– Chery Automobile Co., Ltd.
  • Page 718 No continuity ground I-030 (J216) or I-006 (16) - Always No continuity Battery positive I-030 (J215) or I -006 (15) - Battery Always No continuity positive Repair or replace instrument panel wire harness and connector 15– Chery Automobile Co., Ltd.
  • Page 719 B-035 (2) B-003 Check for Short Multimeter Specified Condition Connection Condition B-035 B-003 (16) or B-035 (1) - Body Always No continuity ground RT21150280 B-003 (15) or B-035 (2) - Body Always No continuity ground 15– Chery Automobile Co., Ltd.
  • Page 720 (See page 37-54). b. Install new low frequency antenna. c. Connect X-431 3G diagnostic tester to Data Link Connector (DLC) again to check if any DTC is detected. Repair or replace PEPS controller System operates normally 15– Chery Automobile Co., Ltd.
  • Page 721 Abnormality ON Switches of Engine Switch No Subtype B1506-00 Information ENGINE SWITCH I-017 J211 J210 J213 J204 J203 J205 PEPS (J2) I-030 J208 J207 J206 J205 J204 J203 J202 J201 J216 J215 J214 J213 J212 J211 J210 J209 I-017 I-030 ET21140080 15– Chery Automobile Co., Ltd.
  • Page 722 Check if wire harnesses are worn, pierced, pinched or partially broken. f. Look for broken, bent, protruded or corroded terminals. g. Check that the related connector pins are in good condition. Repair or replace related wire harness and connector 15– Chery Automobile Co., Ltd.
  • Page 723 I-030 (J203) or I-017 (5) - Body Always No continuity ground/Battery positive I-030 (J205) or I-017 (8) - Body Always No continuity ground/Battery positive Repair or replace instrument panel wire harness and connector 15– Chery Automobile Co., Ltd.
  • Page 724 Connect the negative battery cable. c. Turn ignition switch ON. d. Connect X-431 3G diagnostic tester to Data Link Connector (DLC) to check if any DTC is detected. Repair or replace PEPS controller System operates normally 15– Chery Automobile Co., Ltd.
  • Page 725 9 10 11 12 13 14 E-073 E-065 E-074 B7 B8 B9 B10 E-067 E-071 J108 J107 J106 J105 J104 J103 J102 J101 J116 J115 J114 J113 J112 J111 J110 J109 I-029 I-013 E-069 ET21140030 15– Chery Automobile Co., Ltd.
  • Page 726 Check if fuses and relays are blown or damaged. Repair or replace damaged fuses and relays. Check engine compartment fuse and relay box ground a. Check engine compartment fuse and relay box ground E-078 (See page 51-42). 15– Chery Automobile Co., Ltd.
  • Page 727 No continuity ground E-069 (F17) or E-071 (8) - Body Always No continuity ground E-069 (F5) or E-071 (10) - Always No continuity Battery positive E-069 (F17) or E-071 (8) - Always No continuity Battery positive 15– Chery Automobile Co., Ltd.
  • Page 728 Multimeter Specified Condition 9 10 11 12 13 14 Connection Condition E-071 E-074 (I2) or E-071 (4) - Body Always No continuity ground RT21150320 E-074 (I2) or E-071 (4) - Always No continuity Battery positive 15– Chery Automobile Co., Ltd.
  • Page 729 9 10 11 12 13 14 Condition Connection Condition E-071 E-065 (K1) or E-071 (9) - Body Always No continuity ground RT21150340 E-065 (K1) or E-071 (9) - Always No continuity Battery positive Repair or replace engine compartment wire harness 15– Chery Automobile Co., Ltd.
  • Page 730 Check the wire harness between instrument panel wire harness connectors I-004 and I-013. Check for Open Multimeter Specified Condition Connection Condition I-004 (11) - I-013 Always Continuity I-013 I-004 (4) - I-013 Always Continuity I-004 (9) - I-013 Always Continuity I-004 RT21150360 15– Chery Automobile Co., Ltd.
  • Page 731 Connect the negative battery cable. c. Turn ignition switch ON. d. Connect X-431 3G diagnostic tester to Data Link Connector (DLC) to check if any DTC is detected. Repair or replace PEPS controller System operates normally 15– Chery Automobile Co., Ltd.
  • Page 732 J105 J104 J103 J102 J101 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 J116 J115 J114 J113 J112 J111 J110 J109 I-035 B-052 I-029 ET21140090 15– Chery Automobile Co., Ltd.
  • Page 733 Check if wire harnesses are worn, pierced, pinched or partially broken. f. Look for broken, bent, protruded or corroded terminals. g. Check that the related connector pins are in good condition. Repair or replace related wire harness and connector 15– Chery Automobile Co., Ltd.
  • Page 734 18 17 16 15 14 13 12 11 10 I-035 (16) - Body Always No continuity I-035 ground I-029 (J112) or I-035 (16) - Always No continuity Battery positive RT21150380 Repair or replace instrument panel wire harness 15– Chery Automobile Co., Ltd.
  • Page 735 Connect the negative battery cable. c. Turn ignition switch ON. d. Connect X-431 3G diagnostic tester to Data Link Connector (DLC) to check if any DTC is detected. Repair or replace PEPS controller System operates normally 15– Chery Automobile Co., Ltd.
  • Page 736 24 23 22 21 20 19 18 17 16 15 14 37 36 35 34 33 32 31 30 29 28 27 26 J108 J107 J106 J105 J104 J103 J102 J101 J116 J115 J114 J113 J112 J111 J110 J109 I-034 I-029 ET21140100 15– Chery Automobile Co., Ltd.
  • Page 737 Check if wire harnesses are worn, pierced, pinched or partially broken. f. Look for broken, bent, protruded or corroded terminals. g. Check that the related connector pins are in good condition. Repair or replace related wire harness and connector 15– Chery Automobile Co., Ltd.
  • Page 738 J106 J105 J104 J103 J102 J101 ground J116 J115 J114 J113 J112 J111 J110 J109 I-029 I-034 (3) or I-029 (J107) - Battery Always No continuity positive RT21150400 Repair or replace instrument panel wire harness 15– Chery Automobile Co., Ltd.
  • Page 739 (See page 25-71). b. Replace the ABS module. c. Connect X-431 3G diagnostic tester to Data Link Connector (DLC) again to check if any DTC is detected. Repair or replace PEPS controller System operates normally 15– Chery Automobile Co., Ltd.
  • Page 740 9 10 11 12 13 14 J116 J115 J114 J113 J112 J111 J110 J109 9 10 11 12 14 15 16 17 18 19 20 21 22 23 24 I-007 87 30 87 30 I-031 ET21140110 15– Chery Automobile Co., Ltd.
  • Page 741 Repair or replace damaged fuses and relays. Check engine compartment fuse and relay box ground a. Check engine compartment fuse and relay box ground E-078 (See page 51-42). Repair or replace ground wire harness or ground point 15– Chery Automobile Co., Ltd.
  • Page 742 Condition Connection Condition I-029 (J111) - Always 11 - 14 V J108 J107 J106 J105 J104 J103 J102 J101 Body ground J116 J115 J114 J113 J112 J111 J110 J109 I-029 Go to step 6 RT21150420 15– Chery Automobile Co., Ltd.
  • Page 743 14 15 16 17 18 19 20 21 22 23 24 Multimeter Specified Condition Connection Condition 87 30 87 30 I-007 (7) or I-029 (J111) - Body Always No continuity I-007 ground RT21150440 I-007 (7) or I-029 (J111) - Battery Always No continuity positive 15– Chery Automobile Co., Ltd.
  • Page 744 Check the CVT connector A. Gearshift Position Terminal No. Specified Condition 1 - 7, 9 - 10 7 - 8 2 - 7, 9 - 10 Continuity 3 - 7 4 - 7 Repair or replace CVT connector A 15– Chery Automobile Co., Ltd.
  • Page 745 No continuity ground I-029 (J113) or E-050 (10) - Body Always No continuity ground I-029 (J110) or E-050 (9) - Always No continuity Battery positive I-029 (J113) or E-050 (10) - Always No continuity Battery positive 15– Chery Automobile Co., Ltd.
  • Page 746 Connect related wire harness connectors. b. Connect the negative battery cable. c. Turn ignition switch ON. d. Connect X-431 3G diagnostic tester to Data Link Connector (DLC) to check if any DTC is detected. System operates normally 15– Chery Automobile Co., Ltd.
  • Page 747 Remove the starter (See page 15-64). b. Replace the starter. c. Connect X-431 3G diagnostic tester to Data Link Connector (DLC) again to check if any DTC is detected. Repair or replace PEPS controller System operates normally 15– Chery Automobile Co., Ltd.
  • Page 748 As shown in the illustration, rotate the clutch pinion clockwise to check that it rotates smoothly. Rotate the clutch pinion counterclockwise to check that it locks. If result is not as specified, replace the starter. Lock Free RT21150070 15– Chery Automobile Co., Ltd.
  • Page 749  As shown in the illustration, connect battery to the solenoid switch, and check that the starter clutch pinion extends. Terminal C Body RT21150100 If the starter clutch pinion does not move, replace the starter assembly. 15– Chery Automobile Co., Ltd.
  • Page 750  The lead to be connected should avoid the pinion side to prevent the lead from getting caught as the pinion rotates. If result is not as specified, replace the starter assembly. Installation Installation is in the reverse order of removal. 15– Chery Automobile Co., Ltd.
  • Page 751 RT21150140 b. Disconnect the ignition starting switch connector (1). c. Remove the fixing screws (arrow) from ignition starting switch. (Tightening torque: 13 ± 2 N·m) RT21150150 d. Remove the ignition starting switch. 15– Chery Automobile Co., Ltd.
  • Page 752 Terminal 4 - Terminal 5 START Continuity Terminal 4 - Terminal 6 Terminal 5 - Terminal 6 If result is not as specified, replace the ignition starting switch. Installation Installation is in the reverse order of removal. 15– Chery Automobile Co., Ltd.
  • Page 753 4. Remove the engine switch. a. Disconnect the engine switch connector (arrow). RT21150170 b. Detach 2 claws on engine switch in the direction of arrow as shown in the illustration, and remove the engine switch. RT21150180 15– Chery Automobile Co., Ltd.
  • Page 754 Battery positive (+) → Terminal 8 Battery negative Always Come on (green) (-) → Terminal 2 If result is not as specified, replace the engine switch Installation Installation is in the reverse order of removal. 15– Chery Automobile Co., Ltd.
  • Page 755  With PEPS controller not matched, do not carelessly turn on and off the power, as the non-matched PEPS controller has 50 chances to turn the power from off to ignition state, PEPS controller will not be used once more than 50 times. 15– Chery Automobile Co., Ltd.
  • Page 756 - MEMO - 15– Chery Automobile Co., Ltd.
  • Page 757 16-8 Circuit Diagram 16-5 Battery Tray and Tray Bracket 16-9 Removal 16-9 DIAGNOSIS & TESTING 16-6 Installation 16-9 Problem Symptoms Table 16-6 Alternator 16-10 Charging System Charging Voltage  Removal 16-10 Inspection 16-6 Installation 16-11 16– Chery Automobile Co., Ltd.
  • Page 758 16– Chery Automobile Co., Ltd.
  • Page 759 DC voltage through a rectifying circuit, as one of main power sources of the vehicle. The alternator operates as a complete assembly. If alternator fails for any reason, the entire unit must be replaced. 16– Chery Automobile Co., Ltd.
  • Page 760 Alternator Output Cable Fixing Nut 18 - 22 Alternator Fixing Bolt 20 + 5 Battery Specification Engine Type Battery Type Specification SQR484F 6-QW-70QR 12 V, 70 Ah, CCA (SAE) 560 A Tool General Tool Digital Multimeter RCH0000002 16– Chery Automobile Co., Ltd.
  • Page 761 E-027 9 10 11 12 38 34 14 15 16 17 18 19 20 21 22 23 24 C1 C2 C3 C4 C5 C7 C8 C9 C10 87 30 87 30 E-023 I-007 E-007 ET21160010 16– Chery Automobile Co., Ltd.
  • Page 762  If charging system warning light comes on, the charging system may have a malfunction.  If noises are heard from alternator or generating capacity is extremely high or low, repair or replace the alternator. 16– Chery Automobile Co., Ltd.
  • Page 763 Remove the battery pressure plate fixing nut (1). (Tightening torque: 7 ± 1 N·m) d. Remove the coupling bolt (2) between battery pressure plate and tank upper crossmember. (Tightening torque: 7 ± 1 N·m) RT21160030 16– Chery Automobile Co., Ltd.
  • Page 764  Replace battery with a new one which conforms to the specifications.  Used battery contains sulfuric acid and lead, so never discard it at will. Please dispose of it at a qualified local waste treatment station. 16– Chery Automobile Co., Ltd.
  • Page 765 4. Remove the battery tray bracket. a. Remove 4 fixing bolts (arrow) from the battery tray bracket. (Tightening torque: 20 ± 2 N·m) RT21160050 b. Remove 2 battery tray brackets. Installation Installation is in the reverse order of removal. 16– Chery Automobile Co., Ltd.
  • Page 766 (Tightening torque: 18 - 22 N·m) b. Disconnect the alternator connector (2). RT21160070 c. Remove 2 fixing bolts (arrow) from the alternator. (Tightening torque: 20 + 5 N·m) RT21160080 d. Remove the alternator from alternator bracket. 16– Chery Automobile Co., Ltd.
  • Page 767 16 - SQR484F CHARGING SYSTEM Installation Installation is in the reverse order of removal. 16– Chery Automobile Co., Ltd.
  • Page 768 - MEMO - 16– Chery Automobile Co., Ltd.
  • Page 769 Inspection 17-56 Removal 17-18 Transmission External Accessory 17-57 Installation 17-19 Removal 17-57 Gear Shift Control Mechanism 17-20 Installation 17-58 Removal 17-20 Transmission Case 17-60 Installation 17-20 Disassembly 17-60 Transmission Assembly 17-21 Assembly 17-63 Removal 17-21 17– Chery Automobile Co., Ltd.
  • Page 770 17– Chery Automobile Co., Ltd.
  • Page 771 17 - QR525MHE TRANSMISSION GENERAL INFORMATION QR525MHE TRANSMISSION Description Input Shaft RT21170010 17– Chery Automobile Co., Ltd.
  • Page 772 16 - 3rd-4th Synchronizer Meshing Key and Spring 17 - 3rd-4th Synchronizer Outer Race 18 - 3rd Synchronizer Ring 19 - 3rd Drive Gear 20 - 3rd Needle Roller Bearing 21 - Input Shaft 22 - Input Shaft Front Bearing 17– Chery Automobile Co., Ltd.
  • Page 773 17 - QR525MHE TRANSMISSION Output Shaft RT21170020 17– Chery Automobile Co., Ltd.
  • Page 774 11 - Snap Ring 12 - 1st-2nd Synchronizer Gear Hub 13 - 1st Synchronizer Ring Set 14 - 1st Driven Gear 15 - 1st Needle Roller Bearing 16 - Output Shaft 17 - Output Shaft Front Bearing 17– Chery Automobile Co., Ltd.
  • Page 775 8 - Oil Guide 9 - Transmission Case 10 - Washer 11 - Transmission Retaining Bolt 12 - Washer 13 - Drain Plug 14 - Bearing Outer Race 15 - Adjustment Washer 16 - Differential Oil Seal 17– Chery Automobile Co., Ltd.
  • Page 776 Transmission Upper Coupling Bolt 60 ± 5 Engine Side Coupling Bolt 60 ± 5 Transmission Gear Ratio Table Gear Ratio Type QR525MHE Gear Gear Gear Ratio 3.583 2.053 1.379 1.03 0.821 Reverse 3.417 Final Drive 4.313 Speedometer 0.806 17– Chery Automobile Co., Ltd.
  • Page 777 Loosen the retaining plug of transmission, add lubricant to QR525 transmission with a special filling device until the lubricant is flowing out from the retaining plug, and then tighten the retaining plug. Tools Special Tools Input Shaft Oil Seal Installer RCH0000008 Differential Oil Seal Installer RCH0000009 Installer Joint RCH0000010 17– Chery Automobile Co., Ltd.
  • Page 778 17 - QR525MHE TRANSMISSION Bearing Remover RCH0000011 Punch RCH0000015 Puller RCH0000059 17– Chery Automobile Co., Ltd.
  • Page 779 17 - QR525MHE TRANSMISSION General Tools Transmission Carrier RCH0000005 Engine Equalizer RCH0000026 Hydraulic Press RCH0000012 17– Chery Automobile Co., Ltd.
  • Page 780 Release fork makes a "click" sound when release fork and hydraulic sub cylinder or clutch pedal is depressed joint surface of release fork and ball joint housing Shift drive train (loose) No shift Driver rocker arm (loose) 17– Chery Automobile Co., Ltd.
  • Page 781 Standard capacity: 2.2 L ± 0.1 L CAUTION  An excessively large or small amount of oil may affect proper functioning of transmission.  After filling oil, run the vehicle, and then check the oil level. 17– Chery Automobile Co., Ltd.
  • Page 782 (Tightening torque: 40 ± 6 N·m) RT21170050 6. Fill transmission oil. CAUTION  Only use transmission oil approved by Chery Automobile Co., Ltd. a. Make sure that transmission drain plug has been tightened in place. 17– Chery Automobile Co., Ltd.
  • Page 783 Replace the retaining plug washer and tighten the retaining plug after filling. (Tightening torque: 40 ± 6 N·m) Transmission Oil Type Model 1.5 L MT Transmission Oil Type API GL-4, 75W-90 Filling Capacity 2.2 L ± 0.1 L 17– Chery Automobile Co., Ltd.
  • Page 784 5. Pull out the oil seal with a puller. RT21170070 Installation 1. Apply an appropriate amount of transmission oil to the lip of new oil seal. 2. Using a special tool and a hammer, tap in the oil seal. RT21170080 17– Chery Automobile Co., Ltd.
  • Page 785 17 - QR525MHE TRANSMISSION CAUTION  DO NOT damage the oil seal during installation. 3. Fill transmission oil. Other procedures are in the reverse order of removal. 17– Chery Automobile Co., Ltd.
  • Page 786 8. Disconnect the select and shift cable from gear shift control mechanism. a. Remove the flexible shaft clamps and cotter pins connecting select and shift cable with gear shift control mechanism. RT21170110 9. Remove the gear select and shift cable. 17– Chery Automobile Co., Ltd.
  • Page 787 17 - QR525MHE TRANSMISSION Installation Installation is in the reverse order of removal. CAUTION  DO NOT install the select and shift cable in reverse position during installation. 17– Chery Automobile Co., Ltd.
  • Page 788 RT21170110 b. Remove the fixing bolts from gear shift control mechanism, and remove the gear shift control mechanism. (Tightening torque: 23 ± 2 N·m) RT21170130 Installation Installation is in the reverse order of removal. 17– Chery Automobile Co., Ltd.
  • Page 789 17.Remove the starter (See page 15-64). 18.Remove the transmission. a. Support transmission assembly with transmission carrier. b. Remove the transmission lower coupling bolts, and remove the seal plate. (Tightening torque: 50 ± 5 N·m) RT21170150 17– Chery Automobile Co., Ltd.
  • Page 790 1. Remove the gear shift mechanism locating bolt. a. Remove the gear shift mechanism locating bolt (arrow) from transmission assembly. RT21170180 2. Remove the back-up light switch. a. Remove the back-up light switch (arrow) from transmission assembly. RT21170190 17– Chery Automobile Co., Ltd.
  • Page 791 Remove the shift shaft locating bolts (1) from transmission assembly. RT21170220 5. Remove the reverse idler gear shaft locating bolt. a. Remove the reverse idler gear shaft locating bolt (arrow) from transmission assembly. RT21170230 17– Chery Automobile Co., Ltd.
  • Page 792 RT21170260 7. Remove the reverse gear fork. a. Remove the fixing bolts (arrow) from reverse gear fork, and remove the reverse gear fork (1). RT21170270 17– Chery Automobile Co., Ltd.
  • Page 793 (2) together from clutch case. RT21170280 9. Remove the input shaft rear washer. a. Remove the input shaft rear washer (1) from input shaft. RT21170290 10.Remove the magnet. a. Remove the magnet (1) from clutch case. RT21170300 17– Chery Automobile Co., Ltd.
  • Page 794  Prevent interference between output shaft bearing cage and differential big ring gear and avoid damaging bearing cage during removal. 12.Remove the gear fork assembly. a. Remove the shift fork assembly (1) from input shaft and output shaft (2). RT21170320 17– Chery Automobile Co., Ltd.
  • Page 795 (1) to the clutch case in the direction of arrow. RT21170340 2. Install the shift fork assembly. a. Install the shift fork assembly (1) to the input shaft and output shaft (2). RT21170320 17– Chery Automobile Co., Ltd.
  • Page 796 RT21170280 5. Install the reverse gear fork. a. Install the reverse gear fork (1) to the clutch case, and tighten the reverse gear fork fixing bolts (arrow). (Tightening torque: 25 ± 2 N·m) RT21170270 17– Chery Automobile Co., Ltd.
  • Page 797 Install the transmission case to the clutch case. RT21170370 CAUTION  Remove the seal gum residues from the case.  Make sure the joint surface of case is free of oil, and uniformly apply seal gum. 17– Chery Automobile Co., Ltd.
  • Page 798 (Tightening torque: 40 ± 4 N·m) RT21170230 10.Install the gear shift mechanism. a. Install gear shift mechanism transmission case. RT21170380 CAUTION  Clean the engagement portion of shifter case and transmission case, and apply seal gum evenly. 17– Chery Automobile Co., Ltd.
  • Page 799 (Tightening torque: 35 ± 5.25 N·m) RT21170180 12.Install the back-up light switch. HINT: Apply thread adhesive to thread before installation. a. Install the back-up light switch (arrow) to the transmission case. (Tightening torque: 20 ± 2 N·m) RT21170190 17– Chery Automobile Co., Ltd.
  • Page 800 Install the shift shaft locating bolts (1) to the transmission case. (Tightening torque: 35 ± 5.25 N·m) RT21171070 Installation Installation is in the reverse order of removal. CAUTION  After installation, add transmission oil and check the oil level. 17– Chery Automobile Co., Ltd.
  • Page 801 6. Tap out the dowel pin (2) with a punch (1). 7. Remove the shift arm (3) and plate (4). RT21170410 8. Tap out the dowel pin (2) with a punch (1). 9. Remove the shift finger (3). RT21170420 17– Chery Automobile Co., Ltd.
  • Page 802 17 - QR525MHE TRANSMISSION Assembly Assembly is in the reverse order of disassembly. CAUTION  Tighten bolts to the specified torque.  Replace damaged dowel pins. 17– Chery Automobile Co., Ltd.
  • Page 803 Remove the reverse gear fork (1) and return spring (2). RT21170440 2. Remove the 3rd-4th gear shift fork. a. Using a punch (1), tap out the dowel pin (3) from  3rd-4th gear shift shaft (2). RT21170450 17– Chery Automobile Co., Ltd.
  • Page 804 Separate the 1st-2nd gear shift fork (1) from gear shift shaft (2). RT21170480 4. Remove the fork. a. Using a punch (1), tap out the dowel pin (3) from gear shift shaft (2). RT21170490 17– Chery Automobile Co., Ltd.
  • Page 805 2. Check release fork for excessive wear or damage. Replace if it is damaged. Assembly Assembly is in the reverse order of disassembly. CAUTION  When installing dowel pin, if there is excessive wear or damage, replace with a new one. 17– Chery Automobile Co., Ltd.
  • Page 806 Using a special tool (1), secure the input shaft rear bearing (2). RT21170530 b. Using a hydraulic press (1), press the input shaft rear bearing (3) out of input shaft (2) and remove the input shaft rear bearing. RT21170540 17– Chery Automobile Co., Ltd.
  • Page 807 6. Remove the 5th needle roller bearing. a. Remove the 5th needle roller bearing (1) from input shaft. RT21170570 7. Remove the 5th drive gear needle roller bearing bushing and 4th drive gear. a. Install a special tool. RT21170580 17– Chery Automobile Co., Ltd.
  • Page 808 9. Remove the 3rd drive gear and 3rd-4th synchronizer gear hub. a. Remove the synchronizer ring (arrow) from 3rd-4th synchronizer gear hub. RT21170610 b. Using snap spring calipers (1), remove the snap ring (2). RT21170620 17– Chery Automobile Co., Ltd.
  • Page 809 10.Remove the 3rd needle roller bearing. a. Remove the 3rd needle roller bearing (1) from input shaft. RT21170650 11. Remove the input shaft front bearing. a. Using a special tool (1), secure the input shaft front bearing (2). RT21170660 17– Chery Automobile Co., Ltd.
  • Page 810  When pressing input shaft front bearing, make sure that pressure is applied to the bearing inner race as the bearing may be damaged due to uneven force. 2. Install the 3rd needle roller bearing. a. Apply transmission oil to the needle roller bearing (1), and install it to the input shaft. RT21170650 17– Chery Automobile Co., Ltd.
  • Page 811 5. Install the 3rd-4th synchronizer gear. a. Using a hydraulic press (3), press the 3rd-4th synchronizer gear (1) into the input shaft. RT21170710 CAUTION  When pressing synchronizer gear, prevent the 3rd drive gear (2) from disengaging. 17– Chery Automobile Co., Ltd.
  • Page 812 RT21170720 9. Install the 5th drive gear needle roller bearing bushing. a. Using a hydraulic press (1), press the 5th drive gear needle roller bearing bushing (2) into the input shaft. RT21170730 17– Chery Automobile Co., Ltd.
  • Page 813 Using a hydraulic press (3), press the 5th synchronizer gear (2) and 5th synchronizer gear hub (1) together into the input shaft. RT21170750 CAUTION  When pressing synchronizer gear hub, prevent the 5th drive gear from disengaging. 17– Chery Automobile Co., Ltd.
  • Page 814 (1) and 3rd-4th synchronizer outer race (2), and install them to the input shaft. RT21170780 15.Install the input shaft rear bearing snap ring. a. Using snap spring calipers, install the rear bearing snap ring. RT21170790 17– Chery Automobile Co., Ltd.
  • Page 815 Standard value: 1.35 mm Limit value: 1.100 - 1.600 mm RT21173041 3. Using a feeler gauge, measure clearance between 2nd drive gear and 3rd drive gear. Standard value: 0.65 mm Limit value: 0.45 - 0.85 mm RT21173042 17– Chery Automobile Co., Ltd.
  • Page 816 3. Remove the 5th driven gear and 4th driven gear. a. Using snap spring calipers (1), remove the snap ring. RT21170820 b. Using a special tool (1), secure the 5th and 4th driven gear set (2). RT21170830 17– Chery Automobile Co., Ltd.
  • Page 817 Using a special tool (1), secure the 2nd driven gear (2). RT21170860 b. Using a hydraulic press (1), press the 2nd and 3rd driven gears (3) out of output shaft (2), and remove the 2nd driven gear and 3rd driven gear. RT21170870 17– Chery Automobile Co., Ltd.
  • Page 818 Remove the 1st-2nd synchronizer ring set (2). b. Remove the 1st-2nd synchronizer outer race (1). RT21170890 c. Using snap spring calipers (1), remove the snap ring (2). RT21170900 d. Secure a special tool to the 1st driven gear. RT21170910 17– Chery Automobile Co., Ltd.
  • Page 819 Using a special tool (1), secure the output shaft front bearing (2). RT21170940 b. Using a hydraulic press (1), press the output shaft front bearing (3) out of output shaft (2), and remove the output shaft front bearing. RT21170950 17– Chery Automobile Co., Ltd.
  • Page 820 Apply transmission oil to the 1st needle roller bearing (1), and install it to the output shaft. RT21170930 3. Install the 1st driven gear. a. Apply transmission oil to the 1st driven gear (1), and install it to the output shaft. RT21170970 17– Chery Automobile Co., Ltd.
  • Page 821 Using snap spring calipers (1), install the snap ring (2). RT21170900 6. Install the synchronizer ring set. a. Apply transmission oil to the synchronizer ring set (arrow), and install it to the output shaft. RT21171000 17– Chery Automobile Co., Ltd.
  • Page 822 Apply transmission oil to the 2nd driven gear (1), and install it to the output shaft. RT21171020 10.Install the 3rd driven gear. a. Using a hydraulic press, press the 3rd driven gear (1) into the output shaft. RT21171030 17– Chery Automobile Co., Ltd.
  • Page 823 Using a special tool (1), secure the 4th and 5th driven gears (2). RT21171040 b. Using a hydraulic press (1), press the 4th and 5th driven gears (3) into the output shaft (2). RT21171050 c. Using snap spring calipers (1), install the snap ring. RT21170820 17– Chery Automobile Co., Ltd.
  • Page 824 Standard value: 1.54 mm Limit value: 1.240 - 1.840 mm RT21173052 3. Using a feeler gauge, measure clearance between 2nd driven gear and 3rd driven gear. Standard value: 1.2 mm Limit value: 0.72 - 1.68 mm RT21173053 17– Chery Automobile Co., Ltd.
  • Page 825 Remove the gear shift mechanism locating bolt (arrow) from transmission case. RT21170180 5. Remove the reverse idler gear shaft locating bolt. a. Remove the reverse idler gear shaft locating bolt (arrow) from transmission case. RT21171080 17– Chery Automobile Co., Ltd.
  • Page 826 (Tightening torque: 35 ± 5.25 N·m) RT21170180 3. Install the back-up light switch. HINT: Apply thread adhesive to thread before installation. a. Install the back-up light switch (arrow) to the transmission case. (Tightening torque: 20 ± 2 N·m) RT21170190 17– Chery Automobile Co., Ltd.
  • Page 827 17 - QR525MHE TRANSMISSION 4. Install the shift shaft locating bolt. HINT: Apply thread adhesive to thread before installation. a. Install the shift shaft locating bolts (1) to the transmission case. (Tightening torque: 35 ± 5.25 N·m) RT21171070 17– Chery Automobile Co., Ltd.
  • Page 828 Secure the bearing outer race puller joint (1) to the bearing outer race (2). RT21171090 b. Install the puller (1) to the bearing outer race remover (2), and pull out bearing outer race (3) with the puller. RT21172000 17– Chery Automobile Co., Ltd.
  • Page 829 Using a flat tip screwdriver (1), pry out the input shaft oil seal (2). RT21172020 4. Remove the output shaft bearing outer race. a. Secure the output shaft end bearing outer race puller joint (1) to the output shaft bearing outer race (2). RT21172030 17– Chery Automobile Co., Ltd.
  • Page 830 Using the puller, pull out the output shaft bearing outer race (3). RT21172040 5. Remove the oil deflector. a. Remove the oil deflector (1) from clutch case. RT21172050 6. Remove the magnet. a. Remove the magnet (1) from clutch case. RT21172060 17– Chery Automobile Co., Ltd.
  • Page 831 (2) to the transmission case (3). RT21172080 CAUTION  Apply a proper amount of transmission oil to the lip when installing the oil seal. 2. Install the oil deflector. a. Install the oil deflector (1) to the clutch case. RT21172090 17– Chery Automobile Co., Ltd.
  • Page 832 Install the joint (1) to the bearing outer race (2), and install the bearing outer race (2) to the case (3) with a rubber hammer (4). RT21173010 5. Install the magnet. a. Install the magnet (1) to the clutch case. RT21173020 17– Chery Automobile Co., Ltd.
  • Page 833 17 - QR525MHE TRANSMISSION 6. Install the oil guide. a. Install the oil guide (1) to the transmission case. RT21173030 17– Chery Automobile Co., Ltd.
  • Page 834 - MEMO - 17– Chery Automobile Co., Ltd.
  • Page 835 Removal 18-115 P0792 18-58 Installation 18-115 P0811 18-62 Turbine Speed Sensor 18-116 P081E 18-62 Removal 18-116 P0894 18-62 Installation 18-116 P0842 18-64 Primary Shaft Pressure Sensor 18-117 P0843 18-64 Removal 18-117 P0847 18-68 Installation 18-117 18– Chery Automobile Co., Ltd.
  • Page 836 Removal 18-119 Removal 18-127 Installation 18-120 Installation 18-128 Valve Body Case 18-121 18-129 Removal 18-121 Removal 18-129 Installation 18-121 Installation 18-129 Valve Body 18-122 CVT Assembly 18-130 Removal 18-122 Removal 18-130 Installation 18-123 Installation 18-133 18– Chery Automobile Co., Ltd.
  • Page 837  It can reduce vehicle emission and NVH (Noise, Vibration, Harshness).  It can improve vehicle economy and reduce fuel consumption.  Accelerator pedal responses rapidly when accelerating. Acceleration is gentle and smooth without impact. 18– Chery Automobile Co., Ltd.
  • Page 838 6 - Input Shaft 7 - Oil Pump Thrust Gasket 8 - Oil Pump 9 - Output Shaft 10 - Differential 11 - Steel Belt 12 - Output Pulley Shaft 13 - Input Pulley Shaft 18– Chery Automobile Co., Ltd.
  • Page 839 18 - QR019CHB CVT RT21180020 1 - Gear Shift Cable 2 - Gear Shift Lever Knob 3 - Gear Indicator Panel 4 - Gear Shift Control Mechanism 5 - Gear Shift Cable Dust Boot 18– Chery Automobile Co., Ltd.
  • Page 840 RT21180030 1 - Turbine Speed Sensor 2 - Secondary Shaft Speed Sensor 3 - Secondary Shaft Pressure Sensor 4 - Primary Shaft Speed Sensor 5 - Primary Shaft Pressure Sensor 6 - Transmission Range Sensor 18– Chery Automobile Co., Ltd.
  • Page 841 Right illustration shows the low speed ratio: Transmission oil passage 1. Input pulley Low speed ratio 2. Output pulley pressure 3. Input circle 4. Output circle V-belt Clamping pressure oil RT21180040 18– Chery Automobile Co., Ltd.
  • Page 842 Transmission gears are regulated by the electronic gear shift system. The TCU processes the input signals and regulates transmission hydraulic system by exploiting the information received. RT21180070 18– Chery Automobile Co., Ltd.
  • Page 843  In the automatic mode, when the engine speed is too low, it will automatically shift down; and shift up when the engine speed is high.  In the manual mode, the driver should shift up the gear in advance based on the experience to prevent the engine speed entering the red area of tachometer. 18– Chery Automobile Co., Ltd.
  • Page 844 RT21180120 Fluid Pressure Sensor The transmission fluid pressure sensor is used to monitor the CVT pulley shaft pressure and send the signals to the TCU. RT21180130 18– Chery Automobile Co., Ltd.
  • Page 845 The gear shift lock solenoid (arrow) is installed in the transmission gear shift control mechanism. Before moving out of the "P" gear, the brake pedal should be fully depressed and the ignition switch set to the "ON" position. RT21180170 18– Chery Automobile Co., Ltd.
  • Page 846 Input pulley shaft oil pressure Secondary shaft speed sensor control solenoid Output pulley shaft oil pressure Oil temperature sensor control solenoid Clutch control solenoid Transmission range sensor Gear shift lock solenoid Mode select switch Oil pressure sensor RT21180190 18– Chery Automobile Co., Ltd.
  • Page 847 18 - QR019CHB CVT Tools Special Tools Puller RCH0000059 Differential Oil Seal Installer RCH0000009 General Tools Engine Equalizer RCH0000026 Transmission Carrier RCH0000005 18– Chery Automobile Co., Ltd.
  • Page 848 Final Drive Ratio 5.141 Pulley Speed Ratio Scope 0.44 - 2.39 Solenoid Quantity Gear Shift Positions P, R, N, D, L, M (manual mode) Fluid Type SP - III Transmission Fluid Capacity (L) 8.0 ± 0.2 18– Chery Automobile Co., Ltd.
  • Page 849 43 44 45 46 47 48 49 50 51 52 53 54 55 56 J2 J1 E-030 E-066 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 ET21180010 18– Chery Automobile Co., Ltd.
  • Page 850 15 16 17 18 19 20 21 22 23 24 25 26 27 28 B-054 9 10 11 12 14 15 16 17 18 19 20 21 22 23 24 B-004 I-007 I-006 87 30 87 30 ET21180020 18– Chery Automobile Co., Ltd.
  • Page 851 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E-050 E-022 9 10 11 12 14 15 16 17 18 19 20 21 22 23 24 87 30 87 30 I-007 I-004 E-069 ET21180030 18– Chery Automobile Co., Ltd.
  • Page 852 15 16 17 18 19 20 21 22 23 24 25 26 27 28 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 E-083 E-049 E-079 E-080 E-054 ET21180040 18– Chery Automobile Co., Ltd.
  • Page 853 33 34 35 36 37 38 39 40 41 42 43 44 45 46 E-029 E-033 17 18 19 20 21 22 23 24 25 26 27 28 29 30 9 10 11 12 13 14 ET21180050 18– Chery Automobile Co., Ltd.
  • Page 854 Primary Shaft Speed Sensor Ground Secondary Shaft Speed Sensor Signal Ground Primary Shaft Speed Sensor Signal Ground Ground Secondary Shaft Speed Sensor Power Primary Shaft Speed Sensor Power Turbine Speed Sensor Power KL15 Power Supply 18– Chery Automobile Co., Ltd.
  • Page 855 5. Remove the battery, battery tray and tray bracket (See page 16-7). 6. Remove the connecting nut (3) of the gear shift cable (1) and shift arm (2). Disconnect the gear shift cable from the shift arm. RT21180210 18– Chery Automobile Co., Ltd.
  • Page 856 Specified Condition 1 - 7, 9 - 10 7 - 8 2 - 7, 9 - 10 Continuity 3 - 7 4 - 7 If result is not as specified, replace the transmission range sensor. 18– Chery Automobile Co., Ltd.
  • Page 857 The inner parts of the sensor are triode and capacitor, and will be affected greatly by the environment and usage condition. Therefore, the actual measured value is within the specified value plus/minus 15% in the table below. Item Multimeter Connection Specified Condition (MΩ) 3.313 Primary Shaft Speed Sensor 6.56 1.649 11.56 18– Chery Automobile Co., Ltd.
  • Page 858 The inner parts of the sensor are triode and capacitor, and will be affected greatly by the environment and usage condition. Therefore, the actual measured value is within the specified value plus/minus 15% in the table below. Item Multimeter Connection Specified Condition (MΩ) 3.397 Turbine/Secondary Shaft Speed 6.79 Sensor 1.77 11.9 18– Chery Automobile Co., Ltd.
  • Page 859 Therefore, the actual measured value is within the specified value plus/minus 15% in the table below. Item Multimeter Connection Specified Condition (KΩ) 1 - 3 45.77 Primary/Secondary Shaft Pressure Sensor 2 - 1 10.06 18– Chery Automobile Co., Ltd.
  • Page 860 7. Inspect and clean all engine control module (ECM) grounds that are related to the latest DTC. 8. If multiple trouble codes were set, use the circuit diagrams and look for any common ground circuit or power supply circuit applied to the DTC. 18– Chery Automobile Co., Ltd.
  • Page 861 Input/Turbine Speed Sensor Circuit P0716 Input/Turbine Speed Sensor Circuit Range P0717 Input/Turbine Speed Sensor Circuit No Signal P0718 Input/Turbine Speed Sensor Circuit Intermittent P0719 Brake Switch 'B' Circuit Low P071A Transmission Sport Mode Switch Circuit 18– Chery Automobile Co., Ltd.
  • Page 862 Intermediate Shaft Speed Sensor 'A' Circuit Range P0793 Intermediate Shaft Speed Sensor 'A' Circuit No Signal P0794 Intermediate Shaft Speed Sensor 'A' Circuit Intermittent P0811 Drive Clutch 'A' Slippage P0814 Transmission Range Display Circuit P0815 Upshift Switch Circuit 18– Chery Automobile Co., Ltd.
  • Page 863 TCM Communication Circuit High P0867 Transmission Fluid Pressure P0868 Transmission Fluid Pressure Low P0869 Transmission Fluid Pressure High P0880 TCM Power Input Signal P0881 TCM Power Input Signal Range P0882 TCM Power Input Signal Low 18– Chery Automobile Co., Ltd.
  • Page 864 Auto Shift Manual Mode Circuit Low P0958 Auto Shift Manual Mode Circuit High P0959 Auto Shift Manual Mode Circuit Intermittent P0960 Pressure Control Solenoid 'A' Control Circuit Open P0961 Pressure Control Solenoid 'A' Control Circuit Range 18– Chery Automobile Co., Ltd.
  • Page 865 Transmission engagement gear P gear Driver request 0.00% Battery voltage 13.00 V Transmission engagement gear Reverse Driver request 0.00% Battery voltage 13.00 V Transmission engagement gear N gear Driver request 0.00% Battery voltage 13.00 V 18– Chery Automobile Co., Ltd.
  • Page 866 Engine torque signal in CAN Engine coolant temperature 93.7°C Transmission engagement gear N gear Drive pulley pressure 2.1 Bar Oil temperature 73°C Driven pulley pressure 9.9 Bar Driver request 0.00% Engine torque signal in CAN Engine coolant temperature 94.5°C 18– Chery Automobile Co., Ltd.
  • Page 867 Driven pulley duty ratio 76.135% Transmission engagement gear (transmission P gear position) Transmission engagement gear (transmission Common code working mode) Transmission engagement gear (transmission fault) Non-default Coolant temperature signal in CAN 93°C Oil temperature 77°C 18– Chery Automobile Co., Ltd.
  • Page 868 Driven pulley speed 0 rpm CAN Network Data Stream Item Engine Idle Speed Engine speed 702.75 rpm Driver request 0.00% Vehicle speed 0.00 km/h Engine coolant temperature 90.75°C Driver request 0.00 NM Torque converter status Unlock 18– Chery Automobile Co., Ltd.
  • Page 869 43 44 45 46 47 48 49 50 51 52 53 54 55 56 J2 J1 E-030 E-066 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 ET21180060 18– Chery Automobile Co., Ltd.
  • Page 870 Check if TCU relay 12 operates normally Replace TCU relay 12 Check if ignition switch to fuse box TCU fuse and relay circuit and battery to fuse box TCU fuse and relay circuit are normal Repair or replace failed circuit 18– Chery Automobile Co., Ltd.
  • Page 871 43 44 45 46 47 48 49 50 51 52 53 54 55 56 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E-030 RT21180810 18– Chery Automobile Co., Ltd.
  • Page 872 Check if the output voltage of the terminal J2 of connector E-066 is normal. J2 J1 E-066 RT21180820 d. Check if the terminal J2 of connector E-066 and ground is conductive. J2 J1 E-066 RT21180830 18– Chery Automobile Co., Ltd.
  • Page 873 Check if the terminal F18 of connector E-069 and ground is conductive. E-069 RT21180850 g. Check if the output voltage of the terminal A2 and A4 of connector E-076 is normal. A3 A4 A5 A7 A8 A9 A10 E-076 RT21180860 18– Chery Automobile Co., Ltd.
  • Page 874 18 - QR019CHB CVT h. Check if the terminal A2 and A4 of connector E-076 and ground is conductive. Replace compartment fuse and relay box A3 A4 A5 A7 A8 A9 A10 E-076 RT21180870 Replace TCU 18– Chery Automobile Co., Ltd.
  • Page 875 43 44 45 46 47 48 49 50 51 52 53 54 55 56 E-030 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 ET21180070 18– Chery Automobile Co., Ltd.
  • Page 876 43 44 45 46 47 48 49 50 51 52 53 54 55 56 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E-030 E-087 RT21180880 18– Chery Automobile Co., Ltd.
  • Page 877 Repair or replace failed circuit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E-030 RT21180890 Replace TCU 18– Chery Automobile Co., Ltd.
  • Page 878 43 44 45 46 47 48 49 50 51 52 53 54 55 56 E-030 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E-050 ET21180080 18– Chery Automobile Co., Ltd.
  • Page 879 Disconnect the negative battery cable. c. Disconnect the transmission range sensor connector and shift the lever to each gear. d. Check if the terminals of the transmission range sensor connector connects well (See page 18-119). Replace transmission range sensor 18– Chery Automobile Co., Ltd.
  • Page 880 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E-030 E-087 RT21180900 Check for DTC a. Using X-431 3G diagnostic tester, select Read Code. b. Check if DTC P0705 still exists. Replace TCU 18– Chery Automobile Co., Ltd.
  • Page 881 18 - QR019CHB CVT System is normal 18– Chery Automobile Co., Ltd.
  • Page 882 43 44 45 46 47 48 49 50 51 52 53 54 55 56 E-030 1 2 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E-049 ET21180090 18– Chery Automobile Co., Ltd.
  • Page 883 After the fault is eliminated, verify DTC and symptom again. Check wire harness connector a. Turn ignition switch to LOCK. b. Disconnect the turbine speed sensor connector. c. Check if the turbine speed sensor connector is dirty, oxidized, loose or damaged. Repair fault 18– Chery Automobile Co., Ltd.
  • Page 884 43 44 45 46 47 48 49 50 51 52 53 54 55 56 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E-030 RT21180930 18– Chery Automobile Co., Ltd.
  • Page 885 Check whether the system is normal. Diagnosis complete Check for DTC a. Using X-431 3G diagnostic tester, select Read Code. b. Check if DTC P0715 or P0716 still exists. Replace TCU System is normal 18– Chery Automobile Co., Ltd.
  • Page 886 43 44 45 46 47 48 49 50 51 52 53 54 55 56 E-030 1 2 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E-079 ET21180100 18– Chery Automobile Co., Ltd.
  • Page 887 After the fault is eliminated, verify DTC and symptom again. Check wire harness connector a. Turn ignition switch to LOCK. b. Disconnect the secondary speed sensor connector. c. Check if the secondary speed sensor connector is dirty, oxidized, loose or damaged. Repair fault 18– Chery Automobile Co., Ltd.
  • Page 888 43 44 45 46 47 48 49 50 51 52 53 54 55 56 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E-030 RT21180960 18– Chery Automobile Co., Ltd.
  • Page 889 Using the X-431 3G diagnostic tester, check whether the system is normal. Diagnosis complete Check for DTC a. Using X-431 3G diagnostic tester, select Read Code. b. Check if DTC P0720 or P1745 still exists. Replace TCU System is normal 18– Chery Automobile Co., Ltd.
  • Page 890 Transmission sensor (check for damage, dirt and other fault) c. Are all checks OK? Repair fault Check transmission system a. Use diagnostic tester to check the transmission system. b. Is there any DTC except for P0730? 18– Chery Automobile Co., Ltd.
  • Page 891 Repair fault Check for DTC a. Using X-431 3G diagnostic tester, select Read Code. b. Refer to "DTC Confirmation Procedure". c. Is DTC P0730 still present? Replace solenoid and wire harness assembly System is normal 18– Chery Automobile Co., Ltd.
  • Page 892 43 44 45 46 47 48 49 50 51 52 53 54 55 56 E-030 1 2 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E-083 ET21180110 18– Chery Automobile Co., Ltd.
  • Page 893 Check wire harness connector a. Turn ignition switch to LOCK. b. Disconnect the primary shaft speed sensor connector. c. Check if the primary shaft speed sensor connector is dirty, oxidized, loose or damaged. Repair fault 18– Chery Automobile Co., Ltd.
  • Page 894 43 44 45 46 47 48 49 50 51 52 53 54 55 56 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E-030 RT21180990 18– Chery Automobile Co., Ltd.
  • Page 895 Using the X-431 3G diagnostic tester, check whether the system is normal. Diagnosis complete Check for DTC a. Using X-431 3G diagnostic tester, select Read Code. b. Check if DTC P0791 or P0792 still exists. Replace TCU System is normal 18– Chery Automobile Co., Ltd.
  • Page 896  If DTC is detected, the malfunction indicated by the DTC is current. Go to the diagnosis procedure - Step 1.  If DTC is not detected, the malfunction indicated by the DTC is intermittent. Please refer to Intermittent DTC Troubleshooting. 18– Chery Automobile Co., Ltd.
  • Page 897 Check for DTC a. Using X-431 3G diagnostic tester, select Read Code. b. Refer to "DTC Confirmation Procedure". c. Is DTC P0811, P081E or P0894 still present? Replace solenoid and wire harness assembly System is normal 18– Chery Automobile Co., Ltd.
  • Page 898 43 44 45 46 47 48 49 50 51 52 53 54 55 56 E-030 1 2 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E-054 ET21180120 18– Chery Automobile Co., Ltd.
  • Page 899 Check wire harness connector a. Turn ignition switch to LOCK. b. Disconnect the primary shaft pressure sensor connector. c. Check if the primary shaft pressure sensor connector is dirty, oxidized, loose or damaged. Repair fault 18– Chery Automobile Co., Ltd.
  • Page 900 43 44 45 46 47 48 49 50 51 52 53 54 55 56 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E-030 RT21181020 18– Chery Automobile Co., Ltd.
  • Page 901 Using the X-431 3G diagnostic tester, check whether the system is normal. Diagnosis complete Check for DTC a. Using X-431 3G diagnostic tester, select Read Code. b. Check if DTC P0842 or P0843 still exists. Replace TCU System is normal 18– Chery Automobile Co., Ltd.
  • Page 902 43 44 45 46 47 48 49 50 51 52 53 54 55 56 E-030 1 2 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E-080 ET21180130 18– Chery Automobile Co., Ltd.
  • Page 903 Check wire harness connector a. Turn ignition switch to LOCK. b. Disconnect the secondary shaft pressure sensor connector. c. Check if the secondary shaft pressure sensor connector is dirty, oxidized, loose or damaged. Repair fault 18– Chery Automobile Co., Ltd.
  • Page 904 43 44 45 46 47 48 49 50 51 52 53 54 55 56 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E-030 RT21181050 18– Chery Automobile Co., Ltd.
  • Page 905 Using the X-431 3G diagnostic tester, check whether the system is normal. Diagnosis complete Check for DTC a. Using X-431 3G diagnostic tester, select Read Code. b. Check if DTC P0847 or P0848 still exists. Replace TCU System is normal 18– Chery Automobile Co., Ltd.
  • Page 906 43 44 45 46 47 48 49 50 51 52 53 54 55 56 E-030 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 ET21180140 18– Chery Automobile Co., Ltd.
  • Page 907 After the fault is eliminated, verify DTC and symptom again. Check if TCU power fuse EF19 and EF46 are normal Replace failed fuse Check if battery to fuse box TCU fuse and relay circuit are normal Repair or replace failed circuit 18– Chery Automobile Co., Ltd.
  • Page 908 Check if the output voltage of the terminals J2 of connector E-066 is normal. J2 J1 E-066 RT21181070 e. Check if the output voltage of the terminals F16 of connector E-069 is normal. E-069 RT21181080 18– Chery Automobile Co., Ltd.
  • Page 909 43 44 45 46 47 48 49 50 51 52 53 54 55 56 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E-030 J2 J1 E-066 RT21181100 18– Chery Automobile Co., Ltd.
  • Page 910 A3 A4 A5 A7 A8 A9 A10 E-076 RT21181120 Check for DTC a. Using X-431 3G diagnostic tester, select Read Code. b. Check if DTC P0890 or P0891 still exists. Replace TCU System is normal 18– Chery Automobile Co., Ltd.
  • Page 911 18 - QR019CHB CVT P0900 Clutch Actuator Circuit Open P0902 Clutch Actuator Circuit Low P0903 Clutch Actuator Circuit High 18– Chery Automobile Co., Ltd.
  • Page 912 43 44 45 46 47 48 49 50 51 52 53 54 55 56 J2 J1 E-030 E-066 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 ET21180150 18– Chery Automobile Co., Ltd.
  • Page 913 After the fault is eliminated, verify DTC and symptom again. Check wire harness connector a. Turn ignition switch to LOCK. b. Disconnect the transmission wire harness connector. c. Check if the transmission wire harness connector is dirty, oxidized, loose or damaged. 18– Chery Automobile Co., Ltd.
  • Page 914 43 44 45 46 47 48 49 50 51 52 53 54 55 56 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E-030 RT21181140 18– Chery Automobile Co., Ltd.
  • Page 915 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E-030 RT21181150 Check for DTC a. Using X-431 3G diagnostic tester, select Read Code. b. Check if DTC P0900, P0902 or P0903 still exists. Replace solenoid and wire harness assembly System is normal 18– Chery Automobile Co., Ltd.
  • Page 916 18 - QR019CHB CVT P0928 Gear Shift Lock Solenoid Control Circuit Open P0930 Gear Shift Lock Solenoid Control Circuit Low P0931 Gear Shift Lock Solenoid Control Circuit High 18– Chery Automobile Co., Ltd.
  • Page 917 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E-066 J2 J1 9 10 11 A3 A4 A5 12 13 14 15 16 17 18 19 20 21 22 E-076 E-069 A7 A8 A9 A10 B-054 ET21180160 18– Chery Automobile Co., Ltd.
  • Page 918 After the fault is eliminated, verify DTC and symptom again. Check wire harness connector a. Turn ignition switch to LOCK. b. Disconnect the gear selector connector. c. Check if the gear selector connector is dirty, oxidized, loose or damaged. 18– Chery Automobile Co., Ltd.
  • Page 919 43 44 45 46 47 48 49 50 51 52 53 54 55 56 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E-030 E-069 RT21181110 18– Chery Automobile Co., Ltd.
  • Page 920 43 44 45 46 47 48 49 50 51 52 53 54 55 56 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E-030 E-029 RT21181160 18– Chery Automobile Co., Ltd.
  • Page 921 43 44 45 46 47 48 49 50 51 52 53 54 55 56 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E-030 RT21181180 18– Chery Automobile Co., Ltd.
  • Page 922 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E-030 RT21181190 Check for DTC a. Using X-431 3G diagnostic tester, select Read Code. b. Check if DTC P0928, P0930 or P0931 still exists. Replace gear shift mechanism System is normal 18– Chery Automobile Co., Ltd.
  • Page 923 43 44 45 46 47 48 49 50 51 52 53 54 55 56 E-030 E-052 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 ET21180170 18– Chery Automobile Co., Ltd.
  • Page 924 After the fault is eliminated, verify DTC and symptom again. Check wire harness connector a. Turn ignition switch to LOCK. b. Disconnect the transmission wire harness connector. c. Check if the transmission wire harness connector is dirty, oxidized, loose or damaged. Repair fault 18– Chery Automobile Co., Ltd.
  • Page 925 43 44 45 46 47 48 49 50 51 52 53 54 55 56 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E-030 RT21181210 18– Chery Automobile Co., Ltd.
  • Page 926 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E-030 RT21181220 Check for DTC a. Using X-431 3G diagnostic tester, select Read Code. b. Check if DTC P0938, P0939 or P0940 still exists. Replace wire harness assembly System is normal 18– Chery Automobile Co., Ltd.
  • Page 927 18 - QR019CHB CVT QR019CHB CVT P0960 Pressure Control Solenoid 'A' Control Circuit Open P0962 Pressure Control Solenoid 'A' Control Circuit Low P0963 Pressure Control Solenoid 'A' Control Circuit High 18– Chery Automobile Co., Ltd.
  • Page 928 43 44 45 46 47 48 49 50 51 52 53 54 55 56 J2 J1 E-030 E-066 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 ET21180180 18– Chery Automobile Co., Ltd.
  • Page 929  If DTC is not detected, the malfunction indicated by the DTC is intermittent. Please refer to Intermittent DTC Troubleshooting. Diagnosis Procedure HINT: After the fault is eliminated, verify DTC and symptom again. Check wire harness connector a. Turn ignition switch to LOCK. b. Disconnect the transmission wire harness connector. 18– Chery Automobile Co., Ltd.
  • Page 930 43 44 45 46 47 48 49 50 51 52 53 54 55 56 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E-030 RT21181240 18– Chery Automobile Co., Ltd.
  • Page 931 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E-030 RT21181250 Check for DTC a. Using X-431 3G diagnostic tester, select Read Code. b. Check if DTC P0960, P0962 or P0963 still exists. Replace solenoid and wire harness assembly System is normal 18– Chery Automobile Co., Ltd.
  • Page 932 18 - QR019CHB CVT P0964 Pressure Control Solenoid 'B' Control Circuit Open P0966 Pressure Control Solenoid 'B' Control Circuit Low P0967 Pressure Control Solenoid 'B' Control Circuit High 18– Chery Automobile Co., Ltd.
  • Page 933 43 44 45 46 47 48 49 50 51 52 53 54 55 56 J2 J1 E-030 E-066 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 ET21180190 18– Chery Automobile Co., Ltd.
  • Page 934  If DTC is not detected, the malfunction indicated by the DTC is intermittent. Please refer to Intermittent DTC Troubleshooting. Diagnosis Procedure HINT: After the fault is eliminated, verify DTC and symptom again. Check wire harness connector a. Turn ignition switch to LOCK. b. Disconnect the wire harness connector. 18– Chery Automobile Co., Ltd.
  • Page 935 43 44 45 46 47 48 49 50 51 52 53 54 55 56 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E-030 RT21181270 18– Chery Automobile Co., Ltd.
  • Page 936 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E-030 RT21181280 Check for DTC a. Using X-431 3G diagnostic tester, select Read Code. b. Check if DTC P0964, P0966 or P0967 still exists. Replace solenoid and wire harness assembly System is normal 18– Chery Automobile Co., Ltd.
  • Page 937 18 - QR019CHB CVT P0970 Pressure Control Solenoid 'C' Control Circuit Low P0971 Pressure Control Solenoid 'C' Control Circuit High 18– Chery Automobile Co., Ltd.
  • Page 938 43 44 45 46 47 48 49 50 51 52 53 54 55 56 J2 J1 E-030 E-066 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 ET21180200 18– Chery Automobile Co., Ltd.
  • Page 939 After the fault is eliminated, verify DTC and symptom again. Check wire harness connector a. Turn ignition switch to LOCK. b. Disconnect the transmission wire harness connector. c. Check if the transmission wire harness connector is dirty, oxidized, loose or damaged. Repair fault 18– Chery Automobile Co., Ltd.
  • Page 940 43 44 45 46 47 48 49 50 51 52 53 54 55 56 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E-030 RT21181300 18– Chery Automobile Co., Ltd.
  • Page 941 15 16 17 18 19 20 21 22 23 24 25 26 27 28 E-030 RT21181310 Check for DTC a. Using X-431 3G diagnostic tester, select Read Code. b. Check if DTC P0970 or P0971 still exists. Replace solenoid and wire harness assembly System is normal 18– Chery Automobile Co., Ltd.
  • Page 942 Carry out following preliminary checks a. Transmission wire harness connector (check for looseness, dirt and other fault). b. Transmission wire harness (check for damage, dirt and other fault). c. Are all checks OK? Repair fault 18– Chery Automobile Co., Ltd.
  • Page 943 Check for DTC a. Using X-431 3G diagnostic tester, select Read Code. b. Refer to "DTC Confirmation Procedure". c. Is DTC P2797 or P2798 still present? Replace solenoid and wire harness assembly System is normal 18– Chery Automobile Co., Ltd.
  • Page 944 2. Start engine to make it run for 1 - 2 min. 3. Step on the brake pedal and move the shift lever at each gear and place it to "N" or "P" position. RT21180310 18– Chery Automobile Co., Ltd.
  • Page 945 4. Pull out the automatic transmission fluid dipstick and clean it with a piece of non-wool paper; then insert the dipstick into the filling pipe as much as possible and then take out to observe whether it reaches the "HOT" position. RT21180200 18– Chery Automobile Co., Ltd.
  • Page 946  Do not wear velutinous gloves when installation.  After installing oil seal, make sure that the oil seal end surface and the transmission case are on the same plane. 3. Other installation steps are in the reverse order of removal. 18– Chery Automobile Co., Ltd.
  • Page 947 (Tightening torque: 22 - 28 N·m) RT21180360 Installation Installation is in the reverse order of removal. CAUTION  Check if transmission fluid is in the normal position. If not, add transmission fluid. 18– Chery Automobile Co., Ltd.
  • Page 948 CAUTION  Keep clean of sensor and contact surface between sensor and transmission, and avoid dust or impurity entering the transmission.  During installation, apply automatic transmission fluid on the O ring of the sensor. 18– Chery Automobile Co., Ltd.
  • Page 949 CAUTION  Keep clean of sensor and contact surface between sensor and transmission, and avoid dust or impurity entering the transmission.  During installation, apply automatic transmission fluid on the O ring of the sensor. 18– Chery Automobile Co., Ltd.
  • Page 950 CAUTION  Keep clean of sensor and contact surface between sensor and transmission, and avoid dust or impurity entering the transmission.  During installation, apply automatic transmission fluid on the O ring of the sensor. 18– Chery Automobile Co., Ltd.
  • Page 951  Keep clean of sensor and contact surface between sensor and transmission, and avoid dust or impurity entering the transmission.  During installation, apply automatic transmission fluid on the O ring of the sensor.  Add automatic transmission fluid (See page 18-110). 18– Chery Automobile Co., Ltd.
  • Page 952 CAUTION  Keep clean of sensor and contact surface between sensor and transmission, and avoid dust or impurity entering the transmission.  During installation, apply automatic transmission fluid on the O ring of the sensor. 18– Chery Automobile Co., Ltd.
  • Page 953 N (neutral) position to release the shift lock. RT21180440 6. Remove the gear shift cable (1) and arm (2) connecting nut (3).  (Tightening torque: 16 - 20 N·m) RT21180450 7. Disconnect the transmission range sensor wire harness connector (arrow). RT21180460 18– Chery Automobile Co., Ltd.
  • Page 954  During installation, align the hole of gear shift arm to the hole of transmission range sensor and fix them with a proper tool.  After installation, inspect the gear shift lever position. Adjust the gear shift cable as necessary. 18– Chery Automobile Co., Ltd.
  • Page 955  Keep the installation parts clean and avoid foreign matter entering the transmission.  During installation, apply sealant on the joint surface of the valve body case and transmission evenly.  After adding fluid, inspect for fluid leakage. 18– Chery Automobile Co., Ltd.
  • Page 956 RT21180500 6. Remove the transmission range sensor (See page 18-119). 7. Raise the vehicle with a lifter. 8. Drain the transmission fluid (See page 18-110). 9. Remove the valve body case (See page 18-121). 18– Chery Automobile Co., Ltd.
  • Page 957 15.Remove the wire harness bracket fixing bolt (2). 16.Remove the solenoid press plate fixing bolts. RT21180530 17.Take out the solenoid and wire harness assembly. Installation Installation is in the reverse order of removal. 18– Chery Automobile Co., Ltd.
  • Page 958  During installation, apply automatic transmission fluid on the O ring of solenoid wire harness assembly.  During installation, apply sealant on the joint surface of valve body case and transmission evenly.  After adding fluid, inspect for fluid leakage. 18– Chery Automobile Co., Ltd.
  • Page 959 7. Disconnect the transmission gear shift cable (1) from the gear shift control mechanism (2). RT21180560 8. Remove the gear shift control mechanism fixing bolts. (Tightening torque: 18 - 22 N·m) 9. Take out the gear shift control mechanism (1). RT21180570 18– Chery Automobile Co., Ltd.
  • Page 960 18 - QR019CHB CVT Installation Installation is in the reverse order of removal. CAUTION  After installation, inspect the gear shift lever for gear shift positions. Adjust the gear shift cable as necessary (See page 18-21). 18– Chery Automobile Co., Ltd.
  • Page 961 7. Remove the connecting nut (3) between the gear shift cable (1) and arm (2). Disconnect the gear shift cable from the shift arm.  (Tightening torque: 16 - 20 N·m) RT21180590 8. Remove the gear shift cable flexible shaft clamp. RT21180600 18– Chery Automobile Co., Ltd.
  • Page 962 10.Take out the gear shift cable. Installation Installation is in the reverse order of removal. CAUTION  After installation, inspect the gear shift lever for gear shift positions. Adjust the gear shift cable as necessary (See page 18-21). 18– Chery Automobile Co., Ltd.
  • Page 963 4. Disconnect the TCU and ECM connector. RT21180621 5. Remove the TCU mounting bracket. RT21180620 6. Remove the TCU fixing bolts (arrow).  (Tightening torque: 6 - 8 N·m) RT21180630 Installation Installation is in the reverse order of removal. 18– Chery Automobile Co., Ltd.
  • Page 964  Transmission solenoid wire harness connector;  Turbine speed sensor wire harness connector;  Primary shaft speed sensor wire harness connector;  Remove the transmission ground wire harness fixing bolt; (Tightening torque: 18 - 22 N·m) RT21180650 18– Chery Automobile Co., Ltd.
  • Page 965 15.Remove the engine front, rear and left mountings (See page 07-64). 16.Remove the bolts connected with the engine at the upper part of the transmission.  (Tightening torque: 75 - 85 N·m) RT21180690 17.Raise the vehicle with a lifter. 18– Chery Automobile Co., Ltd.
  • Page 966 RT21180710 20.Remove the axle shaft. 21.Use transmission carrier (1) to support the transmission (2). RT21180720 22.Remove the transmission and engine front connecting bolt (1). (Tightening torque: 75 - 85 N·m) RT21180730 18– Chery Automobile Co., Ltd.
  • Page 967  Keep transmission parts clean, and prevent foreign matter from entering into the transmission.  Add automatic transmission fluid.  After installation, inspect the gear shift lever for gear shift positions. Adjust the gear shift cable as necessary. 18– Chery Automobile Co., Ltd.
  • Page 968 - MEMO - 18– Chery Automobile Co., Ltd.
  • Page 969 Clutch Release Cylinder Assembly 19-12 Problem Symptoms Table 19-7 Removal 19-12 ON-VEHICLE SERVICE 19-8 Installation 19-13 Clutch Unit 19-14 Clutch Switch 19-8 Removal 19-14 Removal 19-8 Inspection 19-14 Inspection 19-8 Installation 19-15 Installation 19-8 Bleeding Hydraulic Clutch 19-16 19– Chery Automobile Co., Ltd.
  • Page 970 19– Chery Automobile Co., Ltd.
  • Page 971 3 - Clutch Master Cylinder with Inlet Hose Assembly 4 - Pipe Assembly I 5 - Bracket I 6 - Hose Assembly 7 - Bracket II 8 - Pipe Assembly II 9 - Clutch Release Cylinder Assembly 19– Chery Automobile Co., Ltd.
  • Page 972 1 - Flywheel 2 - Clutch Driven Disc 3 - Clutch Pressure Plate 4 - Release Bearing 5 - Release Bearing Clip 6 - Clutch Release Fork 7 - Release Fork Ball Seat 8 - Dust Boot 19– Chery Automobile Co., Ltd.
  • Page 973 16 ± 2 Clutch Release Cylinder Fixing Bolt 22 ± 2 Clutch Pressure Plate 25 ± 2 Clutch Driven Disc Specifications Measurement Item Specification (mm) Clutch Driven Disc Standard Thickness 7.6 ± 0.2 Minimum Rivet Depth 19– Chery Automobile Co., Ltd.
  • Page 974 19 - CLUTCH Tools Special Tool Clutch Pressure Plate Installer RCH0000018 General Tools Vernier Caliper RCH0000019 Digital Multimeter RCH0000002 19– Chery Automobile Co., Ltd.
  • Page 975 Clutch driven disc (improperly installed) 19-14 Clutch driven disc runout (excessive) 19-14 Clutch does not disengage completely Clutch driven disc lining (broken) 19-14 Clutch driven disc (dirty or burned) 19-14 Clutch driven disc (oily) 19-14 19– Chery Automobile Co., Ltd.
  • Page 976 Check for continuity between terminals when clutch switch is turned on or off. Switch Condition Specified Condition ON (not pushed) Continuity OFF (pushed) No continuity RT21190070 Installation Installation is in the reverse order of removal. 19– Chery Automobile Co., Ltd.
  • Page 977 Installation is in the reverse order of removal. CAUTION  Make sure to adjust clutch pedal to standard height before installation.  Be sure to tighten nuts to specified torque.  Check fluid level in reservoir after installation. 19– Chery Automobile Co., Ltd.
  • Page 978 4. Remove the clutch master cylinder. a. Push the locating clip in the direction of arrow, and pull out the pipe from clutch master cylinder. RT21190100 b. Remove the fork retainer (1) and pull out the center pin (2). RT21190080 19– Chery Automobile Co., Ltd.
  • Page 979 (Tightening torque: 25 ± 2 N·m) RT21190110 Installation Installation is in the reverse order of removal. CAUTION  Add brake fluid to "MAX".  Perform bleeding procedure for hydraulic clutch and check brake fluid for leakage after installation. 19– Chery Automobile Co., Ltd.
  • Page 980 Remove the pipe joint and pipe assembly II from clutch release cylinder. (Tightening torque: 16 ± 2 N·m) RT21190150 b. Remove the clutch release cylinder fixing bolts (arrow) and then remove the clutch release cylinder. (Tightening torque: 22 ± 2 N·m) RT21190160 19– Chery Automobile Co., Ltd.
  • Page 981  Be sure to align the push rod of clutch release cylinder assembly with hole in transmission case release fork, and tighten bolts to specified torque.  Perform bleeding procedure for hydraulic clutch and check system line for leakage after installation. 19– Chery Automobile Co., Ltd.
  • Page 982 2. Use a vernier caliper to measure the thickness of clutch driven disc. Standard thickness: 7.6 ± 0.2 mm Minimum rivet depth: 1.2 mm If result is not as specified, replace clutch driven disc. RT21190200 19– Chery Automobile Co., Ltd.
  • Page 983 RT21190220 2. Install the clutch pressure plate and tighten the bolts. (Tightening torque: 25 ± 2 N·m) RT21190190 3. Install the release fork ball seat (1). 4. Install the dust boot (2). RT21190180 19– Chery Automobile Co., Ltd.
  • Page 984  DO NOT allow brake fluid to spray onto body surface. Brake fluid may damage the painted surfaces. If any brake fluid is get onto the painted surfaces, wash it off with water immediately.  Only use brake fluid recommended by Chery Automobile Co., Ltd, otherwise the lines may be subjected to a severe corrosion.
  • Page 985 13.Check clutch pedal stroke. If clutch pedal stroke is excessive, or the condition does not improve, it indicates that some air is still kept in the system. Bleed the clutch again as necessary. 14.Test the vehicle again and make sure clutch operates normally and depressing feel is good. 19– Chery Automobile Co., Ltd.
  • Page 986 - MEMO - 19– Chery Automobile Co., Ltd.
  • Page 987 Inner Ball Cage 20-8 Disassembly 20-8 Description 20-3 Inspection 20-9 Operation 20-4 Assembly 20-10 Specifications 20-4 Outer Ball Cage 20-11 ON-VEHICLE SERVICE 20-5 Disassembly 20-11 Drive Shaft Assembly 20-5 Inspection 20-12 Removal 20-5 Assembly 20-12 Installation 20-7 20– Chery Automobile Co., Ltd.
  • Page 988 20– Chery Automobile Co., Ltd.
  • Page 989 20 - DRIVE SHAFT GENERAL INFORMATION DRIVE SHAFT Description RT21200010 20– Chery Automobile Co., Ltd.
  • Page 990 Drive Shaft Fixing Nut 300 ± 20 Coupling Nut Between Steering Knuckle and Control 180 ± 10 Arm Ball Pin Coupling Bolt Between Front Left Wheel Speed 10 ± 1 Sensor and Front Left Steering Knuckle Assembly 20– Chery Automobile Co., Ltd.
  • Page 991 CAUTION  Loosen the staked part of nut completely, otherwise it will damage the thread of drive shaft. b. While applying brake, remove the drive shaft fixing nut. (Tightening torque: 300 ± 20 N·m) RT21220060 20– Chery Automobile Co., Ltd.
  • Page 992 (Tightening torque: 10 ± 1 N·m) RT21220110 c. Remove the coupling nuts and coupling bolts between front left steering knuckle and shock absorber. (Tightening torque: 180 ± 10 N·m) RT21220150 d. Using a crowbar, pry out the drive shaft. RT21200020 20– Chery Automobile Co., Ltd.
  • Page 993  DO NOT use excessive force to pull the drive shaft to prevent the constant velocity universal joint from dropping.  Use crowbar carefully to prevent damage to oil seal.  Adjust the wheel alignment if necessary. 20– Chery Automobile Co., Ltd.
  • Page 994 Using needle nose pliers, remove the inner ball cage dust boot clamps. RT21200040 3. Remove the inner ball cage. a. Separate the dust boot from inner ball cage in the direction of arrow. RT21200051 20– Chery Automobile Co., Ltd.
  • Page 995 1. Check if spline of drive shaft is in good condition. If it is deformed or damaged, replace it. 2. Check if dust boot is in good condition. If it is scratched or broken, replace it. 3. Check if positioning snap spring of tripod is deformed. If it is deformed, replace it. 20– Chery Automobile Co., Ltd.
  • Page 996 20 - DRIVE SHAFT Assembly CAUTION  Refill grease during assembly.  Operate carefully to prevent the dust boot from being damaged. Assembly is in the reverse order of disassembly. 20– Chery Automobile Co., Ltd.
  • Page 997 RT21200110 b. Put a matchmark (1) on the area with the same height as drive shaft assembly (2) and edge of outer ball cage (3) for correct installation. RT21200120 20– Chery Automobile Co., Ltd.
  • Page 998 2. Check if dust boot is in good condition. If it is scratched or broken, replace it. Assembly CAUTION  Refill grease during assembly.  Install it with new clamps.  Operate carefully to prevent the dust boot from being damaged. Assembly is in the reverse order of disassembly. 20– Chery Automobile Co., Ltd.
  • Page 999 21-4 Installation 21-8 Tools 21-5 Differential Planetary Gear 21-9 DIAGNOSIS & TESTING 21-6 Removal 21-9 Differential Gear Clearance Inspection 21-6 Installation 21-9 ON-VEHICLE SERVICE 21-7 Differential Parts Inspection 21-9 Driven Gear of Final Drive 21-7 21– Chery Automobile Co., Ltd.
  • Page 1000 21– Chery Automobile Co., Ltd.
  • Page 1001 21 - DIFFERENTIAL GENERAL INFORMATION DIFFERENTIAL Description ×8 RT21210010 21– Chery Automobile Co., Ltd.
  • Page 1002  The final drive is a component to reduce the rotation speed and increase the torque of drive train. Specifications Torque Specification Description Torque (N·m) Final Drive Driven Gear Bolt 111 - 118 Clearance Specification Description Acceptable Range (mm) Clearance Between Differential Case and Planetary 0.025 - 0.150 Gear 21– Chery Automobile Co., Ltd.
  • Page 1003 21 - DIFFERENTIAL Tools Special Tools Bearing Remover RCH0000011 Punch RCH0000015 General Tools Hydraulic Press RCH0000012 Dial Indicator and Magnetic Holder RCH0000023 21– Chery Automobile Co., Ltd.

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