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FOREWORD
This manual contains on-vehicle service and diagnosis for Chery A series cars.
For proper repair and maintenance, a thorough familiarization with this manual is important,
and it should always be kept in a handy place for quick and easy reference.
All the contents of this manual, including drawings and specifications, are at latest available
at the time of printing. As modification affecting repair or maintenance occur, relevant
information supplementary to this volume will be made available at Chery dealers. This
manual should be kept up-to-date.
Chery company reserves the right to alter the specifications and contents of this manual
without obligation or advanced notice.
CHERY AUTOMOBLE CO., LTD
ANHUI CHINA
CONTENT
Title Section
General Information GI
Engine B
Lubrication System D
Cooling System E
Fuel and Emission Control System F
Engine Electrical System G
Clutch H
Manual Transmission J
Axles And Suspension System M
Steering System N
Braking System P
Body S
Body Electrical System T
Air Conditioner System U
Technical Data TD
Special Tools ST
GI-1
RANGE OF TOPICS
This manual contains procedures for performing all required service operations. The
procedures are divided into the following five basic operations:
Removal/Installation
Disassembly/Assembly
Replacement
Inspection
Adjustment
Simple operations which can be performing easily just by looking at the vehicle (i.e.,
removal/installation of parts, jacking, vehicle lifting, cleaning of parts and visual
inspection) have been omitted.
SERVICE PROCEDURE
Inspection, adjustment
Inspection and adjustment procedures are divided into steps. Important points regarding the
location and contents of the procedures are explained in detail.
Repair procedure
1. Most repair operations begin with an overview illustration. It identifies the components.,
show how the parts fit together and describes visual part inspection. However, only
removal/ installation procedures that need to be performed methodically have written
instructions.
2. Expendable parts, tightening torques and symbols for oil, grease and sealant are shown in
the overview illustration. In addition, symbols indicating parts requiring the use of special
service tools or equivalent are also shown.
3. Procedures steps are numbered and the part that is the main point of that procedure is
shown in the illustration with the corresponding number. Occasionally, there are
important points or additional or additional information concerning a procedure. Refer to
this information when serving the related part.
ADVISORY MESSAGES
Youll find several Warnings, Cautions, Notes, Specifications and Upper and Lower
Limits in this manual.
Warning
A Warning indicates a situation in which serious injury or death could result if the warning
is ignored.
Caution
A Caution indicates a situation in which damage to the vehicle or parts could result if the
caution is ignored.
GI-2
GI-3
UNIT
GI-4
PROTECTION OF VEHICLE
Always be sure to cover fenders, seats and floor
areas before starting work.
DISASSEMBLY
If the disassembly procedure is complex,
requiring many parts to be disassembled ,all parts
should be marked in a place that will not affect
their performance or external appearance and
identified so that reassembly can be performed
easily and efficiently.
GI-5
CLEANING OF PARTS
All parts to be reused should be carefully and
thoroughly cleaned in the appropriate method.
Warning
Using compressed air can cause dirt and
other particles to fly out causing injury to
the eyes. Wear protective eye wear
whenever using compressed air.
REASSEMBLY
Standard values, such as torques and certain
adjustments, must be strictly observed in the
reassembly of all parts.
Depending on location:
Sealant and gaskets, or both, should be applied to specified locations. When sealant is
applied, parts should be installed before sealant hardens to prevent leakage.
Oil should be applied to the moving components of parts.
Specified oil or grease should be applied at the prescribed locations (such as oil seals)
before reassembly.
GI-6
HOSE CLAMPS
When reinstalling, position the hose clamp in the
original location on the hose and squeeze the clamp
lightly with large pliers to ensure a good fit.
VISE
When using a vise, put protective plates in the jaws of the vise to prevent damage to parts.
GI-7
ELECTRICAL PARTS
Battery cable
Before disconnecting connector or removing
electrical parts, disconnect the negative battery
cable.
Wiring Harness
To remove the wiring harness from the clip in the
engine room, pry up the hook of the clip using a
flathead screwdriver.
CONNECTORS
Disconnecting connectors
When disconnecting connector, grasp the
connectors, not the wires.
GI-8
Inspection
When a tester is used to inspect for continuity or
measuring voltage, insert the tester probe from
the wiring harness side.
Caution
To prevent damage to the terminal, wrap
a thin wire around the tester probe before
inserting into terminal
Terminals
Inspection
Pull lightly on individual wires to verify that they
are secured in the terminal.
GI-9
Wiring Harness
Wiring color codes
Two-color wires are indicated by a two-color code symbol.
The first letter indicates the base color of the wire and the second the color of the stripe.
M/G
CODE COLOR CODE COLOR N/R
V Green R Red BLACK
H Gray Z Purple
A Blue B White
N Black G Yellow
M Brown
Fuse
Replacement
When replacing a fuse, be sure to replace it with
one of the same capacity. If a fuse fails again, the
circuit probably has a short and the wiring should
be inspected.
Be sure the negative battery terminal is
disconnected before replacing a main fuse.
When replacing a pullout fuse, use the fuse
puller.
GI-10
Caution
Do not connect a jumper wire from the
power source line to a body ground. This
wiring harnesses or electronic
components.
Voltmeter
The DC voltmeter is used to measure circuit
voltage. A voltmeter with a range of 15V or more
is used by connecting the positive (+) probe (red
lead wire) to the point where voltage will be
measured and the negative (-) probe (black lead
wire) to a body ground.
Ohmmeter
The ohmmeter is used to measure the resistance
between two points in a circuit and to inspect for
continuity and short circuits.
Caution
Do not connect the ohmmeter to any
circuit where voltage is applied. This will
damage the ohmmeter.
GI-11
Caution
Do not two the vehicle backward with
driving wheels on the ground. This may
cause internal damage to the transaxle.
Caution
Do not tow with sling-type equipment.
This could damage your vehicle. Use
wheel-lift or flatbed equipment.
Caution
Do not use the hook loops under the
front and rear for towing. They are
designed ONLY for tying down the
vehicle when it is being transported.
TOWING HOOKS
Caution
The towing hooks should be used only in an emergency(to get the vehicle out of a
ditch or a snow bank, for example).
when using the towing hooks, always pull the cable or chain in a straight direction
with respect to the hook. Apply no sideways force.
GI-12
REAR
GI-13
DESCRIPTION OF VIN
LVV: International identity code of manufacturer
D: Brand of the Vehicle
A: Type of Vehicle Chassis
1: Type of Transmission
1: Type of Engine
A: Constrain System
7: Check Digit
5: Manufacture Year
D: Assembly Factory Code
023437: Production Serial Number
GI-14
9. The eleventh digit of VIN code stands for the assembly factory. The Chery Automobile
Co., Ltd is represented by the letter D.
10. The twelfth to the seventeenth digits of VIN code stand for production serial number.
GI-15
GI-16
MileageKm
Items 5000 15000 30000
Light, warning flasher, horn: check performance
Wiper and washing system: check performance, add washer fluid if necessary
Oil: Replace
Timing belt: check belt tension and wear, adjust or replace if necessary.
Air filter: clean shell, clean filter element and replace it if necessary.
Steering tie rod joint: check clearance and if dust boot damaged
Power steering system: check if power steering oil level, steering gear & rack
clearance improper
Brake system: visually check if leak or damage and brake fluid level
GI-17
Tire (including spare tire): check tires veins depth, adjust tire pressure, check
wheel bolt tightening torque.
Tires exchange
Note:
For manual transmission, replace gear oil in transmission case every year or 30,000 km. Replace brake fluid
every 2 years or 50,000 km.
When driving mileage reaches 5,000 km, perform 5,000 km maintenance item.
When driving mileage reaches 10,000 km or 6 months after last service, perform 5,000 km
maintenance item.
When driving mileage reaches 15,000 km or 6 months after last service, perform 15,000 km
maintenance item.
When driving mileage reaches 20,000 km or 6 months after last service, perform 5,000 km
maintenance item.
When driving mileage reaches 25,000 km or 6 months after last service, perform 5,000 km
maintenance item.
When driving mileage reaches 30,000 km or 6 months after last service, perform 30,000 km
maintenance item.
When driving mileage reaches 35,000 km or 6 months after last service, perform 5,000 km
GI-18
When driving mileage reaches 40,000 km or 6 months after last service, perform 5,000 km
maintenance item.
When driving mileage reaches 45,000 km or 6 months after last service, perform 15,000 km
maintenance item.
When driving mileage reaches 50,000 km or 6 months after last service, perform 5,000 km
maintenance item.
When driving mileage reaches 55,000 km or 6 months after last service, perform 5,000 km
maintenance item.
When driving mileage reaches 60,000 km or 6 months after last service, perform 30,000 km
maintenance item.
When driving mileage reaches 65,000 km or 6 months after last service, perform 5,000 km
maintenance item.
When driving mileage reaches 70,000 km or 6 months after last service, perform 5,000 km
maintenance item.
When driving mileage reaches 75,000 km or 6 months after last service, perform 15,000 km
maintenance item.
When driving mileage reaches 80,000 km or 6 months after last service, perform 5,000 km
maintenance item.
When driving mileage reaches 85,000 km or 6 months after last service, perform 5,000 km
maintenance item.
When driving mileage reaches 90,000 km or 6 months after last service, perform 30,000 km
maintenance item.
When driving mileage reaches 95,000 km or 6 months after last service, perform 15,000 km
maintenance item.
GI-19
VALVE, VALVE SPRING AND OIL SEAL ASSEMBLY OF THE VALVE B-13
B-1
CAMSHAFT B-25
CRANKSHAFT B-28
B-2
TIMING BELT
1
(SEE B-4 ENGINE TIMING)
VALVE MECHANISM COMPONENTS
2
(SEE B-9 VALVE CLEARANCE)
CYLINDER HEAD GASKET
3
(SEE B-19 CYLINDER HEAD GASKET REPLACEMENT)
FRONT OIL SEAL
4
(SEE B-21 FRONT OIL SEAL REPLACEMENT)
REAR OIL SEAL
5
(SEE B-23 REAR OIL SEAL REPLACEMENT)
CAMSHAFT
6
(SEE B-25 CAMSHAFT)
CRANKSHAFT
7 (SEE B-28 CRANKSHAFT, CRANKSHAFT THRUST SPACER, BEARING SHELL AND
MAIN BEARING CAP)
PISTON AND CONNECTING ROD
8
(SEE B-33 PISTON AND CONNECTING ROD ASSEMBLY)
B-3
Installation
Clean the bottom timing gear cover and fix the
new gasket on the bottom timing gear cover with
glue. Install the bottom timing gear cover and
gasket assembly on the crank shaft, screw in two
bolts by hands and tighten them for a moment of
9.0~11N.m.
Clean the top timing gear cover and fix the new
gasket on the top timing gear cover with glue. Fix
the top timing gear cover and gasket assembly on
the cylinder head with two bolts for a tightening
moment of 9~11N.m.
B-4
B-5
Timing gear
Bush
Key
Bolt: M12*1.5*30
Tightening torque: 52~60Nm
Tension Pulley
Bolt: M8*25
Tightening torque: 16~20Nm
Key
Crankshaft Gear
B-6
B-7
B-8
B-9
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VALVE COVER AND GASKET
Cupped gasket
Valve Cover
Cupped
Removal gasket
Installation
B-10
Removal
Loosen the rocker nuts to take them out.
Installation:
Check whether theire is abnormal abrasion on
the contact surface of the rocker. Replace it if
necessary.
Put the rocker seat gasket into the stud.
Lubricate the rocker arm and rocker seat by
motor oil.
Install the rocker arm and seat, screw in the
new nuts by hands, then tighten them for the
moment of 2529N.m.
B-11
Removal
Take the hydraulic tappets out and place them
into an oil-filled vessel to prevent the hydraulic
tappet oil from leaking out.
Check the top and bottom contact surfaces of
the hydraulic tappet to observe whether there
are abnormal abrasion or scrapes. If yes,
replace it with new one if necessary.
Installation
Apply hyperbolic gear oil or motor oil on the
tappet and external diameter as well as its two
ends and place the tappet into the cylinder
head hole in the original order.
Tappet
B-12
CYLINDER
1
Put one set of valve, valve cotter, spring and spring
seat into one plastic bag, each of which shall be
tagged with numbers for installing them back to the
original position.
B-13
Intakemm Exhaustmm
Class Inner Diameter
Diameter of Inner Diameter
Diameter of Clearance of valve Clearance
valve stem of valve guide
valve guide stem
Free Length
Compression Spring load
of Spring
length (mm) (N)
(mm)
L1=37.084 422
L3=27.0 945
B-14
UAESs new
two-valve
Installation
Before installation, the cylinder head shall be
completely cleaned and there shall be no any trace
of abrasive dust on the cylinder head, valve or
valve guide.
Lubricate the valve stem and valve guide bore with
clean motor oil.
Install the valve. The assembly shall be completed
according to the original valve indicators.
Note: The intake valves are interchangeable, but
the exhaust valves are not.
B-15
Size of exhaust valve seat ring and cylinder head seat ring bore
Diameter of exhaust valve Diameter of cylinder head Interference
Class
seat ring (mm) seat ring bore (mm) (mm)
Standard 38.877 +00..01
01 38.263 0+0.025
Oversized
39.377 +00..01
01 38.763 0+0.025 0.0790.124
0.5
Oversized
39.877 +00..01
01 39.263 0+0.025
1.0
UAESs
new 38.377 +00..01
01 38.263 0+0.025
two-valve
Oversized 0.0790.124
38.877 +00..01
01 38.763 0+0.025
0.5
Oversized
39.377 +00..01
01 39.263 0+0.025
1.0
B-16
Warning
Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage.
Always keep sparks and flames away from fuel.
Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries
or death and damage. Fuel can also irritate skin and eyes. To prevent this, always
complete the Fuel Line Safety Procedure.
If the measured value is less than the limited value, or there is a cylinder whose
compression value varies from that of other cylinders, add a small amount of engine oil
through the spark plug hole. Then measure the compression pressure and perform the
respective operations for the following cases.
If the compression increases, the piston, the piston rings, or cylinder wall may be worn
and overhaul is required.
If the compression stays low, a valve may be stuck or improperly seated and overhaul is
required.
If the compression in adjacent cylinders stays low, the cylinder head gasket may be
damaged or the cylinder head distorted and overhaul is required.
B-17
B-18
Removal
Rotate the cam shaft clockwise until the key slot
goes downwards vertically.
Loosen the bolts on the cylinder head in the order
illustrated in the figure.
B-19
B-20
CRANKSHAFT PULLEY
Removal
Installation
Bolt: M12*35
Clean the pulley and crankshaft journals and wipe Tightening torque: 100~115Nm
clean the lube in the pulley groove. Install the
pulley on the crank shaft journal, with the key slot
to line up with the whiney key.
Put the washer over the bolts and screw it in by
hands. Fasten the flywheel ring gear to disenable
Pulley
the crank shaft to rotate. Tighten the bolts for a
moment of 100-115N.m
B-21
Removal
Fix the crankshaft to disenable it to rotate and
remove the pulley.
Pull the crankshaft gear out by a wheel puller or
two large-size screw drivers and remove the
whiney key.
Installation
Check whether there are abrasion, pit corrosion or
scrapes on the gear.
Install the whiney key, with a protrusion height of
1.392-1.739mm.
Install the gasket and pay attention to its direction
(with the warped surface forward).
Install the crank shaft gear (with the convex
surface forward), place it on the locating abutment
with a auxiliary pulley and bolts.
B-22
Removal
Remove 9 fixing bolts. New bolts shall be used
for installation.
Remove the fly wheel to check whether there
are cracks on the friction surface of the clutch
plate and there is abrasion and pit corrosion on
the teeth of the ring gear, etc.
Installation
The clearance of the ring gear and the fly
wheel is 0.48-0.86mm. The ring gear shall be
pressed into the fly wheel after heating.
The gauge holes of the fly wheel and the
locating journal are easy fit at a clearance of
0.012-0.074mm. It shall be gently pushed into
the journal after alignment. Do not hammer at
the crank shaft.
During the assembly process, align the
installation mark bore and the manufacturing
bore on the crank shaft. Tighten 9 new bolts
applied with a coat of glue in advance at a
moment of 82-92Nm.
Removal
Remove 4 bolts (as indicated by arrows).
Take the rear oil seal support assembly out.
Take the rear oil seal support gasket.
B-23
Installation
Put the support on the vice clamp whose jaw
has a piece of wood.
Make the side with the part numbers of the rear
oil seal outward and align the rear oil seal with
the rear oil seal support bore. Press the rear oil
seal into its support with a vice clamp, with the
clearance between the rear oil seal and oil seal
support bore to be 0.260.50mm.
Seal
Bolt: M6*20(4 pcs)
washer
Tightening torque: 8~11Nm
B-24
CAMSHAFT GEAR
Removal
Rotate the crankshaft to the compression TDC
position of the first cylinder.
Remove the belt.
Put one pole into one hole of the cam shaft gear to
lock it. Loosen the gear bolts and remove them and
the gasket.
Note:
New bolts shall be used for reinstallation. The
camshafts of different engines are not
interchangeable. In case the cam shaft shall be
replaced, replace it with a new one according to
the indicators on the original gear.
Installation
Check whether there are abrasion, pit corrosion or
scrapes on the gear.
Install the whitney key of the cam shaft, with a
protrusion height of 1.64-2.11mm.
Install the camshaft gear onto the camshaft and put
new bolts into the gasket. The new bolts that
havent been applied with a coat of glue in
advance shall be applied with a coat of glue first
and be tightened for a moment of 52-60N.m.
Check whether the crank shaft is in the
compression TDC position.
Removal
Measure the axial clearance of the cam shaft,
which shall be between 0.049~0.129mm.
Loosen the bolts of the thrust spacer to take them
out.
Take the thrust spacer out (as illustrated in the
figure).
B-25
Inspection
Check whether there is any abrasion on the cam
and the journal of the cam shaft. Change the one
with serious abrasion.
Change the thrust space if the axial clearance of
the cam shaft is above the specification.
Measure the bore diameter of the cam shaft of the
cylinder head or check the relative displacement of
the journal and bore with the cam shaft. Change the
cam shaft if the bore is excessively wore.
Cam Height
Engine model Admission cam T (unit: mm) Exhaust cam T (unit: mm)
480 38.602 37.586
480E 37.559 37.559
B-26
1. Standard size
Number of cam shaft Diameter of cam shaft journal Diameter of the cam shaft hold of the
journal (unit: mm) cylinder head (unit: mm)
1 44.7444.76 44.78344.808
2 44.9945.01 45.03345.058
3 45.2445.26 45.28345.308
4 45.4945.51 45.53345.558
5 45.7445.76 45.78345.808
2. Oversized (0.38)
Number of cam shaft Diameter of cam shaft journal Diameter of the cam shaft hold of the
journal (unit: mm) cylinder head (unit: mm)
1 45.1245.14 45.16345.188
2 45.3745.39 45.41345.438
3 45.6245.64 45.66345.688
4 45.8745.89 45.91345.938
5 46.1246.14 45.16345.188
B-27
Inspection
Check the main journal and main bearing shell
clearance.
Clean the main journal of the crank shaft, the
internal bore of the main bearing cap and main
bearing shell with a non-woven fabrics. Place the
plastic clearance gauge (its length slightly shorter
than the length of the main journal) on the main
journal, which shall be in parallel with the
generator of the main journal.
Note: Do not rotate the crank shaft
B-28
Diameter of Thickness of
connecting rod connecting-rod
Class journal bearing shell
(unit: mm) (unit: mm)
Standard 47.8947.91 1.4801.487
Downsized
47.8947.91 1.4921.499
by 0.025
Downsized
47.6447.66 1.6051.612
by 0.25
Downsized
47.3947.41 1.7301.737
by 0.5
Downsized
47.1447.16 1.8551.862
by 0.75
Downsized
47.8946.91 1.9801.987
by1.0
B-29
Size of crank shaft thrust, thrust spacer and cylinder block thrust
Size of cylinder block thrust Size of crank shaft thrust Thickness of thrust
Class
(unit: mm) (unit: mm) spacer (unit: mm)
Standard 24+0.03 28.825-28.875 2.326+0.025
Oversized
24+0.03 29.205-29.255 2.516+0.025
by 0.38
2 thrust spacers
B-30
B-31
B-32
Removal
B-33
480 M cylinder bore (unit: mm) 480 E cylinder bore (unit: mm)
1 79.94-79.95 1 79.94-79.95
Ex-factory 2 79.95-79.96 2 79.95-79.96
grouping 3 79.96-79.97 3 79.96-79.97
4 79.97-79.98 4 79.97-79.98
A 80.23-80.24 A 80.23-80.24
Ex-factory
B 80.24-80.25 B 80.24-80.25
repair
C 80.25-80.26 C 80.25-80.26
Standard 79.965-77.975 Standard 79.965-77.975
For
Maintenance Oversized by 0.29 80.245-80.255 Oversized by 0.29 80.245-80.255
Oversized by 0.5 80.466-80.475 Oversized by 0.5 80.466-80.475
B-34
Diameter of 480M piston pin bore (unit: mm) Diameter of 480E piston pin bore (unit: mm)
White 20.630-20.633 White 20.630-20.633
Red 20.633-20.636 Red 20.633-20.636
Blue 20.636-20.639 Blue 20.636-20.639
Diameter of 480M piston pin bore (unit: mm) Diameter of 480E piston pin bore (unit: mm)
White 20.622-20.625 White 20.622-20.625
Red 20.625-20.628 Red 20.625-20.628
Blue 20.628-20.631 Blue 20.628-20.631
B-35
B-36
B-37
B-38
DISASSEMBLY/ASSEMBLY D-3
DISASSEMBLY/ASSEMBLY D-5
DISASSEMBLY/ASSEMBLY D-6
DISASSEMBLY/ASSEMBLY D-10
D-1
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ENGINE LUBRICATION SYSTEM
D-2
OIL PAN
Disassembly:
To unscrew the oil-tapping bolt and empty the
pan.
To unscrew 18 M6X20 bolts.
To take out the oil pan gasket.
To check if both reinforcing pads are clamped
tightly on the back of the oil pan flange.
D-3
D-4
Disassembly:
To unscrew the locknut of the oil strainer support
and take out the nut and gasket.
To unscrew and take out the support bolt.
To unscrew oil strainer flange bolts (two) and
take out two gasket bolts with spring.
To install the new oil strainer gasket to the oil Oil Strainer Assembly
pump flange, setup the oil strainer assembly and M6X16: M6x16 Bolt
screw up two bolts with gaskets. To screw the Fastening Torque Of 8.0-12.0N.M
Washer Bolts with Spring (Two)
Fastening Torque Of
8.0-12.0N.M
oil strainer support to the cylinder using M8
Nut
bolts, put the support onto the stud on the left of
the second main bearing cap, place back the flat
washer and screw up the nuts manually. Flat
D-5
Disassembly:
To unscrew and take out six M6X30 hexagon
flange bolts.
To take out oil pump and front oil seal assembly.
D-6
D-7
D-8
D-9
Disassembly:
To demount the oil filter by rotating the filter
counterclockwise.
To remove the oil pressure sensor.
Assembly:
To spread engine lubrication oil onto the oil filter
gasket and screw it up to the fitting to 12-17N.m., 8.0-25.0N.M Fastening Torque Of 8.0-25.0N.M
or screw the oil filter manually and screw more
3/4-1 round when the rudder gasket reaches the
cylinder.
To spread Letai 243 seal glue onto the oil
pressure sensor screw threads and screw it to the
cylinder main oil passage to 25-29N.m.
Oil pressure sensor screw threads are 1/4-18NPTF.
Oil Filter
The supply voltage of oil pressure sensor is 6-24V.
The alarm triggering pressure is 3015Kpa.
D-10
D-11
E-1
Hose Assembly
When the temperature of engine coolant is Hose Assembly
Electrically-Driven Fan
relatively low, the thermostat shall turn it off, and the Thermo-Switch
E-2
ENGINE COOLANT
Coolant Discharge:
To demount the pressure cap of expansion
reservoir;
To install a vessel under the radiator, demount
the radiator outlet hose under the radiator and
discharge the coolant.
Cooling System Cleaning:
To discharge coolant, mount the radiator outlet
hose;
To inject clean water up to the position of the
largest water surface of the expansion reservoir
from the expansion reservoir filler, and then close
the pressure cap;
To start up engine to make it operate at idle speed,
E-3
E-4
E-5
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WATER PUMP
Structure:
1Water pump housing
2Water pump impeller
3Water pump gear
4Water pump shaft bearing
5Water pump seal (ceramics-lead)
Disassembly:
To disconnect the negative terminal of battery;
To discharge engine coolant (refer to the coolant
discharge process);
To disconnect poly V-belt and power pump belt;
To demount timing shield;
To unscrew and take 4 bolts out of the front side of
cylinder block.
To demount the water pump assembly;
To demount the water pump gasket.
Assembly:
To install the new gasket on the water pump;
To install the water pump assembly in the cylinder
block and screw up 4 fixing bolts by hand, and
then screw up to 7.010.0Nm;
The water pump impeller installed in the cylinder
block should be able to rotate freely;
To refill engine coolant;
To check leakage occurrences of engine coolant.
Note: Because water pump assembly can not be Gasket
Tightening Torque
repaired, it should be replaced when seal ring or bearing
is worn and torn.
E-6
Disassembly:
To unscrew 3 M640 bolts and then demount the
bolts;
To demount thermostat chassis and thermostat
assembly.
E-7
Assembly:
To clamp the thermostat and then put the gasket
into the thermostat aperture.
To install thermostat (the side with spring facing
outward).
To embed spring clamp to ensure the clip within
the thermostat chassis slot;
To mount new gasket onto thermostat chassis;
To mount the thermostat chassis and thermostat
assembly into the aperture at the rear side of engine
cylinder head, and screw up the bolt by hand to
912N.m.
E-8
Disassembly:
To demount water temperature sensor (at the
exhaust pipe flank and under the lifting eye).
Assembly:
To apply Letai 243 glue on the screw thread,
screw up the bolt to 7.010.0Nm before
installation.
Checking:
Water temperature sensor is a negative temperature coefficient sensor, which is composed of
a thermal resistor. The resistance value of the resistor shall decrease as the engine temperature
rises. The variation is detailed in the following table:
Temperature (C) Resistance Value ()
-20 29,125
-10 16,660
0 9,790
+20 3,748
+25 3,000
+60 747
+80 377
+100 204
+120 117
COOLING FAN
Disassembly:
To disconnect the negative terminal of battery;
E-9
Assembly:
To assemble the cooling fan according to the
disassembly order (the tightening torque of
self-tapping screw is 1.8~2.2Nm)
E-10
Disassembly:
To demount the water pipe connecting with the
expansion reservoir.
E-11
ASSEMBLY OF RADIATOR
Disassembly:
To discharge coolant (refer to the coolant discharge
process)
To demount the cooling fan (refer to the
disassembly process of the cooling fan).
E-12
Assembly:
To assemble the radiator according to the order
opposite of the disassembly order.
To install the 2 wind boards onto the radiator by
using self-tapping screws with their tightening
torque of 67Nm.
E-13
OUTLINE F-9
F-1
THROTTLE BODY
According to drivers stepping force on accelerating pedal, throttle body fixed on intake
manifolds with three bolts, measures air intake volume flowed into the engine. Step motor
adjusts the auxiliary air intake volume when pedal completely released (engine at idle). In
this case, throttle valve opening control handle (3) relies on the anti-deadlock screw (2) to
keep throttle valve from closing.
F-2
F-3
Specification:
The coil resistance is R=53 10 at 20. A max air intake volume will be got when the
lock pin turns back 200 steps (approx 8mm stroke, correspond to about 60kg/h air intake
volume).
Working steps are determined according to the engine running condition, including heater
opening and electrical load air condition opening etc.
Batter terminal shall be disconnected for at least 5 minutes before inserting idling speed step
motor into the throttle body. Accordingly, when the key opened, ECU will reset a new step
motor and define steps according to the coolant temperature to adjust the valve cores axial
moving (forward or backward) with a correct idle speed.
Electronic components can be diagnosed by engine ECU. Through regulating the throttle
valve position, with engine speed and intake pressure signals, the engine ECU can detect
whether the step motor (tested by a diagnosis tester) loses step or not.
Recovery:
If a failure happens, step motor will become invalid, correspondingly the adaptive function of
air fuel ratio at idle is ceased.
F-4
Potentiometer is installed directly on throttle body and fixed with a fast snap ring.
1.Connector 2.Resistance Circuit 3.Throttle Body 4.Throttle Valve Axis 5.Seat Snap Ring
Recovery:
If failure happens, the setting value is calculated through the readings of TDC (top dead
center)/ ESS (engine speed sensor) and absolute pressure sensor.
If there is a failure in the absolute pressure sensor signal, set throttle valve opening angle a
fixed value 50 degree. For the moment, adopting the methods like buffering, idling
adaptability and air fuel ratio adjustment all doesnt work.. Throttle signal cycle is also
malfunctioned when running automatic transmission.
F-5
Recovery:
When a failure in sensor circuit happens, manifolds pressure value will be estimated
according to the method of data-inserting arithmetic based on the rotate speed and related
throttle valve opening angle in a pressure-recovery recorder Then the value shall be modified
by coolant temperature and the air pressure.
Pins:
1. Grounded
2. Outputs Temperature Signal
3. 5V Power Source
4. Outputs Pressure Signal
F-6
Assembly:
Fix the solenoid on the intake manifolds
with a semicircular clamp and tighten
two inner bolts.
Install the solenoid intake pipe between
the activated canister and the solenoid,
then tighten the clamp around the intake
pipe with special tool.
Install solenoid exhaust pipe between the
throttle body and the solenoid. then
tighten the clamp around the exhaust
pipe with special tool.
F-7
A 2
1
B
C E
D
Working principle:
Main function of the oil-vapor separator is leading gas in crankcase to intake manifolds
through oil-vapor separator, which keeps pressure in crankcase within a certain range and
prevent gas in crankcase from mixing and flowing out. Oil-vapor separator shall separate the
oil vapor mixture passed the crankcase to avoid the oil entering into engine where it will
generate carbon grains that causes engine wear.
Oil-vapor separator assembly, air cleaner and ventilating pipe assembly is showed in fig. A
connect to one interface on the engine valve cover; B connect to another interface on the
engine valve cover; C connect to the crankcase interface; D connect to the intake manifold
interface. Connect the ventilating pipe to the interfaces of oil-vapor separator, air cleaner
by-pass hose and engine valve with spring clamp.
Assembly and disassembly:
Fix three iron-ventilating pipes to the bolts in engine intake manifolds using 4 M8 nuts
with a tightening torque of 101Nm.
Maintenance of fuel-vapor separator:
Disassemble it per 5000km and wash it with lead-free gasoline, then blow it to dry.
F-8
OUTLINE
Start the engine and inspect each exhaust system component for exhaust gas leakage.
Warning
When the engine and exhaust system are hot, they can badly burn. Turn off the engine
and wait until they are cool before removing the exhaust system.
OXYGEN SENSOR
To gain max. conversion efficiency from catalytic converter, the engine oxygen sensor always
keeps the concentration of fuel-gas mixture as chemical reaction equivalence ratio.
The sensor shall realize closed loop controlling to the mixture concentration through
measuring the proportion of oxygen in exhaust.
Oxygen sensor is installed in the first section of exhaust pipe near manifolds.
Oxygen sensor is a ZrO2 porcelain (1) with a thin platinum layer on its surface and one end is
sealed with a protection pipe inserted in. (2), the outside bushed with a metal housing (3) to
protect the sensor and to enable it to install on the exhaust manifolds. The outside of porcelain
(b) is exposed in exhaust gas, the inside (a) communicate with outer surroundings. Working
principle: voltages generated by electrode will change with the variation of oxygen
concentration; oxygen sensor measure the components of the exhaust, thus ECU will obtain
F-9
F-9
Oxygen sensor doesnt work under cut-off and full load condition, which is called open loop.
Recovery:
If fault occurs in sensor or resistor, all information will be ignored and the whole system will
work as an opened loop system.
If timing and positioning of TDC (top dead center)/rotate speed sensor is right or not.
F-10
Oxygen sensor heater resistance is about 45 at environment temperature 20C, and its
battery voltage is 12V.
F-11
Lay exhaust hose pad, install front hose assembly on exhaust manifolds.
Connect back hose assembly to the back hose hook with a hang block.
Tighten all bolts in hose clamps and hose clamp assembly with a torque of 303Nm.
F-12
2. Examine gas leakage in exhaust system connection and its adjustment method:
Examine leakage in exhaust system interface after engine warm-up. Certain amount of gas
leakage is permitted (but not permitted in interface between exhaust manifolds and front hose
assembly). It can be taken as a principle of no leakage if no engine wobble and no sound
like pu, pu in interface heard. If the above phenomenon is found, loosen the hose clamp in
interface and rotate it a few circles, then tighten it again after adjusting installation direction
of hose clamp.
Installation of heat insulator
Install each heat insulators to its proper position, and then tighten the clip.
F-13
F-14
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Caution
Connecting the wrong check connector terminal may possibly cause malfunction.
Carefully connect the specified terminal only.
1Short the check connector terminal F/P body GND using a jumper wire.
2Turn the ignition switch to ON position to operate the fuel pump.
3Pressurize the system in this way for at least 5minites to be sure of no leakage.
If there is fuel leakage, inspect the fuel hose, hose clamps, and fuel pipe sealing surface,
and replace as necessary.
4After repair, assemble the system and repeat Steps 1 to 3.
F-15
F-16
Caution
F-17
Caution
When adjusting degree of tightness of
accelerator cable you should ensure
that: Accelerator pedal doesnt need
any part of empty stroke at idle; when
throttle is full open, accelerator pedal
limiting screw assembly is effective
(accelerator pedal can step on
accelerator pedal limiting screw
assembly).
F-18
1. Start engine:
In start process, ECU firstly inject to all cylinder at the same time to shorten start time. After
that, ECU will inject according to phase order.
2. Acceleration:
In acceleration process, ECU will add injection fuel by engine requirement and deal with
sensor signal below: throttle position, absolute pressure, upper dead center/ speed sensor,
multiply basic fuel injection time by a modification factor, which is calculated from engine
cooling temperature, throttle opening speed, and intake manifold pressure increment. When
injector is closed and if calculated injection time has a sudden change, ECU will add injection
Fuel by the modification factor mentioned above, that is to re-open injector (extra pulse) for
compensating fuel as soon as possible. In order to make vehicle more comfortable, torque
control strategy doesnt affect performance and fuel consumption in accelerating by adjusting
spark advance angle. Because exhaust regulatory become much more Stricter, a kind of much
more complicated active manage strategy is developed, which utilize some physics and
hydrokinetics phenomenon (such as fuel film mode) to gain not only a sudden change in
throttle air input but also steady air fuel ratio.
3. Deceleration:
In deceleration process, fuel engine needed is decrease to reduce pollution, ECU identifies
the phase by that throttle potentiometer signal change from high level to low level but do not
back to idle. Furthermore, it can adopt dashpot strategy to decrease output torque (reduce
engine brake), when throttle potentiometer signal shows that throttle is closed and engine is
in very high speed, ECU considers its satisfied condition that ECU will minish by-pass air
input by controlling step motor step by step.
4. Cut off:
ECU will adopt cut off strategy when ECU identifies that throttle is in idle position (throttle
potentiometer signal) and hot engine speed exceeds 1500r/m. The warm up strategy is
determined by the speed when engine coolant temperature increase strategy is running. Fuel
will be supplied again to system if throttle is not closed and hot engine speed is lower than
1400r/m. In high speed, ECU will adopt cut off strategy (part cut off) if throttle is not closed
completely but manifolds pressure is very low.
F-19
8. Fuel pump:
- When engine speed is lower than a certain value close fuel pump (approx, 50r/m);
- Open ignition switch for 2 seconds, but engine does not start fuel pump;
- Fuel pump keeps working when engine is running or vehicle is in its way.
9. Self adapting:
ECU has self adapting function for air fuel ratio. ECU can store difference between basic
pulse diagram and oxygen sensor modification factor continuously generated in running. The
difference will be permanently stored because of ageing of engine and system components. It
permits system to amend engine and components as new.
This function includes automatically consistency test and automatically diagnosis for stored
parameters, special diagnosis instrument can delete those parameters, and modification
parameters will not be lost if batter or ECU is cut off. This strategy is ineffective if canister
solenoid valve is open. After changing ECU, it should run at idle (warm up) for some time
to make ECU restore modification parameter. When engine is in high speed, modification
parameter in memory is the parameter of normal running condition. ECU another self
adapting function can modify step motor opening degree change caused by throttle leakage
and engine natural ageing. The self adaptive parameter will be lost when power off or ECU is
cut off.
F-20
Fuel supply system of this vehicle is belonging to half no scavenge fuel, there is only one
tube connecting fuel tank and fuel rail.
This system has advantages below:
- When accident occurs, no scavenge fuel tube can lower fire possibility to minimum.
-There is comparative less fuel vapor in fuel tank.
- Fuel temperature in fuel tank is lower.
Note
If there is an after market fuel injector tester, perform the following test.
If there is no an after market fuel injector tester, perform Operation Test,
Resistance Inspection, and FUEL Leakage Testto verify the fuel injector is
ok or not.
F-21
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Working pressure: 350kpa
Working temperature: 30110
6Turn the ignition switch to LOCK position
and disconnect the jumper wire.
7Complete the After repair procedure.
Atomization
1Inspect atomization pattern.
If the atomization is faulty, replace the fuel injector.
1.Fuel Supply Module 2.Fuel Filter 3.Fuel Rail 4.Fuel Injector 5.Pressure Regulator
6.Cone Way Valve 7.Fuel Pump 8.Primary Filter 9.Injection Pump
F-22
Fuel pump is located in fuel tank, and there is netlike filter in the fuel pump entrance. Internal
gear positive displacement fuel pump should use unleaded gasoline. Rotor is driven by motor,
while motor power comes from battery through relay.
There is safety valve installed in fuel pump. Safety valve will open to prevent engine from
over hot when pressure in fuel line is over 7bar.
Fuel pump can work in fuel temperature range of -30 ~ +70. Minimum rate of flow is 76
l/h on 4bar-12V(maximal current is 8.5A), while minimum rate of flow is 20 l/h on 3bar-8V.
1.Electric Terminal 2 Fuel sucking Slot 3.Fuel transporting Groove 4.Safety Valve
F-23
Fuel rail
Fuel rail 1 is made of cast aluminum. Its function is distributing fuel to injector 2.
F-24
Fuel injector
This system adopts head supplying single hole Fuel injector, and fuel injection pressure is
3.5bar. Fuel injected from fuel injector keeps in atomization and comes into cone angle (15
degree to injection nozzle axis).
Control logic of Fuel injector is phase, order controlling. These four fuel injectors are
controlled by air input order of four cylinders. Fuel injector is open on expansion stroke till
intake stroke started.
Fuel injector is fixed on fuel rail, and fuel rail can press injector on fixed seat of intake
manifold. Two O-type pads (1) (2) are used in sealing. Fuel is entering from upper side of
fuel injector. Fuel injector includes coil (4) and electric terminal (5) on electric plug (6).
F-25
Remark: Force on fuel injector socket in assembly and disassembly must be less
than 120N, or it will influence function.
Caution
use of a deformed injector retaining clip will cause the injector to not engage
correctly. Always use a new clip when reattaching the injector, otherwise it may
cause the injector to rotate.
F-26
ACTUATORS G-7
G-1
19
18
Diagnostic
connector
G-2
Malfunction
Fuel injector indicator
Ignition coil
Carbon canister
solenoid valve
ENGINE
Throttle valve
Line K
position sensor
Air pressure /
temperature sensor
Knock sensor
Cooling temperature
overheat alarm light
Decoder alarm light
TDC/rotate speed sensor R.P.M. meter
Fan relay
G-3
The fuel injectors of all cylinders are utilizing a sequential phase angle control method
according to the intake sequence and the opening time of the air intake valves; the injection
destinations are stored in the ECU map, and can vary autonomously according to the engine
speeds and intake air pressures. The application of sensors in the system is a basic strategy
used to correct the engine under all operating conditions. The system is implementing an
induction type of electrical discharge ignition, where the power source module in the ECU
controls the ignition timing. The ignition advance angle is calculated according to the engine
compression ratio and intake air volume. The idling speed is maintained at stable condition
through controlling the opening of the branch-connection pipe by a step motor and also
through the changing of the ignition points.
Other than capable of obtaining the input signals and controlling the output components, the
system has also equipped with various other functions. These functions include the following:
- When self-diagnose that the sensor is faulty, adopt the restoration strategic control.
- Restoration of the self-regulating mixed concentration engine and variances in spare parts.
- Exchange data with the diagnostic tester.
The idling speed of the engine and the amount of CO in the air discharged must not be
manually adjusted.
G-4
The ECU software structure is divided into two parts for data processing:
-The Application part obtained the measurement of engineering parameter through sensors
to calculate the control parameters of the fuel injectors, ignition coils and idling speed step
motor for controlling the engine starting.
-The Basic part is collecting the data from the sensors and converts it into engineering data.
After that it controls the actuator through the calculated parameter generated by the
application software, and manages the self-diagnostic programs of the various sensors and
actuators. In addition, it can also communicate with the externally connected diagnostic
tester through the use of K serial cable.
The operating system is capable of ensuring the accurate management of the matters related
with time (such as the management of definite and delay timing) and angles (related to the
engine rotation sequence). This type of management is integrated in the software and
calculated according to the precise priority to ensure the optimization management of the
engine even at its high-speed condition. This type of modular structure design allows the
possibility of achieving all kinds of flexibility control and in the mean time not tampering the
overall characteristic of the system.
G-5
The air intake efficiency is obtained by calculating through the processing of absolute
pressure, air intake temperature, engine speed, throttle valve position and other signals, and
help to determine the air intake quantity of the cylinder. The inbuilt power supply module in
the ECU is controlling the following functions:
- To control the injected fuel quantity through the control of opening timing of the fuel
injector
- Idling speed step motor
- Ignition coils of the 4 high voltage outputs
- Check valve for recirculation the gaseous fuel on top of the air intake manifold (carbon
canister)
- Temporary turnoff of the air condition compressor
- Dual speed cooling fan for the engine
- Overheating alarm light in the coolant of the engine
- Malfunction alarm light
G-6
G-7
G-8
G-9
Knock Sensor KS
Purpose: this sensor is designed to provide ECU with
engine knocking information so as to carry out 1.Knocking
block
knocking control. 2.Casing
3.Piezoelectric
Composition and principle: knock sensor is a sort of ceramics
vibration acceleration sensor, which is fixed on engine 4.Contactor
5.Electric
cylinder block. ECU controls engine ignition via connection
signals detected by pressure-sensing element.
KS with cable
G-10
Oxygen Sensor
Purpose: this sensor is designed to provide the
information that if there is surplus oxygen after full
combustion of fuel, which is injected into engine
cylinder in the intake air. ECU, when applying this
information, can carry out fuel quantitative
closed-loop control so as to achieve utmost conversion
and purification of the three major toxic elements (HC,
CO and NOX) in the engine exhaust with the
application of three-way catalytic converter.
Composition and principle: the sensing element of
oxygen sensor is a porous ceramic pipe, the outer side
of pipe wall is surrounded by engine exhaust, while Oxygen Sensor
inner side vents to atmosphere. According to inside
and outside oxygen concentration difference, sensor
figures out indirectly fuel injection pulse width, and
then transfers the information to ECU, and the ECU
controls the injection again.
G-11
Interior structure of oxygen sensor
G-12
Functions:
Multipoint sequential injection
Controlling ignition
Idle speed control
Independent knocking control on cylinder-by-cylinder
basis (knock sensor KS-1);
Providing sensors with power supply: 5V/100mA
Adopting cylinder-detecting signal (Phase sensor PG1)
closed-loop control with self-adaptation
Controlling carbon canister control valve
Air conditioning switch
Engine-fault indicating lamp
Fuel quantitative correction
Engine speed signal output (TN signal)
Speed signal input
Failure self-diagnosis with flash code function
Accepting engine load signal
G-13
G-14
G-15
Note: As for the car not being used for a long time, it is
possible that such car can not start properly because the
coagulation of fuel in the fuel injector. Under such
circumstance verify carefully that the fuel injector is
coagulated.
Fault diagnosis: The electrical injection system of A15
RHD car can conduct fault diagnosis on the driving
stage of the fuel injector in stead of conducting fault
diagnosis on its self. If the driving stage of the fuel
injector is short or overloaded to the battery power
supply short to ground or open the malfunction flag
G-16
G-17
Pins:
Pin A is connected to the 29# pin of ECU;
Pin B is connected to the 4# pin of ECU;
Pin C is connected to the 26# pin of ECU;
Pin D is connected to the 21# pin of ECU.
Troubleshooting: Verify that the four circuits between
the step motor and the ECU are short or open. Verify
that the step motor is jammed. Verify that there is External appearance of
circuit short or circuit open inside the step motor.
G-18
G-19
Pins:
1# pin is connected to the 87# pin on output terminal of
the main relay;
2# pin is connected to the 46# pin of ECU.
Troubleshooting: The blockage and crack of the
carbon canister will result in the increase of air intake.
G-20
G-21
G-22
G-23
G-24
G-25
G-26
G-27
G-28
G-29
G-30
G-31
G-32
G-33
G-34
G-35
G-36
G-37
G-38
G-39
G-40
G-41
G-42
G-43
G-44
G-45
G-46
G-47
G-48
G-49
G-50
G-51
G-52
G-53
G-54
G-55
G-56
G-57
G-58
G-59
G-60
G-61
A preliminary inspection should be carried out before implementing the steps of fault
diagnosis according to the symptoms of engine:
(1) Verify that there is no abnormal behavior with the ECU and malfunction indicator
light (not applicable for car models without setting of malfunction indicator light).
(2) Inspect with the diagnostic tester or flashing light to verify that there is no
malfunction information record.
(3) Inspect the idle speed data of warmed up engine in the electronic control system
with the diagnostic tester and verify that they are normal.
(4) Verify that the malfunction symptom complained by the car owner exists and
locate the exact position of the symptom.
Then carry out the visual inspection: Verify that the grounding point of the wiring
harness is clean and firm.
Verify that the vacuum pipelines have any ruptures or twists together, and whether its
connections are correct.
Verify that the pipeline has any symptom of blockage.
Verify that the air inlet pipeline is flattened or damaged.
Verify that the sealing between the throttle body and the air intake manifold is in a
good condition.
Verify that the high voltage cable of ignition system has any rupture or ageing, and
whether the wire routing is correct.
Verify that the connection of conducting wire is correct and whether the connector is
loose or poorly contacted.
G-62
G-63
G-64
G-65
G-66
G-67
G-68
G-69
G-70
G-71
G-72
G-73
G-74
G-75
G-76
G-77
G-78
G-79
G-80
G-81
G-82
G-83
G-84
G-85
G-86
G-87
G-88
SAFETY MEASURES
Attention should be paid to the followings so as to avoid the injury of personnel and
damage of the fuel injectors and the ignition device:
(1) If the engine is running or at the start up speed, then it is not allowed to contact or
disconnect the ignition wiring harness;
(2) If the engine is driven by the starting motor instead of starting by itself, such as in
the case of inspecting the compression pressure, then the wiring harness
connectors should be disconnected from the Hall Sensor and crankshaft position
sensor.
G-89
H-1
H-2
H-3
H-4
H-5
H-6
Assemble flywheel.
Screw up flywheel bolt uniformly according to
the diagonal line.
Coat a thin layer of grease on the input axle
and then assemble the transmission with
engine.
Remarks:
When put the input axle of transmission into the
clutch friction disk, the flywheel shall be revolved
until the input axle of transmission and spline
meshed.
H-7
Trouble
Cause Treatment method
symptom
Free travel (free play) of clutch pedal is wrong. Adjust free travel
Abrasion or oil stain for clutch friction disk. Change friction disk
Slip of clutch Distortion for friction disk pressure plate or Change frication disk,
flywheel surface. pressure plate or flywheel
Diaphragm springs become weaker. Change clutch pressure plate
Free travel of clutch pedal is wrong. Adjust free travel
Diaphragm springs become weaker or abrasion for Change pressure plate
stabber fingertip.
Uncompleted Rust for input axle spline. Lubricate
segregation of Mutilation or abrasion for input axle spline of Change the input shaft
clutch transmission.
Excessive nodding action for clutch friction disk Change friction disk
assembly.
Abrasion or oil stain for clutch friction disk. Change friction disk
Brighten of clutch friction disk (to become Repair or change friction
glassiness). disk
Oil stain for clutch friction disk. Change friction disk
Bad skid of segregation bearing on the bearing Lubricate
sleeve of transmission.
Shimmy of clutch friction disk assembly or bad Change friction disk
Vibration of connection of friction disk.
clutch Vibration reduction torsion springs of clutch Change friction disk
friction disk assembly become weaker.
Loose of rivet of clutch friction disk. Change friction disk
Distortion of pressure plate or flywheel surface. Change pressure plate or
flywheel
Loose of the binding bolt of flywheel or loose of Screw down
binding bolt of pressure plate assembly.
Abrasion or mutilation for segregation bearing. Change segregation bearing
Abrasion for front bearing of input axle. Change input shaft bearing
Abnormal noise for clutch friction disk. Change friction disk
Clutch noise
Crack for clutch friction disk. Change friction disk
Abnormal noise for pressure plate and diaphragm Change pressure plate
spring.
Clutch friction disk has fat liquor. Change friction disk
Non-separation of Serious wear of clutch friction disk. Change friction disk
clutch Rivet head is displayed in surface of disk. Change friction disk
Torsion springs become weaker Change friction disk
H-8
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MANUAL TRANSMISSION
SPECIFICATION J-3
DISASSEMBLY OF THE DRIVE SHAFT J-4
DISASSEMBLY OF THE TRANSMISSION J-6
TRANSMISSION GEARSHIFT MECHANISM DIAGRAMATIC SKETCH J-9
RESOLUTION GRAPH OF THE GEARSHIFT CONTROL MECHANISM J-10
SHIFT ADJUSTMENT J-11
NEUTRAL POSITIONING J-11
FINE ADJUSTMENT J-11
TRANSMISSION RESOLUTION J-12
DISASSEMBLY AND ASSEMBLY OF THE TRANSMISSION J-15
DISASSEMBLY J-15
ASSEMBLY J-21
MAIN POINTS J-24
ADJUSTMENT OF 5TH FORK J-25
ADJUSTMENT J-25
MAIN POINTS J-25
DISASSEMBLY, RESOLUTION GRAPH AND ASSEMBLY OF THE REAR
HOUSING J-26
DISASSEMBLY J-26
RESOLUTION GRAPH J-27
ASSEMBLY J-27
DISASSEMBLY AND ASSEMBLY OF CLUTCH CONTROL ARM, CLUTCH
RELEASE SHAFT OIL SEAL, AND CLUTCH RELEASE BEARING J-28
DISASSEMBLY J-28
ASSEMBLY J-28
DISASSEMBLY AND ASSEMBLY OF THE GEARSHIFT SHAFT OIL SEALJ-29
DISASSEMBLY J-29
ASSEMBLY J-29
J-1
J-2
SPECIFICATION
Transmission AQ015 AA type AQ015 AB type
Main driving 4.133 3.813
1shift 3.455 3.455
2shift 2.056 2.056
3shift 1.370 1.370
Ratio
4shift 1.032 1.032
5shift 0.850 0.850
Reverse gear 3.167 3.167
Speedometer 2.286 2.286
Lubricating oil quantity 2.0L 2.0L
Type of lubricating oil Transmission oil GL-4 SAE75 Transmission oil GL-4 SAE75
Manipulation type of clutch Mechanical Mechanical
Diameter of clutch driven plate 210mm 210mm
Diameter of drive shaft flange 100mm 100mm
General gear ratio of top gear 3.513 3.240
J-3
Tyre disassembly.
J-4
J-5
J-6
J-7
J-8
The transmission control mechanism must meet the requirement that only one
shift can be chosen when the shift is changing and prevent from choosing reverse gear.
The gear should be full length meshed after the gear shifted and prevent the gear out
of position automatically. The transmission of Q/SQR7160 A15RHD car is composing
of internal and external parts because it is positioning on the front driving axle far
away from the driver and can not control directly.
J-9
1. Shift Housing, Fasten The Fixing Bolt By 20Nm 2. Tubular RivetTo Fix Reverse Gear Guide Rail
3. Reverse Gear Guide Rail 4. Self-Tapping ScrewTo Fix The Dashboard 5. Seal 6. Gasket
7. Ball Holder 8. Spacer 9. Ball 10. Spring 11. Spring Plunger 12. Bracket Plate
13. Locknut, 10Nm 14. Plastic Ring 15. Shift Lever With Positioning Eccentric RingBefore
Installation, Installation FinishedAssemble Bracket Plate, Spring And Ball, Fixed By Spring Plunger
16. BushingShift LeverInstallation, Make Sure That Do Not Press The Housing Open 17. Shield Plate
18. Selector Arm Assembly 19. Lock Washer 20. Gear Shift Arm 21. Selector RodBefore
Disassembly Press The Plastic Ball Clamp By Screw Driver 22. Shift Lever (Different End Angle:
Mark (Groove) Towards Selector Rod/ Gearshift Lever) 23. Gearshift Shaft 24. Gear Shift Arm
SubassemblyOnly One Position Can Assemble This Rod 25. Locknut 25Nm 26. Selector Lever
Press The Plastic Ball Clamp By Screw Driver Before Disassembly 27. Selector Rod Arm Subassembly
28. O Ring 29. Left Back Bracket 30. Gear Shift Shaft Subassembly 31. Hexagon Bolt With
Flange 35Nm 32. Gear Shift Shaft Bracket Sub-Assembly 33. Support Bushing 34. Shift Rod
J-10
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SHIFT ADJUSTMENT
Neutral positioning
Disassemble gearshift knob and protective
cover and fix the gearshift knob according to
the positioning requirement, see the chart (the
black one is positioning assist)
Fine adjustment:
After a long time using of the vehicle, there will
be wear and tear between gearshift mechanism
parts which makes the space between shifts
Eccentric Ring
too much bigger and difficult for gear shifting
then you need fine adjustment. Bolt
st
Check the 1 shift position, loosen nut B, do as
the chart show: Put transmission on 1st shift
position, fasten bolt B by adjusting the
eccentric ring position to a=1.5mm.
Fasten clamp bolt (the transmission on the
neutral position), try all the shifts, which should
be smooth and easy.
Try all the shifts gear shifting should be smooth
and without stop, secure the validity of the
reverse gear lockup.
J-11
1. Fastening Screw (4 Pieces, Fasten Moment Is25n.M) 2. Fixing Screw (2 Pieces, Fasten
Moment Is 25N.M) 3. Bleed Bolt 4. Transmission Rear Housing 5. 5th Synchronizer
Assembly 6. 5th Driven Gear Snap Ring 7. 5th Driven Gear 8. 5th Fork Pad
th th
9. 5 Fork Assembly 10. 5 Gear Holder Fixing Turnbuckle 11. Dish Washer 12. Shim
J-12
J-13
J-14
Disassembly
Raise up the transmission, take off the drain
plug on the transmission differential side, and
at the same time take off the drain plug on the
rear cover( see the arrowhead pointed stud).
Discharge all the oil.
J-15
Special Tool
J-16
Prize up the 5th fork pad and turn left the 5th
fork bushing, take off the 5th fork assembly.
Special Tool
J-17
Special Tool
Take off the bearing shift slice clamping bolt
behind of input shaft by a special tool.
J-18
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Take off the fork shaft and its upper and lower
spring, take off 5th fork guide assembly,
reverse gear fork guide, 3rd-4th shift fork and
1st-2nd fork.
Special Tool
J-19
J-20
J-21
J-22
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Assemble the fork assembly into its right
position, and then assemble the idler shaft.
11st and 2nd fork
23rd and 4th fork
35th fork guide and bushing
4reverse gear fork guide
J-23
J-24
Main points:
Move the slip cap and fork slightly to eliminate the
free space when measuring the space a.
J-25
J-26
1. Clamprelease arm 2. Release arm assembly 3. Clutch release shaft oil seal 4. Rear
housing 5. Fixing bolt 6. Rear housing fixing bolt 7. Clutch release bearing 8. Return
spring 9. Clutch release finger 10. Back cover 11. Fixing clip 12. Drain bolt 13. Flat
spacer 14. Spring washer
Assembly
The assemble process of rear housing is opposite to its disassemble process.
J-27
Disassembly:
Drive car to the platform.
Disassemble the clutch control cable
assembly.
Disassemble engine bracket on the
transmission side.
Lift the vehicle by lifter.
Discharge all the transmission oil by screw
off the drain bolt under the differential.
Get off the back cover by punch, do not hurt
the contact surface. Disassemble the fixing
clip of the separated finger; pull off clutch
release shaft, separated finger and spring.
Take off clutch release bearing, and punch off
clutch release shaft oil seal assembly. Do not
hurt the contact surface.
Assembly:
Assembly is opposite to the disassembly process,
pay attention to the following items:
Lubricate the oil seal surface and put it in by a
special tool.
Assemble clutch separated finger to the
position shows in the picture, and then
assemble release bearing, spring and clip. The
spring position shows in the picture.
Press the new back cover to its right position
by special tool. If it is assembled on the
vehicle, extra work as below: fill transmission
oil to the specified level.
Lower the vehicle on the platform and
connect to clutch control cable.
J-28
Assembly:
Lubricate the lip of oil seal and press oil seal Special Tool
into transmission housing completely by a
special tool.
J-29
Disassembly:
It needs to take off the gearshift shaft and oil Special Tool
seal as changing the gearshift shaft bearing.
Penetrate the special tool into gearshift shaft Special Tool
housing, see the picture, and tap it slightly
until the gearshift shaft out from the other
side.
Assembly:
Special Tool
Assemble the bearing inside of the position
which can contain the gearshift shaft.
Press the bearing to its right position by
special tool and then assemble the gearshift
shaft. Special Tool
J-30
Disassembly:
Remove the needle bearing by special tool,
see the picture.
Special Tool
Special Tool
Assembly:
Press the needle bearing to its right position
by special tool.
J-31
Special Tool
J-32
Disassembly:
See the picture, dismantle the needle bearing
by special tool.
Special Tool
Special Tool
Assembly:
See the picture, assemble the input shaft Special Tool Special Tool
needle bearing by special tool, and make sure
press it to the right position.
J-33
Disassembly:
It need not to break down the transmission
when disassemble the input shaft oil seal.
Special Tool
See the picture, disassemble the input oil seal
according to the arrowhead direction by special
tool
Assembly:
See the picture, lubricate the lip of the oil seal
and press the oil seal to its right position by
special tool.
Special Tool
J-34
J-35
1. Rear housing 2. 5th Driven gear snap ring 3. 5th Driven gear 4. Transmission housing
5. Needle bearing 6. 4th Driven gear snap ring 7. 4th Driven gear 8. 3rd Driven gear
snap ring 9.3rd Driven gear 10. 2nd Driven gear 11. 2nd Driven gear and bushing 12. 2nd
Synchronizer ring 13. 1st-2nd Synchronizer assembly 14. Steel spring 15. 1st-2nd Gear
sleeve 16. 1st-2nd Hub 17. Gate 18. 1st Synchronizer ring 19. 1st Driven gear 20. 1st
Needle bearing snap ring 21. Adjustment shim 22. Front bearing external ring 23.
Clutch housing 24. Output shaft front bearing 25. Output shaft 26. Output shaft
intermediate shaft 27. Intermediate bearing pedestal 28. Bearing fixing bolt Output
shaft break down
J-36
J-37
Adjustment:
You need adjust the thickness of the output
Special Tool
shaft shim after you replaced any part of
clutch housing,output shaft,output shaft
Special Tool
intermediate bearing pedestal, output shaft
intermediate bearing or output shaft front
bearing.
See the picture, insert adjustment shim with
0.65mm thickness, and press front bearing
external ring of output shaft to bearing
pedestal.
Insert the output shaft assembly, put on
bearing pedestal and fasten with 40Nm
moment. See the picture.
J-38
Disassembly:
For bearing pre fasten it needs thickness of
the adjustment shim 0.20m; if the reading of
the dial indicator is 0.30mm, and the
thickness of the shim put in advance is
0.65mm, then the thickness of the adjustment
shim should be 0.20mm+0.30mm+0.65mm
=1.15mm.
See the picture, screw off bearing plate bolt
and take out output shaft.
Take out front bearing external ring of output
shaft.
Take out the original adjustment shim.
J-39
Adjustment:
Press differential bearing external ring
completely by special tool.
Special Tool
Press differential bearing external ring to the
Special Tool
right position on transmission housing
without any adjustment shim, and put
differential assembly. Assemble transmission
housing on to clutch housing and fasten the
connecting bolt by 25Nm moment.
Put a special tool on small axle shaft and put a dial indicator with magnetic base on the
benchmark. Set the dial indicator to zero when the pre fasten force is 1mm. Move the
differential assembly up and down from one side and record the indication of the indicator.
Notice: during measuring, do not roll the differential assembly otherwise it will influence the
accuracy.
Calculate the adjustment shim thickness:
For bearing pre fasten it needs thickness of the adjustment shim 0.40m; if the reading of the
dial indicator is 0.90mm, then the thickness of the adjustment shim should be
0.40mm+0.90mm=1.30mm.
Disassemble the connecting bolt of differential housing and clutch housing, take out
differential bearing external ring, and buildup the needed adjustment shim thickness by the
least shim, put it to its right position on clutch and press differential bearing external ring
completely. Assemble gasket and transmission housing, and fasten the fixing bolt by 25Nm
moment.
J-40
1, Final drive driven gear 2, Rivet 3, 11, Needle bearing 4,12, Needle bearing
external ring 5,13, Adjustment shim 6, Clutch housing 7, Rivet (may not use) 8,
Oil seal holder 9, Oil seal 10, Small axle shaft 14, Transmission housing 15,
Output flange snap ring 16, Output flange dish washer 17, Output flange 18,
Compression spring 19, Spring seat ring 20, Damper ring 21, Differential
housing 22, Knob gasket 23, Snap ring 24, Planet gear shaft 25, Planet gear snap
ring 26, Axle shaft gear and planet gear 27, Output flange cover
Break down of differential assembly
J-41
J-42
Fasten the special tool on oil seal, rotate the Special Tool
special tool threaded shaft by wrench until
screw off the oil seal.
Assembly:
Use the right size oil seal and lubricate its lip. Special Tool
Put it to its right position by special tool and
rotate the screw of the special tool make oil
seal to its true position.
J-43
M-1
Item Front wheel Rear wheel Spare wheel Mini spare wheel
M-2
Note:
The above tire-rim combination is suitable for the steel or aluminum alloy rim. Please
do not use rims and tires of other models which may lead to improper consequence.
Preaution: Be sure to consult the relevant instruction if non-standard tires or rims (such
as light weight alloy rims or wheels of winter tire)should be installed.
M-3
Precaution: Using the snow chain may affect the vehicle maneuverability, so the vehicle
speed should not excess 50km/h (30mph) or the speed limited by the snow chain
manufacturer(less than 50km/h). Please stop the car and tighten the snow chain
immediately when hearing collision between the snow chain and the vehicle body or the
chassis when using the snow chain. Abrupt turning, concussion and passing the
chuckhole, the vehicle locking and braking should be avoided. The instruction of the
snow chain manufacturer should be also complied. Improper utilization of the snow
chain will cause interference between the snow chain and the vehicle body.
M-4
----During installing the wheel and the tire assy, pre-screw the wheel bolt on the rim by hand
first, and then tighten the screws with the special purpose tools under the way of diagonal
method, (the tightening torque is 10010Nm). No impact wrench is allowed in order to
avoid screwing too tight or loose. Do not use lubricating grease while installing the wheel
bolt. (The wheel bolt should be tightened to maintain the tightening torque after the initial
100km driving since the new installation of the wheel and tire assy. The check of the
tightening torque of the wheel bolt is one of the daily service items.)
----Decussating method is adopted to tighten the set nut. The tightening degrees should be
similar so that the wheels can turn freely. The wheel should stand on the ground during
the last tightening.
----Install the trim cover or place it as required. Clip trim cover should be installed into
through beating by hand or prying by rubber tools.
M-5
M-6
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Degradation of tire Replace
Adjust
Insufficient tire pressure
Adjust
Road noise or Unbalance of tire
vehicle vibration Repair or
Deformation of rim or tire
Replace
Uneven wear of tire
--
Overbeating of tire and rim
Replace
Looseness of wheel nut
Lock
Up-and-down Unbalance of tire
shaking of steering Adjust
Breach or wear of engine bearing
wheel
pad Replace
Breach or wear of transmission Replace
bracket rubber
Overbeating of tire and rim
Replace
Looseness of wheel bolt
Lock
Unbalance of tire
Adjust
Uneven wear of tire
Circular vibration of --
steering wheel Insufficient tire pressure
Adjust
Damage or wear of front wheel
Replace
bearing
--
Malfunction of steering system
--
Malfunction of suspension system
Improper tire pressure Adjust
Serious or uneven wear of tire --
One side deflection
Malfunction of steering system --
of steering wheel
Malfunction of braking system --
Malfunction of suspension system --
Uneven tire pressure of both sides Adjust
Deformation of rim or tire Repair or
Unstable running
Looseness of wheel bolt Replace
M-7
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Malfunction of suspension system --
--
Check whether the connection of the transmission rod of steering system is loose,
deformed, etc.
Check the status of the ball joint and the rubber bush of front and rear suspension
Check whether the shock absorber works normally
------Check whether the shock absorber leaks grease
------Check whether the bush wears out
------Check whether the shock absorber is improper through shaking the vehicle body up and
down by pressing the foreside and the tail of the vehicle
Pre-check before wheel alignment
------Check the status of the tire inflation. Adjust to the recommended pressure if necessary.
------Check the clearance of the front wheel bearing. Adjust it if necessary.
------Check the flop of the vehicle and the tire.
------Check whether the ball joint and the steering linkage are too loose.
------Check the shock absorber by shaking the vehicle.
Note:
The vehicle must be on the level ground with no-load.
No-load: Full gasoline in the oil reservoir, engine coolant and the oil filled at the specified
level; the spare tire, jack and tools in the pointed position.
M-8
It is recommended to utilize the four-wheel alignment tester with thrust line positioning
method on this type of chassis.
Note: thrust line positioning is defined as adjusting the front wheel toe-in based on the
rear wheel thrust line.
With the thrust line positioning, the adjustment of the rear wheel toe-in will influence the
single front wheel toe-in, so during four-wheel alignment, the rear wheel should be adjusted
before the front wheel alignment.
Measure the vehicle height
------Rear measure point
From ground to the center of the joint bolt of
the rear axle and the body (as the arrow
shows)
Precaution: Check whether the height from
left and right are same before processing
the wheel alignment
------If there is a difference of the heights from
left and right, that means there are
damaged or deformed components of the
front and rear suspension.
Install the wheel alignment tester on wheel
------Please refer to the specific instruction of
manufacturer for the wheel alignment
tester.
M-9
Note: The rear wheel caster cannot be adjusted. If there is abnormal wear on the tire of
the rear wheel, so check whether there are worn or deformed parts on the rear
suspension
Check the rear wheel toe-in
Note: The rear wheel toe-in out of standard range may lead to wear on shoulder of
tire on both sides. If the differences of the rear wheel toe-in both rear wheel are too
much, the vehicle running direction may be affected. Therefore the rear wheel toe-in
is a vital parameter of the alignment angles.
Angle Value
Front wheel camber -3020
Kingpin caster 13030
Note: Adjust the caster before the camber
Kingpin caster
There is no need to adjust the kingpin caster for it is assured by the structure of design
M-10
M-11
M-12
The functions of axle and suspension system include receiving the torque generated by
engine and passed via transmission system; producing the traction force between the road
surface and the vehicle body through the adhesive force between the driving wheel and the
ground in order to keep the whole vehicle steering normally; passing and bearing the
counterforce on the wheel from different directions and relieving the impact and shake from
the road to the vehicle body in order to ensure the stability and maneuverability of the whole
vehicle. The front suspension is composed of the sub-frame, lateral stabilizer bar, control arm
and etc.
M-13
M-14
M-15
M-16
M-17
M-18
M-19
M-20
M-21
M-22
M-23
M-24
M-25
M-26
M-27
M-28
N-1
Figure 1
The rack & pinion power steering gear is composed of three sections: control valve,
mechanical steering gear and servo cylinder. The control valve is widely utilized overseas due
to its advanced structure and high sensitivity. The mechanical steering gear is rack & pinion
pattern.
Contr ol Valve
The control valve is a normally open rotary valve and consisted of: torsion bar1, input shaft
2, valve bush 3 and other components. The hydraulic oil flows into the left and right oil
chambers through the pre-opened clearance of the input shaft 2 and the valve bush 3. The
structure is shown as Figure 2.
Mechanical Steering Mechanism
The mechanical steering mechanism is rack & pinion pattern and composed of three
sections: pinion shaft, steering rack piston assy and steering link.
Servo Cylinder
The servo cylinder has metallic hull, which is divided into right and left oil chambers by the
inner rack piston and connected with the two oil inlets of control valve.
N-2
To Left Chamber
WORKING PRINCIPLE
Middle Position
When the vehicle moves straight (the steering wheel does not turn), the hydraulic oil
which is supplied by the oil pump enters the oil inlet through the pre-opened
clearance of the rotary valve. As the rotary valve keeps immovable, the hydraulic oil
flows back to the oil reservoir from the return oil inlet. No power is produced
because the oil pressures of the two chambers of the steering gear are same.
Steering Process
When the steering wheel turns, the clearance of the valve spool between the valve
bush and the input shaft will be changed, so the hydraulic oil which flows to the two
oil chambers forms the oil pressure difference. This difference acts on the piston and
pushes it to overcome the steering resistance and make movements. Therefore, the
steering link assy is moved to realize power steering.
Return Process
Once the steering is completed, the force on the steering wheel will disappear. As the
effect of the torsion bar elasticity, the input shaft returns to the relative balance
position of the valve bush and the oil pressure difference between the two oil
chambers of the steering gear follows to disappear. And then the vehicle will convert
to straight-line motion by the effect of the vehicle self aligning torque of the front
wheels until it enters the straight-line position.
Road Sense Effect
The road sense effect is also called the ability of feeling steering. The driver applies
the force on the steering wheel, which also act on the torsion bar of the steering gear
and makes it deform. The amount of deformation which increases as the steering
resistance grows, depends on the wheel steering resistance. Therefore, the driver can
judge the variation of the steering resistance by the force applied on the steering
wheel to obtain the road sense effect.
N-3
The power steering gear of the steering system of A15LHD is a standard feature, and the
mechanical steering gear is optional.
In fact, the power steering gear of A15LHD is based on the mechanical rack & pinion
steering gear and enhanced with a set of power mechanism which is composed of the engine
used as energy sources, the steering oil pump, the steering control valve, the power oil
cylinder and other components. Under the working condition, the power of the engine drives
the steering oil pump through the ribbed belt. The power steering fluid (ATF oil) is suck out
from the oil reservoir by the steering oil pump and formed pressure oil to get into the control
valve. After distributed by the control valve, the pressure oil enters the power cylinder to
push the working piston which is connected with one end of the steering rack. So the steering
power can be formed by the pressure oil through the working piston.
If the power steering system is in failure, the steering of the vehicle can be also completed by
the driver.
The optional mechanical steering gear is a rack & pinion steering gear which the power
source is the physical force (strength of the hand) of the driver. All the dynamic components
are mechanical.
N-4
N-5
20
N-6
STEERING GEAR
Exploded view of the rack & pinion power steering gear
Code Description Quantity
1. Left pull rod outboard joint assy 1
2. Right pull rod outboard joint assy 1
3. Hexagon nut 2
4. Clamp 2
5. Rack shield 2
6. Single ear no-level clamp 2
7. Inner ball joint 2
8. Seal ring 4
9. Dust cover 1
10. Snap ring for hole 1
11. Oil seal 1
12. Bearing 1
13. Valve core assy 1
14. Bearing 1
15. Oil seal 1
16. Conical connector 2
17. Hull oil cylinder assy 1
N-7
N-8
Tightening Torque
Description Specification Quantity
N.m
Hexagon flange bolt Q1840812 1 20~30
Plug cap M30X1.5 1 35~45
Lock nut M32X1.5 1 40~50
Oil tube connector bolt M12X1 2 15~25
Inner ball joint-rack M12X1 2 70~90
Hexagon nut - outboard joint M14X1.5 2 4.9~9.8
Illustration 5
N-9
Illustration 7
Illustration 8
Illustration 9
N-10
Illustration 10
Illustration 12
N-11
Illustration 13
N-12
N-13
Illustration 19
N-14
Illustration 20
N-15
Illustration 23
If it is easy to adjust the lock nut of the rack holder, it is not required to remove the
steering gear from the vehicle. Therefore the adjustment can be completed on vehicle.
N-16
N-17
REGULAR INSPECTION
Initial Check
The maintaining staff should pay attention to the steering system troubles reflected by the
user first. In this way, it could save a lot of repairing time. For example, as the user
complains that the steering is heavy, it is necessary to clear that it is heavy on left or right;
or on spot; or discontinuous heaviness or even no steering power at all.
If possible, try to drive the vehicle under the available condition in order to get the direct
sense about the troubles complained by the user. After the trouble confirmation, do not
hurry to remove the steering gear or the fuel pump as the other components of the steering
system may cause the troubles in fact. Please check these components first and then the
steering gear.
First, check if there are proper, equal and conform to the standard.
Second, check the front wheel alignment (caster, king pin inclination, camber and toe-in)
and the tightness of the steering tie rod, joint and king pin.
If the oil tubes have been replaced by consumers, the following cases must be taken into
consideration: installation in a wrong way; too small diameter of the tube; clogging;
twisting or overbending which would cause the unsmooth flowing or insufficient flux. The
unqualified oil tubes must be replaced.
Next, check the power steering oil reservoir and make sure that the oil level reaches the
specified point.
Check if there is bending on the steering column; Wear or damage on the safety coupling;
invalidation of the spring elasticity. Repair or replace, if necessary.
Basic Check
---- Check if the set bolt of the steering system is loose.
---- Check if the free play of the steering wheel is appropriate. If necessary, check, adjust or
replace the components of the steering system.
Overhaul of the steering tie rod
---- Check if the steering tie rod ball joint is loose inside. Replace it, if necessary.
---- Check if the steering tie rod dust cover is damaged. Repair or replace it, if necessary.
Overhaul of the steering gear
---- Check if the dust cover of the steering gear is broken. Replace it, if necessary. Otherwise
the water and dust will enter the cover easily which would result the initial damage of
the components. Check if the clamp of the dust cover is fixed firmly.
---- Check if the clearance of the steering gear is appropriate. Adjust it, if necessary.
N-18
N-19
N-20
N-21
SYSTEM
The frequent malfunctions of the hydraulic power steering system are the oil leakage,
infiltration of air, failure of the power steering pump, and damage of the steering control
valve and mechanical transmission mechanism of the hydraulic transmission mechanism. All
these malfunctions show in different forms, such as steering heavily, noise, unsmoothness,
vibration and so on. When the power steering system is in trouble, please diagnose the failure
and eliminate it at once.
Steering heavily
Malfunction symptom
In general, the steering should be easy for a vehicle with power steering system. If it fails, the
steering would be heavy and the steering wheel would be hard to turn.
Malfunction reason
Generally, it is caused by the invalidation or the insufficient power of the hydraulic power
steering system; Damage or improper adjustment of the mechanical transmission mechanism.
The specific reasons are shown below:
The oil reservoir leakage or oil level is lower than the specified value.
The oil tube connectors is not well sealed, leakage always happens.
The oil tube is deformed; Oil pipeline is blocked; oil pressure or flux of the oil pump is
insufficient.
The tension of the power steering pump driving-belt is insufficient and the belt slides.
The wear and leakage in the steering pump are serious, which makes the output pressure of
the oil pump lower than the standard.
The pressure regulator oil pump fails, and the output pressure is too low.
There is internal leakage in the steering control valve and power hydraulic cylinder
The steering pinion mechanism is damaged or adjusted improperly, steering link system
components are bended, and friction force on every ball pin is too large.
The tire pressure is too low.
N-22
Adjust the ball pins which locate in the connection of the steering transmission mechanism
to ensure them run smoothly.
The piston of the pressure regulator in the steering oil pump is blocked.
N-23
The steering core of the steering control valve is deviated from the center position.
The relief piston of the steering pump pressure regulator is clamped which makes the flux of
the pump and the pressure difference between the left and right power cylinders too large.
Clearance of the steering transmission mechanism connectors are too large, the connectors
are loose or overworn.
Diagnosis and Troubleshooting
First, check if the connectors of the steering transmission mechanism are loose, the
clearances of the components are too large, the transmission is slack, in order to eliminate
the trouble in the steering transmission mechanism.
Check if the oil is polluted. If the vehicle is new or repaired or the maintenance and
oil-change regulars are not carried out, the oil may be polluted. The polluted oil should be
replaced.
Check the steering control valve. Turn the steering wheel without starting the engine to
judge that whether the control valve can open and close smoothly. If there is abnormal,
disassemble and check it.
Finally, check if the pressure regulator of the steering pump works normally and the relief
piston is clogged. If necessary, measure the output pressure of the steering pump and then
judge it.
Steering noise
Malfunction symptoms
There is abnormal noise when the vehicle turns.
Malfunction reason
The noise in the steering system when the vehicle turns is normal; the noise in the early
N-24
The power steering pump is damaged or overworn or air is mixed into the liquid which
causes the loud noise.
The power steering pump driving belt pulley is loose or the belt sliding which causes the
loud noise.
The performance of the steering control valve is poor.
The oil-filter strainer is blocked or there are too much sediments in the hydraulic circuit.
N-25
Caution: The steering gear is an important danger-proof component which can affect
the driving security. If failure appears during use, the vehicle should be sent to
the service station designated by Chery; the company is not responsible for the
accidents due to self-disassembling, self-maintenance and improper operation.
The peak rate of flow in the system could not exceed 10L/min, maximal working oil
pressure could not exceed 8Mpa at any time.
After the new steering gear has run for about 2500km, it is required to change the hydraulic
oil and clean the strainer in the oil reservoir. Thereforth, change the oil and do the clean of
every year or 50000km.
Check the tire regularly and keep the tire pressure meets the specification.
If the improper clearance block or yawing appears, find out and analyze where the failure
locates in the steering transmission system, power steering system or steering link system
and then resolve it.
Check regularly if the components of the steering system bear the improper impact. Replace
the damaged ones in time.
Do not weld the components of the steering gear and system rod in any means.
Be sure not to touch, knock or wear the tube during use. Each segment should be smooth,
and no knots.
Check the hydraulic oil every month to determine whether it is decreasing, deteriorating or
polluted. The oil should be changed at once when the problem is detected. The No. of the
new added hydraulic oil should be as same as the origin. Mixture is forbidden.
Adding oil of the steering system
Hydraulic oil for the steering system
Fill the steering oil reservoir with the specified hydraulic oil. Keep the engine idling, turn
the steering wheel to the left and right limit position (Do not keep the steering wheel stay at
the limit position more than 5 seconds), and continue to refuel the oil reservoir with the
hydraulic oil until the oil level do not decline and no air bubbles appear. The oil level
should reach the half height of the filter core.
N-26
Precaution: Keep the impurities away from the system when refueling.
Caution: Dead steering (i.e. turning the steering wheel to the limit position) is forbidden
during use. Even if necessary, do not keep the steering wheel stay at the limit
position more than 10 seconds. If the minimum turning radius tests in the
general assy test drive ground to detect the interference, it is also forbidden to
do so. When the steering wheel is turned to the limit position and the louder
noise comes from the power steering pump, you can turn the steering wheel
back a little until the noise disappears. It is forbidden to run the power steering
pump without oil. If the steering is suddenly heavy during use, park the vehicle
to check and repair.
N-27
APPENDIX I P-42
APPENDIX II P-43
P-1
P-2
AIR BLEEDING
Warning:
* The proper fluid level shall be kept inside the brake fluid reservoir when air
bleeding.
Specified fluid type: DOT3 or DOT4
Caution: The brake system shall bleed air once one of brake pipelines disconnects. If
one of hydraulic pipes disconnects from the master cylinder, the air bleeding
starts from the wheel cylinder most away from the brake master cylinder, and
then from the next wheel cylinder till all the four wheel cylinders bleed air. If
the disconnection point is a point other than the one at the master cylinder, the
air bleeding shall start from the wheel cylinder nearest the disconnection
point, and then from the next cylinder till all the four-wheel cylinders bleed
air.
* Remove the oil drain plug, and fix a vinyl insulating sleeve on the thread of oil drain plug
hole.
* Put the other end of the vinyl insulating sleeve into a clean container available to fill the
fluid.
* Step down the brake pedal several times, and then keep it in the position.
* Fluid Level
To Engine
P-3
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Inspection of the check valve of vacuum hose (power assisted brake unit)
* Detach the clips and vacuum hoses
* Pump the engine-side hoses and apply the pressure force on it, and verify that the air
blows only to this side.
* If there are air flow in the both directions or not air flow at all, Replace the vacuum hose.
P-4
P-5
P-6
P-7
P-8
P-9
P-10
P-11
Installation:
P-12
P-13
MAINTENANCE OF SPRING
-- Check the breakage, deformation or elastics
weakening of the spring, and replace it, if any.
P-14
The piston of brake wheel cylinder pushes out the brake shoe with the force of brake
fluid to rotate it outward around the contact point of the brake shoe and the support plate
when braking, and thus the friction lining of brake shoe is pressed towards the brake drum,
which creates the brake torque to brake the vehicle.
The braking pressure disappears when the braking is released, and the brake shoe
returns back to its original position with the help of the return springs 3, 4 and 11.
P-15
P-16
The parking brake is realized by adding a set of manual operating mechanism on the
rear wheel brake, as shown in the figure below. Due to the common use of a set of brake with
the rear wheel brake, it simplifies the structure and reduces the weight.
P-17
Disassembly/Assembly and Installation of Parking Brake System (as shown in the figure above)
Fit the parking brake dust cover assy. tightly on the parking brake control mechanism, and
use the nuts to secure the parking brake control mechanism assy. onto the welding pegs on
the vehicle body.
* Remove the tire and rear wheel brake drum, and detach the brake cable clip and parking
brake cable suspension clamp, which the tightening clips on the rear axle are available for
the bottom of body
* Remove the auxiliary instrument panel (see the Disassembly/Assembly of Auxiliary
Instrument Panel)
* Remove the parking brake cable and compensation rod connection adjusting nut and lock
nut; And the tightening torque of lock nut is 93 Nm.
* Install the hand brake cable and control rod in the reverse order of removal.
P-18
P-19
P-21
P-22
Communicate or
not?
Check it in accordance with
the Non-DTC Failure Check
Sheet
DTC
Repair it in accordance with the Random Failure Repair it in accordance with the DTC Failure
Diagnostic Details Check Sheet
End
P-23
If the failure is removed after pressing the Yes button, the DTC can be cleared
completely.
P-24
Coding: 01901
WSC: 000001
P-25
P-26
Phenomena
Description
Sometimes, the sounds like the knock sound come from
System self-check the engine compartment after the engine starts, which is
sound the sound from the ABS self-check and doesn't indicate
it is abnormal.
1. Sound from the motor inside the ABS hydraulic unit.
2. Sound generated together with the brake pedal
vibration.
Sound while the ABS
3. The suspension knocking sounds created due to
operates
braking or the Creak sounds generated due to the
contact of tire with the ground when the ABS operates.
CAUTION: The tire may still give out the Creak
sound when the ABS operates normally.
The braking distance of the vehicle with ABS is longer
ABS operates but long than that of vehicle without ABS when the vehicle
brake distance travels on a snow or sand-gravel road, and thus a driver
shall be reminded to pay more attention to the road
condition when driving on the road above.
P-27
When the major reason may be the over-high contact resistance in the power supply circuit.
* Turn on all electrical switches, including the headlamp and rear defroster switches.
If the failure doesnt reoccur here, it may be diagnosed and repaired only when the failure occurs at
next time. The random failure will generally become worse only, and is difficult to get better.
P-28
Condition of Failure
Turn the ignition switch to ON (under the engine shut down), and the ABS
warning lamp doesnt light
The warning lamp doesn't extinguish after the engine starts
Uneven braking force at both sides
Braking force shortage
ABS fails to operate when slightly stepping on the brake
Abnormal ABS
pedal (the vehicle is in stationary state)
operation
ABS operates when slightly stepping on the brake pedal
(the vehicle is in driving state)
The brake pedal vibrates seriously when the ABS works
Too long brake pedal travel
Great force required to step on the brake pedal
Without DTC output (fail to communicate with the diagnostic tester)
Caution: If the battery discharges excessively, the motor will fails to be driven, and thus we
shall confirm firstly whether the battery voltage is normal before the motor drive
testing is conducted, and the vehicle shall be in stationary state when the motor drive
testing is conducting.
P-29
Check the fuses and ABS Abnormal Replace the fuse or harness
ECU connections
Normal
Connect the motor harness
Turn the ignition switch to ON
Clear the DTC
Use the diagnostic tester to conduct the
hydraulic control unit diagnosis
Yes
Whether the failure reoccurs or not Replace the electronic control unit
No
of Random Failure
P-30
Abnormal
Check every sensor Repair or replace
P-31
Correct
Abnormal Abnormal
Check the sensor output voltage at Check all sensor gear Replace
ABS pin 25# plug rings
Normal Normal
Normal
Abnormal
Check wheel bearing
Repair or replace
clearance
Normal
P-32
Normal
Remove the ABS Check the Abnormal
related sensor Repair the connector
ECU connector, and
connector
check whether the
resistances between Normal
the following
The failure No Refer to the
terminals of ABS
Repair
ECU conform to the reoccurs or not?
Details of
standard values?
Yes Random
Standard value: 1.0
Failure
to 1.3 k
Measure the
Check the electrical
resistances, and, at
wirbetween the ABS ECU
the same time,
and sensores
swing the sensor
harness and
connector.
MK20I/E
FL: 1 to 2
FR: 19 to 20
RL: 5 to 6
RR: 22 to 23
Normal
P-33
Supply terminal 30
6. The DTC is 00668 Possible Cause
[Description] The DTCs will appear when the * ABS systems fuse broken
supply terminal 30# provides the * Too low or over-high battery
voltage or over-high voltage. voltage
* ABS electrical harness connections
damaged
* ABS ECU damaged
Abnormal
Check the ABS systems 30# fuse Replace the fuse
Normal
Abnormal Abnormal
Disconnect the connection of ABS Check the ABS harness connections Repair the connections
electrical harness with the ECU,
turn the ignition switch to ON, Normal No
and measure the voltage between Retest. The abnormal reoccur? Refer to Repair Details
Normal
No Abnormal
Check the sensor output voltage Check sensor Replace sensor
Normal Normal
Replace ABS ECU
Check the harness between
ECU and sensor
P-35
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Check the ABS warning lamps fuse Abnormal
in the central electrical box Replace
Normal
Abnormal
Check the central electrical box fuse socket Replace the fuse socket
Normal
Remove the ABS ECU connection Abnormal Check whether the bulb of ABS Yes
Ignition switch: ON warning lamp is burnt or not Replace
The warning lamp lights?
No
Yes
Abnormal Check the open short circuit of Abnormal
Check the short circuit or earth of electrical warning lamp supply circuit and Replace the electrical harness
wire, in ABS harness, connecting with ABS ground circuit in ABS harness
Normal
Yes
Check the connectors of warning Abnormal Repair the connector
Replace the electrical harness lamp supply and ground circuits
Yes
Replace the warning lamp controller
P-36
No Abnormal
Check the ABS warning lamp controller Replace
Normal
P-37
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No
Sensor is installed properly or not Install it properly
Yes
Abnormal Abnormal
Check the sensor output voltage Check all sensors Replace
Normal Normal
Abnormal Abnormal
Use the diagnostic tester to Check all sensor gear rings
conduct the HCU diagnosis Replace
Abnormal Normal
Abnormal
Check wheel bearing clearance
Replace the ABS HCU Repair or replace
Normal
Normal
No
Refer to Repair Details
Failure reoccurs or not of Random Failure
Normal
MK20I/E
Normal
P-38
Possible Cause
[Description] Firstly take the visual inspection to
* Brake fluid leakage
determine the outside leakage or
* NC valve leakage
mechanical failure. Use the air bleeding
* Air kept in the system
method to check the air in the system. And
* Serious brake disc
use the diagnostic tester and hydraulic
wear
testing to check the leakage of normally
* Hand brake
closed valve (NC valve).
adjustment improper
Abnormal
Visually inspect the leakage of hydraulic Tighten the pipe joint according to the requirement
Normal Abnormal
Normal Abnormal
Check hand brake adjusting Replace the hand brake adjusting equipment
Normal
Abnormal
Air bleeding check
Air bleeding again
Normal
Abnormal
Use the diagnostic tester HCU to
diagnose the sealing of NC valve
Replace HCU (Hydraulic Control Unit)
[Description] Use the traditional method to check and control Possible Cause
the booster and brake pedal travel. The failure of NO * Booster failure
(Normally Open) valve can be checked using the * NO valve failure
diagnostic testers hydraulic control unit function.
Normal
P-39
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Without DTC output (fail to communicate with the diagnostic tester)
The diagnostic tester communicates with the No The diagnostic tester failure, and
MK20 ABS ECU on the other vehicles conduct the check after repair
Yes
Abnormal
Check ABS supply fuse Replace
ABS harness (terminal 7 for MK20 I/E) with Repair the diagnostic socket or ABS harness
the diagnostic socket (terminal 7 in the
diagnostic tester)
Yes
P-40
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ABS SYSTEM CHECK
Ignition Terminal
Check Item Standard Value Unit
Position MK20I/E
Battery voltage (motor) OFF 25-8 10.1-14.5 V
Battery voltage (solenoid
9-24 V
valve)
Supply insulating property 8-4 0.00-0.5 V
Earth insulating property 8-24 V
Supply voltage ON 8-4 10.0-14.5 V
Warning lamp Visual
OFF
ECU not extinguishes inspection
connected Warning lamp Visual
ON
lights inspection
Warning lamp Visual
ABS warning lamp OFF
extinguishes inspection
Connect the The warning lamp
ECU lights and then Visual
ON
extinguishes after inspection
lasting for 1.7 s
Braking lamp switch
functional pedal not stepped ON 8-18 0.0-0.5 V
down
Braking lamp switch
functional pedal stepped ON 8-18 10.0-14.5 V
down
Resistance value of FL
OFF 1-2 1.0-1.3
wheel speed sensor
Resistance value of FR
OFF 19-20 1.0-1.3
wheel speed sensor
Resistance value of RL
OFF 5-6 1.0-1.3
wheel speed sensor
Resistance value of RR
OFF 22-23 1.0-1.3
wheel speed sensor
FL wheel sensor output
OFF 1-2 3.4-14.8 mV/HZ
voltage
FR wheel sensor output
OFF 19-20 3.4-14.8 mV/HZ
voltage
RR wheel sensor output
OFF 5-6 >12.2 mV/HZ
voltage
RR wheel sensor output
OFF 22-23 >12.2 mV/HZ
voltage
Maximum peak volt
Sensor output voltage ratio
2
Minimum peak volt
P-41
P-42
FOUR DOS
Do step on the brake pedal using your foot at all times, which can ensure sufficient and
continuous braking force to make the ABS effectively play its role.
Do maintain the sufficient brake distance. At least 3 s braking duration away from the front
vehicle shall be ensured when the vehicle travels on a better road, and the braking duration
shall be longer if the vehicle travels on a bad road.
Do learn how to use the ABS to make you prepare for the brake pedal chattering when the
ABS works and have the adaptive ability. The parking lot and squire is the best site to learn
the emergency braking and the use of ABS.
Do read the drivers manual carefully, and further understand all kinds of operation
description provided by the vehicle manufacturer which installs the ABS.
FOUR DONTS
Dont drive the vehicle with ABS at your more pleasure than drive the vehicle without
ABS. It is also improper and insecure for the ABS vehicle short-radius turning and quick
driveway changing and other rapid steering wheel turning.
Dont step on the brake pedal repeatedly. When driving the vehicle with ABS, the repeat
step on the brake pedal will make the ABS connect and disconnect, which causes the low
brake efficiency and larger brake distance. In fact, the ABS itself will automatically
increase/decrease the braking force at higher speed, and provide the efficient steering wheel
controlled capacity.
Dont forget to turn the steering wheel. The ABS provide the driver with the steering wheel
controlled capacity, but it itself doesnt automatically implement the vehicle steering
operation.
Don't be afraid of the normal hydraulic working voice and brake pedal chattering when the
ABS works, the sound and chattering of which are normal and can make the driver feel
hereto that the ABS is playing its role.
P-43
S-1
S-2
S-3
INSTALLATION:
------Install in the reverse order of removal.
ADJUSTMENT:
------To ensure an even clearance of 4
0.5mm, consistent height and smooth
transition around the hood, the hinge is
designed with slot in it to make final
adjustment of engine hood.
------In making transverse adjustment of the
hood, loosen the bolt as shown in the
figure to move the hood till the desired
value is reached.
------In making vertical adjustment of the
front part of the hood, adjust the pin with
the rubber stopper to keep front fender
and engine hood on the same level.
S-4
INSTALLATION:
-----Install in the reverse order of removal.
S-5
INSTALLATION
----Install in the reverse order of installation
ADJUSTMENT
----Keep the size at (40.5mm and flatness
error between cap rim and the fender at
0.5mm, which shall not affect the
appearance.
REMOVAL & INSTALLATION OF
EXTERIOR REARVIEW MIRROR
REMOVAL
----In removing the mirror, relevant
instructions shall be followed to remove
front door trim panel (refer to REMOVAL
& INSTALLATION OF FRONT DOOR
TRIM PANEL)
----Remove inner triangular block of the
mirror.
----Remove the three screws connecting the
mirror and door trim panel. Pull the mirror
connector off to remove the mirror.
INSTALLATION
----Install in the reverse order of removal.
Tightening torque for bolts is 30.3Nm.
REMOVAL
----Take out the four bolts between the grille
top and front end panel to remove radiator
grille as shown in the right figure.
INSTALLATION
---- Install in the reverse order of removal.
Tightening torque for bolts is 3.52Nm.
S-6
REMOVAL
----Remove the screw of trim panel frame.
----Pry open the plastic clip with screwdriver to
remove trunk lid trim panel.
INSTALLATION
---- Install in the reverse order of removal.
REMOVAL
----Pry the moulding starting from where back
window is with a plastic wedge. Loosen the
clips of drip channel by hand and then open
them with screwdriver.
INSTALLATION
---- Install in the reverse order of removal.
NOTE
----All clips can be used once only.
S-7
REMOVAL
----Loosen the screw between front wheel
house and its inner fender.
INSTALLATION
---- Install in the reverse order of removal.
REMOVAL
---- Loosen the screw between front wheel
house and its inner fender.
INSTALLATION
---- Install in the reverse order of removal.
S-8
INSTALLATION
---- Install in the reverse order of removal.
NOTE
----Tightening torque for bumper bracket is
828Nm.
REMOVAL OF BRACKETS
----Loosen the bolts between bumper and its
brackets to remove the brackets.
----Install the bumper in the reverse order of
removal. Note that tightening torque for
the bolt between the brackets and floor
side member is 25Nm. Place the brackets
horizontally with ground.
S-9
REMOVAL OF BRACKETS
----Loosen the bolts between bumper and its
brackets to remove the brackets.
----Install the bumper in the reverse order
of removal. Note that tightening torque
for the bolt between the brackets and
floor cross member is 25Nm. Place the
brackets horizontally with ground.
S-10
REMOVAL:
S-11
S-12
S-13
INSTALLATION
------Install in the reverse order of removal.
S-14
S-15
PRECAUTION:
As the fixed position of belt has come
away, wrap the belt in reverse on
automatic device, and you should
prevent the belt twisting up.
INSTALLATION:
----Install in the reverse order of removal.
PRECUATION
Lubricative grease shall be applied in both sides
of tracks.
INSTALLATION
----Install in the reverse order of removal.
Tightening torque for middle seat belt
and the lock is 5010Nm.
S-16
S-17
Disassembly:
S-18
Attention:
S-19
S-20
DISASSEMBLY
Pull out the lifting stem of the rear door frame,
after that pull out the rear chassis so as to loose
it from the fastening position of the frame.
Assembly:
Assembly steps are the reverse of disassembly.
S-21
Disassembly:
Remove the fastening screws at the top and bottom of the rear seat safety belt (applicable only
for the car model with safety belt). Loosen the four screws of the frame and dismantle it.
Assembly:
The assembly steps are reverse with the above and remember that the tightening for the safety
belt is 5010N.m.
S-22
Safety measures to be taken when working on the airbag system: the works include inspection,
assembly and maintenance. These operations can only be carried out by the appropriate
professionals.
1. Generally diagnostic tester must be used for diagnosis. Never use volt-meter or any other
open wire tester.
2. The negative grid of battery must be disconnected before working on the airbag. After
dismantling, wait for at least 90 minutes before carrying the following work and no body
should stay in the car when connecting the airbag to the battery supply.
3. The airbag must be installed immediately after taken out from the packing.
4. If the assembly stops, the airbag must be placed back into packing, because it is not allowed
to leave the air bag out of control.
5. When handling the airbag, face the inflating device outwards, and should never hold the
cable.
6. When dismantling the airbag and parts awaiting assembly, you must place them on the
surface of the bottom seat, face the side with welded split upwards and do not place the
steering gear with steering wheel on the floor.
7. If an air bag unit is dropped from a height of more than 70cm, or if it appears to have signs of
damage, then it cannot be reinstalled.
8. If there is no appropriate monitor, then the disposal of the airbag cannot be carried out. If this
device is activated, then you should place it in an appropriate container. If it is not activated,
then you should mark the content and use a packing for the new device to pack it and return
to the manufacturer through the spare part shop.
9. Do not try to repair the module, sensor and ignition device.
10. Only use dry or dipped cloth to clean the filling materials in the steering wheel.
11. Do not use sharp or other protruded object to contact the surface of the airbag.
12. When it is necessary to do paint spraying or welding on the vehicle equipped with airbag,
then the airbag must be first removed.
S-23
HAIRSPRING
S-24
S-25
DISASSEMBLY OF COLUMN B:
Take off the cap, loosen the lock nut between
the internal lining and column B; Remove the
seal of the door opening partly within the
working area.
S-26
S-27
DISASSEMBLY/ASSEMBLY OF CARPET
FOR PASSENGER COMPARTMENT
Disassembly:
Remove the fixed decoration between the seal
and the carpet. Loosen the fastening bolt
between the floor and the safety belts of
passenger seats. Remove the oil pan. Use a
plug extraction tool to remove the fastening
plug for the carpet
Assembly:
Assembly is the reverse of disassembly.
Remember that the tightening torque of safety
belt is 5010Nm.
S-28
S-29
S-30
----SPECIAL ATTENTION
Install the waterproof film correctly. The top
part, the two sides, and the bottom part shall
all be pasted in place, thus to enable a correct
water outflow, and to prevent water leakage
into car or damage of door panel.
S-31
NOTE:
When door is closed, the sealing ability is assured through the seal around the door
opening. If the seal is not perforated for easy entry of air, or the pressure is too large
when door is shut, it would most possibly fail for door shut due to an abnormal pressure.
If any following parts on the door are to be removed, the door trim panel must be
removed first as per the instruction on Lining & Trim.
NOTE
Red thread adhesive shall be applied when
installing the two bolts.
S-32
INSTALLATION
Install in the reverse order of removal.
ADJUSTMENT
----If adjust door lock striker erroneously,
which normally causes a failure in closing
the door, position of lock striker shall be
adjusted. The adjusting operation means
that the lock striker is to be loosened with
15mm spanner, and then move as per
requirement. Tightening torque is
505Nm.
S-33
S-34
S-35
INSTALLATION:
Install in the reverse order of removal.
NOTE
Do not tighten the screw before until the
glass is installed in place properly.
S-36
NOTE
Do not tighten the screw before until the
glass is installed in place properly.
INSTALLATION
Install in the reverse order of removal.
S-37
INSTALLATION
Install in the reverse order of removal.
NOTE
----Tightening torque for bolts or nuts of
window regulator is M=91N.m.
----Installation size for glass bracket is 105mm
as shown in the figure.
----Tighten the six screws of window regulator
only after the glass is fully raised till the top
and can run up and down smoothly.
----After installation and adjustment, the glass
should run up and down smoothly. Any
shaking, vibration or shock is not allowed.
The up or down movement of glass shall
be finished within 31S.
S-38
INSTALLATION
Install in the reverse order of removal.
NOTE:
----Tightening torque for bolts or nuts of
window regulator is M=91Nm.
----Installation size for glass bracket is 105mm
as shown in the figure.
----After installation and adjustment, the glass
should run up and down smoothly. Any
shaking, vibration or shock is not allowed.
The up or down movement of glass shall be
finished within 31S.
S-39
S-40
RECTIFICATION:
The car body and chassis are produced in the production line through low temperature
tempering, and cold state of casting technology.
Therefore, when part of the metal is damaged in the accident, similar technology must be
used to return to its shape and heating is strictly not allowed.
If it is too damaged to return the original shape the damaged part should be removed after
rectifying the surface of terminal.
Surface Coating
Intermediate Coating
The Structure of Paint Spraying
Paint Filler (Putty)
Electrophoretic Primer Coating
Zinc Phosphate Coating
Steel Plate
S-41
PVC
Lacquer Putty
S-42
TEST DATA
A=40.5 B=6.51 C=40.5 D=6.51 E=40.5 F=7.51 G=40.5
S-43
S-44
S-45
S-46
S-47
Protection wax at openings contains 60% solid solution, and is coated in an immersion
method at 120.
S-49
When a damaged vehicle is maintained, if damage is not found with chassis or suspension,
then it could lead to more serious damage or breakage in the future. If a big distortion has
occurred with chassis in the accident, then, besides measurement of axles and different fixing
positions stipulated in this Chapter, the following parts are also to be tested.
1. Steering system and steering clutch manipulating system: Check if the functions between
locks are normal or not, and if there exists any distortion or breakage or not.
2. Chassis: Check if there is any distortion or breakage with steering arm, general assembly
of shock absorber, double-headed studs, stabilizer bar, bracing piece, or fasteners of engine,
or not.
3. Wheelbase and tyre: Check if there is any damage, and if there is any unbalance or
mismatching or not; check if any profile or wall is cut off or not; and check the air pressure
inside the tyres.
Engine mounting, transmission case, and exhausting system: Check if there is any wear and
tear or not.
Finally, sufficient driving test will ensure a good condition of vehicles for them to be
delivered to customers without question.
S-50
After the body is operated or maintained, this is the most important instruction in this
Chapter.
If these instructions are not followed, water leakage will frequently happen inside the car, and
it would be very difficult to determine the exact position of leakage, as water inside the car
has many uncertain flows, and can possibly flow directly along the water channel.
One pattern will also be observed that there will be more or less rain leakage when vehicle is
being directionally driven in rain, while no water leakage can be found when it passes
through car cleaning station or high-pressure nozzle. The reason for this happening is because
of unevenness of the ground surface and the impact of bending and buckling stress on work
of mechanical parts, so that rainwater enters rather poorly sealed areas.
The above indicates that it is necessary for the general assembly of body to be airproofing so
as to prevent water leakage. Therefore, after parts with body are replaced or the body is
maintained, proper adhesives are to be used as per models of joints.
Adhesives should have proper viscosity, elasticity, and resistance, so that they wont break or
loosen under the motion of body and change in temperature.
Thanks to the advanced properties of manufacturing process for general assembly, sealing
materials are not required for some positions. However, as the requirement of such process
cannot be generally met during maintenance, all the welds must be well insulated, and
corresponding sealing materials are to be applied for similar positions stipulated in this
Chapter.
S-51
S-52
S-53
S-54
S-55
S-56
Material
Code Applied Positions
Model
-Connecting Position between Body Control Lever
C
and Wheel House
9
-Connecting Position between Floor Board and Front
C
Instrument Panel
-Connecting Position between Floor Board, Shift
10 Lever and Center Reinforced Fitting (to be maintained C
when necessary)
-Connecting Position between Sections of Brackets for C
11
Front and Rear Chairs
-Inner-side Connecting Position between Rear Bracing
C
Piece and Floor Board
-Connecting Position between Floor Board and Center
12 D
Reinforced Fitting
-Connecting Position between Center and Rear Floor
C
Boards
S-57
S-58
S-59
GUARD PLATE
S-60
S-61
S-62
S-63
S-64
Position Name
1 Glass panel
2 Glass panel fastening device
3 Guide bolt
4 Mechanical devices left / right
5 Seal
6:7 Interior trim rim with gray sunshade
6:7 Interior trim rim with beige sunshade
8 Sunroof motor
9 Sunroof module
10 Cover of control buttons
11 Upper frame
12 Interior fastening frame
13 Wind strip
14 Sunshade assembly
15 Harness
16 Rack + pinion / cover
17 Fastening bolts
1. GLASS PANEL
One of main parts of sunroof, is installed on the mechanical device, and airproof with the
seal of upper frame.
2. UPPER FRAME
Plastic part is used to support the mechanical devices and the glass panel, and achieve
good airproof with the body.
3. MECHANICAL DEVICES
Main parts of sunroof are installed on the upper frame with one on each side. They are the
actuators for sunroof glass inclining and opening. The glass panel is installed on the
mechanical devices.
4. MODULE MOTOR ASSEMBLY
The sunroof control panel is mounted on its surface, all programs to perform various
sunroof functions and motor actions are stored in the modules memory, and the motor is
the drive source for the sunroof opening and closing.
5. RACK + PINION
Installed on the upper frame with one on each side, one end is connected to the motor,
another end is connected to the mechanical devices, and transmits the power from the
motor to the mechanical devices evenly to open or incline the sunroof.
S-65
S-66
4. PRESET POSITIONS
Firstly press the button to open the sunroof
to a proper position, press the button (more
than 3seconds) continuously, after the sound of
CREAK is heard from the sunroof, this
position will be automatically memorized as
the preset position 1 of sunroof.
S-67
5. AUTOMATIC CLOSING
When the sunroof is opened to any position,
cut off the power supply of sedan, the sunroof
will make a sound of CREAK.
S-68
INSTRUCTIONS OF SUNROOF
MAINTENANCE
S-69
S-70
S-71
S-72
S-73
Assembly:
10. Apply silicon gel with a width of 3 cm on
the position indicated in the figure.
S-74
S-75
S-76
Assembly
5.Slide the new glass panel into the mechanical
devices in parallel.
S-77
REPLACEMENT OF SEAL
1. Fully open the sunroof.
S-78
Assembly:
7. As shown in the figure, apply silicon gel
with a diameter of 3mm on the inner side of
upper frame and apply double layers of
silicon gel under the fastening block of glass
panel.
S-79
S-80
S-81
S-82
Assembly
7. Install the right guide device and the rear
supporter of sunshade.
S-83
S-84
Assembly:
14. Place the new guide lock in the guide rail.
S-85
S-86
S-87
S-88
S-89
S-90
S-91
S-92
S-93
T-1
T-2
T-3
Inspection procedure:
Battery inspection
Battery
Inspect the battery according to the following procedure
Procedure Inspection description Results Measures
Above 12.4V Proceed to step 3
Measure the open circuit voltage of
1 Proceed to next
battery Below 12.4V
step
Proceed to next
Quick charge for 30 minutes Above 12.4V
2 step
After that, re-inspect the voltage
Below 12.4V Replace the battery
Use load tester to apply load current Yes Battery is normal
(refer to the load test table) for battery,
3 record the battery voltage after 15
No Replace the battery
seconds. Is the battery voltage exceeding
the specified value?
T-4
CHARGING OF BATTERY
Warning: Keep the battery away from any flammable materials. If not, the gas emitted
from the battery liquid that is easily flammable may cause severe injury or
even death of people.
Note: In order to prevent the battery and other components from being damaged, all
attached devices and the generator should be shut down before maintaining or
charging the battery.
T-5
As heat discharged by the exhaust manifold could damage the generator, you must
ensure that the heat discharging guard and insulation device are firmly installed on the
generator.
T-6
Overhaul of generator:
Inspect the accuracy of deflexion and
tension value of the driving belt, if it does
not comply with the requirement, then the
driving belts should be replaced.
Shut down all the electro-devices, turn the
ignition switch to start the engine, inspect
the rotation process of the engine to see
whether the rotation of generator is smooth
without any noise.
T-7
INSPECTION OF GENERATOR
Warning lamp of generator
1. Confirm that the battery has been fully charged;
If it necessary, the battery should be charged.
2. Confirm the accuracy of deflexion and tension values of the wedge type belts.
If it does not comply with the requirement, then replace it with a new type of wedge type
belt.
3. Turn on the ignition switch, and inspect the generator warning lamp to see whether it is
indicating.
If it does not comply with the specified requirement, then inspect the generator warning
lamp, or check whether the generator connectors are connected firmly.
4. Confirm whether the generator warning lamp is off after the engine is turned off.
If it does not comply with the requirement, then inspect the instrument connector to see
whether they are connected properly; if the instrument is malfunction free, then you need
to further inspect the generator itself to see whether there is any short circuit.
T-8
OVERHAUL OF STARTER
No load test:
Verify that the battery is fully charged.
Close the circuit of the starter, battery, voltmeter and ammeter according to the following
diagram.
Initiate the starter and check whether it operates smoothly.
When the starter is rotating, measure its voltage and current values. If these values do not
meet the requirements, then replace the starter.
T-9
T-10
T-11
T-12
T-13
T-14
Warning:
The bulb will generate heat of very high temperature during working. So if the
surface of the bulb becomes dirty, the excessive heat will be accumulated, which
would result in shortening the life span of the bulb. When replacing the bulb, pay
attention to hold the metal edge rather than the bulb itself.
T-15
T-16
Malfunction
Malfunction Diagnosis Troubleshooting
symptom
1. The bulb of the fast flashing
Left and right
frequency side has been damaged. 1. Replace the bulb.
flashing
2. The bulb power does not comply with 2. Replace the standard bulb.
frequencies are
the specification. 3. Check and replace the
not the same or
3. The relay of turn signal lamp is faulty. relay.
one side is not
4. The conducting wire or grounding is 4. Check the circuit.
flashing.
faulty.
1. The bulb has been damaged.
1. Replace the bulb.
2. The fuse has been burned down.
2. Replace the fuse.
3. The relay of turn signal lamp is faulty.
Both sides are not 3. Check the relay.
4. The switch of turn signal lamp is
flashing 4. Check the switch of turn
faulty.
signal lamp.
5. The conducting wire or grounding is
5. Check the circuit.
faulty.
1. Check the battery and
1. Battery voltage is too low.
recharge battery.
The flashing 2. The bulb power does not comply with
2. Change into the standard
frequency is too specification.
bulb.
low 3. The relay of turn signal lamp is faulty.
3. Check/replace the relay.
4. The circuit is faulty.
4. Check the circuit.
T-17
T-18
T-19
T-20
T-21
INTRODUCTION OF INSTRUMENTS
SYSTEM DESCRIPTION
The Chery sedan A15LHD employs indicator needles and digital combination instruments,
the combination instruments including various instruments and measuring equipments that
are used to indicate the conditions of the car, various warning lamps that are used to monitor
the abnormal conditions and notify the driver quickly, indicator lamps that are used to notify
the driver for the condition of all parts, with the function of illuminating the instruments and
meters.
It includes speedometer with mileage, water temperature meter, fuel meter, engine tachometer,
fuel warning lamp, warning lamp for unclosed door, engine warning lamp, warning lamp for
engine oil, brake system warning lamp, ABS warning lamp, seat belt warning lamp, air bag
warning lamp, generator warning lamp, turning signal indicator lamp, danger warning
flashing indicator lamp, headlight high beam indicator lamp, fog lamp, multi-function display,
control unit, power supply assembly unit, printed circuit board, etc. (Illustration -1)
T-22
T-23
T-24
water fuel
engine door switch engine ECU fuel sensor light switch light relay light relay
temperature pressure
signal of ECU switch
Multiplexer multi function display fuel pressure warning lamp high beam warning lamp
voltage regulator ABS warning lamp engine over temperature warning fuel warning lamp
fuel sensor left turn light lamp digital clock
coolant temperature sensor right turn light instrumental panel illuminator single socket plug in connector
RPM sensor generator charging warning lamp instrumental panel illuminator
preset level comparator hand brake warning lamp instrumental panel illuminator
T-25
T-26
Speedometer (Illustration-2)
The indicator needle is located at the scale zero when the speedometer is not in use. When the
car is driving, the transmission gear in the gearbox is activating and cutting the magnetic flux
of the permanent-magnet of the Hall Speed Sensor, so that the latter will produce pulse
signals to the cross coil type Speed Odometer to drive the indicator needle of speedometer,
and meanwhile it will also provide the same signal to the mileage-recording multifunction
liquid crystal display to control the mileage counting.
2. WATER TEMPERATURE METER
Water temperature meter
The Chery sedan A15LHD employs the water temperature meter equipped with cross coil
type indicator needle. See figure (Illustration-3)the water temperature meter is located at
left.
T-27
T-28
5. FUEL METER
The operation of the fuel meter is basically the same as the water temperature meter. It is also
the cross coil type of indicator needle meter. See figure below (Illustration-5)the fuel meter
is located at right of the figure.
T-29
T-30
T-31
T-32
T-1
T-33
T-34
SYSTEM DESCRIPTION
The wiper is mainly consisted of the wiper motor assembly, the three-linkage mechanism,
and the pendulum rod and wiper blade with the tri-directional flexible ball joint. See figure
(wiper-1). The wiper motor is shown in figure (wiper-2).
Wiper
Wiper motorwiper-2
The wiper motor is a speed reducer comprised of a mini permanent magnetic DC motor and a
worm-gear. In order to ensure that the pendulum rod and wiper blade could be positioned
under and parallel with low end of the front window each time after it has stopped. An
automatic stop conducting strip is installed on the back of the worm output shaft of the speed
reducer and 3 conducting contacts that contact with the conducting strip are installed on the
rear cover of the speed reducer. The strip and the contacts jointly perform the automatic stop
function together with the contact of the 0 position of wiper switch.
T-35
1-Water inlet
2-Impeller blade
3-Pump body
4-Water outlet
5-Permanent magnet DC motor
Washer Motorwiper-3)
As shown in figure (wiper-4), this assembly is installed on the liquid storage container and
make up the washer assembly together with the liquid storage container. The washer
assembly is installed on the left-hand impeller blade and the capacity of the liquid storage
container is 5.1 L.
T-36
to horn relay
washer
green
green
green
blown and blue green and black black and blue black and gray
and yellow
horn
button
blown wiper switch wiper motor
blown
black and gray green and black brown and yellow
The circuit schematic diagram of the front window wiper and washer.
T-37
Intermittent
V5 washer Wiper switch Wiper motor
wiper relay
(state of (state of (state of
(state of
Gear conduction conduction conduction Remarks
conduction
between the between the between the
between the
pins) pins) pins)
pins)
B+
5/53s 53e (power
53
Low gear 2/53m 53 supply
B+
B+ B+ positive
grid)
B+
53b (power
53b
High gear 53a supply
B+
B+ positive
grid)
B+
1/J
int (power
Intermittent 2/53m 53
53a supply
gear B+ B+
B+ positive
8/15
grid)
B+
53
5/53s 53 (power
53e
Reset gear 2/53m 53e supply
53a
B+ B+ positive
B+
grid)
B+
6/T
1 53a (power
Washing 2/53m 53
B+ 53c supply
gear 8/15 B+
B+ positive
B+
grid)
T-38
Functioning Malfunction
Malfunction Malfunction
state of the diagnosis and Remarks
symptom reasons
component troubleshooting
The wiper motor When the (1) The power (1) Check the circuit
does not ignition switch supply circuit of of the wiper power to
function. is turned on, turn the wiper motor see whether there is
the wiper switch is open. any open circuit. If
to (intermittent (2) Poor contact there is, fix it
wiping), (slow of the ignition immediately.
wiping), (fast switch and the (2) Test the voltage of
wiping), wiper switch. each point of the
(short-time (3) There is an motor winding with
wiping) position, open circuited multimeter, and verify
the wiper motor point in the that the motor circuit
always does not wiper motor. is open. If it is open,
function. replace the motor.
T-39
T-40
The fast wiping When the (1) The fast (1) Power supply of
does not ignition switch wiping circuit of ignition switch ON.
function. is turned on, turn the wiper motor (2) If the power supply
the wiper switch is open. of ignition switch
to (fast wiping) (2) There is ON is normal, check
position, the malfunction the wiper switch.
wiper motor with the wiper (3) If the wiper switch
does not run. switch. works properly, verify
(3) The circuit that the fast wiping
of wiper motor circuit of the wiper is
fast wiping open, wiper motor
winding is open. terminal 4/53 wiper
motor terminal 5/31
brown/yellow wire
grounding.
The short-time When the (1)There is (1)The wiper motor
wiping of the ignition switch malfunction in can rotate under
wiper motor is turned on, turn the wiper slowly and fast
does not the wiper switch switch. wiping, except the
function. to (short time (2) The wiper short-time wiping. It
wiping) position, switch fails to indicates the switch
T-41
T-42
T-43
SYSTEM DESCRIPTION
The Chery sedan A15LHD employs an electric steel wire type window regulator. The
structure is shown in figure (window-1).
The up/down operation of the window can be centrally controlled by the driver through
pushing buttons, and also can be controlled individually by the door switch to adjust the door
window opening. The mechanism transmission route is as follows: motor speed reducer
steel wire roller steel wire window supporting bracket window up/down. The
control module is installed under the left-hand rear seat, as shown in the figure (window-2).
T-44
T-45
SYSTEM DESCRIPTION
The Chery sedan A15 employs a complete electronic control central lock system. The central
lock system is consisted of one 4-wire type controlling module, three supplemental door lock
actuating motors and one luggage boot cover actuating motor. The lock and unlock of the
interlock mechanism for the central lock system are all controlled by the driver side door lock
switch. The central door lock module is installed in the driver side door panel.
T-46
T-47
T-48
OPERATION PROCESS
----The activation process of the airbag.
T-49
T-50
T-51
Specification:
External diameter96m
Number of cycles: maximum cycles of 6.
Storage temperature : -4085
Operation temperature: -3585
Operation voltage: DC 916V
Working current (airbag configuration): 16A40V6ms max.
Current carry capacity: Carrying up to 5S maximum under a load current of 5A
Voltage carry capacity: Carrying up to 100ms maximum under a voltage of DC 20V
Operation torque: 0.15ms max.
Hairspring
It is installed on the steering column.
It is also a part of the horn circuit.
Attention: The hairspring will be damaged if the steering wheel is turned by more than
4.5 cycles.
Turn the steering wheel:
Rotate the steering wheel to one direction will tighten the coil.
Rotate the steering wheel to the other direction will loosen the coil.
The hairspring will be damaged if the steering wheel is turned by more than 4.5 cycles.(The
total rotation range: 9 cycles)
Warning: Removal of the hairspring will cause injury and vehicle damage. Do not
remove the hairspring. If the airbag has already been inflated, the hairspring
must be replaced. Please remove the airbag components, hairspring and
T-52
4. AIRBAG COMPONENTS
(1) Airbag components
The airbag components consist of the airbag decoration cover, airbag and inflating
components. The airbag is made of nylon fabric. The internal layer was treated with synthetic
glue for sealing air. When the airbag is not open, it is folded like a bag of the unopened
parachute and installed between the upper part of air inflator and the airbag cover. There is a
impression line for tearing on the surface of the airbag decoration cover so that the decoration
cover can be torn off easily during the inflation of the airbag and reduce its resistance to let
the airbag passes through.
When the vehicle is collided, normally the airbag will start to inflate within 10ms after the
first collision, and the total inflation time from the starting of inflation through the entirely
activation of the airbag is about 30mS. When the airbag is activated, it spreads out along the
steering column to the direction of the windshield and thus prevents the drivers face to
collide with the windshield, and his chest to collide with the steering wheel.
There is an air discharging hole at the back of airbag (opposite to the driver). When the driver
T-53
lid
preheat
machine base
2 bolts
tightening torque
inflation assembly
T-54
T-55
T-56
T-57
T-58
T-59
T-60
T-61
T-62
T-63
4. SPIRAL CABLE
The spiral cable (see the figure) is used for the
circuit linking the vehicle body and the
steering wheel. The steering wheel must be
properly installed on the steering column
when the spiral cable is located in the middle,
otherwise the spiral cable may come loose or
cause other malfunctions. Please refer to the
instruction for proper installation of steering
wheel in this manual.
T-64
T-65
T-66
T-67
T-68
T-69
T-70
T-71
T-72
2. INSTALLATION OF ANTENNA
z Disconnect the negative grid of the battery.
z Install the antenna on the installation hole and align it with the vehicle body;
z Fasten it with washers and non-standard nuts, and connect the conducting wires properly;
z Place the front end of the antenna wiring harness until it reaches the rear of the recorder,
and plug the rear end of the antenna wiring harness into the socket of the antenna;
z Bind the antenna wiring harness along the interior left-hand wiring harness.
T-73
5. INSTALLATION OF CD EXCHANGER
z Disconnect the negative grid of the battery.
z Install the bracket of the CD exchanger onto the two sides of the exchanger with washers
and screws.
z Fasten the base onto the flat surface of the trunk with the self-tapping screws.
z Ensure the wires between instrument panel and trunk are connected properly.
z Ensure the front of the CD box upwards, and install the CD exchanger vertically on the
base bracket.
The installing steps are reverse to those for removal.
T-74
Malfunction Reasons/Troubleshooting
No power supply Connection malfunction. Please check the connection.
The player fails to function
Check the fuse (player and vehicle) and the connector.
and display.
The player functions but
Adjust the volume of the player.
without sound or with poor
Check the sound balancing function.
sound effect.
Check the antenna and its connection.
Verify that the antenna is sufficiently spread out and the
The player fails to receive the connection is proper.
signal of desired station. Verify that the negative grid is grounded.
The signal of desired station is too poor.
The disc is incorrectly placed. Insert the disc again correctly.
Displaying NO DISC when
There is water vapor or dirt on the disc.
searching disc
Remove the vapor or dirt away from the disc.
The disc is too dirty. Please clean it.
The disc is twisted or seriously damaged. Compare it with
Noise, jumping of music
other discs.
If the disc is defective, please discard it.
Lack of treble sound or lose
tracks when the tape is Clean the magnetic head.
playing
Check and ensure that the loosened tape has been tightened
Tape is loosened.
properly before inserting it into the recorder again.
The disc ejects when it is The disc has been inserted incorrectly. Insert it correctly
inserted into the player. again.
Note: The sound system in the maintenance manual may be different with the actual situation
of the user. We request our staff of the service stations to notify the vehicle owners that there
is a users manual for sound system delivered together with all the instruction material of the
vehicle. Thank you!
T-75
U-1
Evaporator
Compressor
U-2
Downloaded from www.Manualslib.com manuals search engine
The coolant vapor will be compressed by the compressor as the high-temperature,
high-pressure gas which enters into the condenser. In the condenser, the coolant is cooled by
the ambient air, and condensed into the fluid after emitting its heat outwards, then the
moisture content is filtered and removed from the fluid via the fluid reservoir. The
high-temperature, high-pressure coolant fluid is throttled down through the expansion valve
(installed in the inlet pipe of evaporator) to reduce its pressure and temperature, and then the
fluid enters into the evaporator. The low-temperature and low-pressure coolant fluid also
absorb the heat from the inside of vehicle, and gasifies again to the low-temperature and
low-pressure coolant vapor, and then is inhaled into the compressor. In such a manner, the
coolant cycles recurrently to make the indoor temperature of vehicle reduce. The pipelines
for coolant are shown in the figure below:
Compresso
Condenser
Evaporator
Fan
Drying
Expansion Bottle/Collector
Valve
2. Heating system It adopts the engine coolant as the heat source and introduces the
coolant into the radiator located at the compartment to heat the indoor air via the blower, and,
at the same time, it is also used to defrost and defog the front windscreen.Chery A15LHDs
air conditioning unit adopts the reheating mixed type unit, the heating system of which is
used not only to individually heat the circulating air from the inside of vehicle or the fresh air
from the outside, but also to firstly cool these two kinds of airs and then heat the whole or
part to obtain the air temperature required. It is available to dehumidify the air, and also to
filter the air so as to get the clean air with desired humidity.
U-3
into the vehicle via all air ducts, and then discharge along the same route as that of natural
ventilation to the atmosphere.
U-4
Evaporator Assembly
Air-Conditi
on Harness
4. Control system The control system mainly consist of the electrical component, vacuum
hose and control mechanism. On one side, it is available to control the temperature and
pressure of refrigeration and heating system, and, on the other side, it is also used to control
the temperature of air inside the vehicle, the blowing rate and direction.
5. Air purification system The air purification system mainly indicates the dust filter,
which is used to filter the outside air inhaled, and continuously discharge the vitiated air
generated inside the vehicle to make the air inside the vehicle clean and hygienic.
U-5
Caution:
If there are some moist materials or other
foreign materials circulating in the Low
Low
pressur
High
High pressur
refrigeration system, the cooling pressur pressur
U-6
U-7
U-8
U-9
2Vacuum inhaling
Low-pressure manual valve
Vacuumize the refrigeration system to 30psi, High-pressure manual valve
and then start to charge the refrigerant oil, the Low-pressure side hose Air return
(1) Turn off the high-pressure manual valve, Vacuum pump High-pressure side hose
U-10
U-11
system.
Conduct the leak check firstly before
vacuumizing. If vacuumizing without the leak Vacuumizing
check, it is difficult to find out the leaking 1- Connect to low-pressure service valve hose
position after vaccumizing when there is a 2- Connect to high-pressure service valve hose
certain leakage phenomenon. 3-Low-pressure gauge
The purpose of vacuumizing is to further check 4-High-pressure gauge
the air tightness of the refrigeration system 5-Low-pressure manual valve
under the vacuum condition, and prepare for 6-High-pressure manual valve
the systems refrigerant charging. Its 7-Vacuum pump
procedures are as follows:
(1) Connect the high-pressure gauge hose to
the high-pressure service valve joint of
refrigerant tank, shown in the figure below,
connect the low-pressure gauge hose to the
low-pressure service valve joints on the
pipe from the evaporator to the A/C
compressor, and connect the intermediate
hose to the interface of vacuum pump.
(2) Turn on the high- and low-pressure valves
of manifold pressure gauge, and start up
the vacuum gauge.
(3) The vacuum pump works for at least 15
min to make the vacuum reading of
low-pressure gauge below 30psi . If the
vacuum reading cant be obtained, turn off
the manual valves at the high- and
low-pressure sides, stop vacuumizing, and
check the leaking position.
(4) Turn off the valves, and the gauge needle
doesnt return back within 10 min, which it
is called the vacuum leakage check method.
If the vacuum down, it shows that there is a
leaking position which can be found out by
using a leakage detector.
(5) If the gauge needle doesnt considerably
U-12
WARNING:
(1) When the recycling receiver is required, take care to operate it according to the
requirements of device manufacturer's instructions.
(2) After the completion of recycling work, measure the level of compressor oil recycled so
that the same quantity of oils are added to the refrigeration device in the future.
Operation guide for refrigerant recycling receiver
1. Install the manifold pressure gauge kit on the service valve.
2. Recycle the refrigerant from the refrigeration device.
(a) Connect the intermediate hose to the recycling receiver.
(b) Operate the recycling receiver.
(c) Open the manual high- and low-pressure valves on the refrigeration pressure gauge kit.
1. After the completion of recycling work, turn off the recycling receiver.
2. Remove the manifold pressure gauge kit from the service valve.
U-13
U-14
Number of cylinders 7
Travel (mm)
max 342
min 22
Displacement (cm/r)
max 1613
min 104
Coolant R134a
U-15
U-16
U-17
U-18
U-19
U-20
Coolant treatment
1. The operator shall pay more attention to prevent the coolant fluid from spraying into
your eye or on your skin because the fluid-state coolant is very dangerous. Only one drop
of coolant will cause your skin to be damaged partially if it drops up the skin of the skin.
You must put on your grooves and protective goggles. When the coolant sprays into your
eye or on your skin
(a) Use the cold water to clean those parts
(b) Do not wipe your eye or skin
(c) Immediately get to a hospital to have a professional personnel treat it.
It is recommended to use such equipment as the recovered, recycling, or reused equipment. If
there is any emergency system failure, it is recommended that the equipment is placed on a
ventilation treatment site before the implementation of the equipment maintenance service.
2. Do not dispose the coolant located at a closed place or near fire. If the coolant gas contacts
with sparks or the similar heat source (such as: cigarette or heater), it will generate the toxic
gas.
Storage of coolant
A6E851001039W02
1. The coolant shall be stored in the high-pressure resistance equipment, and take care to
slightly place the fluid reservoir to prevent the reservoir from being impacted by some sharp
materials. Heating the coolant fluid reservoir or taking it near the fire will make it explode,
and the metal fragment generated and the sputtered fluid-state coolant will cause the serious
injury to people. It is recommended to store the coolant under the environment of 400C
(1040F) below.
Safety Notices
1. Do not sit inside the vehicle which operates at the idle speed for a long time, and also do
not leave a child in the vehicle.
2. Switchover the air conditioner to the external circulation mode and inhale the fresh air
into the vehicle from the outside, and change the blower switch to the High-Speed
position when the engine has operated in an unclosed environment for a long time.
3. Avoid the open of luggage boot cover during driving because the gas emitted from the
engine may enter into the vehicle. If the boot cover must be opened, please close all
windows, and change the air conditioner to the external circulation mode to inhale the
fresh air into the vehicle from the outside.
4. Do not open the high-pressure valve of manifold pressure gauge during the operation of
compressor. If the high-pressure valve is opened, the coolant will flow in the reverse
direction and cause the fluid reservoir to be broken.
U-21
U-22
TD-1
TD-2
Cam Height:
Engine model Admission cam T (unit: mm) Exhaust cam T (unit: mm)
480 38.602 37.586
480E 37.559 37.559
Standard Size
Number of cam shaft Diameter of cam shaft journal Diameter of the cam shaft hole of
journal (unit: mm) the cylinder head (unit: mm)
1 44.7444.76 44.78344.808
2 44.9945.01 45.03345.058
3 45.2445.26 45.28345.308
4 45.4945.51 45.53345.558
5 45.7445.76 45.78345.808
Oversized (0.38)
Number of cam shaft Diameter of cam shaft journal Diameter of the cam shaft hole of
journal (unit: mm) the cylinder head (unit: mm)
1 45.1245.14 45.16345.188
2 45.3745.39 45.41345.438
3 45.6245.64 45.66345.688
4 45.8745.89 45.91345.938
5 46.1246.14 45.16345.188
TD-3
Size of Intake Valve Seat Ring And Cylinder Head Seat Ring Bore
0.079~
Oversized by 0.5 44.377 +00..01
01 44.263 0+0.025
0.124
Size of Exhaust Valve Seat Ring And Cylinder Head Seat Ring Bore
TD-4
480 M cylinder bore (unit: mm) 480 E cylinder bore (unit: mm)
1 79.94-79.95 1 79.94-79.95
2 79.95-79.96 2 79.95-79.96
Ex-factory
grouping
3 79.96-79.97 3 79.96-79.97
4 79.97-79.98 4 79.97-79.98
A 80.23-80.24 A 80.23-80.24
C 80.25-80.26 C 80.25-80.26
TD-5
Ex-factory
B 80.21-80.22 80.215-80.225 80.215-80.225
repair
Oversized by
Spare parts 80.21-80.235 80.245-80.255
0.29
Oversized by
0.5 80.43-80.455 80.465-80.475 80.435-80.455
Diameter of 480M piston pin bore (unit: mm) Diameter of 480E piston pin bore (unit: mm)
TD-6
Diameter of 480M piston pin bore (unit: mm) Diameter of 480E piston pin bore (unit: mm)
TD-7
TD-8
Size of cylinder block thrust Size of crank shaft thrust (unit: Thickness of thrust
Class
(unit: mm) mm) spacer (unit: mm)
Oversized
24+0.03 29.205-29.255 2.516+0.025
by 0.38
TD-9
Coolant Mixing Ratio 50% glycol +50% soft water (volume ratio)
TD-10
Diameter: 280mm
Number of blades: 6
TD-11
TD-12
CLUTCH
Item Specification
Clutch Pedal stroke mm 150~165
d l
Clutch Run out limit mm 0.25
TD-13
Gearbox AQ015
Main 4.133
1st 3.455
2nd 2.056
3rd 1.370
4th 1.032
Gear ratio
5th 0.850
Reverse 3.167
Speedometer 2.286
TD-14
Item Specification
REFRIGERANT SYSTEM
Type R-134
Refrigerant
Regular amount (g) 85025
BASIC SYSTEM
Number of cylinders 7
Cylinder diameter (mm) 29.3
Max 34.2
Stroke (mm)
Min 2.2
Max 161.3
Displacement (cm/r)
A/C compressor Min 10.4
Max instantaneous rotation speed allowed(r/min) 8000
Max continuous rotation speed allowed (r/min) 7000
Cooling oil volume (cm) 11515
Rated voltage (V) 12
Rated power (W) 48
CONTROL SYSTEM
Clearance (mm) 0.4~0.8
Magnetic clutch
Mass (kg) 2.2
TD-15
Brake power distribution ratio Front wheel 65%, rear wheel 35%
TD-16
Suspension
Item Specification
Secondary Spare
Item Front Wheel Rear Wheel Spare Wheel
Wheel
TD-17
ENGINE ST-2
ST-1
ENGINE
ST-2
ST-3
ST-4
ST-5
ST-6
ST-7
ST-8
ST-9
ST-10