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Chery automobile Service Manual

Chery

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User manual (148 pages)

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WARNING

Servicing a vehicle can be dangerous. If you have not received service-related

training, the risks of injury, property damage, and failure of servicing

increase. The recommended servicing procedures for the vehicle in this

service manual were developed with Chery-trained technicians in mind. This

manual may be useful to non-Chery trained technicians, but a technician

with our service-related training and experience will be at less risk when

performing service operations. However, all users of this manual are

expected to at least know general safety procedures.

This manual contains "Warnings" and "Cautions" applicable to risks not

normally encountered in a general technician's experience. They should be

followed to reduce the risk of injury and the risk that improper service or

repair may damage the vehicle or render it unsafe. It is also important to

understand that the "Warnings" and "Cautions" are not exhaustive. It is

impossible to warn of all the hazardous consequences that might result from

failure to follow the procedures.

The procedures recommended and described in this manual are effective

methods of performing service and repair. Some require tools specifically

designed for a specific purpose. Persons using procedures and tools which

are not recommended by Chery Company must satisfy themselves

thoroughly that neither personal safety nor safety of the vehicle will be

jeopardized.

The contents of this manual, including drawings and specifications, are the

latest available at the time of printing, and Chery Company reserves the

right to change the vehicle designs and alter the contents of this manual

without notice and without incurring obligation.

Parts should be replaced with genuine Chery replacement parts. Persons

using replacement parts of lesser quality than that of genuine Chery

replacement parts must take all the consequences.

Chery Company is not responsible for any problems which may arise from

the use of this manual. The cause of such problems includes but is not limited

to insufficient service-related training, use of improper tools, use of

replacement parts of lesser quality than that of genuine Chery replacement

parts, or not being aware of any revision of this manual.

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Troubleshooting

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Summary of Contents for Chery automobile

Page 1 The contents of this manual, including drawings and specifications, are the latest available at the time of printing, and Chery Company reserves the right to change the vehicle designs and alter the contents of this manual without notice and without incurring obligation.
Page 2 Chery dealers. This manual should be kept up-to-date. Chery company reserves the right to alter the specifications and contents of this manual without obligation or advanced notice. CHERY AUTOMOBLE CO., LTD...
Page 3: Table Of Contents
GENERAL INFORMATION HOW TO USE THIS MANUAL… … … … … … … … … … … … … … … … GI-2 RANGE OF TOPICS… … … … … … … … … … … … … … … … … … …GI-2 SERVICE PROCEDURE …...
Page 4: How To Use This Manual
HOW TO USE THIS MUNUAL RANGE OF TOPICS · This manual contains procedures for performing all required service operations. The procedures are divided into the following five basic operations: Removal/Installation Disassembly/Assembly Replacement Inspection Adjustment ·Simple operations which can be performing easily just by looking at the vehicle (i.e., removal/installation of parts, jacking, vehicle lifting, cleaning of parts and visual inspection) have been omitted.
Page 5 Note ·A Note provides added information that will help you to complete a particular procedure. Specification ·The values indicate the allowable range when performing inspections or adjustments. Upper and lower limits ·The values indicate the upper and lower limits that must not be exceeded when performing inspections or adjustments.
Page 6: Units
UNIT UNIT Electric current A ampere Electric power W watt Electric resistance Electric voltage V volt Length mm millimeter kPa kilo pascal Negative pressure Kg/cm kilogram force per square centimeter Bar (bar) kPa kilo pascal Positive pressure Kg/cm kg/square centimeter Torque N.m Newton meter L liter...
Page 7: Fundamental Procedure
FUNDAMENTAL PROCEDURES PROTECTION OF VEHICLE ·Always be sure to cover fenders, seats and floor areas before starting work. PREPARATION OF TOOLS AND MEASURING EQUIPMENT ·Be sure that all necessary tools and measuring equipment are available before starting any work. DISASSEMBLY ·If the disassembly procedure is complex, requiring many parts to be disassembled ,all parts should be marked in a place that will not affect...
Page 8: Arrangement Of Parts
ARRANGEMENT OF PARTS ·All disassembled parts should be carefully arranged for reassembly. ·Be sure to separate or otherwise identify the parts to be replaced from those that will be reused. CLEANING OF PARTS ·All parts to be reused should be carefully and thoroughly cleaned in the appropriate method.
Page 9: Adjustment
ADJUSTMENT ·Use suitable gauges and/or testers when making adjustment. RUBBER PARTS AND TUBING ·Prevent gasoline or oil from getting on rubber parts or tubing. HOSE CLAMPS ·When reinstalling, position the hose clamp in the original location on the hose and squeeze the clamp lightly with large pliers to ensure a good fit.
Page 10: Electrical System
ELECTRICAL SYSTEM ELECTRICAL PARTS Battery cable ·Before disconnecting connector or removing electrical parts, disconnect the negative battery cable. Wiring Harness ·To remove the wiring harness from the clip in the engine room, pry up the hook of the clip using a flathead screwdriver.
Page 11 Locking connector ·when locking connectors, listen for a click indicating they are securely locked. Inspection ·When a tester is used to inspect for continuity or measuring voltage, insert the tester probe from the wiring harness side. ·Inspect the terminals of waterproof connectors from the connector side since they cannot be accessed from the wiring harness side.
Page 12: Connector
Replacement ·Use the appropriate tools to remove a terminal as shown. When installing a terminal, be sure to insert it until it locks securely. ·Insert a thin piece of metal from the terminal side of the connector and with the terminal locking tab pressed down, pull the terminal out from the connector.
Page 13: Electrical Troubleshooting Tool
ELECTRICAL TROUBLESHOOTING TOOLS Jumper wire ·A jumper wire is used to create a temporary circuit. Connect the jumper wire between the terminals of a circuit to bypass a switch. Caution ·Do not connect a jumper wire from the power source line to a body ground. This wiring harnesses or electronic components.
Page 14: Towing
TOWING TOWING ·Proper lifting and towing are necessary to prevent damage to the vehicle. Government and local laws must be followed. ·A towed vehicle should have its front wheels off the ground. If excessive damage or other conditions prevent this, use wheel dollies. ·When towing with the rear wheels on the ground, release the parking brake.
Page 15 FRONT REAR GI-13...
Page 16: Identification Number Location
023437: Production Serial Number 1. LVV is the code of vehicles manufactured by Chery Automobile Co., Ltd. 2. The fourth digit of VIN code stands for the brand of the vehicle. The brand “Chery” is represented by letter “D”. GI-14...
Page 17: Engine Identification Number
2007 2010 9. The eleventh digit of VIN code stands for the assembly factory. The “Chery Automobile Co., Ltd” is represented by the letter “D”. 10. The twelfth to the seventeenth digits of VIN code stand for production serial number.
Page 18: Pre-Delivery Inspection
PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION TABLE Setting and checking of clock Appearance and interior Defects of appearance and interior Shut down engine Paint, galvanized components and interior trim Alarming lamp of “not shut down lamps” Carrying items, tools, spare tire, operation manual for jack and keys Remove anti-vibration cover for tires and body protective film Shut down all the lamps...
Page 19: Schedule Maintenance
SCHEDULE MAINTENANCE SCHEDULE MAINTENANCE TABLE Mileage Km Items 5000 15000 30000 Light, warning flasher, horn: check performance Wiper and washing system: check performance, add washer fluid if necessary Check clutch free pedal travel, adjust it if necessary Cooling system: check antifreeze level, replace if necessary Oil: Replace Oil filter: Replace Engine: check leakages (oil, antifreeze, fuel, A/C system)
Page 20 Mileage Km Items 5000 15000 30000 Engine oil sump bolt: check if loose, tighten if necessary Control arm rubber boot: check if damaged Braking hose: check if aged or damaged Braking pipe: check if damaged, eroded or leaky connection Fuel system connections: check if aged, damaged, abnormal loosening or rubbing Tire (including spare tire): check tires veins depth, adjust tire pressure, check wheel bolt tightening torque.
Page 21 maintenance item. When driving mileage reaches 40,000 km or 6 months after last service, perform 5,000 km maintenance item. When driving mileage reaches 45,000 km or 6 months after last service, perform 15,000 km maintenance item. When driving mileage reaches 50,000 km or 6 months after last service, perform 5,000 km maintenance item.
Page 22 ENGINE LOCATION INDEX … … … … … … … … … … … … … … … … … … …………B-3 MECHANICAL LOCATION INDEX … … … … … … … … … … … … ……B-3 ENGINE TIMING… … … … … … … … … … … … … … … … … …… …… ……B-4 TOP AND BOTTOM TIMING GEAR COVER ASSEMBLY ……...
Page 23 REAR OIL SEAL REPLACEMENT … …… … …… … …… … …… … …… …B-23 CAMSHAFT … … …… … …… … …… … …… … …… … …… … …… … …… B-25 CAMSHAFT GEAR … …… … …… … …… … …… … …… … …… … … …B-25 CAMSHAFT AND CAMSHAFT THRUST SPACER …...
Page 24: Location Index
LOCATION INDEX MECHANICAL LOCATION INDEX TIMING BELT (SEE B-4 ENGINE TIMING) VALVE MECHANISM COMPONENTS (SEE B-9 VALVE CLEARANCE) CYLINDER HEAD GASKET (SEE B-19 CYLINDER HEAD GASKET REPLACEMENT) FRONT OIL SEAL (SEE B-21 FRONT OIL SEAL REPLACEMENT) REAR OIL SEAL (SEE B-23 REAR OIL SEAL REPLACEMENT) CAMSHAFT (SEE B-25 CAMSHAFT) CRANKSHAFT...
Page 25: Engine Timing
ENGINE TIMING TOP AND BOTTOM TIMING GEAR COVER ASSEMBLY Removal Loosen and unscrew two bolts of the top timing gear cover assembly. Remove the top timing gear cover and gasket assembly. Remove the gasket from the top timing gear cover. Remove the crank pulley.
Page 26: Timing Belt Installation And Alignment
Note: After the belt is taken out, do not rotate the gear to a large extent, otherwise the piston head and the valve will be damaged due to collision. To continue using the removed belt, carefully check whether there is abnormal abrasion, stratified cracks (especially those around the root) or fouling on the belt.
Page 27 Hold the middle of the right belt that is away from both the crankshaft gear and camshaft gear with the thumb and the first finger. If the tension of the belt is up to standard, the belt shall be able to twist at 90 at this point. To adjust the tension of the belt, loosen the two fixing bolts of the tension pulley, push the tension pulley to the right with a screwdriver as...
Page 28: Driver Belt, Tension Pulley And Generator
DRIVER BELT, TENSION PULLEY AND GENERATOR Removal Pull the abutment on the tension pulley by tools to the direction of the generator (or align the gauge holes on the front and rear part of the tensioning device and drive a pin to fix the tensioning device).
Page 29 Check whether the TDC indicator on the cam shaft gear lines up with that on the front end of cylinder head. If not, rotate the crank shaft clockwise in one full circle to make them line up with each other. At this time, the engine is in the position of TDC of the first cylinder.
Page 30: Valve Clearance
VALVE CLEARANCE VALVE MECHANISM COMPONENTS Rocker nut (16 pcs) Rocker arm (8 pcs) Tightening torque: 25~29Nm Rocker ram seat (8 pcs) Rocker ram seat washer (8 pcs) Valve keeper (16 pcs) Hydraulic tappet (8 pcs) Clearance: 0.023~0.065 Upper seat of valve spring (8 pcs) Valve spring (8 pcs) Rocker arm stud (8 pcs)
Page 31: Valve Cover And Gasket
VALVE COVER AND GASKET Valve Cover Cupped Removal gasket Remove 9 bolts to take out the cupped gasket and high tension wire support, clutch and throttle cable support. Remove the valve cover and gasket assembly. Take the sheet gasket out. Installation Clean the junction face of the cylinder head and the valve cover.
Page 32: Rocker Mechanism
ROCKER MECHANISM Removal Loosen the rocker nuts to take them out. Take the level bracket out. Take the rocker arm out. Take the gasket of the level bracket out. Place each set of rock arm and level bracket in one same plastic bag for distinction.
Page 33: Hydraulic Tappet
HYDRAULIC TAPPET Removal Take the hydraulic tappets out and place them into an oil-filled vessel to prevent the hydraulic tappet oil from leaking out. Check the top and bottom contact surfaces of the hydraulic tappet to observe whether there are abnormal abrasion or scrapes. If yes, replace it with new one if necessary.
Page 34: Valve, Valve Spring And Oil Seal Assembly Of The Valve
VALVE, VALVE SPRING AND OIL SEAL ASSEMBLY OF THE VALVE Removal Compress the valve spring with a special compression device and take the valve cotter out. Do not over compress the spring, which shall be compressed to the travel stroke that the valve cotter can slide from the groove, otherwise the valve stem may bend.
Page 35 Valve stem size and fit clearance Intake mm Exhaust mm Inner Diameter Class Diameter of Inner Diameter Diameter of Clearance of valve Clearance valve stem of valve guide valve guide stem 8.043 8.017 Standard 8.063—8.094 8.063—8.094 − − 0.02— 0.046— 0.069 0.095 Oversized...
Page 36 Grinding valve and valve seat ring UAES’s new two-valve Face angle of intake valve 44º30 ---45º30 Width of the sealing band for the intake valve seat 1.75---2.32mm ring Face angle of exhaust 91º (0º-0º30 ) valve Width of the sealing band for the exhaust valve seat 1.44 0.1 ring...
Page 37 Size of intake valve seat ring and cylinder head eat ring bore Diameter of Diameter of Interfer intake the seat ring ence Class valve seat bore of ring (unit: cylinder (mm) head (mm) 43.877 43.763 Standard − 0.079 Oversized — 44.377 44.263 −...
Page 38: Compression Pressure
COMPRESSION PRESSURE COMPRESSION INSPECTION Warning ·Hot engines and oil can cause severe burns. Be careful not to burn yourself during removal/installation of each component. 1. Verify that the battery is fully charged. ·Recharge it if necessary. 2. Warm up the engine to the normal operating temperature. 3.
Page 39 Cylinder Pressure Standard Value 1.00-1.35 Mpa (10-13.5 kgf/cm2) 11. Disconnect the compression gauge. 12. Install the spark plugs. 13. Connect the ignition coil connector. 14. Install the fuel pump relay. B-18...
Page 40: Cylinder Head Gasket
CYLINDER HEAD GASKET CYLINDER HEAD GASKET REPLACEMENT Removal Rotate the cam shaft clockwise until the key slot goes downwards vertically. Loosen the bolts on the cylinder head in the order illustrated in the figure. Note: The bolts removed from the cylinder head must be changed and cannot be reused.
Page 41 Put the cylinder gasket into the dowel. Note: The side with indicator of the cylinder gasket shall be upward. Install the cylinder head in place with the key slot of the cam shaft downward vertically. Note: The cylinder gasket can only be used for A.
Page 42: Front Oil Seal
FRONT OIL SEAL CRANKSHAFT PULLEY Removal Removal 3 fixing bolts on the starter to take it out. Fasten the flywheel ring gear with a proper screwdriver or rod to disenable the crank shaft to rotate. Loosen the fixing bolts of the crank pulley and take out the bolts and washer to pull out the pulley (use a gear puller, if necessary).
Page 43: Crankshaft Gear
CRANKSHAFT GEAR Removal Fix the crankshaft to disenable it to rotate and remove the pulley. Pull the crankshaft gear out by a wheel puller or two large-size screw drivers and remove the whiney key. Installation Check whether there are abrasion, pit corrosion or scrapes on the gear.
Page 44: Rear Oil Seal
REAR OIL SEAL FLY WHEEL REMOVAL AND INSTALLATION Removal Remove 9 fixing bolts. New bolts shall be used for installation. Remove the fly wheel to check whether there are cracks on the friction surface of the clutch plate and there is abrasion and pit corrosion on the teeth of the ring gear, etc.
Page 45 Pries the rear oil seal out of the rear oil seal support with a chisel or a screwdriver. Note: do not damage the rear oil seal support. Installation Put the support on the vice clamp whose jaw has a piece of wood. Make the side with the part numbers of the rear oil seal outward and align the rear oil seal with the rear oil seal support bore.
Page 46: Camshaft
CAMSHAFT CAMSHAFT GEAR Removal Rotate the crankshaft to the compression TDC position of the first cylinder. Remove the belt. Put one pole into one hole of the cam shaft gear to lock it. Loosen the gear bolts and remove them and the gasket.
Page 47 Draw the cam shaft assembly out from the rear end of the cylinder head and be careful not to damage the cam shaft hole of the cylinder head during this process. Inspection Check whether there is any abrasion on the cam and the journal of the cam shaft.
Page 48: Size Of Camshaft Journal And Hole Of The Cylinder Head
SIZE OF CAMSHAFT JOURNAL AND HOLE OF THE CYLINDER HEAD Installation To replace the cam shaft, observe the shape of the rear end of the cam shaft for right selection. Before installation, apply the cam of the cam shaft with hyperbolic gear oil or motor oil. The cam shaft shall be assembled from the cylinder head in a back-to-front order.
Page 49: Crankshaft
CRANKSHAFT CRANKSHAFT, CRANKSHAFT THRUST SPACER, BEARING SHELL AND MAIN BEARING CAP Removal Check the axial clearance of the crank shaft before removal. Kiss the end side of the crank shaft with the contacts of a dial gauge (less degree of shrinkage). Push the crank shaft away from the contacts and adjust the dial gauge to 0, then push the crank shaft to the direction of contacts as possible with a0 stout...
Page 50 Install the main bearing cap. Tighten the bolts of the main bearing cap at the moment of 90-100N.m by hands. Do not rotate the crank shaft. Remove the main bearing bolts. Carefully take out the main bearing cap and arrange them in order. Read the bearing clearance according to the ratio on the envelope of the plastic clearance gauge.
Page 51 Diameter of main journal and size of main bearing shell Diameter of the main bearing Thickness of the main Diameter of main Class bore of the cylinder block bearing shell journal (unit: mm) (unit: mm) (unit: mm) Standard 57.98—58.00 62.2935+0.0065 2.131—2.138 Oversized by 0.4 57.98—58.00...
Page 52 Installation Before installation, tap the threaded hole on cylinder block with tapping drill, especially those of the cylinder head bolts and main bearing bolts. Cylinder head bolt: M10X1.5~6H Main bearing bolt: M12X1.75~6H Installation of the whiney key of the crank shaft: gently drive the whiney key into the key slot.
Page 53 shall be installed on the left threaded hole of the fourth main bearing cap (seeing from the front). Apply some motor oil on the head joint before installing the main bearing cap bolts. Tighten the main bearing cap bolts and stud by hands, then tighten them to the moment of 90~100Nm.
Page 54: Piston And Connecting Rod Assembly
PISTON AND CONNECTING ROD ASSEMBLY PISTON REMOVAL, MEASURE AND INSTALLATION Removal Rotate the crank shaft to the bottom dead center (BDC) of the removed cylinder, check whether there is a cylinder number on the connecting rod body and cap, which shall be on the left of the rod (seeing from the front).
Page 55 Rinsing and inspection Rinse and clean the carbon deposit on the piston, piston ring and pin. Rinse and clean the carbon deposit on the bottom of the cylinder bore. Measure the diameter of the cylinder bore. 480 M cylinder bore (unit: mm) 480 E cylinder bore (unit: mm) 79.94-79.95 79.94-79.95...
Page 56 Diameter of UAES’s Diameter of 480M piston skirt Diameter of 480E new two-valve piston (unit: mm) piston skirt (unit: mm) skirt (unit: mm) 79.91-79.92 79.915-79.925 79.915-79.925 Ex-factory 79.92-79.93 79.925-79.935 79.925-79.935 grouping 79.93-79.94 79.935-79.94 79.935-79.94 79.94-79.95 79.945-79.955 79.945-79.955 80.20-80.21 80.205-80.215 80.205-80.215 Ex-factory 80.21-80.22 80.215-80.225...
Page 57 Measure the axial clearance of piston ring in the piston groove Height of the piston Size of piston ring Fit clearance ring (unit: mm) groove (unit: mm) (unit: mm) +0.06 1.60 First compression ring 0.050-0.082 +0.04 -0 012 Second compression +0.06 0.050-0.082 -0.012...
Page 58 Installation Piston weights and spare piston skirts are not grouped, but the piston pin holes shall be grouped. Before assembly, check the piston crown marks. The marks of the four cylinders must be same. Heat the small end of the connecting rod to Forward 230~400 , apply SAE50 lube or glue type of pointing bump...
Page 59: Installation Of The Piston And Connecting Rod Assembly
Size of piston ring 480# piston ring Paint mark (type) Paint mark (type) No paint (Standard) No paint (Standard) Purple paint (oversized by 0.29) Purple paint (oversized by 0.29) Blue paint (oversized by 0.5) Blue paint (oversized by 0.5) INSTALLATION OF THE PISTON AND CONNECTING ROD ASSEMBLY Apply some motor oil in the piston, piston ring and cylinder, with the first and second...
Page 60 LUBRICATION SYSTEM DESCRIPTION OF LUBRICATION SYSTEM …… … …… ……… … …… ………D-2 OIL PAN …… … …… ……… … …… ……… … …… ……… … …… ……… … …D-3 DISASSEMBLY/ASSEMBLY …… ……… … ………… ……… … ………… …D-3 OIL FILLING …… ……… … …………………………… … ………… ……… … …D-5 OIL STRAINER ASSEMBLY ……...
Page 61: Description Of Lubrication System
ENGINE LUBRICATION SYSTEM DESCRIPTION OF LUBRICATION SYSTEM The rotor oil pump (1) at the front end of the crankshaft sucks oil out of the oil pan (3) by oil strainer (2) and pressurizes oil, and then the pressurized oil will enter the full-flow oil filter through the auxiliary oil passage (4) at the left side of the cylinder(view from the front).
Page 62: Oil Pan
Hydraulic jib gets oil through the oil passage through which the oil tank at the camshaft supplies oil to the cylinder cap. The interface between valve rocker and hydraulic jib is lubricated by oil through the oil hole in hydraulic jib. Rocker seat is lubricated by oil through cylinder cap oil passage.
Page 63 Assembly: To spread Letai 598 seal glue or GY409 anaerobic glue on the connecting areas between cylinder oil pan flange and oil pump body and rear oil seal support. A From crankcase to oil pump body r F om crankcase to rear oil seal support To put the new rubber gasket on the cylinder body, placing both ends of the gasket into the rear oil seal support and oil pump rut.
Page 64: Oil Filling
OIL FILLING To fill the engine with 3.1 0.15L of oil (SAE10W/30SF grade, or SAE5W/30SJ grade at temperature lower than -18 ) The oil surface shall be between “max” and “min” on the dipstick. OIL STRAINER ASSEMBLY Disassembly: To unscrew the locknut of the oil strainer support and take out the nut and gasket.
Page 65: Oil Pump And Front Oil Seal
OIL PUMP AND FRONT OIL SEAL Disassembly: To unscrew and take out six M6X30 hexagon flange bolts. To take out oil pump and front oil seal assembly. To use a screwdriver or chisel to take out the crankshaft front oil seal and pay attention not to touch or damage the front oil seal.
Page 66 To take out the internal and external rotors. To check out the clearance between the pump external rotor and pump body. The oil pump external rotor shall have a clearance of 0.06-0.19mm with oil pump body. To check out the radial clearance between oil pump internal rotor and external rotor.
Page 67 To check out the rotor end clearance. The rotor end clearance shall be 0.014-0.100mm. To unscrew and take out the horizontal internal hexagon bolts (small ones). To take out relive vale spring and relief valve ball. To check out the spring load and free length. The free length is 46mm;...
Page 68 Assembly: To place external and internal rotors into the oil pump body, making sure the installation marks on the external and internal rotors are upward. To place the oil pump cover plate onto the oil pump, screw up the 7 bolts to 7-10N.m. To install the relief valve and relief spring into the oil pump hole.
Page 69: Oil Filter And Oil Pressure Sensor
To remove the thing plastic strip. OIL FILTER AND OIL PRESSURE SENSOR Disassembly: To demount the oil filter by rotating the filter counterclockwise. To remove the oil pressure sensor. Assembly: To spread engine lubrication oil onto the oil filter gasket and screw it up to the fitting to 12-17N.m., 8.0-25.0N.M Fastening Torque Of 8.0-25.0N.M or screw the oil filter manually and screw more 3/4-1 round when the rudder gasket reaches the...
Page 70: Oil Pressure Testing Parameter List
OIL PRESSURE TESTING PARAMETER LIST Serial Pressure Kpa Index Subject Judgment r/min (Kgf/cm Achievement Oil yield Oil Yield Starting Time s starting Oil output L/min 196 2 >6 Oil output L/min 3000 294 3 >28 440 20 Opening Pressure of Oil yield Pressure Limit Valve: Kpa 2000...
Page 71: Cooling System
COOLING SYSTEM DESCRIPTION OF COOLING SYSTEM … … …… …… … …… …… … …… …E-2 COMPONENTS OF 480 ENGINE COOLING SYSTEM … … ……………………E-2 WORKING PRINCIPLE OF COOLING SYSTEM … … …… …… … …………E-2 PARAMETERS OF COOLING SYSTEM … … …… …… … …… …… … …… E-3 ENGINE COOLANT …...
Page 72: Description Of Cooling System
COOLING SYSTEM DESCRIPTION OF COOLING SYSTEM COMPONENTS OF 480 ENGINE COOLING SYSTEM Engine cooling system is used to cool engine to prevent the engine from overheating, ensuring the Expansion Tank Warm Air/Heat Exchanger Pressure Cap normal operation of engine. It is composed of the Hose Hose Hose...
Page 73: Parameters Of Cooling System
PARAMETER OF COOLING SYSTEM Cooling system Parameter Total system capacity L Engine capacity L Coolant capacity Radiator capacity L Expansion reservoir capacity L Diameter: 280mm Number of blades: 6 Operating voltage: 9-15V Rotating speed Ι gear: high-speed engine 2000±200 low-speed engine 1800±200 Rotating speed II gear: high-speed engine 2800±200 low-speed engine 2600±200 Diameter of impeller: ф72mm...
Page 74: Coolant Filling
preheat up to normal operating temperature, shut down and cool down; ――To discharge coolant; ――To repeat the above-mentioned steps until the discharged water is the same as the clean water; ――To clean the cooling system according to the following methods if the coolant is not correctly used and replaced to meet the requirements in the former utilization: a.
Page 75: Cooling System Checkup
the expansion reservoir descends quickly, coolant should be injected up to the highest position to cut down the air circulation in the system. ――To shut the engine down to have it fully cooled if possible, leave the engine alone for one night. ; ――To open the pressure cap to check the coolant level, and inject coolant up to the highest position.
Page 76: Water Pump
WATER PUMP Structure: 1 Water pump housing 2 Water pump impeller 3 Water pump gear 4 Water pump shaft bearing 5 Water pump seal (ceramics-lead) Disassembly: ——To disconnect the negative terminal of battery; ——To discharge engine coolant (refer to the coolant discharge process);...
Page 77: Thermostat
THERMOSTAT Disassembly: ——To unscrew 3 M6×40 bolts and then demount the bolts; ——To demount thermostat chassis and thermostat assembly. ——To pry out the spring clamps by using chisel or screwdriver. ——To take the thermostat out; ——To clean up the thermostat;...
Page 78 ——To take the seal ring out, and replace it if it being worn and torn. ——To demount the gasket from the thermostat chassis. To replace with new gasket if it is worn and torn, and allow no repeated use. ——To measure the thermostat opening temperature under hot water.
Page 79: Water Temperature Sensor
WATER TEMPERATURE SENSOR Disassembly: ——To demount water temperature sensor (at the exhaust pipe flank and under the lifting eye). Assembly: ——To apply Letai 243 glue on the screw thread, screw up the bolt to 7.0—10.0Nm before installation. Checking: Water temperature sensor is a negative temperature coefficient sensor, which is composed of a thermal resistor.
Page 80: Guideline For Disassembly
——To demount the matching plug of the cooling fan. ——To remove the fastening self-tapping screw from the cooling fan. ——To take the cooling fan out. Assembly: ——To assemble the cooling fan according to the disassembly order (the tightening torque of self-tapping screw is 1.8~2.2Nm) ——To start up the engine and check if the cooling fan is under normal operation.
Page 81: Expansion Reservoir
EXPANSION RESERVOIR Disassembly: ——To demount the water pipe connecting with the expansion reservoir. ——To pry out the protecting hood of expansion reservoir by using a screw drive. ——To demount the fastening bolts of the expansion reservoir by using M10 sleeve. ——To pull out the plug of liquid level sensor.
Page 82: Assembly Of Radiator
Assembly: ——To assemble the expansion reservoir according to the order opposite to the disassembly order the tightening torque self-tapping screw 4.0~5.0Nm . ——To refill coolant. ASSEMBLY OF RADIATOR Disassembly: ——To discharge coolant (refer to the coolant discharge process) ——To demount the cooling fan (refer to the disassembly process of the cooling fan).
Page 83 ——To take out the radiator Assembly: ——To assemble the radiator according to the order opposite of the disassembly order. ——To install the 2 wind boards onto the radiator by using self-tapping screws with their tightening torque of 6 7Nm. ——To install the radiator onto the front transom and put it straightly towards the positioning hole.
Page 84 FUEL AND EMISSION CONTROL SYSTEMS … … … … … … … … … … … … … … … … … … … … … INTAKE-AIR SYSTEM INTEGRAL INTAKE MANIFOLDS … … … … … … … … … … … … … … … … THROTTLE BODY …...
Page 85: Intake-Air System
INTAKE-AIR SYSTEM INTEGRAL INTAKE MANIFOLDS Warning ·When the engine and intake-air system are hot, they can badly burn. Turn off the engine and wait until they are cool before removing the intake-air system. ·Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
Page 86: Idle Speed Step Motor
To avoid the mixture condensing and freezing in certain condition, throttle valve adjuster is supported by anti-deadlock screw to prevent it from completely closing, and heated by circulating coolant. Idling speed step motor (4) and throttle position sensor (5) are installed on throttle body.
Page 87 1.Idling Speed Step Motor 2. By-pass Hose 3. Lock Pin 4. Throttle Valve 5. Throttle Body 6. ECU Electrical Control Unit 7.Steel Lock Ring Qo. Air Leakage Volume Of Throttle By-pass Air Volume Of Step Motor Specification: The coil resistance is R=53 ± 10Ω at 20 . A max air intake volume will be got when the lock pin turns back 200 steps (approx 8mm stroke, correspond to about 60kg/h air intake volume).
Page 88: Throttle Position Sensor
THROTTLE POSITION SENSOR The sensor, including a potentiometer, the movable part of which is controlled by the throttle axis. ECU supplies a voltage approx. 5V to the potentiometer when working. From idling to throttle full open, oil injection process is administrated by parameters gained from throttle valve opening angle.
Page 89: Integral Air Pressure/Temperature Sensor
INTEGRAL AIR PRESSURE/TEMPERATURE SENSOR Pressure signals are obtained from the voltage of one among four resistors in Wheatstone bridge marked on a special diaphragm. This diaphragm is compressed and stretched under the absolute pressure from inside of the manifolds (thus the above resistor is under pressure too).
Page 90: Aseembly And Disassembly Of Intake System
ASEEMBLY AND DISASSEMBLY OF INTAKE SYSTEM Remove accessories around the engine: 1.Loosen fastening clamp, demount air cleaner and air intake hose. 2.Remove throttle cable and clutch cable. 3.Remove all intake pipes and vacuum hoses around engine. 4.Put down water hose to discharge anti-freeze liquid.
Page 91: Oil-Vapor Separator
OIL-VAPOR SEPARATOR 1.Oil-vapor separator 2. Air cleaner 3.Others---ventilating pipe in crankcase Working principle: Main function of the oil-vapor separator is leading gas in crankcase to intake manifolds through oil-vapor separator, which keeps pressure in crankcase within a certain range and prevent gas in crankcase from mixing and flowing out.
Page 92: Exhaust System
EXHAUST SYSTEM OUTLINE Exhaust system inspection ·Start the engine and inspect each exhaust system component for exhaust gas leakage. ·If leakage is found, repair or replace as necessary. Exhaust system removal/installation Warning ·When the engine and exhaust system are hot, they can badly burn. Turn off the engine and wait until they are cool before removing the exhaust system.
Page 93 the mixture concentration value in time and change mixture thicker or thinner to make it always be close to chemical reaction equivalence ratio. The voltage range of which is 0.980~1.020V. To reach working temperature rapidly (~300°C), a resistor (4) installed in the sensor can shorten the starting electric time of the porcelain.
Page 94: Assembly And Disassembly Of Exhaust System
Exhaust gas emission HC (p.p.m.) CO2 (%) Before catalytic converter 0.4 - 1 < 600 > 12 After catalytic converter < 0.35 < 90 > 13 See the above table, using three-way catalyst converter can reduce three types of harmful gases in exhaust gas at the same time: HC, CO, NO , while harmless CO increases.
Page 95 Install Oxygen sensor assembly on front hose assembly with a tightening torque of —— 45±4.5Nm. Install 3 M10 double head studs on exhaust manifolds. —— Lay exhaust hose pad, install front hose assembly on exhaust manifolds. —— Mount 3 M10 copper nuts with a tightening torque of 60±3Nm. ——...
Page 96 Note: ·Eccentricity between front silencer and the intake/exhaust hose is 18mm. Adjust front silencer position in assembly to guarantee a gap between the front silencer and the channel heat insulator more than 10mm. ·In assembly, hose clamp should not be aslant installed around the exhaust hose. ·Distance between the expanding section on exhaust hose and the section of hose clamp should be 1 4mm in assembly.
Page 97: Fuel System
FUEL SYSTEM ASSEMBLY AND DISASSEMBLY OF FUEL SYSTEM Before repair procedure Warning · Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. ·Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage.
Page 98 Caution ·Connecting the wrong check connector terminal may possibly cause malfunction. Carefully connect the specified terminal only. 1 Short the check connector terminal F/P body GND using a jumper wire. 2 Turn the ignition switch to ON position to operate the fuel pump. 3 Pressurize the system in this way for at least 5minites to be sure of no leakage.
Page 99 Installation of fuel case assembly: Install fuel tank assembly. Install 2 tapping screws (M6) on fuel tank mouth. Set up 3 fuel tank fixed belts and 5 M8 bolts. Tighten 5 M8 bolts (tightening torque is ) and 2 tapping screws (tightening torque Install fuel mouth cap and steel wire stopper.
Page 100 Installation of fuel filter: Set up fuel filter assembly in fuel filter protection box assembly. Connect import and export tube in both end of fuel filter, clamp tube lock hoop by special tool. Using two M8 lock nuts to install protection box assembly under vehicle ground board.
Page 101 counter-clockwise, slowly bring forward fuel pump assembly. Pull out fuel level sensor with little upwards strength. Installation of accelerator cable: Install rubber jacket on vehicle front boarding. Thread accelerator cable through rubber jacket, then push it to right position. Install hook of accelerator cable in gluey block of accelerator pedal.
Page 102: Operation Control Of Engine Fuel Supply System
OPERATION CONTROL OF ENGINE FUEL SUPPLY SYSTEM 1. Start engine: In start process, ECU firstly inject to all cylinder at the same time to shorten start time. After that, ECU will inject according to phase order. 2. Acceleration: In acceleration process, ECU will add injection fuel by engine requirement and deal with sensor signal below: throttle position, absolute pressure, upper dead center/ speed sensor, multiply “basic”...
Page 103 5. Full load: In full load status (distinguished from throttle potentiometer and absolute pressure sensor), ECU obtains maximal output power by increase basic fuel injection time, while temperature of catalysis converter is kept in prescriptive range. 6. Air pressure modification: Air pressure will change with different altitude, which will cause change to volumetric efficiency.
Page 104: Fuel System Working Components
10. Electric power balance: Normal working of electric components (front light, heat back window, etc.) will make battery voltage lower than 12.2V, electric components power demanded in that time is larger than electric power from generator. That is to say, negative “electric power balance” may cause damage to battery.
Page 105 Working pressure: 350kpa Working temperature: 6 Turn the ignition switch to LOCK position and disconnect the jumper wire. 7 Complete the After repair procedure . Atomization 1 Inspect atomization pattern. ·If the atomization is faulty, replace the fuel injector. Half no scavenge fuel supply integrated module Fuel supply module is in fuel tank, which includes: - Fuel pump;...
Page 106 Fuel pump Fuel pump inspection Note ·When ignition switch is at ON position, it is normal to hear the sound of fuel pump running. Fuel pump is located in fuel tank, and there is netlike filter in the fuel pump entrance. Internal gear positive displacement fuel pump should use unleaded gasoline.
Page 107 Fuel Pump Hold Pressure Inspection Warning · Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped. Caution ·Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector.
Page 108 1.Fuel Rail 2.Fuel Injector 3.Fuel Feeding Port Fuel injector This system adopts head supplying single hole Fuel injector, and fuel injection pressure is 3.5bar. Fuel injected from fuel injector keeps in atomization and comes into cone angle (15 degree to injection nozzle axis). Control logic of Fuel injector is “phase, order”...
Page 109 Specification: Voltage: 12V Resistance: 13.8 ~ 15.2 ± 10% on 23°C Remark: Force on fuel injector socket in assembly and disassembly must be less than 120N, or it will influence function. Caution ·use of a deformed injector retaining clip will cause the injector to not engage correctly.
Page 110 ENGINE ELECTRONIC SYSTEM INPUT / OUTPUT COMPONENTS OF CONTROL SYSTEM … …… … … … …G-2 WORKING MODULE TABLE OF FUEL INJECTION / IGNITION SYSTEM …G-3 WORKING PRINCIPLE … …… … … … …… …… … … … …… …… … …G-4 ELECTRICAL CONTROL UNIT ……...
Page 111: Input / Output Components Of Control System
INPUT / OUTPUT COMPONENTS OF CONTROL SYSTEM Diagnostic connector Engine ECU 11 Fuel injector Air pressure / temperature sensor 12 Oxygen sensor (heater) Engine speed sensor for top dead center 13 Fuel pump Throttle valve position sensor 14 Carbon canister solenoid valve Knock sensor 15 Two step speed fan controller Coolant temperature sensor...
Page 112: Working Module Table Of Fuel Injection / Ignition System
WORKING MODULE TABLE FOR FUEL INJECTION / IGNITION SYSTEM Power supply relay Power supply (Power supply +12V) Fuel pump Power supply (15/54) A/C relay Idling speed step motor Malfunction Fuel injector indicator Ignition coil Carbon canister solenoid valve Coolant temperature sensor Throttle valve Line K position sensor...
Page 113: Working Principle
WORKING PRINCIPLE This system is capable of controlling the actual tested air-fuel ratio under all engine speeds to stay close to the equivalent proportion of the chemical reaction, so as to protect the catalyst package and subsequently reduce the discharge of pollution. The oxygen sensor analyses the oxygen content of the discharge gas using real-time principle and makes it possible for the ECU to control the amount of injecting fuel to correct the air-fuel ratio.
Page 114: Electronic Control Unit
ELECTRONIC CONTROL UNIT The ECU is located on the left of engine firewall. The ECU handles various signals from the sensors and controls the actuator so as to achieve the best possible operating condition. Many extra functions are added as compared with the previous model. While by the usage of a custom-made circuit board that can achieve many special functions, the integrated functions are enhanced so that the structure has considerably reduced in size and become much more compact.
Page 115 - Engine coolant temperature - Air conditioning operation - Signal from oxygen sensor - Knock sensor for the accelerator meter on top of the engine crankshaft housing The air intake efficiency is obtained by calculating through the processing of absolute pressure, air intake temperature, engine speed, throttle valve position and other signals, and help to determine the air intake quantity of the cylinder.
Page 116: Working Principle Of Electronic Fuel Injection Control And
WORKING PRINCIPLE OF ELECTRONIC FUEL INJECTION CONTROL AND ACTUATORS Intake Pressure and Intake Air Temperature Sensor Purpose: detects manifold absolute pressure from 0.1~0.2bar and intake air temperature, provides engine with load information. Composition and principle: this sensor is composed of two different sensors (i.e. manifold absolute pressure sensor and intake temperature sensor), and is installed above pressurizer.
Page 117 Troubleshooting: mainly check if there is short circuit or open circuit on the connection between 4 lines on sensor and ECU. If there is short circuit, open circuit or grounding between sensor wire harnesses. Sectional view of intake pressure and intake air temperature sensor 1 Seal ring 5 Casing...
Page 118 Pins: 1 sensor signal ground (ECU17#) 2 5V power (ECU32#) 3 sensor signal (ECU16#) Troubleshooting: mainly check if there is short circuit or open circuit on the connection between 3 lines on sensor and ECU. Check to see if there is short circuit, open circuit or grounding between sensor wire harnesses.
Page 119 Hints: the vehicle is equipped with 2 water temperature sensors, single-pin water temperature sensor, providing the water temperature gauge with water temperature signal; the other is double-pin, providing the engine ECU with water temperature signal. Pins: this sensor has 3 pins, which can interchange for use.
Page 120 value, failure mark restores. Installation hint: tightening torque is 20±5Nm. Pins: 1 Knock sensor signal 1 (ECU19#) 2 Knock sensor signal 2 (ECU20#) Troubleshooting: mainly check if there is short circuit or open circuit on the connection between 2 lines on sensor and corresponding ECU pins.
Page 121   M anifold absolute pressure signal is unreliable   E ngine coolant temperature signal is unreliable.   I njector driver stage failure After oxygen sensor failure mark is set, fuel quantification closed-loop control is shut down, and the primitive fuel injection time stored in ECU is used to carry out fuel quantification.
Page 122 Installation: to be fixed by the support of bracket under pilot trench of front windshield. Pay attention to waterproofing. Functions: Multipoint sequential injection Controlling ignition Idle speed control Independent knocking control on cylinder-by-cylinder basis (knock sensor KS-1); Providing sensors with power supply: 5V/100mA Adopting cylinder-detecting signal (Phase sensor PG1) closed-loop control with self-adaptation Controlling carbon canister control valve...
Page 123 Fuel injector 4 (the 2 Fuel injector 3 (the 4 Output Output cylinder) cylinder) Fuel injector 2 (the 3 Output cylinder) Output of engine speed Output signal Control of low speed fan Output Electronic ground 2 Ground Sustained power supply Input Electronic ground 1 Ground...
Page 124 Electrical fuel pump Function: Supply the fuel from the fuel tank to the engine at required pressure and flow (vary from individual system). Structure and working principle: The electrical fuel pump is comprised of direct current motor, vane pump and end cover (integrated with non-return valve, release valve and anti-electromagnetic interference elements).
Page 125 Troubleshooting: The common malfunctions of the fuel pump are representation of insufficient fuel pressure, not pumping fuel and so on. It shall be verified firstly in troubleshooting that the fuel pressure is within rated range and the pipeline is leaked. In addition both the positive and negative pressure of the fuel tank will have impacts on the fuel system.
Page 126 supply, short to ground or open, the malfunction flag bit is set. The closed loop control of the oxygen sensor and its memory precontrol are disabled, but the last data stored in its memory is valid. After the malfunction is fixed, the malfunction flag bit will be reset.
Page 127 Structure and working principle: The step motor is a micro-motor, which is comprised of steel stators installed in a circle and a rotor. Each steel stator has a coil. The rotor is permanent magnet and the center of the magnet is a nut. All the coils of stators are always on.
Page 128 coil resistance. The ignition coil produces quite a lot heat under normal operation and the over temperature of ignition coil will result in such malfunctions as Ignition coil with double spark increase of the ignition coil’s resistance, unstable operation of the engine and engine stall. Primary winding: 0.47 ohms Secondary winding: 8 ohms Pins:...
Page 129 The ECU can indirectly control the purge airflow Carbon canister control valve through controlling the charging time of the carbon canister solenoid valve based on the signals provided by various sensors of the engine. Fault diagnosis: The ECU doesn’t have the function of self-diagnosis for the carbon canister control valve, but has the function of self-diagnosis for the driving stage of control valve of carbon canister.
Page 130: Injection System
BASIC PRINCIPLE OF FAULT DIAGNOSIS FOR ELECTRONIC FUEL INJECTION SYSTEM ·RECORD OF MALFUNCTION INFORMATION The electronic control unit consistently monitors the operations of sensors, actuators, related circuits, malfunction alarm lights, voltage of battery and so on, even the operation of the electronic control unit itself, as well as carries out the examination on reliabilities of the signals output by the sensors, driving signals of actuators, and internal signals (such as oxygen closed loop control, knock control, idle speed control, battery voltage control and etc.).
Page 131 Illogical malfunction, there is signal but the signal is not logical. ·LIMP DRIVE If some detected important malfunctions last longer than the setting stabilizing time, ECU will take proper software measures, for example, disable some control functions including the oxygen sensor closed loop control and the like, replace some unreliable data with the setting values and etc..
Page 132 The detailed procedures are: Turn on the ignition switch, but not start up the engine, ground the 7# pin of ECU by K wire for more than 2.5 seconds, then open the ground connection, after that the coding light starts flashing. After the K wire is grounded for more than 2.5 seconds the output of flashing code is the value of P-CODE.
Page 133 DETAILED TABLE OF DIAGNOSTIC TROUBLE CODES Diagnostic trouble code: P0107 “Undervoltage in circuit of air intake pressure sensor” Item Inspection Follow-up Operation procedure results procedure Connect the diagnostic tester and adaptor, Proceed to next and turn the ignition switch to “ON” step.
Page 134 Diagnostic trouble code: P0118“Over temperature indicated by engine coolant temperature sensor” Item Inspection Operation procedure Follow-up procedure results Connect the diagnostic tester and adaptor, and turn the ignition switch to Proceed to next step. “ON” position. Observe the “coolant temperature” in Proceed to Step 6 data flow to verify that it matches to the engine temperature (the exact value is...
Page 135 Diagnostic trouble code: P0122 “Undervoltage in circuit for throttle position sensor” Item Inspection Follow-up Operation procedure results procedure Connect the diagnostic tester and adaptor, Proceed to next and turn the ignition switch to “ON” step. position. Observe the item of “throttle absolute Proceed to next opening”...
Page 136 Diagnostic trouble code: P0123 “Overvoltage in circuit for throttle position sensor” Item Inspection Follow-up Operation procedure results procedure Connect the diagnostic tester and adaptor, Proceed to next and turn the ignition switch to “ON” step. position. Observe the item of “throttle absolute Proceed to next opening”...
Page 137 Diagnostic trouble code: P0130 “Malfunction in signal circuit of upstream oxygen sensor” (Note: The following diagnostic procedures are applicable only under the circumstances that the trouble code of P0135 does not appear simultaneously, in case that such trouble code appears at the same time, overhaul shall be carried out based on the following procedures after dealing with the malfunction of P0135 firstly.) Item Inspection...
Page 138 Diagnostic trouble code: P0132 “Overvoltage of circuit for upstream oxygen sensor” (Note: the following diagnostic procedures are applicable only under the circumstances that the trouble code of P0135 does not appear simultaneously, in case that such trouble code appears at the same time overhaul shall be carried out based on the following procedures after dealing with the malfunction of P0135 firstly.) Item Inspection...
Page 139 Diagnostic trouble code: P0134 “Signal malfunction of upstream oxygen sensor” (Note: The following diagnostic procedures are applicable only under the circumstances that the trouble code of P0135 does not appear simultaneously, in case that such trouble code appears at the same time, overhaul shall be carried out based on the following procedures after dealing with the malfunction of P0135 firstly.) Item Inspection...
Page 140 Diagnostic trouble code: P0135 “Malfunction in heating circuit of upstream oxygen sensor” Item Inspection Follow-up Operation procedure results procedure Connect the diagnostic tester and adaptor, Proceed to next and turn the ignition switch to “ON” step. position. Disconnect the connector of the oxygen Proceed to next sensor on the wiring harness and inspect step.
Page 141 Diagnostic trouble code: P0171 “Self adapting of closed loop control for air fuel ratio exceeding the upper limit” (Note: the following diagnostic procedures are applicable only under the circumstances that the trouble codes of intake air pressure sensor, carbon canister control valve, oxygen sensor and so on do not appear simultaneously, in case that such trouble codes appear at same time, overhaul shall be carried out based on the following procedures after dealing with other malfunctions firstly.)
Page 142 Diagnostic trouble code: P0172 “Self adapting of closed loop control for air fuel ratio exceeding the lower limit” (Note: The following diagnostic procedures are applicable only under the circumstances that the trouble codes of intake air pressure sensor, carbon canister control valve, oxygen sensor and so on do not appear simultaneously, in case that such trouble codes appear at same time, overhaul shall be carried out based on the following procedures after dealing with other malfunctions firstly.)
Page 143 Diagnostic trouble code: P0201 “Circuit malfunction of the 1 cylinder fuel injector” Item Inspection Operation procedure Follow-up procedure results Connect the diagnostic tester and adaptor, and turn the ignition switch to “ON” Proceed to next step. position. Disconnect the connector of the 1 Proceed to Step 4 cylinder fuel injector on the wiring harness, and inspect with multimeter to...
Page 144 Diagnostic trouble code: P0202 “Circuit malfunction of the double cylinder fuel injector” Item Inspection Follow-up Operation procedure results procedure Connect the diagnostic tester and adaptor, Proceed to next and turn the ignition switch to “ON” step. position. Disconnect the connector of the double Proceed to Step 4 cylinder fuel injector on the wiring harness, and inspect with multimeter to...
Page 145 Diagnostic trouble code: P0203 “Circuit malfunction of the triple cylinder fuel injector” Item Inspection Follow-up Operation procedure results procedure Connect the diagnostic tester and adaptor, Proceed to next and turn the ignition switch to “ON” step. position. Disconnect the connector of the triple Proceed to Step 4 cylinder fuel injector on the wiring harness, and inspect with multimeter to...
Page 146 Diagnostic trouble code: P0204 “Circuit malfunction of the 4 cylinder fuel injector” Item Inspection Follow-up Operation procedure results procedure Connect the diagnostic tester and adaptor, Proceed to next and turn the ignition switch to “ON” step. position. Disconnect the connector of the 4 Proceed to Step 4 cylinder fuel injector on the wiring harness, and inspect with multimeter to...
Page 147 Diagnostic trouble code: P0230 “Malfunction in control circuit of fuel pump” Item Inspection Follow-up Operation procedure results procedure Connect the diagnostic tester and adaptor, Proceed to next and turn the ignition switch to “OFF” step. position. Pull out the relay of fuel pump, turn the Proceed to Step4 ignition switch to “ON”...
Page 148 Diagnostic trouble code: P0325 “Malfunction in circuit of knock sensor” Item Inspection Follow-up Operation procedure results procedure Connect the diagnostic tester and adaptor, Proceed to next and turn the ignition switch to “OFF” step. position. Disconnect the connector of knock sensor Proceed to next on the wiring harness, inspect with step.
Page 149 Diagnostic trouble code: P0335 “Signal malfunction of crankshaft position sensor” Item Inspection Operation procedure Follow-up procedure results Connect the diagnostic tester and adaptor, and turn the ignition switch to Proceed to next step. “OFF” position. Disconnect the connector of rotary Proceed to next step.
Page 150 Diagnostic trouble code: P0336 “Malfunction of improper signal of crankshaft position sensor” Item Inspection Operation procedure Follow-up procedure results Connect diagnostic tester adaptor, and turn the ignition switch to Proceed to next step. “OFF” position. Disconnect the connector of rotary Proceed to next step.
Page 151 Diagnostic trouble code: P0340 “Malfunction of phase angle sensor signal” Item Inspection Follow-up Operation procedure results procedure Connect the diagnostic tester and adaptor, Proceed to next and turn the ignition switch to “ON” step. position. Disconnect the connector of phase angle Proceed to Step 4 sensor on the wiring harness, inspect with multimeter to verify that the voltage...
Page 152 Diagnostic trouble code: P0443 “Malfunction in control circuit of drive stage of carbon canister control valve” Item Inspection Follow-up Operation procedure results procedure Connect the diagnostic tester and adaptor, and Proceed to next turn the ignition switch to “ON” position. step.
Page 153 Diagnostic trouble code: P0444 “Undervoltage in control circuit of drive stage of carbon canister control valve” Item Inspection Operation procedure Follow-up procedure results Connect the diagnostic tester and adaptor, and turn the ignition switch to Proceed to next step. “ON” position. Disconnect the connector of carbon Proceed to Step 4 canister control valve on the wiring...
Page 154 Diagnostic trouble code: P0445 “Overvoltage in control circuit of drive stage of carbon canister control valve” Item Inspection Operation procedure Follow-up procedure results Connect the diagnostic tester and adaptor, and turn the ignition switch to Proceed to next step. “ON” position. Disconnect the connector of carbon Proceed to Step 4 canister control valve on the wiring...
Page 155 Diagnostic trouble code: P0480 “Malfunction in control circuit of relay of A/C condenser fan A” Item Inspection Operation procedure Follow-up procedure results Connect the diagnostic tester and adaptor, and turn the ignition switch to Proceed to next step. “OFF” position. Pull out the relay of A/C condenser Proceed to Step 4 fan, turn the ignition switch to “ON”...
Page 156 Diagnostic trouble code: P0481 “Malfunction in control circuit of relay of A/C condenser fan B” Item Inspection Follow-up Operation procedure results procedure Connect the diagnostic tester and adaptor, Proceed to next and turn the ignition switch to “OFF” step. position. Pull out the relay of A/C condenser fan, Proceed to Step 4 turn the ignition switch to “ON”...
Page 157 Diagnostic trouble code: P0500 “Malfunction of improper speed signal” Item Inspection Follow-up Operation procedure results procedure Connect the diagnostic tester and adaptor, Proceed to next and turn the ignition switch to “OFF” step. position. Check and service For the vehicles equipped with ABS the ABS system.
Page 158 Diagnostic trouble code: P0506 “Idle speed lower than nominal idle speed” Item Inspection Follow-up Operation procedure results procedure Connect the diagnostic tester and adaptor, Proceed to next and turn the ignition switch to “OFF” step. position. Proceed to next Verify that the adjusting screw of throttle, step.
Page 159 Diagnostic trouble code: P0507 “Idle speed higher than nominal idle speed” Item Inspection Follow-up Operation procedure results procedure Connect the diagnostic tester and adaptor, Proceed to next and turn the ignition switch to “OFF” step. position. Proceed to next Verify that the adjusting screw of throttle, step.
Page 160 Diagnostic trouble code: P0508 “Undervoltage in control circuit of idle speed regulator” Item Inspection Follow-up Operation procedure results procedure Connect the diagnostic tester and adaptor, Proceed to next and turn the ignition switch to “ON” step position. Disconnect the connector of idle speed Proceed to next regulator and inspect with multimeter to step...
Page 161 Diagnostic trouble code: P0509 “Overvoltage in control circuit of idle speed regulator” Item Inspection Operation procedure Follow-up procedure results Connect diagnostic tester adaptor, and turn the ignition switch to Proceed to next step “ON” position. Disconnect the connector of idle speed Proceed to next step regulator and inspect with multimeter to verify that the resistances between pin A...
Page 162 Diagnostic trouble code: P0511 “Malfunction in control circuit of idle speed regulator” Item Inspection Operation procedure Follow-up procedure results Connect diagnostic tester adaptor, and turn the ignition switch to Proceed to next step. “ON” position. Disconnect the connector of idle speed Proceed to next step.
Page 163 Diagnostic trouble code: P0560 “Improper voltage signal of system” Item Inspection Follow-up Operation procedure results procedure Connect the diagnostic tester and adaptor, Proceed to next and turn the ignition switch to “OFF” step position. Proceed to next Inspect with multimeter to verify that the step.
Page 164 Diagnostic trouble code: P0562 “Undervoltage of system” Item Inspection Operation procedure Follow-up procedure results Connect the diagnostic tester and adaptor, and turn the ignition switch to Proceed to next step “OFF” position. Inspect with multimeter to verify that Proceed to next step. the voltage of battery is about 12V.
Page 165 Diagnostic trouble code: P0563 “Overvoltage of system” Item Inspection Follow-up Operation procedure results procedure Connect the diagnostic tester and adaptor Proceed to next and turn the ignition switch to “OFF” step position. Proceed to next Inspect with multimeter to verify that the step voltage of battery is about 12V.
Page 166 Diagnostic trouble code: P0601 “Malfunction of non-programmed check code in electronic control unit” Item Inspection Follow-up Operation procedure results procedure Connect the diagnostic tester and adaptor Proceed to next and turn the ignition switch to “ON” step position. Clear the diagnostic trouble code and Proceed to next reconfirm that this malfunction is a steady step...
Page 167 Diagnostic trouble code: P0645 “Malfunction in control circuit of A/C compressor relay” Item Inspection Follow-up Operation procedure results procedure Connect the diagnostic tester and adaptor Proceed to next and turn the ignition switch to “OFF” step position. Pull out the A/C compressor relay, turn the Proceed to step 4 ignition switch to “ON”...
Page 168 Diagnostic trouble code: P0646 “Undervoltage in control circuit of A/C compressor relay” Item Inspection Follow-up Operation procedure results procedure Connect the diagnostic tester and adaptor and turn the ignition switch to “OFF” Proceed to next step position. Pull out the A/C compressor relay, turn Proceed to Step 4 the ignition switch to “ON”...
Page 169 Diagnostic trouble code: P0647 “Overvoltage in control circuit of A/C compressor relay” Item Inspection Follow-up Operation procedure results procedure Connect the diagnostic tester and adaptor and turn the ignition switch to “OFF” Proceed to next step position. Pull out the A/C relay, turn the ignition Proceed to Step 4 switch to “ON”...
Page 170 Diagnostic trouble code: P1651 “Malfunction in control circuit of malfunction alarm light” Item Inspection Operation procedure Follow-up procedure results Connect diagnostic tester and adaptor, and turn the ignition switch to “ON” Proceed to next step position. Check the action of engine malfunction Proceed to next step alarm light by using the “actuator action testing"...
Page 171 PROCEDURES FOR FAULT DIAGNOSIS ACCORDING TO THE SYMPTOMS OF THE ENGINE A preliminary inspection should be carried out before implementing the steps of fault diagnosis according to the symptoms of engine: (1) Verify that there is no abnormal behavior with the ECU and malfunction indicator light (not applicable for car models without setting of malfunction indicator light).
Page 172 1) The engine is not running or running slowly during starting Inspection Item Operation procedure Follow-up procedure results Inspect with multimeter to see whether there Proceed to next step is a voltage of about 10-12.5V between two Repair or replace the battery terminals.
Page 173 2) The engine can run but cannot successfully start up during starting Item Inspection Operation procedure Follow-up procedure results Turn the ignition switch to “ON” position. Fix the indicated Inspect with the diagnostic tester to see malfunction whether there is any malfunction information Proceed to next step.
Page 174 Verify that the fuel is deteriorated or Replace the fuel contaminated by water. Proceed to Step 18. Verify that the fuel pressure is lower than Proceed to next step. 350kPa. Proceed to Step 17. Close the fuel manometer valve. Connect the Proceed to next step.
Page 175 3) Difficult start-up of hot engine Item Inspection Follow-up Operation procedure results procedure Turn the ignition switch to “ON” position. Fix the indicated Inspect with the diagnostic tester to see malfunction whether there malfunction Proceed to next information record. step. Proceed to next Connect the fuel manometer valve.
Page 176 Replace the fuel and try the hot start again. Replace the ECU Observe whether it can successfully start up. Repair or replace Verify that the fuel pipe has any blockage or Proceed to next bending and to see whether the pressure step.
Page 177 4) Difficult start-up under normal engine speed Item Inspection Operation procedure Follow-up procedure results Turn the ignition switch to “ON” Fix the indicated position. Inspect with the diagnostic malfunction tester to see whether there is any Proceed to next step. malfunction information record.
Page 178 Replace the fuel pump Repair or replace the Verify that the fuel return pipe has any fuel return pipe leakage or bending. Replace the fuel pressure regulator Disconnect the connector of idle speed Proceed to next step. actuator before the temperature of engine coolant reaches 35 C in order to Repair or replace the...
Page 179 5) Difficult start-up of cold engine Item Inspection Operation procedure Follow-up procedure results Turn the ignition switch to “ON” Fix the indicated position. Inspect with the diagnostic malfunction tester verify that there is any Proceed to next step. malfunction information record. Inspect with multimeter to see Proceed to next step.
Page 180 (the connecting point will depend on the types of car models). Ground the 86# pin of the fuel pump relay directly. Connect the ignition switch Proceed to Step 12 to operate the fuel pump relay and the fuel pump in order to verify that the fuel pressure is maintained at about 350kPa.
Page 181 6) Unstable idle speed at all time Turn the ignition switch to “ON” Fix the indicated position. Inspect with the diagnostic malfunction tester to see whether there is any Proceed to next step. malfunction information record. Repair or replace idle Verify that the EWD3 idle speed actuator speed actuator or idle speed actuator with step motor is...
Page 182 the ignition switch again to re-operate the fuel pump in order to verify that the fuel Proceed to Step 16. pressure can be established. Open the fuel manometer valve and Replace the fuel pressure clamp the fuel return pipe with the fuel regulator tube clamp to stop the fuel return in order Repair or replace the fuel...
Page 183 7) Unstable idle speed during engine warm-up Turn the ignition switch to “ON” position. Fix the indicated Inspect with the diagnostic tester to see malfunction whether there is any malfunction information Proceed to next step. record. Proceed to next step. Verify that the air filter is free of any blockage.
Page 184 8) Unstable idle speed or stall with load (A/C and etc.) Turn the ignition switch to “ON” position. Fix the indicated Inspect with the diagnostic tester to see malfunction whether there malfunction Proceed to next step. information record. Turn on the A/C switch and connect the Proceed to next step.
Page 185 9) Unstable idle speed after engine warm-up Turn the ignition switch to “ON” position. Fix the indicated Inspect with the diagnostic tester to see malfunction. whether there malfunction Proceed to next step. information record. Turn the ignition switch to “ON” position Proceed to next step.
Page 186 tube clamp to stop the fuel return in order Repair or replace the to verify that the fuel pressure can be fuel injector or the fuel established quickly. pipe. Repair or replace the Verify that the fuel inlet pipe has any fuel air inlet pipe.
Page 187 10) A/C system malfunction Verify that there is enough refrigerant and Proceed to next step. the A/C belt, A/C clutch and pressure switch Fix the malfunction. are in good condition. Run the engine at idle speed and turn on the Fix the indicated A/C switch.
Page 188 11) Periodically instability (the memory has to be restored after ECU’s power-off) Turn the ignition switch to “ON” position. Fix the indicated Inspect with the diagnostic tester to see malfunction. whether there malfunction Proceed to next step. information record. Verify that the air filter is free of any Proceed to next step.
Page 189 voltage cable have any damaged parts or Proceed to next step. cracks. Replace the ECU. Verify that the spark plug is normal. Replace the spark plug. G-80...
Page 190 12) Too high idle speed (the memory has to be restored after ECU’s power-off) Turn the ignition switch to “ON” position. Fix the indicated Inspect with the diagnostic tester to see malfunction. whether there malfunction Proceed to next step. information record. Verify that the fastener connected to the Adjust or replace.
Page 191 13) Malfunction to increase the speed or stall during acceleration Turn the ignition switch to “ON” position. Fix the indicated Inspect with the diagnostic tester to see malfunction. whether there malfunction Proceed to next step. information record. Verify that the air filter is free of any Proceed to next step.
Page 192 Repair or replace the Verify that the fuel inlet pipe has any fuel air inlet pipe. leakage or blockage. Replace the fuel pump. Repair or replace the Verify that the fuel return pipe has any fuel return pipe. leakage or bending. Replace the fuel pressure regulator.
Page 193 14) Slow respond during acceleration Turn the ignition switch to “ON” position. Fix the indicated Verify with diagnostic tester to see malfunction whether there malfunction Proceed to next step. information record. Proceed to next step. Shut down the engine and verify that the air filter is free of any blockage.
Page 194 Turn off the fuel manometer valve. Proceed to next step. Connect the ignition switch again to re-operate the fuel pump in order to verify Proceed to Step 14 that the fuel pressure can be established. Turn on the fuel manometer valve and Replace the pressure clamp the fuel return pipe with the fuel regulator.
Page 195 15) Poor and weak performance during acceleration Verify that there are any malfunctions such Repair as slipping of clutch, low pressure of tires, delay in braking, and wrong size of tires or Proceed to next step. inaccurate four-wheel alignment. Proceed to next step. Verify that the throttle can be fully opened.
Page 196 contaminated with water. Proceed to Step 16. Verify that the fuel pressure is lower than Proceed to next step. 350kPa. Proceed to Step 15. Turn off the fuel manometer valve. Connect Proceed to next step. the ignition switch again to re-operate the fuel pump in order to verify that the fuel Proceed to Step 14.
Page 197 SAFETY PRECAUTIONS OF SYSTEM MAINTENANCE SAFETY PRECAUTIONS IN DIAGNISIS AND MAINTENANCE OF THE GASOLINE INJECTION ELECTRONIC CONTROL SYSTEM (1) Removal/installation requirements of controller The battery negative grid must be disconnected first, followed by the removal of controller prior to carrying out electric welding or baking finish; In removing/installing the controller, the ignition switch must be turned to “OFF”...
Page 198 The spare parts should be taken out from its packing only before the assembly. Any part without proper packing is not allowed to be used; Pay attention not to damage the O ring while assembling the fuel injector. A small amount of lubricating oil should be applied on the O ring for assembly convenient.
Page 199 CLUTCH CLUTCH INTRODUCTION… … … … … … … … … … … … … … … … … … H-2 CLUTCH STRUCTURE … … ……………… … … … … … … … … … …H-2 OPERATING PRINCIPLE OF CLUTCH … … … … … … … … … … … …H-2 CLUTCH CABLE ASSEMBLY STRUCTURE …...
Page 200: Clutch Introduction
CLUTCH INTRODUCTION CLUTCH STRUCTURE ·As picture below, the clutch is dry diaphragm with single leaf. It consists of clutch driven disk (2), release disk (4), intermediate disk (6), pressure plate (7) and flywheel (1). ·There are diaphragm springs in the pressure plate (7), which are fixed in the crankshaft by intermediate disk (6) and bolt (5).
Page 201: Clutch Cable Assembly Structure
a. Clutch Connection State b. Clutch Disconnection State 1.Diaphragm Spring 2.Flywheel 3.Driven Disk 4.Pusher 5.Seperator Disk 6.Transmission Axle CLUTCH CABLE ASSEMBLY STRUCTURE 1.Clip 2.Cable Latch 3.Washer 4.Cable Cushion 5.Jacket Tie-in 6.Jacket 7.Inner Pipe 8.Cable 9.Dust Cover 10.Adjust Rod 11.Jam Nut 12.Adjust Bushing 13.Clip Ring 14.Retainer...
Page 202: Assembly And Adjustment Of Clutch Cable
Clutch Adjustment shall not be less than 18mm. See Pic.2). ·Carry out the driving examination for the whole automobile. Clutch and gear shifting operation shall be normal. ·Screw jam nut (11) down to close with adjustment bushing (12), and then put...
Page 203: Clutch Disassembly
CLUTCH DISASSEMBLY ·Disassemble the transmission. ·Unscrew 9 fixed bolts in flywheel cornerwise and dismount the flywheel. ·Remove clutch plate. ·Pry out snap ring of release disk by screwdriver and remove the release disk. ·Unscrew 6 connection bolts in clutch pressure plate output crankshaft, and remove the clutch pressure...
Page 204: Clutch Overhaul
CLUTCH OVERHAUL · Clutch friction disk: measure the dent depth of rivet head, i.e. the distance between the rivet head and the friction disk surface. In case it is found that the depth reaches the using limit for any hole, the friction disk shall be changed.
Page 205: Clutch Installation
CLUTCH INSTALLATION Before the assembly, flywheel surfaces and pressure plate shall be clear and dry. ——Assemble the pressure plate on the crankshaft and screw up bolts in accordance with prescribed moment. Pressure plate N•m Kg-m 1b-ft assembly bolt 57-65 5.7-6.5 41.5-47.0 Torque ——...
Page 206: Trouble Diagnosis
TROUBLE DIAGNOSIS Trouble Cause Treatment method symptom •Free travel (free play) of clutch pedal is wrong. Adjust free travel •Abrasion or oil stain for clutch friction disk. Change friction disk Slip of clutch •Distortion for friction disk pressure plate or Change frication disk,...
Page 207: Manual Transmission
MANUAL TRANSMISSION SPECIFICATION… … … … … … …… … … … … … …… … … … … … ………J-3 DISASSEMBLY OF THE DRIVE SHAFT… … … … … … …… … … … … … ……J-4 DISASSEMBLY OF THE TRANSMISSION… … … … … … …… … … … J-6 TRANSMISSION GEARSHIFT MECHANISM DIAGRAMATIC SKETCH …J-9 RESOLUTION GRAPH OF THE GEARSHIFT CONTROL MECHANISM ……J-10 SHIFT ADJUSTMENT…...
Page 208 DISASSEMBLY AND ASSEMBLY OF THE GEARSHIFT SHAFT BEARING…J-30 DISASSEMBLY… … … … … … … … … … … … … … … … … …J-30 ASSEMBLY… … … … … … … … … … … … … … … … … …J-30 RESOLUTION GRAPH OF THE INPUT SHAFT…...
Page 209: Specification
Clutch Assembly Schematic 1. Clutch Housing 2. Differential 3. Input Shaft 4. Output Shaft 5. 1 Shift 6. Reverse 7. 2 Shift 8. 3 Shift 9. 4 Shift 10. 5 Shift 11. Transmission Housing 12. Rear Housing SPECIFICATION Transmission AQ015 AA type AQ015 AB type...
Page 210: Disassembly Of The Drive Shaft
DISASSEMBLY OF THE DRIVE SHAFT Tyre disassembly. Disassemble two bolts of the brake cylinder and brake shoe assembly. And hang the assembly on the shock absorber by the hook. Disassemble the connecting bolt of brake disc and front axle, and make front axle ball joint off by pressing it downward.
Page 211 Disassemble the round head bolt of steering knuckle and steering rod, prize up the round head bolt upward. Turn the brake disc and disassemble the 6 torx head bolts of driving shaft and differential output shaft, and take off the shim and bolt. Take off the 2 fixing bolts under the brake disc and shock absorber, pull off the driving shaft and brake disc assembly.
Page 212: Disassembly Of The Transmission
DISASSEMBLY OF THE TRANSMISSION Discharge the transmission oil. Disassemble the driving shaft. Disassemble those 3 fixing bolt of the transmission lower shim. Disassemble the crankshaft position sensor. Disassemble the backup lamp switch plug. Disassemble the speed sensor plug. Prize up the round head clamp by screw driver, take off the selector rod.
Page 213 Disassemble cathode cable of the accumulator; disassemble the anode cable and plug of the starter. Disassemble the fixing bolt between engine front overhang bracket and front cross member. Sling the engine. Disassemble the fixing bolt of the starter. Take off front overhang bracket of the starter and the engine.
Page 214 Loosen those 5 bolts between transmission housing and engine. Rise engine to the ceiling, turning around it clockwise 90 . Lay down transmission end slowly, and sway outside off the transmission and engine. Take off the transmission assembly.
Page 215: Transmission Gearshift Mechanism Diagramatic Sketch
TRANSMISSION GEARSHIFT MECHANISM DIAGRAMMATIC SKETCH ABOVE IS GEARSHIFT MECHANISM CONTROL CONFIGURATION The transmission control mechanism must meet the requirement that only one shift can be chosen when the shift is changing and prevent from choosing reverse gear. The gear should be full length meshed after the gear shifted and prevent the gear out of position automatically.
Page 216: Resolution Graph Of The Gearshift Control Mechanism
RESOLUTION GRAPH OF THE GEARSHIFT CONTROL MECHANISM 1. Shift Housing, Fasten The Fixing Bolt By 20Nm 2. Tubular Rivet To Fix Reverse Gear Guide Rail 3. Reverse Gear Guide Rail 4. Self-Tapping Screw To Fix The Dashboard 5. Seal 6. Gasket 7.
Page 217: Shift Adjustment
SHIFT ADJUSTMENT Neutral positioning Disassemble gearshift knob and protective cover and fix the gearshift knob according to the positioning requirement, see the chart (the black one is positioning assist) Leave the pipe clamp at its natural position. Clamp nut, fasten by 25Nm. Try all the shifts, gear shifting should be smooth and without stop, secure the validity of the reverse gear lockup.
Page 218: Transmission Resolution
TRANSMISSION RESOLUTION 1. Fastening Screw (4 Pieces, Fasten Moment Is25n.M) 2. Fixing Screw (2 Pieces, Fasten Moment Is 25N.M) 3. Bleed Bolt 4. Transmission Rear Housing 5. 5 Synchronizer Assembly 6. 5 Driven Gear Snap Ring 7. 5 Driven Gear 8.
Page 219 1. Input Shaft Rear Bearing Plate Screw (4 Pieces, Fasten Moment Is 15N.M) 2. Transmission Housing Assembly 3. Fixing Screw (12 Pieces, Fasten Moment Is 25N.M) 4. O-Ring 5. Gearshift Shaft Plug Cover 6. Gearshift Shaft Pressing Spring 7. Gearshift Assembly 8. Gearshift Positioning Holder Assembly 9.
Page 220 1. 4 Driven Gear Snap Ring 2. 4 Driven Gear 3. 3 Driven Snap Ring 4. 3 Driven Gear 5. Driven Gear 6. 2 Synchronizer Ring 7. 2 Roller Bearing 8. 2 Roller Bearing Lining 9. Synchronizer Assembly 10. 1 Synchronizer Ring 11.
Page 221: Disassembly And Assembly Of The Transmission
DISASSEMBLY AND ASSEMBLY OF THE TRANSMISSION Disassembly Raise up the transmission, take off the drain plug on the transmission differential side, and at the same time take off the drain plug on the rear cover( see the arrowhead pointed stud). Discharge all the oil.
Page 222 Disassemble the gearshift shaft bolt by special tools and take off compression spring and gearshift shaft assembly. Special Tool Disassemble the reverse gear lockup screw (see as the arrowhead pointed). Disassemble left and right output flange cover. Take out the internal snap ring and dish ring, and disassemble the output flange.
Page 223 Shift to 5th and reverse gear. Glide the synchronizer downward according to arrowhead 1 direction and shift to 5th. Move the first fork downward according to the arrowhead 2 direction and shift to reverse gear. Take off fixing bolt and washer of the 5th synchronizer by a special tool.
Page 224 Take off 5th driven gear snap ring and 5th driven gear. Special Tool Take off the bearing shift slice clamping bolt behind of input shaft by a special tool. Disassemble the fixing bolt of transmission front and rear housing, take off the transmission housing and front/rear housing gasket.
Page 225 Take off the fork shaft and its upper and lower spring, take off 5th fork guide assembly, reverse gear fork guide, 3rd-4th shift fork and 1st-2nd fork. Take off 4th driven gear snap ring and 4th driven gear (by a special tool). Special Tool Take off input shaft A assembly, pay attention that the reverse gear B are not the shift.
Page 226 Take off 3rd driven gear snap ring B from output shaft, and take off 3rd driven gear. And take off 2nd driven gear, needle bearing, and Special Tool synchronizer ring from output shaft. (by special tool) Prize up reverse shaft by reverse gear idler until both of them are off clutch housing.
Page 227: Assembly
Assembly: The assembly of the transmission is in reverse of its disassembly, pay attention to the below items: 1. Assemble differential assembly on clutch housing, at first do not assemble output flange. 2. Assemble output shaft and output shaft front bearing plate, plug into fixing bolt and fasten by 40Nm moment.
Page 228 Assemble the needle bearing, synchronizer ring, and gear of 2nd and 3rd driven gear. When you assemble the 3rd driven gear, make sure that the side with bulge towards 2nd driven gear. Use snap ring to adjust the axial size after the assembly of 3rd driven gear.
Page 229 Assemble the fork assembly into its right position, and then assemble the idler shaft. 1 1st and 2nd fork 2 3rd and 4th fork 3 5th fork guide and bushing 4 reverse gear fork guide Assemble input shaft rear axle pump plate A, pay attention that the position of A should be the same as in the picture.
Page 230: Main Points
Main points 1. Please do not take off the fork shaft from 5th fork bushing otherwise the fork and guide plate will deviate its right position and fallout. 2. Before assemble the gearshift shaft please put the transmission at it neutral position. Inset gearshift shaft and big compression spring, fasten the bolt cover by 50Nm moment.
Page 231: Adjustment Of 5
ADJUSTMENT OF 5 FORK Adjustment: Adjust the 5th fork as below: Turn fork bushing right until the fork bushing out X=5mm. Pull off selector shaft and turn left shift to 5th. Lift 5th coupling housing sleeve slightly by the fork to eliminate the space between the driving elements.
Page 232: Disassembly, Resolution Graph And Assembly Of The Rear
DISASSEMBLY, RESOLUTION GRAPH AND ASSEMBLY OF THE REAR HOUSING Disassembly: The disassembly of the rear housing can be finish even if the transmission is not disassembled from the car. The disassembly as below: 1 Drive the car to the platform. 2 Disassemble clutch control...
Page 233: Resolution Graph
Resolution graph: 1. Clamp—release arm 2. Release arm assembly 3. Clutch release shaft oil seal 4. Rear housing 5. Fixing bolt 6. Rear housing fixing bolt 7. Clutch release bearing 8. Return spring 9. Clutch release finger 10. Back cover 11. Fixing clip 12. Drain bolt 13. Flat spacer 14.
Page 234: Disassembly And Assembly Of Clutch Control Arm, Clutch
DISASSEMBLY AND ASSEMBLY OF CLUTCH CONTROL ARM, CLUTCH RELEASE SHAFT OIL SEAL, AND CLUTCH RELEASE BEARING Disassembly: Drive car to the platform. Disassemble the clutch control cable assembly. Disassemble engine bracket on the transmission side. Lift the vehicle by lifter. Discharge all the transmission oil by screw off the drain bolt under the differential.
Page 235: Disassembly And Assembly Of The Gearshift Shaft Oil Seal
DISASSEMBLY AND ASSEMBLY OF THE GEARSHIFT SHAFT OIL SEAL The disassembly and assembly of the gearshift shaft oil seal can be done when the transmission is not broke down. Disassembly: See the picture, remove the oil seal by a flat spade or punch.
Page 236: Disassembly And Assembly Of The Gearshift Shaft Bearing
DISASSEMBLY AND ASSEMBLY OF THE GEARSHIFT SHAFT BEARING Disassembly: Special Tool It needs to take off the gearshift shaft and oil seal as changing the gearshift shaft bearing. Penetrate the special tool into gearshift shaft Special Tool housing, see the picture, and tap it slightly until the gearshift shaft out from the other side.
Page 237 DISASSEMBLY AND ASSEMBLY OF THE OUTPUT SHAFT NEEDLE BEARING Disassembly: Remove the needle bearing by special tool, see the picture. Special Tool Special Tool Assembly: Press the needle bearing to its right position by special tool. J-31...
Page 238 DISASSEMBLY AND ASSEMBLY OF THE GEARSHIFT SHAFT It need not to break down the transmission assembly. Disassembly: Put transmission assembly on the shelf or workbench. Leave it on the neutral position. (The gearshift shaft move smoothly on arrowhead direction) Screw off the gearshift positioning holder assembly.
Page 239 DISASSEMBLY AND ASSEMBLY OF INPUT SHAFT NEEDLE BEARING Disassembly: See the picture, dismantle the needle bearing by special tool. Special Tool Special Tool Assembly: See the picture, assemble the input shaft Special Tool Special Tool needle bearing by special tool, and make sure press it to the right position.
Page 240 DISASSEMBLY AND ASSEMBLY OF THE INPUT SHAFT OIL SEAL Disassembly: It need not to break down the transmission when disassemble the input shaft oil seal. Special Tool See the picture, disassemble the input oil seal according to the arrowhead direction by special tool Assembly: See the picture, lubricate the lip of the oil seal...
Page 241: Resolution Graph Of The Input Shaft
RESOLUTION GRAPH OF INPUT SHAFT 1. 5 Synchronizer fixing bolt 2. Fixing bolt shim 3. 5 Synchronizer assembly 4. 5 Synchronizer gate bracket 5. 19 Steel spring 6. 5 sleeve 7. 5 Clutch hub 8. 18 Gate 9. Fixing screw of rear bearing plate 10.
Page 242: Resolution Graph Of Output Shaft
RESOLUTION GRAPH OF OUTPUT SHAFT 1. Rear housing 2. 5 Driven gear snap ring 3. 5 Driven gear 4. Transmission housing 5. Needle bearing 6. 4 Driven gear snap ring 7. 4 Driven gear 8. 3 Driven gear snap ring 9.3 Driven gear 10.
Page 243: Adjustment Table
ADJUSTMENT TABLE Adjustment items: During the repair of Adjusted items transmission assembly, you Changed parts Output Differential should think about to adjust shaft the output shaft or differential Transmission housing Adjust assembly installing dimension Clutch housing Adjust Adjust when you change any of the Differential cone bearing Adjust below element.
Page 244: Adjustment Of Output Shaft
ADJUSTMENT OF OUTPUT SHAFT Adjustment: You need adjust the thickness of the output Special Tool shaft shim after you replaced any part of clutch housing,output shaft,output shaft Special Tool intermediate bearing pedestal, output shaft intermediate bearing or output shaft front bearing.
Page 245: Disassembly
CALCULATE THE THICKNESS OF THE ADJUSTMENT SHIM Put a platform benchmark on the clutch housing, and put a dial indicator with magnetic base on the benchmark. Set to zero when the pre fasten force is 1mm. Move the input shaft up and down according to the arrowhead direction, read and record the indication of the indicator.
Page 246: Assembly
Assembly: Put the propriety adjustment shim to it right position and press output shaft front bearing external ring. Lubricate the bearing by gear oil and insert output shaft. Put on bearing Special Tool plate and bolt fasten by 40Nm moment. After changing one of below parts: Clutch housing, transmission housing, differential bearing and differential housing, you need...
Page 247: Resolution Graph Of The Differential Assembly
RESOLUTION GRAPH OF THE DIFFERENTIAL ASSEMBLY RESOLUTION GRAPH 1, Final drive driven gear 2, Rivet 3, 11, Needle bearing 4,12, Needle bearing external ring 5,13, Adjustment shim 6, Clutch housing 7, Rivet (may not use) 8, Oil seal holder 9, Oil seal 10, Small axle shaft 14, Transmission housing 15, Output flange snap ring 16, Output flange dish washer 17, Output flange 18, Compression spring 19, Spring seat ring 20, Damper ring 21, Differential housing 22, Knob gasket 23, Snap ring 24, Planet gear shaft 25, Planet gear snap...
Page 248: Disassembly
DISASSEMBLY AND ASSEMBLY OF OIL SEAL AND OUTPUT FLANGE The disassembly of this part can be carried out at the condition not break down the transmission assembly. Disassembly: Disassemble the connecting bolt between propeller s haft and flange, disassemble drive shaft and fix it on somewhere.
Page 249: Assembly
See the picture, fix the special tool on flange Special Tool by M8 bolt, rotate the shaft of special tool by wrench to disassemble the output flange. Take off spring seat and compression spring. Special Tool Fasten the special tool on oil seal, rotate the special tool threaded shaft by wrench until screw off the oil seal.
Page 250 AXLE AND SUSPENSION SYSTEM ALIGNMENT OF THE WHEEL … … … … … … …… … … … … … … … …M-2 BASIC INSPECTION BEFORE THE ALIGNMENT……………………… … …M-2 USUAL TROUBLE OF THE TIRE… … … … … …… … …… … … …… … …M-5 ALIGNMENT OF THE REAR WHEEL …...
Page 251: Axle And Suspension System
AXLE AND SUSPENSION SYSTEM ALIGNMENT OF THE WHEEL It is easy to understand that the theory of the four wheels alignment related to the definitions and the functions of various angles. However, the corresponding theory can hardly be applied to the four wheels alignment tester and chassis maintenance due to the chassis structure of the vehicle body, which all the angles of the four wheels alignment bear on the mechanical structure of the chassis.
Page 252 im and Tire A15LHD wheel No. Tire No. Rim No. Note: The above tire-rim combination is suitable for the steel or aluminum alloy rim. Please do not use rims and tires of other models which may lead to improper consequence. Preaution: Be sure to consult the relevant instruction if non-standard tires or rims (such as light weight alloy rims or wheels of winter tire)should be installed.
Page 253 Adjusting the snow chain of the tire should accord to the type of the road condition. Inspection must be applied before install the snow chain. Please refer to the instruction of the snow chain manufacturer when install the snow chain on the tire. Please remove the wheel house before install the snow chain which may score the wheel house.
Page 254: Usual Trouble Of The Tire
final assy imbalance is expected to be less than 100g·cm, approximately equal to a 5g balance block on the inside and outside brims of the rim. Precaution: No more than one balance block with 70g weight at most is allowed to set on each side of a wheel.
Page 255 Maintenance: Adjusting the positioning angle of the front wheel ------Wear on center of tire The wear on center of tire means the abnormal wear on the center surface of the tire. The theoretical reason for this kind of wear is that the diameter elongation at the center of the tire surface is larger than that on the shoulder of the tire.
Page 256 Degradation of tire Replace Adjust Insufficient tire pressure Adjust Unbalance of tire Road noise or Repair or vehicle vibration Deformation of rim or tire Replace Uneven wear of tire Overbeating of tire and rim Replace Looseness of wheel nut Lock Up-and-down Unbalance of tire shaking of steering...
Page 257 Malfunction of suspension system Uneven tire pressure of both sides Adjust One side deflection of braking Malfunction of braking system Insufficient tire pressure Adjust Heavily steering of Malfunction of steering system steering wheel Malfunction of suspension system Insufficient tire pressure Adjust Improper returnability of...
Page 258: Alignment Of The Rear Wheel
------Measure the height from the wheel center to the mudguard edge. The measured difference from left and right should be not more than 10mm. ALIGNMENT OF THE REAR WHEEL It is recommended to utilize the four-wheel alignment tester with thrust line positioning method on this type of chassis.
Page 259: Alignment Of The Front Wheel
Check the rear wheel toe-in Car No. Chery A15LHD Rear wheel toe-in 20′±10′ Note: The rear wheel toe-in out of standard range may lead to wear on shoulder of tire on both sides.
Page 260 Influence of caster The main function of the caster is to keep the vehicle running straight forward. If the caster is positive, the inside of the vehicle descends and the chassis ascends which increase the steering knuckle load when the front wheel turns. If the casters of two wheels are same, the vehicle will return forward after turning.
Page 261 Loosen the joint bolt, move the wheel and adjust the camber. Check the front wheel toe-in Toe-in (general) Car No. Chery A15LHD Front wheel toe-in 0′±10′ Tightening torque of toe-in: 55±5N•m. Adjust the toe-in Optical tester or mechanical toe-in adjuster can be used to adjust the toe-in.
Page 262: Front Suspension
FRONT SUSPENSION The functions of axle and suspension system include receiving the torque generated by engine and passed via transmission system; producing the traction force between the road surface and the vehicle body through the adhesive force between the driving wheel and the ground in order to keep the whole vehicle steering normally;...
Page 263 ----Suspend the engine and transmission assy, loosen the bolts at the two supporting points from the engine and transmission to the sub-frame. Caution: The removal process is extremely dangerous which could cause serious damage or even death. Please make sure the power assy is well fixed.
Page 264: Overhaul Of The Front Suspension
OVERHAUL OF THE FRONT SUSPENSION Installation of the front axle Cherry adopts the divided steering drive axle as the front axle. The suspension is the model of shock absorber (also called MacPherson) independent suspension. The front suspension of A15RHD model has the functions of both driving and steering.
Page 265 Removal of the front shock absorber assy Precaution: Before the procedure below, the careless pull may lead the disconnection of the harness if the ABS vehicle speed sensor is not removed first. Therefore, before the following procedure, remove the ABS vehicle speed sensor (the axle side) first and fix it in a proper position in order to keep the sensor untouched during the vehicle maintaining.
Page 266 ----Set on the front coil spring 8 and compress it less than 200~220mm. ----Amount the washer 7, the front spring top tray 6, the bearing and vibration isolator assy 5 in sequence, and tighten the slotted nut 4 to the specified torque (40N•m), then loosen the compressing tools on the coil spring.
Page 267 pressing which means there is a force in lower part and not abruptly in upper part while pulling; there is a force in lower part and not in upper part while pressing. c whether the shock absorber is locked and unable to pull.
Page 268: Removal And Installation Of The Front Wheel Bearing
REMOVAL AND INSTALLATION OF THE FRONT WHEEL BEARING Removal: ----Remove the front brake disc and the dust plate, and then extrude the hub. ----Remove the spring retainer of both sides and extrude the wheel bearing. (shown as the illustration) ----Pull out the bearing inner race. Use the puller with hoop to pull the wheel bearing inner race out of the wheel hub.
Page 269 race and observe whether it runs normally. ----Apply the lubricating grease on the hub spline and the bearing neck, and then press the hub into the bearing. ----Tighten three M6 bolts to fix the dust plate with the tightening torque of 10N·m. ----Use the fuzz-free cloth to clean the working surface of the brake disc.
Page 270 Replace the rear housing of the lower control ----When pressing out the rear housing of the lower control arm, if the elastic housing locks due to rust, please cut away the rubber on outer circle, saw off the steel cover, and then press out the elastic housing.
Page 271 REAR AXLE AND REAR SUSPENSION Longitudinal bracket rear axle and rigid axle suspension are employed in Chery. The wheels on both sides are connected with the vehicle body by an integrated rear axle. The metal rubber holder for the rear axle is a type of holder which the trace is adjustable. It is almost the rigid connection in longitude and can only deform in lateral which ensures that the rear axle cannot turn in axial direction.
Page 272: Removal / Installation Of The Rear Axle Assy
Installation of the rear axle assy: ----Installation of the metal rubber holder: press the metal rubber bush 2 into the axle body, and apply pressure till the edge of metal rubber bush reaches the solid axle. ----Use the bolt for hole 13 of the metal rubber holder to connect the two rear axle brackets.
Page 273 Precaution: Before the procedure below, the careless pull may lead the disconnection of the harness if the ABS vehicle speed sensor is not removed first. Therefore, before the following procedure, remove the ABS vehicle speed sensor (the axle side) first and fix it in a proper position in order to keep the sensor untouched during the vehicle maintaining.
Page 274 REMOVAL AND INSTALLATION OF THE REAR SHOCK ABSORBER ASSY The structure of rear shock absorber assy is shown as the illustration: Illustration. Rear shock absorber assy 1 Hexagon thin nut 15N·m 2 Rear strut upper cover 3 Belleville washer 4 Hexagon thin nut 15N·m 5 Rubber bearing block II 6 Bearing sleeve 7 Rear spring upper holder...
Page 275: Removal / Installation Of The Rear Shock Absorber Assy
Precaution: Before the procedure below, the careless pull may lead the disconnection of the harness if the ABS vehicle speed sensor is not removed first. Therefore, before the following procedure, remove the ABS vehicle speed sensor (the axle side) first and fix it in a proper position in order to keep the sensor untouched...
Page 276 ----Install upward the rear shock absorber assy from the vehicle body bottom and extend the piston rod into the carriage through the rear shock absorber holder; ----Inside the carriage, cover bowl washer 17, rubber bearing block 18 and support disc 19 onto the piston rod in sequence, and then tighten the hexagon nut 20 with tightening torque of 20N·m.
Page 277: Overhaul Of The Front And Rear Axle
OVERHAUL OF THE FRONT AND REAR AXLE Trouble Causes Solutions 1. Different tire pressure of both sides 2. Half way releasing of front 1. Adjust braker 2. Overhaul, adjust 3. Invalidation of front spring or 3. Replace housing Deflecting of 4.
Page 278: Steering System
STEERING SYSTEM INTRODUCTION OF STEERING SYSTEM …… …… … ……… …… … ……… N-2 INTRODUCTION OF STRUCTURE …… … ………… … ………… … ……N-2 WORKING PRINCIPLE … ……… … ………… … ……… … ………… …N-3 INTRODUCTION OF PERFORMANCE … … ………… … ………… … ……N-4 REMOVAL/INSTALLATION OF STEERING COLUMN ……...
Page 279: Introduction Of Steering System
INTRODUCTION OF STEERING SYSTEM INTRODUCTION OF STRUCTURE The structure of the Power Steering System is shown as Figure 1: Steering Oil Reservoir Steering Oil Pump Steering Hose Power Steering Gear Figure he rack & pinion power steering gear is composed of three sections: control valve, mechanical steering gear and servo cylinder.
Page 280: Working Principle
1. Torsion Bar 2. Input Shaft 3. Valve Bush Figure 2 To Left Chamber Oil Inlet Return oil inlet To Right Chamber WORKING PRINCIPLE Middle Position ·When the vehicle moves straight (the steering wheel does not turn), the hydraulic oil which is supplied by the oil pump enters the oil inlet through the pre-opened clearance of the rotary valve.
Page 281: Introduction Of Performance
INTRODUCTION OF PERFORMANCE The steering force of the steering wheel can be decreased. Power can be felt obviously, especially when the vehicle turns on spot or turns with great corner at low-speed. The steering sensitivity is enhanced. The impact of kickback from ground on the steering wheel is reduced. In the case of tire burst, the sudden turning of the wheels can be effectively avoided.
Page 282: Removal/Installation Of Steering Column
REMOVAL/INSTALLATION OF STEERING COLUMN Removal and Installation of the Steering Column The inner spline of the steering gear is ·Remove the nuts on the steering wheel shown as the picture below: ·Remove the upper and lower protector of the instrument cluster and the switch ·Remove the instrument panel assy.
Page 283: Removal/Installation And Check Of Steering Gear
Disassembling Illustration of the Steering Column 1- Horn Button Cap 2-Nut 40N·m 3- Spring Washer; 4-Steering Wheel 5- Serrated Set Bush; 6-Spring 7-Lower Trim Cover 8- Upper Trim Cover 9- Steering Gear Lock Housing and Steering Column Switch 10- Support ring 11-Steering Shaft 12-Nut 30N·m 13- Steering Universal Joint...
Page 284: Gear
and 25±3N·m respectively. ·Remove the four bolts of the steering gear. ·Remove the fixing bracket of the steering gear and the rubber hose. ·Install the steering column in the reverse order of the removal. Note: The right picture shows the status of the power steering oil tube of the steering gear removed.
Page 285 Conical connector Left oil tube assy Lock nut Adjusting plug Spring Rack holder Hexagon flange bolt Bearing Plug cap Right oil tube assy O rubber ring Washer Oil seal Steering rack piston assy Piston ring O rubber ring Housing Stop collar Wire stopper...
Page 286 Removal and Dismantling of Steering Gear Repair and adjust after the removal of the steering gear Tightening Torque for the Fastener Set Components Shown as the table below Tightening Torque Description Specification Quantity Hexagon flange bolt Q1840812 20~30 Plug cap M30X1.5 35~45 Lock nut...
Page 287 Remove the left and right protector (Refer to Illustration 7) ·Remove the single ear no-level clip 6, then the clamp 4 and take off the protector 5. Illustration 7 Remove the left and right oil tube assy Refer to Illustration 8 ·Loosen the joint nuts of the left oil tube assy 19 and right oil tube assy 27, and then remove the left and the right oil tube assy.
Page 288 Remove the support device of the rack Refer to Illustration 10 ·Screw down the lock nut 20 with an special purpose spanner first, then the adjusting plug 21, and remove the spring 22 and the rack holder 23 in sequence.. Illustration 10 Remove the valve core assy Refer to...
Page 289 Remove the rack assy Refer to Illustration · Press the rack assy 31out with a special purpose tool. Illustration 13 Check and Replacement of the Components of the Steering Mechanism Check the steering rack piston assy Refer to Illustration 14 Check(1) Inspect the stagger of the rack 31 of the rack piston assy, which the maximum value is 0.15mm.
Page 290 Check the oil seal of the stop collar assy. Refer to Illustration 16 Check (3): Inspect if there is flake or indention on the working surface of the oil seal 30 of the stop collar assy and damage on the lip. Examine if there is scratch on the inner surface of the housing 34 and damage on the O rubber ring 28.
Page 291 Precaution: When replace, all the set bolt, adjusting screw, seal component, lock nut and the other components must be conformed to the technical specification of Chery and can not be substituted arbitrarily. Get the clean MoS Lithium lubricating grease or the same performance grease ready during assembling.
Page 292 Install the valve core assy Refer to Illustration 20 ·Install the valve core assy 31 as the direction of the skew gear tooth into the hull oil reservoir Illustration 20 Install the stop collar assy Refer to Illustration 21 ·Coat the cylinder side rack 31 with vinyl tape. ·Apply the white special grease on the inner surface of the oil seal 30 ·Press the stop collar assy into the oil reservoir...
Page 293 Install the left and right oil tube assy Refer to Illustration 23 · Install the new conical connectors 18 and 16 on the ends of the left oil tube assy 19 and right oil tube assy 27. ·Tighten the left and right oil tube assy with the tightening torque of 15~25N.m Illustration 23 Assembling and adjustment Refer to...
Page 294 Install the rack lock-plate and the inner ball joint assy Refer to Illustration 25 ·Apply Kerui 5242 sealant on the thread of the inner ball pin. · Install and screw the inner ball joint assy with a special purpose tool. The tightening torque is 70~90N.m.
Page 295: Check Of Steering System
CHECK OF STEERING SYSTEM REGULAR INSPECTION Initial Check ·The maintaining staff should pay attention to the steering system troubles reflected by the user first. In this way, it could save a lot of repairing time. For example, as the user complains that the steering is heavy, it is necessary to clear that it is heavy on left or right;...
Page 296: Check Of The Seal Of Power Steering System
Overhaul of the hydraulic power pump ---- Check if the hydraulic power pump is clogged. Replace it, if necessary. ---- Check if there is abnormal noise in the hydraulic power pump Replace it, if necessary. Check if there is leakage in the hydraulic system. Replace it, if necessary. ---- CHECK OF THE SEAL OF POWER STEERING SYSTEM Please follow the below steps:...
Page 297: Check And Replacement Of The Hydraulic Power Oil
CHECK AND REPLACEMENT OF THE HYDRAULIC POWER OIL Check the hydraulic power oil ----Repeat turning the steering wheel from one limit position to another when the engine is idling in order to increase the temperature of the power steering oil to 40~80 ----Check the oil volume left in the oil reservoir, the oil surface should reach...
Page 298: Check Of The Output Pressure Of Power Steering Pump
10mm. If the belt is too slack, please go to the nearby service station of Chery to adjust and repair it. N-21...
Page 299 DIAGNOSIS AND TROUBLESHOOTING OF POWER STEERING SYSTEM The frequent malfunctions of the hydraulic power steering system are the oil leakage, infiltration of air, failure of the power steering pump, and damage of the steering control valve and mechanical transmission mechanism of the hydraulic transmission mechanism. All these malfunctions show in different forms, such as steering heavily, noise, unsmoothness, vibration and so on.
Page 300 · Measure if the tire pressure is normal. If necessary, inflate it according to the specified pressure. · Check if there is leakage in the oil tube connectors of the steering hydraulic steering system. If there is leakage, screw them tightly. Inspect if there is damage, deformation or crack on the oil tube.
Page 301 piston; Weakening of the pressure regulator spring, damage on the seal components. Find out the malfunctions and eliminate them. If necessary, replace the oil pump. Steering wheel floating or deflecting when the Vehicle runs straight Malfunction symptom It is difficult to keep the vehicle running straight. Malfunction reason ·...
Page 302 2~3min, which appears in the steering pump is normal when the engine is started in cold weather (20 or even colder) . But when the noise is abnormal and the turning performance is affected, the noise can be considered as malfunction. The reasons are shown below ·...
Page 303: Precaution Of Steering System Maintenance
Caution: The steering gear is an important danger-proof component which can affect the driving security. If failure appears during use, the vehicle should be sent to the service station designated by Chery; the company is not responsible for the accidents due to self-disassembling, self-maintenance and improper operation.
Page 304 · After refueling, check if there is leakage in every component. Precaution: Keep the impurities away from the system when refueling. Caution: Dead steering (i.e. turning the steering wheel to the limit position) is forbidden during use. Even if necessary, do not keep the steering wheel stay at the limit position more than 10 seconds.
Page 305: Brake System
BRAKE SYSTEM INDUCTION TO BRAKE SYSTEM … … … … … … … … …… … … … … … …P-2 REGULAR BRAKE SYSTEM … … … … …… … … … …… … … … …… … …P-3 AIR BLEEDING… … … … …… … … … …… … …… … …… …… … …… …P-3 INSPECTION OF THE CHECK VALVE OF VACUUM HOSE…...
Page 306: Induction To Brake System
INDUCTION TO BRAKE SYSTEM A15LHD is equipped with a diagonally split dual-circuit vacuum-assisted hydraulic brake system, which consists of service brake and parking brake. A disc brake is used for the front wheels, while a drum brake is for the rear wheels. And the servo system adopts the high-performance vacuum booster and dual-circuit hydraulic master brake cylinder.
Page 307: Regular Brake System
Brake System of A15LHD 1 Brake master cylinder 4 Brake pedal 7 Front disc brake 2 Brake fluid reservoir 5 Brake pipeline 3 Vacuum booster 6 Rear drum brake REGULAR BRAKE SYSTEM AIR BLEEDING Warning: * The proper fluid level shall be kept inside the brake fluid reservoir when air bleeding.
Page 308: Adjustment And Maintenance Of Brake Pedal
Inspection of the check valve of vacuum hose (power assisted brake unit) * Detach the clips and vacuum hoses * Pump the engine-side hoses and apply the pressure force on it, and verify that the air blows only to this side. * If there are air flow in the both directions or not air flow at all, Replace the vacuum hose ADJUSTMENT AND MAINTENANCE OF BRAKE PEDAL Adjustment of Clearance between Brake...
Page 309: Disassembly/Assembly And Inspection Of Front Wheel Disc Brake
* Maintenance of Brake Pedal -- Check the smooth operation of brake pedal, and remove it for inspection if its operation is abnormal. Check whether the brake pedal is distorted or deformed, and replace it if any. -- Check whether the brake pedal shaft is worn seriously or deformed, and replace it if any. All shaft pins shall be lubricated when assembling.
Page 310 REPLACEMENT OF FRICTION SHOES OF FRONT WHEEL DISC BRAKE Lift up the vehicle and remove the front wheel, and then detach the lower fixing bolt of the caliper housing. -- Lift up the brake caliper from the bottom to top, and remove the brake lining (as shown in the figure).
Page 311 -- Use the compressed air to press the piston out of the brake caliper housing. Place a wooden block in the piston indent when pressing so as to avoid the piston damage, as shown in the figure. -- Apply a tool to carefully pry out the sealing ring, as shown in the figure.
Page 312 INSPECTION OF FRONT WHEEL DISC BRAKE Maintenance of brake lining * Check whether there are some oil stains on the surface of brake lining, and use an abrasive cloth to grind off it, if any. * Check the crack, dropout and other defectives on the brake lining, and replace the brake lining, if any.
Page 313 Maintenance of brake caliper assy. * Check the crack and deformation of the brake caliper, and correct or replace it as appropriate. * Check the breakage and crack of the dust boot of piston, and replace the boot, if any. * Check the aging, crack and other defectives of the sealing ring of piston, and replace the ring, if any.
Page 314 1 Front wheel hub 7 Bolt 13 Piston damping washer 2 Dust cover 8 Bolt 14 Bracket 3 Brake pad assy. 9 Left caliper housing 15 Lock screw 4 Dust boot 10 Piston 16 Brake disc 5 Guide rod 11 Piston gasket 17 Screw 6 Bleeder valve screw 12 Piston dust cover...
Page 315: Disassembly/Assembly And Inspection Of Rear Wheel Drum Brake
DISASSEMBLY/ASSEMBLY AND INSPECTION OF REAR WHEEL DRUM BRAKE 1. Stop dowel 7. Regulating plate 13. Parking braking cable 2. Bolt 8. Push rod 14. Brake shoe assy. 3. Brake wheel cylinder 9. Regulating plate spring 15. Limit spring 4. Brake back plate 10.
Page 316 DISASSEMBLY/ASSEMBLY OF BRAKE SHOE OF REAR WHEEL DRUM BRAKE Removal: -- Remove the rear wheel. -- Insert the turning tool into the tire bolt fastening hole on the brake drum, press the shoe clearance regulating wedge-shaped block upwards to make the brake shoe return back to its original position.
Page 317 -- Install the brake shoe and parking brake lever, and reassemble the return spring, as shown in the figure. -- Fix the parking brake cable on the parking brake lever, and install the brake shoe on the brake wheel cylinder. -- Install the lower return spring, and adjust the return spring and the spring of wedge-shaped block.
Page 318 -- Measure the thickness of friction lining, as shown in the figure. Caution: The service limit is 2 mm. -- Check the contact between the friction lining of brake and the brake drum, as shown in the figure. MAINTENANCE OF BRAKE WHEEL CYLINDER -- Check the oil leakage of brake wheel cylinder, and the damage of dust boot.
Page 319 STRUCTURAL DIAGRAM OF REAR WHEEL DRUM BRAKE adopts the non-balanced drum brake (leading trailing shoe brake) for its rear A15LHD wheels, as shown in the figure below. Structural Diagram of Rear Wheel Drum Brake 1 Brake back plate 9 Support plate 17 Brake shoe with wedge-shaped 2 Pin shaft 10 Rivet...
Page 320: Related Parameters Of Vacuum Booster And Master Brake Cylinder
The braking clearance of rear brake is adjusted automatically. In case the braking clearance exceeds the set value due to the shoe plate wear, the wedge-shaped regulating block 20 located between the lever and brake shoe will move downwards with the help of spring force of tension spring 12 to compensate the clearance increase between the lever and wedge-shaped regulating block so as to make the brake shoe further open toward the brake drum to compensate the friction lining wear.
Page 321: Parking Brake System
INSPECTION OF VACUUM BOOSTER Inspection of brake performance The driver will feel the brake pedal difficult to step down and its resistance force considerably increase compared with normal condition when he step it after the vacuum booster fails. In this case, the booster assy. shall be replaced in time. The condition of vacuum booster is also determined in accordance with the following convenient method: -- Shut down the engine, and forcefully step on the brake pedal several times to remove the vacuum kept inside the vacuum booster.
Page 322 1. Brake control rod 5. Compensation rod 2. Tie rod 6. Nut (20Nm) 3. Adjusting nut 7. Parking brake cable 4. Lock nut (8Nm) 8. Parking brake dust cover assy. (as shown in the figure above) Disassembly/Assembly and Installation of Parking Brake System Fit the parking brake dust cover assy.
Page 323: Abs (Anti-Lock Brake System) Control System
ABS (ANTI-LOCK BRAKE SYSTEM) CONTROL SYSTEM INTRODUCTION TO ABS CONTROL SYSTEM Chery’s A15LHD series vehicle adopts the MK series ABS system manufactured based on the imported technology. The system is the current newest generation of anti-lock brake system all...
Page 324 Notices: Use the diagnostic tester to find out the seasons of failures, and then repair it; Unpack the spare part packaging just before the beginning of installation; Only the original parts are available; Pay more attention to the cleanliness during repair, and wipe it only with the non-woolen cloth;...
Page 325 central valve of main bump and thus the brake fluid can’t flow out from the outlet when the system activates; * Remove the brake pipe A and B (connected to the main pump) from the HCU, and then mark them and use the plugs to block the outlet immediately;...
Page 326: Msabs Control System Diagnostic
Refit of ABS Assy. Caution: The plug of hydraulic opening on the ABS assy. can be removed only when installing the brake pipe, the purpose of which is to avoid the foreign material entering into the brake system. * Install the ABS assy. on its support, with the tightening torque of 20+4Nm; * Remove the plugs from the hydraulic opening, and install the brake pipe to determine the right connection of the pipe;...
Page 327 Begin Connect the diagnostic tester under the Power Off condition Turn the key switch to “ON” Turn on the power switch of instrument, and select the “A15LHD Series” Select "MK20-I/E Type ABS System” Select “Universal OBD-16 Diagnostic Connection” Communicate or not? Check it in accordance with the Non-DTC Failure Check...
Page 328: Operation Method And Function Introduction Of Diagnostic Tester
OPERATION METHOD AND FUNCTION INTRODUCTION OF DIAGNOSTIC TESTER * Connect the diagnostic tester with the diagnostic socket (behind the glove box) under the condition of power off, and then turn on the ignition switch. * Turn on the power supply of the diagnostic instrument, and select the “A15LHD Series” * Select the “MK20-I/E Type ABS System”...
Page 329 * ECU coding The new ECUs shall be coded when replacing the HECUs or ECUs, otherwise the ABS warning lamp will flash and the system fails to operate normally. The original diagnostic tester is available to code the ECUs, the procedure of which is as follows: Connect the diagnostic tester with the diagnostic socket...
Page 330: Troubleshooting Quick Indexing Table
Fluid Refilling and Air Bleeding * Wet type HCU If the spare part is a wet type HCU, it is required to only refill the fluid and bleed the air in accordance with the method available to the general brake system after replacing the HCU. * Dry type HECU If the spare part is a dry type HCU, apart from refilling the fluid and bleeding the air in accordance with the method available to the general brake system, it is also required to...
Page 331: Caution When Failure Diagnosing
CAUTION WHEN FAILURE DIAGNOSING The ABS adopts the electronic hydraulic control, so it is normal that the phenomena listed in the table below occur under the normal operation of the ABS system, which shows they aren't the failures. Phenomena Description Sometimes, the sounds like the knock sound come from System self-check the engine compartment after the engine starts, which is...
Page 332 Repair Details of Random Failure: In the electronic control system, the instantaneous and poor contact problem may occur in such positions as the electrical circuit and input/output signal passage. Thus it causes the random failure or generates the DTC when ECU self-checking. If the reason of failure still exists, the abnormal parts can be found only in accordance with the DTC Failure Check Sheet, but sometimes the reason to cause the failure will disappear automatically, so it is difficult to find out the reason of problem.
Page 333: Dtc Failure Check Sheet Index
DTC Failure Check Sheet Index Condition of Failure Turn the ignition switch to “ON” (under the engine shut down), and the ABS warning lamp doesn’t light The warning lamp doesn't extinguish after the engine starts Uneven braking force at both sides Braking force shortage ABS fails to operate when slightly stepping on the brake Abnormal ABS...
Page 334 Pull out the harness Abnormal connector the motor, directly connect the battery Replace the hydraulic control unit supply to the battery terminals and check whether the motor operate normally. Normal Abnormal Replace the fuse or harness Check the fuses and ABS ECU connections Normal Connect the motor harness...
Page 335 Sensor is installed Install it normally normally or not? Abnormal Abnormal Check all sensor gear Replace Check the sensor’s output voltage rings at the ABS pin 25# plug Abnormal Normal Check the wheel Replace Replace the ABS ECU bearing clearance Abnormal Repair or replace Check every sensor...
Page 336 Speed sensor 3. The DTCs are 00283, 00285, 00290, 00287 Possible Cause [Description] When the vehicle speed > 20 km/h, the Poor contact or short circuit DTCs will appear if the sensor signal exceeds between the sensor coil or the tolerance range. harness [Hint] It is very possible that the too feeble signals from Excessive or undersized air...
Page 337 Speed sensor 4. The DTCs are 00283, 00285, 00290, 00287 Possible Cause [Description] The DTCs will appear when the Open circuit of sensor connector sensor has the recognizable open circuit, Short circuit of sensor short circuit and other failures. Short circuit between the sensor [Hint] It may be caused due to the poor contact of connection or harness with the sensor, the short circuit of coil or harness,...
Page 338 ABS coding error 5. The DTC is 01044 Possible Cause [Description] The DTC will appear when the The error connection of pin ECU’s software coding is inconsistent with in ABS harness the hardware connection of ABS harness. ABS coding error Incorrect Use the diagnostic tester to check whether the ABS ECU software...
Page 339 ABS operation abnormal P-34 7. The DTC is 01130 Possible Cause [Description] The DTC will appear when the ABS * High-frequency interfered high-frequency electromagnetic wave electromagnetic wave or when the interference microprocessor believes that * Sensor damaged or sensor input speed signal is incredible. electrical harness damaged ABS ECU damaged Abnormal...
Page 340: Possible Cause
Abnormal Check the ABS warning lamp’s fuse Replace in the central electrical box Normal Abnormal Replace the fuse socket Check the central electrical box fuse socket Normal Remove the ABS ECU connection Check whether the bulb of ABS Abnormal Replace Ignition switch: ON warning lamp is burnt or not The warning lamp lights?
Page 341 Caution: This failure mode is available only when the system can communicate with the diagnostic instrument (ABS ECU power supply normal) and there is no DTC. Check the open circuit of wires between Replace harness ECU and ABS warning lamp controller Abnormal Replace Check the ABS warning lamp controller...
Page 342 Sensor is installed properly or not Install it properly Abnormal Abnormal Check the sensor output voltage Check all sensors Replace Normal Normal Abnormal Abnormal Use the diagnostic tester to Check all sensor gear rings Replace conduct the HCU diagnosis Abnormal Normal Abnormal Check wheel bearing clearance...
Page 343 Too long brake pedal travel Possible Cause [Description] Firstly take the visual inspection to Brake fluid leakage determine outside leakage NC valve leakage mechanical failure. Use the air bleeding Air kept in the system method to check the air in the system. And Serious brake disc use the diagnostic tester and hydraulic wear...
Page 344 Without DTC output (fail to communicate with the diagnostic tester) [Description] If it is difficult to communicate with the Possible Cause diagnostic tester, it is possible that the supply The fuse broken circuit of ABS ECU or the diagnostic circuit is The diagnostic circuit open circuit.
Page 345: Abs System Check
ABS SYSTEM CHECK Ignition Terminal Check Item Standard Value Unit Position MK20I/E 25-8 10.1-14.5 Battery voltage (motor) Battery voltage (solenoid 9-24 valve) Supply insulating property 0.00-0.5 Earth insulating property 8-24 Supply voltage 10.0-14.5 Warning lamp Visual ECU not extinguishes inspection connected Warning lamp Visual...
Page 346 APPENDIX I: ABS Q&A 1. What‘s ABS? ABS, the abbreviation of Anti-lock Brake System, means the function of Anti-lock Brake System (ABS), which is available to ensure that the vehicle traveling on different roads can get the optimal brake distance, and, at the same time, has the better brake stability and steering capacity.
Page 347 “FOUR DOS” and “FOUR DONTS” for the use of ABS “FOUR DOS” Do step on the brake pedal using your foot at all times, which can ensure sufficient and continuous braking force to make the ABS effectively play its role. Do maintain the sufficient brake distance.
Page 348 BODY EXTERIOR ACCESSORIES… … … …… … … …… … … …… … … …… … … S-4 REMOVAL, INSTALLATION & ADJUSTMENT OF ENGINE HOOD… … … …S-4 REMOVAL & INSTALLATION OF HOOD LOCK… … … …… … … …… … …S-5 REMOVAL &...
Page 349 DISASSEMBLY AND ASSEMBLY OF INTERIOR CEILING… … … …… … …S-26 DISASSEMBLY AND ASSEMBLY OF REAR DOOR TRIM PANEL… … … …S-28 DISASSEMBLY/ASSEMBLY OF CARPET FOR PASSENGER COMPARTMEN.S-28 DISASSEMBLY AND ASSEMBLY OF SEATS… … … …… … … …… … … …S-29 DOORS &...
Page 350 MEASUREMENT SYSTEM… … … …… … … …… … … …… … … …… …S-61 SUNROOF… … … …… … … …… … … …… … … …… … … …… … … …… …S-63 BRIEF INTRODUCTION OF SUNROOF’S MODEL AND FUNCTION… … … S-63 DESCRIPTION OF SUNROOF FUNCTION…...
Page 351: Removal, Installation & Adjustment Of Engine Hood
EXTERIOR ACCESSORIES REMOVAL, INSTALLATION & ADJUSTMENT OF ENGINE HOOD REMOVAL ------Brace engine hood to remove washer nozzle of windshield. ------Loosen the four screws securing engine hood and hinges, two each side, while the other operator removes the hood. INSTALLATION: ------Install in the reverse order of removal. ADJUSTMENT: ------To ensure an even clearance of 4 0.5mm, consistent height and smooth...
Page 352: Removal & Installation Of Hood Lock
REMOVAL & INSTALLATION OF HOOD LOCK REMOVAL: ------Remove the upper hood lock. Tightening torque for the bolt as shown in the figure is 14 2N·m. ------Remove the lower hood lock.. When removing the grid of radiator, remove the four screws on the central part to remove front panel.
Page 353: Removal & Installation Of Fuel Filler Cap
REMOVAL & INSTALLATION OF FUEL FILLER CAP REMOVAL ----Loosen the two screws between the filler cap and car body. INSTALLATION ----Install in the reverse order of installation ADJUSTMENT ----Keep the size at (4±0.5 mm and flatness error between cap rim and the fender at ±0.5mm, which shall not affect the appearance.
Page 354: Removal & Installation Of Trunk Lid Trim Panel
REMOVAL & INSTALLATION TRUNK LID TRIM PANEL REMOVAL ----Remove the screw of trim panel frame. ----Pry open the plastic clip with screwdriver to remove trunk lid trim panel. INSTALLATION Install in the reverse order of removal. REMOVAL & INSTALLATION OF ROOF TRIM MOULDING REMOVAL ----Pry the moulding starting from where back...
Page 355: Removal & Installation Of Front Wheel House Inner Fender
REMOVAL & INSTALLATION FRONT WHEEL HOUSE INNER FENDER REMOVAL ----Loosen the screw between front wheel house and its inner fender. INSTALLATION ---- Install in the reverse order of removal. REMOVAL & INSTALLATION OF REAR WHEEL HOUSE INNER FENDER REMOVAL Loosen the screw between front wheel house and its inner fender.
Page 356 ----Remove radiator grille (refer REMOVAL & INSTALLATION RADIATOR GRILLE). ----Remove the bolts between bumper bracket and front floor cross member. ----Slide the bumper forward until it is disconnected with the side bracket. INSTALLATION ---- Install in the reverse order of removal. NOTE ----Tightening torque for bumper bracket is 82±8N·m.
Page 357: Removal & Installation Of Rear Bumper
REMOVAL & INSTALLATION OF REAR BUMPER REMOVAL: ----Remove partial lining of rear wheel house. Loosen the bolts between the lining and rear bumper. ----Loosen the bolts between trunk support and trunk floor. ----Loosen the bolt between rear bumper and trunk. ----Remove the bolt between rear bumper and floor bottom.
Page 358: Interior Accessories A11 Interior Trim
INTERIOR ACCESSORIES A11 INTERIOR TRIM REMOVAL & INSTALLATION OF INSTRUMENT PANEL REMOVAL: ------Disconnect the negative cable of battery and pry open the trim panel of steering wheel. Loosen the locking nut of steering wheel and take the wheel off. ------Remove the screw under steering column cover and disconnect the combination switch wiring harness connector.
Page 359 Pry out the vents from instrument panel with screwdriver and remove the six screws of instrument panel. Open up the glove box and remove the four screws on the top and two sides of glove box. Pull outward the upper part of the box to take out the glove box.
Page 360 ------Take the ash tray out and remove the clip on the top of the ash tray. Remove the two screws behind central console and instrument panel. ------Pull out the clip of shift lever dust boot and central console. Turn in counter clockwise way the shift lever to remove it.
Page 361: Removal & Installation Of Front Seat Belt
------Remove the four screws on the two sides of instrument panel. Remove the two bolts at where instrument panel and firewall meet from near wiper motor. Remove the two bolts connecting the instrument panel center and the bracket. ------Remove the central electrical box and pull out the connector connecting the box and the instrument.
Page 362: Removal & Installation Of Rear Seat Belt
Remove the nuts, loosen the bolt secured to the inner lining of B-pillar, and remove the B-pillar protective panel. Loosen the two fixing screws of bottom-lining panel of B-pillar; remove the protective panel at the bottom of B-pillar. Remove the decoration cap and loosen the fixing bolt between the safety seat belt and the floor as well as loosen the fixing bolt between the automatic lock...
Page 363: Removal & Installation Of Front Seat
Loosen fixed bolt automatic rewinding to remove seat belt. PRECAUTION: As the fixed position of belt has come away, wrap the belt in reverse on automatic device, should prevent the belt twisting up. REMOVAL & INSTALLATION OF FRONT SEAT REMOVAL Remove the limiting screw of the seat.
Page 364: Removal & Installaton Of Inner Rearview Mirror
REMOVAL & INSTALLATON INNER REARVIEW MIRROR Turn inner rearview mirror, making a 1 angle between pole and beeline of vehicle. Install in reverse order of removal. REMOVAL & INSTALLATON OF SUN VISOR & ITS BRACKET Remove sun visor after remove bracket and its fixed bolt.
Page 365: Interior Accessories A15 Interior Trim
INTERIOR ACCESSORIES (A15 INTERIOR TRIM) DISASSEMBLY AND ASSEMBLY OF INSTRUMENT PANEL Disassembly: A. Begin from engine compartment 1. Remove the negative grid of battery. 2. Remove the right-hand-side wiper of windshield. Loosen the four fastening clamps at the bottom side of the windshield trim plate.
Page 366 B. Begin the disassembly process from the interior part of the car Dismantle the steering wheel, pull the airbag upwards and then remove it. (See disassembly of airbag) 1. Loosen the lock nut between the steering wheel and the Steering-axis. 2.
Page 367 4. Loosen two fastening screws of the cover of the instrument panel and remove the cover. 5. Remove the instrument fastening screws on the partition in the driving compartment and remove the instrument panel. Dismantle the switch and the left bottom side cover of the steering wheel.
Page 368: Disassembly And Assembly Of Package Tray Trim Panel
8. Remove the plug; loosen the fastening screws in the left side of instrument panel and the screws of the left bottom side of the supporting frame. Loosen the fastening screws of the control device. 9. Remove the instrument panel, separate the cable from the clamps and dismantle the necessary electrical components.
Page 369: Disassembly And Assembly Of Rear Speaker
DISASSEMBLY AND ASSEMBLY OF REAR SPEAKER Disassembly: Remove the fastening screws at the top and bottom of the rear seat safety belt (applicable only for the car model with safety belt). Loosen the four screws of the frame and dismantle it. Assembly: The assembly steps are reverse with the above and remember that the tightening for the safety belt is 50±10N.m.
Page 370: Disassembly And Assembly Of Airbag
DISASSEMBLY AND ASSEMBLY OF AIRBAG Safety measures to be taken when working on the airbag system: the works include inspection, assembly and maintenance. These operations can only be carried out by the appropriate professionals. ATTENTION ON SAFETY MATTERS 1. Generally diagnostic tester must be used for diagnosis. Never use volt-meter or any other open wire tester.
Page 371 Disassembly: 1. Disconnect the negative grid of the battery, place the steering wheel at the center position and face the hand wheel upwards. Loosen the two hexagonal bolts between the driver’s airbag and steering wheel. Remove the cable of the airbag. When placing the removed cable, pay attention to face the protruded side down.
Page 372 DISASSEMBLY AND ASSEMBLY OF THE CONTROL DEVICE Disassembly Disconnect the negative grid of the battery. Disconnect the wiring terminal of the airbag control unit, which is located on the vent under the instrument panel. Remove the air intake, which is beside the airbag control unit under the auxiliary instrument panel.
Page 373: Disassembly And Assembly Of Interior Ceiling
DISASSEMBLY AND ASSEMBLY OF INTERIOR CEILING Disassembly: Remove the armrest, sun visor and bracket according to the instruction. Pry the mirror and the interior lamp in the headliner with a minus screwdriver and remove them. Remove two lamps if the car is equipped with two lamps.
Page 374 DISASSEMBLY OF COLUMN C: Remove the decorative cap, after that loosen the lock nut between the internal lining and column C. Use a plug extraction tool to remove the fastening plug in the headliner of the car ceiling. Other worker will remove the headliner and pull it out from the rear door opening.
Page 375: Disassembly And Assembly Of Rear Door Trim Panel
DISASSEMBLY AND ASSEMBLY OF REAR DOOR TRIM PANEL Disassembly: 1. Remove the armrest decorative fastening bolt, and dismantle the armrest cover and armrest base. Remove the inner door open handle guard frame. Remove the safety handle. 2. Remove the fastening bolt between the trim panel and doorframe.
Page 376: Disassembly And Assembly Of Seats
DISASSEMBLY AND ASSEMBLY OF SEATS DISASSEMBLY AND ASSEMBLY OF FRONT SEATS. Disassembly: 1. Move the seat forward, remove the rear brake. Loosen the fastening bolt of the regulator and remove the guide rail. 2.Loosen the nut and remove the locking bolts. 3.
Page 377 DISASSEMBLY AND ASSEMBLY OF REAR SEATS Disassembly: 1. Pull out the rear adjusting lever so as to disconnect the seat, and fold it forward. 2. Remove the guard plate for the seat cushion and car fastening bolts. 3. Loosen the fastening bolt between the seat of the rear beam and the car floor.
Page 378: Doors & Windows
DOORS & WINDOWS REMOVAL & INSTALLATON OF DOORS REMOVAL ----Remove two-side screws of door trim panel. ----Turn the door lock knob off in a counter clockwise way. ----Loosen the nut of retainer gasket and the bolt pin. ----Removal of inside door handle. Unscrew the screw which secures the handle on door trim panel.
Page 379 ----Remove electrical wiring connector, and pull out the bolts between door and the hinge on front column, door check, while another operator remove door. Tightening torque is 56 N·m. ----A layer of protective material shall be added between the door and the surface on which the front door is to be placed.
Page 380: Removal & Installaton Of Trunk Lid
----Loosen the bolts between central locking unit and doorframe. Disconnect the lock rod with lock to remove cable and servomotor. INSTALLATION Install in the reverse order of removal. ADJUSTMENT ----If adjust door lock striker erroneously, which normally causes a failure in closing the door, position of lock striker shall be adjusted.
Page 381 ------Remove the gas spring which raises and supports the trunk lid. Its one end is fixed on the door, while the other end is fixed on the drain channel of the strut. ------In removing gas spring, screwdriver is to be used to move the lock hook to take out the gas spring from swivel pin of the bolt.
Page 382 ------If the trunk lid is to be adjusted horizontally, move the hinge on the side until the value of movement becomes consistent to the designed adjusting value. Adjustment can also be conducted through moving the center of the top. ------After adjustment finished, connecting surface of rear door and the...
Page 383: Removal & Installaton Of Front Door Glasses
------Remove the two screws between the bottom part of central lock and rear end panel. For CHERY model—A15RHD with luggage boot trim panel available, the trim panel shall be removed before removing the screws. ------Install lock in the reverse order of its removal.
Page 384: Removal & Installaton Of Rear Door Glasses
REMOVAL & INSTALLATON OF REAR DOOR GLASSES REMOVAL ----Before removal of front door glasses, the trim panel and waterproof film shall be removed first following instructions. ----Pull out the inner and outer door waterproof strips; begin the removal from the rib of the internal side of the central door frame.
Page 385: Removal & Installaton Of Front Window Regulator
REMOVAL & INSTALLATON OF FRONT WINDOW REGULATOR REMOVAL ----Before removal of front window regulator, the trim panel and waterproof film shall be removed first following instructions. ----Loosen six screws that secure window regulator to the inner panel of the door as shown in the figure.
Page 386: Removal & Installaton Of Rear Window Regulator
REMOVAL & INSTALLATON OF REAR WINDOW REGULATOR REMOVAL ----Before removal of front window regulator, the trim panel and waterproof film shall be removed first following instructions. ----Loosen six screws that secure window regulator to the inner panel of the door as shown in the figure.
Page 387: Maintenance Of Body Beam
MAINTENANCE OF BODY BEAM BAISC EXPLANATION OF MAINTENANCE OF CAR BODY The maintenance of a car body should be carried out by professional personnel in accordance with the manufacturer’s requirement, this is the only way to ensure the effectiveness of the commitment for “no corrosion”...
Page 388: Process For Anti-Corrosive Protection Layer
must not exceed 80 . In the process of welding, the following measures must be taken to prevent the vibration of the electronic devices. 1. Directly connect the earth wire of the electronic welding device to the welding point. Attention must be taken to inspect the connection, and ensure that there is no unnecessary part or insulation part in between the earth wire terminal and spot welding point.
Page 389 The quality of spray coating process for surface protective layer plays a decisive part for the quality of anticorrosive function with protective layer. The processes include. 1. General cleaning, and coating with phosphate. 2. General spray coating with alkyl ester-based paint. 3.
Page 390: Size Adjustment For Movable Parts
SIZE ADJUSTMENT FOR MOVABLE PARTS To facilitate test and re-installation of the body moveable parts, the correct clearances of these parts after adjustment are listed below. TEST DATA S-43...
Page 391 OPENING SIZE ENGINE COMPARTMENT AND WINDSCREEN Size Code STD Value Part Measured A1090 ±2mm Front Mount Installation Center B1550 ±2mm Diagonal Line between Fixing Bolts of Fenders C628 ±2mm Space between Mount Installation Center and Fender D997 ±2mm Space between Center of Fire Wall and Fixing Bolts of Fender...
Page 392: Inspect The Space Between Column B & Column C
Size Code STD Value Part Measured 1235±2mm Opening of Boot 1142±2mm Y-Directional Distance of Boot Inspect the length of diagonal lines in the outer frame of luggage boot. Values of a pair of diagonal lines should be equal: A1=A2 INSPECT THE SPACE BETWEEN COLUMN B &...
Page 393 INSPECT SPACE BETWEEN HINGES OF COLUMN A Size Code STD Value Part Measured 360±0.5mm Z-Directional Distance of Hinges with Column A S-46...
Page 394: Inpect The Space Between Hinges With Column B
INPECT THE SPACE BETWEEN HINGES WITH COLUMN B Size Code STD Value Part Measured 360±0.5mm Z-Directional Distance Hinges with Column B INSPECT THE OPENING SIZES OF FRONT DOOR & REAR DOOR Size Code STD Value Part Measured 938±1mm Space between Column B and the Installation Position of Locking Column...
Page 395 S-48...
Page 396: Protection Wax Inside Car
PROTECTION WAX INSIDE CAR Protection wax at openings contains 60% solid solution, and is coated in an immersion method at 120 . S-49...
Page 397: Protection Wax Outside Car
PROTECTION WAX OUTSIDE CAR Protection Wax for Engine Compartment OUTSIDE PROTECTION WAX DIAGNOSIS OF DAMAGES WITH CAR When a damaged vehicle is maintained, if damage is not found with chassis or suspension, then it could lead to more serious damage or breakage in the future. If a big distortion has occurred with chassis in the accident, then, besides measurement of axles and different fixing positions stipulated in this Chapter, the following parts are also to be tested.
Page 398 WATER TIGHTNESS After the body is operated or maintained, this is the most important instruction in this Chapter. If these instructions are not followed, water leakage will frequently happen inside the car, and it would be very difficult to determine the exact position of leakage, as water inside the car has many uncertain flows, and can possibly flow directly along the water channel.
Page 399: Application Of Putty Adhesives On The Front Exterior Part Of Body
PROTECTION OF UNDERBODY PANEL It is to be reiterated here that during maintenance or replacement of welds or moveable parts of the body, if the protection paint inside the underbody panel or on the appearance is to be removed, then anti-rusting and sound insulating protection layer must be substituted after maintenance or replacement.
Page 400 TABLE FOR APPLICATION OF PUTTY ADHESIVE Code Applied Position Material Model -Around the Gasket of Engine Hood and the Edge of Joints between Outer Frames -Contacting Part between Gasket of Engine Hood and Outer Frame -Connecting Part of Front Doorframe (For waterproofing) -Connecting Part of Rear Doorframe (For...
Page 401: Application Of Putty Adhesive For Rear Exterior Part
APPLICATION OF PUTTY ADHESIVE FOR REAR EXTERIOR PART S-54...
Page 402 TABLE FOR APPLICATION OF PUTTY ADHESIVE Code Applied Position Material Model - Joint of the Car Top and Side - Joint between the Rear Door or the Edge of Tail Door Plank and the Outer Frame - Joint of the Rear Wheel House - Reinforced Bracket for Rear Shock Absorber - Assembly Section of Driving System - Connecting Part between Rear Lining Board and the...
Page 403: Body Interior Spray Coated With Putty Adhesive
BODY INTERIOR SPRAY COATED WITH PUTTY ADHESIVE S-56...
Page 404 TABLE FOR APPLICATION OF PUTTY ADHESIVE Material Code Applied Positions Model -Connecting Position between Body Control Lever and Wheel House -Connecting Position between Floor Board and Front Instrument Panel -Connecting Position between Floor Board, Shift Lever and Center Reinforced Fitting (to be maintained when necessary) -Connecting Position between Sections of Brackets for Front and Rear Chairs...
Page 405 BODY FRONT INTERIOR SPRAY COATED WITH PUTTY ADHESIVE Table for Application of Putty Adhesive Code Applied Position Material Model -Joint of Roof Panel and Side Panel -Joint of the Rear Door or the Tail Door Plank Edge with Outer Case -Joint of the Rear Wheel House -Reinforced Bracket for Rear Shock Absorber...
Page 406: Checking The Size Of Underbody Panel
CHECKING THE SIZE OF UNDERBODY PANEL Point A-a Fixing Position for Bracing Piece of Engine Point B-b Fixing Position for Bracing Piece of Differential Gear Housing Point C-c Fixing Position of Rear Axle Point D-d Fixing Position for Bracket of Rear Bumper Size Code STD Value Part Measured...
Page 407 STRUCTURE OF GUARD PLATE 1. Distance between Reference Line and Point A-a = 246 2. Distance between Reference Line and Point B-b = 140 3. Distance between Reference Line and Point C-c = 94.2 4. Distance between Reference Line and Point D-d = 246 Reference Line = -100Z S-60...
Page 408: Inspect The Body By Using The Framework Of Special
INSPECT BODY USING FRAMEWORK SPECIAL MEASUREMENT SYSTEM S-61...
Page 409 INSPECT BODY USING FRAMEWORK SPECIAL MEASUREMENT SYSTEM (Fixed mechanical tools are to be used during inspection) S-62...
Page 410: Sunroof
BRIEF INTRODUCTION OF SUNROOF’S MODEL AND FUNCTION The agate super 300 auto sunroof, which is a new generation product manufactured by German Webster Auto Sunroof Manufacturing Company, is the new option sunroof of Chery A15 sedan. The good looking computer control panel features...
Page 411 PARTS OF SUNROOF S-64...
Page 412 PARTS LIST OF SUPER 300 Position Name Glass panel Glass panel fastening device Guide bolt Mechanical devices left / right Seal Interior trim rim with gray sunshade Interior trim rim with beige sunshade Sunroof motor Sunroof module Cover of control buttons Upper frame Interior fastening frame Wind strip...
Page 413: Description Of Sunroof Function
DESCRIPTION SUNROOF FUNCTION 1. CONTROL PANEL a) This button is preset position 1; b) This button is preset position 2; This button is control button for inclining and rearward sliding; This button is control button for forward sliding; c) This is control button for immediately closing.
Page 414 3. SELECTION OF TILT HEIGHT When the sunroof is closed, press the button continuously, the glass panel will open to the maximum tilt position automatically. When the sunroof is positioned at maximum tilt height, press the button continuously, the glass panel will close in stagewise, and there are 4 tilt heights available for selection.
Page 415 Gently press the button (less than 0.1 second), the sunroof will open to the preset position preset position automatically, and these two positions can be set repeatedly. 5. AUTOMATIC CLOSING When the sunroof is opened to any position, cut off the power supply of sedan, the sunroof will make a sound of “CREAK”.
Page 416: Instructions Of Sunroof Maintenance
If the sunroof encounters any obstruction during its automatic closing, it will open to the maximum position again, and try to close repeatedly until the obstruction is eliminated. If press the button continuously, the anti obstruction mechanism will be disabled. INSTRUCTIONS SUNROOF MAINTENANCE...
Page 417 Remove the two fastening bolts in the front of interior trim rim. Remove the interior trim rim (pull downward as the order shown in the figure), pay attention not to damage the control buttons. Move the fastening clip to the direction of computer box, disconnect the connectors of motor and the SCU, disengage the fastening hook between the SCU and the motor, and...
Page 418 Install the motor and the SCU in the reverse order of step 7. Install in the reverse order of step 6. Pay attention on the engagement of drive shaft and the gear of motor. Install the interior trim rim (push upwards as the order shown in the figure, note that the clamp should be aligned to the groove).
Page 419: Disassembly And Assembly Of Sunroof
Install the cover of control buttons. DISASSEMBLY AND ASSEMBLY OF SUNROOF Disassembly: 1. Fully open the sunroof. 2. Turn off the ignition switch, keep pressing the control button to prevent the sunroof from automatic closing. 3. Remove the cover of control buttons. S-72...
Page 420 4. Remove the 2 fastening bolts in the front of interior trim rim. 5. Remove the interior trim rim (pull upwards as the order shown in the figure), pay attention not to damage the control buttons. 6. Disconnect the harness of SCU. Remove the 4 fastening bolts of motor and the SCU, and pull upwards to remove the motor and the SCU.
Page 421 8. Remove the interior fastening frame, make the rear part to be inclined downwards, push forward and then the interior fastening frame can be removed. 9. Remove the sunroof as the method shown in the figure. Assembly: 10. Apply silicon gel with a width of 3 cm on the position indicated in the figure.
Page 422 12. Install the interior fastening frame with an angle of 45 degrees, front high rear low respectively, firstly fasten the front part, and then push the rear section rearward. A fastening bolt shall be tightened in the rear middle area of interior fastening frame to prevent dropping.
Page 423: Replacement Of Glass Panel
16. Tighten the fastening bolts of interior trim rim. 17. Install the cover of control buttons. REPLACEMENT OF GLASS PANEL 1. Fully open the sunroof. 2. As shown in the figure, disengage the latch of glass panel lock and the fastening base with screwdriver, then remove the lock of glass panel.
Page 424 3. Turn the fastening pin of glass panel by 90 degrees in clockwise with flat screwdriver to remove the fastening pin of glass panel. (Perform on another side in the same way). 4. Pull out the glass panel from the mechanical devices in parallel with proper attention.
Page 425: Replacement Of Seal
7.Push the fastening pin of glass panel to the proper position. REPLACEMENT OF SEAL 1. Fully open the sunroof. 2.As shown in the figure, disengage the latch of glass panel lock and the fastening base with screwdriver, then remove the lock of glass panel.
Page 426 4. Pull out the glass panel from the mechanical devices in parallel with proper attention. 5. Remove the old seal from the middle-front part of sunroof frame by flat screwdriver. 6. Remove the remaining sealant and clean the groove thoroughly. Assembly: 7.
Page 427 8. Place the seal on the upper frame naturally, and the rabbet center of seal must be aligned with the center of fastening block of glass panel. Strech this part of seal with proper attention in assembly. 9. Push the seal into the groove by a depth of about 1mm starting from the middle-front part, then both sides, and finally the rear part.
Page 428 12. Install the fastening pin of glass panel by rotating 90 degrees only. 13. Push the lock of glass panel to the proper position. 14. Remove the excessive silicon gel. 15. The sunroof can be operated after at least two hours. S-81...
Page 429 REPALCEMENT OF SUNSHADE 1. Fully open the sunroof. 2. Turn off the ignition switch and press the control button to prevent the sunroof from automatic closing. 3. Remove the cover of control buttons. 4. Remove the two fastening bolts in the front of interior trim rim.
Page 430 5. Remove the interior trim rim (pull downward as shown in the figure). Pay attention not to damage the control buttons. 6. Remove the damaged sunshade. Assembly 7. Install the right guide device and the rear supporter of sunshade. S-83...
Page 431 8. Wind up the sunshade and wrap the string on the right guide roller. 9. Place the string in the sliding fastening cap and the guide device. 10.Place the mechanical devices in a tilt position. Remove the lock from the pin joint and then remove the latter.
Page 432 12. Push out the guide lock as shown in the figure. 13. Remove the lock from the guide rail. Assembly: 14. Place the new guide lock in the guide rail. 15. Install the guide lock in the proper position. S-85...
Page 433 16. Disengage the front riser and the rail slide device, then remove the latter. 17. Inspect the new rail slide device. 18. Install in the reverse order of step 16. S-86...
Page 434 19. Install in the reverse order of step 11. 20. Install in the reverse order of step 10. 21. Install in the reverse order of step 9. 22. Install in the reverse order of step 8. S-87...
Page 435 23. Install in the reverse order of step 7. 24. Install in the reverse order of step 6. 25. Fully close the sunroof by pulling the rack (make sure that it is done properly), and verify that the pin joint not being jammed in the mechanical devices.
Page 436 26. Install the rack, the pinion and the pinion cover. Note that the pinion should be placed at the center. 27. Slide the glass panel into the mechanical devices in parallel. 28. Install the fastening pin of glass panel through rotating 90 degrees only. 29.
Page 437: Program Description
PROGRAM DESCRIPTION In the case of power-failure and service of sunroof, all of sunroof’s functions can be restored only after the re-program of sunroof is performed. If the sunroof fails to function properly, try to re-program the sunroof. 1. Program and turn on ignition switch. 2.
Page 438: Notes On Maintenance And Useage
NOTES MAINTENANCE USEAGE 1. MAINTENANCE OF SUNROOF The glass panel is designed with the function of heat and ultraviolet ray insulation. Please clean with soft cloth and detergent, don’t use any sticky detergent. Please clean the sunshade with soft cloth and detergent, don’t use any sticky detergent.
Page 439 2. NOTES: It is not allowed to open the sunroof while raining or washing. The sunroof should not be opened after at least 5 minutes of driving in a rainy day or after washing. It’s not allowed to put head or hand through the sunroof.
Page 440 Note: Make sure that there is no obstruction on the top of sedan to disturb the movement of glass panel prior opening the sunroof. When the sedan is running in high speed, the sunshade should not be shut completely under the condition that the sunroof is opened.
Page 441: Body Electrical System
BODY ELECTRICAL SYSTEM CHARGING AND STARTING SYSTEM … …… … …… …… … ………… ……… T-4 REMOVAL/INSTALLATION OF THE BATTERY …… … …… …… … ……T-4 INSPECTION OF THE BATTERY …… … …… …… … ………… …… ……T-4 CHARGING OF THE BATTERY …… … …… …… … ……… …… … …… ……T-5 REMOVAL/INSTALLATION OF THE GENERATOR ……...
Page 442 COMMON FAILURES AND TROUBLESHOOTING OF TURN SIGNAL LAMP..T-17 IGNITION SYSTEM … ……… ……… ……… ……… ……… ……… ……… ……T-18 SUMMERY OF IGNITION SYSTEM … ……… ………… ……… ……… ……T-18 REMOVAL OF IGNITION COIL AND SPARK PLUP … ………… ……… ……T-19 OVERHAUL OF IGNITION SYSTEM …...
Page 443 AIRBAG SYSTEM … ……… ……… ……… ……… ……… ……… ……… ………T-48 WORKING PRINCIPLE OF AIRBAG … ……… ……… ……… ………… ……T-48 OPERATION CONDITIONS … ……… ……… ……… ……… ………… ………T-49 OPERATION PROCESS ………………… ……… ……… ……… ………… ……T-49 ASSEMBLY PARTS AND WORKING PRINCIPLE OF AIRBAG … ………… …T-51 FAULT DIAGNOSIS AND OVERHAUL …...
Page 444: Charging And Starting System
CHARGING AND STARTING SYSTEM REMOVAL/INSTALLATION OF BATTERY AND INSPECTION Removal: ----Disconnect the negative and positive cables of battery. ----Loosen the bolt of front battery clamping steel plate, and remove the clamping steel plate. ----Move the battery forward, isolate the back clamping plate and take down the battery.
Page 445: Removal/Installation Of The Generator
Approximate temperature of battery Minimum voltage (V) 21°C 70°F 16°C 61°F 10°C 50°F 4°C 39°F -1°C 30°F -7°C 19°F -12°C 10°F -18°C 0°F CHARGING OF BATTERY Warning: Keep the battery away from any flammable materials. If not, the gas emitted from the battery liquid that is easily flammable may cause severe injury or even death of people.
Page 446 part of the battery away from water. Connect the battery to the charger, and adjust the charging current accordingly. As heat discharged by the exhaust manifold could damage the generator, you must ensure that the heat discharging guard and insulation device are firmly installed on the generator.
Page 447 Installation of driving belt and tensioner assembly: Disconnect the negative grid of the battery. Use 3 M8 Allen screws to install the tensioner assembly on the bracket of the generator, with a tightening torque of 25±2N.m. Install the multi-wedged belting; Pull out the pin on the tensioner assembly so as to tension the driving belts in the tensioner pulley.
Page 448: Inspection Of Generator
—Use voltmeter to measure the voltage value of the generator output terminal. Standard value: Engine idling; Temperature: 20 , Output voltage: 13-15V. —Switch on the following devices and observe the increase of readings of the voltmeter: • Headlamp • Air conditioning •...
Page 449: Removal/Installation Of Starter
REMOVAL/INSTALLATION OF STARTER Warning: When connecting wires of the battery are in on-state, and at this time if you contact the generator terminal to the car body, sparks will happen. This may cause body injury, fire and the sparks may damage the electrical components. Therefore before carrying the following operation, you must disconnect the negative grid of the battery first.
Page 450: Load Inspection Of Starter
Technical parameters Voltage value V Current value Less than 90 LOAD INSPECTION OF STARTER 1. Verify that the battery is fully charged. 2. Initiate the engine, and check whether any block or noise during the rotation of the starter rotor. ●...
Page 451: Lighting System
LIGHTING SYSTEM REMOVAL/INSTALLATION OF LIGHTINGS FOR THE COMPLETE CAR 1. Headlamp Removal Disconnect the negative grid of the battery Remove the radiator grille, and use sleeve to remove the four fixing bolts of the headlamp. Unplug the wiring harness connector behind the headlamp holder.
Page 452: Removal/Installation Of License Lamp
Place the fog lamp into the installation hole from the front, and ensure that the 3 screw holes are concentric with the holes on the front bumper; Tighten the 3 self-tapping screws, with a tightening torque of 1.5±0.2N.m; Install the grilles on the bottom part (see instruction in car body) 3.
Page 453: Removal/Installation Of Trunk Lamp
Align lock core of the trunk with the hole, so as to match the guard plate with the car body properly; Tighten 2 self-tapping screw, pay attention to adjust the facial gap, spacing and other differences between the car body and the movable part, feel the difference in height with hand and make necessary adjustment while tightening;...
Page 454: 10.Removal/Installation Of Door Switch
10.Removal/installation of door switch Disconnect the negative grid of the battery. Loosen the self-tapping screw of the door switch with a cross screw driver. Pull out the door switch, and separate the wiring harness connectors. 11.Removal/installation of control switch for dash lights Disconnect the negative grid of the battery.
Page 455 COMMON MALFUNCTIONS OF LIGHTING SYSTEM / TROUBLESHOOTING 1.COMMON MALFUNCTIONS OF FRONT HEADLAMP / TROUBLESHOOTING Malfunction Malfunction Diagnosis Troubleshooting 1.All of bulbs have been damaged. 1.Replace the bulb. 2.The fuse has been burned down. 2.Replace the fuse. Neither high beam or low 3.Headlamp switch is faulty.
Page 456 Warning: The bulb will generate heat of very high temperature during working. So if the surface of the bulb becomes dirty, the excessive heat will be accumulated, which would result in shortening the life span of the bulb. When replacing the bulb, pay attention to hold the metal edge rather than the bulb itself.
Page 457 COMMON MALFUNCTIONS TURN SIGNAL LAMP TROUBLESHOOTING Malfunction Malfunction Diagnosis Troubleshooting symptom 1. The bulb of the “fast flashing Left right frequency” side has been damaged. 1. Replace the bulb. flashing 2. The bulb power does not comply with 2. Replace the standard bulb. frequencies the specification.
Page 458: Ignition System
IGNITION SYSTEM SUMMARY OF IGNITION SYSTEM The ignition system is integrated with the fuel injection system. It is an electronic system equipped with built-in power supply module. It can provide various kinds of optimum ignition angular values. This task is being carried out through referencing of the input instantaneous physical parameter related with the engine working conditions.
Page 459 REMOVAL /INSTALLATION OF IGNITION COIL AND SPARK PLUGS: 1. Disconnect the wiring harness terminal post from the negative grid of the battery 2. Pull out the 4 connectors of high voltage cable and ignition module plug. 3. Unscrew the three fastening screws for the ignition module, and remove the ignition module.
Page 460: Inspection Of Ignition Timing
Secondary coil resistance: 4900Ω±10% at the temperature of 23±5°C If the resistance of ignition coils does not comply with the specification, please replace with the original spare parts designated by Chery Automobile so as to prevent the improper operation of the ignition system.
Page 461 (4) Wait until the cooling fan stops. 3. With the help of WDS or corresponding instrument, check whether the ignition timing falls within the scope of the specification. Ignition timing: Approx.: 10±5 degrees advancing TDC 4. When the engine speed is gradually increasing, confirm that the ignition timing is also correspondingly advanced forward.
Page 462: Introduction Of Instruments
INTRODUCTION OF INSTRUMENTS SYSTEM DESCRIPTION The Chery sedan A15LHD employs indicator needles and digital combination instruments, the combination instruments including various instruments and measuring equipments that are used to indicate the conditions of the car, various warning lamps that are used to monitor...
Page 463: Speedometer
System components and functions are as follows: Name of Component Function The indicator needle of speedometer is moving as Speedometer per the signal from speed sensor, indicating the driving speed of the car. The indicator needle of tachometer is moving as per Tachometer the signal from ignition, indicating the engine rotation speed.
Page 464 The switch is installed on the engine body. When Warning switch for low oil pressure the oil pressure drops, the switch will be activated and switched on the warning lamp. The switch is installed in the engine oil tank. When Warning switch for engine oil level the level of engine oil drops, the warning lamp will be switched on.
Page 465 hand brake diagnosi air bag seat belt left turn right turn rotary speed speed, switch light light, signal steering device computer, / brake purple black and black brown and gray brown black red and black brown and green and brown black and white and black...
Page 466 The 28-socket connector of the wiring harness of combination instrument The function of each socket is described in the table below: Socket Function Socket Function Connecting to the terminal D+ of No connected generator Connecting to the water warning Air bag warning signal switch of water tank Terminal 31# (ground) Door light...
Page 467: Water Temperature Meter
1. SPEED ODOMETER The Chery sedan A15LHD employs the cross coil type speedometer to indicate the driving speed and accumulated road mileage, as well as equipped with digital odometer. The section for measuring car speed employs a magnetic type of structure, while the section for recording mileage is controlled by multifunction liquid crystal display.
Page 468 3. FUNCTION AND PREINCIPLE OF WATER TEMPERATURE SENSOR The water temperature sensor of Chery sedan A15 LHD employs the thermo-sensitive resistance, which is shown in the figure above: The coolant temperature sensor is used to inspect working temperature of the engine; the ECM will provide the best control program for the engine according to different temperature environment;...
Page 469 The thermo-sensitive resistance is made of a kind of semiconducting material with negative temperature coefficient, where its resistance will sharply decrease as the temperature increases. 5. FUEL METER The operation of the fuel meter is basically the same as the water temperature meter. It is also the cross coil type of indicator needle meter.
Page 470 Malfunction Malfunction Malfunction diagnosis Components Remarks symptoms reasons and troubleshooting Hall Speed Sensor of (1) If the speedometer does speedometer. not function, firstly inspect (2) The indicator the engagement of Hall needle Speed Sensor and the drive speedometer gear to verify that there is jammed.
Page 471: Fuel Meter
water temperature meter or voltage regulator is faulty. (3) Remove the instrument panel and maintain the normal connection of the wiring harness. Connect a multimeter between the output terminal voltage regulator positive grid and the grounding terminal 2 to measure the voltage.
Page 472 of the plug of the fuel meter sensor, and the 21# socket of the connector of combined instrumentation is open, the route of the circuit is: purple /black wire of the plug of the fuel meter sensor→ the 3# socket of the connector M of the relay plate →...
Page 473 Connect diode-testing light high-pressure switch and increase the engine speed slowly. When pressure reaches 160-200KPa, light-emitting diode should be lighted. If it is not lighted, then it indicates that the high pressure switch is faulty; further increase the engine speed up to 2000r/min, then the oil pressure should reach at least 200KPa.
Page 474 (1) Inspect to see whether engine coolant temperature is actually too high and the level of the storage tank is too low. above inspection are normal, then (1) Coolant level pull out the connector of in storage tank is storage tank level The warning...
Page 475 ELECTRIC WIPER AND WINDSHIELD WASHER SYSTEM SYSTEM DESCRIPTION The wiper is mainly consisted of the wiper motor assembly, the three-linkage mechanism, and the pendulum rod and wiper blade with the tri-directional flexible ball joint. See figure (wiper-1). The wiper motor is shown in figure (wiper-2). Wiper 1.
Page 476 The washer is consisted of 5 parts which including a mini permanent magnet DC motor, centrifugal water pump, nozzle, liquid storage container and water pipe. The motor and water pump make up the assembly of the washer motor and the water pump as shown in figure (Wiper-3): 1-Water inlet 2-Impeller blade...
Page 477: Washer
The circuit schematic diagram of the front window wiper and washer of Chery sedan A15: to horn relay blown and black black and blue black and blue Intermittent wiper relay washer glay and black green green and red green and red...
Page 478 The working list of wiper/washer components Intermittent V5 washer Wiper switch Wiper motor wiper relay (state of (state of (state of (state of Gear conduction conduction conduction Remarks conduction between the between the between the between the pins) pins) pins) pins) 5/53s (power...
Page 479 Place the wiper link-rod inside and concentric the fastening hole with the welded nut of car body; Tighten it with 3 bolts and washers, and the tightening torque is 9N·m; Install the water channel guard for the front window and other parts (see car body instruction for details);...
Page 480 (3) Verify that the wiper switch and the X-contact off-load relay function normally. Otherwise, replace corresponding parts. The intermittent When (1) The circuit (1) Verify that the fuse wiping does not ignition switch wiper S8 in the relay box and function.
Page 481 slowly When (1) The slowly (1) Power supply of wiping motor ignition switch wiping circuit of ignition switch ON. does is turned on, turn the wiper motor (2) If the power supply function. the wiper switch is open. of ignition switch ON (slowly There works properly, check...
Page 482 the wiper motor be reset. contact does short-time wiping of function. the wiper switch has a poor contact. Replace the switch. Improve flexibility of the wiper switch. When handle being released, the switch automatically reset. The wiper fails When the wiper There Check reset...
Page 483 is open. (4) If the circuit of the motor power works properly, replace the washer motor. washer When The intermittent The washer functions, functions, ignition switch controller of the but the wiper does not the wiper does is turned on, turn wiper function, it is mainly not function.
Page 484: Electric Window Regulator System
ELECTRIC WINDOW REGULATOR SYSTEM SYSTEM DESCRIPTION The Chery sedan A15LHD employs an electric steel wire type window regulator. The structure is shown in figure (window-1). Electric window regulator (window-1) The up/down operation of the window can be centrally controlled by the driver through pushing buttons, and also can be controlled individually by the door switch to adjust the door window opening.
Page 485: Fault Diagnosis And Troubleshooting
FAULT DIAGNOSIS AND TROUBLESHOOTING 1. THE ELECTRIC WINDOW CAN NOT BE ACTIVATED When the electric window can not be activated, the followings should be checked: (1) Whether the voltage of the battery is normal; (2) The voltage supply of the thermo-sensitive fuses and the control relay; (3) The window regulator switches and the voltage supply, including the front left, front right, rear left and rear right windows;...
Page 486: Principle Of Central Door Lock Control
CENTRAL LOCK SYSTEM SYSTEM DESCRIPTION The Chery sedan A15 employs a complete electronic control central lock system. The central lock system is consisted of one 4-wire type controlling module, three supplemental door lock actuating motors and one luggage boot cover actuating motor. The lock and unlock of the interlock mechanism for the central lock system are all controlled by the driver side door lock switch.
Page 487 Malfunction symptom 1) None of the central door locks can be unlocked after closing the door. Malfunction reasons 1) Malfunction in the central door lock module. Troubleshooting Replace the central door lock module. 3. NONE OF THE CENTRAL DOOR LOCKS CAN BE LOCKED Malfunction symptom None of the central door locks can be locked after opening the door.
Page 488: Airbag System
The airbag is an option for the Chery sedan A15 RHD, and the airbag model employed is Dongfangjiule. The purpose of the airbag design is: During the short...
Page 489: Operation Conditions
OPERATION CONDITIONS ----The airbag system will function under the following conditions: 1) When the vehicle is collided with a stationary object with a speed over 25Km/H, the airbag will be activated. 2) When two vehicles have a head-on collision both with a speed over 25Km/H, the airbags of the two vehicles will be activated.
Page 490 ----- -The accident happens; Sensing; Triggering; The airbag is activated and inflated; ----The airbag inflates completely; The driver moves forward; ----The driver’s head and upper body bump into the airbag; The air is discharged through the rear end of the airbag. ----The air is totally discharged from the safety airbag.
Page 491 microprocessor will activate the ignition circuit. If the electric safety sensor is turned off at the same time, the ignition current will induce the igniter, and activate the safety airbag. THE ASSEMBLY PARTS OF AIRBAG AND WORKING PRINCIPLE SRS (airbag system) includes: Steering wheel airbag components;...
Page 492 3. HAIRSPRING In order to ensure that the steering wheel has a sufficient turning angle other than damages the connection wiring harness of the airbag assembly, the spiral wiring harness is adopted between the steering wheel and the steering column. Install the wiring harness into the spiral spring first, and then install the spiral spring into the spring housing, which is called as hairspring.
Page 493 safety memory unit before handling with the steering system. In order to remove or install the airbag components, please disconnect the negative grid of the battery and wait for at least 1 minute. Removal/Installation The hairspring is installed between the steering wheel and the steering column. When installing the hairspring, pay attention to the installing position and direction, otherwise it would cause insufficient turning angle or heavy rotation of the steering wheel.
Page 494 presses on the airbag due to the effect of inertia, the airbag is pressed and the air will be discharged from the discharging hole, so that the kinetic energy resulted by the collision between the driver and the airbag can be absorbed, which preventing the driver from injuring. The function of the inflator components is such that when the igniter activates the ignition agent, generating air and inflating the airbag, causing the airbag to spread out.
Page 495 components: ·Safety sensor ·Capacitor ·Collision sensor or accelerometer (4) Capacitor The capacitor provides the backup power. (5) Bulb When the operation voltage is increased to the BCM point, the BCM will trigger the warning lamp and we can now check the bulb. The BCM turns on the warning lamp for 4 seconds and then turn it off during the bulb inspection.
Page 496 milliseconds X25=10 second), the malfunction mark will be cancelled. The warning lamp will be turned off under this condition, and it is called the “historical malfunction”. 2. DIAGNOSIS OF THE DIAGOSTIC TESTER The diagnostic tester can read data from the BCM memorizer to carry on the continuous data exchanging.
Page 497 BCM should not be used any more. When replacing the BCM, the arrow on the BCM must point to the direction right ahead of the vehicle. The BCM must be horizontally installed onto the installation plane, and parallel with the coordinate axis of the vehicle body.
Page 498 A dimension measurement for the steering column must be carried out. Check whether there is any crack or other damage on the instrument panel and steering column guard. Check whether there is any deformation, bending, crack or other damage on the instrument panel support Check the seat belt and installation fastening point.
Page 499 wiring harnesses of at least 10 meters long each. Peel off the 13 mm insulated outer layer of the 2 extra wiring harness ends, and tie the two ends of the wiring harnesses together. Place the tied ends beside the battery use to activate the airbag, but do not connect it to the battery at this moment.
Page 500 Connect the airbag and the airbag activation purpose battery with two extra wiring harnesses of at least 10 meters long each; Peel off the 13 mm insulated outer layer of the two extra wiring harness ends; Tie the two ends of the two extra wiring harnesses where its insulated outer layers have been peeled off;...
Page 501: Removal/Installation Of Airbag
REMOVAL/INSTALLATION OF AIRBAG SYSTEM 1. REMOVAL/INSTALLATION OF AIRBAG Removal: ----Disconnect the negative cable of the battery (—) Warning: When the ignition is turned off and at the same time the fuse is taken out, the airbag control module (BCM) can provide the sufficient voltage for 1 minute to activate the airbag.
Page 502 Installation: ----Connect wiring harness plug of the horn and airbag to the airbag socket. Install the airbag Install the airbag bolt Use a tightening torque of 13~17N.m to tighten the airbag bolt Connect it to the negative grid of the battery 2.
Page 503 Move the safety interlock head of the connector to “Lock” position. Install the decoration panel on the left and right of the instrument panel. Connect the SRS system. Please refer to the “Connection of the airbag system” of this manual. Warning: All the BCM bolts must be tightened carefully.
Page 504 3. WIRING AND CONNECTOR Note: The wirings assembly of the SRS protective supplementary system and that of COWL are joined together. All the wirings of this system are installed in a yellow corrugated conduit, and all the connectors is normal yellow.
Page 505 signal, the airbag will be activated and inflated. ----When removing the liner of the steering wheel or installing the new one, the upper surface of the liner should face upward. At this moment, place the lock rod of the double-lock connector at the locking state and place it carefully to prevent it from Incorrect placement damaging the connector.
Page 506: Control Module
6. BCM AIRBAG CONTROL MODULE ----The BCM (airbag control module) (See figure) is installed on the floor under the heat exchanging radiator. The BCM (Airbag control module) includes airbag sensor, safety sensor, diagnosis circuit, ignition controlling and driving circuit. It receives the signal from airbag sensor and determines whether to trigger the SRS system.
Page 507: Notes On Safety Operation
NOTES ON SAFETY OPERATION During the maintenance, if the proper procedures are not followed, the airbag system may activate unexpectedly resulting in serious accident. The fault arising during the maintenance work may cause the inability of the activation of airbag when it is required to function. Therefore before carrying out any maintenance (including removing, installing, testing or changing for the components), the maintaining personnel must read all the instructions below carefully, and carry out the maintenance according to the following proper procedures...
Page 508 followed. (13) After finishing the maintenance work for the supplementary protective system, the status of SRS warning lamp should be inspected. T-68...
Page 509: Sound System
SOUND SYSTEM VDO INTERFACE FUNCTION 1. Preset key 1 10. BAND RANDOM Start/stop of CD Radio frequency scan/ CD songs list scan 2. Preset key 2 High end/low end search (radio) 3. Preset key 3 Forward/backward songs list (CD) REPEAT CD player repeat start/stop Music searching system 4.
Page 510: Operation Instruction
OPERATION INSTRUCTION Tape playing 1. Press POWER button to switch on the power, and rotate to the right to increase the volume. 2. Face the tape open side to the right. Push it into the cassette door No.18 to lock position, and the player begins to work.
Page 511 starting from the initial frequency point. When one station is locked in, the player will pause the scanning. The frequency of the station will flash for 10 seconds while broadcasting the program of the tuned station. After that it will continue to scan the higher frequency end till it reaches the highest end and return automatically.
Page 512: Other Functions
OTHER FUNCTIONS Sound setting 1. Press the SOUND button for at least 2 seconds to enter into the SOUND setting mode. 2. Press the SOUND button to select the desired sound effect mode. -BASS (bass, under the BASS-TREB mode) -TREBLE (treble, under the BASS-TREB mode) -BALANCE: The left and right volume balancing -FADER: Front and back speaker control -LOUDNESS (off, bass, mediant, treble, under the BASS-TREB mode)
Page 513: Removal/Installation Of Sound System
REMOVAL/INSTALLATION OF SOUND SYSTEM The sound system includes sound source, speaker and antenna. The sound source includes recorder assembly, optional CD player assembly and VCD player assembly. The CD player assembly and VCD player assembly includes the host, power signal line and disks exchanger. 1.
Page 514 Align it at the correct direction and press the speaker cover into it. 5. INSTALLATION OF CD EXCHANGER Disconnect the negative grid of the battery. Install the bracket of the CD exchanger onto the two sides of the exchanger with washers and screws.
Page 515 TROUBLESHOOTING Malfunction Reasons/Troubleshooting No power supply Connection malfunction. Please check the connection. The player fails to function Check the fuse (player and vehicle) and the connector. and display. The player functions but Adjust the volume of the player. without sound or with poor Check the sound balancing function.
Page 516: Air Conditioner System
AIR CONDITIONER SYSTEM AIR CONDITIONING SYSTEM OVERVIEW … … … … … … …… …… …… … U-2 REFILLING OF REFRIGERANT AND REFRIGERANT OIL … … … … … … … U-6 A/C SYSTEM COMPONENTS … … … … … … …… … … … … … …… ……… U-14 FAILURES AND SHOOTING ANALYSIS SHEET …...
Page 517: Air Conditioning System Overview
AIR CONDITIONING SYSTEM OVERVIEW Based on its function, the Chery A15LHD air conditioning unit may be divided into such five basic components as the refrigeration system, heating system, ventilation system, control system and air purification system. 1. Refrigeration system It is available to cool the air inside the vehicle based on the refrigeration principle of vapor compression refrigerator.
Page 518 A15LHD’s air conditioning unit adopts the reheating mixed type unit, the heating system of which is...
Page 519 Chery A15LHD adopts the natural ventilation and forced ventilation. The open/close fresh air inlet is controlled by the fresh/circulating air vacuum valve.
Page 520 Air-Conditioner Compressor Evaporator Assembly Air-Conditi on Harness 4. Control system The control system mainly consist of the electrical component, vacuum hose and control mechanism. On one side, it is available to control the temperature and pressure of refrigeration and heating system, and, on the other side, it is also used to control the temperature of air inside the vehicle, the blowing rate and direction.
Page 521: Refilling Of Refrigerant And Refrigerant Oil
REFILLING OF REFRIGERANT AND REFRIGERANT OIL Caution: · If there are some moist materials or other foreign materials circulating High pressur High pressur refrigeration system, cooling pressur pressur performance of the refrigeration system will considerably decrease and generate the abnormal noise. So, after any refrigeration and circulation part is removed, the Charging the refrigerant openings shall be immediately plugged to...
Page 522 (3) Do not allow the refrigerant to contact with 2-Refrigerant Tank Refilling Valve fire. Otherwise it may generate the toxic gas. 3-Plate-shaped Nut (4) The O-ring can be applied once only. 4- Needle Valve (5) Chery model-A15LHD adopts 5-Refilling Valve Joint refrigerant R134a which cannot interchanged with R12.
Page 523 clockwise direction and tighten it by hand as possible. (4) Turn the butterfly handle 1 in the clockwise direction to make the valve needle 4 in its front end punch a small hole in the dummy club of refrigerant tank. (5) Turn the butterfly handle 1 in the counterclockwise direction, which the refrigerant will flow into the manifold...
Page 524 200 g or more refrigerants shall be charged every time, and turn the compressor several times by hand after the completion of charging. (5) Turn off the high-pressure manual valve 4, shown in the figure below, and turn on the low-pressure manual valve 3 to let the refrigerant in gas-state charge into the refrigeration...
Page 525 reservoir. (2) Tighten the propane reservoir 16 to the leak detector. (3) Insert a lighting match into lighting device 9, and then slowly turn the adjusting handle counterclockwise direction till the torch is lit. (4) Adjust the flame to smallest. The smaller the flame, the more sensitive to the leak of refrigerant.
Page 526 auxiliary valve so as to prevent the air from being inhaled into the system. (5) Connect the high-pressure side hose joint to the manifold pressure gauge, turn on the high-pressure manual valve, and start up the vacuum pump to vacuumize the high-pressure side hose.
Page 527 6. Methods of Refrigerant Vacuumizing It is difficult to pump out the water from the refrigeration system when vacuumizing. But High the vacuumizing can reduce the fluidization pressu pressure point of water after the vacuum is generated in the refrigeration system, which enables the water to boil at the lower temperature, and pump out it in the form of steam from the system.
Page 528 return back within 10 min, it indicates that the system is normal and the refrigerant can be charged into the system. (6) Restart the vacuum pump, and turn on the low-pressure valve manifold pressure gauge to continuously vacuumize 15 min. Then, turn off the low-pressure valve to stop vacuumizing, and prepare for charging the refrigerant.
Page 529: A/C System Components
(6) Install it in the reverse order of removal Compressor Position Related Performance Parameters: Chery A15LHD with the electronic fuel injection type engine adopts the SD7V16 type compressor, the performance parameters of which are shown in the table below. U-14...
Page 530 Swash Plate Number of cylinders Cylinder diameter (mm) 29 3 Travel (mm) 34 2 Displacement (cm³/r) 161 3 10 4 Allowable maximum instantaneous speed 8000 (r/min) allowable maximum continuous speed 7000 (r/min) Coolant R134a Refrigerant oil (cm 115±15 Electromagnetic clutch mass (kg) Rated voltage (V) Rated power (W) U-15...
Page 531 The compressor is driven by engine crankshaft pulley via the M belt. When the shift lever on the A/C control mechanism is shifted to the refrigeration position, the electromagnetic clutch of A/C compressor engages, and the compressor pulley make the main shaft and swash plate rotate and then pull the rocking plate to swing.
Page 532 Introduction to the fluid reservoir: Removal/Installation (see the Removal of Condenser) Chery A15LHD’s fluid reservoir is located under the condenser (i.e., the outlet of condenser), the structure of which is shown in the figure. In fact, the fluid reservoir is a pressure container used to...
Page 533 2) Pressure switch Chery A15LHD’s A/C pressure switch adopts the dual-pressure (high and low pressures) and four-wire pressure switch which is installed on the high pressure pipe located at the front end of expansion valve, with 50...
Page 534 · Use a flat headed screwdriver to straighten it if a bent is found. The Chery A15LHD adopts the tube-fin type evaporator which is installed in the air conditioning unit assy. under the instrument panel. The function of evaporator is opposite to that of condenser.
Page 535: Failures And Shooting Analysis Sheet
FAILURES AND SHOOTING ANALYSIS SHEET 1. Precautions on A/C system installation (1) For the pipes fixed using the fixing nuts, two wrenches must be applied to ensure that the pipes don't deform or break; (2) Do not use the compressed air to clean the pipes, and the nitrogen or coolant gas is available;...
Page 536: Precautions On The Security Of A/C System
PRECAUTIONS ON THE SECURITY OF A/C SYSTEM Coolant treatment 1. The operator shall pay more attention to prevent the coolant fluid from spraying into your eye or on your skin because the fluid-state coolant is very dangerous. Only one drop of coolant will cause your skin to be damaged partially if it drops up the skin of the skin.
Page 537 Coolant shortage treatment · If it is found that there is the coolant shortage during checking the failure, it is recommended to add the coolant. The reason is: there is the difference between the pressure values indicated by the different pressure gauges, so it is difficult to add the coolant with accurate quantity in accordance with the pressure reading.
Page 538 TECHNICAL DATA TECHNICAL DATE … … … … … … … … … … … … … … … … …TD-2 ENGINE… … … … … … … … … … … … … … … … … … … … …TD-2 LUBRICATION SYSTEM …...
Page 539: Technical Data
TECHNICAL DATA ENGINE Model 480ED-1000010 Magneti 480ED-1000010EA UAES Parameter Marelli (new) (new) Four-cylinders In-Line, Four-cylinders In-Line, Type four-stokes, water-cooled four-stokes, water-cooled Cylinder bore (mm) 79.94 79.94 Stroke (mm) 79.52 79.52 Displacement (L) 1.596 1.596 Compression ratio 10:1 10:1 Max Output/speed (kw/r/min) 65/5500 65/5500 Max.
Page 540 Size of Hydraulic Tappet: Hole diameter of the Outside circle diameter Class cylinder head tappet Fit clearance (unit: mm) (unit: mm) (unit: mm) Standard 22.200~ 22.212 22.25 0.015 0.023~0.065 22.454~ 22.466 22.50 0.015 0.023~0.065 Cam Height: Engine model Admission cam T (unit: mm) Exhaust cam T (unit: mm) 38.602 37.586...
Page 541 Valve Stem Size And Fit Clearance Intake valve (unit: mm) Exhaust valve (unit: mm) Inner Inner Class Diameter of Diameter of Diameter of Diameter of Clearance Clearance valve stem valve stem valve guide valve guide 8.063~8.09 8.043 8.017 8.063~8.094 Standard 0.02 0.046 −...
Page 542 Size of Valve Guide And Valve Guide Bore Valve guide bore Diameter of cylinder head Interference Class (unit: mm) guide hole (unit: mm) (unit: mm) 13.555 Standard 13.481—13.519 − 14.305 Oversized 14.231—14.269 0.026—0.07 − 14.505 Oversized 14.481—14.519 − Size of Cylinder Bore 480 M cylinder bore (unit: mm) 480 E cylinder bore (unit: mm) 79.94-79.95...
Page 543 The Diameter of Piston Skirt Diameter of 480E Diameter of UMC’s Diameter of 480M piston skirt piston skirt (unit: new two-valve piston (unit: mm) skirt (unit: mm) 79.91-79.92 79.915-79.925 79.915-79.925 79.92-79.93 79.925-79.935 79.925-79.935 Ex-factory grouping 79.93-79.94 79.935-79.94 79.935-79.94 79.94-79.95 79.945-79.955 79.945-79.955 80.20-80.21 80.205-80.215...
Page 544 The Diameter of The Piston Pin Diameter of 480M piston pin bore (unit: mm) Diameter of 480E piston pin bore (unit: mm) White 20.622-20.625 White 20.622-20.625 20.625-20.628 20.625-20.628 Blue 20.628-20.631 Blue 20.628-20.631 The End Clearance of The Piston Ring First compression ring: 0.30-0.50mm Second compression ring: 0.30-0.50mm Oil ring: 0.40-1.40mm The Axial Clearance of Piston Ring In The Piston Groove...
Page 545 Size of Piston Ring 480# piston ring Paint mark (type) Size of gauge No paint (Standard) 79.94 Purple paint (oversized by 0.29) 80.23 Blue paint (oversized by 0.5) 80.44 Size of Connecting Rod Journal And Connecting-rod Bearing Shell Diameter of connecting Thickness of connecting-rod bearing Class rod journal (unit: mm)
Page 546 Diameter of Main Journal And Size of Main Bearing Shell Diameter of the main bearing Diameter of main Thickness of the main Class bore of the cylinder block journal (unit: mm) bearing shell (unit: mm) (unit: mm) Standard 57.98~58.00 62.2935+0.0065 2.131~2.138 Oversized by 0.4 57.98~58.00...
Page 547: Lubrication System
LUBRICATION SYSTEM Lubricant Spec. (at above -10 C) SAE10W/30 50 SG grade Fuel Spec. 93 # Regular unleaded gasoline Oil pressure (Idling Speed) 100Kpa Oil pressure 2000r/min (water temperature 80 ) 280Kpa Oil capacity (L) 3.86 Opening pressure of the pressure control valve, oil pump 440 20 (Kpa) Opening pressure of the bypass valve, Oil Filter (Kpa)
Page 548: Cooling System
COOLING SYSTEM Cooling System Parameters Overall system capacity L Engine capacity L Capacity of Coolant Radiator capacity L Capacity of expansion tank L Diameter: 280mm Number of blades: 6 Working voltage: 9-15V Rotating speed: Gear I: High-speed motor 2000 Low-speed motor 1800 200 Rotating speed: Gear II: High-speed motor 2800 200 Low-speed motor 2600 200 Diameter of impeller:...
Page 549: Engine Electrical Fuel Injection System
ENGINE ELECTRICAL FUEL INJECTION SYSTEM Marelli Electronic Fuel Injection System-New Camshaft+ New Standard: Parameters Normal value Minimal value Maximal value Engine Rotation Speed 880 (when air (rpm) conditioner is turned of) Water Temperature ( ) >80 Throttle opening angle Accelerator is released 0 4.2ms (when air Fuel injection duration (ms) 3.4ms...
Page 550: Clutch
UAES M7 Electronic Fuel Injection System: Parameter name Value Unit Storage battery voltage (V) 14 15 Engine Rotation Speed 850 50 Temperature of cooling fluid, sensor 0.9 1.1 voltage Temperature of cooling fluid 85 95 In-take temperature sensor voltage 1.5 2.8 In-take temperature 30-60 In-take pressure sensor voltage...
Page 551: Manual Transaxle
MANUAL TRANSAXLE Gearbox AQ015 Main 4.133 3.455 2.056 1.370 1.032 Gear ratio 0.850 Reverse 3.167 Speedometer 2.286 Volume of Lubrication oil 2.0L Type of oil GL-4 SAE75 Operation method Mechanical type Diameter of driven disk of clutch 210mm Diameter of flange of driving shaft 100mm Overall gear ratio at 5 gear...
Page 552: Heater And Air Conditioner Systems
HEATER AND AIR CONDITIONER SYSTEMS Item Specification REFRIGERANT SYSTEM Type R-134 Refrigerant Regular amount 850±25 BASIC SYSTEM Number of cylinders Cylinder diameter (mm) Stroke (mm) Displacement (cm³/r) A/C compressor Max instantaneous rotation speed allowed(r/min) Max continuous rotation speed allowed (r/min) Cooling oil volume (cm³) Rated voltage...
Page 553: Braking System
BRAKING SYSTEM Brake master cylinder φ22.2mm Vacuum booster Φ228.6mm Vacuum booster boost ratio 3.9:1 Primary chamber travel 16 mm Secondary chamber travel 18 mm Front wheel disk brake: wheel cylinder Φ54mm diameter Brake disk outer diameter Φ256mm Brake disk thickness 13mm Brake disk service limit 10mm...
Page 554: Suspension
SUSPENSION Suspension Item Specification Front wheel camber angle -30 ±20 Front wheel Kingpin caster angle 1 30 alignment Front wheel toe-in 0 ±10 Rear wheel toe-in Rear wheel alignment Rear wheel camber angle -1°30 ±20 Tire And Wheel Secondary Spare Item Front Wheel Rear Wheel...
Page 555: Special Tools
SPECIAL TOOLS SPECIAL TOOLS… … … … … … … … … … … … … … … …………………ST-2 ENGINE… … … … … … … … … … … … … … … … ……………… … …ST-2 MANUAL TRANSMISSION… … … … … … … … … … … …………… … …ST-5 ST-1...
Page 556 SPECIAL TOOLS ENGINE Tool Number Name WX-001 Camshaft Oil Seal Installer WX-002 Crankshaft Rear Oil Seal Installer WX-003 Push Crankshaft Rear Oil Seal Tool WX-004-1 Crankshaft Front Oil Seal Installer ST-2...
Page 557 Tool Number Name WX-004-2 Duct- Crankshaft Oil Seal Installer WX-005 Valve Oil Seal Installer WX-006 Clutch Orientation Tool WX-007 Ignition Switch Disassembly Tool WX-008 Rear Axes cover Installer ST-3...
Page 558 Tool Number Name WX-009 Subframe Orientation Tool WX-010 Valve Spring Compressor WX-011 Cylinder Head Charge Connecter WX-012 Shift Handle Orientation Tool WX-013 Fuel Pump Disassembly Tool ST-4...
Page 559 MANUAL TRANSMISSION Tool Number Name GZ101 Fifth Gear Fork Tool GZ210 Flange Push Tool GZ310 First Shaft Lock Tool GZ401 Cover Installer ST-5...
Page 560 Tool Tool Number Number Name Name GZ530 Middle Bearing Push Tool GZ410 Gear Haul Tool GZ434 Bearing Inside Track Haul Tool GZ411 First Shaft Oil Seal Installer GZ413 Fifth Gear Lock Plate Tool ST-6...
Page 561 Tool Number Name GZ421 Shift Shaft Oil Seal Installer GZ427 Second Shaft Front Bearing Inside Track Tool GZ428 Middle Bearing Inside Track Tool GZ430 Second Shaft Front Bearing Outside Track Haul Tool GZ432 Flange Push Shaft ST-7...
Page 562 Tool Number Name GZ511 Rear Hull Body Haul Tool GZ518 Oil Seal Seat Tool GZ523 Flange Oil Seal Tool GZ524 Differential Bearing Outside Track Tool GZ526 Second Shaft Front Bearing Outside Track Tool ST-8...
Page 563 Tool Number Name GZ529 Differential Bearing Inside Track Tool GZ541 Release Mandril Oil Seal Tool GZ542 Clutch Mandril Bush Tool GZ544 First Shaft Front Bearing Tool GZ546 Second Shaft Rear Bearing Tool ST-9...
Page 564 Tool Number Name GZ550 First Shaft Rear Bearing Tool ST-10...

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