Chery A113 Maintenance Manual
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Chery A113 Maintenance Manual

Chery A113 Maintenance Manual

Chassis
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Maintenance Manual of Chery A113
(Chassis)
Chery Automobile Co., Ltd

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Summary of Contents for Chery A113

  • Page 1 Maintenance Manual of Chery A113 (Chassis) Chery Automobile Co., Ltd...

  • Page 2: Table Of Contents

    CONTENT Chapter 1 Brake System .........................4 I. System Checking Parameters ....................4 1. Check brake disc........................4 2. Thickness checking.........................4 3. Checking of brake friction lining thickness................4 4. Checking of brake disc run-out ....................4 II. Removal/Installation and Overhaul of Front Brake and Brake Calliper......5 1.
  • Page 3 5. Installation Procedure......................29 III. Adjustment of Four-Wheel Alignment ................30 1. Adjustment of Front Wheel Toe-In ..................30 2. Adjustment of Front Wheel Camber Angle................30 3. Adjustment of Caster Angle and Kingpin Inclination ............30 4. Adjustment of Rear-Wheel Alignment Parameters ..............31 IV. Tire Installation and Air Pressure Adjustment..............31 1.

  • Page 4: Chapter 1 Brake System

    Chapter 1 Brake System I. System Checking Parameters 1. Check brake disc: The friction surface of brake disc should be flat and has no apparent grooves; otherwise, brake disc should be replaced. 2. Thickness checking The standard thickness of front disc (ventilation disc) is 17 mm with its operating limit of 15 mm; when exceeding the operating limit, the front disc should be replaced.

  • Page 5: Removal/Installation And Overhaul Of Front Brake And Brake Calliper

    II. Removal/Installation and Overhaul of Front Brake and Brake Calliper 1. System Structural Diagram Structural Diagram of Front Brake Assembly (1) Brake disc positioning bolt (2) Brake disc (3) Wheel hub bearing unit; (4) ABS speed sensor plug (5) Dust cover (6) Steering joint (7) Fixing bolt (8) Friction lining...

  • Page 6: Preparations

    2. Preparations Tools: Ratchet wheel, ratchet lever, 13#, 14#, 16#, 18#, 19#, 8#, 30# socket, 10#, 13#, 14#, 16# ring wrench, vice, torque wrench, measure ruler.. Accessories: brake fluid 3. Notices 3.1 Please wear necessary labor protection supplies to avoid accidents.
  • Page 7 4.5 Remove the nuts from brake hose with 13# wrench. Notice: The brake liquid is one toxic liquid. Do not splash the brake liquid to the clothes or skin during the removal of the brake hose. Torque: 16±3 Nm. 4.6 Pull out the brake disc with hand. 4.7 Measure the thickness of friction lining.
  • Page 8 4.10 Remove the piston. Prepare one wood board to hold the piston and place the wood board between the piston and the wall of the brake calliper. Press out the piston with the compressed air carefully through the connecting bore. Place the guard plate (such as hard wood) at the notch of the brake calliper to protect the piston.
  • Page 9 4.14 The area between the dustproof seal ring and the brake clamp housing must be kept dry. It should be kept away from the brake cylinder cream or the brake liquid, in order to ensure the correct position of dustproof seal ring. 4.15 Secure the brake piston with the reinforcement parts available in market and press it onto the dustproof seal ring slightly.

  • Page 10: Removal/Installation And Overhaul Of Rear Brake

    III. Removal/Installation and Overhaul of Rear Brake 1. System Structural Diagram 1. Rear brake assembly 2. Brake drum 3. Rear wheel hub bearing assembly 4. Oil seal 5. End cap 6. Bolt 7. Rear wheel sensor 8. Rear brake hose retaining clip 9.

  • Page 11: Removal Procedure

    4. Removal Procedure 4.1 Remove the rear wheels (see the removal procedure of front wheels). 4.2 Remove two position bolts from the brake drum with the cross screwdriver. 4.3 Remove the bearing dust cap with slotted screwdriver. 4.4 Vibrate the brake drum to remove it. 4.5 Observe the rear braking structure.
  • Page 12 4.7 Remove the handbrake cable with calliper. 4.8 Remove the upper return tension spring with calliper. 4.9 Remove the lower return tension spring with calliper. 4.10 Depress the spring strip of the brake shoe positioning tie rod with calliper and then rotate clockwise or counter clockwise for 90° to remove two brake shoe position tie rods.

  • Page 13: Installation Procedure

    4.12 Remove the tension spring to separate the brake shoe. Remove this tension spring. 4.13 In the event of detection of over-tight rear brake, it may adjust the length of the push rod: Rotate clockwise to eliminate the friction. 4.14 Remove the three bolts shown in the figure with 10# ring Bolts wrench.

  • Page 14: Adjustment And Replacement Of Handbrake

    IV. Adjustment and Replacement of Handbrake 1. System Composition Illustration To right rear brake assembly left rear brake assembly 1. Handle 2. Fixing bolts 3. Cable 4, 5. Left/Right rear wheel cable 2. Preparations Tools: Ratchet wheel, ratchet lever, 10#, 13#, 14#, 16# socket, 10# 13#, 14# ring wrench, vice, torque wrench, slotted screwdriver.
  • Page 15 4.2 Remove the handbrake clip with priers. Notice: It’s under the rear wheels. 4.3 Remove the fixing bracket bolts of the handbrake cable shown below with 8# ring wrench. Torque: 9~12 Nm 4.5 Pry out the protective cover at the handbrake and gear position with slotted screwdriver.
  • Page 16 4.6 Remove all fixing screws from the secondary instrument panel assembly with ring screwdriver to remove the secondary instrument panel assembly. 4.7 Remove the handbrake adjustment nuts with 10# wrench. 4.5 Loosen the two handbrake cables with hand.
  • Page 17 4.9 Pull out the handbrake cable from the underside of the vehicle body. Notice: Remove the handbrake cable at another side in accordance with the same method. 4.10 (Handbrake adjustment) The length of the handbrake cable equipped on this model is designed to be the fixed length. To adjust Rotate this place the handbrake effects, refer to the part “removal of rear brake”.

  • Page 18: Chapter 2 Adjustment Of Suspension System And Four-Wheel Alignment

    I. Removal/Installation and Overhaul of Front Axle and Suspension 1. System Structural Diagram The front axle of Chery S21 model adopts the split steering drive axle, with MacPherson independent suspension. The upper end of the suspension is connected with the vehicle body as the lower end is connected with the secondary vehicle frame.
  • Page 19 1 Nut 17 Nut 2 Gasket 10 Left control arm 18 Nut 3 Rubber gasket I 10 Right control arm 19 Bolt 4 Rubber gasket II 11 Nut 20 Bolt 5 Left propelling rod weldment assembly 12 Secondary vehicle frame 21 Clamp 5 Right propelling rod weldment assembly 13 Front strut assy.

  • Page 20: Preparations

    2. Preparations Tools: 8#, 15#, 18#, 19# socket; 10#, 13#, 15# wrench. 3. Notices 2.1 Please wear necessary labor protection supplies to avoid accidents. 2.2 When carry out maintenance and repair to chassis, please note that whether the safety lock of lifting machine is locked.

  • Page 21: Removal Of Control Arm Assembly

    4.1.4 Remove the three fixing bolts of shock absorber assembly from the vehicle frame with 13# socket. Torque: 60±5 Nm 4.1.5 Remove the shock absorber assembly. 4.2 Removal of Control Arm Assembly 4.2.1 Remove the fixing bolts of front connecting rod assembly from the control arm with 15# socket.

  • Page 22: Removal Of Front Axle Assembly

    4.3 Removal of Front Axle Assembly 4.3.1 Remove the fixing bolts from the chassis mud guard to remove the mud guard assembly. Torque: 3±0.5 Nm 4.3.2 Remove the front bracket bolts of the transmission from the secondary vehicle frame with 19# socket. Torque: 110±10 Nm 4.3.3 Remove the rear bracket bolts of the transmission from the secondary vehicle frame with 19# socket.
  • Page 23 4.3.6 Remove the fixing bolts at the right side of the booster steering gear with 13# wrench. Torque: 75±5 Nm 4.3.7 Remove the fixing bolts at the left side of the booster steering gear with 15# wrench. Torque: 75±5 Nm 4.3.8 Remove the fixing bolts of propelling rod and secondary vehicle frame with 19# socket.

  • Page 24: Installation Procedure

    4.3.11 Remove the four connecting nuts of secondary vehicle frame and vehicle body with 18# socket to remove the front axle assembly. Torque: 150±10 Nm 4.3.12 Remove the fixing bolts and nuts from the rubber sleeve of the stabilizer rod with 10# wrench. Torque: 50±5 Nm 5.

  • Page 25: Removal/Installation And Overhaul Of Rear Axle And Suspension

    II. Removal/Installation and Overhaul of Rear Axle and Suspension 1. System Structural Diagram Rear trailing arm assembly Rear shaft welding assembly 13 Nut Bolt Cross stay assembly 14 Nut Rear shock absorber assembly 9 Rear spring cushion 15 Bolt 10 Rear bumper block 16 Lock nut Bolt 11 Rear coil spring...

  • Page 26: Preparations

    2. Preparations Tools: 11#, 13#, 15#, 16#, 16#, 19#, 30# socket, Slotted screwdriver, priers. 3. Notices 3.1 Please wear necessary labor protection supplies to avoid accidents. 3.2 Notice to lock the safety lock of the elevator during the repair of the chassis.

  • Page 27: Cross Stay Assembly

    4.1.4 Pry out the rear coil spring with screwdriver. 4.1.5 Vibrate from side to side with force with hand to remove the rear bumper block. 4.2 Cross Stay Assembly 4.2.1 Remove the connecting bolts of cross stay and left side of vehicle body with 16# socket.

  • Page 28: Removal Of Rear Axle Assembly

    4.3.2 Remove the connecting bolts from the middle side of rear axle and trailing arm assembly with 13# socket. Torque: 100±10 Nm 4.3.3 Remove the connecting bolts of trailing arm and vehicle body with 15# wrench to remove the rear trailing arm assembly. Torque: 100±10 Nm 4.4.

  • Page 29: Installation Procedure

    4.4.4 Remove the lock nuts from the rear brake band drum assembly with 30# socket to remove the rear brake band drum assembly. Torque: 180±10 Nm 4.4.5 Remove the rear axle assembly. 5. Installation Procedure The installation procedure is reverse to that of removal.

  • Page 30: Adjustment Of Four-Wheel Alignment

    III. Adjustment of Four-Wheel Alignment Please conduct the measurement and adjustment of parameters on the four-wheel alignment instrument recommended by Chery Auto. 1. Adjustment of Front Wheel Toe-In The toe-in can be adjusted by means of the optical testing instrument or mechanical toe-in adjustment instrument.

  • Page 31: Adjustment Of Rear-Wheel Alignment Parameters

    2.4 The description concerning the uniformity, dynamic balance and static balance testing marks for tires will be additionally provided in writing by the product division of Chery Company or suppliers. In addition, this kind of descriptions will clearly be indicated on process sheet.

  • Page 32: Tire Inflation

    2.5 Carry out tire inflation strictly in accordance with specified pressure. During inflating process, air pressure shall not exceed 10% of rated pressure. When performing separate packaging to spare wheel assembly, the rated inflation pressure shall be 3.0bar, and the spare wheel assembly shall be stored separately from four wheels.

  • Page 33: Chapter 3 Removal/Installation And Overhaul Of Steering System

    Chapter 3 Removal/Installation and Overhaul of Steering System I. Removal/Installation of Steering Gear 1. System Composition Illustration 1. Booster steering liquid reservoir 2. Bracket fixing bolt 3. Bracket fixing nut 4. Outlet pipeline 5. Reservoir fixing bracket 6. Steering pump 7.

  • Page 34: Preparations

    The breakdown illustration of steering gear is shown below: 1 – Lock nuts 2 – Track rod 3 – Input shaft 4 – Left installation bracket 5 – Right installation bracket The illustration of steering universal joint and protective sleeve is shown below: S21-3404060 (Steering universal knuckle protective sleeve assembly)

  • Page 35: Removal/Installation Procedure

    4. Removal/Installation Procedure 4.1 Remove the fixing nuts at the both sides of steering ball joint with 19# socket. Torque: 40±5 Nm 4.2 Loosen the fixing nuts under the booster steering hose with 17# non-adjustable wrench. Torque: 25±5 Nm 4.3 Loosen the fixing nuts above the booster steering hose with 12# non-adjustable wrench.

  • Page 36: Installation Procedure

    4.6 Remove the fixing screws above the left bracket of power steering gear with 13# socket. Torque: 100±10 Nm 4.7 Remove the fixing screws under the left bracket of power steering gear with 13# socket. Torque: 100±10 Nm 4.8 Remove the fixing bolts of the steering universal joint with 10# socket wrench to remove the steering gear assembly.

  • Page 37: Removal/Installation Of Steering Column

    II. Removal/Installation of Steering Column 1. System Composition Illustration Steering Wheel Steering column assembly Steering universal joint assembly 1 – Steering wheel 2 – Steering column assembly 3 – Steering universal joint assembly 2. Preparations Tools: Cross screwdriver, 5#, 6# inner hex wrench, 10#, 13#, 22# socket wrench. 3.

  • Page 38: Removal Procedure

    4. Removal Procedure 4.1 Loosen the two screws under the steering wheel with 5# inner hex wrench. 4.2 Remove the horn cover from the steering wheel. 4.3 Remove the fixing nuts of the steering wheel with 22# socket wrench. 4.4 Remove the steering wheel after screw off the nuts.
  • Page 39 4.5 Screw off the two screws from the front surface of combined switch guard plate with cross screwdriver. 4.6 After screw off the screws, open upward to remove the upper protective cover. 4.7 Screw off the three screws from the lower side of combined switch guard plate with cross screwdriver.
  • Page 40 4.9 Remove the two fixing screws from the combined switch with cross screwdriver. 4.10 Pull out all plugs from the combined switch. (Total 5 plugs)
  • Page 41 4.11 Remove the combined switch. 4.12 Pull out the plug of ignition switch. 4.13 Screw off the fixing screws from ignition lock with 5# inner hex wrench and remove the ignition lock assembly.
  • Page 42 4.14 Screw off the 4 fixing screws from the upper end cap with 6# inner hex wrench. 4.15 Remove the outer caliper with the outer caliper pliers. 4.16 Remove the retainer and spring with hand. 4.17 Remove the upper end cap with hand. 4.18 Remove the two upper fixing nuts from the steering column with 13# socket.

  • Page 43: Installation Procedure

    4.19 Remove the two lower fixing nuts from the steering column with 13# socket. Torque: 25±3 Nm 4.20 Remove the connecting nuts of steering column and steering universal joint with 10# socket to remove the steering column assembly. Torque: 25±3 Nm 4.21 Remove the connecting bolts of steering universal joint and steering gear with hand.

  • Page 44: Adjustment Of Steering Gear Clearance

    III. Adjustment of Steering Gear Clearance 1. Place the wheels at linear driving position; 2. Rotate the steering wheel towards both sides; 3. If heard noise of steering gear, adjust the screw as shown in the diagram until no impinge noise is heard when turning steering wheel;...
  • Page 45 4. When in service, it is prohibited to turn the steering wheel to limit position, even if it has to do so, never maintain at this position over 10 seconds. It is strictly prohibited to use power steering pump without oil. If the driver suddenly feels the steering heavy in service, immediately stop the vehicle, dismantle and repair accordingly.
  • Page 46 Maintenance Manual of Chery A113 (Body Accessories & Dimensions) After Sales Service Department of Chery Automobile Sales Co., Ltd...
  • Page 47 CONTENT Chapter I Front Hood & Trunk ......................6 I. Removal and Installation of Front Hood ................... 6 1. Preparations ........................6 2. Notes..........................6 3. Removal and Installation of Front Hood Accessories............6 3.1. Removal Steps......................6 3.2. Installation Steps ....................... 6 4.
  • Page 48 II. Removal & Installation of Rear Doors .................. 32 1. System Constitution Diagram..................32 2. Preparations ........................32 3. Notes..........................33 4. Removal Steps ........................ 33 5. Installation Steps......................36 Chapter IV Removal, Installation & Maintenance of Front/Rear Bumper ......... 37 I.
  • Page 49 II. Removal of Instrument Panel crossbeam................66 1. Removal Steps ........................ 66 2. Installation Steps......................68 Chapter VIII Air Conditioning System....................69 I. System Constitution ........................ 69 II. Removal of Evaporator Assembly ..................69 1. Preparations ........................69 2. Removal and Installation Steps..................69 3.
  • Page 50 III. Removal and Installation of In-door harness.............. 131 (I). Preparations......................131 (II). Notes ........................131 (III). Removal Steps ..................... 131 Section V Removal and Installation of Instrument Panel Harness ........... 141 I. Harness sketch....................... 141 II. Instructions on Main Connectors ................. 142 III.

  • Page 51: Chapter I Front Hood & Trunk

    Chapter I Front Hood & Trunk I. Removal and Installation of Front Hood 1. Preparations Tools: Flat head/cross head screwdriver, socket wrench, snipe nose pliers 2. Notes 2.1. During removal and installation, be particularly careful to apply proper strength and no abrupt or violent operation is allowed. 2.2.

  • Page 52: Removal & Adjustment Of Of Front Hood Assembly

    4. Removal & Adjustment of of Front Hood Assembly Preparation of Tools: 13# sleeve, wheel wrench and extension bar 4.1. Turn and remove the four adjusting bolts off the front hood, and then the front hood can be taken down. And the positing of the front hood can be adjusted in all directions by loosening the four adjusting bolts.

  • Page 53: Removal Of Front Hood Lock

    6. Removal of Front Hood Lock 6.1. Removal Steps 6.1.1. Turn and remove two screws off the front hood to take down its lock. 6.1.2. Remove the front hood lock cable off the front hood lock assembly. 6.2. Installation Steps The installation steps are reverse to those for removal.

  • Page 54: Installation Steps

    7.1.2. Use snipe nose pliers to remove the front hood cable off the pull cover. 7.1.3. Drag out the cable. 7.2. Installation Steps The installation steps are reverse to those for removal. II. Removal of Rear Trunk Cover 1. Preparations Tools: flat head screwdriver, 13# sleeve, wrench and cross head screwdriver Material(s): Clip...

  • Page 55: Removal And Installation Of Trunk Lock

    3. Removal and Installation of Trunk Lock 3.1. Removal Steps 3.1.1. Remove the pull rod off the upper lock. 3.1.2. Pull off the connector on top of the upper lock. 3.1.3. Use a cross head screwdriver to remove the three screws on the upper lock.

  • Page 56: Installation Steps

    3.2. Installation Steps The installation steps are reverse to those for removal. Installation notes: Is the lock column deformed? Is the riveting adequate? Is the lock jacket on the trunk in good condition? Or can the lock tongue open and shut freely? 4.

  • Page 57: Removal Of Rear Wiper Nozzle

    5. Removal of Rear Wiper Nozzle 5.1. Removal Steps 5.1.1. Pry open the shield of the high mount ceiling light with a flat head screwdriver. 5.1.2. Pull off the connector, and then use a cross head screwdriver to remove the two screws on the high mount ceiling light and take it down.

  • Page 58: Installation Steps

    5.1.4. Remove the spoiler. 5.1.5. Pull off the rear water nozzle (You can pry with a flat head screwdriver, but try to avoid any paint scratch), and then pull off the water nozzle hose. 5.2. Installation Steps The installation steps are reverse to those for removal. Note: Water injection opening should be opposite to wiper motor steering shaft.

  • Page 59: Installation Steps

    6.1.3. Remove the three fixing bolts on the rear wiper motor. Installation torque is 12±2Nm 6.1.4. Remove the motor. 6.2. Installation Steps The installation steps are reverse to those for removal.

  • Page 60: Removal And Installation Of Seat Belts

    Chapter II Removal of Trims I. Removal and Installation of Seat belts 1. Preparations Tools: flat head screwdriver, wrench, sleeve wrench Spare parts: disposable clip 2. Notes Keep the seat belts clean and free of oil, and check them for any damage.
  • Page 61 3.4. Remove the decorative covers at the upper and lower ends of the seat belt with a flat head screwdriver. 3.5. Use a 17# wrench to loosen the upper and lower fastening nuts before you remove the seat belt. Installation Torque: 50±5Nm 3.6.

  • Page 62: Installation Steps

    3.7. Use a cross head screwdriver to remove the pre-tension belt assembly. 4. Installation Steps The installation steps are reverse to those for removal. Note: 4.1. Keep the seat belt clean and free of oil, and check it for any damage.

  • Page 63: Removal Of Rear Seats

    2. Removal of Rear Seats 2.1. Use a 13# socket wrench to remove the fixing bolts in the rear seat cushion. Torque: 25±3Nm 2.2. There are two rear seat cushions, a left one and a right one, secured by four bolts respectively. Torque: 25±3Nm 2.3.

  • Page 64: Installation Steps

    2.6. Open the trunk and take out the trunk vehicle carpet. 2.7. Loosen off the fixing seat of the spare tire and take it out. 2.8. Use a 13# socket wrench to loosen off the fixing bolts in the rear seat back, and then the rear seat back can be removed. Torque: 25±3Nm 3.

  • Page 65: Removal Steps

    2.6. Open the trunk and take out the trunk vehiclepet. 2.7. Loosen off the fixing seat of the spare tire and take it out. 2.8. Use a 13# socket wrench to loosen off the fixing bolts in the rear seat back, and then the rear seat back can be removed. Torque: 25±3Nm 3.
  • Page 66 1.2. Use a cross head screwdriver to loosen off the fixing screws of the shield 1.3. Use a flat head screwdriver to pry open the shield at the hand brake and gears. Note: Please pry carefully. 1.4. Use a cross head screwdriver to remove the two fixing screws below the shield.

  • Page 67: Removal And Installation Of Vehicle Carpet

    1.6. Use a cross head screwdriver to remove the front fixing screws of the auxiliary Instrument Panel (One on the left and the other one the right). 1.7. Use a cross head screwdriver to remove the rear fixing screws of the auxiliary Instrument Panel (One on the left and the other one the right), and then the suxiliary Instrument Panel can be dismounted.
  • Page 68 1.5. Use a flat head screwdriver to pry up the top cover of footrest plate. 1.6. Use a 10# wrench to remove the footrest plate covers Installation Torque: 7±1N.m 1.7. Remove the rear seat cushion (See Removal of Seats) Use a cross head screwdriver to remove the left shield of the rear seat cushion.

  • Page 69: Removal Of Damping Mat

    2. Installation Steps 2.1. Put the vehicle vehicle carpet inside the vehicle, and take out the harness connected with the seats, and then press the vehicle vehicle carpet besideds the middle passage tightly. 2.2. Keep the seat holes visible. 2.3. Spread the vehicle vehicle carpet till it gets to the footrest plate and press it tightly.
  • Page 70 2. Installation Steps 2.1. The installation steps are reverse to those for removal. 2.2. Notes: When installing, sort out the harness, and at the same time the damping mat should fit well with the vehicle body plate work.

  • Page 71: Chapter Iii Removal & Maintenance Of Vehicle Doors

    Chapter III Removal & Maintenance of Vehicle Doors I. Removal, Installation & Maintenance of Front Doors 1. System Constitution Diagram 2. Preparations Tools: flat head screwdriver, cross head screwdriver, 10#, 13# sleeve, wrench and pliers.

  • Page 72: Notes

    3. Notes 3.1. Please wear necessary labour protection supplies to avoid any accident. 3.2. Disconnect the battery to avoid damaging the eletrical equipment. 3.3 Use the correct method to disassemble and assemble the glass to avoid damage. 4. Removal Steps 4.1.
  • Page 73 4.5. Use a cross head screwdriver to loosen off the four screws that fix the shield inside the door. 4.6. Use a cross head screwdriver to loosen off the screw that fixes the handle inside the vehicle door. 4.7. Use a flat head screwdriver to pry off the plastic cover of the screw hole for the handle inside the vehicle door, and then remove the fixing screw with a cross head screwdriver so as to disassemble the lock assembly inside the door.
  • Page 74 4.8. Pull of the vehicle alarm connector. 4.9. Remove the shield inside the door. 4.10. Pull off the power window up-down switch connector. 4.11. Use a cross head screwdriver to loosen off the two screws of the front door handle fixing mount. 4.11.
  • Page 75 4.13. Take out the glass carefully. 4.14. Use a 10# sleeve to loosen off the five screws that fix the window glass up-down regulator. 4.15. Loosen off the screws, and then pull off the window glass up-down motor connector to take out the window glass up-down regulator assembly.

  • Page 76: Installation Steps

    4.16. Use a 10# sleeve wrench to loosen off the two fixing screws and remove the lock outside the door. 4.17. Use a cross head screwdriver to loosen off the three screws fixing the lock core and remove it. 4.18. Use a 13# sleeve wrench to loosen off the four fixing screws at the hinge that fixes the vehicle door, and then the vehicle door can be disassembled.

  • Page 77: Removal & Installation Of Rear Doors

    II. Removal & Installation of Rear Doors 1. System Constitution Diagram 2. Preparations Tools: flat head screwdriver, cross head screwdriver, and 10# / 13# sleeve, wrench.

  • Page 78: Notes

    3. Notes 3.1. Please wear necessary labor protection supplies to avoid accidents. 3.2. Disconnect the battery so as to avoid damaging the eletrical equipment. 3.3. Take correct steps during removal and installation of glass to avoid any damage. 4. Removal Steps 4.1.
  • Page 79 4.3. Use a flat head screwdriver to pry off the plastic cover of the screws that fix the handle inside the vehicle door. 4.4. Use a cross head screwdriver to loosen off the screws that secure the handle inside the door, and then disassemble it. 4.5.
  • Page 80 4.9. Tear off the anti-water plastic sheeting on the rear door. 4.10. Connect the battery, lower the window glass to a proper position and loosen off the two screws that fix the glass, and then carefully diassemble the glass. 4.11. Use a 10# wrench to loosen off the five screws that fix the window up-down regulator and remove it.

  • Page 81: Installation Steps

    4.13. Use a cross head screwdriver to loosen off the three screws that fix the rear door lock core and then remove it. 4.14. Use a 13# sleeve wrench to loosen off the four screws (at the hinge) that fix the right-rear vehicle door and then remove it. 5.

  • Page 82: Chapter Iv Removal, Installation & Maintenance Of Front/Rear Bumper

    Chapter IV Removal, Installation & Maintenance of Front/Rear Bumper I. Removal, Installation & Maintenance of Front Bumper 1. Preparations Tools: 8# wrench, 8#sleeve, cross head screwdriver, flat head screwdriver Spare parts: disposable clips 2. Notes 2.1. Please wear necessary labor protection supplies to avoid accidents.
  • Page 83 3.6. Use a 8# sleeve wrench and a cross head screwdriver to loosen off the screws and fixing screws below the mud fender and the bumper. Installation Torque: 2±0.5 Nm 3.7 Raise the vehicle with a hoister. 3.8. Use a cross head screwdriver and 8#sleeve to loosen off the fixing bolts and the screws below the mud fenderand the bumper.

  • Page 84: Removal Steps

    4. Installation Steps The installation steps are reverse to those for removal. II. Removal, Installation & Maintenance of Rear Bumper 1. Preparations Tools: cross head screwdriver, flat head screwdriver, No.8 sleeve. Spare parts: disposable clips. 2. Notes 2.1. Please wear necessary labor protection supplies to avoid accidents.

  • Page 85: Installation Steps

    3.5 Pull off the connector of the rear license plate lights. 3.6 Disassemble the connector of the reverse radar and remove the rear bumper assembly. 松 紧 3.7 Unplug the reverse radar. 3.8 Use a cross head screwdriver to loosen the clip seat of the reverse radar.

  • Page 86: Chapter V Removal And Installation Of Headlights Fog Lights & Tail Lights

    Chapter V Removal and Installation of Headlights, Fog Lights & Tail Lights 1. Preparations Tools: 10# open-ended wrench, cross head screwdriver. 2. Notes 2.1. Please wear necessary labour protection supplies to avoid any accidents. 2.2. Try to avoid scratching the painted surface of the bumper when removing it.
  • Page 87 3.3. Hold the headlight with both hands and apply a forward force to loosen off the right headlights. 3.4. Unplug the right headlights harness to take out the right headlights assembly. 3.5. Turn open the the high beam headlight holder shield by hand. 3.6.
  • Page 88 3.7. Unplug the right-front position light harness to take out the bump. 3.8. Turn open the low beam light holder shield by hand. 3.9. Unplug the low beam light harness. 3.10. Press down the bulb fixing clip by hand and turn the clip over to take out the bulb.

  • Page 89: Removal Of Front Fog Lights

    3.11. Turn the right-front turning light shield counterclockwise to disassemble the bulb. (See the above steps for removal of the left headlight) 4. Removal of Front Fog Lights 4.1. Diassemble the bumper assembly. (Refer to removal of bumper) 4.2. Unplug the right-front fog lights harness connector. 4.3.

  • Page 90: Removal Of Tail Lights

    5. Removal of Tail Lights 5.1. Open the rear door. 5.2. Use a cross head screwdriver to loosen off the screws fixing the left tail light. 5.3. Remove the left tail light, unplug the left tail light harness connector, and then disassemble the left tail light assembly. 5.4.

  • Page 91: Removal Of License Plate Lights

    5.5. Turn the bulb counterclockwise by hand and then the bulb can be removed. 6. Removal of License Plate Lights 6.1. Use a flat head screwdriver to pry off the license plate light. 6.2. Unplug the harness plug to disassemble the license plate light.

  • Page 92: Installation & Adjustment Of Headlights

    7. Installation & Adjustment of Headlights 7.1. Installation Steps for the Headlights The installation steps of headlights are reverse to those for removal. 7.2. Functions of Headlights 7.2.1. Front view See right figure: High beam light Position light Low beam light Turn light 7.2.2.

  • Page 93: Installation & Adjustment Of Front Fog Lights

    8. Installation & Adjustment of Front Fog Lights 8.1. The installation of front light The installation steps of front fog light are reverse to those for removal. 8.2. The adjustment of the front fog lights The front fog lights can be adjusted by turning the device with your hand or a cross head screwdriver.

  • Page 94: Preparations

    Chapter VI Removal and Installtion of Vehicle Ceiling 1. Preparations Tools: sleeve wrench, cross head screwdriver, flat head screwdriver 2. Notes 2.1. During the removal and installtion, make sure to apply proper force and no violent operation is allowed. 2.2. During removal and installation of the inner decoration parts, make sure to protect the decoration parts from being scratched.

  • Page 95: Removal And Installation Of Vehicle-Top Armrest

    4. Removal and Installation of Vehicle-top Armrest 4.1. Removal Steps 4.1.1. Open the ceiling armrest screw cover over the co-driver’s seat by hand, and then use a cross head screwdriver to loosen off the left and right fixing screws. As shown in the figure: Torque: 9±3Nm 4.1.2.

  • Page 96: Removal Steps

    5. Removal and Installation of Front Ceiling light 5.1. Removal Steps 5.1.1. Align a flat head screwdriver with the groove along the ceiling light edge to pry it open, as shown in the figure: Note: Do not scratch part surface. 5.1.2.

  • Page 97: Removal And Installation Of Reverse Radar Display

    6． Removal and Installation of Reverse Radar Display 6.1. Removal Steps 6.1.1. Use a cross head screwdriver to loosen off the screws of the reverse radar display. 6.1.2. Unplug the harness and remove the reverse radar display. 6.2. Installation Steps The installation steps are reverse to those for removal.

  • Page 98: Installation Steps

    7.1.3. Follow the the removal steps of the right A-pillar shield for that of the left one. 7.2. Installation Steps The installation steps are reverse to those for removal. 8. Removal and Installation of B-pillar Shield 8.1. Removal Steps 8.1.1. Disassemble the shield below the left B-pillar (See Removal and Installation of Seat belt).

  • Page 99: Removal And Installation Of C-Pillar Shield

    9. Removal and Installation of C-pillar Shield 9.1. Removal Steps 9.1.1. Use a sleeve wrench to loosen off the seat belt bolts (See Removal and Installation of Rear Seats & Seat belts). 9.1.2. Use a flat head screwdriver to pry open the C-pillar upper shield.

  • Page 100: Removal And Installation Of Vehicle Ceiling

    10. Removal and Installation of Vehicle Ceiling 10.1. Removal Steps 10.1.1. Disassembling the left/right front sun visors. (See Removal and Installation of Sun Visor) 10.1.2. Disaasembling the front ceiling light. (Refer to removal and installation of front ceiling light) 10.1.3. Disassembling all interior ceiling armrests. (See removal and installation of ceiling armrest) 10.1.4.

  • Page 101: Installation Steps

    10.1.7. Open the trunk and disassemble the vehicle ceiling. 10.2. Installation Steps The installation steps are reverse to those for removal.

  • Page 102: Chapter Vii Removal And Installation Of Instrument Panel & Instrument Panel Crossbeam

    Chapter VII Removal and Installation of Instrument Panel & Instrument Panel Crossbeam I. Removal of Instrument Panel Tools: 8 #sleeve, extension bar, 飞扳[MS1], cross head screwdriver, flat head screwdriver, etc. 1. Removal Steps 1.1. Open the storage box over the console, and use a cross head screwdriver to loosen off the two screws.
  • Page 103 1.4. Use a flat head screwdriver to pry open the control panel of the airconditioner switch and take it out. 1.5. Use a cross head screwdriver to loosen off the four screws that connect the airconditioner switch and the Instrument Panel. 1.6.
  • Page 104 1.7. Use a 8# sleeve wrench to loosen off the four fixing bolts that connect the audio system with the Instrument Panel. 1.8. When taking out the audio system, unplug the antenna and harness. 1.9. Use a cross head screwdriver to loosen off the two screws that connect the cup-holder and the Instrument Panel, and then take out the cup-holder.
  • Page 105 1.10. Disassemble the auxiliary Instrument Panel (See Chapter I Removal, Installation & Adjustment of of the Brake System). 1.11. Use a cross head screwdriver to pry open the decoration sheet on the ash tray and take it out. 1.12. Use a cross head screwdriver to loosen off the four screws that connect the cigarette lighter with the Instrument Panel, and unplug the harness when removing the lighter.
  • Page 106 1.14. Disassemble the steering wheel, combination switches and ignition switch. 1.15. Use a cross head screwdriver to loosen off the two screws on the instrument panel shield and the Instrument Panel, and then pull it out with both hands. 1.16. Use a cross head screwdriver to loosen off the four screws on the instrument panel and the Instrument Panel.
  • Page 107 1.18. Push out the two harness plugs from behind the fog light switch. 1.19. Disassemble the left-front and the right-front door seal strip. 1.20. Disassemble the decorative shields of the left and righte A-pillars (See Removal of Vehicle Ceiling for details). 1.21.
  • Page 108 1.23. Use a cross head screwdriver to loosen off the two screws on the console. 1.24. Pull off the central switch box shield to the left Instrument Panel. 1.25. Use a 8# wrench to disassemble the bolts to the left and right of the Instrument Panel (with 3 bolts for the top/middle/bottom part respectively, i.e.
  • Page 109 1.26. Use a 8# sleeve wrench to loosen off the four bolts that connect the console and the instrument beam and another bolt behind the instrument panel.
  • Page 110 1.27. Unplug the harness plugs of the left and right loudspeakers. 1.28. Take out the Instrument Panel. Notes: 1. Disconnect the battery negative before disassembling the electrical equipment. 2. Don’t wait until all the Instrument Panel bolts are disassembled before you disassemble the ones on the other side, or the Instrument Panel are likely to get deformed.

  • Page 111: Installation Steps

    2. Installation Steps 2.1. The installation steps are reverse to those for removal. 2.2. Notes ① . Double -wind channels should agree with the air-conditioner outlet connector and be installed properly without any air leak, and the Instrument Panel air channel should not conflict with the Instrument Panel crossbeam, the evaporator and other parts, or the Instrument Panel and its accessories will not be installed properly.
  • Page 112 1.3. Use a 13# wrench to loosen off the bolts at the place as shown in the figure. 1.4. Use a 10# wrench to loosen off the four bolts at the places as shown in the figure. 1.5. Use a 10# wrench to loosen off the four bolts at the places as shown in the figure.

  • Page 113: Installation Steps

    1.6. Use a 10# wrench to disassemble the two bolts of the ground wire earth at the places as shown in the figure. 1.7. Loosen off the single bolt and four nuts on the side pillars (See Chassis Maintenance Manual: side pillars), and then relase the side pillar.

  • Page 114: Chapter Viii Air Conditioning System

    Chapter VIII Air Conditioning System I. System Constitution Air adjustment and distributing system: HVAC air mixing and distributor part, inside/outside circulation air inlet, air outlet, outside circulation air filter. Control system: control panel assembly, micro motor, blower, speed regulating mode, high/low voltage switch, AC thermostat.
  • Page 115 2.3. Use a sleeve wrench to loosen off the fixing bolts of the high/low pressure pipes. 2.4. Loosen the fastening nuts of the high/low pressure pipes, and then pull them out. 2.5. Loosen off the three nuts fixed on the plate work.
  • Page 116 2.6. Use pliers to remove the inlet/outlet water pipes of the evaporator and pull out the pipes. Note: Coolant will flow out from the water pipe, pay attention to recycle the coolant. 2.7. Loosen off the 8 fixing nuts that fix the evaporator assembly on the plate work from the front compartment (See the following figures for detailed positions).

  • Page 117: Installation Of Evaporator Assembly

    2.8. Take the evaporator assembly from the driver’s cab.. 3. Installation of Evaporator Assembly The installation steps are reverse to those for removal. 4. Removal and Installation of Evaporator Interior Preparation of Tools: cross head screwdriver, sleeve wrench. 1. Replacement of Blower 1.1.
  • Page 118 1.1.2. Remove the blower cooling jacket. 1.1.3. Push down the clip and drag out the blower clockwise. 1.2. Installation Steps The installation steps are reverse to those for removal.

  • Page 119: Removal And Installation Of Blower Speed Regulation Module

    2. Removal and Installation of Blower Speed Regulation Module 2.1. Removal Steps 2.1.1. Pull out the speed regulation module plug. 2.1.2. Use a cross head screwdriver to loosen off the 2 fixing screws on Speed Regulation Module. 2.1.3. Pull out the speed regulation module. 2.2.
  • Page 120 3.1.4. Unplug the plug of the evaporator thermostat. 3.1.5. Disassemble the mode throttle hitch bar. 3.1.6. Remove the temperature control throttle bar. 3.1.7. Loosen off the 8 screws on the heater shiled, and disassemble the evaporator shield. Notes: The sponge weather strips around the shield are for single use only.

  • Page 121: Removal And Installation Of Mode Throttle Related Mechanism

    3.1.9. Remove the air conditioner cover plate assembly. 3.1.10. Tear open the sponge around the inlet/outlet water pipes and remove the fixing clips. 3.1.11. Remove the heater exchanger. 3.2. Installation Steps The installation steps are reverse to those for removal. After the installation, the system should be evacuated, proper pressure should be maintained and anti-freeze agent should be filled to check for any leakage.

  • Page 122: Removal And Installation Of Blend Throttle Related Mechanism

    4.1.2. Loosen off the three screws and washers behind the control panel that control defroster, blowing head, blowing foot and control arm. 4.2. Installation Steps The installation steps are reverse to those for removal. 5. Removal and Installation of Blend Throttle Related Mechanism 5.1.

  • Page 123: Removal And Installation Of Int./Ext. Throttle Motor & Related Mechanism

    6. Removal and Installation of Int./Ext. Throttle Motor & Related Mechanism 6.1. Removal Steps 6.1.1. Unplug the motor plug. 6.1.2. Loosen off the 4 fixing screws to remove the shield. 6.1.3 Loosen 3 screws of inside/outside circulation ventilator motor, and disassemble the motor. 6.1.4.

  • Page 124: Removal And Installation Of Evaporator

    6.1.5 Remove the inside/outside circulation ventilator. 6.2. Installation Steps The installation steps are reverse to those for removal. 7. Removal and Installation of Evaporator 7.1. Removal Steps 7.1.1. Disassemble the evaporator assembly (See removal of Eevaporator assembly) 7.1.2. Remove the air-conditioner harness (See removal of air-conditioner harness) 7.1.3 Disassemble evaporator water thermostat (Refer to removal of evaporator water thermostat)

  • Page 125: Trouble Shooting

    7.1.7 Remove the evaporator assembly. 7.1.8. Use a wrench to disassemble the expansion valve. 7.2. Installation of the Evaporator Assembly The installation steps are reverse to those for removal. After the installation, the system should be evacuated, proper pressure should be maintained and anti-freeze agent should be filled to check for any leakage.
  • Page 126 The pressure at the high pressure side is The refrigerant in the refrigerant Evacuate the refrigerant ●If the volume of the refrigerant is normal higher than the specified value or is too pipelines is excessive high; the pressure at the low pressure The expansion valve fails or the Replace the expansion valve side is too high;...

  • Page 127: Chapter Ix Body Dimension

    CHAPTER IX Body Dimension I. Basic Instructions on BIW Maintenance Vehicle body maintenance should be carried out by professionals according to the requirements of the manufacturer, and only in this way will the promises of “rust free” and “paint defect free” be effective. Only adopt the materials specified by the manufacturer;...

  • Page 128: Vehicle Door Structure

    strict, so the car doors are difficult to maintain and the quality requirements are fairly high, and only the service personnel understand the structure of the car doors thoroughly and are qualified for the maintaining operations. 1. Vehicle Door Structure Generally speaking, the vehicle doors consist of outside plates, inside plates, window frames, glass guide rails, hinges, locks and window accessories and so on.

  • Page 129: Main Contents Of Door Panel Maintenance

    （2） Clean the vehicle doors. Use fresh water or detergent to clean the dirt and greasy spots on the door panels, and let them thoroughly dry for tests. （3） Maintenance appraisal. Appraise the scope and degree of damage to the door panels by testing and decide the maintenance methods.

  • Page 130: Basic Methods For Door Panel Maintenance

    3． Cracks or breaks: The metal plates may develop fatigue under repeated inner/outer stress where the stress concentrates and the structure is the weakest, causing cracks and even breaks. 4． Dents or wrinkles: Dents develop because the door panel is subjected to bumping or pressing, leading to elastic or plastic deformations.
  • Page 131 When beating with a hammer from above the underlay rion, the hand-held underlay iron should be placed against the back of the metal panels, and then beat the convex part. The beating of hand hammer can make the metal panel contract and finally smooth the metal panel. ②...

  • Page 132: Restoration Of Stretched Parts

    Slide hammer 惯 性 锤 Slide hammer Handle 惯 性 锤 手 柄 Flat gasket 平 垫 片 Handle 手 柄 Puncturing: Drill a small hole in the dent with a hand power drill, and then insert a pull-rod with threaded head or hook-shaped head into the hole. Slide the slide hammer on the metal pull-rod and impact the handle repeatedly so as to pull up the dent gradually.

  • Page 133: Restoration Of Cutting & Patching

    Stretched area 伸胀区 Spot heating 点状加热 Waved edge 边缘呈波浪状 伸胀区 加热位置 Stretched area Heated spots · Triangle heating 三角形加热 图 11 （3）Cooling-contracting way: When the flame is taken away, proper cooling ways should be chosen according to the stretched degrees of the metal panels. Different cooling ways bring about different contracting effects.

  • Page 134: Restoration Of Wrinkled Parts

    part to be removed. （5） Apply the patch to the intended position and press it tightly, draw a line along the edge of the part to be removed and cut it out, using methods like gas cutting or excising according to the actual situation, and then align the patch with the excised area. （6）...

  • Page 135: Vehicle Body Assembly Dimensions

    easy to separate, and then beat the welded part with an iron hammer to restore it. No welding spatter is allowed at the welded seam, and the overlapped seam should be nice-looking with no defects like air holes or cracks. Defects like undercut, welding beading and burning through are also not allowed.
  • Page 136 1.1. Clearance between front hood and air inlet grid at C-C: 8±1 Latch supporting plate Inner layer of front compartment cover Front compartment cover Front compartment cover seal strip...
  • Page 137 1.2. Clearance between front hood and headlamp at 2-2: 5±1mm Front compartment cover 前仓盖 Headlamp 前照灯 Front bumper 前保险杠...
  • Page 138 1.3. Clearance between headlamp and air inlet grid at 3-3: 1±1mm 进气格栅 Air inlet grid 前照灯 Headlamp 1.4. Clearance between the front windscreen and the vehicle roof at 4-4: 6±1mm 车 顶 Vehicle roof Front windscreen 前 挡 风 玻 璃...

  • Page 139: Left-Front View

    2. Left-front View...
  • Page 140 2.1. Clearance between front bumper and front fender at 5-5: 前翼子板 Bumper Front fender 保险杠 2.2. Clearance between front hood and front fender at 6-6: 4mm 前仓盖 Front compartment cover Front fender 前翼子板...
  • Page 141 2.3. Clearance between front fender and A-pillar (side wall) at 7-7: 3mm A 柱 A-pillar Front fender 前翼子板 2.4. Clearance between front fender and front vehicle doors at 8-8: 前翼子板 Front fender 前门 Front door...

  • Page 142: Front Door

    2.5. Clearance between front door and A-pillar (Side wall) at 9-9: 5±1mm 车顶 Vehicel roof A 柱 A-pillar 前门 Front door 2.6. Clearance between front vehicle doors and vehicle roof 10-10: 车顶 Vehicel roof Front door 前门...

  • Page 143: Rear Door

    2.7. Clearance between front door and rear door at 11-11: 后门 Rear door 前门 Front door 2.8. Clearance between front door and rear door at 12-12: 前门 后门 Front door Rear door...
  • Page 144 2.9. Clearance between rear door and rear fender (side wall) at 13-13: 后门 Rear door 后翼子板 Rear fende 2.10. Clearance between rear door and rear fender (side wall) at 14-14: C 柱 C-pillar 后备门 Trunk door...
  • Page 145 2.11. Clearance between rear door and C-pillar at 15-15: C 柱 C-pillar 后门 Rear door 2.12. Clearance between rear windscreen and C-pillar at 16-16: 5±1mm 后挡风玻璃 Rear windscreen C-pillar C 柱...
  • Page 146 2.13. Clearance between gas tank cover and rear fender (side wall) at 17-17 and 18-18: 后翼子板 Rear fender 加油口盖 Gas tank cover 2.14. Clearance between rear bumper and rear fender at 19-19: 后保险杠 Rear bumper 后翼子板 Rear fender...
  • Page 147 2.15. Clearance between front fender and sill decorative board (side wall) at 20-20: 前翼子板 Front fender 门槛饰板 Sill decorative board 2.16. Clearance between front door and sill decorative board (side wall) at 21-21: 6±1mm 前门 Front door 门槛饰板 Sill decorative board...

  • Page 148: Back View

    3. Back View...
  • Page 149 3.1. Clearance between vehicle roof and trunk door at 22-22: 7±1mm 车顶 Vehicle roof Trunk door 后备门 Rear windscreen 后挡风玻璃 3.2. Clearance between rear windscreen and trunk door at 23-23: 4±1mm 后挡风玻璃 Rear windscreen Trunk door 后备门...

  • Page 150: Rear Bumper

    3.3. Clearance between trunk door and rearbumper at 24-24: 21±1mm 后备门 Trunk door 后保险杠 Rear bumper 3.3. Clearance between rear windscreen and tail light at 25-25: 5±1mm 后翼子板 Rear fender 后挡风玻璃 Rear windscreen Tail light 尾灯...
  • Page 151 3.4. Clearance between tail lights and rear fender (side wall) at 26-26: 4±1mm Rear fender 后翼子板 Rear fender 后翼子板 Tail light 尾灯 3.5. Clearance between tail light and rear bumper at 27-27: 2±1mm 尾灯 Tail light 后保险杠 Rear bumper...

  • Page 152: Engine Compartment Dimensions

    III. Engine Compartment Dimensions Name Diameter Φ11 Front bumper crossbeam mounting hole Φ7 C/D/E/F Headlight mounting hole Φ13 Engine right suspension bracket mounting hole Φ8 Installation of fender Φ76 Shock absorber mounting hole...

  • Page 153: Various Opening Dimensions

    IV. Various Opening Dimensions V. Windshield Dimensions Corner Up-turning Down-turn Joint between where point of the point the front wall roof cover rear of the rear upper cover side windshield windshield assembly and wall join (right=left) (right=left) Inner A-pillar (right=left) plate (right and left are...

  • Page 154: Chapter X Harness

    Chapter X Harness Section I Battery Negative Harness I. Harness Sketch Hole type Vehicle body earth Connector II. Instructions on Main Connectors Connector Name Pins Connection Remark Hole type joint Battery Negative Vehicle body Vehicle body Below left-front ground fender...

  • Page 155: Removal And Installation Of Battery Harness

    III. Removal and Installation of Battery Harness Part number: S12-3703010AC (I). Preparations Tools: 10#. 13# wrench (II). Notes Make sure to disconnect the power supply when disassembling the electrical components and harnesses. Ignition switch must be OFF. (III). Removal Steps 1.

  • Page 156: Section Ii Front Compartment Harness

    Section II Front Compartment Harness I. Harness Sketch Fan motor 1 Ground B Horn (1) Horn (2) Ground C Right front combined Right headlight turning light Engine compartment contact switch Fan motor 2 Washing fluid pipe wheel sensor To in-door harness Left turning light Ground A Washing fluid pipe...

  • Page 157: Instructions On Main Connectors

    II. Instructions on Main Connectors Connector Name Pins Connection Remark In-door harness connector In-door harness Instrument harness Instrument harness A connector Instrument harness Instrument harness B connector Washing fluid piping ABS connector Ground A Vehicle body ABS on the left-front side member Left-front combination...

  • Page 158: Removal And Installation Of Front Compartment Harness

    III. Removal and Installation of Front Compartment Harness Part number: S12-3724010 (I). Preparations Tools: sleeve wrench, cross head screwdriver, flat head screwdriver (II). Notes Make sure to disconnect the power supply when disassembling the electrical components and harnesses. The ignition switch must be OFF. (III).
  • Page 159 1.1.5. Unplug the washing fluid piping connector. 1.1.5. Disassemble the battery. (See Removal and Installtion of Battery). 1.1.6. Unplug the ABS plug. 1.1.7. Remove the ground wire. (ABS on left-front side member) 1.1.8. Unplug the connector to left headlight.
  • Page 160 1.1.9. Unplug the connector of left-front fog light. 1.1.10. Unplug the engine harness connector. 1.1.11. Use a sleeve wrench to loosen off the lower fixing screws of the fuse box. 1.1.12. Use a sleeve wrench to loosen off the upper fixing screws of the fuse box.
  • Page 161 1.1.14. Unplug the connector to the brake fluid level sensor. 1.1.15. Unplug the connector to the wiper motor 1.1.16. Use a flat head screwdriver to pry out the left-front wheel ABS sensor plug fixed on the vehicle body. (Near ABS) 1.1.17.
  • Page 162 1.1.19. Unplug the plug of the left-front turning light. 1.1.20. Unplug the two connectors of the fan motor. 1.1.21. Loosen off the ground wire on the side member. (Fan) 1.1.22. Unplug the two connectors to the speaker. 1.1.23. Disassemble the front compartment contact switch.
  • Page 163 1.1.24. Unplug the connectors of the front/rear washing motors. 1.1.25. Disassemble the ground wire. (Washing fluid tank on the right-front side member) 1.1.26. Use a flat head screwdriver to pry open right-front turning light. 1.1.27. Unplug the plug of the right-front turning light. 1.1.28.
  • Page 164 1.1.29. Unplug the right-front fog light connector. 1.1.30. Unplug the high/low voltage switch plug of the air-conditioner. 1.1.31. Unplug the right-front wheel ABS sensor plug. 2. Installation The installation steps are reverse to those for removal.

  • Page 165: Section Iii Removal And Installation Of Electronic Fuel Injection Harness

    Section III Removal and Installation of Electronic Fuel Injection Harness I. Harness Sketch Charging 充 电 显 示 pressure sensor display Generator 发 电 机 插 件 connector connector 进 气 压 力 传 感 器 插 件 Camshaft sensor connector 凸...

  • Page 166: Instructions On Harness Connectors

    II. Instructions on Harness Connectors Connector Name Pins Connection Ground Recharging display To ECU harness connector connector —— Motor connector To ECU harness connector To ECU harness Intake pressure sensor connector To ECU harness connector Ground Ground Carbon canister solenoid To ECU harness valve connector connector...
  • Page 167 Ground Water thermostat To ECU harness connector connector To ECU harness connector Engine rotation speed To ECU harness sensor connector connector —— To ECU harness connector Rear oxygen sensor Ground connector Ground To ECU harness connector To ECU harness connector Front oxygen sensor Ground connector...

  • Page 168: Removal And Installation Of Harness

    III. Removal and Installation of Harness Part number: S12-3724180 Tools: flat head screwdriver, cross head screwdriver, sleeve wrench Notes: (1) The ignition switch must be OFF. (2) When disassembling the electrical components and harnesses, disconnect the power supply. (3) When disassembling common plugs (connectors), first press down the locking device, and then separate the plug and socket by force.
  • Page 169 1.1.4. Use a sleeve wrench to loosen off the inlet air filter fastening nuts. 1.1.5. Pull out the hose that connects the air filter and engine inlet manifold by hand. 1.1.6. Remove the air filter. 1.1.7. Disassemble the battery fixed mounting. 1.2.
  • Page 170 2.1.2. Disassemble the electronic throttle connector. 2.1.3.The ignition coil connector can be diassembled by pressing at the place shown in the right figure. 2.1.4. Disassemble the camshaft sensor connector. 2.1.5. Disassemble the carbon canister solenoid valve connector.
  • Page 171 2.1.6. Disassemble the inlet pressure sensor connector. 2.1.7. Disassemble the recharging display connector. 2.1.8. Disassemble the generator connector. 2.1.9. Disassemble the starter connector. 2.1.10. Unplug the air-conditioning compressor connector.
  • Page 172 2.1.11. Disassemble the power steering pump connector. 2.1.12. Disassemble the knock sensor connector. 2.1.13. Disassemble the reverse light switch connector. 2.1.14. Disassemble the water thermostat connector. 2.1.15. Disassemble the front/rear oxygen sensor connector. Simply pull out the red lid on the connector as shown in the figure.

  • Page 173: Installation Of Harness

    2.1.17. Disassemble the vehicle speed sensor connector. Use a flat head screwdriver to pry open the clips on the connector and then pull it out. 2.1.18. Disassemble the engine rotation speed sensor connector. 2.1.19. Take out the electronic fuel injection harness assembly. 2.

  • Page 174: Section Iv In-Door Harness

    Section IV In-door Harness: I. Harness Sketch Butt joint with LR BCM module A BCM module B door Seat belt switch LR group tail lamp LF door contact switch Butt joint with back Ground door License plate lamp Rear loudspeaker Hand brake switch Trunk light Ground...

  • Page 175: Instructions On Main Connectors

    III. Instructions on Main Connectors Connector Name Pins Connection Remark License plate lights connector License plate lights harness Left-rear combination tail light connector Left-rear combination tail light harness Trunk light connector Trunk light harness Left-rear speaker connector Left-rear speaker harness Fuel pump connector Fuel pump harness Right-rear speaker connector...

  • Page 176: Removal And Installation Of In-Door Harness

    III. Removal and Installation of In-door harness Part number: S12-3724050 (I). Preparations Tools: sleeve wrench, cross head screwdriver, flat head screwdriver (II). Notes When disassembling the electrical components and harness, make sure to disconnect the power supply. The ignition switch must be OFF. (III).
  • Page 177 4. Unplug the plug of the left-rear speaker harness. 5. Removal of fuel pump harness. 5.1. Pull off the right-rear seat, and take down the plastic cover on the fuel pump. 5.2. Unplug the fuel pump harness plug. 6. Unplug right-rear speaker harness plug. 7.
  • Page 178 8. Removal of BCM MODULE. ８.１. Open BCM module box. ８.２. Unplug the BCM module A plug. ８.３. Unplug the BCM Module B plug. ９. Removal of hand brake harness ９.１. Disassemble the auxiliary Instrument Panel assembly. (See Removal and Instalaltion of Auxiliary Instrument Panel) ９.２.
  • Page 179 11. Unplug the seat belt switch harness plug. 12. Removal of instrument harness butt joint 12. １ . Disassemble the Instrument Panel. (See Removal and Installation of Instrument Panel ) 12.２. Unplug the instrument harness butt joint. 13. Removal of instrument harness butt joint 13.
  • Page 180 15. Removal of left-rear wheel ABS sensor harness 15.1. Raise the vehicle by hoister. (Take care of your safety) 15.2. Unplug the left-rear wheel ABS sensor connector. 16. Removal of right-rear wheel ABS sensor harness. 16.1. Raise the vehicle by hoister. (Take care of your safety) 16.2.
  • Page 181 19. Disassemble the ground. 20. Removal of right-rear door contact switch harness 20.1. Open the right-rear door and disassemble the crews that fix the contact switch with a cross head screwdriver, and then take off the right-rear door contact switch. 20.2.
  • Page 182 23. Removal of left-front door harness butt joint 1. 23.1. Disassemble the left A-pillar inner shield, and push down the plastic lock that fixed the connector of the left-front door harness butt joint 1. (See Removal of A-pillar inner shield ) 23.2.
  • Page 183 26. Removal of interior and right-front door butt joint 2. 26.1. Disassemble the right A-pillar inner shield, push down the connector plastic lock that fixes the right-front door harness butt joint 2. (See Removal of A-pillar Inner Shield). 26.2. Unplug the plug of Right-front Door harness butt joint 1. 27.
  • Page 184 29. Removal of the harness butt jointed with the left-rear door harness. 29.1. Disassemble the left B-pillar inner shield. (See Removal and Installation of B-pillar Inner Shield) 29.2. Push down the plastic clips that fixes the harness connector butt jointed left-rear door harness, and then unplug the harness plug that butt joints the left-rear door harness.
  • Page 185 34. Removal of sunroof controller harness. 34.1. Disassemble the left vehicle ceiling. (See Removal and Installation of Vehicle Ceiling) 34.2. Remove the sunroof controller harness plug. (Note: Optional for some vehicle types and the sunroof controller connectors are reserved for this vehicle type. ) 35.

  • Page 186: Harness Sketch

    Section V Removal and Installation of Instrument Panel Harness I. Harness sketch Audio Cluster gauge circulation motor Blower relat conditioner Brake switch The bracket should be Fog light switch thermostat Right loudspeaker Blower power Nightlight switch fitted together with the electric box, the torque Left loudspeaker is:7±1NM...
  • Page 187 II. Instructions on Main Connectors Connector Name Pins Connection Combination instrument Instrument to interior Anti-sheft module →instrument to connector engine Ground —— Ground Fog lights →c200 (instrument to interior ) C200 (instrument to interior ) —— C209 (instrument to engine) C209 (instrument to engine) Instrument electric box Instrument to interior (c200)
  • Page 188 Instrument electric box connector → instrument electric box Nightlight switch Headlight switch C100 〔instrument to front connector compartment 〕 —— C200 (instrument to interior ) Instrument electric box Ground Brake light switch Instrument electric box connector Ignition switch (IGN1) C200 (instrument to interior ) C209〔instrument to engine〕...
  • Page 189 —— Inside/outside motor —— connector A/C switch Ignition switch (IGN2) Ground A/c switch —— Blower relay connector Ground Blower switch Speaker resistor Ground Blower power supply Air-conditioner reconditionang connector Blower relay Air-conditioner Blower switch reconditionang connector Blower switch Blower switch Blower power supply Blower relay connector C105 instrument to front...
  • Page 190 To instrument electric box connector Wiper switch Wiper switch Wiper switch Ignition switch(IGN1) C211 instrument to To instrument electric box interior connector connector C212 instrument to engine Ignition switch(acc) Instrument electric box C200 instrument to Trouble diagnosis socket front compartment Ground connector Left loud speaker...
  • Page 191 C212 instrument to Instrument electric device box engine connector C211 C209 instrument to Instrument panel to plug engine connector Instrument panel to plug Instrument panel to plug Instrument panel to plug Instrument panel to plug Instrument panel to plug Instrument panel to plug Headlight switch Nightlight switch Brake light switch...
  • Page 192 Speaker button Instrument electric box Ignition switch C100 (instrument to front connector compartment ) Instrument electric box Ground (ACC) auxiliary electrical equipment bus Ignition switch(IGN2) Headlights switch Instrument electric box connector Fog light switch Ground C200 (instrument to interior ) ——...
  • Page 193 Blower switch → Air-conditioner switch connector air-conditioner reconditionang Inside/outside circulation motor Inside/outside circulation motor —— C100(instrument to front compartment ) Blower relay —— Ground —— C200 (instrument to interior ) Ignition switch(IGN2) —— —— —— To instrument electric box —— Cigar lighter Ground wire Ignition switch(ACC)
  • Page 194 —— —— Instrument electric box —— Wiper relay —— —— To instrument electric Wiper relay box connector Instrument electric box —— —— —— —— —— C100 (instrument to front compartment ) Air-conditioner temperature switch connector C211 (instrument to interior ) Fog lights switch connector Ignition switch (IGN2) ——...
  • Page 195 —— Blower relay Blower switch —— Ground —— C105 (instrument to front compartment ) —— Ignition switch(IGN2) —— Steering relay Ground Alarm switch Ground —— —— Alarm switch Audio system→C200 (instrument to interior )

  • Page 196: (I). Preparation Of Tools

    III. Removal and Installation of Instrument Panel Harness (I). Preparation of Tools Tools: 10＃/13＃sleeve wrench, cross head screwdriver, flat head screwdriver (II). Notes (1) When disassembling the electrical components and harness, the power supply should be disconnected. (2) Make sure the ignition switch is OFF. (3) When disassembling common connectors, push down the latch device on the connector, and then separate the plug from the socket by force, but do not pull at the wires so as not to damage the wires...
  • Page 197 1.1.7. Disassemble the two connectors of the instrument harness and the interior floor harness, as shown in the right figures: 1.1.8. Disassemble the two connectors of the instrument harness and the engine wiring harnes, as shown in the right figures:...
  • Page 198 1.1.9. Unplug the blower relay, steering relay, and wiper relay, as shown in the right figures: 1.1.10. Unplug the instrument electric box connector as shown in the right figures: 1.1.11. Here is the failure diagnosis socket. 2. Installation of instrument panel harness The installation steps are reverse to those for removal...

  • Page 199: Section Vi Left-Front Door Harness

    Section VI Left-front Door Harness I. Harness Sketch Left-front window motor 左前窗电机 Left-front window 左前窗开关 switch 接室内线束B To in-door harness B 左前门锁 Left-front door lock 接室内线束A To in-door harness A 电动后视镜电机/ Power rearview mirror Left-front loudspeaker 左前扬声器 motor/Left turning light 左侧转向灯...

  • Page 200: Instructions On Main Connectors

    II. Instructions on Main Connectors Connector Name Pins Connection Remark To in-door harness B connector In-door harness B Left-front window motor connector Left-front window motor Left-front window switch connector Left-front window switch To in-door harness A connector In-door harnessA Left-front speaker connector Left/front speaker Power rearview mirror /left turning Power rearview mirror /left turning...
  • Page 201 1.4. Unplug the door lock connector. (See Removal of Door Lock) 1.5. Unplug the outside left-front door rearview mirror harness connector. 1.6. Unplug the left-front door speaker connector. 1.7. Unplug the two connectors that connect the left-front door in-door harness and interior floor harness. (See Removal of In-door harness) 1.8.
  • Page 202 19. Unplug the left-front door lock connector. 2.0. Unplug the elevating motor connector. 21. Unplug the inside door harness shield, and then remove the harness. 2. Installation. The installation steps are reverse to those for removal..

  • Page 203: Section Vii Right-Front Door Harness

    Section VII Right-front Door Harness I. Harness Sketch Right-front window 右前窗开关 右前窗电机 Right-front window switch motor Right-front door to in-door harness 右前门接室内线束 右前门锁 Right-front door lock 电动后视镜电机/ Power rearview mirror motor/Right turning light Right-front loudspeaker 右前扬声器 右侧转向灯...

  • Page 204: Instructions On Main Connectors

    II. Instructions on Main Connectors Connector Name Pins Connection Remark Right-front door in-door harness In-door harness connector Right-front window motor connector Right-front window motor Right-front window switch connector Right front window switch Right-front door lock connector Right-front door lock Right-front speaker connector Right-front speaker Power rearview mirror motor / right Power rearview mirror motor /...

  • Page 205: Section Viii Rear Door Harness

    Section VIII Rear Door Harness I. Harness Sketch Right-rear window switch 右后窗开关 To in-door harness B 接室内线 Right-rear door lock 束插件B 右后门锁 Rear window motor To in-door harness A 接室内 线束A Right-rear loudspeaker 右后扬声器...

  • Page 206: Instructions On Main Connectors

    II. Instructions on Main Connectors Connector Name Pins Connection Remark Right-rear window switch connector Right-rear window switch Right-rear door lock connector Right-rear door lock To in-door harness connector A In-door harness A Rear window motor connector Rear window motor III. Removal and Installation of Right-rear Door In-door Harness Part number: S21-3724180 (I).
  • Page 207 1.5. Unplug the elevating motor connector. 1.5. Disassemble the lower-right B-pillar shield. (See Removal and Installation of Door Shield ) 1.6. Unplug the connector that connects the inside door harness and in-door harness. 1.7. Unplug door contact switch connector. 1.8. Pull out the inside door harness protective rubber jacket, and take out the harness assembly from inside the door.

  • Page 208: Section Ix Tail Door Harness

    Section IX Tail Door Harness I. Harness Sketch High mounted brake light Trunk switch defroster positive harness in-door harness Rear wiper motor Ground 搭铁...

  • Page 209: Instructions On Main Connectors

    II. Instructions on Main Connectors Connector Name Pins Connection Remark To in-door harness connector In-door harness High mount brake light High mount brake light connector Trunk switch connector Trunk switch To defroster positive harness Defroster positive harness connector Rear wiper motor connector Rear wiper motor Ground Vehicle body plate work...
  • Page 210 1.1.3. Disassemble the high mount brake light shield by hand. 1.1.4. Unplug the harness plug connecting the high mount brake light. 1.1.5. Use a flat head screwdriver to disassemble the tail door shield. 1.1.6. Unplug the rear defroster positive harness plug. 1.1.7.
  • Page 211 1.1.8. Unplug the rear wiper motor plug. 1.1.9. Disassemble the vehicle body ground wire. (On the tail door) 1.1.10. Removal of tail door in-door harness 2. Installation The installation steps are reverse to those for removal, and special auxiliary tools (thin steel wire) can be used to accomplish it.

  • Page 212: Section X Defroster Harness

    Section X Defroster Harness I. Harness Sketch Rear defroster Harness to tail door negative Ground 搭铁 Rear defroster 后除霜负极 negative...

  • Page 213: Instructions On Main Connectors

    II. Instructions on Main Connectors Connector Name Pins Connection Remark Defroster positive Defroster positive connector Defroster negative Defroster negative connector Tail door harness Tail door harness connector Vehicle body ground wire Vehicle body On the tail door III. Removal and Installation of Rear Defroster Harness Defroster harness positive part number: S12-3724530 Defroster harness negative part number: S12-3724540 (I).

  • Page 214: (Iv) Installation Steps

    3 Unplug the right-rear defroster connector. (IV) Installation Steps The installation steps are reverse to those for removal.
  • Page 215 Maintenance Manual for Chery A113 (Circuit Diagram)
  • Page 216 Content Chapter 1 Illustration Instruction ....................3 I. Definition of Main Harness Inserters ..................3 II. Definition of Body Earth Points...................7 1. Earth Definition ......................7 2. Distribution of Various Earth Points and Main Modules ..........7 3. Photos of Earth Points....................8 III. Instruction of Main Circuit Symbols ..................9 IV.

  • Page 217: Chapter 1 Illustration Instruction

    Chapter 1 Illustration Instruction I. Definition of Main Harness Inserters Engine/ECU (inserter of engine harness and ECU harness) ECU/front (plug of ECU and front compartment harness) ECU/instrument (plug of ECU and instrument harness) I n t e r i o r /i n s t r u m e n t A ( p lu g A o f i n te r i o r h a r n e s s a n d i n s t r u m e n t h a r n e s s ) 1 1 1 0 2 0 1 9...
  • Page 218 Interior/front (plug of interior harness and front compartment harness) Instrument/engine A (plug A of instrument harness and engine) 11 10 Instrument/engine B (plug B of instrument harness and engine) Instrument/front A (plug A of instrument harness and front compartment harness) 10 11 18 19 Instrument/front B (plug B of instrument...
  • Page 219 ECU pin definition pin definition 15 16 9 10 18 19 2526 COMBINED INSTRUMENTS 14 13 12 11 32 31 23 22 21 20 19...
  • Page 220 Interior/left front B (plug B of interior harness and left front door harness) Interior/left front A (plug A of interior harness and left front door harness) 9 10 （ Interior/left rear plug of interior harness and left rear ） door harness （...

  • Page 221: Definition Of Body Earth Points

    II. Definition of Body Earth Points 1. Earth Definition G100: Body earth, ABS earth G101: Left front compartment earth (radiator fan, low beam, high beam, position lamp, turn signal lamp, front fog lamp, wiper, brake liquid level, anti-deterrent horn) G102: Right front compartment earth (high beam, low beam, position lamp, turn signal lamp, side turn signal lamp, front fog lamp, horn) G200: Power train, fuel position sensor, left front door, left rear door, front ceiling lamp G201: Electric sunroof...

  • Page 222: Photos Of Earth Points

    3. Photos of Earth Points G100 G100(Below battery) G100 G209, 210(Left lower side of front wall) G101 (at left front longitudinal beam) G102 (at right front longitudinal beam) G201(At right front ceiling armrest) G207, 208(at secondary instrument panel) G202 (left rear side of luggage boot)

  • Page 223: Instruction Of Main Circuit Symbols

    G204 (below right pillar C) G206 (near BCM) G200 (below left pillar B) III. Instruction of Main Circuit Symbols Symbol Meaning Symbol Meaning Wiring joint Motor Fuse position and Bulb specification Relay Switch control Shield wire Resistance unit Shield wire Electromagnetic coil This part is not covered within this...

  • Page 224: Auxiliary Instruction Of Circuit Diagram

    IV. Auxiliary Instruction of Circuit Diagram 1. Instruction of Power Supply and Earth Wire 30: Primary live wire from the battery 30a: Primary live wire from the battery 15: From the ignition switch (IGN1) 15a: From the ignition switch (IGN2) Ka: From ignition switch (ACC, disconnect at start) 58b(RHEO): power supply for noctilucence illumination 30–(GROUND): Earth wire, from cathode terminal of the battery...

  • Page 225: Fuse Definition

    “Instrument/interior/A/6” indicates the #6 pin of plug A of instrument harness and interior harness connectors; 4.2. “To anti-deterrent module A5” indicates “to #5 pin of plug A of anti-deterrent module”; 4.3. “To ECU25” indicates “to #25 pin of ECU"; V. Fuse Definition 1.

  • Page 226: Fuse Position And Function Instruction

    2. Fuse Position and Function Instruction 2.1. Front Compartment Relay Box Fuse The front compartment relay box is located near the front compartment battery, with the detailed function instructions of the fuses are as follows: Fuse No. Capacity Function Fuse No. Capacity Function Fan, high speed...

  • Page 227: Instrument Relay Box Fuse

    2.2. Instrument Relay Box Fuse D iagnosis A ccess B low er Relay Steering relay Integrated relay plug Front w iper relay The instrument relay box is located within the left cover plate of the dashboard, with the detailed function instructions of the fuses are as follows: Functions Functions Specification...

  • Page 228: Chapter 2 Circuit Control Theory Diagram

    Chapter 2 Circuit Control Theory Diagram I. Starter Charging System circuit diagram Instrument/front B2 Instrument/front B3 Instrument/front REVERSE LAMPS Vehicle speed sensor To instrument charging indicator Ignition Switch Instrument/engine B1 engine Interior/instrument Motor Starter Battery Battery body transmission earth earth Body Body earth...

  • Page 229: Abs Control System

    II. ABS Control System Diagnosis Access 7# Instrument 14# Instrument/engine Instrument/front Interior/instrument...

  • Page 230: Airbag

    III. Airbag Left side Right side sensor sensor PAB switch Airbag indicator lamp PAB indicator lamp Diagnosis Access7# Instrument/airbag plug Air Bag Driver side Driver airbag Passenger side Passenger seat Driver seat Passenger airbag airbag airbag belt switch belt switch Special earth point of 30（-）...

  • Page 231: Backup Radar

    IV. Backup Radar circuit diagram backup radar Display Engine/ECU26 Backup radar control To gear switch module Engine/ECU27 ECU/Front 4 Interior/front 2 Probe Probe...

  • Page 232: Electric Rear View Mirror

    V. Electric Rear View Mirror Interior/left front Electric rearview mirrors Interior/left Interior/left front front Interior/left front Interior/right front Interior/right Interior/right front front...

  • Page 233: Engine Anti-Deterrent

    VI. Engine Anti-Deterrent Anti-deterrent module Instrument/engine Instrument/engine Diagnosis Access...

  • Page 234: A/C, Defroster System

    VII. A/C, Defroster System A/C switch Instrument/front conditioner relay A/C switch Instrument plug 9# Interior circulation switch Instrument/front Blower Instrument plug 10# 高 High/lo 低 Interior/instrument 压 pressure Fan regulator swithc 开 Instrument resistor 关 plug 1# Interior/luggage boot door 2 Blower Relay ECU/Front 11...

  • Page 235: Ceiling Lamp, Luggage Boot Lamp, And Sunroof System

    VIII. Ceiling Lamp, Luggage Boot Lamp, and Sunroof System Interior/instrument Interior/instrument Interior/instrument Front ceiling Ceiling lamp switch lamp Interior/luggage boot door 4 Automatic off Sunroof To instrument Interior/instrument Speed signal Self Self Self Self earth earth earth earth...

  • Page 236: Front/Rear Wiper System

    IX. Front/Rear Wiper System Wiper combined switch Terminal number Front washer Rear washer Interior/instrument Instrument/front Interior/instrument Instrument/front Interior/luggage boot door 5 Instrument/front Interior/luggage boot door Instrument/front 室/仪 Rear Front washer washer motor motor Rear Wiper Motor Front wiper motor...

  • Page 237: Turn Signal Lamp System

    X. Turn Signal Lamp System To running relay To BCM24 Alarm switch Flash relay Turning Switch Interior/instrument Instrument Interior/instrument 15 Instrument 22 Left Right Right Left turn rear rear turn lamp turn turn lamp lamp lamp...

  • Page 238: Radio/Player, Horn, Cigarette Lighter

    XI. Radio/Player, Horn, Cigarette Lighter To antenna To rear fog lamp 仪/前 Instrument/engine Instrument/engine Instrument/engine Instrument/engine Instrument/engine Instrument/engine Instrument/engine Instrument/engine Interior/right Interior/left Interior/left Interior/right front front front front...

  • Page 239: Headlamp, Fog Lamp System

    XII. Headlamp, Fog Lamp System To instrument 11# Instrument Instrument Instrument/engine plug /11 ceiling Lam p lamp control sw itch G re en lam p Clearance lamp Switch H eadlamp Clearance Fro nt lamp Rear lamp relay Lamp control N octilucence adjustment switch Instrument 32# Instrument/front...

  • Page 240: Bcm System

    XIII. BCM System Interior/right Interior/le ft fro nt front Interior/left front Interior/left Interior/le ft front Interior/right rear 6 rear 6 L eft Front W indow （ ） S w itch right rear B rake left rear right front w indow w indow lam p w indow...

  • Page 241: Instrument System

    XIV. Instrument System four-door contact switch Speed generator fuel Position front rear Sensor level Handbrake lamp sensor switch lamp switch lamp To airbag switch switch 发/ airbag coolant Instrument/front To headlamp temperature sensor switch To right turn signal lamp To Left turn signal lamp To airbag Right Left...
  • Page 242 XV. 473 Engine and Liandian Electric Injection System engine / /前 9 / front / front / front 14 / front 前 氧 传 感 engine engine engine/ engine engine Ignition Coil 器 发 / engine 发 / engine engine engine engine engine...
  • Page 243 Mando MGH-25 Anti-Lock Brake System User’s Manual...
  • Page 244 CONTENT Common Abbreviations and Acronyms in This Manual………………………………… 2 I. Product Instruction………………………………………………………………………. 3 1． ABS Overview ……………………………………………………………………….. 3 1.1 System Function…………………………………………………………………… 3 1.2 Comparison between with and without ABS braking effects…………………... 3 2． System Structure…………………………………………………………………….. 5 3． System Functioning Theory…………………………………………………………. 6 3.1 ABS Control Theory…………………………………………………………………...

  • Page 245: Common Abbreviations And Acronyms In This Manual

    Common Abbreviations and Acronyms in This Manual FL——Front Left FR——Front Right RL——Rear Left RR——Rear Right ABS——Anti-lock Brake System EBD——Electronic Brake Distribution ECU——Electronic Control Unit HU、HCU——Hydraulic (Control) Unit HECU——ECU+HCU LPA——Low Pressure Accumulator MCP——Master Cylinder Primary, one of two outlet of master cylinder. P refers to primary.

  • Page 246: Product Instruction

    I. Product Instruction 1． ABS Overview 1.1 System Function ① Promotion of vehicle stability; ② Guarantee of vehicle steering ability; ③ Guarantee of shortest brake distance. 1.2 Comparison between with and without ABS braking effects Without ABS With ABS Braking on Bisectional Roads (Split) Without ABS With ABS Evading the obstacles during braking...
  • Page 247 1.3 Tire Dynamic Characteristics Slip Ratio Brake Force Steering Force Slip Rate [%] Page 4 of 38...

  • Page 248: 2． System Structure

    2． System Structure Motor Including: The sensor will calculate the speed and acceleration/deceleration of four wheels and judge the skid status of the wheels and Electronic Control Unit therefore drive the electromagnetic valve and motor, control the pressure increment and pressure reduction, maintain the status, and etc.

  • Page 249: 3． System Functioning Theory

    3． System Functioning Theory 3.1 ABS Control Theory Slip Ratio ABS Control Range Start Start Body Speed – Wheel Speed Pressure Pressure Reduction Increment Body Speed Tire braking force (μs) Tire transversal friction force (μs) Skid Ratio λ= 100%: The status that the wheels λ= 0%: The status that the brake is are locked not functioning...
  • Page 250 ② Functioning (Pressure Reduction) Status For the vehicles equipped with ABS, if the applied braking pressure is too big, the wheels will have rapider deceleration than that of vehicle body, which will be ready to result the lock of the wheels.
  • Page 251 ④ Functioning (Pressure Increment) Status During the implementation of the pressure reduction, if the excessive brake liquid is drained or the friction coefficient between the wheels and the road is increased, it’s necessary to increase the pressure of various wheels. Under such case, the ECU will transmit the code for wheel pressure increment to the HCU, namely turn on the normal open valve and turn off the normal close valve to increase the pressure of wheel branch pump.

  • Page 252: Ebd Control Mode

    EBD Control Mode In order to guarantee the operation stability, the EBD function is designed in such manner that front wheels are stopped ahead of the rear wheels. As the front brakes undertake more works than that of the rear brakes, it will cause that the rear wheels will be stopped firstly when apply with same braking pressure.

  • Page 253: Removal And Installation

    II. Removal and Installation Spare Part Supply Status ① Differentiation between Dry Type HECU and Wet Type HECU The biggest differentiation between the dry type HECU and wet type HECU is that the no air discharge is conducted in the 2nd circuit (namely the circuit from the normal close valve to the general pump) of the dry type HECU.
  • Page 254 ② Notices for HECU Bracket Assembling During the assembling of HECU bracket: † During the tightening of the bolt (3 pcs), it may cause the incorrect Bracket assembling friction resistance of the cushion pad. It’s Installation bolt preferable to use the lubricating oil with the physical properties that will Bumper block not impair the cushion pad.

  • Page 255: 3． Hecu Replacement

    3． HECU Replacement ① When the vehicle is stopped, remove the 25-pin connector and harness wiring of the HECU located within the engine compartment. 25-Pin Connector Used in MGH-25 ABS (P/No：AMP 368482-1) ② Screw off in counter clockwise direction the 6 bolts (M10x1.0) connected to the HECU brake hose with 11mm tool (wrench) (rotate in clockwise direction during refit).
  • Page 256 ⑤ Screw off in counter clockwise direction the 6 bolts from the after-service HECU with 6mm tool (hex wrench). ⑥ Screw on in clockwise direction 3 embedded bolts to assemble the after-service HECU and the bracket with 5mm tool (hex wrench). The tightening torque for the embedded bolts is 80 ~ 100 kgf·cm.

  • Page 257: Trouble Diagnosis And Troubleshooting

    III. Trouble Diagnosis and Troubleshooting 1． Checking Sequence Checking of wheel Regular checking Checking of valve Record checking speed sensor and terminal result • ECU ID determination • Valve status determination • Sensor air gap determination • Trouble code • ECU trouble code •...

  • Page 258: Trouble Code Readout And Deletion Without Trouble Diagnosis Instrument

    2.3 Trouble Code Readout and Deletion without Trouble Diagnosis Instrument ① Purpose and condition of trouble code readout without trouble diagnosis instrument If without the trouble diagnosis instrument, it may display the trouble status of the ABS via the ABS warning lamp and read out the trouble code to facilitate the trouble determination and troubleshooting.
  • Page 259 The meaning of symbols in the figure is as follows: Code Symbol Description Duration The symbol for diagnosis start. The warning lamp starts flashing 3.0s For differentiation of the duration of various trouble codes during 3.0s the display of multi trouble codes Flashing interval of warning lamp at the presence of trouble code 0.5s For differentiation of the interval of various digits of trouble code...

  • Page 260: Trouble Checklist Of Trouble Code

    of which the operation method is same with that of the trouble code diagnosis. In addition, when the ECU of the ABS has no trouble code, ground the line L and rotate the key to the power on position. The flashing of the ABS warning lamp is conducted in accordance with the type in following figure, of which the symbol meaning is same with the foregoing section.
  • Page 261 ② Trouble checklist of trouble code Table 1 C1 200(11) C1 203(21) Note: If the malfunctions corresponding to Trouble Code C1 206(31) C1 209(41) more than 2 trouble codes can be determined, Open-circuit/short-circuit of sensor: after the trouble codes are deleted (erasable trouble codes), drive the vehicle to above At short-circuit or open-circuit 40km/h to determine the malfunctions to that...
  • Page 262 Table 2 Note: ①The air gap refers to the gap between Trouble Code C1 202(13) C1 205(23) C1 208(33) C1 211(43) the gear ring and the sensor; ② If the malfunctions corresponding to more Possible Case Air gap error: than 2 trouble codes can be determined, after Air gap too big or self short-circuit of sensor (resistance value at 0) that the trouble codes are deleted (erasable trouble...
  • Page 263 Table 3 Note: ① The sensor signal is not uniform Trouble Code C1 201(12) C1 204(22) C1 207(32) C1 210(42) when the gears are adhered with engine oil and the impurities such as slag; ② The air gap refers to the air gap between Possible Cause Interference of gear ring or sensor: Occurred when installed with non-...
  • Page 264 Table 4 Trouble C1 101(51) C1 102(52) Note: If the malfunctions corresponding to more Code than 2 trouble codes can be determined, after the trouble codes are deleted (erasable trouble codes), Possible Abnormal battery voltage: drive the vehicle to above 40km/h to determine the Cause Occurred when the voltage is too high or too malfunctions to that the trouble codes correspond...
  • Page 265 Table 5 Trouble Code 402(55) Note: If the malfunctions corresponding to more than 2 trouble codes can be determined, after the Possible Cause Malfunction of motor fuse/motor trouble codes are deleted (erasable trouble codes), drive the vehicle to above 40km/h to determine the malfunctions to that the trouble codes correspond and check in accordance with the registered trouble codes (determine the same one...
  • Page 266 Table 6 Trouble Code 112(54) Note: If the malfunctions corresponding to more than 2 trouble codes can be determined, after the Possible Cause Malfunction of valve fuse and relay: trouble codes are deleted (erasable trouble codes), a) Broken of primary relay or fuse drive the vehicle to above 40km/h to determine b) Short-circuit of primary relay the malfunctions to that the trouble codes...
  • Page 267 Table 7 Trouble Code 604(53) Note: If the malfunctions corresponding to more than 2 trouble codes can be determined, Possible Cause Malfunction of ECU internal circuit after the trouble codes are deleted (erasable and valve coil trouble codes), drive the vehicle to above 40km/h to determine the malfunctions to that the trouble codes correspond and check in accordance with the registered trouble codes...

  • Page 268: Trouble Checklist Without Trouble Code

    2.5 Trouble Checklist without Trouble Code Table 1 Trouble The ABS warning lamp doesn’t illuminate when the engine is started Evidence ● ● Possible Cause Burn of fuse Burn of ABS warning lamp bulb ● ● Open-circuit of power line Damage of ABS warning lamp control Troubleshooting Flow...
  • Page 269 Table 2 Trouble The ABS warning lamp constantly illuminates after the vehicle start Evidence ● Possible Cause Damage of ABS warning lamp control ● Open-circuit of ABS warning lamp control circuit ● ECU damage of ABS Troubleshooting Flow After the harness side connector is removed, confirm if it's powered between the harness side pin 16 and warning lamp drive component.
  • Page 270 Table 3 Trouble Abnormal functioning of ABS Evidence ● Damage of sensor ● Damage of gear ring Possible Cause ● Improper installation of sensor ● Damage of wheel bearing ● Problem of sensor harness ● HCU damage of ABS ● Impurity adherence on sensor ●...
  • Page 271 Table 4 Trouble Brake pedal travel too long Evidence ● Improper adjustment of handbrake Possible Cause ● Leakage of brake liquid ● Severe wearing of brake friction disc ● Leakage of normal close valve ● Air in the system Troubleshooting Flow Check hydraulic pipe connector for leakage...
  • Page 272 Table 5 Trouble Without diagnosis code output (communication failure with trouble diagnosis Evidence instrument) ● Problem of diagnosis instrument Possible Cause ● Burn of fuse ● Broken of diagnosis line or loosening of connector ● ECU damage of ABS Troubleshooting Flow Confirm connection...

  • Page 273: Air Discharge And Oil Refill

    IV. Air Discharge and Oil Refill 1. Regular Operation Procedure Add brake fluid Vacuum Motor Normal Close Valve Procedures The regular operation procedure of air discharge and oil refill is shown in the figure, of which: A : Move the vacuum device and brake oil refill device; B : Start after connected with vacuum and brake oil refill device and SDL;...

  • Page 274: Determination Method For Vehicles With Air Discharge Trouble

    ① During the refilling of brake oil, if the refilling pressure is not maintained for certain period or above, the oil level within the oil reservoir will lower at the finish of the refilling. Therefore, it’s required to refill more brake oil or maintain the refilling pressure for certain period. ②...

  • Page 275: Measures In Event Of Trouble During Checking And Abs Functioning Test

    ④. Check the HECU with repetition device or checking device and determine the existence of trouble code. If with trouble code, firstly conduct the operation for deletion of the trouble code (if the trouble in above item ① is not determined, it’s necessary to determine the existence of trouble code).
  • Page 276 ② Check the HECU with repetition device or checking device and determine if it has trouble code. † If with trouble code, firstly conduct the operation to delete the trouble code. † If the trouble code can’t be deleted, implement with reference to section 2.4 “trouble checklist of trouble code”...

  • Page 277: Annex I Malfunction Cases And Incorrect Repair Cases

    Annex I Malfunction Cases and Incorrect Repair Cases HECU Incorrect Repair Cases ① HECU replacement relating to ABS functioning noise The HECU replacement case that deemed the noise of electromagnetic valve and motor as the malfunction during the functioning of the ABS. †...
  • Page 278 † The union status of the sensor must be checked before the removal of the connectors of connecting wiring (such as incomplete union, pin displacement, with impurity, and etc.)After confirm that the sensor resistance and head are free of abnormalities, centrally check the wiring and connectors.

  • Page 279: Annex Ii Abs Basics

    Annex II ABS Basics Will the braking distance be shortened when equipped with ABS? † The testing data show that the braking distance will be shortened on most road conditions (approximately 5%~20%). However, under some special road conditions (such as snowy road, non-asphalt road and rough road), the braking distance will be lengthened.

  • Page 280: Annex Iii Abs Internal Hydraulic Flow Diagram

    Annex III ABS Internal hydraulic Flow Diagram High pressure accumulator Normal Open Valve Normal Pump Close Valve Low-Pressure Front Rear Accumulator Rear Front right left right left Annex IV Connector Pin Layout of MGH-25 ABS ECU Power supply 2 Power supply 1 Grounding Grounding wire...
  • Page 281 Harness side connector (Front view) Grounding wire Grounding wire Rear right wheel sensor Rear left wheel sensor Front right wheel sensor Front left wheel sensor Wheel speed output Warning lamp Motor cathode Ignition switch anode Brake lamp Motor anode Valve anode Motor Motor module anode...

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