Page 1 ELECTRONIC ENGINE CONTROLS FOREWORD This manual contains on-vehicle service FUEL DELIVERY and diagnosis procedures for the Chery Tiggo. A thorough familiarization with this manual STARTING & CHARGING is important for proper repair and maintenance. It should always be kept in a COOLING handy place for quick and easy reference.
Page 2: Table Of Contents
Adjustments 01-7 Preparation For Vehicle Service 01-3 Rubber Parts and Rubber Tubing 01-7 Tools and Testing Equipment 01-3 Hose Clamps 01-8 Special Tools 01-3 Vise 01-8 Disconnection of the Negative Battery Dynamometer 01-8 Cable 01-4 Chery Automobile Co., Ltd. 01–...
Page 3: How To Use This Manual
• Symptom troubleshooting quickly determines the location of the malfunction according to symptom type. Specifications This manual contains specifications that are divided into the following groups: • Torque specifications • Clearance specifications • Capacity specifications 01– Chery Automobile Co., Ltd.
Page 4: Vehicle Service Preparation
• Be sure that all necessary tools and measuring equipment are available before starting any work. • Inspect the vehicle and reference any needed ser- vice information before starting any work. BESM010005 Special Tools • Use special tools when they are required. BESM010006T Chery Automobile Co., Ltd. 01–...
Page 5: Disconnection Of The Negative Battery Cable
• Disconnecting the battery cable deletes the memo- ries of the clock, audio and DTCs, etc. Therefore, it is necessary to verify those memories before dis- connecting the cable. LTSM010002 01– Chery Automobile Co., Ltd.
Page 6: Proper Service Practices
Identify each part so reassembly can be performed easily and efficiently. BESM010008 Inspection of Parts • When removed, inspect each part for possible mal- function, deformation, damage or other problems. BESM010009 Chery Automobile Co., Ltd. 01–...
Page 7: Arrangement Of Parts
If removed, replace these parts with new ones: − Oil seals − Gaskets − O-rings − Lock washers − Cotter pins − Nylon nuts BESM010012 01– Chery Automobile Co., Ltd.
Page 8: Adjustments
(such as oil seals) before reassembly. reassembly. BESM010013 Adjustments • Use suitable gauges and testers when making adjustments. BESM010014 Rubber Parts and Rubber Tubing • Prevent gasoline or oil from getting on rubber parts or tubing. BESM010015 Chery Automobile Co., Ltd. 01–...
Page 9: Hose Clamps
Exhaust gases can injure or kill. They contain carbon monoxide (CO), which is colorless and odorless. Breathing it can make you unconscious and can eventually poison you. − Cool the exhaust pipes with a fan. − Keep the area around the vehicle uncluttered. − Monitor the engine coolant temperature gauge. 01– Chery Automobile Co., Ltd.
Page 10: Vehicle Information
VEHICLE INFORMATION VEHICLE IDENTIFICATION NUMBER FASTENER USAGE 01-14 Fastener Usage 01-14 (VIN) 01-10 VIN Location 01-10 VIN Identification Codes 01-11 INTERNATIONAL SYMBOLS 01-13 International Symbols 01-13 Chery Automobile Co., Ltd. 01–...
Page 11 Vehicle Identification Number (VIN) Tag Location LTSM010001 The VIN is printed on a plastic tag attached to the top right corner of the upper instrument panel. The VIN is also found on the vehicle certification (VC) label. 01– Chery Automobile Co., Ltd.
Page 12 • Digit #4 The fourth digit of the VIN code represents the brand of the vehicle: − The brand Chery is represented by the letter D . • Digit #5 The fifth digit of the VIN code represents the body configuration of the vehicle: −...
Page 13 − 5 represents the year 2005. • Digit #11 The eleventh VIN position represents the assembly plant code: − D represents the Chery Automobile Co., Ltd. • Digits #12, #13, #14, #15, #16, #17 The last six VIN positions represent the production sequence number.
Page 14 20 - Parking Brake 9 - Front Windshield Defroster 21 - Hood 10 - Blower Motor Fan 22 - Trunk 11 - Rear Window Defroster 23 - Horn 12 - Rear Window Wiper 24 - Cigarette Lighter BESM010003 Chery Automobile Co., Ltd. 01–...
Page 15 Fasteners and torque specification references in this Service Manual are identified in metric format. During any maintenance or repair procedures, it is important to salvage all fasteners (nuts, bolts, etc.) for reassembly. If the fastener is not salvageable, a fastener of equivalent specification must be used. 01– Chery Automobile Co., Ltd.
Page 16: Electrical Circuit Diagnosis Information
ELECTRICAL CIRCUIT DIAGNOSIS INFORMATION DIAGNOSING ELECTRICAL Electrical Circuit Simulation Tests 01-16 Precautions For Handling Control Modules FAILURES 01-16 and Electrical Components 01-18 Performing Efficient Electrical Circuit How To Check Electrical Connectors 01-19 Diagnosis and Troubleshooting 01-16 Chery Automobile Co., Ltd. 01–...
Page 17 A visual inspection may not reveal this without disconnecting the connector. If the problem occurs intermittently, per- haps the problem is caused by corrosion. It is a good idea to disconnect, inspect and clean the terminals on related connectors in the system. 01– Chery Automobile Co., Ltd.
Page 18 On some occasions an electrical incident may occur only when the vehicle is started cold, or it may occur when the vehicle is restarted hot shortly after being turned off. In these cases you may have to keep the vehicle overnight to make a proper diagnosis. Chery Automobile Co., Ltd. 01–...
Page 19 • When using a DMM, be careful not to let the test probes touch each other causing a short circuit. Prevent the power transistor in the control module from being shorted to damaging battery voltage. • When checking input and output signals of the con- trol module, use the specified test adapter (if applicable). LTSMD030028 01– Chery Automobile Co., Ltd.
Page 20 − While holding the wire of the male terminal, attempt to insert the male terminal into the female terminal. − While moving the connector, check whether the male terminal can be easily inserted or not. NOTE : If the male terminal can be easily inserted into the female terminal, replace the female terminal. Chery Automobile Co., Ltd. 01–...
Page 21: Electrical Information
ELECTRICAL INFORMATION HOW TO READ ELECTRICAL HOW TO LOCATE ELECTRICAL SCHEMATICS SCHEMATICS IN THE SERVICE 01-21 Connector Symbols 01-21 MANUAL 01-25 Option Splices 01-22 Electrical Schematic Index 01-25 Electrical Schematic - Example 01-23 01– Chery Automobile Co., Ltd.
Page 22: Connector Symbols
BESMW010003T • In electrical schematics, female terminal end views are shown at the bottom of the page for all compo- nents that are shown on the schematic page. PZSMW010009 Chery Automobile Co., Ltd. 01–...
Page 23 HOW TO READ ELECTRICAL SCHEMATICS Option Splices BESMW010002T • Option splices are shown with solid diamond-shaped boxes with identification numbers inside. 01– Chery Automobile Co., Ltd.
Page 24 HOW TO READ ELECTRICAL SCHEMATICS Electrical Schematic - Example BESMW010001T Chery Automobile Co., Ltd. 01–...
Page 25 Y = Yellow BR = Brown O = Orange GR = Gray Shielded line The line enclosed by broken line circle represents shielded wire. Light-emitting diodes As an illumination tool, in the circuit and instrument cluster. 01– Chery Automobile Co., Ltd.
Page 26: General Information
• Fuel Level Sensor and Fuel Pump • Starter Motor • Ignition Switch 05 - Starting & Charging • Clutch Pedal Switch (if equipped) • Generator • Cooling Fan 06 - Cooling System • None 07 - Exhaust Chery Automobile Co., Ltd. 01–...
Page 27: Transaxle & Transfer Case
13 - Heating & Air Conditioning • A/C Compressor • Refrigerant Pressure Switch • Restraints Control Module • Seat Belt Buckle Switch • Front Crash Sensors 14 - Restraints • Driver Airbag • Passenger Airbag 01– Chery Automobile Co., Ltd.
Page 28: Body & Accessories
Crankshaft Position Sensor Data Link Connector Diagnostic Trouble Code Engine Control Module Engine Coolant Temperature Engine Speed Evaporative Emission EVAP Evaporative Emission Canister EVAP Canister Evaporative Emission System EVAP System Exhaust Gas Recirculation Valve EGR Valve Chery Automobile Co., Ltd. 01–...
Page 29 Oil Pressure Switch Output Shaft Speed Sensor OSS Sensor Positive Crankcase Ventilation Valve PCV Valve Power Supply SRS Airbag Control System Throttle Position Sensor Transaxle Control Module Turbine Speed Sensor Vehicle Identification Number Vehicle Speed Sensor 01– Chery Automobile Co., Ltd.
Page 30: Table Of Contents
02-20 Oil Pump 02-48 Removal & Installation 02-20 Removal & Installation 02-48 Cylinder Head 02-23 Oil Strainer 02-49 Removal & Installation 02-23 Removal & Installation 02-49 Front Crankshaft Oil Seal 02-25 Removal & Installation 02-25 Chery Automobile Co., Ltd. 02–...
Page 31 Specifications 02-70 Disassembly 02-58 Disassembly 02-70 Inspection 02-59 Inspection 02-71 Assembly 02-59 Assembly 02-72 Crankshaft 02-60 Valve Springs 02-73 Specifications 02-60 Specifications 02-73 Disassembly 02-60 Disassembly 02-73 Inspection 02-61 Inspection 02-74 Assembly 02-62 Assembly 02-75 02– Chery Automobile Co., Ltd.
Page 32 SPECIFICATION Type In-Line OHV, DOHC Number of Cylinders Compression Ratio 10.5:1 Compression Pressure 10 - 15 bar Max. Compression Pressure Variation Between Cylinders Stroke 89.5 mm Bore 81 mm Displacement 1845 cc Firing Order 1-3-4-2 Chery Automobile Co., Ltd. 02–...
Page 33 0.022 mm 0.058 mm Journals Cylinder Head Flatness < 0.04 mm Intake Valve Deflection < 0.02 mm Exhaust Valve Deflection < 0.04 mm Spring Height 47.7 mm Spring Height At 620 32.0 mm Newtons Of Pressure 02– Chery Automobile Co., Ltd.
Page 34 Connecting Rod Cap Bolts 2nd Step: Tighten the bolts an additional 90° Crankshaft Holder 1st Step: Tighten the bolts to 45 N·m Crankshaft Main Bearing Cap Bolts 2nd Step: Tighten the bolts an additional 180° Chery Automobile Co., Ltd. 02–...
Page 35 (Apply with Loctite 5910 Thread-Locker) Rear Timing Cover Bolts Timing Belt Upper Cover Bolts Timing Belt Lower Cover Bolts Timing Belt Tensioner Assembly Timing Belt Tensioner Pulley Bolt Throttle Body Bolts Upper Idler Pulley Bolt 02– Chery Automobile Co., Ltd.
Page 36 GENERAL INFORMATION Special Tools Right Engine Mount Bolt Remover CH-20001 Camshaft Seal Installer CH-20002 Crankshaft Holder CH-20003 Valve Spring Compressor Adaptor CH-20004 Rear Crankshaft Oil Seal Installer CH-20005 Chery Automobile Co., Ltd. 02–...
Page 37 GENERAL INFORMATION Rear Crankshaft Oil Seal Guide CH-20006 Front Crankshaft Seal Installer CH-20007 Front Crankshaft Seal Guide CH-20008 Camshaft Holder CH-20010 Valve Seal Installer CH-20011 02– Chery Automobile Co., Ltd.
Page 38 GENERAL INFORMATION Valve Stem Seal Installer Guide CH-20012 Valve Seal Remover CH-20013 Valve Keeper Installer CH-20017 Valve Spring Compressor CH-20018 Crankshaft Belt Pulley Fixture CH-20019 Chery Automobile Co., Ltd. 02–...
Page 39: Lubrication System
The pump inner rotor is driven by the crankshaft. Engine Oil Pressure Specifications Lower Idle Speed (800 ± 50 RPM) 1.2 - 1.5 bar High Idle Speed (2000 RPM) 3.2 - 3.5 bar High Speed (4000 RPM) 3.7 ± 0.5 bar 02– Chery Automobile Co., Ltd.
Page 40 27 - Crankshaft Front Oil Seal 13 - Oil Filter Connector 28 - Oil Pump Bolt 14 - Oil Filter 29 - Oil Pump Assembly 15 - Dowel Pin 30 - Oil Pump Assembly Gasket LTSM020161 Chery Automobile Co., Ltd. 02–...
Page 41 13 - Oil Filter Bracket 6 - To Cylinder Head 14 - Oil Pressure Switch 7 - Oil Return Passage 15 - Oil Cooler 8 - To Front Bearing Cap 16 - Oil Filter BESM020088 02– Chery Automobile Co., Ltd.
Page 42 8. Perform exhaust restriction test. 8. Plugged or restricted exhaust Install new parts. system. 9. Test and replace if necessary. 9. Faulty ignition coil(s). (Refer to Appropriate Diagnostic 10. Burned spark plugs. Information) 10. Replace spark plugs. Chery Automobile Co., Ltd. 02–...
Page 43 Repair if necessary. 6. Crankshaft journal out-of-round or 5. Check thrust bearing for wear on worn. flanges. 7. Loose flywheel or torque 6. Replace crankshaft or grind converter. journals. 7. Tighten to correct torque. 02– Chery Automobile Co., Ltd.
Page 44 4. Rings fitted too tightly in grooves. Fouled 4. Remove rings and check grooves. 5. Worn valve guide(s). If groove is not proper width, replace 6. Valve stem seal(s) worn or piston. damaged. 5. Replace cylinder head. 6. Replace seal(s). Chery Automobile Co., Ltd. 02–...
Page 45 • Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are: − Engine overheating − Loss of coolant − Excessive steam (white smoke) emitting from exhaust − Coolant foaming 02– Chery Automobile Co., Ltd.
Page 46 1. While using a suitable tool and securely holding the hexagonal portion of the drive belt tensioner, rotate the pulley counterclockwise to loosen the drive belt. WARNING! Avoid placing hands near the drive belt tensioner while it is being held. Chery Automobile Co., Ltd. 02–...
Page 47: Air Cleaner Element
• If necessary, clean the inside of the air cleaner housing before installing new air cleaner element. Air Cleaner Housing Removal & Installation 1. Disconnect the negative battery cable. 2. Disconnect the air flow sensor electrical connector (1.8L Engine). 02– Chery Automobile Co., Ltd.
Page 48: Cylinder Head Cover
4. Disconnect the camshaft position sensor electrical connector. 5. Remove the camshaft position sensor (2) and set it aside. 6. Remove the spark plug wires (3) and set them aside. 7. Remove the PCV hose (1) from cylinder head cover. BESM020022 02– Chery Automobile Co., Ltd.
Page 49 3. Remove the cylinder head cover (See Cylinder Head Cover Removal & Installation in Section 02 Engine). 4. Remove the intake or exhaust camshaft timing belt pulley. (Tighten: Camshaft timing belt pulley bolt to 120 N·m) Chery Automobile Co., Ltd. 02–...
Page 50 7. Remove the camshaft bearing caps and place them in proper order. NOTE: The camshaft bearing caps are marked for identification. 8. Remove the camshafts and then remove the cam- shaft seals. BESM020035 9. Installation is in the reverse order of removal. 02– Chery Automobile Co., Ltd.
Page 51 • Use special tool CH-20002 (1), to install the camshaft seal. • Install the intake and exhaust camshaft bearing caps in the proper order. • Slowly tighten bolts to the specified torque. LTSM020215 • Follow the torque sequence as shown. BESM020036 Chery Automobile Co., Ltd. 02–...
Page 52: Cylinder Head
4. Remove intake manifold (See Intake Manifold Removal & Installation in Section 02 Engine). 5. Remove exhaust manifold (See Exhaust Manifold Removal & Installation in Section 02 Engine). 6. Remove water pipe and thermostat assembly. 02– Chery Automobile Co., Ltd.
Page 53 • Position the new cylinder head gasket on the engine block with the part number facing up. Ensure gasket is seated over the locating dowels in the block. • Before installing the bolts, the threads should be lightly coated with engine oil. Chery Automobile Co., Ltd. 02–...
Page 54 1. Remove the accessory drive belt (See Accessory Drive Belt Removal & Installation in Section 02 Engine). 2. Remove the crankshaft vibration damper bolts (1). (Tighten: Crankshaft vibration damper bolts to 25 N·m) BESM020055 3. Remove the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine). Chery Automobile Co., Ltd. 02–...
Page 55 7. Installation is in the reverse order of removal. Installation Notes: • Lubricate the new front seal with engine oil prior to assembly. • Use the front crankshaft seal installer CH-20008 (1), to install the new seal. LTSM020216 02– Chery Automobile Co., Ltd.
Page 56 (1) and then remove the clutch pressure plate. (Tighten: Clutch pressure plate bolts to 25 N·m) BESM080046 4. Remove the flywheel bolts (1) and then remove the flywheel. (Tighten: Flywheel bolts to 75 N·m) BESM020058 Chery Automobile Co., Ltd. 02–...
Page 57 • Position the seal over the rear crankshaft seal guide. • Use special tool CH-20005 (2) CH-20006 (1), to install the rear crankshaft oil seal. • Ensure that the lip of the seal is facing toward the crankcase during installation. LTSM020217 02– Chery Automobile Co., Ltd.
Page 58: Engine Mounts
5. Remove the engine left mount retaining bolts (2) and remove the engine left mount bracket bolts (1). (Tighten: Engine left mount bolts to 70 N·m) 6. Installation is in the reverse order of removal. LTSM020156 Chery Automobile Co., Ltd. 02–...
Page 59 2. Support the engine with the engine hoist. 3. Remove the bolts (1) securing the front engine mount. (Tighten: Engine front mount bolts to 60 N·m) 4. Installation is in the reverse order of removal. BESM080035 02– Chery Automobile Co., Ltd.
Page 60: Engine Assembly
The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may result in serious personal injury. Chery Automobile Co., Ltd. 02–...
Page 61 11. Disconnect and remove the fuel line at the fuel rail. 12. Remove the air inlet hose and the air cleaner case assembly. NOTE: For 1.8L engine, disconnect the air flow sensor electrical connector. LTSM020226 13. Remove the ground cable bolt from the cylinder head. 02– Chery Automobile Co., Ltd.
Page 62 16. Disconnect the heater hoses (1) on the vehicle. 17. Remove the vacuum line from the brake booster (2). 18. Remove the dipstick. BESM020025 19. If equipped with a manual transaxle remove the transaxle shift cable (1). BESM080051 02– Chery Automobile Co., Ltd.
Page 63 40 ± 5 N·m) BESM110011 24. Remove the exhaust manifold heat shield bolts (1) and then remove heat shield. (Tighten: Exhaust manifold heat shield bolts to 15 N·m) BESM020078 25. Disconnect the upstream and downstream oxygen sensor connectors. 02– Chery Automobile Co., Ltd.
Page 64 31. Remove the bolts (1) securing the front engine mount. (Tighten: Engine front mount bolt to 60 N·m) BESM080035 32. Remove the bolts (1) securing the rear engine mount. (Tighten: Engine rear mount bolt to 60 N·m) LTSM020207 Chery Automobile Co., Ltd. 02–...
Page 65 36. Remove the front sub-frame (See Front Sub-Frame Removal & Installation in Section 10 Suspension). 37. Hoist the engine from vehicle. CAUTION: Verify all electrical connectors are disconnected prior to engine/transaxle removal. 38. Separate the engine and transaxle. 02– Chery Automobile Co., Ltd.
Page 66 & Air Conditioning). BESM020029 43. Remove the power steering pump (1) with the pip- ing connected and set the pump aside. Secure the pump with wire. BESM020028 44. Installation is in the reverse order of removal. Chery Automobile Co., Ltd. 02–...
Page 67 The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may result in serious personal injury. 02– Chery Automobile Co., Ltd.
Page 68 LTSM020218 5. Remove the accessory drive belt (See Accessory Drive Belt Removal & Installation in Section 02 Engine). 6. Remove the crankshaft vibration damper bolts (1). (Tighten: Crankshaft vibration damper bolts to 25 N·m) BESM020055 Chery Automobile Co., Ltd. 02–...
Page 69 NOTE: The camshaft holder will prevent the cam- shafts from rotating in either direction. CAUTION: Rotating the camshafts or crankshaft with timing components loosened or removed can cause seriou damage to the valves or pistons. pistons. BESM020016 02– Chery Automobile Co., Ltd.
Page 70: Exhaust Manifold
Removal & Installation 1. Remove the engine cover. 2. Remove the bolts (1) attaching the exhaust mani- fold heat shield. (Tighten: Exhaust manifold heat shield bolts to 15 N·m) 3. Remove the exhaust manifold heat shield. BESM020078 Chery Automobile Co., Ltd. 02–...
Page 71 LTSM020201 6. Remove the exhaust manifold nuts (1). (Tighten: Exhaust manifold nuts to 25 N·m) BESM020033 7. Remove and discard manifold gasket (1). LTSM020169 8. Installation is in the reverse order of removal. 02– Chery Automobile Co., Ltd.
Page 72: Intake Manifold
Failure to follow these instructions may result in serious personal injury. 4. Remove the coolant fan & radiator assembly (See Coolant Fan & Radiator Assembly Removal & Installation in Section 06 Cooling). Chery Automobile Co., Ltd. 02–...
Page 73 10. Loosen the clamp between the air intake hose and the air cleaner. 11. Loosen the clamp between the air intake hose and the throttle body and then remove the intake pipe. 12. Loosen the clamp on the PCV hose and then disconnect the PCV hose. 02– Chery Automobile Co., Ltd.
Page 74 1. While using a suitable tool and securely holding the hexagonal portion of the drive belt tensioner, rotate the pulley counterclockwise to loosen the drive belt. WARNING! Avoid placing hands near the drive belt tensioner while it is being held. Chery Automobile Co., Ltd. 02–...
Page 75: Oil Filter
The oil filter gasket must be removed from the engine before installing the new oil filter. LTSM020206 2. Installation is in the reverse order of removal. Installation Notes: • Clean the surface, and verify the oil filter does not leak. 02– Chery Automobile Co., Ltd.
Page 76: Oil Pan
• Oil pan sealing surfaces must be free of grease or oil. • Install the four oil pan corner bolts in the sequence shown (1-2-3-4). • Install the remaining oil pan bolts. • Torque all the oil pan bolts to the proper specification. VISM020013 Chery Automobile Co., Ltd. 02–...
Page 77: Oil Pump
10. Installation is in the reverse order of removal. Installation Notes: • Before installing, prime the new oil pump. Fill the oil pump with engine oil and rotate the oil pump. • Replace the oil pump gasket. 02– Chery Automobile Co., Ltd.
Page 78 3. Remove the oil strainer retaining bolts (1). (Tighten: Oil strainer bolts to 18 N·m) BESM020018 4. Carefully remove the oil strainer. 5. Installation is in the reverse order of removal. Installation Notes: • Install new O-rings on the oil strainer pipe. Chery Automobile Co., Ltd. 02–...
Page 79: Engine Block
3. For each connecting rod/piston assembly to be removed, rotate the crankshaft to the bottom dead center position for each cylinder. NOTE : Before removing the connecting rod/piston assembly, check the connecting rod side clearance. 02– Chery Automobile Co., Ltd.
Page 80 7. Remove the connecting rod bearings (See Con- necting Rod Removal & Installation in Section 02 Engine). BESM020045 CAUTION: When removing the connecting rod side bearings, note the installation position. Keep them in the correct order. Chery Automobile Co., Ltd. 02–...
Page 81 Assemble all components in their original position. 1. Install the pistons to the connecting rods. 2. Using a piston ring expander, install the piston rings. 3. Assemble all components in the reverse order of disassembly. 02– Chery Automobile Co., Ltd.
Page 82 First Ring End Gap 0.2 - 0.4 mm 0.8 mm Second Ring End Gap 0.4 - 0.6 mm 1.0 mm Clearance Specifications - Piston to Piston Pin DESCRIPTION SPECIFICATION (mm) Piston To Piston Pin 0.002 - 0.013 Chery Automobile Co., Ltd. 02–...
Page 83 BESM020046 • Piston Pin Snap Ring Removal − Using snap ring pliers, remove the snap ring (1). − Heat the pistons if necessary. BESM020048 02– Chery Automobile Co., Ltd.
Page 84 − Push out the piston pin with a suitable tool. BESM020049 • Connecting Rod & Piston Disassembly − Remove the piston from the connecting rod. BESM020041 Inspection Check the piston diameter. BESM020050 PISTON DIAMETER All Pistons 80.946 - 80.964 mm Chery Automobile Co., Ltd. 02–...
Page 85 13 mm from bottom of cylinder bore and below the bottom of the oil ring travel where the cylinder bore has minimal wear. Check gap with feeler gauge. BESM020052 02– Chery Automobile Co., Ltd.
Page 86 1. Install the piston to the connecting rod. Assemble the components in their original positions. 2. Using a piston ring expander, install the piston rings. Assemble the components in their original positions. 3. Assemble all components in the reverse order of disassembly. Chery Automobile Co., Ltd. 02–...
Page 87 3. Using a hammer handle or similar tool, push the piston and connecting rod assembly (1) out through the cylinder head side of the engine block. NOTE: Before removing the piston and connecting rod assembly, check the connecting rod side clearance. BESM020044 02– Chery Automobile Co., Ltd.
Page 88 • 1st Step: Tighten bolts to 25 N·m • 2nd Step: Tighten the connecting rod bolts an additional 90° LTSM020208 4. Using a feeler gauge check connecting rod side clearance. • Check axial clearance of connecting rod. BESM020064 Chery Automobile Co., Ltd. 02–...
Page 89 7. Remove the main bearings and thrust bearings from the cylinder block and lower cylinder block. NOTE: If reusing the bearings, identify and number the bearings so that they are assembled in the same position and direction. 02– Chery Automobile Co., Ltd.
Page 90 − Limits of oil clearance of crankshaft rod and main journals should be 0.058 mm Standard oil clearance of crankshaft main journal should be 0.022 mm. Limits of oil clearance of crank- shaft main journal should be 0.058 mm. BESM020077 Chery Automobile Co., Ltd. 02–...
Page 91 1. Install the main bearings and thrust bearings to the upper cylinder block and lower cylinder block. NOTE: Identify and number the bearings, if reusing them, so that they are assembled in the same position and direction. 2. Assemble the crankshaft and main bearings in the reverse order of disassembly. 02– Chery Automobile Co., Ltd.
Page 92 • CH-20017 - Valve Keeper Installer • CH-20018 - Valve Spring Compressor NOTE : Replacement cylinder head comes complete with valves, seals, springs, retainers, keepers, tappets, and camshafts. 1. Remove camshafts. 2. Remove the hydraulic tappet assembly (1). BESM020071 Chery Automobile Co., Ltd. 02–...
Page 93 5. Push the valve stem from the cylinder head and remove the valve (4). VISM080041 6. Using special tool CH-20013 (1), remove the valve oil seal. LTSM020225 7. Remove the valve guide. 8. Remove the spark plugs. 02– Chery Automobile Co., Ltd.
Page 94 3. Using special tool CH-20011 (1) and CH-20012 (2), install the new valve oil seal. LTSM020224 4. Install the valves into the cylinder head (larger diameter on intake side). 5. Install the valve springs. 6. Install the valve spring retainers. Chery Automobile Co., Ltd. 02–...
Page 95 Cam Bearing #2, #3, #4, #5, Inner Diameter 24 - 24.021 Journal #1 Clearance 0.05 - 0.091 Journal #2, #3, #4, #5 Clearance 0.04 - 0.074 Intake Camshaft Axial Clearance 0.15 - 0.20 Exhaust Camshaft Axial Clearance 0.15 - 0.20 02– Chery Automobile Co., Ltd.
Page 96 Inspection • Measure the camshaft cam lobe height. • If wear is beyond the limit, replace the camshaft. BESM020037 CAMSHAFT CAM LOBE HEIGHT Intake Cam Lobe Height 37.15 mm Exhaust Cam Lobe Height 37.05 mm Chery Automobile Co., Ltd. 02–...
Page 97 • Calculation of camshaft journal clearance Journal clearance = (inner diameter of camshaft bearing) - (outer diameter of camshaft journal) CAMSHAFT JOURNAL CLEARANCE Journal #1 Clearance 0.05 - 0.091 mm Journal #2, #3, #4, #5 Clearance 0.04 - 0.074 mm 02– Chery Automobile Co., Ltd.
Page 98 2. Installation is in the reverse order of removal. Installation Notes: • Install the intake and exhaust camshaft bearing caps in the proper order. • Slowly tighten bolts to the specified torque. • Follow the torque sequence as shown. BESM020036 Chery Automobile Co., Ltd. 02–...
Page 99 • CH-20012 - Valve Stem Seal Installer Guide • CH-20013 - Valve Seal Remover • CH-20017 - Valve Keeper Installer • CH-20018 - Valve Spring Compressor 1. Using the special tool CH-20018 (1), compress the valve springs. BESM020067 02– Chery Automobile Co., Ltd.
Page 100 • Clean all valves thoroughly and discard burned, warped and cracked valves. • Check valve seats and valve faces for damage. • When reconditioning valves follow the specifications outlined for both intake and exhaust valves. BESM020066 Chery Automobile Co., Ltd. 02–...
Page 101 Intake 0.012 - 0.043 mm Exhaust 0.032 - 0.063 mm Assembly 1. Install the valves into the cylinder head (larger diameter on intake side). 2. Install the valve springs. 3. Install the valve spring retainers. 02– Chery Automobile Co., Ltd.
Page 102 • CH-20012 - Valve Stem Seal Installer Guide • CH-20013 - Valve Seal Remover • CH-20017 - Valve Keeper Installer • CH-20018 - Valve Spring Compressor 1. Using the special tool CH-20018 (1), compress the valve springs. BESM020067 Chery Automobile Co., Ltd. 02–...
Page 103 • The following specifications apply to both intake and exhaust valve springs. BESM020072 VALVE SPRING LENGTH/HEIGHT Spring Free Length 47.7 mm Spring Height At 620 Newtons Of Pressure 32.0 mm If it is not within specifications, replace the valve spring. 02– Chery Automobile Co., Ltd.
Page 104 2. Install the valve spring retainers. 3. Using valve spring compressor CH-20018 (1), com- press the valve springs. 4. Install the valve keepers. BESM020067 5. Strike the valve stem lightly with a plastic hammer after installation to verify proper assembly. Chery Automobile Co., Ltd. 02–...
Page 105 02-144 Intake Manifold 02-117 Assembly 02-145 Removal & Installation 02-117 Valve Springs 02-146 Idler Pulley 02-119 Specifications 02-146 Removal & Installation 02-119 Disassembly 02-146 Oil Filter 02-119 Inspection 02-147 Removal & Installation 02-119 Assembly 02-148 02– Chery Automobile Co., Ltd.
Page 106 0.15 mm Inner Diameter 83.500 - 83.510 mm Engine Block Clearance Out-Of-Round < 0.008 mm Taper < 0.01 mm First Ring 0.04 - 0.08 mm Piston Ring Groove Clearance Second Ring 0.0251 - 0.01 mm Chery Automobile Co., Ltd. 02–...
Page 107 32 - 32.025 mm Inner Diameter Camshaft Cam Bearing #2, #3, #4, #5, Inner 24 - 24.021 mm Diameter Camshaft Journal #1 0.05 - 0.091 mm Clearance Camshaft Journal #2, #3, 0.04 - 0.074 mm #4, #5 Clearance 02– Chery Automobile Co., Ltd.
Page 108 2nd Step: Tighten the bolt an additional 90 ± 5° 3rd Step: Tighten the bolt an additional 90 ± 5° Dipstick Bracket Bolts Drive Plate Bolts (automatic transaxle) Engine Left Mount Bolt Engine Right Mount Bolt Engine Front Mount Bolt Engine Rear Mount Bolt Chery Automobile Co., Ltd. 02–...
Page 109 (Apply with Loctite 5910 Thread-Locker) Rear Timing Cover Bolts Timing Belt Upper Cover Bolts Timing Belt Lower Cover Bolts Timing Belt Tensioner Assembly Timing Belt Tensioner Pulley Bolt Throttle Body Bolts Upper Idler Pulley Bolt 02– Chery Automobile Co., Ltd.
Page 110 GENERAL INFORMATION Special Tools Right Engine Mount Bolt Remover CH-20001 Camshaft Seal Installer CH-20002 Crankshaft Holder CH-20003 Valve Spring Compressor Adaptor CH-20004 Rear Crankshaft Oil Seal Installer CH-20005 Chery Automobile Co., Ltd. 02–...
Page 111 GENERAL INFORMATION Rear Crankshaft Oil Seal Guide CH-20006 Front Crankshaft Seal Installer CH-20007 Front Crankshaft Seal Guide CH-20008 Camshaft Holder CH-20010 Valve Seal Installer CH-20011 02– Chery Automobile Co., Ltd.
Page 112 GENERAL INFORMATION Valve Stem Seal Installer Guide CH-20012 Valve Seal Remover CH-20013 Valve Keeper Installer CH-20017 Valve Spring Compressor CH-20018 Crankshaft Belt Pulley Fixture CH-20019 Chery Automobile Co., Ltd. 02–...
Page 113 The pump inner rotor is driven by the crankshaft. Engine Oil Pressure Specifications Lower Idle Speed (800 ± 50 RPM) 1.2 - 1.5 bar High Idle Speed (2000 RPM) 3.2 - 3.5 bar High Speed (4000 RPM) 3.7 ± 0.5 bar 02– Chery Automobile Co., Ltd.
Page 114 27 - Crankshaft Front Oil Seal 13 - Oil Filter Connector 28 - Oil Pump Bolt 14 - Oil Filter 29 - Oil Pump Assembly 15 - Dowel Pin 30 - Oil Pump Assembly Gasket LTSM020161 Chery Automobile Co., Ltd. 02–...
Page 115 13 - Oil Filter Bracket 6 - To Cylinder Head 14 - Oil Pressure Switch 7 - Oil Return Passage 15 - Oil Cooler 8 - To Front Bearing Cap 16 - Oil Filter BESM020088 02– Chery Automobile Co., Ltd.
Page 116 8. Perform exhaust restriction test. 8. Plugged or restricted exhaust Install new parts. system. 9. Test and replace if necessary. 9. Faulty ignition coil(s). (Refer to Appropriate Diagnostic 10. Burned spark plugs. Information) 10. Replace spark plugs. Chery Automobile Co., Ltd. 02–...
Page 117 Repair if necessary. 6. Crankshaft journal out-of-round or 5. Check thrust bearing for wear on worn. flanges. 7. Loose flywheel or torque 6. Replace crankshaft or grind converter. journals. 7. Tighten to correct torque. 02– Chery Automobile Co., Ltd.
Page 118 4. Rings fitted too tightly in grooves. Fouled 4. Remove rings and check grooves. 5. Worn valve guide(s). If groove is not proper width, replace 6. Valve stem seal(s) worn or piston. damaged. 5. Replace cylinder head. 6. Replace seal(s). Chery Automobile Co., Ltd. 02–...
Page 119 • Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are: − Engine overheating − Loss of coolant − Excessive steam (white smoke) emitting from exhaust − Coolant foaming 02– Chery Automobile Co., Ltd.
Page 120 1. While using a suitable tool and securely holding the hexagonal portion of the drive belt tensioner, rotate the pulley counterclockwise to loosen the drive belt. WARNING! Avoid placing hands near the drive belt tensioner while it is being held. Chery Automobile Co., Ltd. 02–...
Page 121 1. Unhook the air cleaner case side clips (1) and raise the air cleaner case (upper). LTSM020238 2. Remove the air cleaner element. 3. Install a new air cleaner element. 4. Installation is in the reverse order of removal. 02– Chery Automobile Co., Ltd.
Page 122 3. Use compressed air to blow dirt and debris off the cylinder head cover prior to removal. 4. Disconnect the camshaft position sensor electrical connector. 5. Remove the camshaft position sensor (2) and set it aside. Chery Automobile Co., Ltd. 02–...
Page 123 3. Remove the cylinder head cover (See Cylinder Head Cover Removal & Installation in Section 02 Engine). 4. Remove the intake or exhaust camshaft timing belt pulley. (Tighten: Camshaft timing belt pulley bolt to 120 N·m) 02– Chery Automobile Co., Ltd.
Page 124 7. Remove the camshaft bearing caps and place them in proper order. NOTE: The camshaft bearing caps are marked for identification. 8. Remove the camshafts and then remove the cam- shaft seals. BESM020035 9. Installation is in the reverse order of removal. 02– Chery Automobile Co., Ltd.
Page 125 • Use special tool CH-20002 (1), to install the camshaft seal. • Install the intake and exhaust camshaft bearing caps in the proper order. • Slowly tighten bolts to the specified torque. LTSM020215 • Follow the torque sequence as shown. BESM020036 Chery Automobile Co., Ltd. 02–...
Page 126 4. Remove intake manifold (See Intake Manifold Removal & Installation in Section 02 Engine). 5. Remove exhaust manifold (See Exhaust Manifold Removal & Installation in Section 02 Engine). 6. Remove water pipe and thermostat assembly. 02– Chery Automobile Co., Ltd.
Page 127 • Position the new cylinder head gasket on the engine block with the part number facing up. Ensure gasket is seated over the locating dowels in the block. • Before installing the bolts, the threads should be lightly coated with engine oil. Chery Automobile Co., Ltd. 02–...
Page 128 1. Remove the accessory drive belt (See Accessory Drive Belt Removal & Installation in Section 02 Engine). 2. Remove the crankshaft vibration damper bolts (1). (Tighten: Crankshaft vibration damper bolts to 25 N·m) BESM020055 3. Remove the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine). 02– Chery Automobile Co., Ltd.
Page 129 • CH-20006 - Rear Crankshaft Oil Seal Guide • CH-20043 - Flywheel Fixture 1. Remove the transaxle assembly (See Transaxle Assembly Removal & Installation in Section 08 Transaxle and Transfer Case). 2. Using special tool CH-20043 (1), hold the flywheel. LTSM080145 Chery Automobile Co., Ltd. 02–...
Page 130 (1) and then remove drive plate. (Tighten: Drive plate bolts to 75 N·m) BESM020031 6. Remove the rear oil seal using a suitable tool. 7. Installation is in the reverse order of removal. 02– Chery Automobile Co., Ltd.
Page 131 • Position the seal over the rear crankshaft seal guide. • Use special tool CH-20005 (2) and CH-20006 (1), to install the rear crankshaft oil seal. • Ensure that the lip of the seal is facing toward the crankcase during installation. LTSM020217 Chery Automobile Co., Ltd. 02–...
Page 132 4. Remove the engine left mount retaining bolts (2) and remove the engine left mount bracket bolts (1). (Tighten: Engine left mount bolts to 70 N·m) 5. Installation is in the reverse order of removal. LTSM020156 02– Chery Automobile Co., Ltd.
Page 133 2. Support the engine with the engine hoist. 3. Remove the bolts (1) securing the front engine mount. (Tighten: Engine front mount bolts to 60 N·m) 4. Installation is in the reverse order of removal. BESM080035 Chery Automobile Co., Ltd. 02–...
Page 134 4. Remove the battery, battery hold downs, and battery tray (See Battery Removal & Installation in Section 05 Starting & Charging). 5. Discharge air conditioning system (See A/C System Evacuation and Recharge in Section 13 Heating & Air Con- ditioning). 02– Chery Automobile Co., Ltd.
Page 135 10. Disconnect and remove the fuel line at the fuel rail. 11. Remove the air inlet hose and the air cleaner case assembly. NOTE: For 1.8L engine, disconnect the air flow sensor electrical connector. LTSM020226 12. Remove the ground cable bolt from the cylinder head. Chery Automobile Co., Ltd. 02–...
Page 136 16. Remove the vacuum line from the brake booster (2). 17. Remove the dipstick. BESM020025 18. If equipped with a manual transaxle remove the transaxle shift cable (1). 19. Remove the hydraulic pipe from the clutch slave cylinder. BESM080051 02– Chery Automobile Co., Ltd.
Page 137 40 ± 5 N·m) BESM110011 23. Remove the exhaust manifold heat shield bolts (1) and then remove heat shield. (Tighten: Exhaust manifold heat shield bolts to 15 N·m) BESM020078 24. Disconnect the upstream and downstream oxygen sensor connectors. Chery Automobile Co., Ltd. 02–...
Page 138 30. Remove the bolts (1) securing the front engine mount. (Tighten: Engine front mount bolt to 60 N·m) BESM080035 31. Remove the bolts (1) securing the rear engine mount. (Tighten: Engine rear mount bolt to 60 N·m) LTSM020207 02– Chery Automobile Co., Ltd.
Page 139 35. Remove the front sub-frame (See Front Sub-Frame Removal & Installation in Section 10 Suspension). 36. Hoist the engine from vehicle. CAUTION: Verify all electrical connectors are disconnected prior to engine/transaxle removal. 37. Separate engine and transaxle. Chery Automobile Co., Ltd. 02–...
Page 140 Removal & Installation in Section 13 Heat- ing & Air Conditioning). BESM020029 42. Remove the power steering pump (1) with piping connected and set aside with wire. BESM020028 43. Installation is in the reverse order of removal. 02– Chery Automobile Co., Ltd.
Page 141 The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may result in serious personal injury. Chery Automobile Co., Ltd. 02–...
Page 142 LTSM020218 5. Remove the accessory drive belt (See Accessory Drive Belt Removal & Installation in Section 02 Engine). 6. Remove the crankshaft vibration damper bolts (1). (Tighten: Crankshaft vibration damper bolts to 25 N·m) BESM020055 02– Chery Automobile Co., Ltd.
Page 143 NOTE: The camshaft holder will prevent the cam- shafts from rotating in either direction. BESM020016 CAUTION: Rotating the camshafts or crankshaft with timing components loosened or removed can cause serious damage to the valves or pistons. Chery Automobile Co., Ltd. 02–...
Page 144 Removal & Installation 1. Remove the engine cover. 2. Remove the bolts (1) attaching the exhaust mani- fold heat shield. (Tighten: Exhaust manifold heat shield bolts to 15 N·m) 3. Remove the exhaust manifold heat shield. BESM020078 02– Chery Automobile Co., Ltd.
Page 145 6. Remove the exhaust manifold nuts (1). (Tighten: Exhaust manifold nuts to 25 N·m) BESM020033 7. Remove the exhaust manifold. 8. Remove and discard manifold gasket (1). LTSM020169 9. Installation is in the reverse order of removal. Chery Automobile Co., Ltd. 02–...
Page 146 The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may result in serious personal injury. 02– Chery Automobile Co., Ltd.
Page 147 Install new O-rings on the fuel injectors. 13. Remove the screws securing the vacuum valve bracket to the intake manifold. 14. Set aside the vacuum valve and pipe. 15. Disconnect intake manifold electrical harness, and vacuum hose. Chery Automobile Co., Ltd. 02–...
Page 148 The following special tools are required to perform the repair procedure: • CH-10003 - Oil Filter Remover CAUTION: When servicing the oil filter, avoid deforming the filter by installing the special tool against the base of the filter. 02– Chery Automobile Co., Ltd.
Page 149 4. Remove oil pan bolts (1). (Tighten: Oil pan bolts to 18 N·m) LTSM020205 5. Using a putty knife, loosen seal around oil pan. 6. Remove the oil pan. 7. Installation is in the reverse order of removal. Chery Automobile Co., Ltd. 02–...
Page 150 (Tighten: Crankshaft timing belt pulley bolt to 130 N·m and an additional 65°) 5. Remove the key-way from the crankshaft. 6. Using an appropriate tool, remove the front crank- shaft oil seal (1). LTSM020199 02– Chery Automobile Co., Ltd.
Page 151 3. Remove the oil strainer retaining bolts (1). (Tighten: Oil strainer bolts to 18 N·m) BESM020018 4. Carefully remove the oil strainer. 5. Installation is in the reverse order of removal. Installation Notes: • Install new O-rings on the oil strainer pipe. Chery Automobile Co., Ltd. 02–...
Page 152 3. For each connecting rod/piston assembly to be removed, rotate the crankshaft to the bottom dead center position for each cylinder. NOTE : Before removing the connecting rod/piston assembly, check the connecting rod side clearance. 02– Chery Automobile Co., Ltd.
Page 153 Rod Removal & Installation in Section 02 Engine). CAUTION: When removing the connecting rod side bearings, note the installation position. Keep them in the correct order. BESM020045 8. Installation is in the reverse order of removal. Chery Automobile Co., Ltd. 02–...
Page 154 Assemble all components in their original position. 1. Install the pistons to the connecting rods. 2. Using a piston ring expander, install the piston rings. 3. Assemble all components in the reverse order of disassembly. 02– Chery Automobile Co., Ltd.
Page 155 First Ring End Gap 0.2 - 0.4 mm 0.8 mm Second Ring End Gap 0.4 - 0.6 mm 1.0 mm Clearance Specifications - Piston to Piston Pin DESCRIPTION SPECIFICATION (mm) Piston To Piston Pin 0.002 - 0.013 Chery Automobile Co., Ltd. 02–...
Page 156 BESM020046 • Piston Pin Snap Ring Removal − Using snap ring pliers, remove the snap ring (1). − Heat the pistons if necessary. BESM020048 02– Chery Automobile Co., Ltd.
Page 157 − Push out the piston pin with a suitable tool. BESM020049 • Connecting Rod & Piston Disassembly − Remove the piston from the connecting rod. BESM020041 Inspection • Check the piston diameter. BESM020050 PISTON DIAMETER All Pistons 83.451 - 83.469 mm Chery Automobile Co., Ltd. 02–...
Page 158 13 mm from bottom of cylinder bore and below the bottom of the oil ring travel where the cylinder bore has minimal wear. Check gap with feeler gauge. BESM020052 02– Chery Automobile Co., Ltd.
Page 159 1. Install the piston to the connecting rod. Assemble the components in their original positions. 2. Using a piston ring expander, install the piston rings. Assemble the components in their original positions. 3. Assemble all components in the reverse order of disassembly. Chery Automobile Co., Ltd. 02–...
Page 160 3. Using a hammer handle or similar tool, push the piston and connecting rod assembly (1) out through the cylinder head side of the engine block. NOTE: Before removing the piston and connecting rod assembly, check the connecting rod side clearance. BESM020044 02– Chery Automobile Co., Ltd.
Page 161 • 1st Step: Tighten bolts to 25 N·m • 2nd Step: Tighten the connecting rod bolts an additional 90° LTSM020208 4. Using a feeler gauge check connecting rod side clearance. • Check axial clearance of connecting rod. BESM020064 Chery Automobile Co., Ltd. 02–...
Page 162 7. Remove the main bearings and thrust bearings from the cylinder block and lower cylinder block. NOTE: If reusing the bearings, identify and number the bearings so that they are assembled in the same position and direction. 02– Chery Automobile Co., Ltd.
Page 163 − Remove the main bearing cap. − Measure the oil clearance with the plastic- gauge. Standard oil clearance of crankshaft main journal should be 0.022 mm. Limits of oil clearance of crank- shaft main journal should be 0.058 mm. BESM020077 Chery Automobile Co., Ltd. 02–...
Page 164 1. Install the main bearings and thrust bearings to the upper cylinder block and lower cylinder block. NOTE: Identify and number the bearings, if reusing them, so that they are assembled in the same position and direction. 2. Assemble the crankshaft and main bearings in the reverse order of disassembly. 02– Chery Automobile Co., Ltd.
Page 165 NOTE : Replacement cylinder head comes complete with valves, seals, springs, retainers, keepers, tappets, and camshafts. 1. Remove camshafts (See Camshaft Removal & Installation in Section 02 Engine). 2. Remove the hydraulic tappet assembly (1). BESM020071 Chery Automobile Co., Ltd. 02–...
Page 166 5. Push the valve stem from the cylinder head and remove the valve (4). VISM080041 6. Using special tool CH-20013 (1), remove the valve oil seal. LTSM020225 7. Remove the valve guide. 8. Remove the spark plugs. 02– Chery Automobile Co., Ltd.
Page 167 3. Using special tool CH-20011 (1) and CH-20012 (2), install the new valve oil seal. LTSM020224 4. Install the valves into the cylinder head (larger diameter on intake side). 5. Install the valve springs. 6. Install the valve spring retainers. Chery Automobile Co., Ltd. 02–...
Page 168 Cam Bearing #2, #3, #4, #5, Inner Diameter 24 - 24.021 Journal #1 Clearance 0.05 - 0.091 Journal #2, #3, #4, #5 Clearance 0.04 - 0.074 Intake Camshaft Axial Clearance 0.15 - 0.20 Exhaust Camshaft Axial Clearance 0.15 - 0.20 02– Chery Automobile Co., Ltd.
Page 169 Inspect the camshaft for the following: • Measure the camshaft cam lobe height. • If wear is beyond the limit, replace the camshaft. BESM020037 CAMSHAFT CAM LOBE HEIGHT Intake Cam Lobe Height 37.15 mm Exhaust Cam Lobe Height 37.05 mm Chery Automobile Co., Ltd. 02–...
Page 170 • Calculation of camshaft journal clearance Journal clearance = (inner diameter of camshaft bearing) - (outer diameter of camshaft journal) CAMSHAFT JOURNAL CLEARANCE Journal #1 Clearance 0.05 - 0.091 mm Journal #2, #3, #4, #5 Clearance 0.04 - 0.074 mm 02– Chery Automobile Co., Ltd.
Page 171 2. Installation is in the reverse order of removal. Installation Notes: • Install the intake and exhaust camshaft bearing caps in the proper order. • Slowly tighten bolts to the specified torque. • Follow the torque sequence as shown. BESM020036 Chery Automobile Co., Ltd. 02–...
Page 172 • CH-20012 - Valve Stem Seal Installer Guide • CH-20013 - Valve Seal Remover • CH-20017 - Valve Keeper Installer • CH-20018 - Valve Spring Compressor 1. Using the special tool CH-20018 (1), compress the valve springs. BESM020067 02– Chery Automobile Co., Ltd.
Page 173 • Clean all valves thoroughly and discard burned, warped and cracked valves. • Check valve seats and valve faces for damage. • When reconditioning valves follow the specifications outlined for both intake and exhaust valves. BESM020066 Chery Automobile Co., Ltd. 02–...
Page 174 Intake 0.012 - 0.043 mm Exhaust 0.032 - 0.063 mm Assembly 1. Install the valves into the cylinder head (larger diameter on intake side). 2. Install the valve springs. 3. Install the valve spring retainers. 02– Chery Automobile Co., Ltd.
Page 175 • CH-20012 - Valve Stem Seal Installer Guide • CH-20013 - Valve Seal Remover • CH-20017 - Valve Keeper Installer • CH-20018 - Valve Spring Compressor 1. Using the special tool CH-20018 (1), compress the valve springs. BESM020067 Chery Automobile Co., Ltd. 02–...
Page 176 • The following specifications apply to both intake and exhaust valve springs. BESM020072 VALVE SPRING LENGTH/HEIGHT Spring Free Length 47.7 mm Spring Height At 620 Newtons Of Pressure 32.0 mm If it is not within specifications, replace the valve spring. 02– Chery Automobile Co., Ltd.
Page 177 2. Install the valve spring retainers. 3. Using a valve spring compressor CH-20018 (1), compress the valve springs. 4. Install the valve keepers. BESM020067 5. Strike the valve stem lightly with a plastic hammer after installation to verify proper assembly. Chery Automobile Co., Ltd. 02–...
Page 178: Table Of Contents
Engine Timing Belt 02-189 Disassembly 02-234 Removal & Installation 02-189 Inspection 02-236 Inspection 02-194 Assembly 02-237 Timing Belt Automatic Tensioner 02-196 Removal & Installation 02-196 Inspection 02-197 Upper Balance Shaft Timing Belt 02-198 Removal & Installation 02-198 02– Chery Automobile Co., Ltd.
Page 179 02-250 Inspection 02-242 Valve Seats 02-251 Assembly 02-242 Assembly 02-252 Camshaft 02-243 Valve Springs 02-252 Specifications 02-243 Specifications 02-252 Disassembly 02-244 Disassembly 02-253 Camshaft 02-245 Inspection 02-254 Hydraulic Adjusters 02-245 Assembly 02-255 Rocker Arms 02-246 Chery Automobile Co., Ltd. 02–...
Page 180 Tensioner Arm Depression (98-196 N) Air-In 37.50 37.00 Cam Height Camshaft Air-Out 36.99 36.49 Shaft Diameter 45.0 Lower Surface Flatness 0.03 Surface Grinding Limit* Total Grinding of Cylinder Block Cylinder Head and Cylinder Head Full Height 119.9 - 120.1 02– Chery Automobile Co., Ltd.
Page 181 0.50 O.S. 11.50 - 11.52 0.30 O.S. 34.435 -34.455 Intake Valve Replacement Valve Cylinder Head Seats 0.60 O.S. 34.735 - 34.755 0.30 O.S. 31.935 - 31.955 Exhaust Valve Replacement Valve Seats 0.60 O.S. 32.235 - 32.255 Chery Automobile Co., Ltd. 02–...
Page 182 Exhaust Manifold Nut (M10) Fuel Pressure Regulator Fuel Return Pipe Injector and Distribution Pipe Intake Manifold Bolt Intake Manifold Bracket Thermostat Housing Bolt Water Pump Bolts Rocker Cover Bolt Rocker and Camshaft Assembly Bolt Trust Bearing Cover Bolt 02– Chery Automobile Co., Ltd.
Page 183 Oil Seal Cover Screw Bolts 1st Step: Tighten the bolts to 25 N·m Crankshaft Main Bearing Bolts 2nd Step: Tighten the bolts an additional 90°-100° Special Tools Camshaft Pulley Spanner Wrench MB-990767 Driver Handle MB-990938 Chery Automobile Co., Ltd. 02–...
Page 184 GENERAL INFORMATION Balance Shaft Bearing Puller Limiter MB-991603 Cylinder Cover Bolt Spanner MB-991654 Plug Spanner MD-998162 Crankshaft Front Oil Seal Duct MD-998285 Balance Shaft Bearing Puller MD-998371 02– Chery Automobile Co., Ltd.
Page 185 GENERAL INFORMATION Balance Shaft Bearing Puller MD-998372 Crankshaft Front Oil Seal Installer MD-998375 Hydraulic Adjuster Leak Tester MD-998440 Hydraulic Adjuster Keeper MD-998441 Hydraulic Adjuster Wiring MD-998442 Chery Automobile Co., Ltd. 02–...
Page 186 GENERAL INFORMATION Hydraulic Adjuster Keeper MD-998443 Balance Shaft Bearing Installer MD-998705 Camshaft Oil Seal Installer MD-998713 Pin For Belt Gear MD-998719 Oil Pan Remover MD-998727 02– Chery Automobile Co., Ltd.
Page 187 GENERAL INFORMATION Valve Spring Compressor MD-998735 Automatic Tensioner Socket MD-998767 Valve Spring Compressor MD-998772 Valve Oil Seal Installer MD-998774 Crankshaft Rear Oil Seal Installer MD-998776 Chery Automobile Co., Ltd. 02–...
Page 188 GENERAL INFORMATION Crankshaft Pulley Puller MD-998778 Piston Disassembling and Assembling Tool MD-998780 Flywheel Holder MD-998781 Plug Spanner Fixer MD-998783 Upper Balance Shaft Pulley Holder MD-998785 02– Chery Automobile Co., Ltd.
Page 189 • The lubrication system is a fully force-fed, full-flow filtration type. The oil pump is a gear type which is driven by the crankshaft via the timing belt. Chery Automobile Co., Ltd. 02–...
Page 190 8 - Oil Filter Adaptor LTSM020045 Oil Pump 1 - Front End Cover 4 - Oil Pump Driven Gear 2 - Front End Cover Pad 5 - Oil Pump Driving Gear 3 - Oil Pump Rear Cover LTSM020046 02– Chery Automobile Co., Ltd.
Page 191 Oil Filter and Oil Filter Adaptor 1 - Oil Filter Adaptor 5 - Spacer 2 - Gasket 6 - Plug Screw 3 - Pressure Limiting Valve Plunger 7 - Oil Filter 4 - Spring LTSM020047 Chery Automobile Co., Ltd. 02–...
Page 192 8. Perform exhaust restriction test. 8. Plugged or restricted exhaust Install new parts. system. 9. Test and replace if necessary. 9. Faulty ignition coil(s). (Refer to Appropriate Diagnostic 10. Burned spark plugs. Information) 10. Replace spark plugs. Chery Automobile Co., Ltd. 02–...
Page 193 Repair if necessary. 6. Crankshaft journal out-of-round or 5. Check thrust bearing for wear on worn. flanges. 7. Loose flywheel or torque 6. Replace crankshaft or grind converter. journals. 7. Tighten to correct torque. 02– Chery Automobile Co., Ltd.
Page 194 NOTE : The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. Chery Automobile Co., Ltd. 02–...
Page 195: Engine Oil Pressure Test
8. Remove the oil pressure gauge. 9. Apply the specified sealant to the thread (1) of oil pressure switch. 10. Install the oil pressure switch (Tighten: Oil pres- sure switch to 10 ± 2 N·m). LTSM020146 02– Chery Automobile Co., Ltd.
Page 196 7 - A/C Compressor Belt 4 - A/C Compressor 8 - Generator Belt LTSM020176 WARNING! Inspect the drive belt only when the engine is stopped. 1. Loosen the power steering pump adjustment bolt (1). LTSM020185 Chery Automobile Co., Ltd. 02–...
Page 197 Removal & Installation 1. Loosen the air cleaner case side clamps (1) and raise the air cleaner case (upper). 2. Remove the air cleaner element. 3. Installation is in the reverse order of removal. LTSM020239 02– Chery Automobile Co., Ltd.
Page 198 4. Remove the retaining bolt (1), securing the air cleaner housing to its base. (Tighten: Air cleaner housing retaining bolts to 10 N·m) LTSM020240 5. Remove the air cleaner housing. LTSM020160 6. Installation is in the reverse order of removal. Chery Automobile Co., Ltd. 02–...
Page 199 8. Remove the cylinder head cover from the cylinder head. 9. Remove the cylinder head cover gasket if necessary. 10. Installation is in the reverse order of removal. NOTE : Install a new cylinder head cover gasket during installation. 02– Chery Automobile Co., Ltd.
Page 200 14 - Camshaft LTSM020081 NOTE : The following special tools are required to perform the repair procedure: • MD-998719 - Camshaft Belt Gear Holder • MD-990767 - Camshaft Belt Gear Holder • MD-998443 - Hydraulic Post Keeper Chery Automobile Co., Ltd. 02–...
Page 201 10. Remove the camshaft thrust plate retaining bolt. (Tighten: Camshaft thrust plate bolt to 19 ± 3 N·m) 11. Remove the O-ring. 12. Remove the camshaft. 13. Installation is in the reverse order of removal. 02– Chery Automobile Co., Ltd.
Page 202 • Assemble the rocker shaft springs to the rocker shafts from the upper side of the shaft. Install the rocker shafts to the cylinder head and install the rocker shaft bolts and hand tighten only. CAUTION: The rocker shaft springs should be installed first and then install the rocker shaft bolts. LTSM020085 Chery Automobile Co., Ltd. 02–...
Page 203 • Make sure that the rocker shafts are installed properly (1) as shown in the illustration. CAUTION: The oil hole in the rocker shafts should be aligned with the cylinder head to ensure cor- rect installation position. LTSM020086 • Using special tool MD-998713 (1), install the camshaft oil seal. LTSM020087 02– Chery Automobile Co., Ltd.
Page 204 5. Remove the intake manifold (See Intake Manifold Removal & Installation in Section 02 Engine). 6. Remove the exhaust manifold (See Exhaust Manifold Removal & Installation in Section 02 Engine). 7. Remove the water pipe and thermostat assembly. Chery Automobile Co., Ltd. 02–...
Page 205 − 2nd Step: Completely loosen the bolt − 3rd Step: Retighten the bolt to 20 N·m − 4th Step: Tighten the bolt an additional 90° − 5th Step: Finish tightening the bolt an addi- tional 90° LTSM020098 02– Chery Automobile Co., Ltd.
Page 206 5. Remove the crankshaft timing belt pulley bolt. 6. Using special tool MD-998778 (1), remove the crankshaft timing belt pulley from the crankshaft. LTSM020052 7. Remove the key-way from the crankshaft. 8. Using an appropriate tool, remove the front crankshaft oil seal. Chery Automobile Co., Ltd. 02–...
Page 207 • Tighten the crankshaft timing belt pulley bolt in the following sequence. − 1st step: Tighten the crankshaft timing belt pulley bolt to 130 N·m. − 2nd step: Tighten the bolt an additional 65° LTSM020220 02– Chery Automobile Co., Ltd.
Page 208 The following special tools are required to perform the repair procedure: • MD-998776 - Crankshaft Rear Oil Seal Installer 1. Remove the transaxle assembly (See Transaxle Assembly Removal & Installation in Section 08 Transaxle & Transfer Case). Chery Automobile Co., Ltd. 02–...
Page 209 4. Remove the crankshaft rear oil seal using a suitable tool. 5. Installation is in the reverse order of removal. Installation Notes: • When installing seal, lubricate seal guide with clean engine oil. • Position the seal over the rear crankshaft seal guide. 02– Chery Automobile Co., Ltd.
Page 210 4. Remove the engine left mount retaining bolts (2) and remove the engine left mount bracket bolts (1). (Tighten: Engine left mount bolts to 70 N·m) 5. Installation is in the reverse order of removal. LTSM020156 Chery Automobile Co., Ltd. 02–...
Page 211 2. Support the engine with the engine hoist. 3. Remove the bolts (1) securing the front engine mount. (Tighten: Engine front mount bolts to 60 N·m) 4. Installation is in the reverse order of removal. BESM080035 02– Chery Automobile Co., Ltd.
Page 212 7. Remove the coolant fan & radiator assembly (See Coolant Fan & Radiator Assembly Removal & Installation in Section 06 Cooling). 8. Remove the starter motor wiring. 9. Remove the negative battery cable from the engine. Chery Automobile Co., Ltd. 02–...
Page 213 Four fuel injectors Air flow sensor Canister solenoid valve EGR control solenoid valve Throttle position sensor A/C compressor Oil pressure sensor Power steering pump pressure switch Generator Upstream oxygen sensor Knock sensor Idle air control motor 02– Chery Automobile Co., Ltd.
Page 214 18. Remove the dipstick. 19. Remove the accessory drive belt (See Accessory Drive Belt Removal & Installation in Section 02 Engine). 20. Remove the A/C compressor high and low pres- sure pipe bolts (1) & (2). LTSM130008 Chery Automobile Co., Ltd. 02–...
Page 215 27. Drain the engine oil. 28. Remove the power steering pump fluid line and set aside (See Power steering pump Removal & Installation in Section 11 Steering). 29. Lower the vehicle and install engine lift chain hangers. 02– Chery Automobile Co., Ltd.
Page 216 (Tighten: Engine rear mount bolt to 60 N·m) LTSM020188 32. Remove the bolts (2) securing the left transaxle mount and the bolts (1) securing the mount bracket. (Tighten: Left transaxle mount bolt to 70 N·m) LTSM020156 Chery Automobile Co., Ltd. 02–...
Page 217 Verify all electrical connectors are disconnected prior to engine/transaxle removal. 37. Separate engine and transaxle. (Tighten: M12×1.75 bolts to 70 ± 5 N·m) (Tighten: M10×1.5 bolts to 50 ± 5 N·m) 38. Installation is in the reverse order of removal. 02– Chery Automobile Co., Ltd.
Page 218 ON-VEHICLE SERVICE Engine Timing Belt Removal & Installation Chery Automobile Co., Ltd. 02– LTSM020048...
Page 219 Failure to follow these instructions may result in serious personal injury. 2. Attach an engine hoist to the engine. 3. Raise the engine with the engine hoist, just enough to support the engine. 02– Chery Automobile Co., Ltd.
Page 220 (Tighten: Timing belt lower cover bolts to 11 N·m) 9. Loosen the timing belt tensioning pulley bolt. 10. Remove the timing belt. NOTE: Remember the rotation direction of the timing belt in order to avoid any error when reassembling. Chery Automobile Co., Ltd. 02–...
Page 221 Installation Notes: • Rotate the camshaft pulley and align the timing marks (1) with the cylinder head cover. LTSM020073 • Rotate the crankshaft pulley and align the timing marks (1) with the front cover. LTSM020074 02– Chery Automobile Co., Ltd.
Page 222 20-25 mm, the lower balance shaft pulley should be rotated one revolution and the timing marks should be then be aligned. Keep the holder installed until the installation of the timing belt is complete. • Make sure all timing marks are aligned properly. • Install the timing belt. LTSM020076 Chery Automobile Co., Ltd. 02–...
Page 223 LTSM020078 • Measure distance “A” between the tensioner arm and the automatic tensioner. − Standard distance is 3.84 mm LTSM020080 Inspection 1. Inspect the timing belt back rubber for signs of aging and glistening. LTSM020057 02– Chery Automobile Co., Ltd.
Page 224 LTSM020058 3. Inspect the timing belt (1) for abnormal abrasion in the side of the belt (2). LTSM020059 4. Inspect the timing belt for abnormal abrasion (2) or teeth missing (1) from the belt. LTSM020060 Chery Automobile Co., Ltd. 02–...
Page 225: Timing Belt Automatic Tensioner
(1) and housing hole (2) are aligned. − Insert a steel wire (1.4 mm diameter) into the aligned hole. − Remove the automatic tensioner from the vise. LTSM020070 • The automatic tensioner is now ready to be installed on the engine. 02– Chery Automobile Co., Ltd.
Page 226 6. Rotate the handle of the vise to push the rod of the automatic tensioner into the tensioner. If the rod is easy to push in, replace the automatic tensioner. The rod should have some resistance when you push the rod into the tensioner. LTSM020062 Chery Automobile Co., Ltd. 02–...
Page 227: Upper Balance Shaft Timing Belt
5. Remove the upper balance shaft timing belt. NOTE: Remember the rotation direction of the timing belt in order to avoid any error when reassembling. 6. Installation is in the reverse order of removal. LTSM020053 02– Chery Automobile Co., Ltd.
Page 228 (standard deflection is 5-7 mm). • If the belt deflection is not within specifications, adjust if necessary. LTSM020068 • Reinstall the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine). Chery Automobile Co., Ltd. 02–...
Page 229 4. Disconnect the catalytic converter assembly from the manifold. 5. Remove the exhaust manifold nuts. (Tighten: Exhaust manifold nuts to 29 ± 3 N·m) 6. Remove the exhaust manifold from the cylinder head. 7. Remove and discard exhaust manifold gasket. 02– Chery Automobile Co., Ltd.
Page 230 2 - Knock Sensor 7 - Intake Manifold Support Bracket 3 - Coolant Hose 8 - Intake Manifold 4 - Coolant Hose 9 - Engine Hanger 5 - Coolant Temperature Sensor LTSM020178 1. Disconnect the negative battery cable. Chery Automobile Co., Ltd. 02–...
Page 231 9. Remove the fuel injector O-rings. 10. Remove the screws securing the vacuum valve bracket to the intake manifold. 11. Set aside the vacuum valve and pipe. 12. Disconnect the intake manifold electrical harness, and vacuum hose. 02– Chery Automobile Co., Ltd.
Page 232 17. Installation is in the reverse order of removal. Installation Notes: • Clean all surfaces of the manifold and cylinder head. • Install a new intake manifold gasket during installation. • Install new O-rings on the fuel injectors. Chery Automobile Co., Ltd. 02–...
Page 233: Upper Balance Shaft
10 - Crankshaft Front Oil seal 22 - Oil Pump Cover 11 - Oil Filter Adapter Gasket 23 - Lower Balance Shaft 12 - Oil Filter Adapter 24 - Lower Balance Shaft Rear Bearing LTSM020133 02– Chery Automobile Co., Ltd.
Page 234 20-25 mm, the lower balance shaft pulley should be rotated one revolution and the timing marks should be then be aligned. Keep the holder installed until the installation of the timing belt is complete. LTSM020186 Chery Automobile Co., Ltd. 02–...
Page 235 19. Remove the front cover gasket. 20. Remove the upper balance shaft. 21. Remove the upper balance shaft bearings (See Upper Balance Shaft Bearing Replacement in Sec- tion 02 Engine). 22. Installation is in the reverse order of removal. LTSM020172 02– Chery Automobile Co., Ltd.
Page 236 There is NO oil hole in the rear bearing. LTSM020141 3. Using special tool MD-998705 (1), install the front bearing. NOTE : Align the oil holes in the front bearing and the cylinder block. LTSM020187 Chery Automobile Co., Ltd. 02–...
Page 237: Lower Balance Shaft
10 - Crankshaft Front Oil Seal 22 - Oil Pump Cover 11 - Oil Filter Adapter Gasket 23 - Lower Balance Shaft 12 - Oil Filter Adapter 24 - Lower Balance Shaft Rear Bearing LTSM020133 02– Chery Automobile Co., Ltd.
Page 238 20-25 mm, the lower balance shaft pulley should be rotated one revolution and the timing marks should be then be aligned. Keep the holder installed until the installation of the timing belt is complete. LTSM020186 Chery Automobile Co., Ltd. 02–...
Page 239 19. Remove the front cover gasket. 20. Remove the lower balance shaft. 21. Remove the lower balance shaft bearings (See Lower Balance Shaft Bearing Replacement in Sec- tion 02 Engine). 22. Installation is in the reverse order of removal. LTSM020172 02– Chery Automobile Co., Ltd.
Page 240 LTSM020138 3. Using special tool MD-998705 (2), install the rear bearing. NOTE : Align the oil holes (1) in the rear bearing and the cylin- der block. LTSM020139 Chery Automobile Co., Ltd. 02–...
Page 241 3. Raise and support the vehicle. 4. Remove the oil pan drain plug and drain the oil out of the engine. WARNING! The engine oil is hot and can burn your skin. 5. Remove the under cover. 02– Chery Automobile Co., Ltd.
Page 242 3. Remove the oil pan drain plug (2) and drain the engine oil. (Tighten: Oil pan drain plug to 45 N·m) 4. Remove the oil pan (3) retaining bolts (1). (Tighten: Oil pan bolts to 18 N·m) LTSM020192 Chery Automobile Co., Ltd. 02–...
Page 243 • Oil pan sealing surfaces must be free of grease or oil. • Install the four oil pan corner bolts in the sequence shown (1-2-3-4). • Install the remaining oil pan bolts. • Torque all the oil pan bolts to the proper specification. LTSM020241 02– Chery Automobile Co., Ltd.
Page 244 • Before installing the new oil pump, prime the oil pump by filling the oil pump with engine oil and rotate the oil pump. • Align the oil pump timing marks (1). • Check oil pump side clearance. LTSM020145 Chery Automobile Co., Ltd. 02–...
Page 245 3. Remove the oil strainer retaining bolts. (Tighten: Oil strainer bolts to 18 N·m) 4. Carefully remove the oil strainer. 5. Installation is in the reverse order of removal. Installation Notes: • Install new O-rings on the oil strainer pipe. 02– Chery Automobile Co., Ltd.
Page 246 1st Step: Tighten the bolts to 25 N·m Main Bearing Cap Bolts 2nd Step: Tighten the bolts an additional 90°-100° Clearance Specifications DESCRIPTION SPECIFICATION (mm) Surface Distortion Limit 0.15 Cylinder Diameter Standard 86.50 - 86.53 Out-Of-Round < 0.008 Taper < 0.01 Chery Automobile Co., Ltd. 02–...
Page 247 3. For each connecting rod/piston assembly to be removed, rotate the crankshaft to the bottom dead center position for each cylinder. NOTE : Before removing the connecting rod/piston assembly, check the connecting rod side clearance. 02– Chery Automobile Co., Ltd.
Page 248 Rod Removal & Installation in Section 02 Engine). CAUTION: When removing the connecting rod side bearings, note the installation position. Keep them in the correct order. BESM020045 8. Installation is in the reverse order of removal. Chery Automobile Co., Ltd. 02–...
Page 249 Assemble all components in their original position. 1. Install the pistons to the connecting rods. 2. Using a piston ring expander, install the piston rings. 3. Assemble all components in the reverse order of disassembly. 02– Chery Automobile Co., Ltd.
Page 250 0.8 mm Second Ring 0.40 - 0.55 mm 0.8 mm Oil Control Ring 0.10 - 0.40 mm 1.0 mm Clearance Specifications - Piston to Piston Pin DESCRIPTION SPECIFICATION (mm) Piston To Piston Pin 0.002 - 0.013 Chery Automobile Co., Ltd. 02–...
Page 251 • Using a suitable ring expander, remove upper and intermediate piston rings. • Remove the upper oil ring side rail, lower oil ring side rail and then oil ring expander from piston. • Clean ring grooves of any carbon deposits. 02– Chery Automobile Co., Ltd.
Page 252 • Attach the tool guide into the piston and to the push rod. LTSM020180 Connecting Rod & Piston Disassembly • Connecting Rod & Piston Disassembly. − Remove the piston from the connecting rod. BESM020041 Chery Automobile Co., Ltd. 02–...
Page 253 − Clean the ring slot using a suitable tool. − Measure piston ring to groove side clearance. LTSM020121 RING GROOVE SIDE CLEARANCE DESCRIPTION SPECIFICATION LIMIT First Ring 0.02 - 0.06 mm 0.1 mm Second Ring 0.02 - 0.06 mm 0.1 mm 02– Chery Automobile Co., Ltd.
Page 254 0.40 - 0.55 mm 0.8 mm Oil Control Ring 0.10 - 0.40 mm 1.0 mm Piston Pin Clearance • Check the diameter of the piston pin bore. • Check the outer diameter of the piston pin. BESM020053 Chery Automobile Co., Ltd. 02–...
Page 255 • Screw on guide block B into guide pipe A to gain clearance between guide block A (2) and guide block B (1) equal to the value of Value L (L=[(A-C)-(B-D)] / 2) plus 3 mm. LTSM020112 • Keep the forward mark of piston upward. Install piston and connecting rod in tool base of piston pin installer. 02– Chery Automobile Co., Ltd.
Page 256 Do not use a piston ring expander to install the oil control rings. Oil Control Ring Installation • Install the main ring of oil control ring into oil ring groove. NOTE : There is no difference between the upper and lower oil control rings. Chery Automobile Co., Ltd. 02–...
Page 257 BESM020047 Top Compression Ring Installation (1st Ring) • Using a piston ring expander, install the top compression ring. • Ensure the ring can turn from the left to the right freely after installation. BESM020047 02– Chery Automobile Co., Ltd.
Page 258 Clearance Specifications DESCRIPTION SPECIFICATION (mm) Connecting Rod Radial Clearance 0.016 - 0.051 Connecting Rod Axial Clearance 0.002 - 0.013 Disassembly 1. Remove the connecting rod cap nuts. BESM020042 2. Remove the connecting rod bearing cap. BESM020043 Chery Automobile Co., Ltd. 02–...
Page 259 − Torque the connecting rod cap nuts to 20 N·m − Carefully disassemble the connecting rod cap. − Use the measuring rule imprinted on the plas- tigauge package to measure the width of the widest part of the plastigauge. LTSM020122 02– Chery Automobile Co., Ltd.
Page 260 • Using a suitable tool, tap the piston and connecting rod assembly into cylinder. NOTE : The piston direction mark (2) should point toward the timing belt side (1). LTSM020118 • Check the axial clearance of the connecting rods. BESM020064 Chery Automobile Co., Ltd. 02–...
Page 261 Group 1 in the table. If the crankshaft has been replaced, check the identification color applied to the new crankshaft journal. If the journal is yellow, the crankshaft bearing will be from Group 1, and the connecting rod bearing will be identified as 1. 02– Chery Automobile Co., Ltd.
Page 262 47.884 - 47.9 Out-of-Round Maximum of Crankshaft Main Journals 0.008 Axial Clearance of Crankshaft 0.07 - 0.265 Radial Clearance of Crankshaft 0.0035 - 0.034 Coaxality Crankshaft Main Journal 0.05 Thrust Washer Thickness 2.4 - 2.405 Chery Automobile Co., Ltd. 02–...
Page 263 3 - Crankshaft Rear Oil Seal 8 - Bearing Cap 4 - Crankshaft Thrust Bearing 9 - Bearing Cap Bolt 5 - Upper Crankshaft Bearing LTSM020194 1. Remove the engine front cover. 2. Remove the crankshaft rear oil seal. 02– Chery Automobile Co., Ltd.
Page 264 NOTE: Before removing the piston and connecting rod assembly, check the connecting rod side clearance. BESM020044 6. Remove the connecting rod bearings. CAUTION: When removing the connecting rod side bearings, note the installation position. Keep them in the correct order. BESM020045 Chery Automobile Co., Ltd. 02–...
Page 265 − Torque the main bearing cap to the specified torque. − Carefully disassemble the main bearing cap. − Use the measuring rule imprinted on the plas- tigauge package to measure the width of the widest part of the plastigauge. BESM020077 02– Chery Automobile Co., Ltd.
Page 266 Before installing the main bearing bolts, clean the threads and oil the bolts with clean engine oil. Crankshaft Main Bearings • Perform the following when replacing the crankshaft main bearings: − Measure and record the external diameter of the crankshaft main journals. LTSM020119 Chery Automobile Co., Ltd. 02–...
Page 267 As an example, if the identification color of the crankshaft main journal is yellow and the identification mark of spindle bore is “1”, choose the No. 1,2,4,5 bearing of which identification mark is “2” and identification color is “yellow” and No.3 bearing of which identification mark is “1” and identification color is “green”. 02– Chery Automobile Co., Ltd.
Page 268 If the bolts are over tightened (exceed angle of 100°), loosen the bolts and restart the torque sequence from Step 1 LTSM020130 • After installing the main bearing caps, assure that the crankshaft rotates smoothly. Chery Automobile Co., Ltd. 02–...
Page 269 • Inspect the crankshaft axial clearance. − If the crankshaft axial clearance exceeds the maximum limit, replace the No.3 crankshaft thrust bearing. BESM020076 CRANKSHAFT AXIAL CLEARANCE DESCRIPTION SPECIFICATION MAXIMUM LIMIT Crankshaft 0.05 - 0.18 mm 0.25 mm 02– Chery Automobile Co., Ltd.
Page 270: Cylinder Head Unit Repair
2. Using the special tool MD-998772 (1), compress the valve spring. 3. Remove the valve keeper, valve spring retainer and valve spring. 4. Push the valve stem from the cylinder head and remove the valve. LTSM020092 Chery Automobile Co., Ltd. 02–...
Page 271 3. Using special tool MD-998774 (1), install the new valve oil seal. LTSM020094 4. Install the valves into the cylinder head (larger diameter on intake side). 5. Install the valve springs. 6. Install the valve spring retainers. 02– Chery Automobile Co., Ltd.
Page 272 9. Strike the valve stem lightly with a plastic hammer after installation to verify proper assembly. LTSM020092 Camshaft Specifications Camshaft Specifications DESCRIPTION SPECIFICATION MINIMUM LIMIT Intake Cam Lobe Height 37.5 mm 37 mm Exhaust Cam Lobe Height 36.99 mm 36.49 mm Chery Automobile Co., Ltd. 02–...
Page 273 7 - Rocker Arm and Rocker Shaft 14 - Camshaft LTSM020081 1. Remove the rocker shaft retaining bolt. 2. Remove the rocker arms. 3. Remove the camshaft thrust plate retaining bolts. 4. Remove the camshaft and then remove the camshaft seal. 02– Chery Automobile Co., Ltd.
Page 274 If the plunger is still loose, the hydraulic adjuster should be replaced. LTSM020088 CAUTION: After the hydraulic adjuster has been prepared, it should be kept erect to avoid the loss of diesel oil. Chery Automobile Co., Ltd. 02–...
Page 275: Rocker Arms
Exhaust Valve Edge Thickness 1.2 mm 0.7 mm Intake Valve Height 112.30 mm 111.80 mm Exhaust Valve Height 114.11 mm 113.61 mm Intake Valve Guide Height 49.30 mm 49.80 mm Exhaust Valve Guide Height 49.30 mm 49.80 mm 02– Chery Automobile Co., Ltd.
Page 276 4 - Valve Spring 9 - Valve 5 - Valve Oil Seal 10 - Cylinder Head LTSM020090 NOTE : The following special tools are required to perform the repair procedure: • MD-998772 - Valve Spring Compressor Chery Automobile Co., Ltd. 02–...
Page 277 • Check valve seats and valve faces for damage. • When reconditioning valves follow the specifications outlined for both intake and exhaust valves. BESM020066 • Measure valve deflection. VALVE DEFLECTION LIMIT (DIAL GAUGE READING) Intake Valve 0.02 mm Exhaust Valve 0.04 mm 02– Chery Automobile Co., Ltd.
Page 278 • Check the valve edge thickness and valve contact area. Repair or replace the valve if necessary. BESM020066 VALVE EDGE THICKNESS DESCRIPTION SPECIFICATION LIMIT Intake Valve Edge Thickness 1.0 mm 0.5 mm Exhaust Valve Edge Thickness 1.2 mm 0.7 mm Chery Automobile Co., Ltd. 02–...
Page 279: Valve Guides
When replacing valve guides, do not use a new valve guide that is the same size as the original valve guide. − Enlarge valve guide size 0.05 (11.05 - 11.068 mm) − Enlarge valve guide size 0.25 (11.25 - 11.268 mm) − Enlarge valve guide size 0.50 (11.50 - 11.518 mm) 02– Chery Automobile Co., Ltd.
Page 280: Valve Seats
Enlargement size 0.30 mm 34.435 - 34.455 mm Intake valve seat Enlargement size 0.60 mm 34.735 - 34.755 mm Enlargement size 0.30 mm 31.935 - 31.955 mm Exhaust valve seat Enlargement size 0.60 mm 32.235 - 32.255 mm Chery Automobile Co., Ltd. 02–...
Page 281 7. Strike the valve stem lightly with a plastic hammer after installation to verify proper assembly. LTSM020092 Valve Springs Specifications Valve Spring Specifications DESCRIPTION SPECIFICATION LIMIT Spring Free Length 51.0 mm 50.0 mm ≤ 2.0° ≤ 4.0° Spring Center Line 02– Chery Automobile Co., Ltd.
Page 282 4 - Valve Spring 9 - Valve 5 - Valve Oil Seal 10 - Cylinder Head LTSM020090 NOTE : The following special tools are required to perform the repair procedure: • MD-998772 - Valve Spring Compressor Chery Automobile Co., Ltd. 02–...
Page 283 • Check the valve spring length/height. Discard the springs that do not meet specifications. • The following specifications apply to both intake and exhaust valve springs. BESM020072 VALVE SPRING LENGTH/HEIGHT DESCRIPTION SPECIFICATION LIMIT Spring Free Length 51.0 mm 50.0 mm 02– Chery Automobile Co., Ltd.
Page 284 3. Using valve spring compressor MD - 998772, com- press the valve springs. 4. Install the valve keepers. 5. Strike the valve stem lightly with a plastic hammer after installation to verify proper assembly. LTSM020039 Chery Automobile Co., Ltd. 02–...
Page 285: Electronic Engine Controls
P0204 - Cylinder 4 - Injector Circuit 03-142 P0102 - Mass Or Volume Air Flow P0221 - Throttle Position Sensor B Circuit Low Input 03-57 Performance 03-149 P0103 - Mass Or Volume Air Flow Circuit High Input 03-63 Chery Automobile Co., Ltd. 03–...
Page 286 Removal & Installation 03-225 Removal & Installation 03-218 Engine Control Module (ECM) 03-226 Oxygen Sensor 03-218 Description 03-226 Description 03-218 Operation 03-226 Operation 03-218 Removal & Installation 03-226 Upstream Oxygen Sensor 03-219 Downstream Oxygen Sensor 03-219 03– Chery Automobile Co., Ltd.
Page 287 The ECM is a pre-programmed, microprocessor-based digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The ECM can adapt its programming to meet changing operating conditions. Chery Automobile Co., Ltd. 03–...
Page 288 • Air conditioner does not operate. • Fuel injector control failure. • Engine stalls out. • Unstable idle. • Lack of engine power. • Poor fuel economy. Ignition Coil Replace • Excessive exhaust emissions. • Weak spark. 03– Chery Automobile Co., Ltd.
Page 289 Oxygen Sensors Crankshaft Position (CKP) Sensor Camshaft Position (CMP) Sensor Air Flow Sensor Bolts Engine Control Module (ECM) Bolts Accelerator Pedal Position (APP) Sensor Electronic Throttle Control Actuator Vehicle Speed Sensor Manifold Absolute Pressure (MAP) Sensor Chery Automobile Co., Ltd. 03–...
Page 290 GENERAL INFORMATION Special Tools Diagnostic Scan Tool X-431 Engine Analyzer KES-200 Digital Multimeter Fluke 15B & 17B 03– Chery Automobile Co., Ltd.
Page 291 GENERAL INFORMATION Compression Gauge Fuel Pressure Gauge Chery Automobile Co., Ltd. 03–...
Page 292 Power Into 12 V DC Power To Diagnose Mitsubishi To Connect The Diagnostic Mitsubishi-12+16 Main Cable Electronic Control Systems Connector and Smartbox Pin Connector On Chery B11 Series To Perform Vehicle Smartbox To Diagnose Vehicles With Diagnosis Fiat-3 Pin Fiat-3 Pin Diagnostic Connector...
Page 293 GENERAL INFORMATION Electrical Schematics Electronic Engine Controls (Page 1 of 11) LTSMW030080T Chery Automobile Co., Ltd. 03–...
Page 294 GENERAL INFORMATION Electronic Engine Controls (Page 2 of 11) LTSMW030081T 03– Chery Automobile Co., Ltd.
Page 295 GENERAL INFORMATION Electronic Engine Controls (Page 3 of 11) LTSMW030082T Chery Automobile Co., Ltd. 03–...
Page 296 GENERAL INFORMATION Electronic Engine Controls (Page 4 of 11) LTSMW030083T 03– Chery Automobile Co., Ltd.
Page 297 GENERAL INFORMATION Electronic Engine Controls (Page 5 of 11) LTSMW030084T Chery Automobile Co., Ltd. 03–...
Page 298 GENERAL INFORMATION Electronic Engine Controls (Page 6 of 11) LTSMW030085T 03– Chery Automobile Co., Ltd.
Page 299 GENERAL INFORMATION Electronic Engine Controls (Page 7 of 11) LTSMW030086T Chery Automobile Co., Ltd. 03–...
Page 300 GENERAL INFORMATION Electronic Engine Controls (Page 8 of 11) LTSMW030087T 03– Chery Automobile Co., Ltd.
Page 301 GENERAL INFORMATION Electronic Engine Controls (Page 9 of 11) LTSMW030088T Chery Automobile Co., Ltd. 03–...
Page 302 GENERAL INFORMATION Electronic Engine Controls (Page 10 of 11) LTSMW030089T 03– Chery Automobile Co., Ltd.
Page 303 GENERAL INFORMATION Electronic Engine Controls (Page 11 of 11) LTSMW030090T Chery Automobile Co., Ltd. 03–...
Page 304 (With EOBD) Air Compressor Relay (Without EOBD) Fuel Pump Relay Diagnostic Link K MIL Lamp Regulated Sensor Supply 3 Regulated Sensor Supply 2 Regulated Sensor Supply 1 Clutch Pedal Switch Crankshaft Position Sensor A/C Stand By 03– Chery Automobile Co., Ltd.
Page 305 Headlamp Switch Manifold Absolute Pressure Sensor (With 1.6L Engine) Sensor (GND) Air Flow Sensor (With 1.8L Engine) Electronic Throttle Control Actuator Camshaft Position Sensor (Position Sensor) Engine Coolant Temperature Sensor GND (Power) Accelerator Pedal Position Sensor Chery Automobile Co., Ltd. 03–...
Page 306: Ground Inspection
6. If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the wires are clean, securely fastened and providing a good ground path. If multiple wires are crimped to one eyelet, make sure no excess wire insulation has been crimped creating a bad ground. 03– Chery Automobile Co., Ltd.
Page 307 B Camshaft Position - Timing Over - Advanced or System Performance P0015 B Camshaft Position - Timing Over - Retarded P0016 Crankshaft - Camshaft Position Correlation P0030 Sensor Heater Control Circuit (Bank 1 Sensor 1) P0031 Sensor Heater Control Circuit (Bank 1 Sensor 1) Low Chery Automobile Co., Ltd. 03–...
Page 308 Engine Overspeed Condition P0221 Throttle/Pedal Position Sensor/Switch B Range/Performance P0222 Throttle/Pedal Position Sensor/Switch B Low Input P0223 Throttle/Pedal Position Sensor/Switch B High Input P0261 Cylinder 1 - Injector Circuit Low P0262 Cylinder 1 - Injector Circuit High 03– Chery Automobile Co., Ltd.
Page 309 P0562 System Voltage Low Voltage P0563 System Voltage High Voltage P0571 Brake Switch A Circuit P0601 Internal Control Module EEPROM Error P0602 Control Module Programming Error P0604 Internal Control Module Random Access Memory (RAM) Error Chery Automobile Co., Ltd. 03–...
Page 310 Accelerator Pedal Position Sensor Signal Correlation Error P2177 System Too Lean off Idle P2178 System Too Rich off Idle P2187 System Too Lean at Idle P2188 System Too Rich at Idle P2195 Sensor Signal Stuck Lean; Bank 1 Sensor 1 03– Chery Automobile Co., Ltd.
Page 311 Lost Communication with ECM U104 Lost Communication with Cruise Control Module U0121 Lost Communication with Anti-Lock Brake System (ABS) Control Module U0155 Lost Communication with Instrument Panel Cluster Control Module U0415 Invalid Data Received from ABS Control Module Chery Automobile Co., Ltd. 03–...
Page 312 DIAGNOSIS & TESTING ECM Power Supply and Ground Circuit Test Power Supply and Ground Circuit LTSMW030042T 03– Chery Automobile Co., Ltd.
Page 313 € Ignition switch: OFF € More than a few EMS Relay (Main Relay) Voltage (11 - 14 V) seconds after turning ignition switch OFF Switched Supply Voltage € Ignition switch: ON Voltage (11 - 14 V) (SSV) 03– Chery Automobile Co., Ltd.
Page 314 DIAGNOSIS & TESTING LTSMW030043T 03– Chery Automobile Co., Ltd.
Page 315: Diagnostic Procedure
• Turn ignition switch off and then on. • Check voltage between the ECM terminal 13 and ground. • Battery voltage should exist. Is the check result normal? >> Go to step 4. >> Go to step 3. LTSMD030061 Chery Automobile Co., Ltd. 03–...
Page 316 • Check harness for open or short between ECM terminals 3, 51, 53, 61, 80 and ground. Is the check result normal? >> Go to the next step. >> Repair or replace circuit for an open or short to power in harness or connectors. 03– Chery Automobile Co., Ltd.
Page 317 • Also check harness for a short to ground and short to power. Is the check result normal? >> Go to step 11. >> Repair circuit for an open or short to power in harness or connectors. Chery Automobile Co., Ltd. 03–...
Page 318 Replace the ECM. NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> Replace front fuse and relay box. 03– Chery Automobile Co., Ltd.
Page 319 DIAGNOSIS & TESTING Diagnostic Trouble Code (DTC) Tests P0016 - Camshaft Position-Crankshaft Position Correlation Error LTSMW030051T Chery Automobile Co., Ltd. 03–...
Page 320 DIAGNOSIS & TESTING LTSMW030046T 03– Chery Automobile Co., Ltd.
Page 321 • If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 03 Electronic Engine Controls for more information. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. Chery Automobile Co., Ltd. 03–...
Page 322 • Check CMP sensor supply voltage between sensor connector E-007, terminal 3 and ground in the sen- sor electrical connector. • 12 V should exist. Is the check result normal? >> Go to step 5. >> Go to the next step. LTSMD030044 03– Chery Automobile Co., Ltd.
Page 323 >> Go to the next step. >> Repair or replace circuit for an open or short to power or short to ground in harness or connectors. If circuit is normal, go to the next step. Chery Automobile Co., Ltd. 03–...
Page 324 Is the sensor mounting area OK? >> Go to the next step. >> Repair or replace the sensor as necessary. PZSMD030003 03– Chery Automobile Co., Ltd.
Page 325 Monitor the CMP sensor signal on the KES-200 screen. − If the CMP sensor signals were normal, the system is OK. − If the CMP sensor signals were still irregular or missing, go to step 13. >> Replace CMP sensor. Chery Automobile Co., Ltd. 03–...
Page 326 • Check signal between CKP sensor (1) terminal 1 and ground, terminal 2 and ground when engine is running. VISMD030200 CKP SENSOR SIGNAL ENGINE ANALYZER (KES-200) Is the CKP output signal normal? >> Go to step 16. >> Go to the next step. 03– Chery Automobile Co., Ltd.
Page 327 Monitor the CKP sensor signal on the KES-200 screen. − If the CKP sensor signals were normal, the system is OK. − If the CKP sensor signals were still irregular or missing, go to step 14. >> Replace CKP sensor. Chery Automobile Co., Ltd. 03–...
Page 328 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 329 DIAGNOSIS & TESTING P0031 - O Sensor 1 Heater Control Circuit Low LTSMW030054T Chery Automobile Co., Ltd. 03–...
Page 330 DIAGNOSIS & TESTING LTSMW030055T 03– Chery Automobile Co., Ltd.
Page 331 • If the DTC is not detected, the DTC condition is intermittent (See Diagnosis & Testing Diagnostic Help in Sec- tion 03 Electronic Engine Controls). NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. Chery Automobile Co., Ltd. 03–...
Page 332 • Check supply voltage between O sensor terminal 2 and ground in the O sensor electrical connector E-004. • Battery voltage should exist. Is the check result normal? >> Go to Step 5. >> Go to the next step. LTSMD030029 03– Chery Automobile Co., Ltd.
Page 333 • 1 (Without EOBD) • Check harness short to ground. Is the check result normal? >> Go to the next step. >> Repair or replace the circuit for an open or short in harness or connectors. Chery Automobile Co., Ltd. 03–...
Page 334 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 335 DIAGNOSIS & TESTING P0032 - O Sensor 1 Heater Control Circuit High LTSMW030054T Chery Automobile Co., Ltd. 03–...
Page 336 DIAGNOSIS & TESTING LTSMW030055T 03– Chery Automobile Co., Ltd.
Page 337 • If the DTC is not detected, the DTC condition is intermittent (See Diagnosis & Testing Diagnostic Help in Sec- tion 03 Electronic Engine Controls). NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. Chery Automobile Co., Ltd. 03–...
Page 338 2 and ground in the O sensor electri- cal connector E-004. • Battery voltage should exist. Is the check result normal? >> Go to Step 5. >> Go to the next step. LTSMD030029 03– Chery Automobile Co., Ltd.
Page 339 (Without EOBD) • Check harness short to power supply circuit. Is the check result normal? >> Go to the next step. >> Repair or replace circuit for a short to power in harness or connectors. Chery Automobile Co., Ltd. 03–...
Page 340 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 341 DIAGNOSIS & TESTING P0102 - Mass Or Volume Air Flow Circuit Low Input LTSMW030058T Chery Automobile Co., Ltd. 03–...
Page 342 • Inspect ground connections E-207 and E-208 mounting position (See Vehicle Wiring Harness Layout - Engine Room Harness (With 1.6L/1.8L Engine) in Section 16 Wiring). Is ground connections OK? >> Go to the next step. >> Repair or replace ground connections. 03– Chery Automobile Co., Ltd.
Page 343 • Check voltage between MAF sensor terminal 2 and ground in the MAF sensor electrical connector E-009. • Battery voltage should exist. Is the check result normal? >> Go to step 6. >> Go to the next step. LTSMD030041 Chery Automobile Co., Ltd. 03–...
Page 344 • Check harness continuity between MAF sensor terminal 3 and ECM terminal 17. • Continuity should exist. • Check harness for short to ground. Is the check result normal? >> Go to the next step. >> Repair or replace circuit for an open in harness or connectors. 03– Chery Automobile Co., Ltd.
Page 345 • If without the X-431, check voltage between MAF sensor terminal 5 and ground. DATA TERMINAL (AVERAGE ITEM CONDITION VOLTAGE) • Engine is running • ECT: 78°C • Idle: 795 Approximately flow 1.39 V sensor • IAT: 36°C • IAT signal: 1.88 V Chery Automobile Co., Ltd. 03–...
Page 346 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 347 DIAGNOSIS & TESTING P0103 - Mass Or Volume Air Flow Circuit High Input LTSMW030058T Chery Automobile Co., Ltd. 03–...
Page 348 • If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 03 Electronic Engine Controls for more information. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. 03– Chery Automobile Co., Ltd.
Page 349 • Disconnect the MAF sensor (1) electrical connector. • Inspect the electrical connector for damage. Is the electrical connector OK? >> Go to the next step. >> Repair or replace the electrical connector as necessary. LTSMD030075 Chery Automobile Co., Ltd. 03–...
Page 350 • Continuity should exist. • Also check harness for short to power. Is the check result normal? >> Go to the next step. >> Repair or replace circuit for short to power in harness or connectors. 03– Chery Automobile Co., Ltd.
Page 351 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 352 DIAGNOSIS & TESTING P0105 - Manifold Absolute Pressure/Barometric Pressure Circuit P0106 - Manifold Absolute Pressure Or Barometric Pressure Range/Performance LTSMW030052T 03– Chery Automobile Co., Ltd.
Page 353 • Inspect ground connections E-207 and E-208 mounting position (See Vehicle Wiring Harness Layout - Engine Room Harness (With 1.6L/1.8L Engine) in Section 16 Wiring). Is ground connections OK? >> Go to the next step. >> Repair or replace ground connections. Chery Automobile Co., Ltd. 03–...
Page 354 • Check MAP sensor supply between MAP sensor connector terminal 1 and 3. • 5 V should exists. Is the check result normal? >> Go to step 5. >> Go to the next step. VISMD030010 03– Chery Automobile Co., Ltd.
Page 355 • Check for harness continuity between MAP sensor terminal 4 and ECM terminal 37. • Continuity should exist. Is the check result normal? >> Go to the next step. >> Repair or replace circuit for an open or high resistance in harness or connectors. Chery Automobile Co., Ltd. 03–...
Page 356 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 357 DIAGNOSIS & TESTING P0107 - Manifold Absolute Pressure Or Barometric Pressure Low Input P0108 - Manifold Absolute Pressure Or Barometric Pressure High Input LTSMW030052T Chery Automobile Co., Ltd. 03–...
Page 358 • If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 03 Electronic Engine Controls for more information. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. 03– Chery Automobile Co., Ltd.
Page 359 • Disconnect the MAP sensor (1) electrical connector. • Inspect the electrical connector for damage. Is the electrical connector OK? >> Go to the next step. >> Repair or replace the electrical connector as necessary. VISMD030201 Chery Automobile Co., Ltd. 03–...
Page 360 • Check harness short to ground or short to power. Is the check result normal? >> Go to the next step. >> Repair or replace the circuit for open or short to ground or short to power in harness or connectors. 03– Chery Automobile Co., Ltd.
Page 361 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 362 DIAGNOSIS & TESTING P0112 - Intake Air Temperature Circuit Low Input LTSMW030052T 03– Chery Automobile Co., Ltd.
Page 363 DIAGNOSIS & TESTING LTSMW030058T Chery Automobile Co., Ltd. 03–...
Page 364 Room Harness (With 1.6L/1.8L Engine) in Section 16 Wiring). Are the ground connections OK? >> For 1.8L engine go to next step. For 1.6L engine go to Step 4. >> Repair or replace ground connections. 03– Chery Automobile Co., Ltd.
Page 365 1 and ground in the IAT sensor electrical con- nector E-009. • 5 V should exist. Is the check result normal? >> Go to Step 6. >> Repair circuit for an open or short to power in harness or connectors. LTSMD030031 Chery Automobile Co., Ltd. 03–...
Page 366 • Check harness for a short to ground between IAT connector terminal 1 and ECM connector E-001, terminal 42. Is the check result normal? >> Go to the next step. >> Repair circuit for a short to ground in harness or connectors. 03– Chery Automobile Co., Ltd.
Page 367 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 368 DIAGNOSIS & TESTING P0113 - Intake Air Temperature Circuit High Input LTSMW030058T 03– Chery Automobile Co., Ltd.
Page 369 DIAGNOSIS & TESTING LTSMW030052T Chery Automobile Co., Ltd. 03–...
Page 370 Room Harness (With 1.6L/1.8L Engine) in Section 16 Wiring). Are the ground connections OK? >> For 1.8L engine go to next step. For 1.6L engine go to Step 4. >> Repair or replace ground connections. 03– Chery Automobile Co., Ltd.
Page 371 1 and ground in the IAT sensor electrical connector E-009. • 5 V should exist. Is the check result normal? >> Go to Step 6. >> Repair circuit for an open or short to power in harness or connectors. LTSMD030031 Chery Automobile Co., Ltd. 03–...
Page 372 2 and ground in the IAT sensor electrical connector E-033. • 5 V should exist. Is the check result normal? >> Go to the next step. >> Repair circuit for an open or short to power in harness or connectors. LTSMD030056 03– Chery Automobile Co., Ltd.
Page 373 • Continuity should exist. • Check harness for short to power. Is the check result normal? >> Go to the next step. >> Repair circuit for an open or short to power in harness or connectors. Chery Automobile Co., Ltd. 03–...
Page 374 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 375 DIAGNOSIS & TESTING P0117 - Engine Coolant Temperature Circuit Low Input LTSMW030053T Chery Automobile Co., Ltd. 03–...
Page 376 • Before performing this DTC diagnostic procedure, verify that the engine coolant temperature is normal. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. 03– Chery Automobile Co., Ltd.
Page 377 • Check ECT sensor reference voltage between sen- sor terminal 2 and ground in the sensor electrical connector E-019. • 5 V should exist. Is the check result normal? >> Go to step 5. >> Go to the next step. LTSMD030032 Chery Automobile Co., Ltd. 03–...
Page 378 1.89 V ECT sensor ECT: 78°C 1.25 V Ignition switch on ECT: 90°C 0.94 V Sensor (GND) Approximately 0 V Is the check result normal? >> Go to the next step. >> Replace ECT sensor. 03– Chery Automobile Co., Ltd.
Page 379 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 380 DIAGNOSIS & TESTING P0118 - Engine Coolant Temperature Circuit High Input LTSMW030053T 03– Chery Automobile Co., Ltd.
Page 381 • Inspect ground connections E-207 and E-208 mounting position (See Vehicle Wiring Harness Layout - Engine Room Harness (With 1.6L/1.8L Engine) in Section 16 Wiring). Are the ground connections OK? >> Go to the next step. >> Repair or replace ground connections. Chery Automobile Co., Ltd. 03–...
Page 382 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). CHECK ECT SENSOR GROUND CIRCUIT FOR AN OPEN AND SHORT TO POWER • Check harness continuity between following terminals. SENSOR CONNECTOR CONTINUITY CONNECTOR TERMINAL TERMINAL 03– Chery Automobile Co., Ltd.
Page 383 1.89 V ECT sensor ECT: 78°C 1.25 V Ignition switch on ECT: 90°C 0.94 V Sensor (GND) Approximately 0 V Is the check result normal? >> Go to the next step. >> Replace ECT sensor. Chery Automobile Co., Ltd. 03–...
Page 384 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 385 DIAGNOSIS & TESTING P0122 - Throttle Position Sensor A Circuit Low Input LTSMW030044T Chery Automobile Co., Ltd. 03–...
Page 386 • If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 03 Electronic Engine Controls for more information. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. 03– Chery Automobile Co., Ltd.
Page 387 • Disconnect the TPS (1) electrical connector. • Inspect the electrical connector for damage. Is the electrical connector OK? >> Go to the next step. >> Repair or replace the electrical connector as necessary. VISMD030203 Chery Automobile Co., Ltd. 03–...
Page 388 • Check harness for an open or short to ground between TPS connector terminal 2 and ECM connector E-001, terminal 78. Is the check result normal? >> Go to the next step. >> Repair or replace harness or connectors. 03– Chery Automobile Co., Ltd.
Page 389 12 V or 0 V Motor 3 Motor 2 12 V or 0 V Motor 1 Is the check result normal? >> Go to the next step. >> Replace the TPS. Perform the TPS self-learning. Chery Automobile Co., Ltd. 03–...
Page 390 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 391 DIAGNOSIS & TESTING P0123 - Throttle Position Sensor A Circuit High Input LTSMW030044T Chery Automobile Co., Ltd. 03–...
Page 392 • If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 03 Electronic Engine Controls for more information. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. 03– Chery Automobile Co., Ltd.
Page 393 • Disconnect the TPS (1) electrical connector. • Inspect the electrical connector for damage. Is the electrical connector OK? >> Go to the next step. >> Repair or replace the electrical connector as necessary. VISMD030203 Chery Automobile Co., Ltd. 03–...
Page 394 • Check the TPS ground circuit for an open. • Check harness for a short to power. Is the check result normal? >> Go to the next step. >> Repair circuit for an open or short to power in harness or connectors. 03– Chery Automobile Co., Ltd.
Page 395 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 396 DIAGNOSIS & TESTING P0132 - O Sensor 1 Circuit High Voltage LTSMW030054T 03– Chery Automobile Co., Ltd.
Page 397 DIAGNOSIS & TESTING LTSMW030055T Chery Automobile Co., Ltd. 03–...
Page 398 • If the DTC is not detected, the DTC condition is intermittent (See Diagnosis & Testing Diagnostic Help in Sec- tion 03 Electronic Engine Controls). NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. 03– Chery Automobile Co., Ltd.
Page 399 Repair or replace the circuit for an open or short to power in harness or connectors. CHECK O SENSOR INPUT SIGNAL CIRCUIT FOR AN OPEN AND SHORT • Check harness continuity between ECM terminal and O sensor terminal as follows. SENSOR ECM TERMINAL SENSOR TERMINAL Upstream O sensor Chery Automobile Co., Ltd. 03–...
Page 400 • Warm-up 100 - Idle condition 900 mV • Check with O 600 - sensor 2500 RPM 1,000 mV signal Is the check result normal? >> Go to the next step. >> Replace the O sensor. 03– Chery Automobile Co., Ltd.
Page 401 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 402 DIAGNOSIS & TESTING P0171 - Fuel Trim System Too Lean LTSMW030052T 03– Chery Automobile Co., Ltd.
Page 403 DIAGNOSIS & TESTING LTSMW030058T Chery Automobile Co., Ltd. 03–...
Page 404 DIAGNOSIS & TESTING LTSMW030048T 03– Chery Automobile Co., Ltd.
Page 405 DIAGNOSIS & TESTING LTSMW030049T Chery Automobile Co., Ltd. 03–...
Page 406 Before performing the following procedure, confirm that battery voltage is more than 12 V. • Turn ignition switch off. • Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available. • Turn ignition switch on. 03– Chery Automobile Co., Ltd.
Page 407 • Engine: Warm up • Shift: P or N Injector pulse Idle Approximately 2.5 ms • Air condition: Off • No load Is the check result normal? >> Go to step 6. >> Go to the next step. Chery Automobile Co., Ltd. 03–...
Page 408 • Continuity should exist. • Check harness for short to ground. Is the check result normal? >> Go to the next step. >> Repair or replace circuit for an open or short to power in harness or connectors. 03– Chery Automobile Co., Ltd.
Page 409 • Press Approximately accelerator pedal quickly (instantaneous) Is the check result normal? >> Go to the next step. >> Check connectors for rusted terminals or loose connectors in the air flow sensor circuit or ground. Chery Automobile Co., Ltd. 03–...
Page 410 − Fuel lines − Fuel filter for clogging Is the check result normal? >> If with the X-431, go to the next step. If without the X-431, go to step 10. >> Repair or replace malfunctioning part. 03– Chery Automobile Co., Ltd.
Page 411 Go to the next step. CHECK FUNCTION OF INJECTOR • Listen to each injector operating sound. • Operating sound should exist. Is the check result normal? >> Go to step 12. >> Go to the next step. Chery Automobile Co., Ltd. 03–...
Page 412 • Check harness for short to power. Is the check result normal? >> Go to step next step. >> Repair or replace circuit for an open or short to power or short to ground in harness or connectors. 03– Chery Automobile Co., Ltd.
Page 413 • Fuel should be sprayed evenly by each injector. Is the check result normal? >> Go to next step. >> Clean any injector that sprays unevenly or replace any injector that does not spray fuel. Chery Automobile Co., Ltd. 03–...
Page 414 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 415 DIAGNOSIS & TESTING P0172 - Fuel Trim System Too Rich LTSMW030052T Chery Automobile Co., Ltd. 03–...
Page 416 DIAGNOSIS & TESTING LTSMW030058T 03– Chery Automobile Co., Ltd.
Page 417 DIAGNOSIS & TESTING LTSMW030048T Chery Automobile Co., Ltd. 03–...
Page 418 DIAGNOSIS & TESTING LTSMW030049T 03– Chery Automobile Co., Ltd.
Page 419 • Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available. • Turn ignition switch on. • With the scan tool, record and erase stored DTCs in the ECM. Chery Automobile Co., Ltd. 03–...
Page 420 • Disconnect upstream O sensor (1) harness con- nector. • Inspect the electrical connector for damage. Is the electrical connector OK? >> Go to the next step. >> Repair or replace the electrical connector as necessary. BESM030017 03– Chery Automobile Co., Ltd.
Page 421 • Observe the following fuel pressures when testing (See Fuel Pressure Test in Section 04 Fuel Delivery). FUEL PRESSURES Key On 400 kPa (4.0 bar) Key Off 380 kPa (3.8 bar) in 10 minutes Engine: Idle 400 - 420 kPa (4.0 - 4.2 bar) Chery Automobile Co., Ltd. 03–...
Page 422 Is the check result normal? >> If with the X-431, go to the next step. If without the X-431, go to step 9. >> Check connectors for damaged or air flow signal circuit for short to power. 03– Chery Automobile Co., Ltd.
Page 423 CHECK INJECTOR CONTROL CIRCUIT • Turn ignition switch off. • Disconnect injector harness connector (1). BESM040006 • Disconnect ECM harness connector. • Check harness for a short to ground between the following terminals. INJECTOR INJECTOR NO. TERMINAL TERMINAL Chery Automobile Co., Ltd. 03–...
Page 424 • Crank engine for about 3 seconds. • Make sure fuel does not drip from injector. Is the check result normal? >> Go to next step. >> Replace the injectors from which fuel is dripping. Always replace O-ring with new one. 03– Chery Automobile Co., Ltd.
Page 425 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 426 DIAGNOSIS & TESTING P0201 - Cylinder 1 - Injector Circuit P0202 - Cylinder 2 - Injector Circuit P0203 - Cylinder 3 - Injector Circuit P0204 - Cylinder 4 - Injector Circuit LTSMW030048T 03– Chery Automobile Co., Ltd.
Page 427 DIAGNOSIS & TESTING LTSMW030049T Chery Automobile Co., Ltd. 03–...
Page 428 • Inspect ground connections E-207 and E-208 mounting position (See Vehicle Wiring Harness Layout - Engine Room Harness (With 1.6L/1.8L Engine) in Section 16 Wiring). Are the ground connections OK? >> Go to the next step. >> Repair or replace ground connections. 03– Chery Automobile Co., Ltd.
Page 429 • Disconnect the injector electrical connector (1). • Inspect the electrical connector for damage. Is the electrical connector OK? >> Go to the next step. >> Repair or replace the electrical connector as necessary. BESM040006 Chery Automobile Co., Ltd. 03–...
Page 430 Repair or replace malfunctioning parts. CHECK INJECTOR CONTROL CIRCUITS FOR AN OPEN • Check injector control circuit voltage. • 3.6 V should exist. Is the check result normal? >> Go to step 10. >> Go to the next step. 03– Chery Automobile Co., Ltd.
Page 431 • Check fuel injector voltage between the following terminals and ground. DATA (AVERAGE DC TERMINAL NO. ITEM CONDITION VOLTAGE) • Engine is running • Warm-up condition Injector Voltage: 11 - 14 V • Idle • Accelerate suddenly Chery Automobile Co., Ltd. 03–...
Page 432 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 433 DIAGNOSIS & TESTING P0221 - Throttle Position Sensor B Performance LTSMW030044T Chery Automobile Co., Ltd. 03–...
Page 434 DIAGNOSIS & TESTING LTSMW030045T 03– Chery Automobile Co., Ltd.
Page 435 • If the DTC is not detected, the DTC condition is intermittent (See Diagnosis & Testing Diagnostic Help in Sec- tion 03 Electronic Engine Controls). NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. Chery Automobile Co., Ltd. 03–...
Page 436 • Disconnect the TPS (1) electrical connector. • Inspect the electrical connector for damage. Is the electrical connector OK? >> Go to the next step. >> Repair or replace the electrical connector as necessary. VISMD030203 03– Chery Automobile Co., Ltd.
Page 437 TPS terminal 3 APP sensor terminal 3 APP sensor terminal 6 Is the check result normal? >> Go to the next step. >> Repair circuit for short to ground or short to power in harness or connectors. Chery Automobile Co., Ltd. 03–...
Page 438 • Also check harness for a short to power and short to ground. Is the check result normal? >> Go to the next step. >> Repair circuit for an open or short to power or short to ground in harness or connectors. 03– Chery Automobile Co., Ltd.
Page 439 Sensor 1 • Engine (TPS1) stopped • 4.62 V Accelerator pedal: Fully depressed Is the check result normal? >> Go to the next step. >> Replace electronic throttle control actuator, and perform throttle valve position learning. Chery Automobile Co., Ltd. 03–...
Page 440 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 441 DIAGNOSIS & TESTING P0261 - Cylinder 1 Injector Circuit Low P0264 - Cylinder 2 Injector Circuit Low P0267 - Cylinder 3 Injector Circuit Low P0270 - Cylinder 4 Injector Circuit Low LTSMW030048T Chery Automobile Co., Ltd. 03–...
Page 442 DIAGNOSIS & TESTING LTSMW030049T 03– Chery Automobile Co., Ltd.
Page 443 • Inspect ground connections E-207 and E-208 mounting position (See Vehicle Wiring Harness Layout - Engine Room Harness (With 1.6L/1.8L Engine) in Section 16 Wiring). Are the ground connections OK? >> Go to the next step. >> Repair or replace ground connections. Chery Automobile Co., Ltd. 03–...
Page 444 • Disconnect the Injector (1) electrical connector. • Inspect the electrical connector for damage. Is the electrical connector OK? >> Go to the next step. >> Repair or replace the electrical connector as necessary. BESM040006 03– Chery Automobile Co., Ltd.
Page 445 Repair malfunctioning parts. CHECK INJECTOR CONTROL CIRCUITS FOR A SHORT • Check injector control circuit voltage. • 3.6 V should exist. Is the check result normal? >> Go to step 10. >> Go to the next step. Chery Automobile Co., Ltd. 03–...
Page 446 • Check the fuel injector voltage as shown in the following: DATA (AVERAGE DC TERMINAL NO. ITEM CONDITION VOLTAGE) Injector 2 • Engine is running Injector 3 • Warm-up condition Voltage: 11 - 14 V • Idle Injector 1 • Accelerate suddenly Injector 4 03– Chery Automobile Co., Ltd.
Page 447 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 448 DIAGNOSIS & TESTING P0262 - Cylinder 1 Injector Circuit High P0265 - Cylinder 2 Injector Circuit High P0268 - Cylinder 3 Injector Circuit High P0271 - Cylinder 4 Injector Circuit High Injector Circuit High LTSMW030048T 03– Chery Automobile Co., Ltd.
Page 449 DIAGNOSIS & TESTING LTSMW030049T Chery Automobile Co., Ltd. 03–...
Page 450 • Inspect ground connections E-207 and E-208 mounting position (See Vehicle Wiring Harness Layout - Engine Room Harness (With 1.6L/1.8L Engine) in Section 16 Wiring). Are the ground connections OK? >> Go to the next step. >> Repair or replace ground connections. 03– Chery Automobile Co., Ltd.
Page 451 • Disconnect the Injector (1) electrical connector. • Inspect the electrical connector for damage. Is the electrical connector OK? >> Go to the next step. >> Repair or replace the electrical connector as necessary. BESM040006 Chery Automobile Co., Ltd. 03–...
Page 452 Repair or replace malfunctioning parts. CHECK INJECTOR CONTROL CIRCUITS FOR A SHORT • Check injector control circuit voltage. • 3.6 V should exist. Is the check result normal? >> Go to step 10. >> Go to the next step. 03– Chery Automobile Co., Ltd.
Page 453 • Engine is running • Warm-up condition Injector 3 Voltage: 11 - 14 V • Idle Injector 1 • Accelerate suddenly Injector 4 Is the check result normal? >> Go to the next step. >> Replace injector. Chery Automobile Co., Ltd. 03–...
Page 454 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 455 DIAGNOSIS & TESTING P0321 - Distributor Engine Speed In Phase Circuit Performance LTSMW030046T Chery Automobile Co., Ltd. 03–...
Page 456 • Inspect ground connections E-207 and E-208 mounting position (See Vehicle Wiring Harness Layout - Engine Room Harness (With 1.6L/1.8L Engine) in Section 16 Wiring). Are the ground connections OK? >> Go to the next step. >> Repair or replace ground harness or connections. 03– Chery Automobile Co., Ltd.
Page 457 E-006, terminal 1 and ground, terminal 2 and ground in the sensor electrical connector. • 3 V should exist. Is the check result normal? >> Go to step 5. >> Go to the next step. LTSMD030048 Chery Automobile Co., Ltd. 03–...
Page 458 • Connect CKP sensor connector. • Check sensor output signal when engine is running. CKP SENSOR SIGNAL ENGINE ANALYZER (KES-200) Is the CKP sensor output signal normal? >> Go to step 9. >> Go to the next step. 03– Chery Automobile Co., Ltd.
Page 459 Go to the next step. >> Reinstall CKP sensor. CHECK GEAR TOOTH • Visually check for chipping signal plate gear tooth. Is the check result normal? >> Go to the next step. >> Replace the signal plate Chery Automobile Co., Ltd. 03–...
Page 460 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 461 DIAGNOSIS & TESTING P0324 - Knock Control System Error LTSMW030047T Chery Automobile Co., Ltd. 03–...
Page 462 • Inspect ground connections E-207 and E-208 mounting position (See Vehicle Wiring Harness Layout - Engine Room Harness (With 1.6L/1.8L Engine) in Section 16 Wiring). Are the ground connections OK? >> Go to the next step. >> Repair or replace ground harness or connections. 03– Chery Automobile Co., Ltd.
Page 463 • Continuity should exist. • Check harness for short to ground and short to power. Is the check result normal? >> Go to step 4. >> Repair circuit for an open or short in harness or connectors. Chery Automobile Co., Ltd. 03–...
Page 464 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 465 DIAGNOSIS & TESTING P0343 - Camshaft Position Sensor Circuit High Input LTSMW030051T Chery Automobile Co., Ltd. 03–...
Page 466 • Inspect ground connections E-207 and E-208 mounting position (See Vehicle Wiring Harness Layout - Engine Room Harness (With 1.6L/1.8L Engine) in Section 16 Wiring). Are the ground connections OK? >> Go to the next step. >> Repair or replace ground harness or connections. 03– Chery Automobile Co., Ltd.
Page 467 − Front fuse and relay box F3, A1, A13, G5, H2, H3 − Fuse 22, fuse 24, fuse 12, fuse 27 Is the check result normal? >> Go to the next step. >> Repair or replace the malfunctioning parts. Chery Automobile Co., Ltd. 03–...
Page 468 • Check signal voltage between CMP sensor terminal 2 and ground when engine is running. • Approximately 6 V square wave signal should exist. CMP SENSOR SIGNAL ENGINE ANALYZER (KES-200) Is the CMP output signal normal? >> Go to step 10. >> Go to the next step. 03– Chery Automobile Co., Ltd.
Page 469 − Accumulation of debris to the signal plate of camshaft rear end − Chipping signal plate of camshaft rear end Is the check result normal? >> Go to the next step. >> Remove debris and clean the signal plate of camshaft rear end or replace camshaft. Chery Automobile Co., Ltd. 03–...
Page 470 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 471 DIAGNOSIS & TESTING P0444 - Evaporative Emission System Purge Control Valve Circuit Open LTSMW030050T Chery Automobile Co., Ltd. 03–...
Page 472 • Use the scan tool X-431 ACTIVE TEST function of the EVAP canister valve, touch the EVAP canister valve body, perform the action test. • A slight vibration should exist. Is the check result normal? >> Go to step 7. >> Go to the next step. 03– Chery Automobile Co., Ltd.
Page 473 − Front fuse and relay box F3, A1, A13, G5, H2, H3 − Fuse 22, fuse 24, fuse 12, fuse 27 Is the check result normal? >> Go to the next step. >> Repair or replace malfunctioning part. Chery Automobile Co., Ltd. 03–...
Page 474 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 475 If DTC P0506 is displayed with other DTCs, perform this diagnostic procedure before other DTCs. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. Chery Automobile Co., Ltd. 03–...
Page 476 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 477 • If the DTC is not detected, the DTC condition is intermittent (See Diagnosis & Testing Diagnostic Help in Sec- tion 03 Electronic Engine Controls). NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. Chery Automobile Co., Ltd. 03–...
Page 478 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 479 • With the scan tool X-431, match the ECM before replacing it (See ECM Removal & Installation in Section 03 Electronic Engine Controls), and view the DTC with the X-431. Is DTC P0602 still present? >> Go to the next step. >> The DTC was caused by a programming error. Chery Automobile Co., Ltd. 03–...
Page 480 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 481 DIAGNOSIS & TESTING P0645 - A/C Clutch Relay Circuit LTSMW030065T Chery Automobile Co., Ltd. 03–...
Page 482 DIAGNOSIS & TESTING LTSMW030066T 03– Chery Automobile Co., Ltd.
Page 483 • If the DTC is not detected, the DTC condition is intermittent (See Diagnosis & Testing Diagnostic Help in Sec- tion 03 Electronic Engine Controls). NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. Chery Automobile Co., Ltd. 03–...
Page 484 − A/C compressor relay, EMS relay (R2) − Check harness for an open or short between ECM terminal 69 and fuse 12. Is the check result normal? >> Go to the next step. >> Repair or replace malfunctioning part. 03– Chery Automobile Co., Ltd.
Page 485 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 486 DIAGNOSIS & TESTING P1545 - Throttle Position Control Malfunction LTSMW030044T 03– Chery Automobile Co., Ltd.
Page 487 DIAGNOSIS & TESTING LTSMW030045T Chery Automobile Co., Ltd. 03–...
Page 488 • If the DTC is not detected, the DTC condition is intermittent (See Diagnosis & Testing Diagnostic Help in Sec- tion 03 Electronic Engine Controls). NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. 03– Chery Automobile Co., Ltd.
Page 489 • Disconnect the TPS (1) electrical connector. • Inspect the electrical connector for damage. Is the electrical connector OK? >> Go to the next step. >> Repair or replace the electrical connector as necessary. VISMD030203 Chery Automobile Co., Ltd. 03–...
Page 490 TPS terminal 3 APP sensor terminal 3 APP sensor terminal 6 Is the check result normal? >> Go to the next step. >> Repair circuit for short to ground or short to power in harness or connectors. 03– Chery Automobile Co., Ltd.
Page 491 • Check harness for short to power and short to ground. Is the check result normal? >> Go to the next step. >> Repair circuit for an open or short to power or short to ground in harness or connectors. Chery Automobile Co., Ltd. 03–...
Page 492 • Engine terminal 6) actuator stopped • Accelerator 4.62 V pedal: Fully depressed Is the check result normal? >> Go to the next step. >> Replace electronic throttle control actuator, and perform throttle valve position learning. 03– Chery Automobile Co., Ltd.
Page 493 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 494 DIAGNOSIS & TESTING P2138 - Pedal Position Sensor Performance LTSMW030045T 03– Chery Automobile Co., Ltd.
Page 495 DIAGNOSIS & TESTING LTSMW030044T Chery Automobile Co., Ltd. 03–...
Page 496: Reference Values Between Ecm Terminals/Ground
• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 03 Electronic Engine Controls for more information. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. 03– Chery Automobile Co., Ltd.
Page 497 • Check harness connectors E-102, C-102. • Check harness for an open and short between APP sensor 1 and ECM. Is the check result normal? >> Go to the next step. >> Repair or replace malfunctioning part. Chery Automobile Co., Ltd. 03–...
Page 498 • Check harness for short to power and short to ground between following terminals. ECM TERMINAL TPS TERMINAL Is the check result normal? >> Go to the next step. >> Repair circuit for short to ground or short to power in harness or connectors. 03– Chery Automobile Co., Ltd.
Page 499 • Continuity should exist. • Check harness for short to power. Is the check result normal? >> Go to the next step. >> Repair circuit for an open or short to power in harness or connectors. Chery Automobile Co., Ltd. 03–...
Page 500 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 501 3. Disconnect the coolant temperature sensor electri- cal connector. CAUTION: Remove the coolant temperature sensor when the engine is cold. 4. Remove the engine coolant temperature sensor (1). (Tighten: Engine coolant temperature sensor to 20 N·m) LTSM030035 5. Discard the O-ring. Chery Automobile Co., Ltd. 03–...
Page 502: Knock Sensor
Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. 03– Chery Automobile Co., Ltd.
Page 503 1. Disconnect the negative battery cable. 2. Disconnect the oxygen sensor electrical connector. CAUTION: Remove the oxygen sensor after the exhaust pipe has cooled. 3. Remove the downstream oxygen sensor (2). (Tighten: Downstream oxygen sensor to 45 N·m) BESM030017 Chery Automobile Co., Ltd. 03–...
Page 504 The CMP sensor senses the piston position. When the Crankshaft Position (CKP) sensor becomes inoperative, the CMP sensor provides various controls of engine parts instead, utilizing timing of cylinder identification signals. The sensor consists of a permanent magnet and Hall IC. 03– Chery Automobile Co., Ltd.
Page 505: Vehicle Speed Sensor
(Tighten: Vehicle speed sensor mounting bolt to 10 N·m) 4. Remove the vehicle speed sensor carefully. 5. Installation is in the reverse order of removal. BESM030024 Accelerator Sensor Description The accelerator sensor is located on the right front crossbeam. Chery Automobile Co., Ltd. 03–...
Page 506 The MAP sensor monitors the pressure in the intake manifold. The pressure in the manifold moves a diaphragm connected to resistors which alter their resistance values. The output voltage of the MAP sensor signals the ECM about the pressure in the intake manifold. Removal & Installation 1. Disconnect the negative battery cable. 03– Chery Automobile Co., Ltd.
Page 507 The ECM detects the air flow by means of this voltage signal change. Removal & Installation 1. Disconnect the negative battery cable. 2. Remove the engine cover. 3. Disconnect the air flow sensor electrical connector. Chery Automobile Co., Ltd. 03–...
Page 508 5 V from the Engine Control Module (ECM). The information regarding accelerator position is supplied to the ECM by means of two voltages. Removal & Installation 1. Disconnect the negative battery cable. 2. Remove the instrument panel lower trim panel. 03– Chery Automobile Co., Ltd.
Page 509 ECM to determine throttle position. The ECM controls the electronic throttle control to meter air into the engine. This regulates engine power. The vehicle is in sense a “Drive by Wire” system. Removal & Installation 1. Remove the engine cover. 2. Disconnect the negative battery cable. Chery Automobile Co., Ltd. 03–...
Page 510 − Choose input code . − Input the safety code. − Click the small keyboard. − Click OK . − Choose Immobilizer adapt . − Choose read Immobilizer to ECM immedi- ately. − Click OK . LTSM030025 03– Chery Automobile Co., Ltd.
Page 511 Crankshaft Position (CKP) Sensor 03-430 P0203 - Cylinder 3 - Injector Circuit, Description 03-430 P0204 - Cylinder 4 - Injector Circuit 03-345 Operation 03-430 P0221 - Throttle Position Sensor B Removal & Installation 03-430 Performance 03-352 Chery Automobile Co., Ltd. 03–...
Page 512 Accelerator Sensor 03-432 Description 03-432 Engine Control Module (ECM) 03-440 Operation 03-432 Description 03-440 Removal & Installation 03-432 Operation 03-440 Removal & Installation 03-440 Speed Control System 03-432 Description 03-432 Operation 03-433 Electrical Schematics 03-434 03– Chery Automobile Co., Ltd.
Page 513 The ECM is a pre-programmed, microprocessor-based digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The ECM can adapt its programming to meet changing operating conditions. Chery Automobile Co., Ltd. 03–...
Page 514 • Air conditioner does not operate. • Fuel injector control failure. • Engine stalls out. • Unstable idle. • Lack of engine power. • Poor fuel economy. Ignition Coil Replace • Excessive exhaust emissions. • Weak spark. 03– Chery Automobile Co., Ltd.
Page 515 Torque Specifications DESCRIPTION TORQUE (N·m) Engine Coolant Temperature Sensor Knock Sensor Oxygen Sensors Crankshaft Position Sensor Camshaft Position Sensor Air Flow Sensor Engine Control Module Accelerator Pedal Position Sensor Electronic Throttle Control Actuator Vehicle Speed Sensor Chery Automobile Co., Ltd. 03–...
Page 516 GENERAL INFORMATION Special Tools Diagnostic Scan Tool X-431 Engine Analyzer KES-200 Digital Multimeter Fluke 15B & 17B 03– Chery Automobile Co., Ltd.
Page 517 GENERAL INFORMATION Compression Gauge Fuel Pressure Gauge Chery Automobile Co., Ltd. 03–...
Page 518 GENERAL INFORMATION Electrical Schematics Electronic Engine Controls (Page 1 of 11) LTSMW030093T 03– Chery Automobile Co., Ltd.
Page 519 GENERAL INFORMATION Electronic Engine Controls (Page 2 of 11) LTSMW030094T Chery Automobile Co., Ltd. 03–...
Page 520 GENERAL INFORMATION Electronic Engine Controls (Page 3 of 11) LTSMW030103T 03– Chery Automobile Co., Ltd.
Page 521 GENERAL INFORMATION Electronic Engine Controls (Page 4 of 11) LTSMW030095T Chery Automobile Co., Ltd. 03–...
Page 522 GENERAL INFORMATION Electronic Engine Controls (Page 5 of 11) LTSMW030096T 03– Chery Automobile Co., Ltd.
Page 523 GENERAL INFORMATION Electronic Engine Controls (Page 6 of 11) LTSMW030097T Chery Automobile Co., Ltd. 03–...
Page 524 GENERAL INFORMATION Electronic Engine Controls (Page 7 of 11) LTSMW030098T 03– Chery Automobile Co., Ltd.
Page 525 GENERAL INFORMATION Electronic Engine Controls (Page 8 of 11) LTSMW030099T Chery Automobile Co., Ltd. 03–...
Page 526 GENERAL INFORMATION Electronic Engine Controls (Page 9 of 11) LTSMW030100T 03– Chery Automobile Co., Ltd.
Page 527 GENERAL INFORMATION Electronic Engine Controls (Page 10 of 11) LTSMW030101T Chery Automobile Co., Ltd. 03–...
Page 528 GENERAL INFORMATION Electronic Engine Controls (Page 11 of 11) LTSMW030102T 03– Chery Automobile Co., Ltd.
Page 529 Downstream Oxygen Sensor Heater (With EOBD) Air Compressor Relay (Without EOBD) Fuel Pump Relay Diagnostic Link K MIL Lamp Regulated Sensor Supply 3 Regulated Sensor Supply 2 Regulated Sensor Supply 1 Crankshaft Position Sensor A/C Stand By Chery Automobile Co., Ltd. 03–...
Page 530 CIRCUIT IDENTIFICATION Sensor (GND) Power Steering Switch Sensor (GND) Headlamp Switch Air Flow Sensor Sensor (GND) Electronic Throttle Control Actuator (Position Camshaft Position Sensor Sensor) Engine Coolant Temperature Sensor GND (Power) Accelerator Pedal Position Sensor CAN-L 03– Chery Automobile Co., Ltd.
Page 531 • Battery voltage is more than 12 V. Electronic Throttle Control Actuator Self-Learning Operating Procedure Turn the ignition switch on for 10 seconds, then turn the ignition switch off. During the procedure, do not operate any other components. Chery Automobile Co., Ltd. 03–...
Page 532 EPC lamp will be on. If this condition occurs, perform the Self-Learning operating again after the DTCs be erased in ECM. Diagnostic Tools • Scan Tool X-431 • Engine Analyzer KES-200 • Digital Multimeter • Jumper Wire 03– Chery Automobile Co., Ltd.
Page 533 Power Into 12 V DC Power To Diagnose Mitsubishi To Connect The Diagnostic Mitsubishi-12+16 Main Cable Electronic Control Systems Connector and Smartbox Pin Connector On Chery B11 Series To Perform Vehicle Smartbox To Diagnose Vehicles With Diagnosis Fiat-3 Pin Fiat-3 Pin Diagnostic Connector...
Page 534: Diagnostic Trouble Code (Dtc) List
Sensor Circuit Bank 1 - Sensor 2 No Activity Detected P0170 Fuel Trim, Bank 1 Malfunction P0171 Fuel Trim, Bank 1 System too Lean P0172 Fuel Trim, Bank 1 too Rich P0201 Cylinder 1 - Injector Circuit P0202 Cylinder 2 - Injector Circuit 03– Chery Automobile Co., Ltd.
Page 535 P0508 Idle Air Control System Circuit Low P0509 Idle Air Control System Circuit High P0511 Idle Air Control Circuit P0532 A/C Refrigerant Pressure Sensor Circuit Low Input P0533 A/C Refrigerant Pressure Sensor Circuit High Input Chery Automobile Co., Ltd. 03–...
Page 536 Manufacture Controlled Computer and Auxiliary Outputs P1614 Manufacture Controlled Computer and Auxiliary Outputs P1651 Manufacture Controlled Computer and Auxiliary Outputs P2106 Throttle Actuator Control System Forced Limited Power P2122 Throttle/Pedal Position Sensor/Switch D Circuit Low Input 03– Chery Automobile Co., Ltd.
Page 537 Lost Communication with ECM U0104 Lost Communication with Cruise Control Module U0121 Lost Communication with Anti-Lock Brake System (ABS) Control Module U0155 Lost Communication with Instrument Panel Cluster Control Module U0415 Invalid Data Received from ABS Control Module Chery Automobile Co., Ltd. 03–...
Page 538 DIAGNOSIS & TESTING ECM Power Supply and Ground Circuit Test Power Supply And Ground Circuit Diagnostic Check LTSMW030023T 03– Chery Automobile Co., Ltd.
Page 539 • Ignition switch: OFF • More than a few ECM main relay Battery Voltage (11 - 14 V) seconds after turning ignition switch OFF Power supply for ECM Ignition switch: ON Battery Voltage (11 - 14 V) Chery Automobile Co., Ltd. 03–...
Page 540 DIAGNOSIS & TESTING LTSMW030024T 03– Chery Automobile Co., Ltd.
Page 541 • Turn ignition switch off and then on. • Check voltage between ECM terminal 13 and ground. • Battery voltage should exist. Is the check result normal? >> Go to step 4. >> Go to step 3. LTSMD030061 Chery Automobile Co., Ltd. 03–...
Page 542 • Check harness for an open or short to power in harness or connectors. Is the check result normal? >> Go to the next step. >> Repair or replace the circuit for an open or short to power in harness or connectors. 03– Chery Automobile Co., Ltd.
Page 543 • Check harness for short to ground and short to power. Is the check result normal? >> Go to step 12. >> Repair circuit for an open or short to power or short to ground in harness or connectors. Chery Automobile Co., Ltd. 03–...
Page 544 Replace front fuse and relay box. REPLACE AND PROGRAM ECM • Replace the ECM. NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Installation in Section 03 Electronic Engine Controls). 03– Chery Automobile Co., Ltd.
Page 545 DIAGNOSIS & TESTING Diagnostic Trouble Code (DTC) Tests P0016 - Camshaft Position-Crankshaft Position Correlation Error LTSMW030032T Chery Automobile Co., Ltd. 03–...
Page 546 DIAGNOSIS & TESTING LTSMW030027T 03– Chery Automobile Co., Ltd.
Page 547 • If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 03 Electronic Engine Controls for more information. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. Chery Automobile Co., Ltd. 03–...
Page 548 • Check CMP sensor supply voltage between sensor connector E-007, terminal 3 and ground in the sen- sor electrical connector. • Battery voltage should exist. Is the check result normal? >> Go to step 5. >> Go to the next step. LTSMD030044 03– Chery Automobile Co., Ltd.
Page 549 >> Go to the next step. >> Repair or replace circuit for an open or short to power or short to ground in harness or connectors. If circuit is normal, go to the next step. Chery Automobile Co., Ltd. 03–...
Page 550 Is the mounting area OK? >> Go to the next step. >> Repair or replace the sensor as necessary. VISMD030001 03– Chery Automobile Co., Ltd.
Page 551 − If the CMP sensor signals were normal, the system is OK. − If the CMP sensor signals were still irregular or missing, go to step 14. >> Eliminate any condition that would result in an incorrect signal. Chery Automobile Co., Ltd. 03–...
Page 552 • Check signal between CKP sensor (1) terminal 1 or 2 and ground when engine is running. VISMD030200 CKP SENSOR SIGNAL ENGINE ANALYZER (KES-200) Is the CKP output signal normal? >> Go to step 12. >> Go to the next step. 03– Chery Automobile Co., Ltd.
Page 553 • Inspect and clean the CKP sensor and mounting area for any condition that would result in an incorrect signal, such as damage, foreign material, or excessive movement. Is the mounting area OK? >> Go to the next step. >> Repair or replace the sensor as necessary. Chery Automobile Co., Ltd. 03–...
Page 554 Were any problems found? >> Remove debris and clean the signal plate of crankshaft rear end or replace crankshaft. Reinstall the CKP sensor. >> Go to the next step. 03– Chery Automobile Co., Ltd.
Page 555 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 556 DIAGNOSIS & TESTING P0031 - O Sensor 1 Heater Control Circuit Low LTSMW030036T 03– Chery Automobile Co., Ltd.
Page 557 • If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 03 Electronic Engine Controls for more information. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. Chery Automobile Co., Ltd. 03–...
Page 558 • Check supply voltage between O sensor terminal 2 and ground in the O sensor electrical connector E-005. • Battery voltage should exist. Is the check result normal? >> Go to Step 5. >> Go to the next step. LTSMD030029 03– Chery Automobile Co., Ltd.
Page 559 Repair the circuit for an open or short in harness or connectors. CHECK O SENSOR HEATER • Check resistance between O sensor heater terminals. TERMINAL NO. RESISTANCE 1 and 2 (including cable Approximately 9 and connector) Chery Automobile Co., Ltd. 03–...
Page 560 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 561 DIAGNOSIS & TESTING P0032 - O Sensor 1 Heater Control Circuit High LTSMW030036T Chery Automobile Co., Ltd. 03–...
Page 562 • If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 03 Electronic Engine Controls for more information. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. 03– Chery Automobile Co., Ltd.
Page 563 • Check supply voltage between upstream O sensor terminal 2 and ground in the O sensor electrical connector E-004. • Battery voltage should exist. Is the check result normal? >> Go to Step 5. >> Go to the next step. LTSMD030029 Chery Automobile Co., Ltd. 03–...
Page 564 Repair circuit for a short to power in harness or connectors. CHECK THE O SENSOR HEATER • Check resistance between O sensor heater terminals. TERMINAL NO. RESISTANCE 1 & 2 (including Approximately 9 cable and connector) 03– Chery Automobile Co., Ltd.
Page 565 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 566 DIAGNOSIS & TESTING P0102 - Mass Or Volume Air Flow Circuit Low Input LTSMW030033T 03– Chery Automobile Co., Ltd.
Page 567 • Inspect ground connections E-207 and E-208 mounting position (See Vehicle Wiring Harness Layout - Engine Room Harness (With 2.0L Engine) in Section 16 Wiring). Are the ground connections OK? >> Go to the next step. >> Repair or replace ground harness or connections. Chery Automobile Co., Ltd. 03–...
Page 568 • Check voltage between MAF sensor terminal 2 and ground in the MAF sensor electrical connector E-009. • Battery voltage should exist. Is the check result normal? >> Go to step 6. >> Go to the next step. LTSMD030041 03– Chery Automobile Co., Ltd.
Page 569 • Check harness for a short to ground or power. Is the check result normal? >> Go to the next step. >> Repair or replace circuit for an open or short to ground in harness or connectors. Chery Automobile Co., Ltd. 03–...
Page 570 • If the parts malfunctioning, repair or replace them. • If the parts OK, clean the MAF sensor, then check the signal of the MAF sensor. Is the signal voltage of MAF normal? >> Go to the next step. >> Replace MAF sensor. 03– Chery Automobile Co., Ltd.
Page 571 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 572 DIAGNOSIS & TESTING P0103 - Mass Or Volume Air Flow Circuit High Input LTSMW030033T 03– Chery Automobile Co., Ltd.
Page 573 • If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 03 Electronic Engine Controls for more information. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. Chery Automobile Co., Ltd. 03–...
Page 574 • Disconnect the MAF sensor electrical connector (1). • Inspect the electrical connector for damage. Is the electrical connector OK? >> Go to the next step. >> Repair or replace the electrical connector as necessary. VISMD030005 03– Chery Automobile Co., Ltd.
Page 575 • Continuity should exist. • Check harness for short to power. Is the check result normal? >> Go to the next step. >> Repair or replace circuit for short to power in harness or connectors. Chery Automobile Co., Ltd. 03–...
Page 576 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 577 DIAGNOSIS & TESTING P0112 - Intake Air Temperature Circuit Low Input LTSMW030033T Chery Automobile Co., Ltd. 03–...
Page 578 • Inspect ground connections E-207 and E-208 mounting position (See Vehicle Wiring Harness Layout - Engine Room Harness (With 2.0L Engine) in Section 16 Wiring). Are the ground connections OK? >> Go to the next step. >> Repair or replace ground connections. 03– Chery Automobile Co., Ltd.
Page 579 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> Repair or replace the circuit for short to ground in harness or connectors. Chery Automobile Co., Ltd. 03–...
Page 580 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 581 DIAGNOSIS & TESTING P0113 - Intake Air Temperature Circuit High Input LTSMW030033T Chery Automobile Co., Ltd. 03–...
Page 582 • Inspect ground connections E-207 and E-208 mounting position (See Vehicle Wiring Harness Layout - Engine Room Harness (With 2.0L Engine) in Section 16 Wiring). Are the ground connections OK? >> Go to the next step. >> Repair or replace ground connections. 03– Chery Automobile Co., Ltd.
Page 583 If circuit is normal, go to the next step. LTSMD030031 CHECK IAT SENSOR GROUND CIRCUIT FOR AN OPEN OR SHORT • Turn ignition switch off. • Disconnect ECM harness connector. • Check harness continuity between following terminals. IAT SENSOR TERMINAL ECM TERMINAL Chery Automobile Co., Ltd. 03–...
Page 584 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 585 DIAGNOSIS & TESTING P0117 - Engine Coolant Temperature Circuit Low Input LTSMW030034T Chery Automobile Co., Ltd. 03–...
Page 586 • Inspect ground connections E-207 and E-208 mounting position (See Vehicle Wiring Harness Layout - Engine Room Harness (With 2.0L Engine) in Section 16 Wiring). Are the ground connections OK? >> Go to the next step. >> Repair or replace ground harness or connections. 03– Chery Automobile Co., Ltd.
Page 587 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> Repair or replace circuit for a short in harness or connectors. Chery Automobile Co., Ltd. 03–...
Page 588 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 589 DIAGNOSIS & TESTING P0118 - Engine Coolant Temperature Circuit High Input LTSMW030034T Chery Automobile Co., Ltd. 03–...
Page 590 • Inspect ground connections E-207 and E-208 mounting position (See Vehicle Wiring Harness Layout - Engine Room Harness (With 2.0L Engine) in Section 16 Wiring). Are the ground connections OK? >> Go to the next step. >> Repair or replace ground connections. 03– Chery Automobile Co., Ltd.
Page 591 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). CHECK ECT SENSOR GROUND CIRCUIT FOR AN OPEN AND SHORT • Turn ignition switch off. • Check harness continuity between following terminals. ECT SENSOR CONTINUITY TERMINAL TERMINAL Chery Automobile Co., Ltd. 03–...
Page 592 1.89 V ECT sensor ECT: 78°C 1.25 V Ignition switch: ON ECT: 90°C 0.94 V Sensor (GND) Approximately 0 V Is the check result normal? >> Go to the next step. >> Replace ECT sensor. 03– Chery Automobile Co., Ltd.
Page 593 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 594 DIAGNOSIS & TESTING P0122 - Throttle Position Sensor A Circuit Low Input LTSMW030025T 03– Chery Automobile Co., Ltd.
Page 595 • If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 03 Electronic Engine Controls for more information. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. Chery Automobile Co., Ltd. 03–...
Page 596 • Disconnect the TPS electrical connector (1). • Inspect the electrical connector for damage. Is the electrical connector OK? >> Go to the next step. >> Repair or replace the electrical connector as necessary. VISMD030203 03– Chery Automobile Co., Ltd.
Page 597 • Check harness for an open or a short to ground between TPS connector terminal 2 and ECM connector E-001, terminal 78. Is the check result normal? >> Go to the next step. >> Repair or replace harness or connectors. Chery Automobile Co., Ltd. 03–...
Page 598 Motor 3 Motor 2 12 V or 0 V Motor 1 Sensor (GND) Approximately 0 V Is the check result normal? >> Go to the next step. >> Replace the TPS. Perform the TPS self-learning. 03– Chery Automobile Co., Ltd.
Page 599 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 600 DIAGNOSIS & TESTING P0123 - Throttle Position Sensor A Circuit High Input LTSMW030025T 03– Chery Automobile Co., Ltd.
Page 601 • If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 03 Electronic Engine Controls for more information. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. Chery Automobile Co., Ltd. 03–...
Page 602 • Disconnect the TPS electrical connector (1). • Inspect the electrical connector for damage. Is the electrical connector OK? >> Go to the next step. >> Repair or replace the electrical connector as necessary. VISMD030203 03– Chery Automobile Co., Ltd.
Page 603 ECM TERMINAL • Continuity should exist. • Check harness for short to power. Is the check result normal? >> Go to the next step. >> Repair open circuit or short to power in harness or connectors. Chery Automobile Co., Ltd. 03–...
Page 604 12 V or 0 V Motor 3 Motor 2 12 V or 0 V Motor 1 Sensor (GND) Approximately 0 V Is the check result normal? >> Go to the next step. >> Replace the TPS. Perform TPS self-learning. 03– Chery Automobile Co., Ltd.
Page 605 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 606 DIAGNOSIS & TESTING P0132 - O Sensor Circuit 1 High Voltage LTSMW030036T 03– Chery Automobile Co., Ltd.
Page 607 • If the DTC is not detected, the DTC condition is intermittent (See Diagnosis & Testing Diagnostic Help in Sec- tion 03 Electronic Engine Controls). NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. Chery Automobile Co., Ltd. 03–...
Page 608 Repair or replace circuit for an open or short to power in harness or connectors. CHECK O SENSOR INPUT SIGNAL CIRCUIT FOR AN OPEN AND SHORT • Check harness continuity between ECM terminal and O sensor terminal as follows. COMPONENT UPSTREAM O SENSOR TERMINAL 03– Chery Automobile Co., Ltd.
Page 609 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 610 DIAGNOSIS & TESTING P0171 - Fuel Trim System Too Lean LTSMW030033T 03– Chery Automobile Co., Ltd.
Page 611 DIAGNOSIS & TESTING LTSMW030029T Chery Automobile Co., Ltd. 03–...
Page 612 DIAGNOSIS & TESTING LTSMW030030T 03– Chery Automobile Co., Ltd.
Page 613 • If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 03 Electronic Engine Controls for more information. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. Chery Automobile Co., Ltd. 03–...
Page 614 • Disconnect the upstream O sensor (1) electrical connector. • Inspect the electrical connector for damage. Is the electrical connector OK? >> Go to the next step. >> Repair or replace the electrical connector as necessary. BESM030017 03– Chery Automobile Co., Ltd.
Page 615 Approximately 1.39 V • IAT signal: 1.88 V Is the check result normal? >> Go to the next step. >> Check connectors for rusted terminals or loose connectors in the air flow sensor circuit or ground. Chery Automobile Co., Ltd. 03–...
Page 616 − Fuel lines. − Fuel filter for clogging. Is the check result normal? >> If with the X-431, go to the next step. If without the X-431, go to step 10. >> Repair or Replace malfunctioning part. 03– Chery Automobile Co., Ltd.
Page 617 Go to the next step. CHECK FUNCTION OF INJECTOR • Listen to each injector operating sound. • Operating sound should exist. Is the check result normal? >> Go to step 12. >> Go to the next step. Chery Automobile Co., Ltd. 03–...
Page 618 • Check harness for short to power. Is the check result normal? >> Go to the next step. >> Repair or replace circuit for an open or short to power or short to ground in harness or connectors. 03– Chery Automobile Co., Ltd.
Page 619 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 620 DIAGNOSIS & TESTING P0172 - Fuel Trim System Too Rich LTSMW030033T 03– Chery Automobile Co., Ltd.
Page 621 DIAGNOSIS & TESTING LTSMW030029T Chery Automobile Co., Ltd. 03–...
Page 622 DIAGNOSIS & TESTING LTSMW030030T 03– Chery Automobile Co., Ltd.
Page 623 • If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 03 Electronic Engine Controls for more information. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. Chery Automobile Co., Ltd. 03–...
Page 624 Repair or replace the electrical connector as necessary. BESM030017 CHECK UPSTREAM O SENSOR SIGNAL CIRCUIT • Disconnect ECM harness connector. • Check harness continuity between the following terminals. UPSTREAM O SENSOR ECM TERMINAL SENSOR TERMINAL sensor 1 03– Chery Automobile Co., Ltd.
Page 625 Key Off 380 kPa (3.8 bar) in 10 minutes Engine Idle 400 kPa (4.0 bar) - 420 kPa (4.2 bar) Is the check result normal? >> Go to step 7. >> Go to the next step. Chery Automobile Co., Ltd. 03–...
Page 626 Go to the next step. CHECK FUNCTION OF INJECTOR • Listen to each injector operating sound. • Operating sound should exist. Is the check result normal? >> Go to step 11. >> Go to the next step. 03– Chery Automobile Co., Ltd.
Page 627 • Disconnect injector harness connectors (See Fuel Pressure Test in Section 04 Fuel Delivery). • Check the fuel injector resistance as shown in the following: INJECTOR RESISTANCE RESISTANCE INJECTOR INJECTOR (APPROXIMATELY) TERMINAL (20°C) 1 & 2 1 & 2 11 - 16 1 & 2 1 & 2 Chery Automobile Co., Ltd. 03–...
Page 628 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 629 DIAGNOSIS & TESTING P0201 - Cylinder 1 - Injector Circuit P0202 - Cylinder 2 - Injector Circuit P0203 - Cylinder 3 - Injector Circuit P0204 - Cylinder 4 - Injector Circuit LTSMW030029T Chery Automobile Co., Ltd. 03–...
Page 630 DIAGNOSIS & TESTING LTSMW030030T 03– Chery Automobile Co., Ltd.
Page 631 • Inspect ground connections E-207 and E-208 mounting position (See Vehicle Wiring Harness Layout - Engine Room Harness (With 2.0L Engine) in Section 16 Wiring). Are the ground connections OK? >> Go to the next step. >> Repair or replace ground harness or connections. Chery Automobile Co., Ltd. 03–...
Page 632 • Disconnect the injector electrical connector (1). • Inspect the electrical connector for damage. Is the electrical connector OK? >> Go to the next step. >> Repair or replace the electrical connector as necessary. BESM040006 03– Chery Automobile Co., Ltd.
Page 633 Repair or replace malfunctioning part. CHECK INJECTOR CONTROL CIRCUITS FOR AN OPEN • Check injector control circuit voltage. • 3.6 V should exist. Is the check result normal? >> Go to step 10. >> Go to the next step. Chery Automobile Co., Ltd. 03–...
Page 634 • Check the fuel injector voltage as shown in the following: DATA (AVERAGE DC TERMINAL NO. ITEM CONDITION VOLTAGE) Injector 2 • Engine is running • Idle Injector 3 Voltage: 11 - 14 V • Warm-up condition Injector 1 • Accelerate suddenly Injector 4 03– Chery Automobile Co., Ltd.
Page 635 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 636 DIAGNOSIS & TESTING P0221 - Throttle Position Sensor B Performance LTSMW030025T 03– Chery Automobile Co., Ltd.
Page 637 • If the DTC is not detected, the DTC condition is intermittent (See Diagnosis & Testing Diagnostic Help in Sec- tion 03 Electronic Engine Controls). NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. Chery Automobile Co., Ltd. 03–...
Page 638 • Disconnect the TPS electrical connector (1). • Inspect the electrical connector for damage. Is the electrical connector OK? >> Go to the next step. >> Repair or replace the electrical connector as necessary. VISMD030203 03– Chery Automobile Co., Ltd.
Page 639 TPS terminal 3 APP sensor terminal 3 APP sensor terminal 6 Is the check result normal? >> Go to the next step. >> Repair circuit for short to ground or short to power in harness or connectors. Chery Automobile Co., Ltd. 03–...
Page 640 • Also check harness for short to power and short to ground. Is the check result normal? >> Go to the next step. >> Repair circuit for an open or short to power or short to ground in harness or connectors. 03– Chery Automobile Co., Ltd.
Page 641 Fully depressed Is the check result normal? >> Go to the next step. >> Replace the Electronic Throttle Control Actuator (See Electronic Throttle Control Actuator Removal & Installation in Section 03 Electronic Engine Controls). Chery Automobile Co., Ltd. 03–...
Page 642 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 643 DIAGNOSIS & TESTING P0261 - Cylinder 1 Injector Circuit Low P0264 - Cylinder 2 Injector Circuit Low P0267 - Cylinder 3 Injector Circuit Low P0270 - Cylinder 4 Injector Circuit Low LTSMW030029T Chery Automobile Co., Ltd. 03–...
Page 644 DIAGNOSIS & TESTING LTSMW030030T 03– Chery Automobile Co., Ltd.
Page 645 • Inspect ground connections E-207 and E-208 mounting position (See Vehicle Wiring Harness Layout - Engine Room Harness (With 2.0L Engine) in Section 16 Wiring). Are the ground connections OK? >> Go to the next step. >> Repair or replace ground harness or connections. Chery Automobile Co., Ltd. 03–...
Page 646 • Disconnect the injector electrical connector (1). • Inspect the electrical connector for damage. Is the electrical connector OK? >> Go to the next step. >> Repair or replace the electrical connector as necessary. BESM040006 03– Chery Automobile Co., Ltd.
Page 647 Repair malfunctioning part. CHECK INJECTOR CONTROL CIRCUITS FOR A SHORT • Check injector control circuit voltage. • 3.6 V should exist. Is the check result normal? >> Go to step 10. >> Go to the next step. Chery Automobile Co., Ltd. 03–...
Page 648 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> Repair circuit for a short in harness or connectors. 03– Chery Automobile Co., Ltd.
Page 649 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 650 DIAGNOSIS & TESTING P0262 - Cylinder 1 Injector Circuit High P0265 - Cylinder 2 Injector Circuit High P0268 - Cylinder 3 Injector Circuit High P0271 - Cylinder 4 Injector Circuit High LTSMW030029T 03– Chery Automobile Co., Ltd.
Page 651 DIAGNOSIS & TESTING LTSMW030030T Chery Automobile Co., Ltd. 03–...
Page 652 • Inspect ground connections E-207 and E-208 mounting position (See Vehicle Wiring Harness Layout - Engine Room Harness (With 2.0L Engine) in Section 16 Wiring). Are the ground connections OK? >> Go to the next step. >> Repair or replace ground harness or connections. 03– Chery Automobile Co., Ltd.
Page 653 • Disconnect the injector electrical connector (1). • Inspect the electrical connector for damage. Is the electrical connector OK? >> Go to the next step. >> Repair or replace the electrical connector as necessary. BESM040006 Chery Automobile Co., Ltd. 03–...
Page 654 • Disconnect ECM harness connector. • Check if the injector control circuits short to power supply circuits. • Check the following. • Voltage should not exist. INJECTOR NO. POWER SUPPLY CIRCUIT INJECTOR TERMINAL Power supply circuit 03– Chery Automobile Co., Ltd.
Page 655 • Engine is running Injector 3 • Warm-up condition Voltage: 11 V - 14 V • Idle Injector 1 • Accelerate suddenly Injector 4 Is the check result normal? >> Go to the next step. >> Replace injector. Chery Automobile Co., Ltd. 03–...
Page 656 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 657 DIAGNOSIS & TESTING P0321 - Distributor Engine Speed In Phase Circuit Performance LTSMW030027T Chery Automobile Co., Ltd. 03–...
Page 658 • Inspect ground connections E-207 and E-208 mounting position (See Vehicle Wiring Harness Layout - Engine Room Harness (With 2.0L Engine) in Section 16 Wiring). Are the ground connections OK? >> Go to the next step. >> Repair or replace ground harness or connections. 03– Chery Automobile Co., Ltd.
Page 659 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> Repair circuit for an open or short in harness or connectors. Chery Automobile Co., Ltd. 03–...
Page 660 Monitor the CKP sensor signal on the KES-200 screen. − If the CKP sensor signals were normal, the system is OK. − If the CKP sensor signals were still irregular or missing, go to step 7. >> Replace CKP sensor. 03– Chery Automobile Co., Ltd.
Page 661 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 662 DIAGNOSIS & TESTING P0324 - Knock Control System Error LTSMW030028T 03– Chery Automobile Co., Ltd.
Page 663 • Inspect ground connections E-207 and E-208 mounting position (See Vehicle Wiring Harness Layout - Engine Room Harness (With 2.0L Engine) in Section 16 Wiring). Are the ground connections OK? >> Go to the next step. >> Repair or replace ground harness or connections. Chery Automobile Co., Ltd. 03–...
Page 664 CHECK KNOCK SENSOR INPUT SIGNAL CIRCUIT • Disconnect ECM harness connector. • Check harness continuity between sensor connector E-017, terminal 1 and ECM terminal 19,, sensor terminal 2 and ECM terminal 20. KNOCK SENSOR ECM TERMINAL TERMINAL 03– Chery Automobile Co., Ltd.
Page 665 1 & 2 Test Method 2: Knock at sensor slightly • Output signal voltage should exist. Is the check result normal? >> Go to the next step. >> Replace knock sensor. Chery Automobile Co., Ltd. 03–...
Page 666 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 667 DIAGNOSIS & TESTING P0343 - Camshaft Position Sensor Circuit High Input LTSMW030032T Chery Automobile Co., Ltd. 03–...
Page 668 • Inspect ground connections E-207 and E-208 mounting position (See Vehicle Wiring Harness Layout - Engine Room Harness (With 2.0L Engine) in Section 16 Wiring). Are the ground connections OK? >> Go to the next step. >> Repair or replace ground harness or connections. 03– Chery Automobile Co., Ltd.
Page 669 − Fuse 12, fuse 23, fuse 24 − Harness for an open or short between CMP sensor and fuse Is the check result normal? >> Go to the next step. >> Repair or replace malfunctioning part. Chery Automobile Co., Ltd. 03–...
Page 670 • Check signal voltage between CMP sensor terminal 2 and ground when engine is running. • Approximately 6 V square wave signal should exist. CMP SENSOR SIGNAL ENGINE ANALYZER (KES-200) Is the CMP output signal normal? >> Go to step 10. >> Go to the next step. 03– Chery Automobile Co., Ltd.
Page 671 • Check the installed clearance (See CMP Sensor Removal & Installation in Section 03 Electronic Engine Con- trols). • 0.8 - 1.2 mm should exist. Is the check result normal? >> Go to the next step. >> Reinstall CMP sensor. Chery Automobile Co., Ltd. 03–...
Page 672 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 673 DIAGNOSIS & TESTING P0444 - Evaporative Emission System Purge Control Valve Circuit Open LTSMW030031T Chery Automobile Co., Ltd. 03–...
Page 674 • Inspect ground connections E-207 and E-208 mounting position (See Vehicle Wiring Harness Layout - Engine Room Harness (With 2.0L Engine) in Section 16 Wiring). Are the ground connections OK? >> Go to the next step. >> Repair or replace ground harness or connections. 03– Chery Automobile Co., Ltd.
Page 675 • Check supply voltage between EVAP canister con- trol valve terminal 1 and ground. • 12 V should exist. Is the check result normal? >> Go to step 7. >> Go to the next step. LTSMD030046 Chery Automobile Co., Ltd. 03–...
Page 676 • Check air passage continuity and operation when apply 12 V current supply voltage between terminal 1 and 2. • The check results should match specification. Is the check result normal? >> Go to the next step. >> Repair or replace EVAP canister control valve. 03– Chery Automobile Co., Ltd.
Page 677 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 678 • If the DTC is not detected, the DTC condition is intermittent (See Diagnosis & Testing Diagnostic Help in Sec- tion 03 Electronic Engine Controls). NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. 03– Chery Automobile Co., Ltd.
Page 679 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 680 • If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 03 Electronic Engine Controls for more information. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. 03– Chery Automobile Co., Ltd.
Page 681 Reassemble the vehicle and road test to verify the customers complaint is repaired. >> Replace the ECM. NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). Chery Automobile Co., Ltd. 03–...
Page 682 • If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 03 Electronic Engine Controls for more information. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. 03– Chery Automobile Co., Ltd.
Page 683 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 684 DIAGNOSIS & TESTING P0645 - A/C Clutch Relay Circuit LTSMW030063T 03– Chery Automobile Co., Ltd.
Page 685 DIAGNOSIS & TESTING LTSMW030064T Chery Automobile Co., Ltd. 03–...
Page 686 • If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 03 Electronic Engine Controls for more information. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. 03– Chery Automobile Co., Ltd.
Page 687 − Harness connectors C-103, E-103, B-104, C-104 − Harness for open between ECM terminal 69 and fuse 12 Is the check result normal? >> Go to the next step. >> Repair or replace malfunctioning part. Chery Automobile Co., Ltd. 03–...
Page 688 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 689 DIAGNOSIS & TESTING P1545 - Throttle Position Control Performance LTSMW030025T Chery Automobile Co., Ltd. 03–...
Page 690 DIAGNOSIS & TESTING LTSMW030026T 03– Chery Automobile Co., Ltd.
Page 691 • If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 03 Electronic Engine Controls for more information. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. Chery Automobile Co., Ltd. 03–...
Page 692 • Disconnect the TPS electrical connector (1). • Inspect the electrical connector for damage. Is the electrical connector OK? >> Go to the next step. >> Repair or replace the electrical connector as necessary. VISMD030203 03– Chery Automobile Co., Ltd.
Page 693 • Check harness continuity between TPS terminal 3 and ECM terminal 32. • Continuity should exist. Is the check result normal? >> Go to the next step. >> Repair or replace circuit for an open. Chery Automobile Co., Ltd. 03–...
Page 694 • Accelerator pedal: 3.95 V Fully depressed Turn ignition switch • Engine stopped • Accelerator pedal: 0.36 - 0.37 V Fully released Accelerator pedal position sensor • Engine stopped • Accelerator pedal: 1.97 V Fully depressed 03– Chery Automobile Co., Ltd.
Page 695 • Also check harness for short to power and short to ground. Is the check result normal? >> Go to the next step. >> Repair circuit for an open or short to power in harness or connectors. Chery Automobile Co., Ltd. 03–...
Page 696 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 697 DIAGNOSIS & TESTING P2138 - Pedal Position Sensor Performance LTSMW030026T Chery Automobile Co., Ltd. 03–...
Page 698 DIAGNOSIS & TESTING LTSMW030025T 03– Chery Automobile Co., Ltd.
Page 699 • If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 03 Electronic Engine Controls for more information. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. Chery Automobile Co., Ltd. 03–...
Page 700 • Check APP sensor 1 supply voltage between sen- sor terminal 6 and ground in the sensor electrical connector C-009. • Approximately 5 V should exist. Is the check result normal? >> Go to step 5. >> Go to the next step. LTSMD030053 03– Chery Automobile Co., Ltd.
Page 701 Check TPS Power Supply ECM TERMINAL TPS TERMINAL Is the check result normal? >> Go to the next step. >> Repair circuit for a short to ground or short to power in harness or connectors. Chery Automobile Co., Ltd. 03–...
Page 702 • Continuity should exist. • Also check harness for short to power. Is the check result normal? >> Go to the next step. >> Repair circuit for an open or short to power in harness or connectors. 03– Chery Automobile Co., Ltd.
Page 703 NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 704 DIAGNOSIS & TESTING U0001 - High Speed CAN Defective LTSMW030038T 03– Chery Automobile Co., Ltd.
Page 705 • Before performing any DTC diagnostic procedures, verify the ECM power and ground circuits are properly con- nected. • Before performing the diagnostic procedure, settle all other ECM DTCs first. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. Chery Automobile Co., Ltd. 03–...
Page 706 If all of the other modules have the same DTC CAN Communication , go to the next step. If all of the other modules have the DTC Lost communication with ECM , and do not have the CAN Communication , Replace and program the ECM module. >> Go to step 8. 03– Chery Automobile Co., Ltd.
Page 707 Replace the ECM. NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). The problem caused by ECM internal error. Chery Automobile Co., Ltd. 03–...
Page 708 CONNECTOR CONTINUITY TERMINAL TERMINAL CAN- • Also check harness for short to ground and short to power. Is the check result normal? >> Go to the next step. >> Repair or replace the CAN-Bus line. 03– Chery Automobile Co., Ltd.
Page 709 • Turn ignition switch on. • Check CAN-Bus voltage as the standard value. Is the check result normal and DTC U0001 not present? >> Replace TCM. The problem caused by TCM internal error. >> Go to the next step. Chery Automobile Co., Ltd. 03–...
Page 710 Replace the ECM. NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal- lation in Section 03 Electronic Engine Controls). The problem caused by ECM internal error. 03– Chery Automobile Co., Ltd.
Page 711 3. Disconnect the coolant temperature sensor electri- cal connector. CAUTION: Remove the coolant temperature sensor when the engine is cold. 4. Remove the engine coolant temperature sensor (1). (Tighten: Engine coolant temperature sensor to 20 N·m) LTSM030035 5. Discard the O-ring. Chery Automobile Co., Ltd. 03–...
Page 712 Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. 03– Chery Automobile Co., Ltd.
Page 713 1. Disconnect the negative battery cable. 2. Disconnect the oxygen sensor electrical connector. CAUTION: Remove the oxygen sensor after the exhaust pipe has cooled. 3. Remove the downstream oxygen sensor (2). (Tighten: Downstream oxygen sensor to 45 N·m) BESM030017 Chery Automobile Co., Ltd. 03–...
Page 714 2. Disconnect the CKP sensor electrical connector. 3. Remove the CKP sensor retaining bolt (1) and remove the CKP sensor. (Tighten: Crankshaft position sensor retaining bolt to 10 N·m) LTSM030036 4. Installation is in the reverse order of removal. 03– Chery Automobile Co., Ltd.
Page 715 The ECM detects the air flow by means of this voltage signal change. Removal & Installation 1. Disconnect the negative battery cable. 2. Remove the engine cover. 3. Disconnect the air flow sensor electrical connector. Chery Automobile Co., Ltd. 03–...
Page 716 The driver can set vehicle speed in advance between approximately 25 km/h and 130 km/h. ECM controls throttle angle of electronic throttle control actuator to regulate engine speed. If any malfunction occurs in the Speed Control System, it automatically deactivates the system and the cruise indi- cator flashes. 03– Chery Automobile Co., Ltd.
Page 717 • When any of following conditions exist, cruise operation will be canceled. − OFF switch is pressed − Brake pedal is depressed − If any malfunction occurs in Speed Control System, it automatically deactivates control. Chery Automobile Co., Ltd. 03–...
Page 718 ON-VEHICLE SERVICE Electrical Schematics Speed Control System (page 1 of 4) LTSMW030060T 03– Chery Automobile Co., Ltd.
Page 719 ON-VEHICLE SERVICE Speed Control System (page 2 of 4) LTSMW030061T Chery Automobile Co., Ltd. 03–...
Page 720 ON-VEHICLE SERVICE Speed Control System (page 3 of 4) LTSMW030106T 03– Chery Automobile Co., Ltd.
Page 721 ON-VEHICLE SERVICE Speed Control System (page 4 of 4) LTSMW030062T Chery Automobile Co., Ltd. 03–...
Page 722 4. Remove the three APP sensor mounting bolts (1). (Tighten: APP sensor mounting bolts to 11 N·m) 5. Remove the APP sensor with the pedal. 6. Installation is in the reverse order of removal. LTSM030038 03– Chery Automobile Co., Ltd.
Page 723 5. Remove four electronic throttle control actuator mounting bolts. (Tighten: Electronic throttle control actuator bolts to 10 N·m) 6. Remove the throttle control actuator carefully. 7. Installation is in the reverse order of removal. BESM030022 Chery Automobile Co., Ltd. 03–...
Page 724 − Choose input code . − Input the safety code. − Click the small keyboard. − Click OK . − Choose Immobilizer adapt . − Choose read Immobilizer to ECM immedi- ately. − Click OK . 03– Chery Automobile Co., Ltd.
Page 725 Removal & Installation 03-541 Removal & Installation 03-531 Crankshaft Position (CKP) Sensor 03-542 Coolant Temperature Sensor (For Description 03-542 Instrument Cluster) 03-532 Operation 03-542 Description 03-532 Removal & Installation 03-542 Operation 03-532 Removal & Installation 03-532 Chery Automobile Co., Ltd. 03–...
Page 726 The ECM is a pre-programmed, microprocessor-based digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The ECM can adapt its programming to meet changing operating conditions. 03– Chery Automobile Co., Ltd.
Page 727 • Air conditioner does not operate. • Fuel injector control failure. • Engine stalls out. • Unstable idle. • Lack of engine power. • Poor fuel economy. Ignition Coil Replace • Excessive exhaust emissions. • Weak spark. Chery Automobile Co., Ltd. 03–...
Page 728 TORQUE (N·m) Engine Coolant Temperature Sensor Knock Sensor Oxygen Sensors Crankshaft Position Sensor Camshaft Position Sensor Air Flow Sensor Engine Control Module Electronic Throttle Control Actuator Vehicle Speed Sensor Coolant Temperature Sensor (For Instrument Cluster) 03– Chery Automobile Co., Ltd.
Page 729 GENERAL INFORMATION Special Tools Diagnostic Scan Tool X-431 Engine Analyzer KES-200 Digital Multimeter Fluke 15B & 17B Chery Automobile Co., Ltd. 03–...
Page 730 GENERAL INFORMATION Compression Gauge Fuel Pressure Gauge 03– Chery Automobile Co., Ltd.
Page 731 GENERAL INFORMATION Electrical Schematics Electronic Engine Controls (Page 1 of 10) LTSMW030067T Chery Automobile Co., Ltd. 03–...
Page 732 GENERAL INFORMATION Electronic Engine Controls (Page 2 of 10) LTSMW030068T 03– Chery Automobile Co., Ltd.
Page 733 GENERAL INFORMATION Electronic Engine Controls (Page 3 of 10) LTSMW030069T Chery Automobile Co., Ltd. 03–...
Page 734 GENERAL INFORMATION Electronic Engine Controls (Page 4 of 10) LTSMW030070T 03– Chery Automobile Co., Ltd.
Page 735 GENERAL INFORMATION Electronic Engine Controls (Page 5 of 10) LTSMW030071T Chery Automobile Co., Ltd. 03–...
Page 736 GENERAL INFORMATION Electronic Engine Controls (Page 6 of 10) LTSMW030072T 03– Chery Automobile Co., Ltd.
Page 737 GENERAL INFORMATION Electronic Engine Controls (Page 7 of 10) LTSMW030073T Chery Automobile Co., Ltd. 03–...
Page 738 GENERAL INFORMATION Electronic Engine Controls (Page 8 of 10) LTSMW030074T 03– Chery Automobile Co., Ltd.
Page 739 GENERAL INFORMATION Electronic Engine Controls (Page 9 of 10) LTSMW030075T Chery Automobile Co., Ltd. 03–...
Page 740 GENERAL INFORMATION Electronic Engine Controls (Page 10 of 10) LTSMW030076T 03– Chery Automobile Co., Ltd.
Page 741 Engine Coolant Temperature Sensor Throttle Position Sensor Atmosphere Pressure Sensor MIL Lamp Speed In Power Steering Switch Idle Position Switch Main Relay Camshaft Position Sensor Crankshaft Sensor Air Flow Sensor Generator FR P/N Switch Sensor (GND) Chery Automobile Co., Ltd. 03–...
Page 742 Inspect and clean all ECM, engine, and body grounds that are related to the DTC. If numerous trouble codes were set, use a wire schematic and look for any common ground or supply circuits for any camshaft pulley DTCs inspect for dirt/metal debris. 03– Chery Automobile Co., Ltd.
Page 743 Diagnostic Tools 1. Scan Tool X-431 2. Engine Analyzer (KES-200) 3. Digital Multimeter 4. Jumper Wire Hardware Requirements The hardware configuration of X-431 is as follows: Chery Automobile Co., Ltd. 03–...
Page 744 Power Into 12 V DC Power To Diagnose Mitsubishi To Connect The Diagnostic Mitsubishi-12+16 Main Cable Electronic Control Systems Connector and Smartbox Pin Connector On Chery B11 Series To Perform Vehicle Smartbox To Diagnose Vehicles With Diagnosis Fiat-3 Pin Fiat-3 Pin Diagnostic Connector...
Page 745 Air Temperature Sensor Throttle Position Sensor Coolant Temperature Sensor Crankshaft Position Sensor Camshaft Position Sensor Speed Sensor Atmosphere Pressure Sensor Knock Sensor Ignition Signal Terminal Injector Ignition Signal Immobilizer Communication Electronic 4AT Communication ALT FR Signal Chery Automobile Co., Ltd. 03–...
Page 746 DIAGNOSIS & TESTING ECM Power Supply and Ground Circuit Test Power Supply And Ground Circuit Diagnostic Check LTSMW030003T 03– Chery Automobile Co., Ltd.
Page 747 Battery Voltage (11 - 14 V) after turning ignition switch Battery All time Battery Voltage (11 - 14 V) Ignition switch: ON Battery Voltage (11 - 14 V) Ignition switch Ignition switch: OFF Approximately 0 V Chery Automobile Co., Ltd. 03–...
Page 748 DIAGNOSIS & TESTING LTSMW030004T 03– Chery Automobile Co., Ltd.
Page 749 • Turn ignition switch OFF and then ON position. • Check voltage between ECM terminal 66 and ground. • Battery voltage should exist. Is the check result normal? >> Go to step 5. >> Go to step 3. LTSMD030074 Chery Automobile Co., Ltd. 03–...
Page 750 • Repair open circuit or short to power in harness or connectors. Is the check result normal? >> Go to the next step. >> Repair circuit for an open or short to power in harness or connectors. 03– Chery Automobile Co., Ltd.
Page 751 • Also check harness for short to ground and short to power. Is the check result normal? >> Go to the next step. >> Repair circuit for an open or short to ground or short to power in harness or connectors. Chery Automobile Co., Ltd. 03–...
Page 752 • Check front fuse and relay box. • Check harness continuity between front fuse and relay box and battery. Is the check result normal? >> Replace the ECM. >> Replace or repair front fuse and relay box or harness. 03– Chery Automobile Co., Ltd.
Page 753 DIAGNOSIS & TESTING Diagnostic Trouble Code (DTC) Tests 11 - Oxygen Sensor LTSMW030016T Chery Automobile Co., Ltd. 03–...
Page 754 DIAGNOSIS & TESTING LTSMW030017T 03– Chery Automobile Co., Ltd.
Page 755 Before performing the following procedure, make sure that ECM ground connections are in good condition. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. Chery Automobile Co., Ltd. 03–...
Page 756 • Disconnect the downstream O sensor (2) electrical connector. • Inspect the electrical connector for damage. Is the electrical connector OK? >> Go to the next step. >> Repair or replace the electrical connector as necessary. VISMD030204 03– Chery Automobile Co., Ltd.
Page 757 • Check power supply between O sensor E-074, ter- minal 2 and ground. • Battery voltage should exist. Is the check result normal? >> Go to step 8. >> Go to the next step. LTSMD030002 Chery Automobile Co., Ltd. 03–...
Page 758 Approximately 9 connector) 1 & 2 and 1 & 3 (Continuity should not exist) 4 & 2 and 4 & 3 Is the check result normal? >> Go to the next step. >> Replace O sensor. 03– Chery Automobile Co., Ltd.
Page 759 • Refer to DTC Confirmation Procedure . Is DTC 11 still present? >> Replace the ECM. >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 760 DIAGNOSIS & TESTING 12 - Air Flow Sensor LTSMW030013T 03– Chery Automobile Co., Ltd.
Page 761 • Inspect the ground connection E-208 (See Vehicle Wiring Harness Layout - Engine Room Harness (With Mit- subishi 2.4L Engine) in Section 16 Wiring). Is the ground connections OK? >> Go to the next step. >> Repair or replace ground connection. Chery Automobile Co., Ltd. 03–...
Page 762 • Check reference voltage between air flow sensor terminal 7 and ground in the air flow sensor electrical connec- tor E-058. • 4.8 - 5.2 V should exist. Is the check result normal? >> Go to step 7. >> Go to the next step. 03– Chery Automobile Co., Ltd.
Page 763 80 - 95°C • Lamp and all other • Engine is running: 2,500 Air flow sensor 72 - 112 HZ condition: OFF • Transaxle: Neutral Frequency direct • Engine is accelerating proportion with speed Chery Automobile Co., Ltd. 03–...
Page 764 • Check harness for short to power or short to ground. Is the check result normal? >> Go to the next step. >> Repair or replace the circuits for an open or short to power or short to ground in harness or connec- tors. 03– Chery Automobile Co., Ltd.
Page 765 • Refer to DTC Confirmation Procedure . Is DTC 12 still present? >> Replace the ECM. >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 766 DIAGNOSIS & TESTING 13 - Air Temperature Sensor LTSMW030013T 03– Chery Automobile Co., Ltd.
Page 767 Before performing the following procedure, make sure that the ECM connection is in good condition. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. Chery Automobile Co., Ltd. 03–...
Page 768 Go to the next step. >> Repair the circuit for an open or short to power or short to ground in harness or connectors. If the circuit is normal, go to the next LTSMD030006 step. 03– Chery Automobile Co., Ltd.
Page 769 Ignition switch: ON IAT: 40°C 1.5 - 2.1 V IAT: 80°C 0.4 - 1.0 V Sensor (GND) Ignition switch: ON Is the check result normal? >> Go to the next step. >> Replace IAT sensor. Chery Automobile Co., Ltd. 03–...
Page 770 • Refer to DTC Confirmation Procedure . Is DTC 13 still present? >> Replace the ECM. >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 771 DIAGNOSIS & TESTING 14 - Throttle Position Sensor LTSMW030014T Chery Automobile Co., Ltd. 03–...
Page 772 Before performing the following procedure, make sure that the ECM connection is in good condition. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. 03– Chery Automobile Co., Ltd.
Page 773 • Disconnect the TPS (1) electrical connector. • Inspect the electrical connector for damage. Is the electrical connector OK? >> Go to the next step. >> Repair or replace the electrical connector as necessary. LTSM030027 Chery Automobile Co., Ltd. 03–...
Page 774 • Check harness for short to power or short to ground. Is the check result normal? >> Go to the next step. >> Repair the circuit for an open or short to power or short to ground in harness or connectors. 03– Chery Automobile Co., Ltd.
Page 775 • Also check the resistance between TPS terminal 2 and terminal 4 while turn the throttle. • The resistance should linear change. Is the check result normal? >> Go to the next step. >> Replace the TPS. Chery Automobile Co., Ltd. 03–...
Page 776 • Refer to DTC Confirmation Procedure . Is DTC 14 still present? >> Replace the ECM. >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 777 DIAGNOSIS & TESTING 21 - Coolant Temperature Sensor LTSMW030005T Chery Automobile Co., Ltd. 03–...
Page 778 Before performing the following procedure, make sure that the ECM connection is in good condition. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. 03– Chery Automobile Co., Ltd.
Page 779 • Disconnect the ECT (1) electrical connector. • Inspect the electrical connector for damage. Is the electrical connector OK? >> Go to the next step. >> Repair or replace the electrical connector as necessary. LTSM030007 Chery Automobile Co., Ltd. 03–...
Page 780 • Also check harness for short to power and short to ground. Is the check result normal? >> Go to the next step. >> Repair circuit for an open or short to power or short to ground in harness or connectors. 03– Chery Automobile Co., Ltd.
Page 781 • Refer to DTC Confirmation Procedure . Is DTC 21 still present? >> Replace the ECM. >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 782 DIAGNOSIS & TESTING 22 - Crankshaft Position Sensor LTSMW030012T 03– Chery Automobile Co., Ltd.
Page 783 • Inspect the ground connection E-208 (See Vehicle Wiring Harness Layout - Engine Room Harness (With Mit- subishi 2.4L Engine) in Section 16 Wiring). Is the ground connections OK? >> Go to the next step. >> Repair or replace ground connection. Chery Automobile Co., Ltd. 03–...
Page 784 − Front fuse and relay box H3 − Harness connectors A-102, E-105 − Harness open or short between CKP sensor and fuse Is the check result normal? >> Go to the next step. >> Repair or replace malfunctioning parts. 03– Chery Automobile Co., Ltd.
Page 785 • Turn ignition switch on. • Check voltage between CKP sensor terminal 2 and ground. • 4.8 - 5.2 V should exist. Is the check result normal? >> Go to step 9. >> Go to the next step. Chery Automobile Co., Ltd. 03–...
Page 786 Monitor the CKP sensor signal on the KES-200 screen. − If the CKP sensor signals were normal, the system is OK. − If the CKP sensor signals were still irregular or missing, go to step 11. >> Replace CKP sensor. 03– Chery Automobile Co., Ltd.
Page 787 • Refer to DTC Confirmation Procedure . Is the check result normal? >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. >> Replace the ECM. Chery Automobile Co., Ltd. 03–...
Page 788 DIAGNOSIS & TESTING 23 - Camshaft Position Sensor LTSMW030011T 03– Chery Automobile Co., Ltd.
Page 789 • Inspect the ground connection E-208 (See Vehicle Wiring Harness Layout - Engine Room Harness (With Mit- subishi 2.4L Engine) in Section 16 Wiring). Is the ground connections OK? >> Go to the next step. >> Repair or replace ground connection. Chery Automobile Co., Ltd. 03–...
Page 790 • Check supply voltage between CMP sensor con- nector E-056, terminal 3 and ground in the sensor electrical connector E-056. • Battery voltage should exist. Is the check result normal? >> Go to step 5. >> Go to the next step. LTSMD030014 03– Chery Automobile Co., Ltd.
Page 791 • Check harness for open or short between CMP sensor and ground. Is the check result normal? >> Go to the next step. >> Repair or replace the circuit for an open or short in harness or connectors. Chery Automobile Co., Ltd. 03–...
Page 792 Monitor the CMP sensor signal on the KES-200 screen. − If the CMP sensor signals were normal, the system is OK. − If the CMP sensor signals were still irregular or missing, go to step 10. >> Replace the CMP sensor. 03– Chery Automobile Co., Ltd.
Page 793 • Refer to DTC Confirmation Procedure . Is DTC 23 still present? >> Replace the ECM. >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 03–...
Page 794 DIAGNOSIS & TESTING 25 - Atmosphere Pressure Sensor LTSMW030013T 03– Chery Automobile Co., Ltd.
Page 795 Before performing the following procedure, make sure that the ECM ground connection is in good condition. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. Chery Automobile Co., Ltd. 03–...
Page 796 LTSMD030016 CHECK ATMOSPHERE PRESSURE SENSOR GROUND CIRCUIT FOR AN OPEN OR SHORT • Turn ignition switch off. • Disconnect ECM harness connector. • Check harness continuity between following terminals. ATMOSPHERE PRESSURE ECM TERMINAL SENSOR TERMINAL 03– Chery Automobile Co., Ltd.
Page 797 3.2 - 3.8 V 1200 M (88 kPa) • Sea level altitude: 81 kPa 1800 M Sensor (GND) Ignition switch: ON Is the check result normal? >> Go to the next step. >> Replace atmosphere pressure sensor. Chery Automobile Co., Ltd. 03–...
Page 798 • Refer to DTC Confirmation Procedure . Is DTC 25 still present? >> Replace the ECM. >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 799 DIAGNOSIS & TESTING 31 - Knock Sensor LTSMW030006T Chery Automobile Co., Ltd. 03–...
Page 800 • Inspect the ground connection E-208 (See Vehicle Wiring Harness Layout - Engine Room Harness (With Mit- subishi 2.4L Engine) in Section 16 Wiring). Is the ground connections OK? >> Go to the next step. >> Repair or replace ground connection. 03– Chery Automobile Co., Ltd.
Page 801 • Also check harness for short to power and short to ground. Is the check result normal? >> Go to the next step. >> Repair circuit for an open or short in harness or connectors. Chery Automobile Co., Ltd. 03–...
Page 802 • Refer to DTC Confirmation Procedure . Is DTC 31 still present? >> Replace the ECM. >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 803 DIAGNOSIS & TESTING 41 - Injector LTSMW030008T Chery Automobile Co., Ltd. 03–...
Page 804 • Inspect the ground connection E-208 (See Vehicle Wiring Harness Layout - Engine Room Harness (With Mit- subishi 2.4L Engine) in Section 16 Wiring). Is the ground connections OK? >> Go to the next step. >> Repair or replace ground connection. 03– Chery Automobile Co., Ltd.
Page 805 • Disconnect the injector electrical connector (1). • Inspect the electrical connector for damage. Is the electrical connector OK? >> Go to the next step. >> Repair or replace the electrical connector as necessary. LTSM020173 Chery Automobile Co., Ltd. 03–...
Page 806 Repair or replace malfunctioning part. CHECK INJECTOR CONTROL CIRCUITS FOR AN OPEN AND SHORT • Turn ignition switch off. • Disconnect ECM harness connector. • Check harness continuity between following terminals. INJECTOR INJECTOR TERMINAL TERMINAL 03– Chery Automobile Co., Ltd.
Page 807 • Connect ECM connector. • Connect injector connector. TERMINAL NO. ITEM CONDITION DATA (DC VOLTAGE) Injector 1 • Engine is running Injector 3 • Warm-up condition Voltage: 11 - 14 V Injector 2 • Accelerate suddenly Injector 4 Chery Automobile Co., Ltd. 03–...
Page 808 • Refer to DTC Confirmation Procedure . Is DTC 41 still present? >> Replace the ECM. >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 809 DIAGNOSIS & TESTING 44 - Ignition Signal LTSMW030007T Chery Automobile Co., Ltd. 03–...
Page 810 • Inspect the ground connections E-207 and E-208 (See Vehicle Wiring Harness Layout - Engine Room Harness (With Mitsubishi 2.4L Engine) in Section 16 Wiring). Is the ground connections OK? >> Go to the next step. >> Repair or replace ground connection. 03– Chery Automobile Co., Ltd.
Page 811 Ignition coil with power condition • Timing lamp (For check transistor Engine: 2500 RPM 18 - 38° BTDC the actual ignition time) Is the check result normal? >> Go to step 10. >> Go to the next step. Chery Automobile Co., Ltd. 03–...
Page 812 − Front fuse and relay box B8 − Harness connectors A-102, E-105 − Harness open or short between ignition coil and fuse Is the check result normal? >> Go to the next step. >> Repair or replace malfunctioning parts. 03– Chery Automobile Co., Ltd.
Page 813 This test should be completed quickly (in 10 seconds), to prevent ignition coil from burning and power transistor from damaging. • Also check resistance between ignition coil terminals as table shown. • Also check ignition coil signal output. Chery Automobile Co., Ltd. 03–...
Page 814 • Refer to DTC Confirmation Procedure . Is DTC 44 still present? >> Replace the ECM. >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 03– Chery Automobile Co., Ltd.
Page 815 (with a cloth) turn and remove the pressure relief cap. Failure to follow these instructions may result in serious personal injury. 3. Disconnect the coolant temperature sensor electrical connector. CAUTION: Remove the coolant temperature sensor when the engine is cold. Chery Automobile Co., Ltd. 03–...
Page 816 1. Disconnect and isolate the negative battery cable. 2. Disconnect the coolant temperature sensor (for instrument cluster) electrical connector. 3. Remove the coolant temperature sensor (1) (for instrument cluster). (Tighten: Coolant temperature sensor (for instru- ment cluster) to 14 N·m) LTSM030002 03– Chery Automobile Co., Ltd.
Page 817 When there is a lesser amount of oxygen present (caused by a rich air/fuel mixture, can be caused by internal engine problems) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. Chery Automobile Co., Ltd. 03–...
Page 818 3. Remove the upstream oxygen sensor (1). (Tighten: Upstream oxygen sensor to 45 N·m) LTSM030004 4. Installation is in the reverse order of removal. Installation Notes: • Before installing the oxygen sensor, coat the threads with rust inhibiting lubricant. 03– Chery Automobile Co., Ltd.
Page 819 3. Remove the downstream oxygen sensor (1). (Tighten: Downstream oxygen sensor to 45 N·m) LTSM030008 4. Installation is in the reverse order of removal. Installation Notes: • Before installing the oxygen sensor, coat the threads with rust inhibiting lubricant. Chery Automobile Co., Ltd. 03–...
Page 820 (Tighten: Camshaft position sensor retaining bolt to 10 N·m) LTSM030005 4. Remove camshaft position sensor. 5. Pull sensor up out of the cylinder head cover. 6. Installation is in the reverse order of the removal. 03– Chery Automobile Co., Ltd.
Page 821 3. Remove the air flow sensor retaining bolts (1). (Tighten: Air flow sensor retaining bolt to 8 N·m) LTSM030006 4. Remove the air flow sensor. 5. Installation is in the reverse order of removal. Chery Automobile Co., Ltd. 03–...
Page 822 (Tighten: Throttle control actuator bolts to 10 N·m) LTSM030010 7. Remove the throttle control actuator and gasket carefully. 8. Installation is in the reverse order of removal. NOTE : Replace a new throttle control actuator gasket when installing. 03– Chery Automobile Co., Ltd.
Page 823 2. Remove the glove box (See Instrument Panel Removal & Installation in Section 15 Body & Accessories). 3. Disconnect the ECM connector. 4. Remove the ECM retaining bolts (1). (Tighten: ECM retaining bolts to 10 N·m) LTSM030025 5. Remove the ECM. 6. Installation is in the reverse order of removal. Chery Automobile Co., Ltd. 03–...
Page 824 2. Disconnect throttle position sensor electrical con- nector clamp from the wiring harness connector. 3. Remove the throttle position sensor retaining bolts (1). LTSM030027 4. Remove the throttle position sensor. 5. Installation is in the reverse order of removal. 03– Chery Automobile Co., Ltd.
Page 825 3. Remove the idle air control motor retaining bolts (1). (Tighten: Air control motor retaining bolt to 10 N·m) LTSM030013 4. Remove the idle air control motor. 5. Installation is in the reverse order of removal. Chery Automobile Co., Ltd. 03–...
Page 826 Belt Lower Cover Removal & Installation in Section 02 Engine). 6. Remove the crankshaft position sensor retaining bolts (1). (Tighten: Crankshaft position sensor retaining bolt LTSM030012 to 20 N·m) 7. Installation is in the order of removal. 03– Chery Automobile Co., Ltd.
Page 827 Back Fires 03-556 Engine Cranks Normal But Will Not Engine Poor Driveability 03-558 Start 03-545 Low Idle / Stalls During Deceleration 03-562 Engine Will Not Crank 03-547 Idle Speed Slow Return To Normal Idle 03-564 Chery Automobile Co., Ltd. 03–...
Page 828 Engine Will Not Crank Hard Start / Long Crank Time Fast Idle Lack / Loss Of Power Back Fires Engine Poor Driveability Low Idle / Stalls During Deceleration Idle Speed Slow Return To Normal Idle 03– Chery Automobile Co., Ltd.
Page 829 >> Go to the next step. CHECK EXHAUST SYSTEM • Inspect the vehicles exhaust system for restriction. Is there a restriction in the exhaust system? >> Repair as necessary. >> Go to the next step. Chery Automobile Co., Ltd. 03–...
Page 830 CHECK ENGINE CYLINDER COMPRESSION • Perform a compression test on the engine. Is engine compression correct? >> Verify test results. If OK, see Diagnostic Test List to repair any additional symptoms. >> Check for cause. 03– Chery Automobile Co., Ltd.
Page 831 Repair as necessary. >> Go to the next step. CHECK OPERATION OF OTHER ELECTRICAL ACCESSORIES • Check all accessories. Do any other electrical accessories work? >> Go to the next step. >> Check the charging system. Chery Automobile Co., Ltd. 03–...
Page 832 Go to the next step. CHECK STARTING SYSTEM PRIMARY CIRCUITS • Check the starting system primary circuits as follows: − Starter relay − Ignition switch Are components/systems OK? >> Ensure customer’s concern has been resolved. >> Repair as necessary. 03– Chery Automobile Co., Ltd.
Page 833 Go to the next step. >> Check Camshaft Position (CMP) sensor signal at ECM. If CMP sensor is OK, check the following: − Crankshaft Position (CKP) sensor malfunction − Faulty spark plug wires − Faulty spark plugs Chery Automobile Co., Ltd. 03–...
Page 834 >> Go to the next step. CHECK POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM • Remove the PCV valve and shake it. Does PCV valve rattle? >> Go to the next step. >> Replace the PCV valve. 03– Chery Automobile Co., Ltd.
Page 835 >> Go to the next step. VISMD030007 CHECK INTAKE AIR SYSTEM • Check for MAP/MAF sensor. Is there any contamination? >> Install a new MAF/IAT or MAP/IAT sensor. >> See Diagnostic Help for additional information. Chery Automobile Co., Ltd. 03–...
Page 836 • With the scan tool X-431, select view DTC and data stream in ECM. Are there any DTCs present? >> See the Diagnostic Trouble Code (DTC) List. Go to the specific diagnostic test to troubleshoot the DTC. >> See Diagnostic Help for additional information. 03– Chery Automobile Co., Ltd.
Page 837 If the fuel pressure is less than 400 kPa (4.0 bar): − Check the fuel supply system for restrictions or leaks. − If no problems, repair or replace fuel filter, pressure regulator or fuel pump assembly. Chery Automobile Co., Ltd. 03–...
Page 838 Repair as necessary. >> Go to the next step. CHECK AUTOMATIC/MANUAL TRANSAXLE OPERATION • Check the operation of the transaxle. Is the transaxle operation normal? >> Go to the next step. >> Repair as necessary. 03– Chery Automobile Co., Ltd.
Page 839 • If the base timing is not correct, align the engine timing belt (See Engine Timing Belt Removal & Installation in 02 Engine). Are all checks OK? >> See Diagnostic Help for additional information. >> Repair as necessary. Verify the symptom no longer exists. Chery Automobile Co., Ltd. 03–...
Page 840 − Spark plugs CHECK FUEL QUALITY • Check fuel quality (concerns such as correct octane, contamination). Is the fuel quality OK? >> Go to the next step. >> Repair as necessary. Verify the symptom no longer exists. 03– Chery Automobile Co., Ltd.
Page 841 CHECK FOR BASE ENGINE CONCERNS • Check for base engine concerns (such as improper cylinder compression, worn camshaft/valve train, gasket leaks). Is a fault indicated? >> Repair as necessary. >> See Diagnostic Help for additional information. Chery Automobile Co., Ltd. 03–...
Page 842 − Clean the injectors − Fuel filter − Intake air filter − Throttle body − Spark plugs − Spark plug wires Does the engine now stall at idle? >> Repair as necessary. >> Go to the next step. 03– Chery Automobile Co., Ltd.
Page 843 • While checking for RPM drop or engine stall, disconnect ETC actuator connector. Did RPM drop or engine stall when the ETC connector was disconnected? >> Connect ETC actuator connector. Go to the next step. >> Repair as necessary. Chery Automobile Co., Ltd. 03–...
Page 844 Go to the next step. CHECK PCV SYSTEM • Check the Positive Crankcase Ventilation (PCV) system. • Remove PCV valve and shake it. Is PCV valve normal? >> Go to the next step. >> Replace the PCV valve. 03– Chery Automobile Co., Ltd.
Page 845 • Check the following for possible additional causes: − Driveline − Transaxle − Charging system − A/C system (for surge with A/C on) Are the checks OK? >> See Diagnostic Help for additional information. >> Repair as necessary. Chery Automobile Co., Ltd. 03–...
Page 846 • Disconnect ETC actuator connector and check for RPM drop or engine stall. Did RPM drop or engine stall when the ETC connector was disconnected? >> Connect ETC actuator connector. Go to the next step. >> Repair as necessary. 03– Chery Automobile Co., Ltd.
Page 847 CHECK FOR BASE ENGINE CONCERNS • Check for base engine concerns (such as improper compression, worn camshaft/valve train, gasket leaks). Is a fault indicated? >> Repair as necessary. >> See Diagnostic Help for additional information. Chery Automobile Co., Ltd. 03–...
Page 848 Verify test results. If OK, see diagnostic index to repair any additional symptom. >> Check for vacuum leaks, obstructions in the PCV system, oil cap, PCV valve, rocker cover bolt torque/gasket leak. Repair as necessary. 03– Chery Automobile Co., Ltd.
Page 849 Ignition Coil 1.6L & 1.8L & 2.0L 03-571 Spark Plug 1.6L & 1.8L & 2.0L 03-574 Description 03-571 Removal & Installation 03-574 Operation 03-571 Removal & Installation 03-571 Spark Plug 2.4L 03-575 Removal & Installation 03-575 Chery Automobile Co., Ltd. 03–...
Page 850 Camshaft Position (CMP) Sensor to determine which ignition coil to energize. Specifications Torque Specifications DESCRIPTION TORQUE (N·m) Spark Plugs Ignition Coil Bolts Spark Plug Specifications DESCRIPTION FR7DTC 0.7 mm - 1.1 mm 03– Chery Automobile Co., Ltd.
Page 851 GENERAL INFORMATION Special Tools Diagnostic Scan Tool X-431 Engine Analyzer KES-200 Chery Automobile Co., Ltd. 03–...
Page 852 GENERAL INFORMATION Electrical Schematics Ignition Control System - 1.6L / 1.8L (Page 1 of 1) LTSMW030057T 03– Chery Automobile Co., Ltd.
Page 853 GENERAL INFORMATION Ignition Control System - 2.0L (Page 1 of 1) LTSMW030037T Chery Automobile Co., Ltd. 03–...
Page 854 GENERAL INFORMATION Ignition Control System - 2.4L (Page 1 of 1) LTSMW030007T 03– Chery Automobile Co., Ltd.
Page 855 1. Remove the engine cover. 2. Disconnect the negative battery cable. 3. Disconnect the ignition coil electrical connector. 4. Twist the spark plug wires (1) from the ignition coil and remove the four spark plug wires. BESM030028 Chery Automobile Co., Ltd. 03–...
Page 856 4. Remove the ignition coil retaining bolts (2). (Tighten: Ignition coils retaining bolt to 12 N·m) 5. Remove the ignition coils & spark plug wire assem- bly (1). LTSM030022 6. Installation is in the reverse order of removal. 03– Chery Automobile Co., Ltd.
Page 857 8. Installation is in the reverse order of removal. BESM030013 Cylinder Number Part Number A11-3707130HA A11-3707140HA A11-3707150HA A11-3707160HA Length (mm) Resistance (K ) 6.99 - 12.08 5.32 - 9.59 3.92 - 7.48 3.4 - 6.71 Chery Automobile Co., Ltd. 03–...
Page 858 1. Remove the engine cover. 2. Disconnect the negative battery cable. 3. Remove the hose (1), if necessary. 4. Twist the spark plug wire (3) from spark plug then pull the spark plug wire straight up. BESM020022 03– Chery Automobile Co., Ltd.
Page 859 5. Remove the spark plug using a quality socket with a rubber or foam insert. (Tighten: Spark plug to 45 N·m) 6. Inspect the spark plug condition. 7. Installation is in the reverse order of removal. LTSM030018 Chery Automobile Co., Ltd. 03–...
Page 860 03-587 Description 03-584 Removal & Installation 03-587 Operation 03-584 Removal & Installation 03-584 EGR Valve 2.4L 03-588 Description 03-588 Canister Control Solenoid Valve 2.4L 03-584 Operation 03-588 Description 03-584 Removal & Installation 03-589 Operation 03-584 03– Chery Automobile Co., Ltd.
Page 861 Operation 1.6L / 1.8L / 2.0L 1-Fuel Tank 2-Fuel Vapor 7-Throttle Valve 8-Air Filter Assembly 3-Canister 4-Air Intake 9-To Engine 10-Air Intake 5-Hose 6-Canister Control Valve BESM030026 Chery Automobile Co., Ltd. 03–...
Page 862 The ECM will only energize the solenoid when the engine is at operating temperature, but will de-energize it during periods of deceleration. When de-energized, no vapors are purged. The pulse-width modulated canister control valve modulates the fuel vapor purge rate from the vapor canister and fuel tank to the engine intake manifold. 03– Chery Automobile Co., Ltd.
Page 863 GENERAL INFORMATION Electrical Schematics Canister Control Valve 1.6L /1.8L LTSMW030050T Chery Automobile Co., Ltd. 03–...
Page 864 GENERAL INFORMATION Canister Control Valve 2.0L LTSMW030031T 03– Chery Automobile Co., Ltd.
Page 865 GENERAL INFORMATION Canister Control Valve 2.4L LTSMW030009T Chery Automobile Co., Ltd. 03–...
Page 866 GENERAL INFORMATION EGR Control Solenoid Valve 2.4L LTSMW030010T 03– Chery Automobile Co., Ltd.
Page 867 GENERAL INFORMATION Specifications Torque Specifications DESCRIPTION TORQUE (N·m) Vapor Canister Bolts Special Tools Diagnostic Scan Tool X-431 Engine Analyzer KES-200 Chery Automobile Co., Ltd. 03–...
Page 868 The ECM uses a pulse-width modulated canister control valve to regulates the rate of vapor flow from the vapor canister to the throttle body. The ECM con- 03– Chery Automobile Co., Ltd.
Page 869 The Engine Control Module (ECM) purges the canister through the pulse-width modulated canister control valve. The ECM purges the canister at predetermined intervals and engine conditions. Removal & Installation 1. Raise and support the vehicle. Chery Automobile Co., Ltd. 03–...
Page 870 The Engine Control Module (ECM) purges the canister through the pulse-width modulated canister control valve. The ECM purges the canister at predetermined intervals and engine conditions. Removal & Installation 1. Raise and support the vehicle. 03– Chery Automobile Co., Ltd.
Page 871 3. Remove the EGR control solenoid valve retaining bolt (1). (Tighten: EGR control solenoid valve retaining bolt to 15 N·m) LTSM030020 4. Installation is in the reverse order of removal. Chery Automobile Co., Ltd. 03–...
Page 872 It is controlled by the vacuum hose. LTSM030033 Operation The EGR valve can heighten the intake air temperature and reduce the NOx content in the exhaust. It is controlled by the coolant temperature sensor and the throttle position sensor. 03– Chery Automobile Co., Ltd.
Page 873 Removal & Installation 1. Remove the EGR vacuum hose. 2. Remove the EGR valve retaining bolts (1). (Tighten: EGR valve retaining bolts to 25 N·m) LTSM030015 3. Installation is in the reverse order of removal. Chery Automobile Co., Ltd. 03–...
Page 874 Fuel Pressure Regulator - With Operation 04-15 Mitsubishi 2.4L Engine 04-23 Removal & Installation 04-15 Description 04-23 Fuel Pump Inspection 04-17 Operation 04-23 Removal & Installation 04-23 Fuel Filter 04-18 Fuel Pressure Regulator Inspection 04-24 Description 04-18 Operation 04-18 Chery Automobile Co., Ltd. 04–...
Page 875 10 - Fuel Delivery Pipe Assembly 4 - Bolt 11 - Fuel Return Pipe Assembly 5 - Hose Clamp 12 - Hose Clamp 6 - Fuel Filler Hose 13 - Bolt 7 - Fuel Filler Air Hose LTSM040008 04– Chery Automobile Co., Ltd.
Page 876 4 - Fuel Tank Protector 11 - Fuel Delivery Pipe 5 - Fuel Tank Assembly 12 - Electric Fuel Pump Assembly 6 - EVAP Hose 13 - Bolt 7 - Fuel Delivery And Return Pipes Assembly LTSM040009 Chery Automobile Co., Ltd. 04–...
Page 877 ECM. The fuel pump operation is defined in the fuel system control strategy and is controlled by the ECM. Specifications Torque Specifications DESCRIPTION TORQUE (N·m) Fuel Rail Bracket Bolts Fuel Filter Mounting Bolts 04– Chery Automobile Co., Ltd.
Page 878 320 kPa (3.2 bar) - 350 kPa (3.5 bar) Fuel Pressure at Fuel Rail - Key Off 350 kPa (3.5 bar) in 10 minutes Special Tools Digital Multimeter Fluke 15B & 17B Fuel Pressure Gauge Fuel Pump Remover CH-20032 Chery Automobile Co., Ltd. 04–...
Page 879 GENERAL INFORMATION Electrical Schematics Fuel Delivery System (Page 1 of 6) LTSMW040001T 04– Chery Automobile Co., Ltd.
Page 880 GENERAL INFORMATION Fuel Delivery System (Page 2 of 6) LTSMW040002T Chery Automobile Co., Ltd. 04–...
Page 881 GENERAL INFORMATION Fuel Delivery System (Page 3 of 6) LTSMW040003T 04– Chery Automobile Co., Ltd.
Page 882 GENERAL INFORMATION Fuel Delivery System (Page 4 of 6) LTSMW040004T Chery Automobile Co., Ltd. 04–...
Page 883 GENERAL INFORMATION Fuel Delivery System (Page 5 of 6) LTSMW040005T 04– Chery Automobile Co., Ltd.
Page 884 GENERAL INFORMATION Fuel Delivery System (Page 6 of 6) LTSMW040006T Chery Automobile Co., Ltd. 04–...
Page 885: Fuel Pressure Test
(1) on the fuel rail (3). 2. Start and warm the engine and note the pressure gauge reading: 1.6L & 1.8L & 2.0L • Fuel pressure at idle: 400-420 kPa (4.0 - 4.2 bar) 04– Chery Automobile Co., Ltd.
Page 886 · Replace fuel tank. Cannot Refill Fuel Tank/Excessive · Sticking or damaged fuel tank · Inspect, repair vent hose and lines, Pressure in Fuel Tank When Cap is fill/vent valve, hose or lines. replace fuel tank. Removed Chery Automobile Co., Ltd. 04–...
Page 887 · Replace the fuel injector(s) Injector(s) · Failure to start (starting difficulties) · An accumulation of contaminants · Clean injectors regularly with an Reasons For Fuel Injector Failure inside the injector due to lack of approved method maintenance 04– Chery Automobile Co., Ltd.
Page 888: Fuel Pump
The following special tool is required to perform the repair procedure: • CH-20032 - Fuel Pump Remover 1. Release the fuel system pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery). 2. Disconnect the negative battery cable. 3. Remove the rear seat cushion. Chery Automobile Co., Ltd. 04–...
Page 889 • Turn the ignition switch to ON (without starting the engine) to apply fuel pressure to the fuel system, then check the connections for fuel leaks. • Start the engine and let it idle and check for fuel leaks at the fuel system connections. 04– Chery Automobile Co., Ltd.
Page 890 Digital Multimeter Positive (+) to terminal – 2 < 130 Digital Multimeter Negative (-) to terminal – 3 Battery positive (+) to terminal – 2 8 - 16 V Battery negative (-) to terminal – 3 Chery Automobile Co., Ltd. 04–...
Page 891: Fuel Filter
(2) and the ground wire (3). 4. Remove the fuel filter. 5. Installation is in the reverse order of removal. Installation Notes: • Verify there are no leaks at the fuel line connec- tions of the fuel filter. LTSM040003 04– Chery Automobile Co., Ltd.
Page 892 (Tighten: Fuel rail bracket bolts to 11 N·m) BESM040003 7. Remove the fuel rail with the four fuel injectors (1). 8. Installation is in the reverse order of removal. Installation Notes: • Install new seals on the fuel injector sealing surfaces. BESM040005 Chery Automobile Co., Ltd. 04–...
Page 893: Fuel Injector
1. Release the fuel system pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery). 2. Disconnect the negative battery cable. 3. Remove the engine cover. 4. Remove the ground cable on the cylinder head. 04– Chery Automobile Co., Ltd.
Page 894 Never smoke while servicing the vehicle. This may result in personal injury or death. 1. Release the fuel system pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery). 2. Disconnect the negative battery cable. 3. Disconnect four fuel injector electrical connectors (1). LTSM020173 Chery Automobile Co., Ltd. 04–...
Page 895 • Install new seals on the fuel injector sealing surfaces. Fuel Injector Inspection 1. Remove the fuel injector electrical connector. 2. Use a digital multimeter to measure the resistance between the two fuel injector pins (fuel injector side). SPECIFICATION TEMPERATURE 11 - 13 20°C 04– Chery Automobile Co., Ltd.
Page 896 Never smoke while servicing the vehicle. This may result in personal injury or death. 1. Release the fuel system pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery). 2. Disconnect the negative battery cable. Chery Automobile Co., Ltd. 04–...
Page 897 1. Connect a fuel pressure gauge to the inlet fuel pipe. 2. Start and idle the engine (note the fuel pressure). 3. Increase the engine speed to 2500 RPM (note the fuel pressure). SPECIFICATION PRESSURE Idle 350 kPa 2500 RPM 350 kPa 04– Chery Automobile Co., Ltd.
Page 898 Starter Motor Assembly 05-9 Description 05-9 ON-VEHICLE SERVICE 05-7 Operation 05-9 Battery 05-7 Removal & Installation - 1.6L & 1.8L & Description 05-7 2.0L 05-9 Operation 05-7 Removal & Installation - 2.4L 05-10 Removal & Installation 05-7 Chery Automobile Co., Ltd. 05–...
Page 899 The starting system consists of the following components: • Starter motor (including an integral starter solenoid) • Battery • Battery cables • Ignition switch and key lock cylinder • Wire harnesses and connections • Starter relay and fuse • Charge fuse 05– Chery Automobile Co., Ltd.
Page 900 150 amps, and a control circuit that operates on less than 20 amps. Specifications Torque Specifications DESCRIPTION TORQUE (N·m) Starter Mounting Bolts Battery Positive Cable Nut Special Tools Digital Multimeter Fluke 15B & 17B Chery Automobile Co., Ltd. 05–...
Page 901 GENERAL INFORMATION Electrical Schematics Starting System (Page 1 of 2) LTSMW050001T 05– Chery Automobile Co., Ltd.
Page 902 GENERAL INFORMATION Starting System (Page 2 of 2) LTSMW050003T Chery Automobile Co., Ltd. 05–...
Page 903: Diagnosis And Testing
If there is continuity, go to Step 4. If not, replace the faulty starter motor assembly. 4. Using a continuity tester, check for continuity between the solenoid terminal and the solenoid case. There should be continuity. If not, replace the faulty starter motor assembly. VISM050007 05– Chery Automobile Co., Ltd.
Page 904 1. Disconnect the negative battery cable. 2. Disconnect the positive battery cable. 3. Remove the battery hold down retaining nuts (1). LTSM050001 4. Remove the battery. 5. Installation is in the reverse order of removal. Chery Automobile Co., Ltd. 05–...
Page 905 5. Installation is in the reverse order of removal. Battery Hold Down Removal & Installation 1. Remove the retaining nuts (1). LTSM050001 2. Remove the battery hold down. 3. Installation is in the reverse order of removal. 05– Chery Automobile Co., Ltd.
Page 906: Battery Tray
After removing the engine oil dipstick, you should immediately plug the hole in the cylinder block in order to prevent any debris from entering the engine. 5. Remove the starter solenoid nut (1) from the starter. (Tighten: Starter solenoid nut to 10 N·m) BESM050004 Chery Automobile Co., Ltd. 05–...
Page 907 5. Remove the two starter mounting bolts (1) connecting the starter and transaxle. (Tighten: Starter mounting bolts to 30 N·m) 6. Remove the starter from the engine. 7. Installation is in the reverse order of removal. LTSM050005 05– Chery Automobile Co., Ltd.
Page 908 05-12 Removal & Installation - 1.6L & 1.8L & Specifications 05-13 2.0L 05-17 Special Tools 05-13 Removal & Installation - 2.4L 05-18 Electrical Schematics 05-14 Generator Inspection 05-18 DIAGNOSIS & TESTING 05-16 Generator Noise 05-16 Chery Automobile Co., Ltd. 05–...
Page 909 The Y-type stator winding connections deliver the induced AC current to 3 positive and 3 negative diodes for recti- fication. From the diodes, rectified DC current is delivered to the vehicle’s electrical system through the generator, battery, and ground terminals. 05– Chery Automobile Co., Ltd.
Page 910 GENERAL INFORMATION Specifications Torque Specifications DESCRIPTION TORQUE (N·m) Generator Cable Nut Generator Mounting Bolts Generator Adjustment Bracket Bolts Special Tools Digital Multimeter Fluke 15B & 17B Chery Automobile Co., Ltd. 05–...
Page 911 GENERAL INFORMATION Electrical Schematics Charging System (Page 1 of 2) LTSMW050002T 05– Chery Automobile Co., Ltd.
Page 912 GENERAL INFORMATION Charging System (Page 2 of 2) LTSMW050004T Chery Automobile Co., Ltd. 05–...
Page 913 • Worn, loose or defective bearings • Loose or defective drive pulley • Incorrect, worn, damaged or misadjusted drive belt • Loose mounting bolts • Misaligned drive pulley • Defective stator • Damaged internal fins 05– Chery Automobile Co., Ltd.
Page 914 (Tighten: Generator cable nut to 13 N·m) BESM050002 5. Remove two generator mounting bolts (1). (Tighten: Generator mounting bolts to 30 N·m) 6. Remove the generator from the engine. 7. Installation is in the reverse order of removal. BESM050003 Chery Automobile Co., Ltd. 05–...
Page 915 NOTE: If the battery warning lamp illuminates, there may be a problem with the charging system. 2. With the engine running, check the output voltage of the generator with a digital multimeter (note the voltage). 3. If the voltage is between 14.1 V - 14.7 V, the generator is good. 05– Chery Automobile Co., Ltd.
Page 916: Table Of Contents
Cooling System Draining and Filling 06-13 Cooling Fan 06-18 Cooling System Draining Procedure 06-13 Description 06-18 Cooling System Filling Procedure 06-13 Operation 06-19 Thermostat 06-14 Removal & Installation 06-19 Description 06-14 Cooling Fan Inspection 06-19 Operation 06-14 Chery Automobile Co., Ltd. 06–...
Page 917 9 - Three Way Connector 4 - Gasket 10 - Engine Oil Cooler Inlet Hose (Part 2) 5 - Engine Inlet Hose From Radiator 11 - Engine Oil Cooler Outlet Hose 6 - Restrictor Outlet Hose LTSM060006 06– Chery Automobile Co., Ltd.
Page 918 The cooling system consists of the following components: • Radiator • Coolant • Coolant pump • Electric cooling fans • Electric cooling fans control module • Thermostat • Coolant reservoir Chery Automobile Co., Ltd. 06–...
Page 919 This is done by transferring heat from engine metal to cool- ant, moving the heated coolant to the radiator, and then transferring the heat to the ambient air. 06– Chery Automobile Co., Ltd.
Page 920 GENERAL INFORMATION Specifications Torque Specifications DESCRIPTION TORQUE (N·m) Coolant Pump Mounting Bolts Radiator Support Mounting Bolts Coolant Fan Mounting Bolts Thermostat Mounting Bolts Fluid Specifications DESCRIPTION CAPACITY (L) Cooling System Special Tools Cooling System Pressure Tester Chery Automobile Co., Ltd. 06–...
Page 921 GENERAL INFORMATION Electrical Schematics Cooling System (Page 1 of 5) LTSMW060001T 06– Chery Automobile Co., Ltd.
Page 922 GENERAL INFORMATION Cooling System (Page 2 of 5) LTSMW060002T Chery Automobile Co., Ltd. 06–...
Page 923 GENERAL INFORMATION Cooling System (Page 3 of 5) LTSMW060003T 06– Chery Automobile Co., Ltd.
Page 924 GENERAL INFORMATION Cooling System (Page 4 of 5) LTSMW060004T Chery Automobile Co., Ltd. 06–...
Page 925 GENERAL INFORMATION Cooling System (Page 5 of 5) LTSMW060005T 06– Chery Automobile Co., Ltd.
Page 926: Cooling System Pressure Test
The coolant mixture offers optimum engine cooling and protection against corrosion when mixed to a freeze point of -37°C to -46°C. The use of a hydrometer or a refractometer can be used to test coolant concentration. Chery Automobile Co., Ltd. 06–...
Page 927: Cooling System Troubleshooting Chart
· Cooling fan motor(s) · Replace cooling fan motor(s) · Wiring · Repair wiring Electric Cooling Fan(s) On All The · Relay(s) · Replace relay(s) Time · Engine Control Module (ECM) · Replace the ECM 06– Chery Automobile Co., Ltd.
Page 928: Cooling System Draining And Filling
LTSM060015 5. Tighten the radiator drain plug. Cooling System Filling Procedure CAUTION: Failure to purge air from the cooling system can result in an overheating condition and severe engine damage. Chery Automobile Co., Ltd. 06–...
Page 929 Failure to follow these instructions may result in serious personal injury. 1. Drain the cooling system (See Cooling System Draining Procedure in Section 06 Cooling System). 06– Chery Automobile Co., Ltd.
Page 930 3. Remove the thermostat and gasket. 4. Installation is in the reverse order of removal. Installation Notes: • Install a new thermostat gasket during installation. • Verify the cooling system is filled to proper specifications. LTSM060009 Chery Automobile Co., Ltd. 06–...
Page 931: Coolant Pump
4. Remove the water pump and gasket. 5. Installation is in the reverse order of removal. Installation Notes: • Install a new coolant pump gasket during installa- tion (1). • Verify the cooling system is filled to proper specifications. BESM060002 06– Chery Automobile Co., Ltd.
Page 932: Coolant Pump Inspection
The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may result in serious personal injury. Chery Automobile Co., Ltd. 06–...
Page 933: Cooling Fan
The radiator cooling fans are dual-speed electric motor driven fans. The radiator fan assembly includes two electric motors, two five-blade fans, and a support shroud that is attached to the radiator. The radiator fans are serviced as an assembly. 06– Chery Automobile Co., Ltd.
Page 934: Cooling Fan Inspection
1. Using the following table, apply battery voltage to the specified connector terminals. 2. Verify that the fan motor operates smoothly when voltage is applied. 3. If the test results are not as specified, replace the fan motor. Chery Automobile Co., Ltd. 06–...
Page 935 OPERATION INSPECTION DIAGRAM Battery positive (+) to terminal – 1 Turns smoothly Battery negative (-) to terminal – 2 Battery positive (+) to terminal – 1 Turns smoothly Battery negative (-) to terminal – 2 06– Chery Automobile Co., Ltd.
Page 936 OPERATION INSPECTION DIAGRAM Battery positive (+) to terminal – 4 Turns smoothly Battery negative (-) to terminal – 5 Battery positive (+) to terminal – 6 Turns smoothly Battery negative (-) to terminal – 7 Chery Automobile Co., Ltd. 06–...
Page 937 07-6 Description 07-6 DIAGNOSIS AND TESTING 07-4 Operation 07-6 Exhaust System Diagnostic Chart 07-4 Removal & Installation 07-7 ON-VEHICLE SERVICE 07-5 Exhaust Pipe Assembly 07-5 Removal & Installation - 1.6L & 1.8L & 2.0L 07-5 Chery Automobile Co., Ltd. 07–...
Page 938 The exhaust system contains the following components: • Catalytic converter assembly • Muffler assembly • Exhaust brackets with isolators bolted to the body • Heated oxygen sensors mounted to the exhaust pipes • Tailpipe assembly 07– Chery Automobile Co., Ltd.
Page 939 The exhaust system channels exhaust gases from the engine and away from the vehicle. Specifications Torque Specifications DESCRIPTION TORQUE (N·m) Catalytic Converter Mounting Nuts Exhaust Manifold Flange Bolts 49 ± 5 Muffler Mounting Nuts Chery Automobile Co., Ltd. 07–...
Page 940 · Leaks at pipe joints. joints. · Ignition timing incorrect. · Adjust the timing. Excessive Exhaust Temperature · Poor fuel quality. · Change and clean the fuel tank. · Engine running rich. · Repair as needed. 07– Chery Automobile Co., Ltd.
Page 941 1. Raise and support the vehicle. 2. Remove the catalytic converter to exhaust manifold bolts (1). (Tighten: Exhaust manifold flange bolts to 49 ± 5 N·m) LTSM020189 3. Remove all the support isolators. 4. Remove the exhaust pipe assembly. Chery Automobile Co., Ltd. 07–...
Page 942: Catalytic Converter
CAUTION: Unleaded gasoline must be used in order to avoid damaging the catalyst core. 07– Chery Automobile Co., Ltd.
Page 943 5. Clean the ends of the pipes to ensure proper mat- ing of all parts. Discard broken or worn isolators, rusted or overused clamps, supports, and attaching parts. 6. Installation is in the reverse order of removal. LTSM070001 Chery Automobile Co., Ltd. 07–...
Page 944 P0753 - Shift Solenoid Valve 1 (SSV1) Short To Power Supply 08-114 Open Circuit Or Short To Power Supply P2709 - Shift Solenoid Valve 6 (SSV6) Or Short To Ground 08-56 Open Circuit Or Short To Ground 08-119 Chery Automobile Co., Ltd. 08–...
Page 945 DPO Automatic Transaxle Assembly 08-136 Circuit Or Short To Ground 08-125 Removal & Installation 08-136 U0001 - CAN Communication Error 08-130 Automatic Shifter Selector 08-140 Removal & Installation 08-140 Transaxle Control Module (TCM) 08-142 Removal & Installation 08-142 08– Chery Automobile Co., Ltd.
Page 946 The TCM also performs certain self-diagnostic functions and provides comprehensive information (sensor data, DTCs, etc.) which is helpful in proper diagnosis and repair. This information can be viewed with the X-431 scan tool. Chery Automobile Co., Ltd. 08–...
Page 947 GENERAL INFORMATION DP0 Transaxle External View 1 - Rear Cover 4 - Torque Converter Housing 2 - Transaxle Housing 5 - Fluid Filter 3 - Bearing Retainer 6 - Valve Body Cover LTSM080152 08– Chery Automobile Co., Ltd.
Page 948 19 - Ratchet Gear Plate 9 - Transfer Shaft 20 - Accumulator Cover 10 - Brake F3 (1st and 2nd Gear) 21 - Planet Gear 11 - Brake F2 (Reverse Gear) 22 - Primary Differential Drive Gear BESM080056 Chery Automobile Co., Ltd. 08–...
Page 949 The engine speed limit can be reached in the individual gears at full throttle and kickdown. The shift range can be changed in the forward gears while driving, but the TCM employs a downshift safeguard to prevent engine over speed. The system offers the additional advantage of flexible adaptation to different vehicle and engine variants. 08– Chery Automobile Co., Ltd.
Page 950 Gear Ratio Specifications GEAR SELECTOR POSITION RATIO First 2.75 Second Third Overdrive 0.71 Reverse 2.45 Lubrication Specifications DESCRIPTION ITEM Transaxle Fluid Quantity 6.0L Transaxle Fluid Change Quantity 3.0L Fluid Type DEXTRON III Fluid Change Cycle 40000 Km Chery Automobile Co., Ltd. 08–...
Page 951 GENERAL INFORMATION Special Tools Spline Spanner CH-30001 Differential Seal Installer CH-30002 Diagnostic Scan Tool X-431 08– Chery Automobile Co., Ltd.
Page 952 GENERAL INFORMATION Automatic Transaxle Fluid Pressure Gauge Digital Multimeter Fluke 15B & 17B Chery Automobile Co., Ltd. 08–...
Page 953 GENERAL INFORMATION Electrical Schematics Automatic Transaxle (Page 1 of 8) LTSMW080033T 08– Chery Automobile Co., Ltd.
Page 954 GENERAL INFORMATION Automatic Transaxle (Page 2 of 8) LTSMW080034T Chery Automobile Co., Ltd. 08–...
Page 955 GENERAL INFORMATION Automatic Transaxle (Page 3 of 8) LTSMW080035T 08– Chery Automobile Co., Ltd.
Page 956 GENERAL INFORMATION Automatic Transaxle (Page 4 of 8) LTSMW080040T Chery Automobile Co., Ltd. 08–...
Page 957 GENERAL INFORMATION Automatic Transaxle (Page 5 of 8) LTSMW080036T 08– Chery Automobile Co., Ltd.
Page 958 GENERAL INFORMATION Automatic Transaxle (Page 6 of 8) LTSMW080037T Chery Automobile Co., Ltd. 08–...
Page 959 GENERAL INFORMATION Automatic Transaxle (Page 7 of 8 LTSMW080038T 08– Chery Automobile Co., Ltd.
Page 960 GENERAL INFORMATION Automatic Transaxle (Page 8 of 8 LTSMW080039T Chery Automobile Co., Ltd. 08–...
Page 961 Torque Converter Lock Solenoid Valve Secondary Shaft (+) (CDE EVM PRSN) Regulated Sensor Supply Sensor (GND) Fluid Temperature Sensor (-) Pressure Adjust Solenoid Valve (+EVM) Fluid Temperature Sensor (+) Ignition Switch Fluid Pressure Sensor BATT 08– Chery Automobile Co., Ltd.
Page 962 If using a TCM electrical harness test tool, you can diagnose the TCM harness while the TCM is still connected. • Measure sensor and solenoid resistance (always measure resistance with the power off). • Measure the signal voltage of the TCM (always measure voltage with the power on). Chery Automobile Co., Ltd. 08–...
Page 963 EVM (Electronic Valve Modulation) Circuit Open P0775 EVM (Electronic Valve Modulation) Circuit Shorted To Voltage P0795 EVLU Circuit Open P0795 EVLU Shorted To Voltage P0819 Flick Shift Contact Duration P0819 Flick Shift Contacts P0840 Pressure Sensor P0850 P/N Contact 08– Chery Automobile Co., Ltd.
Page 964 Engine Speed Not Sent By EMS U1120 Actual Torque Not Sent By EMS U1121 Pedal Position Not Sent By EMS U1122 Expected Torque Not Sent By EMS U112B Torque Without Reduction Consistency U112B Torque Without Reduction Not Sent By EMS Chery Automobile Co., Ltd. 08–...
Page 965 DIAGNOSIS & TESTING Diagnostic Trouble Code (DTC) Tests P0641 - Sensor Feed LTSMW080015T 08– Chery Automobile Co., Ltd.
Page 966 DIAGNOSIS & TESTING A/T Fluid Temperature Sensor LTSMW080018T Chery Automobile Co., Ltd. 08–...
Page 967 • Disconnect the A/T assembly electrical connector E-037 (1). • Inspect the electrical connector for damage. Is the electrical connector OK? >> Go to the next step. >> Repair or replace the electrical connector as necessary. LTSMD080023 08– Chery Automobile Co., Ltd.
Page 968 Is the check result normal? >> Go to the next step. >> Repair the circuit for an open or short to ground or short to voltage in the harness or connectors. LTSMD080074 Chery Automobile Co., Ltd. 08–...
Page 969 Below 0.2 bar • Engine: Not running Fluid Pressure • Engine: Idle Approximately • TFT: 31°C 0.05 bar • ECT: 30°C Is the check result normal? >> Go to the next step. >> Replace the TCM. 08– Chery Automobile Co., Ltd.
Page 970 • Refer to DTC Confirmation Procedure . Is the check result normal? >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. >> Replace the TCM. Chery Automobile Co., Ltd. 08–...
Page 971 DIAGNOSIS & TESTING P0657 - Solenoid Power Supply Circuit Shorted To Voltage Electronic Valve Solenoid LTSMW080022T 08– Chery Automobile Co., Ltd.
Page 972 Using the appropriate diagnostic test tool, you can diagnose the TCM harness while the TCM is still connected. This will help prevent electrical connector terminal damage. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. Chery Automobile Co., Ltd. 08–...
Page 973 • Turn ignition switch on. • With X-431 scan tool, perform the solenoid actuate test. • The solenoid actuation should be heard. Is the check result normal? >> Go to step 4. >> Go to the next step. 08– Chery Automobile Co., Ltd.
Page 974 • Refer to DTC Confirmation Procedure . Did DTC P0657 reset? >> Replace the TCM. >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 08–...
Page 975 DIAGNOSIS & TESTING P0657 - Solenoid Power Supply Circuit Open Electronic Valve Solenoid LTSMW080022T 08– Chery Automobile Co., Ltd.
Page 976 Using the appropriate diagnostic test tool, you can diagnose the TCM harness while the TCM is still connected. This will help prevent electrical connector terminal damage. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. Chery Automobile Co., Ltd. 08–...
Page 977 • Turn ignition switch on. • With X-431 scan tool, perform the solenoid actuate test. • The solenoid actuation should be heard. Is the check result normal? >> Go to step 5. >> Go to the next step. 08– Chery Automobile Co., Ltd.
Page 978 • Check the solenoid power circuit for battery voltage between the A/T connector E-037 terminal B3 and ground. Is battery voltage present? >> Go to the next step. >> Repair or replace circuit for an open in harness or connectors. LTSMD080026 Chery Automobile Co., Ltd. 08–...
Page 979 • Refer to DTC Confirmation Procedure . Is DTC P0657 still present? >> Replace the TCM. >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. 08– Chery Automobile Co., Ltd.
Page 980 DIAGNOSIS & TESTING P0705 - Multi-Function Switch: Prohibited Position LTSMW080025T Chery Automobile Co., Ltd. 08–...
Page 981 • Using the appropriate diagnostic test tool in this way will help prevent electrical connector terminal damage. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. 08– Chery Automobile Co., Ltd.
Page 982 Is DTC P0705 present and the status active for this DTC? >> Go to the next step. >> The condition that caused this DTC is intermittent (See Diagnostic Help in Section 08 Transaxle & Transfer Case). Chery Automobile Co., Ltd. 08–...
Page 983 Do the circuits check OK, and do the reverse lamps also illuminate? >> The transaxle range switch is normal. Reassemble the vehicle and road test to verify the customers complaint is repaired. >> Go to the next step. 08– Chery Automobile Co., Ltd.
Page 984 After adjusting the transaxle range switch, verify the adjustment with the table. If the test results are still not normal, replace the transaxle range switch. Chery Automobile Co., Ltd. 08–...
Page 985 DIAGNOSIS & TESTING P0710 - Fluid Temperature Sensor LTSMW080018T 08– Chery Automobile Co., Ltd.
Page 986 • If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 08 Transaxle & Transfer Case for more information). NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. Chery Automobile Co., Ltd. 08–...
Page 987 TFT SENSOR RESISTANCE TEMPERATURE RESISTANCE (°C) 93917 28237.4 9826 6079 2528.5 2063 1159.2 810.4 419.1 309.2 176.2 105.9 66.7 Is the check result normal? >> Go to the next step. >> Replace the TFT sensor. 08– Chery Automobile Co., Ltd.
Page 988 • Refer to DTC Confirmation Procedure . Is DTC P0710 still present? >> Replace the TCM. >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 08–...
Page 989 DIAGNOSIS & TESTING P0715 - Turbine Speed Sensor Affected By Interference LTSMW080017T 08– Chery Automobile Co., Ltd.
Page 990 • Monitor the value of turbine speed sensor while driving. Is the check result normal and DTC not present? >> The condition that caused this DTC is intermittent (See Diagnostic Help in Section 08 Transaxle & Transfer Case). >> Go to the next step. Chery Automobile Co., Ltd. 08–...
Page 991 TURBINE SPEED SENSOR RESISTANCE TURBINE SPEED SENSOR RESISTANCE BASED ON TRANSAXLE TEMPERATURE TERMINAL RESISTANCE 23°C D1 - D2 260 - 340 Is the check result normal? >> Go to the next step. >> Replace the turbine speed sensor. 08– Chery Automobile Co., Ltd.
Page 992 • Refer to DTC Confirmation Procedure . Is DTC P0715 present? >> Replace the TCM. >> The system is now operating properly. Reassemble the vehicle and road test to verify the customers complaint is repaired. Chery Automobile Co., Ltd. 08–...
Page 993 DIAGNOSIS & TESTING P0730 - Ratio Of Transaxle Error LTSMW080016T 08– Chery Automobile Co., Ltd.
Page 994 • If the DTC is detected, the DTC condition is current. Go to Diagnostic Procedure - Step 1. • If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou- bleshooting in Section 08 Transaxle & Transfer Case for more information). Chery Automobile Co., Ltd. 08–...
Page 995 Is the check result not normal and DTC P0730, DTC P0715 or DTC P0720 present? >> If DTC P0715 is present, see DTC P0715 diagnostic procedure. If DTC P0720 is present, see DTC P0720 diagnostic procedure. >> Go to the next step. 08– Chery Automobile Co., Ltd.
Page 996 Section 08 Transaxle & Transfer Case). • Check valve body and fluid pump and pipeline. Is the check result normal? >> Go to the next step. >> Replace the damaged components as needed. Chery Automobile Co., Ltd. 08–...
Page 997 − Check brake plate − Check brake disc − Central support − Snap ring − Spring retainer − Brake piston Is the check result normal? >> Go to the next step. >> Replace the damaged components. 08– Chery Automobile Co., Ltd.
Page 998 • Refit the checking dipstick of transaxle. • With the X-431 scan tool, read TCM DTCs. • Refer to DTC Confirmation Procedure . Is DTC P0730 still present? >> Replace the TCM. >> The system is now operating properly. Chery Automobile Co., Ltd. 08–...
Page 999 DIAGNOSIS & TESTING P0753 - Shift Solenoid Valve 1 (SSV1) Open Circuit Or Short To Power Supply Or Short To Ground LTSMW080022T 08– Chery Automobile Co., Ltd.
Page 1000 • Using the appropriate diagnostic test tool in this way will help prevent electrical connector terminal damage. NOTE : While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit and component information. Chery Automobile Co., Ltd. 08–...

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