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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
GENERAL INFORMATION
HOW TO USE THIS MANUAL GI-2
RANGE OF TOPICS GI-2
SERVICE PROCEDURE GI-2
ADVISORY MESSAGES GI-2
UNITS GI-4
UNITS GI-4
FUNDAMENTAL PROCEDURE GI-5
PROTECTION OF VEHICLE GI-5
PREPARATION OF TOOLS AND MEASURING EQUIPMENT GI-5
DISASSEMBLY GI-5
INSPECTION DURING REMOVAL, DISASSEMBLY GI-5
ARRANGEMENT OF PARTS GI-6
CLEANING OF PARTS GI-6
REASSEMBLY GI-6
ADJUSTMENT GI-7
RUBBER PARTS AND TUBING GI-7
HOSE CLAMPS GI-7
VISE GI-7
ELECTRICAL SYSTEM GI-8
ELECTRICAL PARTS GI-8
CONNECTOR GI-8
ELECTRICAL TROUBLESHOOTING TOOL GI-11
TOWING GI-12
TOWING GI-12
TOWING HOOKS GI-12
IDENTIFICATION NUMBER LOCATION GI-14
VEHICLE IDENTIFICATION NUMBER (VIN) GI-14
DESCRIPTION OF VIN GI-14
ENGINE IDENTIFICATION NUMBER GI-15
PRE-DELIVERY INSPECTION GI-16
PRE-DELIVERY INSPECTION GI-16
SCHEDULE MAINTENANCE GI-17
SCHEDULE MAINTENANCE TABLE GI-17
GI-1
HOW TO USE THIS MUNUAL
RANGE OF TOPICS
This manual contains procedures for performing all required service operations. The
procedures are divided into the following five basic operations:
Removal/Installation
Disassembly/Assembly
Replacement
Inspection
Adjustment
Simple operations which can be performing easily just by looking at the vehicle (i.e.,
removal/installation of parts, jacking, vehicle lifting, cleaning of parts and visual
inspection) have been omitted.
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
Note
A Note provides added information that will help you to complete a particular procedure.
Specification
The values indicate the allowable range when performing inspections or adjustments.
Upper and lower limits
The values indicate the upper and lower limits that must not be exceeded when performing
inspections or adjustments.
GI-3
UNIT
UNIT
GI-4
FUNDAMENTAL PROCEDURES
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
ARRANGEMENT OF PARTS
All disassembled parts should be carefully
arranged for reassembly.
Be sure to separate or otherwise identify the parts
to be replaced from those that will be reused.
CLEANING OF PARTS
All parts to be reused should be carefully and
thoroughly cleaned in the appropriate method.
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
ADJUSTMENT
Use suitable gauges and/or testers when making
adjustment.
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 SYSTEM
ELECTRICAL PARTS
Battery cable
Before disconnecting connector or removing
electrical parts, disconnect the negative battery
cable.
Wiring Harness
To remove the wiring harness from the clip in the
engine room, pry up the hook of the clip using a
flathead screwdriver.
CONNECTORS
Disconnecting connectors
When disconnecting connector, grasp the
connectors, not the wires.
GI-8
Locking connector
when locking connectors, listen for a click
indicating they are securely locked.
Inspection
When a tester is used to inspect for continuity or
measuring voltage, insert the tester probe from
the wiring harness side.
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
Replacement
Use the appropriate tools to remove a terminal as
shown. When installing a terminal, be sure to
insert it until it locks securely.
Insert a thin piece of metal from the terminal side
of the connector and with the terminal locking tab
pressed down, pull the terminal out from the
connector.
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
ELECTRICAL TROUBLESHOOTING TOOLS
Jumper wire
A jumper wire is used to create a temporary
circuit. Connect the jumper wire between the
terminals of a circuit to bypass a switch.
Caution
Do not connect a jumper wire from the
power source line to a body ground. This
wiring harnesses or electronic
components.
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
TOWING
TOWING
Proper lifting and towing are necessary to prevent damage to the vehicle. Government and
local laws must be followed.
A towed vehicle should have its front wheels off the ground. If excessive damage or other
conditions prevent this, use wheel dollies.
When towing with the rear wheels on the ground, release the parking brake.
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
FRONT
REAR
GI-13
IDENTIFICATION NUMBER LOCATIONS
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
3. The fifth digit of VIN code stands for the type of chassis of the body. The letter A stands
for the chassis of three-box, five-door, and 4X2 type; B for two-box, five-door, and 4X2
type; C for three-box, four-door, two-lid, and 4X2 type; and D for two-box, five-door, and
4X4 type.
4. The sixth digit of VIN code stands for the type of transmission. 1 stands for manual
transmission and 2 for automatic.
5. The seventh digit of VIN code stands for the type of engine. 1 stands for the electronic
fuel injection gasoline engine of 1.5L~2.0L (excluding 2.0L) series; 2 for below 1.5L
(excluding 1.5L), and 4 for 2.0L~2.5L (excluding 2.5L).
6. The eighth digit of VIN code stands for the Constrain System. A stands for manual safety
belt, and B for manual safety belt and airbag in the front row.
7. The ninth digit of VIN code is the check digit. It is to check accuracy of VIN record, and
is made out through computation after confirming the other sixteen digits of VIN.
8. The tenth digit of VIN code stands for the manufacture year according to the following
table.
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
PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION TABLE
Appearance and interior Setting and checking of clock
Defects of appearance and interior
Paint, galvanized components and interior trim Shut down engine
Carrying items, tools, spare tire, operation manual for jack and Alarming lamp of not shut down lamps
keys
Remove anti-vibration cover for tires and body protective film Shut down all the lamps
Self-lock function of steering wheel
Engine Adjusting of hand-brake
Lock and hinge of engine hood Adjusting of steering wheel angle
Poles of battery Sun visor
Electrolyte level Center lock and remote control(alarming sound)
Main ground Indoor lamp
Main fuse and spare parts Reading lamp
Oil level of engine Front & rear safety belt
Coolant level and water quality Angle of seat back and adjusting of seats
Power steering oil level Open of trunk lid (rear door)
A/T oil level Trunk lamp
Glass washing liquid level Open of fuel filling cover and fuel grade
Degree of tightness of timing belt (power steering, generator and Close of trunk lid and its locking
compressor)
Throttle control cable(A/T control cable) Close the engine hood Open all the four doors
Operation and Control Manual windows
Height and free distance of clutch pedal Rear door children lock
Height and free distance of brake pedal Fill lube for lock & hinge
Acceleration pedal Close doors and inspect the assembly
Inspect the indoor fuse and spare parts
Turn ignition switch to position Lift car
Radio debug Wear or broken of pipes for chassis, engine, brake and fuel
Radio/Cassette/CD and antenna Tightening and bolts of suspension system
M/T oil level
Turn ignition switch to position
Lower car
Inspection of all the alarming lamps, defects of dynamo,
Confirm all the torques for tire nuts
hand-brake, oil pressure, brake, A/T gear display, ABS, SRS
Label of tire pressure
AT startup protector
Tire pressure (including spare tire)
Tool and jack
Start engine
The operation of battery and dynamo as well as the displays of Driving test
various alarming lamps Driving performance
Idle speed Noise from interior, suspension and brake system
Operation of front washer Brake system and hand-brake
The operation of front wiper Automatic return of steering wheel
Turn signal light Vibration and its position of steering wheel
Side light and license plate light A/T gear shift (up and down)
Head lamp and high beam light (high beam indicator) Reading and canceling of odometer
Switch of fog light
Brake light and backup light Final inspection
Instrument light and light adjusting switch Cooling fan
Horn Idle speed/emission
Cigar lighter Leaking of fuel, engine oil, coolant and exhaust gas
Operation of sun roof Performance of hot startup
Fog-remover of rear windscreen and indicator Check ABS performance with ABS tester
Performance of air condition under each gear (refrigeration and
amount of blast) Final preparation
Cycle switch Clean the inside and outside of car
Power rear view mirror Check if water leaking into the car including trunk
GI-16
SCHEDULE MAINTENANCE
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
MileageKm
Items 5000 15000 30000
Engine oil sump bolt: check if loose, tighten if necessary
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
maintenance item.
When driving mileage reaches 40,000 km or 6 months after last service, perform 5,000 km
maintenance item.
When driving mileage reaches 45,000 km or 6 months after last service, perform 15,000 km
maintenance item.
When driving mileage reaches 50,000 km or 6 months after last service, perform 5,000 km
maintenance item.
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
ENGINE
VALVE, VALVE SPRING AND OIL SEAL ASSEMBLY OF THE VALVE B-13
B-1
REAR OIL SEAL REPLACEMENT B-23
CAMSHAFT B-25
CRANKSHAFT B-28
B-2
LOCATION INDEX
MECHANICAL LOCATION INDEX
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
ENGINE TIMING
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
Note: After the belt is taken out, do not rotate
the gear to a large extent, otherwise the
piston head and the valve will be damaged
due to collision. To continue using the
removed belt, carefully check whether
there is abnormal abrasion, stratified
cracks (especially those around the root)
or fouling on the belt. Replace it
immediately even if the slightest suspicion
exists.
B-5
Hold the middle of the right belt that is away
from both the crankshaft gear and camshaft gear
with the thumb and the first finger. If the tension
of the belt is up to standard, the belt shall be
able to twist at 90at this point.
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
DRIVER BELT, TENSION PULLEY AND
GENERATOR
Removal
Pull the abutment on the tension pulley by tools
to the direction of the generator (or align the
gauge holes on the front and rear part of the
tensioning device and drive a pin to fix the
tensioning device).
Remove the driver belt and the two fixing bolts
on the generator to take the generator out.
B-7
Check whether the TDC indicator on the cam
shaft gear lines up with that on the front end of
cylinder head. If not, rotate the crank shaft
clockwise in one full circle to make them line up
with each other. At this time, the engine is in the
position of TDC of the first cylinder.
B-8
VALVE CLEARANCE
B-9
VALVE COVER AND GASKET
Cupped gasket
Valve Cover
Cupped
Removal gasket
Installation
B-10
ROCKER MECHANISM
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
HYDRAULIC TAPPET
Removal
Take the hydraulic tappets out and place them
into an oil-filled vessel to prevent the hydraulic
tappet oil from leaking out.
Check the top and bottom contact surfaces of
the hydraulic tappet to observe whether there
are abnormal abrasion or scrapes. If yes,
replace it with new one if necessary.
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
VALVE, VALVE SPRING AND OIL SEAL
ASSEMBLY OF THE VALVE
Removal
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
Valve stem size and fit clearance
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
Grinding valve and valve seat ring
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 intake valve seat ring and cylinder head
seat ring bore
Diameter of Diameter of
intake the seat ring Interfer
Class valve seat bore of ence
ring (unit: cylinder (mm)
mm) head (mm)
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
COMPRESSION PRESSURE
COMPRESSION INSPECTION
Warning
Hot engines and oil can cause severe burns. Be careful not to burn yourself during
removal/installation of each component.
1. Verify that the battery is fully charged.
Recharge it if necessary.
2. Warm up the engine to the normal operating temperature.
3. Stop the engine and allow it to cool off for about 10 min.
4. Perform Fuel Line Safety Procedures. Leave the fuel pump relay removed.
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
Cylinder Pressure Standard Value1.00-1.35 Mpa (10-13.5 kgf/cm2)
B-18
CYLINDER HEAD GASKET
CYLINDER HEAD GASKET
REPLACEMENT
Removal
Rotate the cam shaft clockwise until the key slot
goes downwards vertically.
Loosen the bolts on the cylinder head in the order
illustrated in the figure.
B-19
Put the cylinder gasket into the dowel.
B-20
FRONT OIL SEAL
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
CRANKSHAFT GEAR
Removal
Fix the crankshaft to disenable it to rotate and
remove the pulley.
Pull the crankshaft gear out by a wheel puller or
two large-size screw drivers and remove the
whiney key.
Installation
Check whether there are abrasion, pit corrosion or
scrapes on the gear.
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
REAR OIL SEAL
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
Pries the rear oil seal out of the rear oil seal
support with a chisel or a screwdriver. Note: do
not damage the rear oil seal support.
Installation
Put the support on the vice clamp whose jaw
has a piece of wood.
Make the side with the part numbers of the rear
oil seal outward and align the rear oil seal with
the rear oil seal support bore. 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
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
Draw the cam shaft assembly out from the rear end
of the cylinder head and be careful not to damage
the cam shaft hole of the cylinder head during this
process.
Inspection
Check whether there is any abrasion on the cam
and the journal of the cam shaft. 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
SIZE OF CAMSHAFT JOURNAL AND
HOLE OF THE CYLINDER HEAD
Installation
To replace the cam shaft, observe the shape of the
rear end of the cam shaft for right selection.
Before installation, apply the cam of the cam shaft
with hyperbolic gear oil or motor oil. The cam
shaft shall be assembled from the cylinder head in
a back-to-front order.
Apply some motor oil to the thrust spacer of the
cam shaft and put the thrust spacer into the groove
of the cylinder head.
Screw two bolts into the threaded holes of the
thrust spacer and tighten them for a moment of
913Nm.
Check the axial clearance of the cam shaft, which
shall be within the specified range.
If adopting oversized hydraulic tappet (0.25), a
carefully selected cam shaft shall be used,
otherwise it will block the hydraulic tappet.
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
CRANKSHAFT
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
Install the main bearing cap. Tighten the bolts of
the main bearing cap at the moment of 90-100N.m
by hands. Do not rotate the crank shaft.
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
Diameter of main journal and size of main bearing shell
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
Installation
Before installation, tap the threaded hole on
the cylinder block with tapping drill,
especially those of the cylinder head bolts and
main bearing bolts.
Cylinder head bolt: M10X1.5~6H
Main bearing bolt: M12X1.75~6H
Installation of the whiney key of the crank
shaft: gently drive the whiney key into the key
slot. The clearance between the whiney key
and key slot is 0.00~0.051mm. Check the
protrusion after the whiney key is installed,
which shall be 1.392~1.739mm.
There are two pieces of crank shaft thrust
spacers, which are installed on the front and
rear thrust surfaces. Before installation, apply
some motor oil on the side of the thrust spacer
with oil groove and make this side towards the
cylinder block and the other side towards the
crank shaft.
Apply some motor oil on the main journal,
connecting rod journal, thrust surface and
bearing shell before the crank shaft is
installed.
The top of the main bearing cap is cast with
numbers- 1, 2, 3, 4, 5 and one arrow. During
the assembly, start the installation in a
front-to-back order and enable the guide
finger towards the front end surface of the
cylinder block. The width of 1, 2, 4, 5 main
bearing cap is same, but that of the third main
bearing cap is larger than others. The location
of the main bearing cap depends on the rabbet
and the rabbet and the cylinder block is
interference fit, with the interference to be
0.025~0.145mm. After the assembly, the sides
of the first and fifth main bearing cap shall be
even with or lower than the back and front
end surface of the cylinder block.
B-31
shall be installed on the left threaded hole of
the fourth main bearing cap (seeing from the
front).
Apply some motor oil on the head joint before
installing the main bearing cap bolts.
Tighten the main bearing cap bolts and stud
by hands, then tighten them to the moment
of 90~100Nm.
B-32
PISTON AND CONNECTING ROD ASSEMBLY
PISTON REMOVAL, MEASURE AND INSTALLATION
Removal
B-33
Rinsing and inspection
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 UAESs
Diameter of 480M piston skirt Diameter of 480E
new two-valve piston
(unit: mm) piston skirt (unit: mm)
skirt (unit: mm)
1 79.91-79.92 79.915-79.925 79.915-79.925
Ex-factory 2 79.92-79.93 79.925-79.935 79.925-79.935
grouping 3 79.93-79.94 79.935-79.94 79.935-79.94
4 79.94-79.95 79.945-79.955 79.945-79.955
A 80.20-80.21 80.205-80.215 80.205-80.215
Ex-factory
B 80.21-80.22 80.215-80.225 80.215-80.225
repair
C 80.22-80.23 80.225-80.235 80.225-80.235
Standard 79.93-79.955 79.965-79.975
Spare
Oversized by 0.29 80.21-80.235 80.245-80.255
parts
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)
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
Measure the axial clearance of piston ring in the piston groove
B-36
Installation
B-37
Size of piston ring
B-38
LUBRICATION SYSTEM
DISASSEMBLY/ASSEMBLY D-3
DISASSEMBLY/ASSEMBLY D-5
DISASSEMBLY/ASSEMBLY D-6
DISASSEMBLY/ASSEMBLY D-10
D-1
ENGINE LUBRICATION SYSTEM
D-2
Hydraulic jib gets oil through the oil passage
through which the oil tank at the camshaft
supplies oil to the cylinder cap.
The interface between valve rocker and hydraulic
jib is lubricated by oil through the oil hole in
hydraulic jib.
Rocker seat is lubricated by oil through cylinder
cap oil passage. The interface between valve
small end and rocker is lubricated through
splashes.
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
Assembly:
To spread Letai 598 seal glue or GY409
anaerobic glue on the connecting areas between
cylinder oil pan flange and oil pump body and
rear oil seal support.
D-4
OIL FILLING
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
OIL PUMP AND FRONT OIL SEAL
Disassembly:
To unscrew and take out six M6X30 hexagon
flange bolts.
To take out oil pump and front oil seal assembly.
D-6
To take out the internal and external rotors.
D-7
To check out the rotor end clearance.
The rotor end clearance shall be 0.014-0.100mm.
D-8
Assembly:
To place external and internal rotors into the oil
pump body, making sure the installation marks
on the external and internal rotors are upward.
D-9
To remove the thing plastic strip.
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
OIL PRESSURE TESTING PARAMETER LIST
D-11
COOLING SYSTEM
DESCRIPTION OF COOLING SYSTEM E-2
COMPONENTS OF 480 ENGINE COOLING SYSTEM E-2
WORKING PRINCIPLE OF COOLING SYSTEM E-2
PARAMETERS OF COOLING SYSTEM E-3
ENGINE COOLANT E-3
COOLANT DISCHARGE E-3
COOLING SYSTEM CLEANING E-3
COOLANT FILLING E-4
COOLING SYSTEM CHECKUP E-5
COOLING SYSTEM MAINTENANCE WARNING E-5
WARNING E-5
WATER PUMP E-6
STRUCTURE E-6
DISASSEMBLY/ASSEMBLY E-6
THERMOSTAT E-7
DISASSEMBLY/ASSEMBLY E-7
WATER TEMPERATURE SENSOR E-9
DISASSEMBLY/ASSEMBLY E-9
CHECKING E-9
COOLING FAN E-9
DISASSEMBLY/ASSEMBLY E-9
GUIDELINE FOR DISASSEMBLY E-10
EXPANSION RESERVOIR E-11
DISASSEMBLY/ASSEMBLY E-11
ASSEMBLY OF RADIATOR E-12
DISASSEMBLY/ASSEMBLY E-12
E-1
COOLING SYSTEM
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
PARAMETER OF COOLING SYSTEM
Cooling system Parameter
Total system capacityL 8
Engine capacityL 3.3
Coolant capacity
Radiator capacityL 2.1
Expansion reservoir capacityL 0.4
Diameter: 280mm
Number of blades: 6
Operating voltage: 9-15V
Fan Rotating speed gear: high-speed engine 2000200
low-speed engine 1800200
Rotating speed II gear: high-speed engine 2800200
low-speed engine 2600200
Diameter of impeller: 72mm
Water pump Transmission rate: 1.053:1
Opening pressure of the pressure cap: 160kPa
Front face area: 0.202m
Radiator
Heat abstraction area: 8.93m
Opening temperature: 85-89
Thermostat
Full opening temperature: 99-102
Switch-on temperature gear95 C gear 102 C
Thermo-switch Switch-off temperature gear84 C gear91 C
Operating voltage: 12V
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
preheat up to normal operating temperature, shut
down and cool down;
To discharge coolant;
To repeat the above-mentioned steps until the
discharged water is the same as the clean water;
To clean the cooling system according to the
following methods if the coolant is not correctly
used and replaced to meet the requirements in the
former utilization:
a. To discharge coolant;
b. To demount the radiator inlet hose, insert the main
water hose into the radiator filler until the outlet
water becomes clean;
c. In order to flush out the engine, you should connect
the main water hose with the water outlet of the
thermostat to clean the engine until the discharged
water flowing from the water pump inlet becomes
clean;
d. To repeat cleaning operations if the radiator is very
dirty, and connect the main water hose with the
radiator water outlet until the water flowing from
the radiator water outlet becomes clean.
Coolant Filling:
To check whether the pipeline is well connected
and fastened before injecting coolant;
To open the pressure cap; fill up coolant into the
expansion reservoir filler slowly. Since the
expansion reservoir is at the highest position in the
cooling system. Therefore, as the coolant level
rises, the air in the system shall be discharged into
the expansion reservoir and shall be discharged out
of the expansion reservoir by injecting coolant
slowly.
To continuously inject coolant up to the highest
coolant level. And then close the filler to prevent
coolant from spilling.
To start up the engine to make it operate at idle
speed and preheat up to normal operating
temperature. And until the fan begins to run,
observe water thermometer and check if the engine
is at overheating condition. If the coolant level in
E-4
the expansion reservoir descends quickly, coolant
should be injected up to the highest position to cut
down the air circulation in the system.
To shut the engine down to have it fully cooledif
possible, leave the engine alone for one night.;
To open the pressure cap to check the coolant level, and
inject coolant up to the highest position.
E-5
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
THERMOSTAT
Disassembly:
To unscrew 3 M640 bolts and then demount the
bolts;
To demount thermostat chassis and thermostat
assembly.
E-7
To take the seal ring out, and replace it if it being
worn and torn.
To demount the gasket from the thermostat chassis.
To replace with new gasket if it is worn and
torn, and allow no repeated use.
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
WATER TEMPERATURE SENSOR
Disassembly:
To demount water temperature sensor (at the
exhaust pipe flank and under the lifting eye).
Assembly:
To apply Letai 243 glue on the screw thread,
screw up the bolt to 7.010.0Nm 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
To demount the matching plug of the cooling fan.
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
EXPANSION RESERVOIR
Disassembly:
To demount the water pipe connecting with the
expansion reservoir.
E-11
Assembly:
To assemble the expansion reservoir according to
the order opposite to the disassembly orderthe
tightening torque of self-tapping screw is
4.0~5.0Nm.
To refill coolant.
ASSEMBLY OF RADIATOR
Disassembly:
To discharge coolant (refer to the coolant discharge
process)
To demount the cooling fan (refer to the
disassembly process of the cooling fan).
E-12
To take out the radiator
Assembly:
To assemble the radiator according to the order
opposite of the disassembly order.
To install the 2 wind boards onto the radiator by
using self-tapping screws with their tightening
torque of 67Nm.
E-13
FUEL AND EMISSION CONTROL SYSTEMS
OUTLINE F-9
F-1
INTAKE-AIR SYSTEM
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
To avoid the mixture condensing and freezing in certain condition, throttle valve adjuster is
supported by anti-deadlock screw to prevent it from completely closing, and heated by
circulating coolant. Idling speed step motor (4) and throttle position sensor (5) are installed
on throttle body.
F-3
1.Idling Speed Step Motor 2. By-pass Hose 3. Lock Pin 4. Throttle Valve
5. Throttle Body 6. ECU Electrical Control Unit 7.Steel Lock Ring
Qo. Air Leakage Volume Of Throttle
Q. By-pass Air Volume Of Step Motor
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
THROTTLE POSITION SENSOR
The sensor, including a potentiometer, the movable part of which is controlled by the throttle
axis. ECU supplies a voltage approx. 5V to the potentiometer when working.
From idling to throttle full open, oil injection process is administrated by parameters gained
from throttle valve opening angle.
ECU identifies whether the throttle is in the open or close position according to the output
voltage and modifies the mixture ratio. When throttle closed, the voltage signal is transferred
to ECU to confirm whether the engine is in idle or fuel cut-off state (differ from engine
speed).
Signals for throttle potentiometer need not adjusting because ECU software can automatically
obtain the idle position (0-950mV) of throttle valve.
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
INTEGRAL AIR PRESSURE/TEMPERATURE SENSOR
Pressure signals are obtained from the voltage of one among four resistors in Wheatstone
bridge marked on a special diaphragm. This diaphragm is compressed and stretched under
the absolute pressure from inside of the manifolds (thus the above resistor is under pressure
too).
Air temperature sensor is a negative factor temperature sensor. So the higher the temperature
is, the lower the resistance and the weaker the pressure signals will be.
When a failure in sensor circuit happens, the air temperature is fixed at 45.
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
ASEEMBLY AND DISASSEMBLY OF INTAKE SYSTEM
Remove accessories around the engine:
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
OIL-VAPOR SEPARATOR
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
EXHAUST SYSTEM
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
the mixture concentration value in time and change mixture thicker or thinner to make it
always be close to chemical reaction equivalence ratio. The voltage range of which is
0.980~1.020V.
To reach working temperature rapidly (~300C), a resistor (4) installed in the sensor can
shorten the starting electric time of the porcelain. It means sensor can be installed in cold area
of exhaust hose. If mixed gas concentration is thinner than chemical reaction equivalence ratio
when working in full speed, ECU will give signal to the oxygen sensor to add mixture thicker
(half-closed loop).
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
Exhaust gas emission CO% HC (p.p.m.) CO2 (%)
Before catalytic converter 0.4 - 1 < 600 > 12
After catalytic converter < 0.35 < 90 > 13
See the above table, using three-way catalyst converter can reduce three types of harmful
gases in exhaust gas at the same time: HC, CO, NOx, while harmless CO2 increases.
The following factors will rapidly damage the catalytic converter:
Fuel contained lead, which will decrease converter efficiency even invalidate catalytic
converter.
Incomplete burned fuel in converter, for example, the catalytic converter will be melt and
damaged only in 30 seconds by the fuel under 800C (temperature in converter).
Do not cut off the high voltage cable no matter the engine is running for any reason to insure
ignition parts (static ignition coil, high voltage cable, spark) are effective.
Oxygen sensor signal is displayed on diagnosis tester.
This value shall continuously wave in a defined range (thin mixture<0.45V, thick
mixture>0.45V).
Oxygen sensor heater resistance is about 45 at environment temperature 20C, and its
battery voltage is 12V.
F-11
Install Oxygen sensor assembly on front hose assembly with a tightening torque of
454.5Nm.
Install 3 M10 double head studs on exhaust manifolds.
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
Note:
Eccentricity between front silencer and the intake/exhaust hose is 18mm. Adjust front
silencer position in assembly to guarantee a gap between the front silencer and the
channel heat insulator more than 10mm.
In assembly, hose clamp should not be aslant installed around the exhaust hose.
Distance between the expanding section on exhaust hose and the section of hose
clamp should be 14mm in assembly.
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
FUEL SYSTEM
ASSEMBLY AND DISASSEMBLY OF FUEL SYSTEM
Before repair procedure
Warning
Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage.
Always keep sparks and flames away from fuel.
Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious
injuries or death and damage. Fuel can also irritate skin and eyes. To prevent
this, always complete the following Fuel Line Safety Procedure.
Fuel Line Safety Procedure
Note
Fuel in the fuel system is under high pressure also when the engine is not
running.
1Remove the fuel-filler cap and release the pressure in the fuel tank.
2Remove the fuel pump relay.
3Start the engine.
4After the engine stalls, crank the engine several times.
5Turn the ignition switch to LOCK position.
6 Install the fuel pump relay.
F-14
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
Installation of fuel case assembly:
Install fuel tank assembly.
F-16
Installation of fuel filter:
Set up fuel filter assembly in fuel filter
Caution
F-17
counter-clockwise, slowly bring forward fuel
pump assembly.
Pull out fuel level sensor with little upwards
strength.
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
OPERATION CONTROL OF ENGINE FUEL SUPPLY SYSTEM
1. Start engine:
In start process, ECU firstly inject to all cylinder at the same time to shorten start time. After
that, ECU will inject according to phase order.
2. Acceleration:
In acceleration process, ECU will add injection fuel by engine requirement and deal with
sensor signal below: throttle position, absolute pressure, upper dead center/ speed sensor,
multiply basic 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
5. Full load:
In full load status (distinguished from throttle potentiometer and absolute pressure sensor),
ECU obtains maximal output power by increase basic fuel injection time, while temperature
of catalysis converter is kept in prescriptive range.
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
10. Electric power balance:
Normal working of electric components (front light, heat back window, etc.) will make
battery voltage lower than 12.2V, electric components power demanded in that time is larger
than electric power from generator. That is to say, negative electric power balance may
cause damage to battery. In that condition, ECU accelerates idle speed step by step (from 800
r/m to 1200 r/m) to make adequate electric power from generator. Accelerating idle will
disappear when electric power balance is positive.
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
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
Fuel pump inspection
Note
When ignition switch is at ON position, it is normal to hear the sound of fuel pump
running.
Fuel pump is located in fuel tank, and there is netlike filter in the fuel pump entrance. Internal
gear positive displacement fuel pump should use unleaded gasoline. 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 Pump Hold Pressure Inspection
Warning
Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries
or death and damage. Always carry out the following procedure with the engine
stopped.
Caution
Disconnecting/connecting the quick release connector without cleaning it may
possibly cause damage to the fuel pipe and quick release connector. Always clean
the quick release connector joint area before disconnecting/connecting using a cloth
or soft brush, and make sure that it is free of foreign material.
Fuel rail
Fuel rail 1 is made of cast aluminum. Its function is distributing fuel to injector 2.
F-24
1.Fuel Rail 2.Fuel Injector 3.Fuel Feeding Port
Fuel injector
This system adopts head supplying single hole Fuel injector, and fuel injection pressure is
3.5bar. Fuel injected from fuel injector keeps in atomization and comes into cone angle (15
degree to injection nozzle axis).
Control logic of Fuel injector is phase, order 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
Specification:
Voltage: 12V
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
ENGINE ELECTRONIC SYSTEM
ACTUATORS G-7
G-1
INPUT / OUTPUT COMPONENTS OF CONTROL SYSTEM
19
18
Diagnostic
connector
G-2
WORKING MODULE TABLE FOR FUEL INJECTION / IGNITION
SYSTEM
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
WORKING PRINCIPLE
This system is capable of controlling the actual tested air-fuel ratio under all engine speeds to
stay close to the equivalent proportion of the chemical reaction, so as to protect the catalyst
package and subsequently reduce the discharge of pollution. The oxygen sensor analyses the
oxygen content of the discharge gas using real-time principle and makes it possible for the
ECU to control the amount of injecting fuel to correct the air-fuel ratio. The fuel with a
pressure of about 3.5 bars is directly injected into the air intake manifold near the throttle
valve.
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
ELECTRONIC CONTROL UNIT
The ECU is located on the left of engine firewall. The ECU handles various signals from the
sensors and controls the actuator so as to achieve the best possible operating condition. Many
extra functions are added as compared with the previous model. While by the usage of a
custom-made circuit board that can achieve many special functions, the integrated functions
are enhanced so that the structure has considerably reduced in size and become much more
compact.
The hard wares in the ECU are as follows:
-16 bit CPU single chip
- 8KB RAM (2KB IRAM + 6KB ERAM)
- 2MB FLASH EPROM (12V programming voltage)
- 2KB SERIAL EEPROM
- 16 CHANNELS 10 MODULES/NO. (A/D) CONVERTER
- 4PWM OUTPUT
- CAN MODULE (CAN2.0B)
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
- Engine coolant temperature
- Air conditioning operation
- Signal from oxygen sensor
- Knock sensor for the accelerator meter on top of the engine crankshaft housing
The air intake efficiency is obtained by calculating through the processing of absolute
pressure, air intake temperature, engine speed, throttle valve position and other signals, and
help to determine the air intake quantity of the cylinder. 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
WORKING PRINCIPLE OF ELECTRONIC FUEL INJECTION
CONTROL AND ACTUATORS
Intake Pressure and Intake Air Temperature
Sensor
Purpose: detects manifold absolute pressure from
0.1~0.2bar and intake air temperature, provides engine
with load information.
Composition and principle: this sensor is composed
of two different sensors (i.e. manifold absolute
pressure sensor and intake temperature sensor), and is
installed above pressurizer.
Pressure-sensitive element inside intake pressure
sensor detects pressure signal on intake manifold for
injection pulse width control of EFI system. This
sensor also serves as the substitute of load signal
sensor.
TMAP
Intake air temperature sensing element is a resistor
of negative temperature coefficient (NTC), which is
similar to water temperature sensor with resistance
value decreasing with the increasing of intake air
temperature. And engine ECU monitors the variation
of intake air temperature via a comparison circuit
inside.
G-7
Troubleshooting: mainly check if there is short circuit
or open circuit on the connection between 4 lines on
sensor and ECU.
If there is short circuit, open circuit or grounding
between sensor wire harnesses.
G-8
Pins:
1 sensor signal ground (ECU17#)
2 5V power (ECU32#)
3 sensor signal (ECU16#)
G-9
Hints: the vehicle is equipped with 2 water
temperature sensors, one is single-pin water
temperature sensor, providing the water temperature
gauge with water temperature signal; the other is
double-pin, providing the engine ECU with water
temperature signal.
Pins: this sensor has 3 pins, which can interchange for
use.
1 coolant temperature sensor signal (ECU 39#)
2 sensor signal ground (ECU 35#)
3 another line connects water temperature signal of
gauge.
Troubleshooting: mainly check if there is short circuit
or open circuit on the connection between 3 lines,
ECU and gauge on sensor.
If there is short circuit, open circuit or grounding
between sensor wire harnesses.
Line grounding or defect grounding is liable to cause
engine water temperature gauge to indicate excessive
temperature.
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
value, failure mark restores.
Installation hint: tightening torque is 205Nm.
Pins:
1 Knock sensor signal 1 (ECU19#)
2 Knock sensor signal 2 (ECU20#)
Troubleshooting: mainly check if there is short circuit
or open circuit on the connection between 2 lines on
sensor and corresponding ECU pins.
If gasket is added during installation; if tightening
torque is proper.
If there is stitching defect between sensor and cylinder,
or there is foreign matter between them.
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
Manifold absolute pressure signal is unreliable
Engine coolant temperature signal is unreliable.
Injector driver stage failure
After oxygen sensor failure mark is set, fuel
quantification closed-loop control is shut down, and
the primitive fuel injection time stored in ECU is used
to carry out fuel quantification.
Interior structure of oxygen sensor
G-12
Installation: to be fixed by the support of bracket
under pilot trench of front windshield. Pay attention to
waterproofing.
Functions:
Multipoint sequential injection
Controlling ignition
Idle speed control
Independent knocking control on cylinder-by-cylinder
basis (knock sensor KS-1);
Providing sensors with power supply: 5V/100mA
Adopting cylinder-detecting signal (Phase sensor PG1)
closed-loop control with self-adaptation
Controlling carbon canister control valve
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
Fuel injector 4 (the 2nd Fuel injector 3 (the 4th
6 Output 47 Output
cylinder) cylinder)
Fuel injector 2 (the 3rd
7 Output 48
cylinder)
Output of engine speed
8 Output 49
signal
9 50 Control of low speed fan Output
10 51 Electronic ground 2 Ground
11 52
12 Sustained power supply Input 53 Electronic ground 1 Ground
13 Ignition switch Input 54
14 The main relay Output 55
15 Engine rotary sensor A Input 56
16 Throttle position sensor Input 57 A/C compressor switch Input
17 Sensor ground 1 Ground 58
18 Oxygen sensor Input 59 Speed signal Input
19 Knock sensor A Input 60
20 Knock sensor B Input 61 Power ground 1 Ground
Non-sustained power
22 63 Input
supply
Phase angle sensor D of
23 64 Output
step motor
Phase angle sensor A of
24 65 Output
step motor
Phase angle sensor B of
25 66 Output
step motor
Phase angle sensor C of
26 67 Output
step motor
Fuel injector 1 (1
27 Output 68 Control of high speed fan Output
cylinder)
28 69 Fuel pump relay Output
29 Inspection light Output 70 A/C compressor relay Output
30 71 Diagnostic K wire I/O
31 72
32 5V power supply 2 Output 73
33 5V power supply 1 Output 74
34 Engine rotary sensor B Input 75 A/C switch Input
35 Sensor ground 3 Ground 76 Blaster switch Input
Sensor ground connector
36 Ground 77 Headlight switch Input
2
Air intake pressure
37 Input 78
sensor
38 79 Phase angle sensor Input
Temperature sensor of Power ground connector
39 Input 80 Ground
engine coolant 2
Temperature sensor of
40 Input 81
air intake
41
G-14
Electrical fuel pump
Function: Supply the fuel from the fuel tank to the
engine at required pressure and flow (vary from
individual system).
G-15
Troubleshooting: The common malfunctions of the
fuel pump are representation of insufficient fuel
pressure, not pumping fuel and so on. It shall be
verified firstly in troubleshooting that the fuel pressure
is within rated range and the pipeline is leaked. In
addition both the positive and negative pressure of the
fuel tank will have impacts on the fuel system.
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
supply, short to ground or open, the malfunction flag
bit is set. The closed loop control of the oxygen sensor
and its memory precontrol are disabled, but the last
data stored in its memory is valid. After the
malfunction is fixed, the malfunction flag bit will be
reset.
Connected to the
Working pressure: 350 kPa 87# pin of the
Resistance of the fuel injector: 11-16 main relay
G-17
Structure and working principle: The step motor is a
micro-motor, which is comprised of steel stators
installed in a circle and a rotor. Each steel stator has a
coil. The rotor is permanent magnet and the center of
the magnet is a nut. All the coils of stators are always
on. If the current direction of any coil is changed, the
rotor will turn by an angle. If all coils of stators change
their currents directions in a proper order, a rotating
magnetic field will be generated and result in the
permanent magnet rotor rotating in designed direction.
Fault diagnosis: The ECU can detect the circuit short The step motor
and circuit open in the two coils of the idle step motor. of the idle actuator
Upon the occurrence of such malfunction the engine
malfunction alarm light will be lit and the engine will Circuit of the stepper of the idle
enter the malfunction operation mode.
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
coil resistance. The ignition coil produces quite a lot
heat under normal operation and the over temperature
of ignition coil will result in such malfunctions as Ignition coil with double spark
increase of the ignition coils resistance, unstable
operation of the engine and engine stall.
Primary winding: 0.47 ohms
Secondary winding: 8 ohms
Pins:
1# pin of the primary winding is connected to the 5# 87# main relay
pin of ECU;
2# pin of the primary winding is connected to the 2#
pin of ECU;
3# and 4# pins are jointly connected to the positive grid Circuit diagram of the ignition coil
of power supply.
High voltage side: 1#, 2#, 3# and 4# pins are
connected respectively to the spark plug of the cylinder
with the same number through the distributor circuit.
Troubleshooting: Verify that there is circuit short or
circuit open in the coils.
Verify that there is electrical leakage and crack on the
shell.
Verify that the electricity for ignition is not sufficient
due to coil ageing.
G-19
The ECU can indirectly control the purge airflow Carbon canister control valve
through controlling the charging time of the carbon
canister solenoid valve based on the signals provided
by various sensors of the engine.
Fault diagnosis: The ECU doesnt have the function of
self-diagnosis for the carbon canister control valve, but
has the function of self-diagnosis for the driving stage
of control valve of carbon canister. If the driving state
of the control valve of carbon canister is short or
overloaded to the battery voltage, short to ground or
open, the basic memory of the closed loop control of
fuel quantity will be closed, the memory of idling air
demand quantity will be closed and the memory data at Carbon canister control valve
that time is valid. The common malfunctions of engine
are unstable idling or excessive high idle speed under Circuit diagram of the solenoid valve
the malfunction of the solenoid valve of carbon of the charcoal canister TEV-2
canister.
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
BASIC PRINCIPLE OF FAULT DIAGNOSIS FOR ELECTRONIC
G-21
Illogical malfunction, there is signal but the signal is not logical.
LIMP DRIVE
If some detected important malfunctions last longer than the setting stabilizing time,
ECU will take proper software measures, for example, disable some control functions
including the oxygen sensor closed loop control and the like, replace some unreliable
data with the setting values and etc.. Therefore even the working condition of the
engine is quite bad at that time, but the car still can be driven. The objective of such
measures is to drive home or drive to service station limpingly so as to avoid the
embarrassment that the car has to be broken down on highway or in field. As soon as
the detected malfunction disappears, the normal data will be reused.
MALFUNCTION ALARM
Some cars equipped with M7.9.7 system have the malfunction alarm light. If some
important components such as ECU, the air intake manifold absolute pressure sensor,
the throttle position sensor, the coolant temperature sensor, the knock sensor, the
oxygen sensor, the phase angle sensor, the fuel injector, two drive stages of idle
actuator with step motor, the carbon canister control valve, the cooling fan relay have
malfunctions, when the corresponding malfunction flag bit is set, ECU will send
alarm through the malfunction alarm light until this malfunction flag bit is reset.
MALFUNCTION READOUT
The malfunction information record can be called from the electronic control unit
through the diagnostic tester, or be read through the flashing code. If the malfunction
is related to the function of fuel air mixing ratio regulator, the corresponding
malfunction information record can be read at least 4 minutes after the engine starts
running.
G-22
The detailed procedures are:
Turn on the ignition switch, but not start up the engine, ground the 7# pin of ECU by
K wire for more than 2.5 seconds, then open the ground connection, after that the
coding light starts flashing.
After the K wire is grounded for more than 2.5 seconds the output of flashing code is
the value of P-CODE. For example, the flashing method of P0203 is: consecutive
flashes of 10 times-pause-consecutive flashes of 2 times-pause,-consecutive flashes of
10 times-pause-consecutive flashes of 3 times.
CLEARING MALFUNCTION INFORMATION RECORD
After the malfunction is fixed, the malfunction information record in the memory
shall be cleared. Such malfunction information, which appeared at the time of ignition
but failed to be maintained to the end of stabilizing period, will not be recorded. If the
value Hz of frequency counter reaches 0, the malfunction information records in the
malfunction memory will be cleared automatically. The malfunction information
record will be cleared upon the demand of clearing the malfunction memory
through the diagnostic tester. The malfunction information records in the external
RAM can be cleared by disconnecting the connector of ECU or removing the wire of
the battery.
TROUBLESHOOTING:
WE ONLY CAN KNOW THE ROUGH POSITion of the malfunction whose
malfunction information record is obtained through the above measures, and it doesnt
mean that we have found out that malfunction exactly. Because any malfunction is
possibly caused by the damage of electric components (such as sensors, actuators or
ECU and the like), the circuit open, or the circuit short to ground or positive stud of
battery, even the mechanical malfunctions.
The malfunction is intrinsic and its appearance is various symptoms. After the
symptom is detected the diagnostic tester or the flashing code shall be used to search
the malfunction information record, and excluding corresponding malfunction based
on the malfunction information. And then carry out the troubleshooting based on the
symptom of the engine.
G-23
DETAILED TABLE OF DIAGNOSTIC TROUBLE CODES
Diagnostic trouble code: P0107 Undervoltage in circuit of air intake pressure
sensor
Item Inspection Follow-up
Operation procedure
No. results procedure
Connect the diagnostic tester and adaptor,
Proceed to next
1 and turn the ignition switch to ON
step.
position.
Observe the air intake pressure in data Yes Proceed to Step 5
flow and verify that it is maintained at
2 Proceed to next
101kPa (the exact value is determined by No
step.
the atmospheric pressure at that time).
Disconnect the connector of the air intake Yes Proceed to Step 5
pressure sensor on the wiring harness and
3 inspect with multimeter to verify that the Proceed to next
No
voltage between the 3# and 1# pins of the step.
connector is about 5V.
Repair or replace
Verify that the circuits between the 17#,
Yes the wiring
33# and 37# pins of ECU and the 1#, 3#,
4 harness.
and 4# pins of the sensor connector are
Proceed to next
short to ground. No
step.
Start up the engine, run at idle speed. Step Refer to diagnosis
on the accelerator pedal slowly until the Yes
help.
nearly full opening, observe the air intake
pressure displayed on the diagnostic
5 tester and verify that the value is stable
without significant change; if step on the Replace the
No
accelerator pedal quickly until nearly full sensor.
opening, whether the value exceeds 90kPa
instantaneously.
Start up the engine, run at idle speed. Refer to diagnosis
Yes
Observe the value of Coolant help.
temperature on the diagnostic tester to
6
verify that the indicated value is increased Replace the
No
along with the temperature increase of the sensor.
engine coolant.
G-24
Diagnostic trouble code: P0118Over temperature indicated by engine coolant
temperature sensor
Item Inspection
Operation procedure Follow-up procedure
No. results
Connect the diagnostic tester and
1 adaptor, and turn the ignition switch to Proceed to next step.
ON position.
Observe the coolant temperature in Yes Proceed to Step 6
data flow to verify that it matches to the
engine temperature (the exact value is
determined by the engine temperature at
2 that time).
No Proceed to next step.
Note: If the indicated value is
maintained at -40 at that time, there
may be some open malfunction occurs
in the circuit.
Disconnect the connector of the coolant
Yes Proceed to next step.
temperature sensor on the wiring
harness, inspect with multimeter to
3 verify that the resistance between 1#
and 2# pins of the sensor matches to the No Replace the sensor.
temperature (see the related part of this
maintenance manual for reference).
Disconnect the connector of the coolant Yes Proceed to Step 6
temperature sensor on the wiring
4 harness, inspect with multimeter to
No Proceed to next step.
verify that the voltage between 1# and
2# pins of this connector is about 5V.
Check whether the circuits between 39# Repair or replace the
Yes
and 35# pins of ECU and the 1# and 2# wiring harness.
5
pins of the sensor connector are short to
No Proceed to next step.
ground.
Start up the engine, run at idle speed. Refer to diagnosis
Yes
Observe the value of Coolant help.
temperature on the diagnostic tester to
6
verify that the indicated value is
No Replace the sensor.
increased along with the temperature
increase of the engine coolant.
G-25
Diagnostic trouble code: P0122 Undervoltage in circuit for throttle position
sensor
Item Inspection Follow-up
Operation procedure
No. results procedure
Connect the diagnostic tester and adaptor,
Proceed to next
1 and turn the ignition switch to ON
step.
position.
Observe the item of throttle absolute Proceed to next
Yes
opening in the data flow to verify that the step.
2 value is maintained within 4%-10% (the
exact value varies from individual auto No Proceed to Step5
model.)
Step on the accelerator pedal slowly until Proceed to next
Yes
full opening, observe the absolute step.
opening of throttle in data flow and verify
3 that the value is increased to 85%-95%
with the increasing of the accelerator pedal No Proceed to Step 5
opening (the exact value varies from
individual auto model).
Repeat the step 3, observe the absolute Yes Replace the sensor.
opening of throttle in data flow to verify
4 Proceed to next
that there is jump during the change of the No
step.
value.
Disconnect the connector of the throttle Repair and replace
Yes
position sensor on the wiring harness to the wiring harness.
verify that the circuits between 17#, 32#,
5
and 16# pins of ECU and 1#, 2#, and 3# Proceed to next
No
pins of the sensor connector are short to step.
ground.
Inspect with multimeter to verify that the Yes Replace the sensor.
6 voltage between 1# and 2# pins of this Refer to diagnosis
No
connector is about 5V. help.
G-26
Diagnostic trouble code: P0123 Overvoltage in circuit for throttle position
sensor
Item Inspection Follow-up
Operation procedure
No. results procedure
Connect the diagnostic tester and adaptor,
Proceed to next
1 and turn the ignition switch to ON
step.
position.
Observe the item of throttle absolute Proceed to next
Yes
opening in the data flow to verify that step.
2 the value is maintained within 4%-10%
(the exact value varies from individual No Proceed to Step5
auto model.)
Step on the accelerator pedal slowly until Proceed to next
Yes
full opening, observe the absolute step.
opening of throttle in data flow and
3 verify that the value is increased to
85%-95% with the increasing of the No Proceed to Step5
accelerator pedal opening (the exact value
varies from individual auto model).
Repeat the step 3, observe the absolute Yes Replace the sensor.
opening of throttle in data flow to verify
4 Proceed to next
that there is jump during the change of No
step.
the value.
Disconnect the connector of the throttle Repair and replace
Yes
position sensor on the wiring harness to the wiring harness.
verify that the circuits between 17#, 32#,
5
and 16# pins of ECU and 1#, 2#, and 3# Proceed to next
No
pins of the sensor connector are open or step.
short to power supply.
Inspect with multimeter to verify that the Yes Replace the sensor.
6 voltage between 1# and 2# pins of this Refer to diagnosis
No
connector is about 5V. help.
G-27
Diagnostic trouble code: P0130 Malfunction in signal circuit of upstream
oxygen sensor
(Note: The following diagnostic procedures are applicable only under the
circumstances that the trouble code of P0135 does not appear simultaneously, in case
that such trouble code appears at the same time, overhaul shall be carried out based on
the following procedures after dealing with the malfunction of P0135 firstly.)
Item Inspection Follow-up
Operation procedure
No. results procedure
Connect the diagnostic tester and adaptor,
Proceed to next
1 and turn the ignition switch to ON
step.
position.
Start up the engine, run at idle speed until Refer to diagnosis
Yes
the temperature of coolant reaches the help.
normal value. Observe the value of
2 Oxygen sensor voltage on the diagnostic
Proceed to next
tester to verify that the indicated value is No
step.
changed quickly within the range of
100mV 900mV.
Verify that the circuits between 36# and Repair and replace
Yes
18# pins of ECU and A# (corresponding to the wiring harness.
grey connecting wire of the oxygen sensor)
3
and B# (corresponding to black connecting Proceed to next
No
wire of the oxygen sensor) pins of the step.
sensor connector are short to ground.
A. Verify that there is quite serious leakage Carry out service
in the air intake system; Yes based on the
B. Verify that there is blockage in the fuel diagnostic results.
injector;
C. Verify that the clearance of spark plug is
4 excessive large;
D. Verify that the resistance of distributor Refer to diagnosis
No
circuit is excessive large; help.
E. Verify that the air intake valve conduit is
worn out;
And etc.
G-28
Diagnostic trouble code: P0132 Overvoltage of circuit for upstream oxygen
sensor
(Note: the following diagnostic procedures are applicable only under the
circumstances that the trouble code of P0135 does not appear simultaneously, in case
that such trouble code appears at the same time overhaul shall be carried out based on
the following procedures after dealing with the malfunction of P0135 firstly.)
G-29
Diagnostic trouble code: P0134 Signal malfunction of upstream oxygen sensor
(Note: The following diagnostic procedures are applicable only under the
circumstances that the trouble code of P0135 does not appear simultaneously, in case
that such trouble code appears at the same time, overhaul shall be carried out based on
the following procedures after dealing with the malfunction of P0135 firstly.)
G-30
Diagnostic trouble code: P0135 Malfunction in heating circuit of upstream
oxygen sensor
Item Inspection Follow-up
Operation procedure
No. results procedure
Connect the diagnostic tester and adaptor,
Proceed to next
1 and turn the ignition switch to ON
step.
position.
Disconnect the connector of the oxygen Proceed to next
Yes
sensor on the wiring harness and inspect step.
with multimeter to verify that the voltage
between C# (corresponding to the white
2
connecting wire of the oxygen sensor)
No Proceed to Step4
and D# (corresponding to the white
connecting wire of the oxygen sensor)
pins of this connector is about 12V.
Inspect with multimeter to verify that the Proceed to next
Yes
resistance between C# (white) and D# step.
3
(white) pins of the oxygen sensor is
No Replace the sensor.
within 1~6 under 20.
Yes Replace the fuse.
Verify that the 8A fuse in heating circuit
4 Proceed to next
of the oxygen sensor is burn out. No
step.
Verify that the circuits between 1# pin of Repair and replace
Yes
ECU, 87# pin of the main relay and C# the wiring harness.
(corresponding to white connecting wire
5 of the oxygen sensor) and D#
Refer to diagnosis
(corresponding to white connecting wire No
help.
of the oxygen sensor) are open or short to
ground or power supply.
G-31
Diagnostic trouble code: P0171 Self adapting of closed loop control for air fuel
ratio exceeding the upper limit
(Note: the following diagnostic procedures are applicable only under the
circumstances that the trouble codes of intake air pressure sensor, carbon canister
control valve, oxygen sensor and so on do not appear simultaneously, in case that such
trouble codes appear at same time, overhaul shall be carried out based on the
following procedures after dealing with other malfunctions firstly.)
Item Inspection Follow-up
Operation procedure
No. results procedure
Connect the diagnostic tester and adaptor,
Proceed to next
1 and turn the ignition switch to ON
step.
position.
Start up the engine, run at idle speed until Proceed to next
Yes
the temperature of coolant reaches the step.
normal value.
Under the full load working condition,
observe the value of Oxygen sensor
2
voltage on the diagnostic tester to verify Refer to diagnosis
No
that the indicated value is maintained at help.
100 mV without significant change for
long time under certain working
conditions.
Connect the fuel pressure gauge to the Proceed to next
Yes
feeding pipe of fuel supply system to step.
3 observe whether the fuel pressure is
Check and repair
maintained at 350kPa under full load No
the fuel system.
working condition.
Verify that the circuits between 36# and Repair and replace
Yes
18# pins of ECU and A# (corresponding to the wiring harness.
the grey connecting wire of oxygen sensor)
4
and B# (corresponding to the black Proceed to next
No
connecting wire of oxygen sensor) pins of step.
the sensor connector are short to ground.
A. Verify that there is quite serious leakage
in the air intake system;
B. Verify that there is blockage in the fuel
injector;
Carry out service
C. Verify that the clearance of spark plug is
5 Yes based on the
excessive large;
diagnostic results.
D. Verify that the resistance of distributor
circuit is excessive large;
E. Verify that the valve clearance is
excessive large; and etc.
G-32
Diagnostic trouble code: P0172 Self adapting of closed loop control for air fuel
ratio exceeding the lower limit
(Note: The following diagnostic procedures are applicable only under the
circumstances that the trouble codes of intake air pressure sensor, carbon canister
control valve, oxygen sensor and so on do not appear simultaneously, in case that such
trouble codes appear at same time, overhaul shall be carried out based on the
following procedures after dealing with other malfunctions firstly.)
Item Inspection Follow-up
Operation procedure
No. results procedure
Connect the diagnostic tester and adaptor,
Proceed to next
1 and turn the ignition switch to ON
step.
position.
Start up the engine, run at idle speed until Proceed to next
Yes
the temperature of coolant reaches the step.
normal value.
Under the full load working condition
2 observe the value of Oxygen sensor
Refer to diagnosis
voltage to verify that the indicated value No
help.
is maintained at 900 mV without
significant change for long time under
certain working conditions.
Connect the fuel pressure gauge to the Proceed to next
Yes
feeding pipe of fuel supply system to step.
3 observe whether the fuel pressure is
Check and repair
maintained at 350kPa under full load No
the fuel system.
working condition.
Verify that the circuits between 36# and Repair and replace
Yes
18# pins of ECU and A# (corresponding the wiring harness.
to the grey connecting wire of oxygen
4
sensor) and B# (corresponding to the Proceed to next
No
black connecting wire of oxygen sensor) step.
are short to power supply.
A. Verify that there is leakage in the fuel Carry out service
injector; Yes based on the
B. Whether there is air leakage in diagnostic results.
exhaust pipe;
C. Whether the ignition timing is correct;
5
D. Whether the air intake valve conduit
Refer to diagnosis
is worn out; No
help.
E. Whether the valve clearance is
excessive small;
And etc.
G-33
Diagnostic trouble code: P0201 Circuit malfunction of the 1 cylinder fuel
injector
Item Inspection
Operation procedure Follow-up procedure
No. results
Connect the diagnostic tester and adaptor,
1 and turn the ignition switch to ON Proceed to next step.
position.
Disconnect the connector of the 1 Yes Proceed to Step 4
cylinder fuel injector on the wiring
harness, and inspect with multimeter to
2
verify that the voltage between 1# pin of No Proceed to next step.
this connector and the negative grid of
power supply is about 12V.
Verify that the circuit between 1# pin of Repair or replace the
Yes
the connector of the 1 cylinder fuel wiring harness.
3
injector and the main relay is open, or
No Proceed to next step.
short to ground.
Inspect with multimeter to verify that the Yes Proceed to next step.
resistance between 1# and 2# pins of the
4 Replace the fuel
1 cylinder fuel injector is within 11~16 No
injector.
under 20.
Inspect with multimeter to verify that the Refer to diagnosis
Yes
voltage between the connector of the 1 help.
5 cylinder fuel injector (2# pin) and the
negative grid of power supply is about No Proceed to next step.
3.7V.
Verify that the circuit between the Repair and replace
Yes
connector of the 1 cylinder fuel injector the wiring harness.
6
(2# pin) and 27# pin of ECU is open or Refer to diagnosis
No
short to ground or power supply. help.
G-34
Diagnostic trouble code: P0202 Circuit malfunction of the double cylinder fuel
injector
Item Inspection Follow-up
Operation procedure
No. results procedure
Connect the diagnostic tester and adaptor,
Proceed to next
1 and turn the ignition switch to ON
step.
position.
Disconnect the connector of the double Yes Proceed to Step 4
cylinder fuel injector on the wiring
harness, and inspect with multimeter to
2 Proceed to next
verify that the voltage between 1# pin of No
step.
this connector and the negative grid of
power supply is about 12V.
Verify that the circuit between 1# pin of Repair and replace
Yes
the connector of the double cylinder fuel the wiring harness.
3
injector and the main relay is open, or Proceed to next
No
short to ground. step.
Inspect with multimeter to verify that the Proceed to next
Yes
resistance between 1# and 2# pins of the step.
4
double cylinder fuel injector is within Replace the fuel
No
11~16 under 20. injector.
Inspect with multimeter to verify that the Refer to diagnosis
Yes
voltage between the connector of the help.
5 double cylinder fuel injector (2# pin) and
Proceed to next
the negative grid of power supply is about No
step.
3.7V.
Verify that the circuit between the Repair or replace
Yes
connector of the double cylinder fuel the wiring harness.
6
injector (2# pin) and 6# pin of ECU is Refer to diagnosis
No
open or short to ground or power supply. help.
G-35
Diagnostic trouble code: P0203 Circuit malfunction of the triple cylinder fuel
injector
Item Inspection Follow-up
Operation procedure
No. results procedure
Connect the diagnostic tester and adaptor,
Proceed to next
1 and turn the ignition switch to ON
step.
position.
Disconnect the connector of the triple Yes Proceed to Step 4
cylinder fuel injector on the wiring
harness, and inspect with multimeter to
2 Proceed to next
verify that the voltage between 1# pin of No
step.
this connector and the negative grid of
power supply is about 12V.
Verify that the circuit between 1# pin of Repair or replace
Yes
the connector of the triple cylinder fuel the wiring harness.
3
injector and the main relay is open or Proceed to next
No
short to ground. step.
Inspect with multimeter to verify that the Proceed to next
Yes
resistance between 1# and 2# pins of the step.
4
triple cylinder fuel injector is within Replace the fuel
No
11~16 under 20. injector.
Inspect with multimeter to verify that the Refer to diagnosis
Yes
voltage between the connector of the help.
5 triple cylinder fuel injector (2# pin) and
Proceed to next
the negative grid of power supply is about No
step.
3.7V.
Verify that the circuit between the Repair or replace
Yes
connector of the triple cylinder fuel the wiring harness.
6
injector (2# pin) and 7# pin of ECU is Refer to diagnosis
No
open or short to ground or power supply. help.
G-36
Diagnostic trouble code: P0204 Circuit malfunction of the 4 cylinder fuel
injector
Item Inspection Follow-up
Operation procedure
No. results procedure
Connect the diagnostic tester and adaptor,
Proceed to next
1 and turn the ignition switch to ON
step.
position.
Disconnect the connector of the 4 Yes Proceed to Step 4
cylinder fuel injector on the wiring
harness, and inspect with multimeter to
2 Proceed to next
verify that the voltage between 1# pin of No
step.
this connector and the negative grid of
power supply is about 12V.
Verify that the circuit between 1# pin of Repair or replace
Yes
the connector of the 4 cylinder fuel the wiring harness.
3
injector and the main relay is open or Proceed to next
No
short to ground. step.
Inspect with multimeter to verify that the Proceed to next
Yes
resistance between 1# and 2# pins of the step.
4
4 cylinder fuel injector is within 11~16 Replace the fuel
No
under 20. injector.
Inspect with multimeter to verify that the Refer to diagnosis
Yes
voltage between the connector of the 4 help.
5 cylinder fuel injector (2# pin) and the
Proceed to next
negative grid of power supply is about No
step.
3.7V.
Verify that the circuit between the Repair or replace
Yes
connector of the 4 cylinder fuel injector the wiring harness.
6
(2# pin) and 47# pin of ECU is open or Refer to diagnosis
No
short to ground or power supply. help.
G-37
Diagnostic trouble code: P0230 Malfunction in control circuit of fuel pump
Item Inspection Follow-up
Operation procedure
No. results procedure
Connect the diagnostic tester and adaptor,
Proceed to next
1 and turn the ignition switch to OFF
step.
position.
Pull out the relay of fuel pump, turn the
Yes Proceed to Step4
ignition switch to ON position, and
verify that the voltage between the power
2 supply terminal of fuel pump relay (i.e.
Proceed to next
30# and 86# pin of the relay) and the No
step.
negative grid of power supply is about
12V.
Repair or replace
Verify that the power supply circuit of the Yes
3 the wiring harness.
relay is open or short to ground.
No Proceed to Step2
Inspect with multimeter to verify that the Replace the fuel
Yes
voltage between the control terminal of pump relay.
4 fuel pump relay (i.e. 85# pin of the relay)
Proceed to next
and the negative grid of power supply is No
step.
about 3.7V.
Verify that the circuit between the control Repair or replace
Yes
terminal of the relay (i.e. 85# pin of the the wiring harness.
5
relay) and 69# pin of ECU is open or short Refer to diagnosis
No
to power supply or ground. help.
G-38
Diagnostic trouble code: P0325 Malfunction in circuit of knock sensor
Item Inspection Follow-up
Operation procedure
No. results procedure
Connect the diagnostic tester and adaptor,
Proceed to next
1 and turn the ignition switch to OFF
step.
position.
Disconnect the connector of knock sensor Proceed to next
Yes
on the wiring harness, inspect with step.
2 multimeter to verify that the resistance
between 1# pin and 2# pin of this sensor No Replace the sensor.
is higher than 1M.
Verify that the circuits between 1# and 2# Repair or replace
Yes
pin of the knock sensor connector and the wiring harness.
3
19# and 20# pins of ECU are open, or are Proceed to next
No
short to ground or power supply. step.
Replace the knock sensor complying with Refer to diagnosis
Yes
the operation instructions, trial run and help.
4 make the rotary speed of engine exceed Verify that it is a
2200 rpm. Verify that the diagnostic code No random
of P0325 appears again. malfunction.
G-39
Diagnostic trouble code: P0335 Signal malfunction of crankshaft position
sensor
Item Inspection
Operation procedure Follow-up procedure
No. results
Connect the diagnostic tester and
1 adaptor, and turn the ignition switch to Proceed to next step.
OFF position.
Disconnect the connector of rotary Yes Proceed to next step.
sensor on the wiring harness, inspect
with multimeter to verify that the
2
resistance between 2# pin and 3# pin of No Replace the sensor.
this rotary sensor is about 770~950
under 20.
Verify that the circuits between 2# and Repair or replace the
Yes
3# pin of the rotary sensor connector wiring harness.
3
and 34# and 15# pins of ECU are open,
No Proceed to next step.
or are short to ground or power supply.
Refer to diagnosis
Yes
Verify that the signal panel of flywheel help.
4
is in good condition. Replace the signal
No
panel.
G-40
Diagnostic trouble code: P0336 Malfunction of improper signal of crankshaft
position sensor
Item Inspection
Operation procedure Follow-up procedure
No. results
Connect the diagnostic tester and
1 adaptor, and turn the ignition switch to Proceed to next step.
OFF position.
Disconnect the connector of rotary Yes Proceed to next step.
sensor on the wiring harness, inspect
with multimeter to verify that the
2
resistance between 2# pin and 3# pin of No Replace the sensor.
this rotary sensor is about 770~950
under 20.
Verify that the circuits between 2# and Repair and replace
Yes
3# pin of the rotary sensor connector and the wiring harness.
3
34# and 15# pins of ECU are open, or are
No Proceed to next step.
short to ground or power supply.
Refer to diagnosis
Yes
Verify that the signal panel of flywheel is help.
4
in good condition. Replace the signal
No
panel.
G-41
Diagnostic trouble code: P0340 Malfunction of phase angle sensor signal
Item Inspection Follow-up
Operation procedure
No. results procedure
Connect the diagnostic tester and adaptor,
Proceed to next
1 and turn the ignition switch to ON
step.
position.
Disconnect the connector of phase angle
Yes Proceed to Step 4
sensor on the wiring harness, inspect with
2 multimeter to verify that the voltage
Proceed to next
between 1# pin and 3# pin of this phase No
step.
angle sensor connector is about 12V.
Verify that the circuit between 3# pin of Repair or replace
phase angle sensor and 87# pin of the main Yes the wiring
3 relay is open or short to ground; harness.
Verify that 1# pin of phase angle sensor is Proceed to next
No
grounded properly. step.
Verify that the voltage between 2# pin of Yes Proceed to Step 6
4 the phase angle sensor connector and the Proceed to next
No
negative grid of power supply is about 9.9V. step.
Repair or replace
Verify that the circuit between 2# pin of the
Yes the wiring
phase angle sensor connector and 79# pin of
5 harness.
ECU is open, or is short to ground or power
Proceed to next
supply. No
step.
Refer to diagnosis
Yes
Verify that the signal panel of camshaft is in help.
6
good condition. Replace the signal
No
panel.
G-42
Diagnostic trouble code: P0443 Malfunction in control circuit of drive stage of
carbon canister control valve
Item Inspection Follow-up
Operation procedure
No. results procedure
Connect the diagnostic tester and adaptor, and Proceed to next
1
turn the ignition switch to ON position. step.
Disconnect the connector of carbon canister Proceed to Step
Yes
control valve on the wiring harness, inspect 4
2 with multimeter to verify that the voltage
Proceed to next
between 1# pin of this connector and the No
step.
negative grid of power supply is about 12V.
Repair or
Verify that the power supply circuit of carbon Yes replace the
3 canister control valve is open or short to wiring harness.
ground. Proceed to Step
No
2
Inspect with multimeter to verify that the Proceed to next
Yes
resistance between 1# and 2# pins of carbon step.
4
canister control valve is within 22-30 under Replace the
No
20. control valve.
Inspect with multimeter to verify that the Refer to
Yes
voltage between 1# pin of carbon canister diagnosis help.
5
control valve connector and the negative grid Proceed to next
No
of power supply is about 3.7V. step.
Repair or
Verify that the circuit between 2# pin of Yes replace the
6 carbon canister control valve connector and wiring harness.
46# pin of ECU is open. Refer to
No
diagnosis help.
G-43
Diagnostic trouble code: P0444 Undervoltage in control circuit of drive stage of
carbon canister control valve
Item Inspection
Operation procedure Follow-up procedure
No. results
Connect the diagnostic tester and
1 adaptor, and turn the ignition switch to Proceed to next step.
ON position.
Disconnect the connector of carbon Yes Proceed to Step 4
canister control valve on the wiring
harness, inspect with multimeter to
2
verify that the voltage between 1# pin No Proceed to next step.
of this connector and the negative grid
of power supply is about 12V.
Verify that the power supply circuit of Repair or replace the
Yes
3 carbon canister control valve is open wiring harness.
or short to ground. No Proceed to Step 2
Inspect with multimeter to verify that Yes Proceed to next step.
the resistance between 1# and 2# pins
4 Replace the control
of carbon canister control valve is No
valve.
within 22-30 under 20.
Inspect with multimeter to verify that Refer to diagnosis
Yes
the voltage between 1# pin of carbon help.
5 canister control valve connector and
the negative grid of power supply is No Proceed to next step.
about 3.7V.
Verify that the circuit between 2# pin Repair or replace the
Yes
of carbon canister control valve wiring harness.
6
connector and 46# pin of ECU is short Refer to diagnosis
No
to ground. help.
G-44
Diagnostic trouble code: P0445 Overvoltage in control circuit of drive stage of
carbon canister control valve
Item Inspection
Operation procedure Follow-up procedure
No. results
Connect the diagnostic tester and
1 adaptor, and turn the ignition switch to Proceed to next step.
ON position.
Disconnect the connector of carbon Yes Proceed to Step 4
canister control valve on the wiring
harness, inspect with multimeter to
2
verify that the voltage between 1# pin No Proceed to next step.
of this connector and the negative grid
of power supply is about 12V.
Verify that the power supply circuit of Repair and replace the
Yes
3 carbon canister control valve is open or wiring harness.
short to ground. No Proceed to Step 2
Inspect with multimeter to verify that Yes Proceed to next step.
the resistance between 1# and 2# pins
4 Replace the control
of carbon canister control valve is No
valve.
within 22-30 under 20.
Inspect with multimeter to verify that Refer to diagnosis
Yes
the voltage between 1# pin of carbon help.
5 canister control valve connector and
the negative grid of power supply is No Proceed to next step.
about 3.7V.
Verify that the circuit between 2# pin Repair or replace the
Yes
of carbon canister control valve wiring harness.
6
connector and 46# pin of ECU is short Refer to diagnosis
No
to power supply. help.
G-45
Diagnostic trouble code: P0480 Malfunction in control circuit of relay of A/C
condenser fan A
Item Inspection
Operation procedure Follow-up procedure
No. results
Connect the diagnostic tester and
1 adaptor, and turn the ignition switch to Proceed to next step.
OFF position.
Pull out the relay of A/C condenser
Yes Proceed to Step 4
fan, turn the ignition switch to ON
position and verify that the voltage
2 between the power supply terminal of
the relay (i.e. 30# and 85# pins of the No Proceed to next step.
relay) and the negative grid of power
supply is about 12V.
Verify that the power supply circuit of Repair or replace the
Yes
3 the relay of A/C condenser fan is open wiring harness.
or short to ground. No Proceed to Step 2
Inspect with multimeter to verify that
Yes Replace the relay.
the voltage between the control
terminal of relay of A/C condenser fan
4
(i.e. 86# pin of the relay) and the
No Proceed to next step.
negative grid of power supply is about
3.7V.
Verify that the circuit between the Repair or replace the
Yes
control terminal of relay (i.e. 86# pin wiring harness.
5 of the relay) and 50# pin of ECU is
Refer to diagnosis
open, or is short to power supply or to No
help.
ground.
G-46
Diagnostic trouble code: P0481 Malfunction in control circuit of relay of A/C
condenser fan B
Item Inspection Follow-up
Operation procedure
No. results procedure
Connect the diagnostic tester and adaptor,
Proceed to next
1 and turn the ignition switch to OFF
step.
position.
Pull out the relay of A/C condenser fan,
Yes Proceed to Step 4
turn the ignition switch to ON position
and verify that the voltage between the
2 power supply terminal of the relay (i.e.
Proceed to next
30# and 85# pins of the relay) and the No
step.
negative grid of power supply is about
12V.
Verify that the power supply circuit of the Repair or replace
Yes
3 relay of A/C condenser fan is open or short the wiring harness.
to ground. No Proceed to Step 2
Inspect with multimeter to verify that the
Yes Replace the relay.
voltage between the control terminal of
4 relay of A/C condenser fan (i.e. 86# pin of
Proceed to next
the relay) and the negative grid of power No
step.
supply is about 3.7V.
Verify that the circuit between the control Repair or replace
Yes
terminal of relay (i.e. 86# pin of the relay) the wiring harness.
5
and 68# pin of ECU is open or is short to Refer to diagnosis
No
power supply or to ground. help.
G-47
Diagnostic trouble code: P0500 Malfunction of improper speed signal
Item Inspection Follow-up
Operation procedure
No. results procedure
Connect the diagnostic tester and adaptor,
Proceed to next
1 and turn the ignition switch to OFF
step.
position.
Check and service
For the vehicles equipped with ABS Yes
the ABS system.
2 system, verify that there is a diagnostic
Proceed to next
trouble code designed for ABS system. No
step.
Proceed to next
Yes
step.
Verify that the indicating needle of
3 Check and service
speedometer works properly.
No the instrument
circuit.
Proceed to next
Yes
Verify that the speed sensor works step.
4
properly. Replace the speed
No
sensor.
Verify that the circuit between the signal Repair or replace
Yes
cable of speed sensor and 59# pin of ECU the wiring harness.
5
is open, or is short to power supply or to Refer to diagnosis
No
ground. help.
G-48
Diagnostic trouble code: P0506 Idle speed lower than nominal idle speed
Item Inspection Follow-up
Operation procedure
No. results procedure
Connect the diagnostic tester and adaptor,
Proceed to next
1 and turn the ignition switch to OFF
step.
position.
Proceed to next
Yes
Verify that the adjusting screw of throttle, step.
2 accelerator pedal stay and working Carry out
condition of throttle are in good condition. No necessary
Overhaul.
Proceed to next
Yes
step.
Verify that the working condition of idle
3 Carry out
speed regulator is correct.
No necessary
Overhaul.
A. Verify that there is under pressure in the Carry out
fuel supplying system; Yes necessary
B. Verify that there is blockage in the fuel Overhaul.
4
injector;
Refer to diagnosis
C. Verify that there is blockage in the No
help.
exhaust system.
G-49
Diagnostic trouble code: P0507 Idle speed higher than nominal idle speed
Item Inspection Follow-up
Operation procedure
No. results procedure
Connect the diagnostic tester and adaptor,
Proceed to next
1 and turn the ignition switch to OFF
step.
position.
Proceed to next
Yes
Verify that the adjusting screw of throttle, step.
2 accelerator pedal stay and working Carry out
condition of throttle are in good condition. No necessary
Overhaul.
Proceed to next
Yes
step.
Verify that the working condition of idle
3 Carry out
speed regulator is correct.
No necessary
Overhaul.
A. Verify that there is air leakage in the Carry out
system; Yes necessary
B. Verify that there is leakage in the fuel Overhaul.
4
injector;
Refer to diagnosis
C. Verify that there is over pressure in the No
help.
fuel supplying system.
G-50
Diagnostic trouble code: P0508 Undervoltage in control circuit of idle speed
regulator
Item Inspection Follow-up
Operation procedure
No. results procedure
Connect the diagnostic tester and adaptor,
Proceed to next
1 and turn the ignition switch to ON
step
position.
Disconnect the connector of idle speed Proceed to next
Yes
regulator and inspect with multimeter to step
2 verify that the resistances between pin A
Replace the step
and D, pin B and C are 535.3 under No
motor.
20.
Verify that the circuits between pin A, B, Repair or replace
Yes
C, and D of idle speed regulator and 65#, the wiring harness.
3
66#, 67#, and 64# pin of ECU are short to Refer to diagnosis
No
ground. help.
G-51
Diagnostic trouble code: P0509 Overvoltage in control circuit of idle speed
regulator
Item Inspection
Operation procedure Follow-up procedure
No. results
Connect the diagnostic tester and
1 adaptor, and turn the ignition switch to Proceed to next step
ON position.
Disconnect the connector of idle speed Yes Proceed to next step
regulator and inspect with multimeter to
2 verify that the resistances between pin A Replace the step
and D, pin B and C are 535.3 under No
motor.
20.
Verify that the circuits between pin A, B, Repair or replace the
Yes
C, and D of idle speed regulator and 65#, wiring harness.
3
66#, 67#, and 64# pin of ECU are short Refer to diagnosis
No
to power supply. help.
G-52
Diagnostic trouble code: P0511 Malfunction in control circuit of idle speed
regulator
Item Inspection
Operation procedure Follow-up procedure
No. results
Connect the diagnostic tester and
1 adaptor, and turn the ignition switch to Proceed to next step.
ON position.
Disconnect the connector of idle speed Yes Proceed to next step.
regulator and inspect with multimeter to
2 verify that the resistances between pin A Replace the step
and D, pin B and C are 535.3 under No
motor.
20.
Repair or replace the
Verify that the circuits between pin A, B, Yes
wiring harness.
3 C, and D of idle speed regulator and 65#,
Refer to diagnosis
66#, 67#, and 64# pin of ECU are open. No
help.
G-53
Diagnostic trouble code: P0560 Improper voltage signal of system
Item Inspection Follow-up
Operation procedure
No. results procedure
Connect the diagnostic tester and adaptor,
Proceed to next
1 and turn the ignition switch to OFF
step
position.
Proceed to next
Inspect with multimeter to verify that the Yes
2 step.
voltage of battery is about 12V.
No Replace the battery.
Verify that the resistances between the Repair or replace
Yes
44#, 45#, and 63# pins of ECU and 87# the wiring harness.
3
pin of the main relay are open or short to Proceed to next
No
ground. step
Start up the engine, and verify that the Proceed to next
Yes
charging voltage of generator is step
4
maintained within 9-16V under different Replace the
No
speeds. generator.
Refer to diagnosis
Yes
Verify that the earth point of engine help.
5
wiring harness is correct. Repair or replace
No
the wiring harness.
G-54
Diagnostic trouble code: P0562 Undervoltage of system
Item Inspection
Operation procedure Follow-up procedure
No. results
Connect the diagnostic tester and
1 adaptor, and turn the ignition switch to Proceed to next step
OFF position.
Inspect with multimeter to verify that Yes Proceed to next step.
2
the voltage of battery is about 12V. No Replace the battery.
Verify that the resistances between the Repair or replace the
Yes
3 44#, 45#, and 63# pins of ECU and 87# wiring harness.
pin of the main relay are excessive. No Proceed to next step
Start up the engine, and verify that the Yes Proceed to next step
charging voltage of generator is
4 Replace the
maintained within 9-16V under different No
generator.
speeds.
Refer to diagnosis
Yes
Verify that the earth point of engine help.
5
wiring harness is correct. Repair or replace the
No
wiring harness.
G-55
Diagnostic trouble code: P0563 Overvoltage of system
Item Inspection Follow-up
Operation procedure
No. results procedure
Connect the diagnostic tester and adaptor
Proceed to next
1 and turn the ignition switch to OFF
step
position.
Proceed to next
Yes
Inspect with multimeter to verify that the step
2
voltage of battery is about 12V. Replace the
No
battery.
Proceed to next
Start up the engine, and verify that the Yes
step
3 charging voltage of generator is maintained
Replace the
within 9-16V under different speeds. No
generator.
Refer to diagnosis
Yes
Verify that the earth point of engine wiring help.
4
harness is correct. Repair or replace
No
the wiring harness.
G-56
Diagnostic trouble code: P0601 Malfunction of non-programmed check code in
electronic control unit
Item Inspection Follow-up
Operation procedure
No. results procedure
Connect the diagnostic tester and adaptor
Proceed to next
1 and turn the ignition switch to ON
step
position.
Clear the diagnostic trouble code and Proceed to next
Yes
2 reconfirm that this malfunction is a steady step
state malfunction. No Normal operation
3 Replace ECU. End
G-57
Diagnostic trouble code: P0645 Malfunction in control circuit of A/C
compressor relay
Item Inspection Follow-up
Operation procedure
No. results procedure
Connect the diagnostic tester and adaptor
Proceed to next
1 and turn the ignition switch to OFF
step
position.
Pull out the A/C compressor relay, turn the
Yes Proceed to step 4
ignition switch to ON position and check
if the voltage between the power supply
2
terminal of relay (i.e. 30# and 85# pins of Proceed to next
No
the relay) and the negative grid of power step
supply is about 12V.
Repair or replace
Check if the power supply circuit of relay is Yes the wiring
3
open or short to ground. harness.
No Proceed to Step 2
Inspect with multimeter to check if the Yes Replace the relay.
voltage between the control terminal of A/C
4 compressor relay (i.e. 86# pin of the relay) Proceed to next
No
and the negative grid of power supply is step
about 3.7V.
Repair or replace
Check if the circuit between the control
Yes the wiring
terminal of A/C compressor relay (i.e. 86#
5 harness.
pin of the relay) and 70# pin of ECU is
Refer to
open. No
diagnosis help.
G-58
Diagnostic trouble code: P0646 Undervoltage in control circuit of A/C
compressor relay
Item Inspection Follow-up
Operation procedure
No. results procedure
Connect the diagnostic tester and adaptor
1 and turn the ignition switch to OFF Proceed to next step
position.
Pull out the A/C compressor relay, turn
Yes Proceed to Step 4
the ignition switch to ON position and
check if the voltage between the power
2
supply terminal of relay (i.e. 30# and 85#
No Proceed to next step
pins of the relay) and the negative grid of
power supply is about 12V.
Repair or replace
Check if the power supply circuit of relay Yes
3 the wiring harness.
is open or short to ground.
No Proceed to Step 2
Inspect with multimeter to check if the Yes Replace the relay.
voltage between the control terminal of
4 A/C compressor relay (i.e. 86# pin of the
No Proceed to next step
relay) and the negative grid of power
supply is about 3.7V.
Check if the circuit between the control Repair or replace
Yes
terminal of A/C compressor relay (i.e. 86# the wiring harness.
5
pin of the relay) and 70# pin of ECU is Refer to diagnosis
No
short to ground. help.
G-59
Diagnostic trouble code: P0647 Overvoltage in control circuit of A/C
compressor relay
Item Inspection Follow-up
Operation procedure
No. results procedure
Connect the diagnostic tester and adaptor
1 and turn the ignition switch to OFF Proceed to next step
position.
Pull out the A/C relay, turn the ignition
Yes Proceed to Step 4
switch to ON position and check if the
voltage between the power supply
2
terminal of relay (i.e. 30# and 85# pins of Proceed to next
No
the relay) and the negative grid of power step.
supply is about 12V.
Repair or replace
Check if the power supply circuit of relay Yes
3 the wiring harness
is open or short to ground.
No Proceed to Step 2
Inspect with multimeter to check if the Yes Replace the relay
voltage between the control terminal of
4 A/C compressor relay (i.e. 86# pin of the
No Proceed to next step
relay) and the negative grid of power
supply is about 3.7V.
Check if the circuit between the control Repair or replace
Yes
terminal of A/C compressor relay (i.e. the wiring harness
5
86# pin of the relay) and 70# pin of ECU Refer to diagnosis
No
is short to supply. help
G-60
Diagnostic trouble code: P1651 Malfunction in control circuit of malfunction
alarm light
Item Inspection
Operation procedure Follow-up procedure
No. results
Connect diagnostic tester and adaptor,
1 and turn the ignition switch to ON Proceed to next step
position.
Check the action of engine malfunction Yes Proceed to next step
alarm light by using the actuator
2 action testing" function of diagnostic
tester and observe whether the light is No Normal operation
always on or off.
Verify that the supply circuit of engine Repair or replace the
Yes
3 malfunction alarm light is open or short wiring harness.
to ground. No Proceed to next step
Check if the supply circuit between the Repair or replace the
Yes
control terminal pin of engine wiring harness.
4 malfunction alarm light and 29# pin of
Refer to diagnosis
ECU is open, or is short to ground or No
help.
power supply.
G-61
PROCEDURES FOR FAULT DIAGNOSIS ACCORDING TO THE
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
1) The engine is not running or running slowly during starting
Inspection
Item Operation procedure Follow-up procedure
results
Inspect with multimeter to see whether there Yes Proceed to next step
1 is a voltage of about 10-12.5V between two Repair or replace the
No
battery terminals. battery
Turn the ignition switch to ON position. Yes Proceed to next step.
Inspect with multimeter to see whether there
2 is a voltage of about 10-12.5V between the Repair the terminal
terminals connecting the ignition switch and No or replace the
the positive grid of the battery. conducting wire
Keep the ignition switch at the startup Yes Proceed to next step.
position and inspect with multimeter to see
whether that there is a voltage of more than
3 Repair or replace the
8V between the terminals connecting the No
ignition switch and the starting motor ignition switch
magnetic clutch.
Repair or replace the
Inspect with multimeter to see whether the Yes
4 starting motor
starting motor has any open or short-circuit.
No Proceed to next step.
Verify that the engine is jammed due to Yes Fix the malfunction
5
poor lubricating. No Proceed to next step.
In case of winter season, inspect to see Replace with
whether there is too much friction in the Yes appropriate
6 lubricating oil
starting motor due to the improper selection
of engine lubricating oil and gearbox oil. No Inspect other items
G-63
2) The engine can run but cannot successfully start up during starting
Item Inspection
Operation procedure Follow-up procedure
No. results
Turn the ignition switch to ON position. Fix the indicated
Yes
Inspect with the diagnostic tester to see malfunction
1
whether there is any malfunction information
No Proceed to next step.
record.
Disconnect the cylinder distribution wire and Yes Proceed to Step 8.
connect it to the spark plugs, make a space of
5-10mm between the grid of the spark plug
2
and engine body. Then turn on the engine No Proceed to next step.
with starting motor, verify that there is any
bluish-white high-voltage spark.
Yes Proceed to next step.
Verify that the resistance of the high voltage
3 Repair or replace high
cable is normal No
voltage cable
Verify that the cylinder-distribution high Yes Replace
4 voltage cable and spark plug have any
No Proceed to next step.
damage.
Verify that the cylinder identification rotor Yes Replace
5
ring in distributor is loose or damaged. No Proceed to next step.
Yes Proceed to next step.
6 Verify that the ignition coil is normal
No Replace
Yes Proceed to next step.
Verify that the plug in connector of the
7 Connect the connector
camshaft is properly connected. No
properly
Turn the ignition switch to ON position. Yes Proceed to next step.
8 Verify that the fuel pump relay and fuel Service the fuel pump
No
pump is functional. circuit
Connect it to the fuel manometer valve. Yes Proceed to next step.
Make the 30# and 87# pins of fuel pump
9 relay short so as to operate the fuel pump,
No Proceed to Step 13.
and then verify that the fuel pressure is
maintained at about 350kPa.
Pull out the fuel distributing pipe together Yes Proceed to Step 12.
with the fuel injector and disconnect the fuel
injector connectors on the wiring harness one
10
by one. Connect a 12V supply directly from No Proceed to next step.
the battery to the fuel injector and verify that
the fuel injector is functioning.
After washing and cleaning the fuel injector, Yes Proceed to next step.
11 verify that it is capable of injecting fuel Replace the fuel
No
again. injector
G-64
Verify that the fuel is deteriorated or Yes Replace the fuel
12
contaminated by water. No Proceed to Step 18.
Verify that the fuel pressure is lower than Yes Proceed to next step.
13
350kPa. No Proceed to Step 17.
Close the fuel manometer valve. Connect the Yes Proceed to next step.
ignition switch again to re-operate the fuel
14
pump in order to verify that the fuel pressure No Proceed to Step 16.
can be established.
Replace fuel and
Open the fuel manometer valve and clamp Yes
pressure regulator
the fuel return pipe with the fuel tube clamp
15 Repair or replace the
to stop the fuel return in order to verify that
No fuel injector or fuel
the fuel pressure can be established quickly.
pipe
Repair or replace the
Verify that the fuel inlet pipe has any Yes
16 fuel inlet pipe
leakage or blockage.
No Replace the fuel pump
Repair or replace the
Yes
Verify that the fuel return pipe has any fuel return pipe
17
leakage or bending. Replace the fuel
No
pressure regulator
Connect an adapter between ECU and the Yes Proceed to next step.
wiring harness. Then verify that there is any
voltage at the ECUs pin No.44, 45, 63, 12
and 13, and to see whether the positive
18 Repair or replace the
power supply wires connected to the above No
ECUs pins and the ground wires connected wiring harness.
to the pin No. 3, 51, 53, 61 and 80 are
normal.
Verify that the parts of air intake system Yes Repair
19
have any air leakage. No Proceed to next step.
Verify that the absolute pressure and Yes Repair or replace
20 temperature sensor of air intake manifold has
No Proceed to next step.
any blockage.
Verify that the coolant temperature sensor is Yes Proceed to next step.
21
normal. No Repair or replace
Verify that the unsuccessful startup is due to Fix the mechanical
Yes
mechanical reasons such as excessive malfunction
22
clearance between the piston and cylinder or
No Replace the ECU
due to cylinder air leakage, etc.
G-65
3) Difficult start-up of hot engine
G-66
Yes End
Replace the fuel and try the hot start again. No Replace the ECU
8
Observe whether it can successfully start up.
No Repair or replace
Verify that the fuel pipe has any blockage or Proceed to next
Yes
bending and to see whether the pressure step.
9
regulating valve functions of fuel pump is
No Repair or replace
normally.
Proceed to next
Yes
Inspect with multimeter to see whether there step.
10 is a voltage between two terminals of the Repair or replace
plug in connector of fuel pump. No fuel pump relay
and wire
Proceed to next
Yes
Inspect with multimeter to see whether the step.
11
resistance of fuel pump is correct. Replace the fuel
No
pump
Replace the fuel
Yes
12 Verify that the fuel pump is jammed. pump
No Replace the ECU
G-67
4) Difficult start-up under normal engine speed
Item Inspection
Operation procedure Follow-up procedure
No. results
Turn the ignition switch to ON Fix the indicated
Yes
position. Inspect with the diagnostic malfunction
1
tester to see whether there is any
No Proceed to next step.
malfunction information record.
Verify that the air filter is free of any Yes Proceed to next step.
2
blockage. No Replace
After start up, verify that the air intake Yes Proceed to next step.
3 manifold pressure is maintained between Fix the leakage of air
No
35-65 kPa at idle speed. intake system
Replace and inspect the
Step on the throttle gently and observe
4 Yes throttle valve and idle
whether its easy to start up.
speed passage
Connect the fuel manometer valve. Short Yes Proceed to next step.
the 30# and 87# pins of the fuel pump
5 relay to operate the fuel pump in order to
No Proceed to Step 9
verify that the fuel pressure is
maintained at about 350kPa.
Apply a voltage supply of 12V directly Yes Proceed to Step 8
between the battery and the fuel injector
6
with special connector, and verify that No Proceed to next step.
the fuel injector functions normally.
After washing and cleaning the fuel Yes Proceed to next step.
7 injector, verify that its function is Replace the fuel
No
normal. injector
Replace the fuel and verify that the fuel Yes Replace the fuel
8
is deteriorated or contaminated by water. No Proceed to Step 14
Verify that the fuel pressure is lower Yes Proceed to next step.
9
than 350kPa. No Proceed to Step 13
Close the fuel manometer valve. Yes Proceed to next step.
Connect the ignition switch again to
10 re-operate the fuel pump in order to
No Proceed to Step 12.
verify that the fuel pressure can be
established.
Open the fuel manometer valve and Replace fuel pressure
Yes
clamp the fuel return pipe with the fuel regulator
11 tube clamp to stop the fuel return in Repair or replace the
order to verify that the fuel pressure can No fuel injector or the fuel
be established quickly. pipe
Verify that the fuel inlet pipe has any Repair or replace the
12 Yes
leakage or blockage. fuel air inlet pipe
G-68
No Replace the fuel pump
Repair or replace the
Yes
Verify that the fuel return pipe has any fuel return pipe
13
leakage or bending. Replace the fuel
No
pressure regulator
Disconnect the connector of idle speed Yes Proceed to next step.
actuator before the temperature of
14 engine coolant reaches 350C in order to Repair or replace the
No
observe whether the engine speed is idle speed actuator
decreasing.
Turn the ignition switch to ON Yes Proceed to next step.
position. verify that the voltages at
Inspect the wiring
15 following ECU pins are normal: 13# is
No harness and plug in
at about 12V of battery voltage; 80# and
connector
61# are at zero.
Run the engine at idle speed; until the Yes Proceed to next step.
coolant temperature reaches normal
16 Adjust the ignition
value, then verify that the ignition No
advance angle
advance angle is normal.
Verify that the compression pressure of Yes Proceed to next step.
17
engine cylinder is normal. No Fix the malfunction
Verify that the absolute pressure and Yes Repair or replace
18 temperature sensor of air intake
No Proceed to next step.
manifold has any blockage.
Verify that the coolant temperature Yes Replace the ECU.
19
sensor is normal. No Repair or replace
G-69
5) Difficult start-up of cold engine
Item Inspection
Operation procedure Follow-up procedure
No. results
Turn the ignition switch to ON Fix the indicated
Yes
position. Inspect with the diagnostic malfunction
1
tester verify that there is any
No Proceed to next step.
malfunction information record.
Inspect with multimeter to see Yes Proceed to next step.
whether the coolant temperature
sensor is normal. (Or connect a
1.5K resistance in series with
ECUs pin of 39# and 35# to replace
2
the function of the coolant No Replace the sensor
temperature sensor to start up the
engine. If the engine can be started, it
indicates that the coolant temperature
sensor is abnormal.)
Turn the ignition switch to ON Yes Proceed to next step.
position and connect the adaptor
between ECU and the wiring harness.
3 Verify that the voltages at following Inspect the wiring harness
No
ECU pins are normal: 13# is at about and plug in connector
12V of battery voltage; 80# and 61#
are at zero.
Verify that the air filter is free of any Yes Proceed to next step.
4
blockage. No Replace
After start up, verify that the air Yes Proceed to next step.
intake manifold pressure is
5 Fix the leakage of air
maintained between 35-65 kPa at idle No
intake system.
speed.
Inspect the throttle valve
Step on the throttle gently to verify Yes
6 and idle speed passage.
that it is easy to be started up.
No Proceed to next step.
Disconnect the connector of idle Yes Proceed to next step.
speed actuator before the temperature
7 of engine coolant reaches 35 in Repair or replace the idle
No
order to observe whether the engine speed actuator
speed is decreasing.
8 Connect the fuel manometer valve Yes Proceed to next step.
(the connecting point will depend on
G-70
(the connecting point will depend on
the types of car models). Ground the
86# pin of the fuel pump relay
directly. Connect the ignition switch
No Proceed to Step 12
to operate the fuel pump relay and the
fuel pump in order to verify that the
fuel pressure is maintained at about
350kPa.
Provide a voltage supply of 12V with Yes Proceed to Step 11
special connector between the battery
9
and the fuel injector, and verify that No Proceed to next step.
the fuel injector functions normally.
After washing and cleaning the fuel Yes Proceed to next step.
10 injector, verify again that it can
No Replace the fuel injector
function normally.
Verify that the fuel is deteriorated or Yes Replace the fuel
11
contaminated with water. No Proceed to Step 17.
Verify that the fuel pressure is lower Yes Proceed to next step.
12
than 350kPa. No Proceed to Step 16.
Close the fuel manometer valve. Yes Proceed to next step.
Connect the ignition switch again to
13 re-operate the fuel pump in order to
No Proceed to Step 15
verify that the fuel pressure can be
established.
Open the fuel manometer valve and Replace the fuel pressure
Yes
clamp the fuel return pipe with the regulator.
14 fuel tube clamp to stop the fuel return
Repair or replace fuel
in order to verify that the fuel No
injector or fuel pipe
pressure can be established quickly.
Repair or replace the fuel
Verify that the fuel inlet pipe has any Yes
15 air inlet pipe
leakage or blockage.
No Replace the fuel pump
Repair or replace the fuel
Yes
Verify that the fuel return pipe has return pipe
16
any leakage or bending. Replace the fuel pressure
No
regulator
Verify that the pressure of engine Yes Proceed to next step.
17
cylinder is normal. No Fix the malfunction
Verify that the engine air intake Yes Repair
18
system has any leakage. No Proceed to next step.
Verify that the absolute pressure and Yes Repair or replace
19 temperature sensor of air intake
No Replace the ECU.
manifold have any blockages.
G-71
6) Unstable idle speed at all time
Turn the ignition switch to ON Fix the indicated
Yes
position. Inspect with the diagnostic malfunction
1
tester to see whether there is any
No Proceed to next step.
malfunction information record.
Verify that the EWD3 idle speed actuator Repair or replace idle
Yes
2 or idle speed actuator with step motor is speed actuator
jammed. No Proceed to next step.
Connect the ignition switch and verify Inspect the wiring
that the links between water temperature Yes harness and plug in
3
sensor, idle speed step motor and ECU connector
are properly connected. No Proceed to next step.
Run the engine at idle speed and cut off Yes Proceed to Step 8
the cylinders one by one in order to
4
observe whether the speed is decreasing No Proceed to next step.
or fluctuating.
Yes Proceed to next step.
Verify that the fuel injector of each
5 Inspect the fuel injector
cylinder functions normally. No
and the wiring harness
Verify that the resistance of each cylinder Yes Proceed to next step.
6
high voltage cable is normal. No Replace
Yes Replace
7 Verify that the ignition coil is damaged.
No Proceed to next step.
Yes Proceed to next step.
8 Verify that the spark plug is normal.
No Replace the spark plug
Connect the fuel manometer valve. Short Yes Proceed to next step.
the 30# and 87# pins of the fuel pump
9 relay to operate the fuel pump in order to
No Proceed to Step 13.
verify that the fuel pressure is being
maintained at about 350kPa.
Provide a voltage supply of 12V with Yes Proceed to Step 12.
special connector between the battery and
10
the fuel injector, and verify that the fuel No Proceed to next step.
injector functions normally.
After washing and cleaning the fuel Yes Proceed to next step.
11 injector, verify again that it can function
No Replace the fuel injector
normally.
Verify that the fuel is deteriorated or Yes Replace the fuel
12
contaminated with water. No Proceed to Step 18
Verify that the fuel pressure is lower than Yes Proceed to next step.
13
350kPa. No Proceed to Step 17.
14 Close the fuel manometer valve. Connect Yes Proceed to next step.
G-72
the ignition switch again to re-operate the
fuel pump in order to verify that the fuel No Proceed to Step 16.
pressure can be established.
Open the fuel manometer valve and Replace the fuel pressure
Yes
clamp the fuel return pipe with the fuel regulator
15 tube clamp to stop the fuel return in order
Repair or replace the fuel
to verify that the fuel pressure can be No
injector or fuel pipe
established quickly.
Repair or replace the fuel
Verify that the fuel inlet pipe has any Yes
16 air inlet pipe
leakage or blockage.
No Replace the fuel pump
Repair or replace the fuel
Yes
Verify that the fuel return pipe has any return pipe
17
leakage or bending. Replace the fuel pressure
No
regulator
Verify that the sensing holes of the Yes Clean
18 pressure and temperature sensor of air
No Proceed to next step.
intake manifold have any blockages.
Run the engine at idle speed. When the Yes Proceed to next step.
coolant temperature reaches the
temperature of activating the close- loop Inspect the oxygen
19
control, verify that oxygen sensor No sensor and the wiring
functions normally. (Fluctuating within harness
the range of 0-1V)
Verify that the engine air intake system Yes Fix the leakage
20 has any leakage. No Proceed to next step.
Verify that the pressure of engine Yes Proceed to next step.
21
cylinder is normal. No Fix the malfunction
Run the engine at idle speed until the Yes Replace the ECU.
coolant temperature reaches its normal
22
range in order to verify that the ignition No Inspect other items
advance angle is normal.
G-73
7) Unstable idle speed during engine warm-up
Turn the ignition switch to ON position. Fix the indicated
Yes
Inspect with the diagnostic tester to see malfunction
1
whether there is any malfunction information
No Proceed to next step.
record.
Yes Proceed to next step.
2 Verify that the air filter is free of any blockage.
No Replace
Run the engine at idle speed. Verify that the air Yes Proceed to next step.
3 intake manifold pressure is maintained Fix the leakage of air
between 35-65 kPa during warm-up. No
intake system
Shut down the engine. Turn on the ignition
Yes Proceed to next step.
switch and connect the adaptor between ECU
and the wiring harness. Verify that the voltages
4 at air intake temperature sensor, water
temperature sensor, and ECUs pins of 32# and No Service
33# (used as sensor power supply of 4.5-5V)
are normal.
Disconnect the connector of idle speed actuator Yes Proceed to next step.
5 before ending the engine warm-up and verify Replace the idle
that the engine speed is changed. No
speed actuator
Verify that the coolant temperature sensor is Yes Proceed to next step.
6
normal. No Replace
Run the engine at idle speed until the coolant Yes Replace the ECU.
temperature reaches its normal range in order
7
to verify that the ignition advance angle is No Inspect other items
normal.
G-74
8) Unstable idle speed or stall with load (A/C and etc.)
Turn the ignition switch to ON position. Fix the indicated
Yes
Inspect with the diagnostic tester to see malfunction
1
whether there is any malfunction
No Proceed to next step.
information record.
Turn on the A/C switch and connect the Yes Proceed to next step.
adaptor between ECU and the wiring
2 harness. Measure and see whether the Overhaul the A/C
ECUs A/C switch and pressure signal No
circuit.
have any signal input.
Verify that the pressure of A/C system, Yes Proceed to next step.
3 the magnetic clutch of compressor and
No Repair or replace.
A/C pump are normal.
Turn the ignition switch to ON position. Yes Proceed to next step.
Verify that the voltages at ECUs pins of
4 Inspect the control
65#, 64#, 67#, and 66# (output connected No
circuit.
to idle actuator) are normal.
Repair or replace the
Remove the step motor to verify that it is Yes
5 step motor.
jammed or runs unfreely.
No Proceed to next step.
Start up the engine and turn on the A/C. Yes Replace the ECU.
Inspect with the diagnostic tester through
the step amount of step motor to see
6 Replace the idle
whether the idle actuator functions No
actuator.
normally. (The normal step amount will
be provided otherwise)
G-75
9) Unstable idle speed after engine warm-up
Turn the ignition switch to ON position. Fix the indicated
Yes
Inspect with the diagnostic tester to see malfunction.
1
whether there is any malfunction
No Proceed to next step.
information record.
Turn the ignition switch to ON position Yes Proceed to next step.
and connect the adaptor between ECU and
the wiring harness. Verify that the
voltages at following ECUs pins such as
absolute pressure sensor output of air Repair or replace the
2
intake manifold, air intake temperature No wiring harness and
sensor output, coolant temperature sensor relevant parts.
output, oxygen sensor output and ECUs
output voltage connected to idle actuators
pin are normal.
Shut down the engine and verify that the Yes Proceed to next step.
3
air filter is free of any blockage. No Replace
Verify that the air intake manifold Yes Proceed to next step.
4 pressure is maintained between 35-65 kPa Fix the leakage of air
No
at idle speed. intake system
Connect the fuel manometer valve (the Yes Proceed to next step.
connecting points will depend on the types
of car models). Short the 30# and 87# pins
5
of the fuel pump relay to operate the fuel No Proceed to Step 9
pump in order to verify that the fuel
pressure is maintained at about 350kPa.
Provide a voltage supply of 12V with Yes Proceed to Step 8
special connector between the battery and
6
the fuel injector, and verify that the fuel No Proceed to next step.
injector is functioning normally.
After washing and cleaning the fuel Yes Replace
7 injector, inspect again to see whether it Replace the fuel
can function normally. No
injector.
Verify that the fuel is deteriorated or Yes Replace the fuel.
8
contaminated with water. No Proceed to Step 14.
Verify that the fuel pressure is lower than Yes Proceed to next step.
9
350kPa. No Proceed to Step 13.
Turn off the fuel manometer valve. Yes Proceed to next step.
Connect the ignition switch again to
10
re-operate the fuel pump in order to verify No Proceed to Step 12.
that the fuel pressure can be established.
Turn on the fuel manometer valve and Replace the fuel
11 Yes
clamp the fuel return pipe with the fuel pressure regulator.
G-76
tube clamp to stop the fuel return in order Repair or replace the
to verify that the fuel pressure can be No fuel injector or the fuel
established quickly. pipe.
Repair or replace the
Verify that the fuel inlet pipe has any Yes
12 fuel air inlet pipe.
leakage or blockage.
No Replace the fuel pump.
Repair or replace the
Yes
Verify that the fuel return pipe has any fuel return pipe.
13
leakage or bending. Replace the fuel
No
pressure regulator.
Run the engine at idle speed until the Yes Proceed to next step.
coolant temperature reaches its normal
14 Adjust the ignition
value in order to verify that the ignition No
advance angle.
advance angle is normal.
Replace the coolant
Disconnect the coolant temperature sensor Yes
15 temperature sensor.
to verify that the engine is normal.
No Proceed to next step.
Verify that the compression pressure of Yes Proceed to next step.
16
engine cylinder is normal. No Fix the malfunction.
Verify that the resistance of each cylinder Yes Proceed to next step.
17
high voltage cable is normal. No Replace
Verify that the ignition coil and high Yes Replace
18 voltage cable have any damage parts or
No Proceed to next step.
cracks.
Yes Replace the ECU.
19 Verify that the spark plug is normal.
No Replace the spark plug.
G-77
10) A/C system malfunction
Verify that there is enough refrigerant and Yes Proceed to next step.
1 the A/C belt, A/C clutch and pressure switch
No Fix the malfunction.
are in good condition.
Run the engine at idle speed and turn on the Fix the indicated
Yes
A/C switch. Inspect with the diagnostic malfunction.
2 tester to see whether there is any
malfunction with the A/C thermo-sensitive No Proceed to next step.
resistance.
Turn on the A/C switch and connect the Yes Proceed to next step.
adaptor between ECU and the wiring
3 harness. Measure and see whether the Inspect the wiring
No
ECUs A/C switch and A/C pressure have harness.
any signal input.
Replace the bulb or
If the car is controlled by low electrical Yes repair the wiring
4 level, verify that the A/C still functions harness.
when it is turned off.
No Proceed to next step.
Repair the A/C relay
Verify that there is any low level output
Yes and the wiring
5 from the ground terminal of A/C relay
harness.
solenoid coil in ECU.
No Replace the ECU.
G-78
11) Periodically instability (the memory has to be restored after ECUs
power-off)
Turn the ignition switch to ON position. Fix the indicated
Yes
Inspect with the diagnostic tester to see malfunction.
1
whether there is any malfunction
No Proceed to next step.
information record.
Verify that the air filter is free of any Yes Proceed to next step.
2
blockage. No Replace
Verify that the air intake pressure is Yes Proceed to next step.
3 maintained between 35-65 kPa at idle Overhaul air intake
No
speed. system and leakage.
Run the engine at idle speed and cut off Yes Proceed to Step 7
4 the cylinder one by one in order to verify
No Proceed to next step.
that the speed is decreased and fluctuated.
Turn the ignition switch to ON position
and connect the adaptor between ECU and Yes Proceed to next step.
the wiring harness. Verify that the
voltages at following ECUs pins
including absolute pressure sensor output
of air intake manifold, air intake
5
temperature sensor output, coolant
temperature sensor output, oxygen sensor Repair or replace the
No
output, electronic grounding, ignition wiring harness.
switch pin, and ECUs pins of 65#, 64#,
67#, and 66# (output connected to idle
actuator) are normal.
Run the engine at idle speed until the Yes Proceed to next step.
coolant temperature reaches its normal
6
value in order to verify that the ignition No Inspect other items.
advance angle is normal.
Verify that the sensing holes of air intake Yes Clean
7 manifold pressure sensor and air intake
temperature sensor have any blockage. No Proceed to next step.
Verify that the fuel is deteriorated or Yes Replace the fuel.
8
contaminated with water. No Proceed to next step.
Apply a voltage supply of 12V directly Yes Proceed to next step.
between the battery and the fuel injector Overhaul the fuel
9
with special connector, and verify that the No injector and relevant
fuel injector functions normally. wiring harness.
Verify that the resistance of each cylinder Yes Proceed to next step.
10
high voltage cable is normal. No Replace
11 Verify that the ignition coil and high Yes Replace
G-79
voltage cable have any damaged parts or
No Proceed to next step.
cracks.
Yes Replace the ECU.
12 Verify that the spark plug is normal.
No Replace the spark plug.
G-80
12) Too high idle speed (the memory has to be restored after ECUs power-off)
Turn the ignition switch to ON position. Fix the indicated
Yes
Inspect with the diagnostic tester to see malfunction.
1
whether there is any malfunction
No Proceed to next step.
information record.
Verify that the fastener connected to the Yes Adjust or replace.
2
accelerator pedal is jammed or too tight. No Proceed to next step.
Verify that the carbon canister control valve, Yes Repair or replace.
the fuel pressure regulator, the crankcase
3 forced ventilation vacuum pipe, the brake
No Proceed to next step.
system vacuum booster hose are assembled
well or damaged.
Run the engine at idle speed, shift at neutral Yes Proceed to next step.
4 position, and step on the brake pedal in order
No Proceed to Step 6
to verify that the idle speed is too high.
Repair or replace the
Clamp the vacuum booster hose to verify Yes
5 vacuum booster.
whether the idle speed is normal.
No Proceed to next step.
Clamp the crankcase forced ventilation Replace the PVC
Yes
6 vacuum pipe to verify whether the idle speed valve
is changed to normal. No Proceed to next step.
Replace the carbon
Clamp the carbon canister control valve hose
Yes canister control
7 to verify whether the idle speed is changed
valve.
to normal.
No Proceed to next step.
Verify that the idle actuator is inflexible or Yes Repair or replace.
8
jammed. No Proceed to next step.
Verify that there is any leakage at other Yes Repair or replace.
9
places of air inlet pipe. No Proceed to next step.
Yes Proceed to next step.
Verify that the seal ring of fuel injector is in
10 Replace the seal
good condition. No
ring.
Verify that the absolute pressure sensor of Yes Replace the ECU.
11 air intake manifold and air intake
No Replace the sensor.
temperature sensor are in proper conditions.
G-81
13) Malfunction to increase the speed or stall during acceleration
Turn the ignition switch to ON position. Fix the indicated
Yes
Inspect with the diagnostic tester to see malfunction.
1
whether there is any malfunction
No Proceed to next step.
information record.
Verify that the air filter is free of any Yes Proceed to next step.
2
blockage. No Replace
Yes Proceed to next step.
Run the engine at idle speed in order to Overhaul according to
3
verify that the idle speed is normal. No the idle speed
malfunction instruction
Verify that the air intake pressure is Yes Proceed to next step.
4 maintained between 35-65 kPa at idle
No Overhaul
speed.
Run the engine at idle speed until the Yes Proceed to next step.
coolant temperature reaches its normal
5 Adjust the ignition
value in order to verify that the ignition No
advance angle
advance angle is normal.
Connect the fuel manometer valve. Yes Proceed to next step.
Short the 30# and 87# pins of the fuel
6 pump relay to operate the fuel pump in
No Proceed to Step 10
order to verify that the fuel pressure is
being maintained at about 350kPa.
Apply a voltage supply of 12V directly Yes Proceed to Step 9
between the battery and the fuel injector
7
with special connector, and verify that the No Proceed to next step.
fuel injector functions normally.
After washing and cleaning the fuel Yes Proceed to next step.
8 injector, verify again that it can function Replace the fuel
No
normally. injector.
Verify that the fuel is deteriorated or Yes Replace the fuel.
9
contaminated with water. No Proceed to Step 15.
Verify that the fuel pressure is lower than Yes Proceed to next step.
10
250kPa. No Proceed to Step 14.
Turn off the fuel manometer valve. Yes Proceed to next step.
Connect the ignition switch again to
11
re-operate the fuel pump in order to verify No Proceed to Step 13.
that the fuel pressure can be established.
Turn on the fuel manometer valve and Replace the fuel
Yes
clamp the fuel return pipe with the fuel pressure regulator.
12 tube clamp to stop the fuel return in order Repair or replace the
to verify that the fuel pressure can be No fuel injector or the fuel
established quickly. pipe.
G-82
Repair or replace the
Verify that the fuel inlet pipe has any Yes
13 fuel air inlet pipe.
leakage or blockage.
No Replace the fuel pump.
Repair or replace the
Yes
Verify that the fuel return pipe has any fuel return pipe.
14
leakage or bending. Replace the fuel
No
pressure regulator.
Turn the ignition switch to ON position
Yes Proceed to next step.
and connect the adaptor between ECU and
the wiring harness. Verify that the
voltages at following pins of ECU
15 including signal output terminal and
Repair or replace the
grounding terminal of the throttle position No
wiring harness.
sensor, and pins of 32# and 33# (used as
sensors power supply of 4.5-5V) are
normal.
Verify that the ignition coil, the high Yes Replace the ECU.
16 voltage cable and the spark plug are Repair the relevant
No
normal. parts.
G-83
14) Slow respond during acceleration
Turn the ignition switch to ON position. Fix the indicated
Yes
Verify with diagnostic tester to see malfunction
1
whether there is any malfunction
No Proceed to next step.
information record.
Shut down the engine and verify that the Yes Proceed to next step.
2
air filter is free of any blockage. No Replace
Yes Proceed to next step.
Run the engine at idle speed in order to Overhaul according to
3
verify that the idle speed is normal. No the idle speed
malfunction instruction
Verify that the air inlet pipe pressure is Yes Proceed to next step.
4 being maintained between 35-65 kPa at
No Overhaul
idle speed.
Turn the ignition switch to ON position Yes Proceed to next step.
and connect the adaptor between ECU and
the wiring harness. Verify that the
voltages at following pins of ECU
5 including signal output terminal and Repair or replace the
grounding terminal of throttle position No
wiring harness
sensor, and pins of 32# and 33# (used as
sensor power supply of 4.5-5V) are
normal.
Operate the engine at idle speed and wait Yes Proceed to next step.
until the coolant temperature has reached
6
its normal value in order to verify that the No Inspect other items
ignition advance angle is normal.
Connect the fuel manometer valve. Short Yes Proceed to next step.
the 30# and 87# pins of the fuel pump
7 relay to operate the fuel pump in order to
verify that the fuel pressure is maintained No Proceed to Step 11.
at about 350kPa.
Apply a voltage supply of 12V directly Yes Proceed to Step 10.
between the battery and the fuel injector
8
with special connector and verify that the No Proceed to next step.
fuel injector functions normally.
After washing and cleaning the fuel Yes Proceed to next step.
9 injector, verify again to see whether it can Replace the fuel
No
function normally. injector.
Verify that the fuel is deteriorated or Yes Replace the fuel.
10
contaminated with water. No Proceed to Step 16.
Verify that the fuel pressure is lower than Yes Proceed to next step.
11
350kPa. No Proceed to Step 15.
G-84
Turn off the fuel manometer valve. Yes Proceed to next step.
Connect the ignition switch again to
12
re-operate the fuel pump in order to verify No Proceed to Step 14
that the fuel pressure can be established.
Turn on the fuel manometer valve and Replace the pressure
Yes
clamp the fuel return pipe with the fuel regulator.
13 tube clamp to stop the fuel return in order Repair or replace the
to verify that the fuel pressure can be No fuel injector or the fuel
established quickly. pipe.
Repair or replace the
Verify that the fuel inlet pipe has any Yes
14 fuel inlet pipe.
leakage or blockage.
No Replace the fuel pump.
Repair or replace the
Yes
Verify that the fuel return pipe has any fuel return pipe.
15
leakage or bending. Replace the fuel
No
pressure regulator.
Verify that the exhaust system and the Yes Replace or clean.
16 3-way catalytic converter have any
No Replace the ECU.
blockages.
G-85
15) Poor and weak performance during acceleration
Verify that there are any malfunctions such Yes Repair
as slipping of clutch, low pressure of tires,
1
delay in braking, and wrong size of tires or No Proceed to next step.
inaccurate four-wheel alignment.
Yes Proceed to next step.
2 Verify that the throttle can be fully opened. Replace or repair the
No
throttle
Turn the ignition switch to ON position. Fix the indicated
Yes
Inspect with the diagnostic tester to see malfunction
3
whether there is any malfunction
No Proceed to next step.
information record.
Run the engine at idle speed until the Yes Proceed to next step.
coolant temperature reaches its normal
4
range in order to verify that the ignition No Inspect other items.
advance angle is normal.
Turn the ignition switch to ON position
and connect the adaptor between ECU and Yes Proceed to next step.
the wiring harness. Verify that the voltages
at following pins of ECU including absolute
pressure sensor of air intake manifold,
throttle valve position sensor, air intake
5
temperature sensor, coolant temperature
Repair or replace the
sensor, oxygen grounding terminal and No
wiring harness.
signal output terminal, sensor signal
grounding terminal and pins of 32# and 33#
(used as sensor power supply of 4.5-5V) are
normal.
Verify that the air intake pressure is being Yes Proceed to next step.
6
maintained between 35-65 kPa at idle speed. No Overhaul
Connect the fuel manometer valve. Short the Yes Proceed to next step.
30# and 87# pins of the fuel pump relay to
7 operate the fuel pump in order to verify that
the fuel pressure is being maintained at No Proceed to Step 11.
about 350kPa.
Apply a voltage supply of 12V directly Yes Proceed to Step 10.
between the battery and the fuel injector
8
with special connector and verify that the No Proceed to next step.
fuel injector functions normally.
Yes Proceed to next step.
After washing and cleaning the fuel injector,
9 Replace the fuel
verify again that it can function normally. No
injector.
10 Verify that the fuel is deteriorated or Yes Replace the fuel.
G-86
contaminated with water. No Proceed to Step 16.
Verify that the fuel pressure is lower than Yes Proceed to next step.
11
350kPa. No Proceed to Step 15.
Turn off the fuel manometer valve. Connect Yes Proceed to next step.
the ignition switch again to re-operate the
12
fuel pump in order to verify that the fuel No Proceed to Step 14.
pressure can be established.
Turn on the fuel manometer valve and Replace the pressure
Yes
clamp the fuel return pipe with the fuel tube regulator.
13 clamp to stop the fuel return in order to Repair or replace the
verify and see whether the fuel pressure can No fuel injector or the
be established quickly. fuel pipe.
Repair or replace the
Yes
Verify that the fuel inlet pipe has any fuel inlet pipe
14
leakage or blockage. Replace the fuel
No
pump.
Repair or replace the
Yes
Verify that the fuel return pipe has any fuel return pipe.
15
leakage or bending. Replace the fuel
No
pressure regulator.
Verify that the data of the absolute pressure Yes Proceed to next step.
16 sensor of air intake manifold and air intake
No Replace the sensor.
temperature sensor are normal.
Verify that the ignition coil, the high voltage Yes Proceed to next step.
17
cable and the spark plug are normal. No Replace or adjust
Inspect the A/C
Yes
18 Verify that it is caused by the A/C system. system
No Replace the ECU.
G-87
SAFETY PRECAUTIONS OF SYSTEM MAINTENANCE
SAFETY PRECAUTIONS IN DIAGNISIS AND MAINTENANCE OF THE
GASOLINE INJECTION ELECTRONIC CONTROL SYSTEM
(1) Removal/installation requirements of controller
The battery negative grid must be disconnected first, followed by the removal of
controller prior to carrying out electric welding or baking finish;
In removing/installing the controller, the ignition switch must be turned to OFF
position to avoid being damaged;
The power supply wire should not be removed from the battery while the engine is
running or the electrical system is in operation;
Dont start the engine with high current of charger;
Pay attention to keep the ambient temperature around controller less than 80.
(2) Cleanliness requirements: following rules shall be complied strictly before
operating the fuel supply system and fuel injector system:
All the dismantled parts must be placed in clean environment and covered properly. It
is not allowed to use the fiber-sloughing cloth.
(3) All the wiring harness and the same for diagnostic tester can only be disconnected
or connected after the ignition switch has been turned off;
Ensure the wiring connection is correct before carrying out the voltage or grounding
measurement for the electronic control system.
Remove the power supply wire from battery or disconnect the wiring harness
controller connectors will cause the loss of diagnostic information and memory.
(4) Notes for maintaining the fuel supply system:
Attention must be paid to the followings when removing and installing the fuel pump
on a fully or semi-fully filled fuel tank:
A device that can fully absorb the potential leaked fuel should be available near the
fuel tank opening before carrying out the operation;
Avoid the skin come into direct contact with fuel;
Thoroughly clean the place and around it before loosening the connecting parts;
Put rags around the connecting parts in order to prevent the fuel from spraying via the
loosened part;
The disassembled parts that are not intended to be repaired immediately should be
covered or closed carefully;
G-88
The spare parts should be taken out from its packing only before the assembly. Any
part without proper packing is not allowed to be used;
Pay attention not to damage the O ring while assembling the fuel injector. A small
amount of lubricating oil should be applied on the O ring for assembly convenient.
After the system has been opened up, as far as possible not to use compression air and
move the car around.
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
CLUTCH
H-1
CLUTCH INTRODUCTION
CLUTCH STRUCTURE
As picture below, the clutch is dry diaphragm with single leaf. It consists of clutch driven
disk (2), release disk (4), intermediate disk (6), pressure plate (7) and flywheel (1).
There are diaphragm springs in the pressure plate (7), which are fixed in the crankshaft by
intermediate disk (6) and bolt (5). Driven disk (2) is pressed on the flywheel (1) by
pressure plate (7), and bolt (8) is used to fix pressure plate (7) and flywheel (1) together;
the clutch pusher (9) is used to push separator disk (4) and then the separator disk (4) to
push the small end of diaphragm springs on pressure plate (7).
H-2
a. Clutch Connection State b. Clutch Disconnection State
1.Diaphragm Spring 2.Flywheel 3.Driven Disk 4.Pusher
5.Seperator Disk 6.Transmission Axle
H-3
ASSEMBLY AND ADJUSTMENT OF CLUTCH CABLE
H-4
CLUTCH DISASSEMBLY
H-5
CLUTCH OVERHAUL
H-6
CLUTCH INSTALLATION
Before the assembly, flywheel surfaces and pressure
plate shall be clear and dry.
Assemble the pressure plate on the crankshaft
and screw up bolts in accordance with
prescribed moment.
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 DIAGNOSIS
Trouble
Cause Treatment method
symptom
Free travel (free play) of clutch pedal is wrong. Adjust free travel
Abrasion or oil stain for clutch friction disk. Change friction disk
Slip of clutch Distortion for friction disk pressure plate or Change frication disk,
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
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
DISASSEMBLY AND ASSEMBLY OF THE GEARSHIFT SHAFT BEARINGJ-30
DISASSEMBLY J-30
ASSEMBLY J-30
RESOLUTION GRAPH OF THE INPUT SHAFT J-35
RESOLUTION GRAPH J-35
RESOLUTION GRAPH OF OUTPUT SHAFT J-36
RESOLUTION GRAPH J-36
ADJUSTMENT TABLE J-37
ADJUSTMENT ITEMS J-37
ADJUSTMENT OF OUTPUT SHAFT J-38
ADJUSTMENT J-38
MAIN POINTS J-38
DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL, AND CALCULATION AND
ADJUSTMENT OF THE ADJUSTMENT SHIM J-39
DISASSEMBLY J-39
ASSEMBLY J-40
ADJUSTMENT J-40
RESOLUTION GRAPH OF THE DIFFERENTIAL ASSEMBLY J-41
RESOLUTION GRAPH J-41
DISASSEMBLY AND ASSEMBLY OF OIL SEAL AND OUTPUT FLANGE J-42
DISASSEMBLY J-42
ASSEMBLY J-43
J-2
Clutch Assembly Schematic
1. Clutch Housing 2. Differential 3. Input Shaft 4. Output Shaft
5. 1 Shift 6. Reverse 7. 2 Shift 8. 3 Shift 9. 4 Shift 10. 5th Shift
st nd rd th
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
DISASSEMBLY OF THE DRIVE SHAFT
Tyre disassembly.
J-4
Disassemble the round head bolt of steering
knuckle and steering rod, prize up the round
head bolt upward.
J-5
DISASSEMBLY OF THE TRANSMISSION
Discharge the transmission oil.
Disassemble the driving shaft.
Disassemble those 3 fixing bolt of the
transmission lower shim.
J-6
Disassemble cathode cable of the accumulator;
disassemble the anode cable and plug of the
starter.
Disassemble the fixing bolt between engine
front overhang bracket and front cross
member.
Sling the engine.
Disassemble the fixing bolt of the starter.
Take off front overhang bracket of the starter
and the engine.
J-7
Loosen those 5 bolts between transmission
housing and engine.
J-8
TRANSMISSION GEARSHIFT MECHANISM DIAGRAMMATIC SKETCH
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
RESOLUTION GRAPH OF THE GEARSHIFT CONTROL MECHANISM
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
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
Check the 1st 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
TRANSMISSION RESOLUTION
1. Fastening Screw (4 Pieces, Fasten Moment Is25n.M) 2. Fixing Screw (2 Pieces, Fasten
Moment Is 25N.M) 3. Bleed Bolt 4. Transmission Rear Housing 5. 5th Synchronizer
Assembly 6. 5th Driven Gear Snap Ring 7. 5th Driven Gear 8. 5th Fork Pad
9. 5th Fork Assembly 10. 5th Gear Holder Fixing Turnbuckle 11. Dish Washer 12. Shim
J-12
1. Input Shaft Rear Bearing Plate Screw (4 Pieces, Fasten Moment Is 15N.M) 2. Transmission
Housing Assembly 3. Fixing Screw (12 Pieces, Fasten Moment Is 25N.M) 4. O-Ring 5. Gearshift
Shaft Plug Cover 6. Gearshift Shaft Pressing Spring 7. Gearshift Assembly 8. Gearshift Positioning
Holder Assembly 9. Pressing Spring-Damper Ring 10. Output Flange 11. Output Flange Dish Washer
12. Output Flange Snap Ring 13. Flange Cover 14. Idler Shaft Fixing Screw 15. Fixing Bolt (2
Pieces, Fasten Moment Is 25N.M)
J-13
1. 4th Driven Gear Snap Ring 2. 4th Driven Gear 3. 3rd Driven Snap Ring 4. 3rd Driven Gear 5.
2nd Driven Gear 6. 2nd Synchronizer Ring 7. 2nd Roller Bearing 8. 2nd Roller Bearing Lining 9.
1st -2nd Synchronizer Assembly 10. 1st Synchronizer Ring 11. 1st Driven Gear 12. 1st Roller
Bearing 13. Bearing Holder Fixing Bolt 14. 1st Roller Bearing Snap Ring 15. Output Shaft
Intermediate Bearing Holder 16. Differential Assembly 17. Damper Ring 18. Pressing
Spring-Damper Ring 19. Output Flange 20. Output Flange Dish Washer 21. Output Flange Snap
Ring 22. Output Flange Cover 23. Fork 24. 5th Fork Sleeve 25. 3rd-4th Fork 26. 5th Fork Guide
Plate 27. Reverse Fork Guide Plate 28. 1st-2nd Fork 29. Input Shaft Assembly 30. Idler Shaft
31. Idler Assembly 32. Clutch Housing assembly
J-14
DISASSEMBLY AND ASSEMBLY OF THE TRANSMISSION
Disassembly
Raise up the transmission, take off the drain
plug on the transmission differential side, and
at the same time take off the drain plug on the
rear cover( see the arrowhead pointed stud).
Discharge all the oil.
J-15
Disassemble the gearshift shaft bolt by special
tools and take off compression spring and
gearshift shaft assembly.
Special Tool
J-16
Shift to 5th and reverse gear.
Glide the synchronizer downward according
to arrowhead 1 direction and shift to 5th.
Move the first fork downward according to
the arrowhead 2 direction and shift to reverse
gear.
Prize up the 5th fork pad and turn left the 5th
fork bushing, take off the 5th fork assembly.
Special Tool
J-17
Take off 5th driven gear snap ring and 5th
driven gear.
Special Tool
Take off the bearing shift slice clamping bolt
behind of input shaft by a special tool.
J-18
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
Take off 3rd driven gear snap ring B from
output shaft, and take off 3rd driven gear. And
take off 2nd driven gear, needle bearing, and Special Tool
synchronizer ring from output shaft. (by
special tool)
J-20
Assembly:
The assembly of the transmission is in reverse
of its disassembly, pay attention to the below
items:
1. Assemble differential assembly on clutch
housing, at first do not assemble output flange.
2. Assemble output shaft and output shaft front
bearing plate, plug into fixing bolt and fasten
by 40Nm moment.
3. Assemble thrust shim needle bearing. Pay
attention to the direction of the thrust shim, the
inside diameter of thrust shim A should be
integrate closely with the bearing holder. Pay
attention that dont mix up the 1st and 2nd
synchronizer ring, 1st synchronizer ring is not
sprayed molybdenum and has three gears
missing.
J-21
Assemble the needle bearing, synchronizer
ring, and gear of 2nd and 3rd driven gear.
When you assemble the 3rd driven gear, make
sure that the side with bulge towards 2nd
driven gear.
J-22
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
Main points
1. Please do not take off the fork shaft from
5th fork bushing otherwise the fork and
guide plate will deviate its right position
and fallout.
2. Before assemble the gearshift shaft please
put the transmission at it neutral position.
Inset gearshift shaft and big compression
spring, fasten the bolt cover by 50Nm
moment.
Screw in gearshift positioning holder
assembly and fasten it by 40Nm moment.
J-24
ADJUSTMENT OF 5TH FORK
Adjustment:
Adjust the 5th fork as below:
Turn fork bushing right until the fork bushing
out X=5mm.
Pull off selector shaft and turn left shift to
5th.
Lift 5th coupling housing sleeve slightly by
the fork to eliminate the space between the
driving elements.
Main points:
Move the slip cap and fork slightly to eliminate the
free space when measuring the space a.
J-25
DISASSEMBLY, RESOLUTION GRAPH AND ASSEMBLY OF THE REAR
HOUSING
Disassembly:
The disassembly of the rear housing can be finish even if the transmission is not
disassembled from the car. The disassembly as below:
1Drive the car to the platform.
2Disassemble clutch control
cable assembly.
3Disassemble the engine bracket on the transmission
side.
4Lift the vehicle by a lifter.
5Screw off the drain bolt under the differential, discharge all the
transmission oil
6 Take off the fixing bolt of rear housing and dismantle the rear
housing.
J-26
Resolution graph:
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 AND ASSEMBLY OF CLUTCH CONTROL ARM, CLUTCH
RELEASE SHAFT OIL SEAL, AND CLUTCH RELEASE BEARING
Disassembly:
Drive car to the platform.
Disassemble the clutch control cable
assembly.
Disassemble engine bracket on the
transmission side.
Lift the vehicle by lifter.
Discharge all the transmission oil by screw
off the drain bolt under the differential.
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
DISASSEMBLY AND ASSEMBLY OF THE GEARSHIFT SHAFT OIL SEAL
Assembly:
Lubricate the lip of oil seal and press oil seal Special Tool
into transmission housing completely by a
special tool.
J-29
DISASSEMBLY AND ASSEMBLY OF THE GEARSHIFT SHAFT BEARING
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 AND ASSEMBLY OF THE OUTPUT SHAFT NEEDLE BEARING
Disassembly:
Remove the needle bearing by special tool,
see the picture.
Special Tool
Special Tool
Assembly:
Press the needle bearing to its right position
by special tool.
J-31
DISASSEMBLY AND ASSEMBLY OF THE GEARSHIFT SHAFT
Special Tool
J-32
DISASSEMBLY AND ASSEMBLY OF INPUT SHAFT NEEDLE BEARING
Disassembly:
See the picture, dismantle the needle bearing
by special tool.
Special Tool
Special Tool
Assembly:
See the picture, assemble the input shaft Special Tool Special Tool
needle bearing by special tool, and make sure
press it to the right position.
J-33
DISASSEMBLY AND ASSEMBLY OF THE INPUT SHAFT OIL SEAL
Disassembly:
It need not to break down the transmission
when disassemble the input shaft oil seal.
Special Tool
See the picture, disassemble the input oil seal
according to the arrowhead direction by special
tool
Assembly:
See the picture, lubricate the lip of the oil seal
and press the oil seal to its right position by
special tool.
Special Tool
J-34
RESOLUTION GRAPH OF INPUT SHAFT
J-35
RESOLUTION GRAPH OF OUTPUT SHAFT
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
ADJUSTMENT TABLE
Adjustment items:
During the repair of Adjusted items
transmission assembly, you Changed parts Output
should think about to adjust Differential
shaft
the output shaft or differential Transmission housing No Adjust
assembly installing dimension Clutch housing Adjust Adjust
when you change any of the Differential cone bearing No Adjust
below element. Output shaft Adjust No
In order to avoid the Output shaft intermediate
Adjust No
ungrateful work we provide bearing pedestal
the right table to you. Differential housing No Adjust
Output shaft intermediate
Adjust No
bearing
Output shaft front bearing Adjust No
J-37
ADJUSTMENT OF OUTPUT SHAFT
Adjustment:
You need adjust the thickness of the output
Special Tool
shaft shim after you replaced any part of
clutch housing,output shaft,output shaft
Special Tool
intermediate bearing pedestal, output shaft
intermediate bearing or output shaft front
bearing.
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
CALCULATE THE THICKNESS OF THE ADJUSTMENT SHIM
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
Assembly:
Put the propriety adjustment shim to it right
position and press output shaft front bearing
external ring. Lubricate the bearing by gear
oil and insert output shaft. Put on bearing
Special Tool
plate and bolt fasten by 40Nm moment.
After changing one of below parts: Clutch
housing, transmission housing, differential
bearing and differential housing, you need
readjust the adjustment shim thickness for
differential bearing pre fasten.
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
RESOLUTION GRAPH OF THE DIFFERENTIAL ASSEMBLY
RESOLUTION GRAPH
1, Final drive driven gear 2, Rivet 3, 11, Needle bearing 4,12, Needle bearing
external ring 5,13, Adjustment shim 6, Clutch housing 7, Rivet (may not use) 8,
Oil seal holder 9, Oil seal 10, Small axle shaft 14, Transmission housing 15,
Output flange snap ring 16, Output flange dish washer 17, Output flange 18,
Compression spring 19, Spring seat ring 20, Damper ring 21, Differential
housing 22, Knob gasket 23, Snap ring 24, Planet gear shaft 25, Planet gear snap
ring 26, Axle shaft gear and planet gear 27, Output flange cover
Break down of differential assembly
J-41
DISASSEMBLY AND ASSEMBLY OF OIL SEAL AND OUTPUT FLANGE
J-42
See the picture, fix the special tool on flange
Special Tool
by M8 bolt, rotate the shaft of special tool by
wrench to disassemble the output flange.
Take off spring seat and compression spring.
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
AXLE AND SUSPENSION SYSTEM
M-1
AXLE AND SUSPENSION SYSTEM
ALIGNMENT OF THE WHEEL
It is easy to understand that the theory of the four wheels alignment related to the definitions
and the functions of various angles. However, the corresponding theory can hardly be applied
to the four wheels alignment tester and chassis maintenance due to the chassis structure of the
vehicle body, which all the angles of the four wheels alignment bear on the mechanical
structure of the chassis. For examples:
The camber will be changed as the toe-in varied. The wheels will be turned while
adjusting the toe-in, which results the camber changing. The larger the caster is, the
more the camber changed.
The wheel setback will be changed as the caster adjusted. When the caster increases or
decreases, the upper fulcrum of the steering shaft can move forwards or backwards and
the lowest fulcrum of the steering shaft (tire) is also movable. The front wheel moves
forwards or backwards along with the caster increasing or decreasing so that the axle
setback will be altered. The turn plate must have the function of sliding forwards and
backwards in order to make the front wheel move forwards and backwards freely.
The toe-in will be changed as the camber varied and vice versa. Various suspension
structures have different ways to adjust the camber. If the upper or lower fulcrum is
moved left or right, not only the camber but also the toe-in will be changed. As a result,
even if the camber is properly adjusted, the stable driving status cannot be achieved
because of the toe-in changing. Therefore, after eliminating of malfunction, another one
will appear.
Changing the toe-in of the rear wheel influences that of each front wheels. The toe-in of
the rear wheel determines the thrust angle of the rear wheel. The method of thrust line
positioning is adopted to determine the toe-in of the front wheel in all the advanced four
wheels alignment testers.
Precaution: The front wheel must be adjusted first and then the rear wheel when
processing the four wheels alignment. The sequence of the rear wheel adjustment is the
camber first, the toe-in second and so on. And the sequence of the front wheel
adjustment is the caster first, the camber second, the toe-in third and so on.
Item Front wheel Rear wheel Spare wheel Mini spare wheel
M-2
----Rim and Tire
A15LHD wheel No.
Note:
The above tire-rim combination is suitable for the steel or aluminum alloy rim. Please
do not use rims and tires of other models which may lead to improper consequence.
Preaution: Be sure to consult the relevant instruction if non-standard tires or rims (such
as light weight alloy rims or wheels of winter tire)should be installed.
M-3
Adjusting the snow chain of the tire should accord to the type of the road condition.
Inspection must be applied before install the snow chain. Please refer to the instruction of the
snow chain manufacturer when install the snow chain on the tire. Please remove the wheel
house before install the snow chain which may score the wheel house. Install the snow chain
firmly on the front tire. It is not recommended to fix the snow chain on the rear wheel. The
snow chain should be retightened after 0.5~1.0km driving with it.
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
final assy imbalance is expected to be less than 100gcm, approximately equal to a 5g
balance block on the inside and outside brims of the rim.
Precaution: No more than one balance block with 70g weight at most is allowed to
set on each side of a wheel. Avoid over hitting on the balance block. If that happened,
replace it immediately. Do not reuse the replaced balance block.
----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
Maintenance: Adjusting the positioning angle of the front wheel
------Wear on center of tire
The wear on center of tire means the abnormal wear on the center surface of the tire. The
theoretical reason for this kind of wear is that the diameter elongation at the center of the tire
surface is larger than that on the shoulder of the tire.
Main reason: Overhigh tire pressure
Maintenance: Readjusting the tire pressure to make it within the range of the specified value.
------Serrated wear
The serrated wear means the wear on the surface of the tire strip in ladder shape. The
theoretical reason for this kind of wear is the uneven deformation of the tread pattern of the
tire contact patch.
Main reason: The toe-in and the camber are not conformed to the specified value
Maintenance: Adjusting the toe-in and the camber to make it within the specified value.
Checking the tire pressure is within the specified range.
------Initial severe wear somewhere on the tire
The initial severe wear is the severe wear on the tread pattern of tire contact patch due to the
wheel locking while emergent braking.
Main reason: Vehicle speed while emergent braking, road conditions, wheel load and the
braking intensity
Maintenance: Avoiding emergent braking and taking precautionary measure as early as
possible
------Nick and crack on the sidewall of tire
The main reason is the sharp things on the road or the little stones, nails and metal flakes
embedded into the tread slot.
------Initial wear on half round of the tire or wear in different places of the shoulders on
both sides
The main reason is the gyration part is in unbalanced state, or the tire and wheel are eccentric,
or the bearing is worn or loose and so on. The eccentricity or bend of the rim or the steering
knuckle may also cause the wear.
Troubleshooting Guide
M-6
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
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
------Measure the height from the wheel center to the mudguard edge. The measured
difference from left and right should be not more than 10mm.
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
Check the caster
Inspection angle Value
Rear wheel caster -13010
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
Influence of caster
The main function of the caster is to keep the vehicle running straight forward. If the caster is
positive, the inside of the vehicle descends and the chassis ascends which increase the
steering knuckle load when the front wheel turns. If the casters of two wheels are same, the
vehicle will return forward after turning. Increasing the positive caster angle will enhance
stability of the steering wheel while the steering force will be increased at the same time.
Decreasing the positive caster may reduce stability of the steering wheel but lightens the
steering force.
The angle of the caster could not make the wear on tire. It is used to stabilize the steering
direction and to return automatically after steering. If the vehicle is equipped with a
traditional manual steering wheel, the caster is small or even tends to negative, which makes
the steering easy. If the vehicle is equipped with a power steering wheel, the caster is usually
set to be large positive in order to offer the driver a better feeling. Increasing the positive
caster will increase the steering force but enhances the stability of straight running.
M-11
----The connection between the lower
control arm of the suspension and the
steering knuckle is clearance fit.
Loosen the joint bolt, move the wheel
and adjust the camber.
M-12
FRONT SUSPENSION
The functions of axle and suspension system include receiving the torque generated by
engine and passed via transmission system; producing the traction force between the road
surface and the vehicle body through the adhesive force between the driving wheel and the
ground in order to keep the whole vehicle steering normally; 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
----Suspend the engine and transmission assy,
loosen the bolts at the two supporting
points from the engine and transmission
to the sub-frame.
M-14
OVERHAUL OF THE FRONT SUSPENSION
Installation of the front axle
M-15
Removal of the front shock absorber assy
Precaution: Before the procedure below, the
careless pull may lead the disconnection of
the harness if the ABS vehicle speed sensor is
not removed first. Therefore, before the
following procedure, remove the ABS vehicle
speed sensor (the axle side) first and fix it in
a proper position in order to keep the sensor
untouched during the vehicle maintaining.
----Remove the wheel. Then loosen the joint
bolt of the propeller shaft and the brake
disc.
----Use the special socket wrench to remove the
joint bolt of the shock absorber strut and
the steering knuckle arm. (shown as the
illustration)
----Use special purpose tools to remove and
install the shock absorber coil spring.
(shown as the illustration) During the
removal, push down the vibration isolator
assy of the coil spring by puller first,
compress the coil spring, and then loosen
the piston rod nut to release the tension of
the coil spring.
Caution: The removal of the piston rod nut is Illustration. The installation of front
extremely dangerous, because the shock strut assy
absorber and the spring will burst out under 1-Front shock absorber assy
tremendous pressure which could cause 2-Front dust cover
injury or even death. Please make sure the 3-Front bumper block
shock absorber is fixed properly before the 4-Slotted nut 40Nm
removal of the piston rod nut. 5-Bearing and vibration isolator assy
6-Front spring top tray
7-Washer 8-Front coil spring
Installation of the front shock absorber
(refer to the installation illustration of the
front strut assy)
----Assemble the front cover dust 2 with the
front bumper block 3, and then cover them
onto the piston rod of the front shock
absorber 1.
M-16
----Set on the front coil spring 8 and compress it
less than 200~220mm.
M-17
pressing which means there is a force in
lower part and not abruptly in upper part
while pulling; there is a force in lower part
and not in upper part while pressing.
c whether the shock absorber is locked and
unable to pull.
d whether the piston rod of shock absorber is
severely loose.
Note: The above phenomenons indicate the
failures of the shock absorber.
Deal with the front shock absorber
Caution:
Whenever drilling on the shock absorber,
please wear the goggles. The air pressure
in the shock absorber could probably blow
the metal flakes into eyes or face.
----Clamp the shock absorber on flat ground or
point the piston downwards to the clamped
absorber.
----Drill a hole of 2-3mm diameter at a distance
of 20-30mm to the bottom of the tube in
order to emit the air of the tube.
----Turn the shock absorber to make the hole
downwards.
----Move the piston rod up and down for times
to concentrate the oil, then cut the tube at
the end.
----Process the waste oil according to the waste
disposal method.
Note:
The shock absorber air is nitrogen.
The shock absorber oil is mineral oil.
M-18
REMOVAL AND INSTALLATION OF THE FRONT WHEEL BEARING
Removal:
----Remove the front brake disc and the dust
plate, and then extrude the hub.
----Remove the spring retainer of both sides and
extrude the wheel bearing. (shown as the
illustration)
----Pull out the bearing inner race. Use the puller
with hoop to pull the wheel bearing inner
race out of the wheel hub. (shown as the
illustration)
Inspection:
----After all the components are disassembled,
please clean and check them, and replace
them with new ones if necessary.
----If the working surface of the brake disc wears
severely beyond the specified value (wearing
limit: 10.0mm), please replace it with a new
one.
Caution: Do not exceed the wearing limit.
----If the dust plate is severely deformed, please
replace it with a new one.
----If the hub spline wears severely and looses,
please replace it with a new one.
----If the spring retainer is not available, please
replace it with a new one.
----If the wheel bearing is damaged, please
replace it with a new one.
Installation and adjustment
----Set the outer spring retainer first, apply the
lubricating grease onto the wheel bearing
holder and then press the bearing down to the
limit position, as shown in the illustration,
and fix the inner spring retainer last.
----Adjust the split positions of the inner and
outer spring retainer so as to make their
difference 180. Then rotate the bearing inner
M-19
race and observe whether it runs normally.
----Apply the lubricating grease on the hub spline
and the bearing neck, and then press the hub
into the bearing.
M-20
Replace the rear housing of the lower control
arm
----When pressing out the rear housing of the
lower control arm, if the elastic housing
locks due to rust, please cut away the rubber
on outer circle, saw off the steel cover, and
then press out the elastic housing. (shown as
illustration)
----The installing position of the elastic housing
of control arm is shown as the illustration.
The arrow B or C points at the upper pit on
the lower control arm, and the kidney-shaped
interspace on the housing (arrow A) points to
the vehicle center.
----Use the special purpose tools to press in the
rear housing of the control arm.
M-21
REAR AXLE AND REAR SUSPENSION
Longitudinal bracket rear axle and rigid axle suspension are employed in Chery. The wheels
on both sides are connected with the vehicle body by an integrated rear axle. The metal
rubber holder for the rear axle is a type of holder which the trace is adjustable. It is almost
the rigid connection in longitude and can only deform in lateral which ensures that the rear
axle cannot turn in axial direction. Therefore, the rear axle processes the function of
preferable control of the vehicle stability at high speed.
REMOVAL AND INSTALLATION OF THE REAR AXLE ASSY
M-22
Installation of the rear axle assy:
----Installation of the metal rubber holder:
press the metal rubber bush 2 into the
axle body, and apply pressure till the
edge of metal rubber bush reaches the
solid axle.
----Use the bolt for hole 13 of the metal
rubber holder to connect the two rear axle
brackets. The standard tightening torque
of the nut is 60 Nm; (shown as the
picture)
M-23
Precaution: Before the procedure below, the
careless pull may lead the disconnection of the
harness if the ABS vehicle speed sensor is not
removed first. Therefore, before the following
procedure, remove the ABS vehicle speed
sensor (the axle side) first and fix it in a
proper position in order to keep the sensor
untouched during the vehicle maintaining.
M-24
REMOVAL AND INSTALLATION OF THE REAR SHOCK ABSORBER ASSY
M-25
Precaution: Before the procedure below, the
careless pull may lead the disconnection of
the harness if the ABS vehicle speed sensor
is not removed first. Therefore, before the
following procedure, remove the ABS
vehicle speed sensor (the axle side) first and
fix it in a proper position in order to keep the
sensor untouched during the vehicle
maintaining.
Assemblage of the rear shock absorber
(refer to the illustration of the rear shock
absorber assy)
----Cover the rear spring bottom tray 15 onto Installation position of the spring holder
the rear shock absorber assy 13, fix it on
the rear shock absorber with the pressure
of 9.5~10kN, and then set the bottom
tray bearing pad with the pressure of
2~3kN.
----Cover the rear coil spring 14 and the valve
cap 12 onto the piston rod of the rear
shock absorber in sequence, and then set
into the rear bumper block 10 and the dust
cover 11 which have been assembled
together;
----Press the rear coil spring 14 to
280~300mm, and then fix the locating
ring 8, the rear spring upper soft pad 9,
the rear spring upper holder 7, the
bearing sleeve 6, and the rubber bearing
block II 5. Tighten the hexagon thin nut 4
to the specified torque (15Nm);
Installation of the shock absorber spring
----As the illustration shows, aperture a must
aim at the bush of the connecting sleeve
2 when install the rear spring bottom tray,
otherwise the spring tray 1 would hit the
tire under extreme steering condition.
----As the illustration shows, please pay
attention to the installation position of
the rear spring upper soft pad.
Installation of the rear shock absorber Installation position of the spring bottom
assy (refer to the illustration of the rear tray
shock absorber assy)
M-26
----Install upward the rear shock absorber assy
from the vehicle body bottom and extend
the piston rod into the carriage through the
rear shock absorber holder;
----Inside the carriage, cover bowl washer 17,
rubber bearing block 18 and support disc
19 onto the piston rod in sequence, and
then tighten the hexagon nut 20 with
tightening torque of 20Nm. (shown as
the assy picture above)
M-27
OVERHAUL OF THE FRONT AND REAR AXLE
M-28
STEERING SYSTEM
N-1
INTRODUCTION OF STEERING SYSTEM
INTRODUCTION OF STRUCTURE
The structure of the Power Steering System is shown as Figure 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
1. Torsion Bar
2. Input Shaft
3. Valve Bush
Figure 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
INTRODUCTION OF PERFORMANCE
The steering force of the steering wheel can be decreased. Power can be felt obviously,
especially when the vehicle turns on spot or turns with great corner at low-speed.
The steering sensitivity is enhanced.
The impact of kickback from ground on the steering wheel is reduced.
In the case of tire burst, the sudden turning of the wheels can be effectively avoided. So the
security of driving can be improved.
The load on the steering wheel is permitted to increase, which can improve the freedom
motion of the general arrangement.
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
REMOVAL/INSTALLATION OF STEERING COLUMN
Removal and Installation of the Steering
Column
The inner spline of the steering gear is
Remove the nuts on the steering wheel
shown as the picture below:
Remove the upper and lower protector of the
instrument cluster and the switch
Remove the instrument panel assy. (Please refer
to the removal of the instrument panel)
Remove the joint bolt of the upper steering
column bracket and the car body upper bracket.
Grind away the safety screw and replace with a
new one when installing.
Remove the joint bolt between the steering gear
and the steering column (tightening torque:
30Nm)
Install the steering column inversely according
to the removal steps.
Removal and Installation of Steering Shaft and Steering Tube
Remove the clip.
Take off the serrated set bush and the steering gear lock housing from the steering column
Draw out the steering shaft and press the lower bearing of the steering column out with a
presser.
Disassemble the lock housing spring of the bracket ring steering shaft with a presser.
Assemble the steering column inversely according to the removal steps.
Precaution
Apply a little grease around the lower bearing and the inner wall of the steering hose
column lower end, press the lower bearing into the steering hose column using a
presser.(Do not move the upper and lower universal joint of the guard column)
Adjust the relative height of the lock housing and the hose column according to the height
of the pre-installed ignition lock cylinder and the combined switch cover.
Apply lithium base grease evenly around the contact ring.
N-5
Disassembling Illustration of the Steering Column
20
N-6
and 253Nm respectively.
Remove the four bolts of the steering gear.
Remove the fixing bracket of the steering
gear and the rubber hose.
Install the steering column in the reverse
order of the removal.
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
18. Conical connector 2
19. Left oil tube assy 1
20. Lock nut 1
21. Adjusting plug 1
22. Spring 1
23. Rack holder 1
24. Hexagon flange bolt 1
25. Bearing 1
26. Plug cap 1
27. Right oil tube assy 1
28. O rubber ring 2
29. Washer 2
30. Oil seal 2
31. Steering rack piston assy 1
32. Piston ring 1
33. O rubber ring 1
34. Housing 1
35. Stop collar 1
36. Wire stopper 1
N-8
Removal and Dismantling of Steering Gear
Repair and adjust after the removal of the steering gear
Tightening Torque for the Fastener Set Components Shown as the table below
Tightening Torque
Description Specification Quantity
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
Remove the left and right protector (Refer to
Illustration 7)
Remove the single ear no-level clip 6, then
the clamp 4 and take off the protector 5.
Illustration 7
Illustration 8
Illustration 9
N-10
Remove the support device of the rack
Refer to Illustration 10
Screw down the lock nut 20 with an special
purpose spanner first, then the adjusting plug 21,
and remove the spring 22 and the rack holder 23
in sequence..
Illustration 10
Illustration 12
N-11
Remove the rack assy Refer to Illustration
13
Press the rack assy 31out with a special
purpose tool.
Illustration 13
N-12
Check the oil seal of the stop collar assy.
Refer to Illustration 16
Check (3): Inspect if there is flake or indention
on the working surface of the oil seal 30 of the
stop collar assy and damage on the lip. Examine
if there is scratch on the inner surface of the
housing 34 and damage on the O rubber ring 28.
Illustration 16
Replace the oil seal, housing or O rubber ring, if
necessary. Apply the white special grease on the
inner and outer surface when install a new one.
N-13
Assemblage of the Steering Mechanism
Preparation:
Clean all components in clean organic solvents before assemblage, then dry them with a
blower
Precaution: Be careful during operation. The organic solvent is flammable and
explosive, keep it away from any tiny sparks. Otherwise, it may lead hurt
or even death.
Precaution: Make sure to wear the goggles while using the compressed air.
Lay the clean components separately and avoid the collision or scratch.
Replace all the oil seal, seal loop and seal ring. Apply the white special grease on the
O-ring and oil seal of the seal sections.
Get the replacing components ready every component must be qualified before
assemblage.
Precaution: When replace, all the set bolt, adjusting screw, seal component, lock nut
and the other components must be conformed to the technical specification
of Chery and can not be substituted arbitrarily.
Get the clean MoS2Lithium lubricating grease or the same performance grease ready
during assembling.
Precaution: If the unclean grease is used, the seal components would be damaged or
scratched, which will impact the steering power and result in accidents.
Assemblage
Precaution: Do not twist any seal components during assembling.
Illustration 19
N-14
Install the valve core assyRefer to
Illustration 20
Install the valve core assy 31 as the direction
of the skew gear tooth into the hull oil reservoir
Illustration 20
N-15
Install the left and right oil tube assyRefer
to Illustration 23
Install the new conical connectors 18 and 16
on the ends of the left oil tube assy 19 and
right oil tube assy 27.
Tighten the left and right oil tube assy with the
tightening torque of 15~25N.m
Illustration 23
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
Install the rack lock-plate and the inner ball
joint assyRefer to Illustration 25
Apply Kerui 5242 sealant on the thread of the
inner ball pin.
Install and screw the inner ball joint assy with
a special purpose tool. The tightening torque is
70~90N.m.
Illustration 25
N-17
CHECK OF STEERING SYSTEM
REGULAR INSPECTION
Initial Check
The maintaining staff should pay attention to the steering system troubles reflected by the
user first. In this way, it could save a lot of repairing time. For example, as the user
complains that the steering is heavy, it is necessary to clear that it is heavy on left or right;
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
Overhaul of the hydraulic power pump
---- Check if the hydraulic power pump is clogged. Replace it, if necessary.
---- Check if there is abnormal noise in the hydraulic power pump Replace it, if necessary.
---- Check if there is leakage in the hydraulic system. Replace it, if necessary.
N-19
CHECK AND REPLACEMENT OF THE HYDRAULIC POWER OIL
Check the hydraulic power oil
----Repeat turning the steering wheel from one
limit position to another when the engine
is idling in order to increase the
temperature of the power steering oil to
40~80
----Check the oil volume left in the oil
reservoir, the oil surface should reach
max mark of the reservoir. When the oil
is not enough, please check there is no
leakage of all the parts, otherwise fill with
the oil to the max.
Precaution: It is recommended to use the special machine for vacuumizing the injection
when filling with the power steering oil. Otherwise (for example, when the vehicle is
repaired). The specifications for filling the power steering oil and exhausting are shown
below: fill the oil reservoir with the power steering oil to the maximal position first, and
then start the engine at low speed (idling) to drive the steering pump so as the steering
system is full of the hydraulic oil. The engine must be kept in idling status to drive the
vane pump during refueling and meanwhile refueling continuously to avoid inhaling the
air of by the vane due to the fall of the oil level.
Replace the hydraulic power oil
---- Lift the vehicle to discharge the oil left in the oil reservoir and backflow hose.
---- Keep the engine idling, discharge the oil and meanwhile turn the steering wheel to the
end position until there is no hydraulic oil left.
Precaution: All these steps should be finished as soon as possible to avoid damaging the
hydraulic power pump.
---- Add the power steering oil.
---- Discharge the air completely in the hydraulic system.
N-20
10 seconds). Repeat this step for several times to discharge all the air of the system from
the oil reservoir. Add the hydraulic oil as the oil level descends.
---- Keep the engine idling, repeat turning the steering wheel from the left limit position to
the right until there is no air bubble and foam in the oil reservoir. If the oil level
descends, fill with the oil to the specified value (max).
---- The exhaust of this type of vehicle is not easy. Please completely discharge the air bubble
left in the system. Otherwise, it would make the abnormal noise in the hydraulic power
pump.
N-21
DIAGNOSIS AND TROUBLESHOOTING OF POWER STEERING
SYSTEM
The frequent malfunctions of the hydraulic power steering system are the oil leakage,
infiltration of air, failure of the power steering pump, and damage of the steering control
valve and mechanical transmission mechanism of the hydraulic transmission mechanism. All
these malfunctions show in different forms, such as steering heavily, noise, unsmoothness,
vibration and so on. 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
Measure if the tire pressure is normal. If necessary, inflate it according to the specified
pressure.
Check if there is leakage in the oil tube connectors of the steering hydraulic steering system.
If there is leakage, screw them tightly. Inspect if there is damage, deformation or crack on
the oil tube. If one of the above-mentioned failures is detected, the oil tube should be
replaced.
Check the rotation movement of the steering rack & pinion mechanism at the wheel return
position and the other position, if the rotating torque is too large, check the bending of the
rack and the adjustment of the rack jacking block. If necessary, adjust the pressure of the
rack jacking block or replace the steering rack & pinion mechanism.
Check if the steering control valve is blocked or returned improperly. Replace it, if
necessary.
Remove and inspect the hydraulic cylinder and replace the damaged components.
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
piston; Weakening of the pressure regulator spring, damage on the seal components. Find
out the malfunctions and eliminate them. If necessary, replace the oil pump.
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
2~3min, which appears in the steering pump is normal when the engine is started in cold
weather (20 or even colder). But when the noise is abnormal and the turning performance
is affected, the noise can be considered as malfunction. The reasons are shown below
The looseness of the steering transmission mechanism causes the abnormal turning noise.
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
PRECAUTION OF STEERING SYSTEM MAINTENANCE
Caution: The steering gear is an important danger-proof component which can affect
the driving security. If failure appears during use, the vehicle should be sent to
the service station designated by Chery; the company is not responsible for the
accidents due to self-disassembling, self-maintenance and improper operation.
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
After refueling, check if there is leakage in every component.
Precaution: Keep the impurities away from the system when refueling.
Caution: Dead steering (i.e. turning the steering wheel to the limit position) is forbidden
during use. Even if necessary, do not keep the steering wheel stay at the limit
position more than 10 seconds. 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
BRAKE SYSTEM
APPENDIX I P-42
APPENDIX II P-43
P-1
INDUCTION TO BRAKE SYSTEM
P-2
Brake System of A15LHD
1 Brake master cylinder 4 Brake pedal 7 Front disc brake
2 Brake fluid reservoir 5 Brake pipeline
3 Vacuum booster 6 Rear drum brake
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
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
* Maintenance of Brake Pedal
-- Check the smooth operation of brake pedal, and remove it for inspection if its operation is
abnormal. Check whether the brake pedal is distorted or deformed, and replace it if any.
-- Check whether the brake pedal shaft is worn seriously or deformed, and replace it if any.
All shaft pins shall be lubricated when assembling.
P-5
REPLACEMENT OF FRICTION SHOES OF FRONT WHEEL DISC BRAKE
-- Lift up the vehicle and remove the front wheel,
and then detach the lower fixing bolt of the caliper
housing.
-- Lift up the brake caliper from the bottom to top,
and remove the brake lining (as shown in the
figure).
-- Press the caliper piston back into the caliper
housing. Use a suction hose to pump some fluids
out from the brake fluid reservoir if its fluid level
is too high before the piston is pressured back, the
purpose of which is to prevent the brake fluid
from overflowing and damaging the paintwork.
Since the brake fluid is corrosive and toxic, it
shall be stored in a special plastic bottle or other
containers.
-- Install the inside brake lining on the brake caliper
bracket of the steering knuckle, and then refit the
outside brake lining.
-- Ensure that the return spring shall be in its proper
position when installing the brake caliper;
otherwise it may cause the brake noise.
-- Tighten the lower fixing bolt of the caliper
housing.
-- Keep the vehicle in its original position after the
completion of installation, and forcefully step on
the brake pedal several times so as to make the
brake lining in its normal working position.
P-6
-- Use the compressed air to press the piston out of
the brake caliper housing. Place a wooden block
in the piston indent when pressing so as to avoid
the piston damage, as shown in the figure.
P-7
INSPECTION OF FRONT WHEEL DISC BRAKE
Maintenance of brake lining
* Check whether there are some oil stains on the surface of brake lining, and use an
abrasive cloth to grind off it, if any.
* Check the crack, dropout and other defectives on the brake lining, and replace the brake
lining, if any.
* Check the thickness of brake lining, and replace it if worn out.
* Check the wear condition of brake lining, and replace it if the thickness of brake lining is
less than the service limit or the lining is worn unevenly. The brake linings on both sides
shall be replaced at the same time when replacing them with new linings, and the new
ones shall be supplied by the same one manufacturer. The wear limit of brake lining shall
be 7 mm, including the backing plate.
Maintenance of brake disc
* Check whether there are some oil stains on the surface of brake disc, and use an abrasive
cloth to grind off it, if any.
* Check the crack, corrosion, severe score and other defectives on the brake disc, and
replace it if any.
* Check the scratch of brake disc, and machine it again if the scratch is too deep.
* Check the thickness of brake disc, and replace it if the thickness is greater than the limit
value. The standard thickness of front wheel brake disc is 13 mm with the service limit of
10 mm.
* Use a dial gauge to measure the face run-out of brake disc, and apply the turning,
polishing and other methods to treat its end surface if the run-out exceeds 0.12 mm, and
replace the brake disc if the derivation is too large.
* The brake discs on the both sides shall be placed at the same time when replacing.
Maintenance of brake caliper assy.
* Check the crack and deformation of the brake caliper, and correct or replace it as
appropriate.
* Check the breakage and crack of the dust boot of piston, and replace the boot, if any.
* Check the aging, crack and other defectives of the sealing ring of piston, and replace the
ring, if any.
* Check the oil leakage, motion blocked, unsmooth return of the piston, and repair it, if
any. Check the damage, corrosion and other defectives of the piston and cylinder wall, and
replace the brake caliper assy., if any.
P-8
Maintenance of brake caliper assy.
* Check the crack and deformation of the brake caliper, and correct or replace it as
appropriate.
* Check the breakage and crack of the dust boot of piston, and replace the boot, if any.
* Check the aging, crack and other defectives of the sealing ring of piston, and replace the
ring, if any.
* Check the oil leakage, motion blocked, unsmooth return of the piston, and repair it, if
any. Check the damage, corrosion and other defectives of the piston and cylinder wall, and
replace the brake caliper assy., if any.
P-9
1 Front wheel hub 7 Bolt 13 Piston damping washer
2 Dust cover 8 Bolt 14 Bracket
3 Brake pad assy. 9 Left caliper housing 15 Lock screw
4 Dust boot 10 Piston 16 Brake disc
5 Guide rod 11 Piston gasket 17 Screw
6 Bleeder valve screw 12 Piston dust cover
P-10
DISASSEMBLY/ASSEMBLY AND INSPECTION OF REAR WHEEL DRUM BRAKE
P-11
DISASSEMBLY/ASSEMBLY OF BRAKE SHOE OF REAR WHEEL DRUM BRAKE
Removal:
-- Remove the rear wheel.
-- Insert the turning tool into the tire bolt fastening
hole on the brake drum, press the shoe clearance
regulating wedge-shaped block upwards to make
the brake shoe return back to its original position.
-- Detach the brake drum.
-- Remove the brake shoe fixing spring and parking
braking cable.
-- Unclip the lower limit spring seat of the shoe, and
remove the limit spring.
Installation:
P-12
-- Install the brake shoe and parking brake lever, and
reassemble the return spring, as shown in the
figure.
-- Fix the parking brake cable on the parking brake
lever, and install the brake shoe on the brake
wheel cylinder.
-- Install the lower return spring, and adjust the
return spring and the spring of wedge-shaped
block.
-- Install the brake drum and rear wheel hub bearing.
-- Forcefully step on the brake pedal several times to
make the friction lining of brake in place.
P-13
-- Measure the thickness of friction lining, as shown
in the figure.
MAINTENANCE OF SPRING
-- Check the breakage, deformation or elastics
weakening of the spring, and replace it, if any.
P-14
STRUCTURAL DIAGRAM OF REAR WHEEL DRUM BRAKE
A15LHD adopts the non-balanced drum brake (leading trailing shoe brake) for its rear
wheels, as shown in the figure below.
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
The braking clearance of rear brake is adjusted automatically. In case the braking
clearance exceeds the set value due to the shoe plate wear, the wedge-shaped regulating
block 20 located between the lever and brake shoe will move downwards with the help of
spring force of tension spring 12 to compensate the clearance increase between the lever and
wedge-shaped regulating block so as to make the brake shoe further open toward the brake
drum to compensate the friction lining wear.
P-16
INSPECTION OF VACUUM BOOSTER
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
2
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
The rear brake is an automatic adjusting intermittent
drum brake, so it is necessary to adjust the parking
brake under the normal use, and it is required to
adjust the brake only when replacing the parking
brake cable, brake shoe assy. or brake wheel
cylinder. Adjust it in accordance with the following Adjusting Nut
procedures:
-- Loosen the handle of parking brake.
Adjusting Nut
-- Forcefully step on the brake pedal once.
-- Pull the handle of parking brake upwards 4
ratchets.
-- Tighten the adjusting nut until the two wheels isn't
available to be turned by hand, as shown in the
figure.
-- Unclip the parking brake, and check whether the
two rear wheels operate freely.
P-19
Notices:
* Use the diagnostic tester to find out the
seasons of failures, and then repair it;
* Unpack the spare part packaging just
before the beginning of installation;
* Only the original parts are available;
* Pay more attention to the cleanliness during
repair, and wipe it only with the non-woolen
cloth;
* Use the cleaning agent without the mineral
oil to wipe the outside surface clean before
repair;
* Do not use the compressed air or move the
vehicle when the system activates;
* Remove the ABS assy., and use the proper
plugs to block all outlets of hydraulic equipment
quickly as possible;
* Remove other parts which may disturb the
repair operation;
* Please use the brake fluid DOT 4, and do
not apply any mineral oil;
* Use the brake fluid to soak the seals and
O-ring, and it is prohibited to use the engine oil
or ointment;
* Check the availability of the regular brake
system and ABS brake function after the
completion of repair;
l Check the leakage of all joints of hydraulic
pipes.
Removal of MK20-I HECU assy.
* Turn off the ignition switch and disconnect the
negative wire of battery;
* Remove the electrical harness from the ABS
assy.;
* Step the pedal downwards >60 mm, and use the
pedal support to fasten it; It will shut down the
P-20
central valve of main bump and thus the brake fluid
cant flow out from the outlet when the system
activates;
* Remove the brake pipe A and B (connected to
the main pump) from the HCU, and then mark
them and use the plugs to block the outlet
immediately;
P-21
Refit of ABS Assy.
Caution: The plug of hydraulic opening on the ABS assy. can be removed only when
installing the brake pipe, the purpose of which is to avoid the foreign
material entering into the brake system.
* Install the ABS assy. on its support, with the tightening torque of 20+4Nm;
* Remove the plugs from the hydraulic opening, and install the brake pipe to determine
the right connection of the pipe;
* Install the brake pipe connected to the main pump;
* The tightening torques to assemble the brake pipe are 12+4 Nm (M101) and 15+3Nm
(M121);
* Add new brake fluid into the reservoir until the level of fluid reaches the MAX marks,
and degas in accordance with the specified method;
* Turn the ignition switch to ON, and ABS warning lamp lights and then switches off
after lasting for 1.7 s;
* Clear the DTC (Diagnostic Trouble Code) memory, and then read it and determine
whether there are some DTCs;
* Finally, drive the vehicle to determine the function of ABS, and you shall feel the
bounce of brake pedal;
P-22
Begin
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
OPERATION METHOD AND FUNCTION INTRODUCTION OF DIAGNOSTIC
TESTER
* Connect the diagnostic tester with the diagnostic socket (behind the glove box) under
the condition of power off, and then turn on the ignition switch.
* Turn on the power supply of the diagnostic instrument, and select the A15LHD Series
* Select the MK20-I/E Type ABS System
* Select the appropriate function item/channel number
* CH 01 Status information display
* CH 02 Failure inquiry
* CH 03 Hydraulic Control Unit Diagnostic
* CH 04 Fluid refilling and air bleeding
* CH 05 Clear DTC memory
* CH 06 End and Exit
* CH 07 Controller coding
* CH 08 Measured data display, such as wheel speed signal and etc.
* For example, ABS, ECUs versionor part number.
A15LHD-3550010
Coding: 01901
* Read the DTCs
* Click the MK20-I/E Type ABS System, select the DTC, and press the OK button,
in this case, the DTC will display on the screen if there is a DTC.
* Clear the DTC
1 Press the Clear button on the instrument after the TDC readout.
2 In this case, the following will display on the screen
If the failure is removed after pressing the Yes button, the DTC can be cleared
completely.
P-24
* ECU coding
The new ECUs shall be coded when replacing the HECUs or ECUs, otherwise the ABS
warning lamp will flash and the system fails to operate normally.
The original diagnostic tester is available to code the ECUs, the procedure of which is as
follows:
Coding: 01901
WSC: 000001
P-25
Fluid Refilling and Air Bleeding
* Wet type HCU
If the spare part is a wet type HCU, it is required to only refill the fluid and bleed the air in
accordance with the method available to the general brake system after replacing the HCU.
* Dry type HECU
If the spare part is a dry type HCU, apart from refilling the fluid and bleeding the air in
accordance with the method available to the general brake system, it is also required to
bleed the air of HECUs second circuit after replacing the HCU.
* DTC display mode
P-26
CAUTION WHEN FAILURE DIAGNOSING
The ABS adopts the electronic hydraulic control, so it is normal that the phenomena listed
in the table below occur under the normal operation of the ABS system, which shows they
aren't the failures.
Phenomena
Description
Sometimes, the sounds like the knock sound come from
System self-check the engine compartment after the engine starts, which is
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
Repair Details of Random Failure:
In the electronic control system, the instantaneous and poor contact problem may occur in such
positions as the electrical circuit and input/output signal passage. Thus it causes the random failure
or generates the DTC when ECU self-checking. If the reason of failure still exists, the abnormal
parts can be found only in accordance with the DTC Failure Check Sheet, but sometimes the reason
to cause the failure will disappear automatically, so it is difficult to find out the reason of problem.
In this case, simulate the failure and check whether it reoccurs in accordance with the following
methods.
When the major reason may be vibration:
* Slightly swing the connection up and down;
* Slightly swing the harness up and down, left and right;
* Slightly swing the sensor up and down, left and right;
* Slightly swing the other motion parts such as wheel bearing.
Caution: If the harness is twisted off or pulled tightly and then broken, it is necessary to
replace it with a new one, especially it may cause the transient open/short circuit of
sensor due to the up and down movement of suspension system when the vehicle is
traveling. Thus the actual vehicle test must be conducted when checking the signals
from the sensor.
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
DTC Failure Check Sheet Index
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
Pull out the harness
Abnormal
connector the motor,
directly connect the battery Replace the hydraulic control unit
supply to the battery
terminals and check whether
the motor operate normally.
Normal
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
No
Sensor is installed Install it normally
normally or not?
Abnormal
Check every sensor Repair or replace
P-31
Speed sensor
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
Speed sensor
4. The DTCs are 00283, 00285, 00290, 00287 Possible Cause
[Description] The DTCs will appear when the * Open circuit of sensor connector
sensor has the recognizable open circuit, * Short circuit of sensor
short circuit and other failures. * Short circuit between the sensor
[Hint] It may be caused due to the poor contact of connection or harness with the
sensor, the short circuit of coil or harness, counter-earth or power supply
or the failure of sensor signal processing * ABS ECU sensor signal
circuit in the ABS ECU. processing circuit failure
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
ABS coding error
5. The DTC is 01044 Possible Cause
[Description] The DTC will appear when the * The error connection of pin
ECUs software coding is inconsistent with in ABS harness
the hardware connection of ABS harness. * ABS coding error
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
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
Caution: This failure mode is available only when the system can communicate with
the diagnostic instrument (ABS ECU power supply normal) and there is no
DTC.
No Abnormal
Check the ABS warning lamp controller Replace
Normal
P-37
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
Too long brake pedal travel
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
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
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
APPENDIX I:
ABS Q&A
1. Whats ABS?
ABS, the abbreviation of Anti-lock Brake System, means the function of Anti-lock Brake
System (ABS), which is available to ensure that the vehicle traveling on different roads can
get the optimal brake distance, and, at the same time, has the better brake stability and
steering capacity.
2. Why the ABS is required?
The lock of front wheel will make the vehicle lose the steering capacity when braking, and
the lock of rear wheel will cause the disalignment or slide. Through preventing the wheel
from being locked, the ABS helps you to keep the operation control on the vehicle when
braking. In this case, you can change the direction and wind off the obstacle.
3. How to recognize whether your vehicle is quipped with ABS?
Two methods are recommended: the first one is to observe the instrument panel or switch
board when the vehicle starts and determine whether there is a ABS warning lamp which
lights at a short time. The second one is simpler, i.e., you consult your provider directly.
4. How the ABS works?
Based on the signals from the wheel speed sensor, the electronic controller in the ABS will
adjust the pressure on all wheel brakes via the solenoid valve in accordance with the
specified control logic, which looks like an experienced driver applies the repeat braking,
but the computer reacts more quickly than brain, and thus its effect is better.
5. How to determine whether the ABS is working?
You will feel the chattering of brake pedal when the ABS is working, and, at the same time,
you will also hear the sound from the hydraulic controller working. Here, keep in your mind
that you shall not be afraid of them, and shall step on the brake pedal reliably. Is the brake
distance of vehicle with ABS shorter than that of vehicle without ABS? In the great
majority of cases, the answer is YES, especially on the snow or wet road. But remember not
to forget to turn the steering wheel and wind off the obstacle at the critical moment.
6. How to do after ABS fails to operate?
The ABS warning lamp will light continuously once the ABS failure. In this case, the ABS
fails to operate, but the regular brake system is good. You just conduct the braking
operation in accordance with the regular method.
7. When the ABS warning lamp lights?
The ABS warning lamp will extinguish after it lights for 1.7 s after the vehicle starts. Since
then, the ABS warning lamp lights only when the ABS fails to operate. So, do not forget to
immediately get to the Service Station once the ABS warning lamp lights. It is
recommended that you dont repair the ABS as your pleasure.
P-42
FOUR DOS and FOUR DONTS for the use of ABS
FOUR DOS
Do step on the brake pedal using your foot at all times, which can ensure sufficient and
continuous braking force to make the ABS effectively play its role.
Do maintain the sufficient brake distance. 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
BODY
EXTERIOR ACCESSORIES S-4
REMOVAL, INSTALLATION & ADJUSTMENT OF ENGINE HOOD S-4
REMOVAL & INSTALLATION OF HOOD LOCK S-5
REMOVAL & INSTALLATION OF FUEL FILLER CAP S-6
REMOVAL & INSTALLATION OF EXTERIOR REARVIEW MIRROR S-6
REMOVAL & INSTALLATION OF RADIATOR GRILLE S-6
REMOVAL & INSTALLATION OF TRUNK LID TRIM PANEL S-7
REMOVAL & INSTALLATION OF ROOF TRIM MOULDING S-7
REMOVAL & INSTALLATION OF FRONT WHEEL HOUSE INNER FENDERS-8
REMOVAL & INSTALLATION OF REAR WHEEL HOUSE INNER FENDER .S-8
REMOVAL & INSTALLATION OF FRONT BUMPER S-8
REMOVAL & INSTALLATION OF REAR BUMPER S-10
INTERIOR ACCESSORIESA11 INTERIOR TRIM S-11
REMOVAL & INSTALLATION OF INSTRUMENT PANEL S-11
REMOVAL & INSTALLATION OF FRONT SEAT BELT S-14
REMOVAL & INSTALLATION OF REAR SEAT BELT S-15
REMOVAL & INSTALLATION OF FRONT SEAT S-16
REMOVAL & INSTALLATON OF REAR SEAT S-16
REMOVAL & INSTALLATON OF INNER REARVIEW MIRROR S-17
REMOVAL & INSTALLATON OF SUN VISOR & ITS BRACKET S-17
REMOVAL & INSTALLATON OF PASSENGER GRAB HANDLE S-17
INTERIOR ACCESSORIESA15 INTERIOR TRIM S-18
DISASSEMBLY AND ASSEMBLY OF INSTRUMENT PANEL S-18
DISASSEMBLY AND ASSEMBLY OF PACKAGE TRAY TRIM PANEL S-21
DISASSEMBLY AND ASSEMBLY OF REAR SPEAKER S-22
DISASSEMBLY AND ASSEMBLY OF SHIFT LEVER S-22
DISASSEMBLY AND ASSEMBLY OF GLOVE BOX S-22
DISASSEMBLY AND ASSEMBLY OF AIRBAG. S-23
S-1
DISASSEMBLY AND ASSEMBLY OF INTERIOR CEILING S-26
DISASSEMBLY AND ASSEMBLY OF REAR DOOR TRIM PANEL S-28
DISASSEMBLY/ASSEMBLY OF CARPET FOR PASSENGER COMPARTMEN.S-28
DISASSEMBLY AND ASSEMBLY OF SEATS S-29
DOORS & WINDOWS S-31
REMOVAL & INSTALLATON OF DOORS S-31
REMOVAL & INSTALLATON OF TRUNK LID S-33
REMOVAL & INSTALLATON OF FRONT DOOR GLASSES S-36
REMOVAL & INSTALLATON OF REAR DOOR GLASSES S-37
REMOVAL & INSTALLATON OF REAR QUARTER GLASS S-37
REMOVAL & INSTALLATON OF FRONT WINDOW REGULATOR S-38
REMOVAL & INSTALLATON OF REAR WINDOW REGULATOR S-39
MAINTENANCE OF BODY BEAM S-40
BAISC EXPLANATION OF MAINTENANCE OF CAR BODY S-40
PROCESS FOR ANTI-CORROSIVE PROTECTION LAYER S-41
SIZE ADJUSTMENT FOR MOVABLE PARTS S-43
OPENING SIZE OF ENGINE COMPARTMENT AND WINDSCREEN S-44
INSPECT THE SPACE BETWEEN COLUMN B & COLUMN C S-45
INSPECT THE SPACE BETWEEN HINGES OF COLUMN A S-46
INPECT THE SPACE BETWEEN HINGES WITH COLUMN B S-47
INSPECT THE OPENING SIZES OF FRONT DOOR & REAR DOOR S-47
PROTECTION WAX INSIDE CAR S-49
PROTECTION WAX OUTSIDE CAR S-50
DIAGNOSIS OF DAMAGES WITH CAR S-50
APPLICATION OF PUTTY ADHESIVES ON THE FRONT EXTERIOR PART OF
BODY S-52
APPLICATION OF PUTTY ADHESIVE FOR REAR EXTERIOR PART... S-54
BODY INTERIOR SPRAY COATED WITH PUTTY ADHESIVE S-56
CHECKING THE SIZE OF UNDERBODY PANEL S-59
INSPECT THE BODY BY USING THE FRAMEWORK OF SPECIAL
S-2
MEASUREMENT SYSTEM S-61
SUNROOF S-63
BRIEF INTRODUCTION OF SUNROOFS MODEL AND FUNCTION S-63
DESCRIPTION OF SUNROOF FUNCTION S-66
INSTRUCTIONS OF SUNROOF MAINTENANCE S-69
DISASSEMBLY AND ASSEMBLY OF SUNROOF S-72
REPLACEMENT OF GLASS PANEL S-76
REPLACEMENT OF SEAL S-78
REPLACEMENT OF SUNSHADE S-82
PROGRAM DESCRIPTION S-90
NOTES ON MAINTENANCE AND USEAGE S-91
S-3
EXTERIOR ACCESSORIES
REMOVAL, INSTALLATION & ADJUSTMENT OF ENGINE HOOD
REMOVAL
------Brace engine hood to remove washer
nozzle of windshield.
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
REMOVAL & INSTALLATION OF HOOD LOCK
REMOVAL:
------Remove the upper hood lock. Tightening
torque for the bolt as shown in the figure is
142Nm.
------Remove the lower hood lock.. When
removing the grid of radiator, remove the
four screws on the central part to remove
front panel.
INSTALLATION:
-----Install in the reverse order of removal.
S-5
REMOVAL & INSTALLATION OF FUEL FILLER CAP
REMOVAL
----Loosen the two screws between the filler
cap and car body.
INSTALLATION
----Install in the reverse order of installation
ADJUSTMENT
----Keep the size at (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 & INSTALLATION OF
TRUNK LID TRIM PANEL
REMOVAL
----Remove the screw of trim panel frame.
----Pry open the plastic clip with screwdriver to
remove trunk lid trim panel.
INSTALLATION
---- Install in the reverse order of removal.
REMOVAL
----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 & INSTALLATION OF
FRONT WHEEL HOUSE INNER FENDER
REMOVAL
----Loosen the screw between front wheel
house and its inner fender.
INSTALLATION
---- Install in the reverse order of removal.
REMOVAL
---- Loosen the screw between front wheel
house and its inner fender.
INSTALLATION
---- Install in the reverse order of removal.
S-8
----Remove radiator grille (refer to
REMOVAL & INSTALLATION OF
RADIATOR GRILLE).
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 & INSTALLATION OF REAR BUMPER
REMOVAL:
----Remove partial lining of rear wheel house.
Loosen the bolts between the lining and
rear bumper.
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
INTERIOR ACCESSORIESA11 INTERIOR TRIM
REMOVAL & INSTALLATION OF INSTRUMENT PANEL
REMOVAL:
S-11
----Pry out the vents from instrument panel
with screwdriver and remove the six
screws of instrument panel.
S-12
------Take the ash tray out and remove the clip
on the top of the ash tray. Remove the
two screws behind central console and
instrument panel.
S-13
------Remove the four screws on the two sides
of instrument panel. Remove the two
bolts at where instrument panel and
firewall meet from near wiper motor.
Remove the two bolts connecting the
instrument panel center and the bracket.
INSTALLATION
------Install in the reverse order of removal.
S-14
----Remove the nuts, loosen the bolt
secured to the inner lining of B-pillar,
and remove the B-pillar protective
panel.
S-15
----Loosen fixed bolt of automatic
rewinding to remove seat belt.
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
REMOVAL & INSTALLATON OF
INNER REARVIEW MIRROR
----Turn inner rearview mirror, making a 1
5 20 angle between pole and
beeline of vehicle.
S-17
INTERIOR ACCESSORIES (A15 INTERIOR TRIM)
Disassembly:
S-18
B. Begin the disassembly process from the
interior part of the car
Dismantle the steering wheel, pull the airbag
upwards and then remove it. (See disassembly
of airbag)
1. Loosen the lock nut between the steering
wheel and the Steering-axis.
2. Remove the control and protective switch
for the steering gear lamp.
Attention:
S-19
4. Loosen two fastening screws of the cover of
the instrument panel and remove the cover.
5. Remove the instrument fastening screws on
the partition in the driving compartment and
remove the instrument panel. Dismantle the
switch and the left bottom side cover of the
steering wheel. Dismantle the left bottom
side cover of the tool case.
S-20
8. Remove the plug; loosen the fastening
screws in the left side of instrument panel
and the screws of the left bottom side of the
supporting frame. Loosen the fastening
screws of the control device.
9. Remove the instrument panel, separate the
cable from the clamps and dismantle the
necessary electrical components.
Assembly
Assembly is the reverse of disassembly.
Remember the tightening torque of lock nut
should be 40N.m. During disassembly and
assembly, steps must be taken to avoid
dirtying those places that are very difficult to
clean. Keeping clean in the car is very
important.
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 AND ASSEMBLY OF REAR SPEAKER
Disassembly:
Remove the fastening screws at the top and bottom of the rear seat safety belt (applicable only
for the car model with safety belt). Loosen the four screws of the frame and dismantle it.
Assembly:
The assembly steps are reverse with the above and remember that the tightening for the safety
belt is 5010N.m.
S-22
DISASSEMBLY AND ASSEMBLY OF AIRBAG
Safety measures to be taken when working on the airbag system: the works include inspection,
assembly and maintenance. These operations can only be carried out by the appropriate
professionals.
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
Disassembly:
1. Disconnect the negative grid of the battery,
place the steering wheel at the center
position and face the hand wheel upwards.
Loosen the two hexagonal bolts between the
drivers airbag and steering wheel.
HAIRSPRING
S-24
DISASSEMBLY AND ASSEMBLY OF THE
CONTROL DEVICE
Disassembly
Disconnect the negative grid of the battery.
Disconnect the wiring terminal of the airbag control
unit, which is located on the vent under the instrument
panel.
Remove the air intake, which is beside the airbag
control unit under the auxiliary instrument panel.
Loosen the lock nut between the airbag control unit and the bracket.
When installing the control unit, the steps are the reverse of disassembly.
Note:
There must be nobody in the drivers compartment when reconnecting the battery
Assembly:
The steps are the reverse of disassembly.
Note:
1. When the lower terminal of hairspring is connected to the steering gear, it will stay at the
bottom position. Unless the following lifting eye indicated by the arrow in the figure, the
hairspring can not be rotated. If the hairspring is found to receive the pressure when tightening
the lock nut of the steering gear with a torque of 5ON.m, then the function is proved to be
normal. Inspect the cable and the hairspring of airbag. Remove the cover of airbag and its
protective cover; remove the battery and control unit.
2. It is dangerous to use the unused airbag inflator to activate the airbag device. In order to
prevent any potential accident, the airbag must be activated before the car is discarded or when
the servicing dates of the airbag activation components have expired. This is very important
because the exposed part may cause injury when it is suddenly activated by itself. The airbag
must be activated in the car with the door closed and the people involved must stay at least 10
meters away from the car during activation. When carrying the activation of the airbag together
with the airbag inflator of driver side, then it is required to remove them from the steering
wheel, and it is only necessary to remove the 2 hexagon lock nuts on that position during
disassembly. Connect the special cable, change the device on the steering wheel with the spare
part and tighten the hexagon lock nuts. The activated airbag can be treated as a common
scrapped container. It can be left in the car if the car has already been scrapped. If there is any
fault found (fault found during inspection that may affect its normal function), then it must be
noted and returned to the manufacturer through the spare parts shop. Use special packing for
new unit when the defective airbag is being returned.
S-25
DISASSEMBLY AND ASSEMBLY OF
INTERIOR CEILING
Disassembly:
Remove the armrest, sun visor and bracket
according to the instruction.
Pry the mirror and the interior lamp in the
headliner with a minus screwdriver and remove
them. Remove two lamps if the car is equipped
with two lamps.
REMOVE COLUMN A.
Take off the decorative cap, and remove the
seal of the door opening partially within the
working area.
Loosen the lock nut between the internal lining
and column A, and remove column A.
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
DISASSEMBLY OF COLUMN C:
Remove the decorative cap, after that loosen
the lock nut between the internal lining and
column C.
S-27
DISASSEMBLY AND ASSEMBLY OF
REAR DOOR TRIM PANEL
Disassembly:
1. Remove the armrest decorative fastening
bolt, and dismantle the armrest cover and
armrest base. Remove the inner door open
handle guard frame. Remove the safety
handle.
2. Remove the fastening bolt between the trim
panel and doorframe.
Assembly:
Assembly is the reverse of disassembly.
The tightening torque of the screw for the inner
handle assembly is 1.50.15Nm.
Note: Appropriate measures should be taken to
avoid dirtying the working area during
disassembly and assembly. It is very important
to maintain the cleanliness inside the car
during working.
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
DISASSEMBLY AND ASSEMBLY OF
SEATS
DISASSEMBLY AND ASSEMBLY OF
FRONT SEATS.
Disassembly:
1. Move the seat forward, remove the rear
brake. Loosen the fastening bolt of the
regulator and remove the guide rail.
S-29
DISASSEMBLY AND ASSEMBLY OF
REAR SEATS
Disassembly:
1. Pull out the rear adjusting lever so as to
disconnect the seat, and fold it forward.
2. Remove the guard plate for the seat cushion
and car fastening bolts.
3. Loosen the fastening bolt between the seat
of the rear beam and the car floor.
Assembly:
Assembly is the reverse of disassembly.
The tightening torque of the specified bolt for
the seat cushion assembly is 2.50.5mm.
REMOVABLE REAR SEAT
DISASSEMBLY AND ASSEMBLY OF THE
ENTIRE OR THE PART OF SEAT
Pull the adjustment lever of the rear seat
upwards and fold it until it disconnects with
the front-folded part of the seat.
Remove the guard plate on the fastening bolt
between the seat and car.
Loosen the fastening bolt of the corresponding
position on the rear beam of the car.
When installing, the steps are the reverse of
disassembly.
DISASSEMBLY AND ASSEMBLY OF
BUILT-IN FITTING ON THE BACK
UPPER SIDE OF REAR SEAT
Disassembly:
Loosen the fastening bolt of the flexible pin of
the built-in fitting.
Assembly:
Assembly is the reverse of disassembly.
S-30
DOORS & WINDOWS
REMOVAL & INSTALLATON OF DOORS
REMOVAL
----Remove two-side screws of door trim
panel.
----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
----Remove electrical wiring connector, and
pull out the bolts between door and the
hinge on front column, door check, while
another operator remove the door.
Tightening torque is 56 Nm.
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
----Loosen the bolts between central locking
unit and doorframe. Disconnect the lock
rod with lock to remove cable and
servomotor.
INSTALLATION
Install in the reverse order of removal.
ADJUSTMENT
----If adjust door lock striker erroneously,
which normally causes a failure in closing
the door, position of lock striker shall be
adjusted. 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
------Remove the gas spring which raises and
supports the trunk lid. Its one end is fixed
on the door, while the other end is fixed
on the drain channel of the strut.
S-34
------If the trunk lid is to be adjusted
horizontally, move the hinge on the side
until the value of movement becomes
consistent to the designed adjusting
value. Adjustment can also be conducted
through moving the center of the top.
------After adjustment is finished, the
connecting surface of rear door and the
side shall be checked as to if it is even or
not, if the joint with sealing rubber is
satisfactory or not. A good joint can
provide the trunk lid with pressure seal,
which can prevent water, air and dust
from admission or give out the chick
sound.
------Check if the transparent plastic adhesive
tape for preventing rubber block from
contacting the coated paint of vehicle
body exists or not. If the tape does not
exist or it has already aged, isopropyl
alcohol or heptane is to be used for
cleaning the contact surface, and new
adhesive tape is to be pasted.
S-35
------Remove the two screws between the
bottom part of central lock and rear end
panel. For CHERY modelA15RHD
with luggage boot trim panel available,
the trim panel shall be removed before
removing the screws.
------Install lock in the reverse order of its
removal. Tightening torque for screws of
side locks is 7.20.7Nm. Tightening
torque for screw on top of lock striker is
7.20.7Nm
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
REMOVAL & INSTALLATON OF REAR
DOOR GLASSES
REMOVAL
----Before removal of front door glasses, the
trim panel and waterproof film shall be
removed first following instructions.
----Pull out the inner and outer door waterproof
strips; begin the removal from the rib of the
internal side of the central door frame.
----Place the glass at the center of the door
frame. Loosen the fixing slot of the
window regulator support.
----When removing the glass, incline the upper
part of the glass towards outside direction
of the door.
Install in the reverse order of removal.
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
REMOVAL & INSTALLATON OF FRONT WINDOW REGULATOR
REMOVAL
----Before removal of front window regulator,
the trim panel and waterproof film shall be
removed first following instructions.
----Loosen six screws that secure window
regulator to the inner panel of the door as
shown in the figure.
----Disconnect the motor connector of window
regulator and take out the regulator. 105
Removal of window regulator is performed
separately from that of glass.
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
REMOVAL & INSTALLATON OF
REAR WINDOW REGULATOR
REMOVAL
----Before removal of front window regulator,
the trim panel and waterproof film shall be
removed first following instructions.
----Loosen six screws that secure window
regulator to the inner panel of the door as
shown in the figure.
----Disconnect the motor connector of window 105
regulator and take out the regulator.
Removal of window regulator is
performed separately from that of glass.
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
MAINTENANCE OF BODY BEAM
S-40
must not exceed 80.
In the process of welding, the following measures must be taken to prevent the vibration of
the electronic devices.
1. Directly connect the earth wire of the electronic welding device to the welding point.
Attention must be taken to inspect the connection, and ensure that there is no unnecessary
part or insulation part in between the earth wire terminal and spot welding point.
2. ECU shall be removed first. The electronic device or electrical circuit should be avoided to
make contact with the earth wire terminal or welding rod.
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
The quality of spray coating process for surface protective layer plays a decisive part for the
quality of anticorrosive function with protective layer. The processes include.
1. General cleaning, and coating with phosphate.
2. General spray coating with alkyl ester-based paint.
3. PVC gel is sprayed at the joints of body, to prevent leakage, and PVC gel is also to be
sprayed for the lower plate underneath the car body (such as gear case, the lower plate of
car body, door sill, and other places), to prevent the general assembly from damage of
sandstones.
4. Primer is to be spray coated through static electric system, as the second protective layer.
5. According to the principle for optimal efficiency, lacquer enamel shall be sprayed one or
two times (as primer or cleaning coat) through static system.
6. Protection wax is to be sprayed in the open area of the general assembly through timed
spraying system.
PROTECTION OF UNDERBODY PANEL
PVC
Lacquer Putty
S-42
SIZE ADJUSTMENT FOR MOVABLE PARTS
To facilitate test and re-installation of the body moveable parts, the correct clearances of
these parts after adjustment are listed below.
TEST DATA
A=40.5 B=6.51 C=40.5 D=6.51 E=40.5 F=7.51 G=40.5
S-43
OPENING SIZE OF ENGINE
COMPARTMENT AND WINDSCREEN
S-44
Size Code STD Value Part Measured
A 12352mm Opening of Boot
B 11422mm Y-Directional
Distance of Boot
S-45
INSPECT THE SPACE BETWEEN
HINGES OF COLUMN A
S-46
INPECT THE SPACE BETWEEN HINGES
WITH COLUMN B
S-47
S-48
PROTECTION WAX INSIDE CAR
Protection wax at openings contains 60% solid solution, and is coated in an immersion
method at 120.
S-49
PROTECTION WAX OUTSIDE CAR
Protection Wax for Engine Compartment
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
WATER TIGHTNESS
After the body is operated or maintained, this is the most important instruction in this
Chapter.
If these instructions are not followed, water leakage will frequently happen inside the car, and
it would be very difficult to determine the exact position of leakage, as water inside the car
has many uncertain flows, and can possibly flow directly along the water channel.
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
PROTECTION OF UNDERBODY PANEL
It is to be reiterated here that during maintenance or replacement of welds or moveable parts
of the body, if the protection paint inside the underbody panel or on the appearance is to be
removed, then anti-rusting and sound insulating protection layer must be substituted after
maintenance or replacement. Special attention should be paid to areas impacted by fatigue
which mainly attributes to clay and sandstones ejected by wheels.
S-52
TABLE FOR APPLICATION OF PUTTY ADHESIVE
S-53
APPLICATION OF PUTTY ADHESIVE FOR REAR EXTERIOR PART
S-54
TABLE FOR APPLICATION OF PUTTY ADHESIVE
S-55
BODY INTERIOR SPRAY COATED WITH PUTTY ADHESIVE
S-56
TABLE FOR APPLICATION OF PUTTY ADHESIVE
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
BODY FRONT INTERIOR SPRAY COATED WITH PUTTY ADHESIVE
S-58
CHECKING THE SIZE OF UNDERBODY PANEL
S-59
STRUCTURE OF
GUARD PLATE
S-60
INSPECT THE BODY BY USING THE FRAMEWORK OF SPECIAL
MEASUREMENT SYSTEM
S-61
INSPECT THE BODY BY USING THE FRAMEWORK OF SPECIAL
MEASUREMENT SYSTEM (Fixed mechanical tools are to be used during inspection)
S-62
SUNROOF
S-63
PARTS OF SUNROOF
S-64
PARTS LIST OF SUPER 300
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
DESCRIPTION OF SUNROOF
FUNCTION
1. CONTROL PANEL
a) This button is preset position 1;
b) This button is preset position 2;
This button is control button for inclining
and rearward sliding;
This button is control button for forward
sliding;
c) This is control button for immediately
closing.
S-66
3. SELECTION OF TILT HEIGHT
When the sunroof is closed, press the button
continuously, the glass panel will open to the
maximum tilt position automatically.
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
Gently press the or button (less than 0.1
second), the sunroof will open to the preset
position 1, or the preset position 2
automatically, and these two positions can be
set repeatedly.
5. AUTOMATIC CLOSING
When the sunroof is opened to any position,
cut off the power supply of sedan, the sunroof
will make a sound of CREAK.
S-68
If the sunroof encounters any obstruction
during its automatic closing, it will open to the
maximum position again, and try to close
repeatedly until the obstruction is eliminated. If
press the button continuously, the anti
obstruction mechanism will be disabled.
INSTRUCTIONS OF SUNROOF
MAINTENANCE
S-69
Remove the two fastening bolts in the front of
interior trim rim.
S-70
Install the motor and the SCU in the reverse
order of step 7.
S-71
Install the cover of control buttons.
S-72
4. Remove the 2 fastening bolts in the front of
interior trim rim.
S-73
8. Remove the interior fastening frame, make
the rear part to be inclined downwards, push
forward and then the interior fastening frame
can be removed.
Assembly:
10. Apply silicon gel with a width of 3 cm on
the position indicated in the figure.
S-74
12. Install the interior fastening frame with an
angle of 45 degrees, front high rear low
respectively, firstly fasten the front part,
and then push the rear section rearward. A
fastening bolt shall be tightened in the rear
middle area of interior fastening frame to
prevent dropping.
S-75
16. Tighten the fastening bolts of interior trim
rim.
S-76
3. Turn the fastening pin of glass panel by 90
degrees in clockwise with flat screwdriver to
remove the fastening pin of glass panel.
(Perform on another side in the same way).
Assembly
5.Slide the new glass panel into the mechanical
devices in parallel.
S-77
7.Push the fastening pin of glass panel to the
proper position.
REPLACEMENT OF SEAL
1. Fully open the sunroof.
S-78
4. Pull out the glass panel from the mechanical
devices in parallel with proper attention.
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
8. Place the seal on the upper frame naturally,
and the rabbet center of seal must be aligned
with the center of fastening block of glass
panel. Strech this part of seal with proper
attention in assembly.
S-80
12. Install the fastening pin of glass panel by
rotating 90 degrees only.
S-81
REPALCEMENT OF SUNSHADE
1. Fully open the sunroof.
S-82
5. Remove the interior trim rim (pull
downward as shown in the figure). Pay
attention not to damage the control buttons.
Assembly
7. Install the right guide device and the rear
supporter of sunshade.
S-83
8. Wind up the sunshade and wrap the string
on the right guide roller.
S-84
12. Push out the guide lock as shown in the
figure.
Assembly:
14. Place the new guide lock in the guide rail.
S-85
16. Disengage the front riser and the rail slide
device, then remove the latter.
S-86
19. Install in the reverse order of step 11.
S-87
23. Install in the reverse order of step 7.
S-88
26. Install the rack, the pinion and the pinion
cover. Note that the pinion should be
placed at the center.
S-89
PROGRAM DESCRIPTION
S-90
NOTES ON MAINTENANCE AND
USEAGE
1. MAINTENANCE OF SUNROOF
S-91
2. NOTES:
S-92
Note: Make sure that there is no obstruction
on the top of sedan to disturb the movement
of glass panel prior opening the sunroof.
S-93
BODY ELECTRICAL SYSTEM
CHARGING AND STARTING SYSTEM T-4
REMOVAL/INSTALLATION OF THE BATTERY T-4
INSPECTION OF THE BATTERY T-4
CHARGING OF THE BATTERY T-5
REMOVAL/INSTALLATION OF THE GENERATOR T-5
INSPECTION OF GENERATOR T-8
REMOVAL/INSTALLATION OF STARTER T-9
OVERHAUL OF STARTER T-9
LOAD INSPECTION OF STARTER T-10
LIGHTING SYSTEM T-11
REMOVAL/INSTALLATION OF LIGHTINGS FOR THE COMPLETE CART-11
REMOVAL/INSTALLATION OF THE HEADLAMP T-11
REMOVAL/INSTALLATION OF THE FRONT FOG LAMP T-11
REMOVAL/INSTALLATION OF THE SIDE TURN SIGNAL LAMP T-12
FIXED REMOVAL/INSTALLATION OF TAIL LAMP T-12
FLEXIBLE REMOVAL/INSTALLATION OF TAIL LAMP T-12
REMOVAL/INSTALLATION OF LICENSE LAMP T-12
REMOVAL/INSTALLATION OF INTERIOR CEILING LIGHT T-13
REMOVAL/INSTALLATION OF TRUNK LAMP T-13
REMOVAL/INSTALLATION OF HIGH MOUNTED STOP LAMP T-13
REMOVAL/INSTALLATION OF DOOR SWITCH T-14
REMOVAL/INSTALLATION OF INSTRUMENT CONTROL SWITCH T-14
REGULATION OF HEADLAMP T-14
COMMON FAILURES OF LIGHTING SYSTEM T-15
COMMON FAILURES TROUBLESHOOTING OF HEADLAMP T-15
COMMON FAILURES AND TROUBLESHOOTING OF FOG LAMP T-15
COMMON FAILURES AND TROUBLESHOOTING OF BACKUP LAMP T-16
COMMON FAILURES AND TROUBLESHOOTING OF STOP LAMP T-16
T-1
COMMON FAILURES AND TROUBLESHOOTING OF TURN SIGNAL LAMP..T-17
IGNITION SYSTEM T-18
SUMMERY OF IGNITION SYSTEM T-18
REMOVAL OF IGNITION COIL AND SPARK PLUP T-19
OVERHAUL OF IGNITION SYSTEM T-20
INSPECTION OF IGNITION TIMING T-20
INSTRUMENT SYSTEM T-22
INTRODUCTION OF INSTRUMENTS T-22
SYSTEM COMPONENTS AND FUNCTION LIST T-23
WORKING SCHEMATIC DIAGRAM OF INSTRUMENT SYSTEM T-24
FUNCTION LIST OF INSTRUMENT SOCKETS T-26
SPEEDOMETER T-27
WATER TEMPERATURE METER T-27
WORKING PRINCIPLE OF WATER TEMERATURE SENSOR T-28
FUEL METER T-29
MALFUNCTION DIAGNOSIS AND TROUBLESHOOTING T-30
ELECTRIC WIPER AND WINDOW WASHER SYSTEM T-35
INTRODUCTION OF WIPER SYSTEM T-35
ELECTRIC SCHEMATIC DIAGRAM OF FRONT WINDOW WIPER AND
WASHER T-37
FUNCTION TABLE OF WIPER AND WASHER COMPONENTS T-38
REMOVAL/INSTALLATION OF WIPER AND WASHER SYSTEM T-38
FAULT DIAGOSIS AND TROUBLESHOOTING T-39
ELECTRIC WINDOW REGULATOR SYSTEM T-44
INTRODUCTION OF ELECTRIC WINDOW REGULATOR SYSTEM T-44
FAULT DIAGNOSIS AND TROUBLESHOOTING T-45
CENTRAL DOOR LOCK SYSTEM T-46
INTRODUCTION OF CENTRAL DOOR LOCK SYSTEM T-46
PRINCIPLE OF CENTRAL DOOR LOCK CONTROL T-46
FAULT DIAGNOSIS AND TROUBLESHOOTING T-46
T-2
AIRBAG SYSTEM T-48
WORKING PRINCIPLE OF AIRBAG T-48
OPERATION CONDITIONS T-49
OPERATION PROCESS T-49
ASSEMBLY PARTS AND WORKING PRINCIPLE OF AIRBAG T-51
FAULT DIAGNOSIS AND OVERHAUL T-55
REMOVAL/INSTALLATION OF AIRBAG T-61
REMOVAL/INSTALLATION OF WIRINGS CONNECTORS T-64
REMOVAL/INSTALLATION OF SPIRAL CABLE T-64
REMOVAL/INSTALLATION OF STEERING WHEEL AIRBAG T-64
CONTROL MODULE T-66
NOTES ON SAFETY OPERATION T-67
SOUND SYSTEM T-69
FUNCTIONS OF CONTROL INSTRUMENATION PANEL T-69
OPERATION INSTRUCTION T-70
OTHER FUNCTIONS T-72
REMOVAL/INSTALLATION OF SOUND SYSTEM T-73
MALFUNCTION DIAGNOSIS AND TROUBLESHOOTING T-75
CIRCUITRY DIAGRAM OF THE COMPLETE CARATTACHMENT
T-3
CHARGING AND STARTING SYSTEM
REMOVAL/INSTALLATION OF BATTERY AND INSPECTION
Removal:
----Disconnect the negative and positive
cables of battery.
----Loosen the bolt of front battery
clamping steel plate, and remove
the clamping steel plate.
----Move the battery forward, isolate
the back clamping plate and take
down the battery.
Note: After removing of the battery,
be sure not to simply dispose
it around; it should be put
horizontally in a designated Bolt of battery clamping plate
place.
The installing steps are reverse to
those for removal.
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
Approximate temperature of battery Minimum voltage (V)
21C70F 9.6
16C61F 9.5
10C50F 9.4
4C39F 9.3
-1C30F 9.1
-7C19F 8.9
-12C10F 8.7
-18C0F 8.5
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
part of the battery away from water.
Connect the battery to the charger, and adjust
the charging current accordingly.
As heat discharged by the exhaust manifold could damage the generator, you must
ensure that the heat discharging guard and insulation device are firmly installed on the
generator.
T-6
Installation of driving belt and tensioner
assembly:
Disconnect the negative grid of the battery.
Use 3 M8 Allen screws to install the
tensioner assembly on the bracket of the
generator, with a tightening torque of
252N.m.
Install the multi-wedged belting; Pull out the
pin on the tensioner assembly so as to
tension the driving belts in the tensioner
pulley. Inspect the driving belts to see
whether they are all inserted properly in the
driving wedge of the pulley wheel.
The installing steps are reverse to those for
removal.
Adjusting method of multi-wedge belting
and tensioner assembly alignment:
Disconnect the negative grid of the battery.
Use spanner to rotate the engine crankshaft
belt pulley to drive the multi-wedged belting
for at least one revolution.
Observe the alignment status of the multi
-wedge belting and tensioner assembly, if
the multi-wedge belting center exceeds the
tensioner assembly center, then remove the
tensioner assembly and add spacers to adjust
the centering.
The installing steps are reverse to those for
removal.
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
Use voltmeter to measure the voltage value
of the generator output terminal.
Standard value: Engine idling; Temperature: 20
, Output voltage: 13-15V.
Switch on the following devices and observe
the increase of readings of the voltmeter:
Headlamp
Air conditioning
Back window defroster
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
REMOVAL/INSTALLATION OF STARTER
Warning:
When connecting wires of the battery are in on-state, and at this time if you contact the
generator terminal to the car body, sparks will happen. This may cause body injury, fire
and the sparks may damage the electrical components. Therefore before carrying the
following operation, you must disconnect the negative grid of the battery first.
Disconnect the negative grid of the
battery.
Apply lubricating grease of about 5
grams evenly on the inserting shaft of the
starter.
Insert the starter into housing of the
clutch.
Screw three bolts and tighten them(one
of the bolts is M10135), with the
tightening torque of 404Nm.
Connect the wiring harness to the
positive grid of the starter, and the starter
wiring harness connector. Pay attention
not to ground the wiring harness so as to
prevent short circuit and catching fire.
The installing steps are reverse to those
for removal.
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
Technical parameters
Voltage valueV Current value
A
11 Less than 90
T-10
LIGHTING SYSTEM
T-11
Place the fog lamp into the installation hole from the front, and ensure that the 3 screw
holes are concentric with the holes on the front bumper;
Tighten the 3 self-tapping screws, with a tightening torque of 1.50.2N.m;
Install the grilles on the bottom part (see instruction in car body)
3. Removal/installation of side turn signal lamp: (Disconnect the negative grid of the
battery)
Connect the wiring harness from the lamp holder;
First align the clipping end with car body in the correct direction, and then press it in by
force.
4. Removal/installation of fixed part of tail
lamps (including position lamp/brake lamp,
and turn signal lamp):
Align at the holes of car body, so as to install
the lamp on the body properly;
Tighten the 3 fixing screws, pay attention to
adjust the facial gap with the car body, feel
the difference in height with hand and make
necessary adjustment while tightening;
Plug the wiring harness onto the lamp
holder, and put back the carpet.
5. Removal/installation of moving part for
the tail lamp (including the backup lamp
and tail fog lamp)
Align at the holes of the car body, so as to
install the lamp on the body properly;
Tighten the 4 fixing screws, pay attention to
adjust the facial gap and spacing (the trunk
lid may be closed) with the car body and
fixing parts, feel the difference in height
with hand and make necessary adjustment
while tightening;
Plug the wiring harness onto the lamp
holder, and put down the trunk lid.
6. Removal/installation of license lamp
Connect the connector of the wiring harness properly;
Align the self-tapping screw with the hole center of expansion nut; tighten two self-tapping
screws with a tightening torque of 1.50.2N.m. Assemble the guard plate of license lamp;
T-12
Align lock core of the trunk with the hole, so as to match the guard plate with the car body
properly;
Tighten 2 self-tapping screw, pay attention to adjust the facial gap, spacing and other
differences between the car body and the movable part, feel the difference in height with
hand and make necessary adjustment while tightening;
Open the trunk lid;
Tighten 2 square nuts of the fixing bolt;
Assemble the linkage rod, lid, etc. of the lock hole (see instruction of car body), and then
put down the trunk lid.
7. Removal/installation of interior ceiling
lamp
Connect the connector of the wiring harness
properly
Place it right into the installation hole of the
ceiling towards the correct direction, firstly
align one end with the ceiling and then press
the ceiling light into the proper position with
hand.
T-13
10.Removal/installation of door switch
Disconnect the negative grid of the battery.
Loosen the self-tapping screw of the door switch with a cross screw driver.
Pull out the door switch, and separate the wiring harness connectors.
11.Removal/installation of control switch for dash lights
Disconnect the negative grid of the battery.
Reach the bottom part of the instrument panel with hand, and press down the clip of the
control switch for dash lights.
Pull the control switch for dash lights forward and remove it.
The installing steps of above components are reverse to those for removal
12. Beam adjustment for headlamp
The correctness of the beam adjustment for front headlamp is vital to the driving safety.
Therefore, only special instruments are allowed to be used to adjust the beam, and pay
attention to the stipulated laws during adjustment.
13. The followings must be fulfilled before adjustment
Air pressure of car tyres must comply with the standard;
The vehicle should be non-load (other than the spare tyre and tool kit, the weight of the car
normally includes the weight of the driver);
The car should be parked on a horizontal road or working site;
The surface of the headlamp reflector must be clean without any contamination;
Check whether power works normally and bulbs are installed properly.
Two screws linking the front headlamp can be adjusted towards the horizontal or vertical
position.
When adjusting the front right headlamp, the protection cover must be removed. The
adjustment screw for the front left headlamp is symmetrical with the front right one. The
adjustment method is the same.
T-14
COMMON MALFUNCTIONS OF LIGHTING SYSTEM / TROUBLESHOOTING
1.COMMON MALFUNCTIONS OF FRONT HEADLAMP / TROUBLESHOOTING
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
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-16
5. COMMON MALFUNCTIONS OF TURN SIGNAL LAMP AND
TROUBLESHOOTING
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
IGNITION SYSTEM
T-18
REMOVAL /INSTALLATION OF IGNITION COIL AND SPARK PLUGS:
T-19
OVERHAUL IGNITION SYSTEM
T-20
(4) Wait until the cooling fan stops.
3. With the help of WDS or corresponding instrument, check whether the ignition timing falls
within the scope of the specification.
Ignition timing:
Approx.: 105 degrees advancing TDC
4. When the engine speed is gradually increasing, confirm that the ignition timing is also
correspondingly advanced forward.
Check idling engine speed
Note:
The ignition timing must not be adjusted.
Checking the ignition timing requires the use of WDS or corresponding instrument.
1. Switch off all the electrical devices in the vehicle.
2. The procedures of preheating the engine are as follows:
1Start the engine.
2Keep the rotation speed of the engine at about 3,000 R.P.M. until the cooling fan starts to
rotate.
3Release the fuel accelerating pedal.
3. With the help of WDS or corresponding instrument, check whether the ignition timing falls
within the scope of the specification.
Engine idle speed (480ED-1000010EA combined with electronics)
T-21
INSTRUMENTATION SYSTEM
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
System components and functions are as follows:
T-23
The switch is installed on the engine body. When
Warning switch for low oil pressure the oil pressure drops, the switch will be activated
and switched on the warning lamp.
The switch is installed in the engine oil tank. When
Warning switch for engine oil level the level of engine oil drops, the warning lamp will
be switched on.
The switch is installed in the main pump oil storage
Warning switch for brake oil level tank of the brake. When the brake oil level drops,
the warning lamp will be switched on.
The switch is installed on the driving brake pedal
Brake switch bracket. When the pedal is pressed, the switch will
be activated to switch on the warning lamp.
When the car door is opened, the switch will be
Courtesy lamp switch
activated to switch on the warning lamp.
When an abnormal condition is detected, the
warning signal will be transmitted or grounded
Warning lamp
automatically, thus switching on the relevant
warning lamp.
The warning signal will be transmitted or grounded
automatically, thus switching on the relevant
Indicator lamp
indicator lamp or keep the driver informed of the
relevant status.
T-24
hand
ABS left turn right turn diagnosi air bag seat belt brake rotary speed speed,
computer, light light, s switch signal of steering device
/ brake ECU
purple oil
and black black
and
b
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
The 28-socket connector of the wiring harness of combination instrument
T-26
1. SPEED ODOMETER
The Chery sedan A15LHD employs the cross coil type speedometer to indicate the driving
speed and accumulated road mileage, as well as equipped with digital odometer. The section
for measuring car speed employs a magnetic type of structure, while the section for recording
mileage is controlled by multifunction liquid crystal display.
See figure (Illustration-2)
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
The pointer head of the cross coil meter is a kind of electromagnetic device. The coils are
round on the surface of its magnetic rotor in four directions, with an included angle of 90
between the two adjacent coils. The strength of the current passing through the coils is
depended on the resistance of the sensor, so that the magnetic flux densities produced by the
coils in four directions are varied correspondingly, which subsequently activates the rotation
of the magnetic rotor and the movement of indicator needle.
3. FUNCTION AND PREINCIPLE OF WATER TEMPERATURE SENSOR
The water temperature sensor of Chery sedan A15 LHD employs the thermo-sensitive
resistance, which is shown in the figure above:
The coolant temperature sensor is used to inspect working temperature of the engine; the
ECM will provide the best control program for the engine according to different temperature
environment;
Composition and working principle: The sensor is a thermo-sensitive resistance of negative
temperature coefficient (NTC). Its resistance will decrease as the coolant temperature
increases, but not linearly related. This thermo-sensitive resistance of negative temperature
coefficient is loaded into a copper heat-conducted sleeve. The ECU converts the changes of
value of the thermo-sensitive resistance into variable voltages supplying the ECU via a
divider circuit so as to monitor the changes of the water temperature. (ECUs internal
structure)
Pin: the sensor has 3 interchangeable pins totally.
1 Coolant temperature sensor signal (ECU39#)
2 Sensor signal ground (ECU35#)
3 Another wire is used to connect the water temperature signal of the instrument.
Installation: the coolant temperature sensor is mounted on the sub-loop passage of the coolant
behind the engine.
T-28
The thermo-sensitive resistance is made of a kind of semiconducting material with negative
temperature coefficient, where its resistance will sharply decrease as the temperature
increases.
5. FUEL METER
The operation of the fuel meter is basically the same as the water temperature meter. It is also
the cross coil type of indicator needle meter. See figure below (Illustration-5)the fuel meter
is located at right of the figure.
T-29
Malfunction Malfunction Malfunction diagnosis
Components Remarks
symptoms reasons and troubleshooting
(1) The Hall
Speed Sensor of
(1) If the speedometer does
speedometer.
not function, firstly inspect
(2) The indicator
the engagement of Hall
needle of
Speed Sensor and the drive
speedometer is
gear to verify that there is
jammed.
any malfunction. If
The (3) Output shaft
everything is normal, then
The speedometer driving gear of
remove and inspect the
speedometer does not gearbox is
speedometer.
does not function or seriously worn
(2) In the case of only
function or there is a large out or the gears
inaccurate indication
have an error between engagement
malfunction, it is caused
excessive the indicated clearance is
usually by the damage of
error. speed and the excessive.
the interior part of the
actual speed. (4) The
meter.
speedometer is
(3) Inspect the link
damaged.
between the speed signal
(5) The engine is
and the ECU, and the
damaged.
signal wire between engine
(6) The
and instrument.
connecting circuit
is faulty.
(1) The water (1) Open the engine bonnet
temperature meter and pull out the connector
is damaged. of the water temperature
(2) The water sensor. Inspect whether the
temperature resistance of water
sensor is temperature sensor is
ineffective. normal; if it is normal,
(3) The circuit of inspect the signal from
water temperature sensor to the ECU, and
The indicator
meter is open. signal from the ECU to
needle of
(4) The voltage instrument.
The water water
regulator is (2) If the above circuits are
temperature temperature
damaged. normal, connect it to the
meter does meter does
(5) The ECU is connector of combination
not function. not function
damaged. instrument and turn on the
after engine
ignition switch. Inspect to
starting.
see whether voltage
appears at the yellow/red
wires of water temperature
sensor connector. If
voltage appears, it
indicates that the water
temperature sensor is
damaged; if there is no
voltage, it indicates that
T-30
water temperature meter or
voltage regulator is faulty.
(3) Remove the instrument
panel and maintain the
normal connection of the
wiring harness. Connect a
multimeter between the
output terminal 1 of
voltage regulator positive
grid and the grounding
terminal 2 to measure the
voltage. If the voltage is
higher than 10.5V or lower
than 9.5V, it indicates that
the voltage regulator is
faulty; Otherwise it
indicates that water
temperature meter is faulty
itself.
(1) The fuel meter (1)Verify that there is
is damaged. gasoline in the tank.
(2) The fuel meter (2)Turn on the ignition
sensor is switch and verify that the
ineffective. water temperature gauge
(3) The circuit of functions properly. If the
fuel meter is water temperature gauge
open. functions properly, it
(4) The voltage indicates that the voltage
regulator is regulator of the combined
damaged. instrumentation functions
(5) There is no properly.
fuel in the fuel (3) Disconnect the plug of
The indicator
tank. the sensor of the fuel See
needle does
The fuel meter, inspect with circuitry
not move after
meter does multimeter that there is diagram of
ignition
not function electricity in the the fuel
switch is
purple/black wire, and then meter
turned on.
inspect the grounds of the
brown wire and the body.
If there is electricity in the
purple/ black wire and the
brown wire is normal,
which indicates that there
is malfunction in the fuel
meter sensor, and it must
be replaced.
(4) If there is no electricity
in the purple/black wire,
then verify that the circuit
between purple/black wire
T-31
of the plug of the fuel
meter sensor, and the 21#
socket of the connector of
the combined
instrumentation is open,
the route of the circuit is:
purple /black wire of the
plug of the fuel meter
sensor the 3# socket of
the connector M of the
relay plate the #12
socket of the connect U1
of the relay plate the
brown wire the #21
socket of the connector of
the combined
instrumentation.
(5) If the circuit is on and
the brown wire is normal,
then there is malfunction
in the fuel meter.
(1) Malfunction Firstly identify whether the
of low pressure lubricating system or
switch (30KPa warning system is faulty.
switch). This is normally done by
(2) Low pressure measuring the oil pressure
switch circuit is to diagnose the
short. malfunction.
(3) Malfunction (1) When connecting the
of high pressure positive grid of the battery
switch (180kPa and the low-pressure
switch). switch with a diode testing
(4) High-pressure light, the latter will be
The warning
switch circuit is lighted. Start up the engine
lamp for
Oil warning open. and increase the speed
engine oil
lamp always (5) Pressure in the slowly. When the pressure
pressure is
on lubricating oil reaches 15-45KPa, the
always on
circulation can diode-testing light should
while driving.
not reach the be off. Otherwise it
specified indicates that the
requirement. low-pressure switch is
faulty; run the engine at
idle speed, with oil
pressure higher than
45KPa, the light-emitting
diode should be off. If the
pressure is lower than
15KPa, it indicates that the
lubricating system is
faulty.
T-32
T-1
(2) Connect the
diode-testing light to
high-pressure switch and
increase the engine speed
slowly. When the oil
pressure reaches
160-200KPa, the
light-emitting diode should
be lighted. If it is not
lighted, then it indicates
that the high pressure
switch is faulty; further
increase the engine speed
up to 2000r/min, then the
oil pressure should reach at
least 200KPa. Otherwise it
indicates that the
lubricating system is
faulty.
Upon the above inspection,
if the lubricating system
and lubricating oil pressure
switch are both normal,
but the warning lamp
keeps on indicating that
the malfunction is still
present, and it should
inspect the circuit
malfunction according to
the circuit diagram.
Pay attention when
carrying out the
inspection: for low
pressure warning switch
circuit, the warning lamp
will be lighted when there
is a short circuit to ground,
so it should emphasize on
inspecting to see whether
there is any grounding;
while for high pressure
warning switch circuit, the
warning lamp will be
lighted when there is an
open circuit as well as
when the engine speed is
over 2000r/min, so it
should emphasize on
inspecting to see whether
there is any open circuit.
T-33
(1) Inspect to see whether
the engine coolant
temperature is actually too
high and the level of the
storage tank is too low.
(2) If all the above
inspection are normal, then
(1) Coolant level pull out the connector of
in storage tank is the storage tank level
The warning too low. switch. If the warning
lamp for (2) Malfunction lamp is off, it indicates that
coolant is of coolant level the liquid level switch is
Coolant always on switch. faulty.
warning lamp while driving, (3) Malfunction (3) If the warning lamp is
is always on. whatever its of warning switch still on, then connect the
in cold for coolant connector of coolant level
condition or temperature. switch and pull out the
hot condition. (4) Warning lamp connector of the coolant
circuit is temperature warning
grounded. switch. If the warning
lamp is off, it indicates that
the warning switch of
coolant temperature is
faulty; If the warning lamp
is still on, it indicates that
the circuit is grounded
somewhere.
(1) Inspect to see whether
the brake oil level is too
low or not.
(2) If the oil level is
normal, then pull out the
(1) Brake oil level connector of brake oil
is too low. level switch. If the
Brake (2) Malfunction warning lamp is off, it
warning lamp of brake oil level indicates that the brake oil
Brake
is still on even switch. level switch is faulty.
warning lamp (3) Malfunction
if the hand (3) If the warning lamp is
is always on. of hand brake
brake is still on, pull out the
switch. connector of the brake
released.
(4) Warning lamp switch. If the warning
circuit is faulty. lamp is off, it indicates that
the brake switch is faulty;
If the warning lamp is still
on, it indicates that the
circuit is grounded
somewhere.
T-34
ELECTRIC WIPER AND WINDSHIELD WASHER SYSTEM
SYSTEM DESCRIPTION
The wiper is mainly consisted of the wiper motor assembly, the three-linkage mechanism,
and the pendulum rod and wiper blade with the tri-directional flexible ball joint. See figure
(wiper-1). The wiper motor is shown in figure (wiper-2).
Wiper
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
The washer is consisted of 5 parts which including a mini permanent magnet DC motor,
centrifugal water pump, nozzle, liquid storage container and water pipe. The motor and water
pump make up the assembly of the washer motor and the water pump as shown in figure
(Wiper-3):
1-Water inlet
2-Impeller blade
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
The circuit schematic diagram of the front window wiper and washer of Chery sedan A15:
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
The working list of wiper/washer components
Intermittent
V5 washer Wiper switch Wiper motor
wiper relay
(state of (state of (state of
(state of
Gear conduction conduction conduction Remarks
conduction
between the between the between the
between the
pins) pins) pins)
pins)
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
z Place the wiper link-rod inside and concentric the fastening hole with the welded nut of car
body;
z Tighten it with 3 bolts and washers, and the tightening torque is 9Nm;
z Install the water channel guard for the front window and other parts (see car body
instruction for details);
z According to the arrow printed on the front window, align the wiper blade with the
assembling arrow on the window; place the wiper arm into the wiper arm shaft, tighten the
fastening nut of the wiper arm and in the mean time press the blade tightly without
moving;
z Tighten the wiper arm with 2 nuts with tightening torque of 1619 Nm, and install the
guard plate.
z The installing steps are reverse to those for removal.
2. INSTALLATION/REMOVAL OF THE WASHER SYSTEM
z Install 6 fastening clips of the washing liquid tube and 1 guard sleeve;
z Install the nozzle on the front hood;
z Insert one end of the washing liquid tube into the washing liquid container, install the
washing liquid tube in the correct direction and insert the connector to the nozzle properly;
z Align the washing liquid container with the stationery jaw of car body, and tighten it with 1
nut and washer.
z The installing steps are reverse to those for removal.
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
(3) Verify that the
wiper switch and the
X-contact off-load
relay function
normally. Otherwise,
replace the
corresponding parts.
The intermittent When the (1) The circuit (1) Verify that the fuse
wiping does not ignition switch of the wiper S8 in the relay box and
function. is turned on, turn intermittent the wiper relay,
the wiper switch controller is 8/15-contact off-load
to (intermittent open. relay are normal.
wiping) position, (2) The internal (2) If the fuse and the
the wiper motor part of the wiper relay are normal,
does not intermittent verify that whether the
function controller is intermittent controller
intermittently. damaged. circuit of the wiper is
open.
The route of the circuit
is as follows:
Turn on the ignition
switch wiper motor
terminal 5F/2 turn
on the intermittent
gear -5F/5
intermittent controller
relay 1/J
intermittent controller
relay function.
Fuse S8 wiper relay
terminal 8/15 wiper
relay terminal 2/53M
the 2# socket of the
relay base connector S
green wire wiper
motor terminal 4/53
wiper motor terminal
5/31 brown/yellow
wire grounding.
(3) If the circuit works
properly, it is the
malfunction of wiper
intermittent controller.
T-40
The slowly When the (1) The slowly (1) Power supply of
wiping motor ignition switch wiping circuit of ignition switch ON.
does not is turned on, turn the wiper motor (2) If the power supply
function. the wiper switch is open. of ignition switch ON
to (slowly (2) There is works properly, check
wiping) position, malfunction in the wiper switch.
the wiper motor the 2/53m (3) If the wiper switch
does not run. intermittent works properly, verify
controller relay that the slowly wiping
and the wiper circuit of the wiper is
switch. open.
(3)The wiper 4) Verify that the
motor slowly green wire of the
wiping winding motor connector has
is open. electricity. If it has, it
indicates that the
slowly wiping winding
of the wiper motor is
open; If it has not, it
indicates that the
slowly wiping circuit
of the wiper is open.
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
the wiper motor be reset. contact of the
does not short-time wiping of
function. the wiper switch has a
poor contact. Replace
the switch.
(2) Improve the
flexibility of the wiper
switch. When the
handle is being
released, the switch
can automatically
reset.
The wiper fails When the wiper (1) There is (1) Check the 0
to be reset motor is malfunction in position contact of the
automatically. working the wiper wiper switch. If it is
respectively switch. poor contact, replace
under the (2) There is it.
intermittently damage in the (2) If the contact
wiping, slowly speed reducer. works properly, check
wiping, fast the automatic stop
wiping and conducting strip
short-time installed on the back
wiping position, of the worm output
turn off the shaft of the speed
wiper switch, reducer, and 3
and the wiper conducting contacts
blade fails to installed on the cover
stop at the of the speed reducer. If
original position. they are defective,
replace them.
The washer When the (1) The circuit (1) Ignition switch.
motor does not ignition switch of the washer (2) If the ignition
function. is turned on, turn motor is open. switch works properly,
the wiper switch (2) There is then verify that the
to the spray malfunction in wiper spray switch has
position, the the ignition a poor contact or is
washer motor switch. defective. If it has a
does not poor contact or is
function. defective, replace the
wiper switch.
(3) If the wiper spray
switch works properly,
verify that the circuit
of washer motor power
T-42
is open.
(4) If the circuit of the
motor power works
properly, replace the
washer motor.
The washer When the The intermittent The washer functions,
functions, but ignition switch controller of the but the wiper does not
the wiper does is turned on, turn wiper is function, it is mainly
not function. the wiper switch defective. because a malfunction
to the spraying in the wiper
position, the intermittent controller
washer results a circuit open
functions, but to the wiper motor, so
the wiper does the wiper cannot
not function. function. Replace the
wiper intermittent
controller.
T-43
ELECTRIC WINDOW REGULATOR SYSTEM
SYSTEM DESCRIPTION
The Chery sedan A15LHD employs an electric steel wire type window regulator. The
structure is shown in figure (window-1).
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
FAULT DIAGNOSIS AND TROUBLESHOOTING
T-45
CENTRAL LOCK SYSTEM
SYSTEM DESCRIPTION
The Chery sedan A15 employs a complete electronic control central lock system. The central
lock system is consisted of one 4-wire type controlling module, three supplemental door lock
actuating motors and one luggage boot cover actuating motor. The lock and unlock of the
interlock mechanism for the central lock system are all controlled by the driver side door lock
switch. The central door lock module is installed in the driver side door panel.
T-46
Malfunction symptom
1) None of the central door locks can be unlocked after closing the door.
Malfunction reasons
1) Malfunction in the central door lock module.
Troubleshooting
Replace the central door lock module.
3. NONE OF THE CENTRAL DOOR LOCKS CAN BE LOCKED
Malfunction symptom
None of the central door locks can be locked after opening the door.
Malfunction reasons
Malfunction in the central door lock module.
Troubleshooting
Replace the central door lock module.
4. THE RATED RESISTANCE FOR THE MOTORS OF ALL THE CENTRAL DOOR
LOCKS
Main central door lock motor (driver side) 315;
Side door motor 20;
Luggage boot cover motor 10;
When the resistance range is exceeded or the resistance value is equals to infinity , please
replace the resistor of the central door lock.
T-47
AIRBAG SYSTEM
T-48
OPERATION CONDITIONS
----The airbag system will function under the
following conditions:
1) When the vehicle is collided with a
stationary object with a speed over
25Km/H, the airbag will be activated.
2) When two vehicles have a head-on
collision both with a speed over 25Km/H,
the airbags of the two vehicles will be
activated.
3) When one vehicle is parked, and anther
vehicle is collided with it face to face with
a speed over 50Km/H, the airbags of the
two vehicles will be activated.
4) Collision within the included angles of 30o
from the left and right of the vehicle.
----The purpose of SRS is to protect the driver
during a serious head-on collision. If the
external force is coming from the included
angle within 30 degree of the vehicle
centerline, the airbag will be activated.
----Note: The above vehicle speed is referring
to the speed measured by the sensor, not
the actual speed of the vehicle. The speed
measured inspected by the sensor is
related with the actual speed, bumper
performance results and the crossbeam
deformation.
OPERATION PROCESS
----The activation process of the airbag.
T-49
----- -The accident happens;
Sensing;
Triggering;
The airbag is activated and inflated;
T-50
microprocessor will activate the ignition
circuit.
If the electric safety sensor is turned off at
the same time, the ignition current will
induce the igniter, and activate the safety
airbag.
T-51
3. HAIRSPRING
In order to ensure that the steering wheel has a
sufficient turning angle other than damages
the connection wiring harness of the airbag
assembly, the spiral wiring harness is adopted
between the steering wheel and the steering
column. Install the wiring harness into the
spiral spring first, and then install the spiral
spring into the spring housing, which is called
as hairspring. Normally, the wiring harness of
the horn is also installed in the spiral spring.
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
safety memory unit before handling with the steering system. In order to
remove or install the airbag components, please disconnect the negative grid
of the battery and wait for at least 1 minute.
Removal/Installation
The hairspring is installed between the steering wheel and the steering column. When
installing the hairspring, pay attention to the installing position and direction, otherwise it
would cause insufficient turning angle or heavy rotation of the steering wheel.
In order to remove and install the hairspring, it is necessary to check the hairspring clearance
during rotating.
Warning: In order to check the clearance, turn the hairspring carefully until we can feel the
resistance. After that turn back for about 4 cycles and align it with the clearance marking.
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
presses on the airbag due to the effect of inertia, the airbag is pressed and the air will be
discharged from the discharging hole, so that the kinetic energy resulted by the collision
between the driver and the airbag can be absorbed, which preventing the driver from injuring.
The function of the inflator components is such that when the igniter activates the ignition
agent, generating air and inflating the airbag, causing the airbag to spread out. When the
computer sends the ignition instruction, the heating element circuit turns on, which is heated
quickly and activates the ignition agent, the activated ignition agent explodes immediately
and generates heat, and then the inflating agent is heated up and decomposed to generate the
air into the airbag.
lid
preheat
machine base
2 bolts
tightening torque
inflation assembly
T-54
components:
Safety sensor
Capacitor
Collision sensor or accelerometer
(4) Capacitor
The capacitor provides the backup power.
(5) Bulb
When the operation voltage is increased to the BCM point, the BCM will trigger the warning
lamp and we can now check the bulb. The BCM turns on the warning lamp for 4 seconds and
then turn it off during the bulb inspection.
Malfunction Display
The airbag control module records the malfunctions of the system in two forms.
1. Current malfunction.
2. Historic malfunction detected before.
(6) Warning lamp
When any malfunction appears, the malfunction warning lamp will be turned on.
It is kept on.
(7) Wiring harness
Most of the wiring harness linkers adopted in the airbag system are yellow.
T-55
milliseconds X25=10 second), the malfunction mark will be cancelled. The warning lamp
will be turned off under this condition, and it is called the historical malfunction.
2. DIAGNOSIS OF THE DIAGOSTIC TESTER
The diagnostic tester can read data from the BCM memorizer to carry on the continuous data
exchanging. The diagnostic tester is used for reading and storing the malfunction codes, and
clears part of the stored data after the maintenance. But it can not clear the interior
malfunctions, such as the accident records and the arithmetic data malfunctions.
The proper usage of the diagnostic tester: firstly, turn off the ignition switch, connect the
diagnostic tester to the OBDII connector, and then turn on the ignition switch. See the
diagnostic tester manual for the follow-up procedure.
T-56
BCM should not be used any more.
When replacing the BCM, the arrow on the BCM must point to the direction right ahead of
the vehicle.
The BCM must be horizontally installed onto the installation plane, and parallel with the
coordinate axis of the vehicle body.
In order to avoid the occurrence of malfunction codes during the diagnosis, do not connect
the power supply to the airbag system or turn on the power supply according to the special
requirements listed in the diagnosis table before all the system components are connected
properly.
The SRS diagnosis system inspection must be the starting point of any SRS system diagnosis.
The SRS diagnosis system inspection can check whether the indicator function is proper, and
direct the accurate method of diagnosing any SRS malfunctions. Omitting these procedures
may result in longer diagnostic time or inaccurate replacement of components.
(4) Maintenance and inspection after the accident
Warning: Any maintenance of the vehicle structure must ensure to restore the vehicle to its
original state. The activated airbag needs to replace the BCM control module and airbag, and
inspect the dimension of the steering column.
All the SRS components must be replaced after been defective. If the installation point for the
SRS component is damaged, it must also be replaced.
Never use SRS spare parts from other vehicles (not including the new type SRS components
from the same model vehicle).
Do not try to repair the hairspring spring, airbag and seat belt. If there is any defect, these
components must be replaced.
Check the part number or part marking of the SRS components after replacement. The airbag
air generators that are alike in the appearance may have different internal structure.
(5) Replacement of activated airbag components after accident
All the SRS components must be replaced immediately after airbag had been activated in the
accident. After the airbag is activated, there may be powder like leftover on the airbag surface.
These leftover mainly includes the amylum and chemical reaction product (for lubricating the
airbag during the inflation).
Airbag
Airbag control module
SRS wiring harness
(6) Inspection of inactivated airbag components after the accident
Irrespective of whether the airbag has been activated or not, a specific inspection must be
carried out after any collision accidents.
T-57
A dimension measurement for the steering column must be carried out.
Check whether there is any crack or other damage on the instrument panel and steering
column guard.
Check whether there is any deformation, bending, crack or other damage on the instrument
panel support
Check the seat belt and installation fastening point.
(7) Activation and spreading of the airbag (in the vehicle)
The airbag must be activated and spread before the vehicle is discarded. If the vehicle is
discarded and disassembled, the airbag may be activated in the vehicle.
(8) Disposal of activated airbag
Warning: In order to prevent any injury in case the airbag is activated in the vehicle, please
follow the preventive measures as follows:
Before spreading the airbag, remove all the removable objects or loose components within
the spreading range.
The airbag shall be activated and spread after closing the vehicle doors and opening side
windows.
Spread the airbag only in the prepared airbag spreading area. The servicemen have to
participate in should stay at least 10 meters away in front of the vehicle.
Do not apply any voltage before completing all the preparation works.
Cool down the airbag for at least 30 minutes before handling with the activated airbag.
Please wear suitable gloves and protective goggles during the discard process.
If the activation and spreading of the airbag fails, cut off the voltage and waiting for at least 5
minutes before approaching the vehicle.
(9) Process of activation and spreading
Warning: When the ignition is turned off and at the same time the fuse is taken out, the airbag
control module (BCM) can provide the sufficient voltage for 1 minute to activate the airbag.
If the airbag is not disconnected, do not start the maintenance work within 1 minute after
disconnecting the power supply to BCM. If the airbag has been disconnected, the
maintenance work can be carried out immediately without waiting for the discharge of 1
minute. The failure of shutting off the SRS system temporarily during the maintenance will
result in false ignition, physical injury and SRS system discarded.
Disconnect the two grids of the battery and place the battery 10 meters away from the vehicle.
Remove the lower panel of the driver side instrument panel from the steering column;
disconnect the two SRS wiring harnesses that connect to the clock spring under the steering
column. Peel off the 13 mm insulated outer layer of the wiring harness end that connects to
the clock spring. Connect the airbag and the battery used to activate the airbag with 2 extra
T-58
wiring harnesses of at least 10 meters long each. Peel off the 13 mm insulated outer layer of
the 2 extra wiring harness ends, and tie the two ends of the wiring harnesses together. Place
the tied ends beside the battery use to activate the airbag, but do not connect it to the battery
at this moment. Connect the other two loose ends of the extra wiring harnesses separately to
join up with the wiring harnesses connecting the airbag, and insulate the connection point
with insulated tape. That means each end of the two extra wiring harnesses should be
connected to the two wiring harnesses of the airbag separately, and the other end of the extra
wiring harnesses should be tied together and place beside the battery. Clear the site.
Loosen the wiring harness end beside the airbag activation purpose battery, connect one wire
to the negative grid of the battery, and the other to the positive grid of the battery, and the
airbag is immediately activated.
Dispose the activated airbag according to the proper preventive measures. Please refer to the
Disposal of activated airbag of this manual.
(10) Activation and spreading of airbag (outside of the vehicle)
If the vehicle is within the guarantee period, please contact with the region maintenance
manager for the approval and other specifications before activating and spreading the airbag.
Please activate the airbag under the following conditions:
The vehicle will be disassembled. Please refer to the Airbag Spreading of this manual.
The airbag is damaged during shipment, storage or maintenance.
Warning: In order to prevent any injury when the airbag is activated outside of the vehicle,
please take the preventive measures as follow:
Spread the airbag only in the preserved airbag spreading area. The servicemen have to
participate in should stay at least 10 meters away in front of the vehicle.
Do not apply any voltage before completion of all the preparation works.
Cool down the airbag for at least 30 minutes before disposal of activated airbag.
Please wear the gloves and protective goggles during the discard process.
If the activation and spreading of airbag fails, approach the vehicle at least 5 minutes after
shutting off the voltage.
Face the front side of the airbag upwards and place it horizontally on the outdoor flat ground
for at least 10 meters away from the people or barriers.
Place the vehicle battery 10 meters away from the airbag.
Activate and spread the airbag:
If there is no airbag spreading tool, please follow the specifications below:
Disconnect the yellow wiring harness connect to the airbag;
Peel off the 13 mm insulated outer layer of the wiring harness end that connect to the airbag;
T-59
Connect the airbag and the airbag activation purpose battery with two extra wiring harnesses
of at least 10 meters long each;
Peel off the 13 mm insulated outer layer of the two extra wiring harness ends;
Tie the two ends of the two extra wiring harnesses where its insulated outer layers have been
peeled off;
Place the tied ends beside the airbag activation purpose battery, but remember not to connect
to the battery at this moment;
Connect the other two loose ends separately to join the wiring harnesses connecting the
airbag;
Bind the joint point with insulated tape;
Each end of the two extra wiring harnesses should be connected to the two wiring harnesses
of the airbag separately, and the other end of the extra wiring harnesses should be tied
together and place beside the airbag activation purpose battery. Clear the site.
Loosen the tied end beside the airbag activation purpose battery;
Connect one wire to the negative grid of the battery, connect the other wire to the positive
grid of the battery, and the airbag is immediately activated.
Dispose the activated airbag according to the proper preventive measures. Please refer to the
Disposal of activated airbag of this manual.
(11) Activating the airbag before discarding
This specification is applicable for all kinds of vehicles to be discarded and disassembled. If
the vehicle is within the guarantee period, please contact the region maintenance manager for
the approval and other specifications before activating and spreading the airbag. Besides the
extra steps listed below, the activated and spread airbag should be treated with the same
measures of other components to be discarded and disassembled.
Place the activated airbag into a tough plastic bag;
Ensure to seal the plastic bag properly;
Wash both hands carefully after disposal of the activated airbag.
(12) Maintenance of SRS system wiring harness
Warning: Before carrying out any maintenance, the SRS system must be disconnected. Please
refer to Disconnection of airbag system of this manual.
The connectors used in the SRS system are made of special material to ensure the good
conductivity of the low power circuit. The airbag wiring harness assembly must be replaced
if the plug is damaged. Do not try to use any other type of connectors to replace the connector
of this connector.
T-60
REMOVAL/INSTALLATION OF AIRBAG SYSTEM
1. REMOVAL/INSTALLATION OF AIRBAG
Removal:
----Disconnect the negative cable of the
battery ()
Warning: When the ignition is turned off
and at the same time the fuse is
taken out, the airbag control
module (BCM) can provide the
sufficient voltage for 1 minute to
activate the airbag. If the airbag is
not disconnected, do not start the
maintenance work within 1 minute
after turning off the power supply
to the BCM. If the airbag has been
disconnected, the maintenance
work can be carried out
immediately without waiting for
the discharging of 1 minute. The
failure of shutting off the SRS
system temporarily during the
maintenance work will result in
false ignition, physical injury and
SRS system discarded.
T-61
Installation:
----Connect wiring harness plug of the horn and airbag to the airbag socket.
Install the airbag
Install the airbag bolt
Use a tightening torque of 13~17N.m to tighten the airbag bolt
Connect it to the negative grid of the battery
T-62
Move the safety interlock head of the connector to Lock position.
Install the decoration panel on the left and right of the instrument panel.
Connect the SRS system. Please refer to the Connection of the airbag system of this
manual.
Warning: All the BCM bolts must be tightened carefully. In order to ensure a proper
functioning of the SRS, the arrow on the BCM must point at the direction right ahead of the
vehicle. Though the BCM can function when the SRS circuit is switched on before installing
the BCM on the vehicle properly, it may cause a potential false activation and consequential
injury.
T-63
3. WIRING AND CONNECTOR
Note: The wirings assembly of the SRS
protective supplementary system and that of
COWL are joined together. All the wirings of
this system are installed in a yellow corrugated
conduit, and all the connectors is normal
yellow.
The wiring or the wiring connectors are to be
replaced under the following conditions:
(a) There are signs of damage found on the
wiring or wiring connectors of the SRS
protective supplementary system during
troubleshooting.
(b) There are signs of damage found on the
wiring or wiring connectors of the SRS
protective supplementary system during
inspection.
Note: If there is any damage found on the
wiring of the SRS protective supplementary
system, the whole wiring assembly should be
replaced.
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
signal, the airbag will be activated and
inflated.
T-65
6. BCMAIRBAG CONTROL MODULE
----The BCM (airbag control module) (See
figure) is installed on the floor under the
heat exchanging radiator. The BCM
(Airbag control module) includes airbag
sensor, safety sensor, diagnosis circuit,
ignition controlling and driving circuit. It
receives the signal from airbag sensor and
determines whether to trigger the SRS
system.
T-66
NOTES ON SAFETY OPERATION
During the maintenance, if the proper procedures are not followed, the airbag system may
activate unexpectedly resulting in serious accident. The fault arising during the maintenance
work may cause the inability of the activation of airbag when it is required to function.
Therefore before carrying out any maintenance (including removing, installing, testing or
changing for the components), the maintaining personnel must read all the instructions below
carefully, and carry out the maintenance according to the following proper procedures
specified by the maintenance manual.
(1) Sometimes the malfunction of SRS (supplementary protective system) is difficult to
ascertain, therefore the malfunction codes become the most important information
resource of troubleshooting. When diagnosing the supplementary protective system,
check the malfunction codes firstly at all time, and then disconnect the battery.
(2) The maintenance work must be carried out at least 5 minutes after turning the ignition
switch to LOCK position and disconnecting the battery negative cable, because the
supplementary protective system has its own backup power supply.
(3) Even if the SRS is not activated after a slight collision, the airbag assembly and the airbag
sensor assembly must be inspected also.
(4) Do not use the SRS components from other vehicle. Only new components are allowed
for replacement if necessary.
(5) Do not repair the steering wheel airbag assembly and the airbag sensor assembly for the
purpose of reusing.
(6) Do not allow the steering wheel liner to shake, or come close to some magnets. Do not
allow the steering wheel liner and the airbag sensor assembly to expose in the hot air or
flame directly.
(7) If the steering wheel liner and the airbag sensor assembly have already been dropped
down, or there are cracks, dents or other defects on the housing, support or connectors,
they should be replaced with new ones. If there is any liquid such as grease, detergent,
engine oil or water on the steering wheel liner, clean it with a dry cloth immediately.
(8) Store the steering wheel liner in a flat and stable place, and face the top side upwards after
the removal. Never place anything on top of it.
(9) The airbag must be disposed firstly when discarding the vehicle or the steering wheel
liner.
(10) The inflating device in the steering wheel liner will become very hot after the airbag is
spread. Discard it only after it has been naturally cooled down.
(11) High resistance (at least 10k/V) type volt-ohm meter should be used for diagnosing the
malfunctions in the electrical circuit.
(12) The notes indicated on the tag at the peripheral of SRS components must be strictly
T-67
followed.
(13) After finishing the maintenance work for the supplementary protective system, the status
of SRS warning lamp should be inspected.
T-68
SOUND SYSTEM
T-69
OPERATION INSTRUCTION
Tape playing
1. Press POWER button to switch on the power, and rotate to the right to increase the
volume.
2. Face the tape open side to the right. Push it into the cassette door No.18 to lock position,
and the player begins to work. At this moment, the display No.9 shows the tape is playing.
3. If there is already a tape in the cassette player, press the SOURCE button selecting the tape
as the source, and start to play the tape.
4. The tape will automatically reverse and continuously to play when it comes to the end, or
you can press button No.17 to manually reverse it.
5. In order to quickly select the song that you want, press fast forward button or fast
backward button for quick play forward or backward, and then press another fast
backward button or fast forward button slightly, the tape will enter into the play mode.
6. If you want to stop the play or change the tape, press the tape eject button No.17, the tape
will eject from the cassette player.
Radio
1. Power switch, volume control, tone adjustment and playback mode.
2. Press BAND button to select the desired band. The display No.9 will show the band to
receive. You can select the one of following bands as you wish: FM1, FM2, FM3, FM AST,
MW (AM) AST, MW (AM) 2, and MW (AM) 1.
Note: You can cancel the MW (AM) band if you do not want to listen to it.
If you do not want to listen to the excessively preset FM or MW (AM) stations, you can
cancel some of them correspondingly.
3. Manual and automatic tuning (selecting stations):
(1) If you want to enter manual tuning mode, please press the SETUP button to enter into the
set mode and select TUN item, after that set it in MAN Mode. The radio will
maintain the manual tuning mode.
(2) Press the tuning button continuously to tune to the lower frequency end station, or
press the tuning button to the high frequency end station.
(3) Press the button continuously or for more than 0.5 second, the player will
complete its automatic tuning till the broadcasting station is received. Repeat step1or
2, you will receive the broadcasting program that you want.
4. Automatic scanning:
If you press the SCAN button for 2 seconds, you can initiate the start/stop automatic scan
function of the player. The player will automatically scan the stations from low to high end
T-70
starting from the initial frequency point. When one station is locked in, the player will pause
the scanning. The frequency of the station will flash for 10 seconds while broadcasting the
program of the tuned station. After that it will continue to scan the higher frequency end till it
reaches the highest end and return automatically. It will then scan from the lowest to the
higher end again.
If you want to listen to any program of a particular station, you just need to press the SCAN
button when the frequency of the station is flashing, the scanning will stop at the position of
the station immediately. If you press the SCAN button again, it will go back to the automatic
scanning mode.
Memory of the station frequency
You can store up to 6 station frequencies in advance with 1 to 6 preset buttons under each
mode of FM1, FM2, FM3 and AM.
1. Manual storing
When you want to use automatic searching mode to search for a particular station, press
anyone of the 1-6 preset buttons for more than 2 seconds, and after hearing the voice from
strong to weak and from weak to strong again, it means that this station frequency has been
stored in the preset button that you have pressed.
When storing the stations of FM, the related RDS information and AF mode (on/off) are also
been stored together.
2. Automatic storing
You can automatically store 6 strongest FM stations in the FM AST band or 6 stations in the
MWAMAST band.
Press button AST to enter into the automatic storing mode, the player will make a voice of
hua, and then becomes mute.
After storing, you will hear the voice of hua again, and you start to listen to the station of
the preset button 1.
CD player
1. This player can be connected to VDO CD player, -CDC 401 A or CDC 601 A or CDC 603
A or CDC1001 A.
2. Press button SOURCE selecting CD player as voice source.
3. Press button DISC+ or DISC- to select the disc you want. After finishing one disc, the
player will automatically turn to the next one to continue playing. If the empty disc is
encountered, it will skip automatically.
4. Press button or to select the song that you want, and start to play from the selected
song.
T-71
OTHER FUNCTIONS
Sound setting
1. Press the SOUND button for at least 2 seconds to enter into the SOUND setting mode.
2. Press the SOUND button to select the desired sound effect mode.
-BASS (bass, under the BASS-TREB mode)
-TREBLE (treble, under the BASS-TREB mode)
-BALANCE: The left and right volume balancing
-FADER: Front and back speaker control
-LOUDNESS (off, bass, mediant, treble, under the BASS-TREB mode)
3. The sound effect mode which could be selected by rotating the volume button. After 5
seconds, the display will return to the last operation mode automatically.
Sound effect setting
Short press the SOUND button to select a sound effect preset by the manufacturer.
-BASS-TREB: You may set the bass or treble of the player by yourself.
-JAZZ: Jazz music
-VOCAL: Voice
-POP: Pop music
-CLASSIC: Classic music
-ROCK: Rock and roll
Clock setting (manual)
1. Short press the SETUP button to enter into the SETUP menu.
2. Press button turning to the TIME item.
3. Press the SETUP button to select the 12H or 24H.
4. Press button to select the hour position.
5. Press the SETUP button to adjust the hour position.
6. Press button to select the minute position, and the minute position will start to flash.
7. Press the SETUP button to adjust the minute. The time will start from the setting time.
8. Press the SETUP button for at least 2 seconds to exit the SETUP menu.
- If the clock mode has been activated, the display will show the time after operating any
button for 10 seconds.
T-72
REMOVAL/INSTALLATION OF SOUND SYSTEM
The sound system includes sound source, speaker and antenna. The sound source includes
recorder assembly, optional CD player assembly and VCD player assembly. The CD player
assembly and VCD player assembly includes the host, power signal line and disks exchanger.
1. INSTALLATION OF THE RECORDER ASSEMBLY
z Disconnect the negative grid of the battery.
z Install the hardware frame into the sub-instrument frame, and using a flat screwdriver to
open the top, bottom, left and right locking plates of the frame;
z Connect the power supply wire, control wires, signal and antenna wires at the back portion
properly;
z Push the playing machine into the mounting frame evenly with your thumbs and
forefingers resting on the left and right of the control panel, till you hear the sound of the
locking plates from both sides of the player.
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
z Align it at the correct direction and press the speaker cover into it.
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
TROUBLESHOOTING
Malfunction Reasons/Troubleshooting
No power supply Connection malfunction. Please check the connection.
The player fails to function
Check the fuse (player and vehicle) and the connector.
and display.
The player functions but
Adjust the volume of the player.
without sound or with poor
Check the sound balancing function.
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
AIR CONDITIONER SYSTEM
U-1
AIR CONDITIONING SYSTEM OVERVIEW
Evaporator
Compressor
U-2
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
3. Ventilation system Apart from the cool and heat the air inside the vehicle, the
centrifugal blower is also used to change and ventilate the air inside the vehicle. The
ventilation system consists of the air filter, air inlet, air duct, vent and etc. The system
introduces the fresh air from the outside of vehicle into the inside while the ventilation and
discharge port extracts the vitiated air from the inside to the outside. Chery A15LHD adopts
the natural ventilation and forced ventilation. The open/close fresh air inlet is controlled by
the fresh/circulating air vacuum valve.
During the natural ventilation, the fresh air enters into the vehicle from the air inlet fixed
under the front windscreen (positive pressure area), and gets into the trunk from the seat belt
notch on the trunk cover, then passes across the vents (negative pressure area) on the body
rear skirt, trunk lining, rear side beam and finally discharges to the atmosphere. Due to the
movement of air in the rear body compartment, it plays a good role to defrost the rear
windows. In addition, the whole process is conducted without pressure, so the air changing
doesnt create any noise and has nothing with the driving speed.
And during the forced ventilation, in case that the fresh air doesnt pass through the heating
radiator (the mixed gate closed) after the air is pressurized by the blower, the air will enter
into the vehicle via all air ducts, and then discharge along the same route as that of natural
ventilation to the atmosphere.
U-4
Air-Conditioner Compressor
Evaporator Assembly
Air-Conditi
on Harness
4. Control system The control system mainly consist of the electrical component, vacuum
hose and control mechanism. On one side, it is available to control the temperature and
pressure of refrigeration and heating system, and, on the other side, it is also used to control
the temperature of air inside the vehicle, the blowing rate and direction.
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
REFILLING OF REFRIGERANT AND REFRIGERANT OIL
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
1. Precautions for Refrigerant Concerned
(1) To avoid the refrigerant contacting with
your skin, wear rubber gloves and safety
goggles while handling the refrigerant.
(2) Handle the refrigerant concerned at a well
ventilated location. Since the refrigerant is
a colorless gas at room temperature and its
density is greater than that of air, the
refrigerant will deposit in the maintenance
location, which may easily cause the Refrigerant Tank Unlock Valve
maintenance personnel choked.
1-Butterfly Handle
(3) Do not allow the refrigerant to contact with
2-Refrigerant Tank Refilling Valve
fire. Otherwise it may generate the toxic
gas. 3-Plate-shaped Nut
U-7
clockwise direction and tighten it by hand
as possible.
(4) Turn the butterfly handle 1 in the
clockwise direction to make the valve
needle 4 in its front end punch a small hole
in the dummy club of refrigerant tank.
(5) Turn the butterfly handle 1 in the
counterclockwise direction, which the
refrigerant will flow into the manifold
pressure gauge along the charging hose.
(6) Then turn the butterfly handle 1 in the
clockwise direction to the lowest position,
and it can close down the refrigerant tank
again. However, do not detach the unlock
valve, otherwise the refrigerant inside the
tank will leak out.
U-8
200 g or more refrigerants shall be charged
every time, and turn the compressor
several times by hand after the completion
of charging.
(5) Turn off the high-pressure manual valve 4,
shown in the figure below, and turn on the
low-pressure manual valve 3 to let the
refrigerant in gas-state charge into the
refrigeration system. The refrigerant
charged from the low-pressure manual
valve must be gas-state. If it is liquid state,
the liquid hammer phenomenon may
appear to damage the compressor. Turn off
the low-pressure manual valve when the
reading of low-pressure gauge reaches
2.8X105 Pa.
Refrigerant Refilling
Regulated amount:R134a85025g
U-9
reservoir.
(2) Tighten the propane reservoir 16 to the
leak detector.
(3) Insert a lighting match into lighting device
9, and then slowly turn the adjusting
handle 14 in the counterclockwise
direction till the torch is lit.
(4) Adjust the flame to smallest. The smaller
the flame, the more sensitive to the leak of
refrigerant.
(5)Move suck pipe 3 to the possible leak
position.
(6) Observe the change of flame color. The
flame has no color if there is no leakage.
The flame is tint green if there is very
small leakage or be blue if there is
relatively big leakage, and it will become
purple if there is too much leakage.
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
auxiliary valve so as to prevent the air
from being inhaled into the system.
(5) Connect the high-pressure side hose joint
to the manifold pressure gauge, turn on the
high-pressure manual valve, and start up
the vacuum pump to vacuumize the
high-pressure side hose. And turn on the
auxiliary valve to vacuumize for the
system to 30psi, and then vacuumize 15
min again so as to remove the air entering
into the system together with the oils. In
this case, the refrigeration oils are in the
high-pressure side, and the oils will return
back to the compressor after the operation
of the system.
U-11
6. Methods of Refrigerant Vacuumizing
It is difficult to pump out the water from the
refrigeration system when vacuumizing. But
Low High
the vacuumizing can reduce the fluidization pressu pressure
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
return back within 10 min, it indicates that
the system is normal and the refrigerant can
be charged into the system.
(6) Restart the vacuum pump, and turn on the
low-pressure valve of the manifold
pressure gauge to continuously vacuumize
15 min. Then, turn off the low-pressure
valve to stop vacuumizing, and prepare for
charging the refrigerant.
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
A/C SYSTEM COMPONENTS
U-14
Swash Plate
Number of cylinders 7
Travel (mm)
max 342
min 22
Displacement (cm/r)
max 1613
min 104
Coolant R134a
U-15
The compressor is driven by engine crankshaft pulley via the M belt. When the shift lever
on the A/C control mechanism is shifted to the refrigeration position, the electromagnetic
clutch of A/C compressor engages, and the compressor pulley make the main shaft and
swash plate rotate and then pull the rocking plate to swing. The swinging of the rocking
plate pushes the piston to move, which creates the air pumping effect to compress the
low-temperature and low-pressure air-state coolant into the high-temperature and
high-pressure air-state coolant.
The motion parts of compressor are lubricated using the sputtered refrigerant oil and the oil
in coolant. During the operation of compressor, due to the rotation and swing of the swash
plate, the refrigerant oil will be sputtered to anywhere. In addition, due to the intersolubility
of coolant and oil, when the coolant flows into the compressor, it also carries a part of
refrigerant oil which is available to lubricate the motion parts inside the compressor.
ADJUSTMENT OF ELECTROMAGNETIC CLUTCH
1. Use a thickness gauge to measure the clearance between the platen and A/C compressor
pulley.
2. Check whether the clearance is in the range specified by the technical specification.
If it is found that the result doesnt conform to the requirement of technical specification,
remove the platen, and use one or several shims to adjust the clearance.
Clearance:
0.6mm0.2mm
3. Removal/Inspection of condenser
(1). Drain off the coolant from the system (see the
coolant recycling procedure)
(2). Remove the front bumper and headlamp crossbeam
assy.
(3). Remove the fluid reservoir and the refrigeration
pipes connecting to the condenser.
Check the condenser:
(1) Check the crack, damage or oily fluid leakage.
Replace the condenser if any failure above occurs.
(2) Check whether the fender position is blocked by dust
or not.
Clean it if blocked.
(3) Check the bent condition of fender position.
Use a flat headed screwdriver to straighten the fender
U-16
position if the bent is found.
Installation of Condenser
(1) Use some self-tapping screws to secure the
condenser and radiator, and assemble the related
screw bush and spacer, with the tightening torque
of 60.6Nm;
(2) Use the bolts (M6) and spacer to secure the
condenser support on the front crossbeam, with the
tightening torque of 1.50.15Nm;
(3) Assemble the integrated condenser-radiator into the
related fixing holes;
(4) Use spacer, shim block and two nuts to fasten the
condenser and front crossbeam, where the tightening
torque of nut is 1.50.15Nm.
The condenser is designated to cool the coolant vapor
discharged from the compressor and condense the vapor
to make it give off its heat and become to the coolant
fluild.
Chery A15LHD adopts the serpentine condenser, as
shown in the figure. The condenser is secured with
engine radiator in a row, and there is an axial fan, which
is driven by a DC motor, behind them to forcedly cool
the condenser and radiator.
U-17
refrigeration system, the fusible plug will metal so as to
drain off the high-temperature and high-pressure coolant
when the temperature and pressure inside the reservoir
reach the specified value, which protects the
refrigeration system.
4. Introduction to the expansion valve and pressure
switch
1) Expansion valve
Chery A15LHD adopts the traditional thermo-expansion
valve, as shown in the figure, fixed on the inlet/outlet
pipes of evaporator.
The temperature sensor inside the expansion valve
adjust the opening of ball valve in accordance with the
temperature of coolant located at the evaporator outlet,
the purpose of which is to control the flow rate of
coolant.
2) Pressure switch
Chery A15LHDs A/C pressure switch adopts the
dual-pressure (high and low pressures) and four-wire
pressure switch which is installed on the high pressure
pipe located at the front end of expansion valve, with 50
PSI or more of low-pressure CLOSE operation and
220 PSI or more of high-pressure CLOSE operation
5. Removal/Installation and inspection of evaporator
(1) Drain off the coolant from the system (see the
coolant recycling procedure)
(2) Remove the expansion valve
(3) Remove the instrument panel (see the
Disassembly/Assembly of Instrument Panel)
(4) Remove the control panel trim plate, and 4
self-tapping screws used to secure the control panel
and console. (tightening torque of 1.50.2Nm)
(5) Remove 1 bolt (M8*25) and 4 nuts secured with the
steering crossbeam and front side respectively
(tightening torque of 3.50.2Nm) from the fixed
evaporator.
(6) Remove the four bolts from the evaporator.
Inspection of evaporator:
U-18
(1) Check the crack, damage or oily fluid leakage.
Replace the evaporation unit if any failure above
occurs.
(2) Check the bent of fender.
Use a flat headed screwdriver to straighten it if a bent
is found.
The Chery A15LHD adopts the tube-fin type evaporator
which is installed in the air conditioning unit assy. under
the instrument panel.
The function of evaporator is opposite to that of
condenser. After expanded in the expansion valve, the
coolant fluid absorbs the heat inside the vehicle from the
evaporator, and evaporates to the coolant gas, then
enters into the compressor to circulate.
Introduction to the evaporator temperature sensor
(thermostat):
The evaporator temperature sensor used by the Chery
A15LHD is the heat-sensitive tube mechanical type
temperature regulator, which is closed when the working
temperature is adjusted to 4 or more while
disconnected when adjusted to 4 or below. Its
installation position is just under the evaporator, as
shown in the figure.
The tightening parameters of A/C pipe fasteners
Inner hexagonal head bolt (M10) secured in the
compressor: 30Nm;
Inner hexagonal head bolt (M6) secured in the
expansion valve: 7Nm;
To connect with condenser inlet pipe and tighten the
nuts: 32 Nm;
To connect with condenser outlet pipe and tighten the
nuts: 11.9 to 13 Nm;
U-19
FAILURES AND SHOOTING ANALYSIS SHEET
U-20
PRECAUTIONS ON THE SECURITY OF A/C SYSTEM
Coolant treatment
1. The operator shall pay more attention to prevent the coolant fluid from spraying into
your eye or on your skin because the fluid-state coolant is very dangerous. Only one drop
of coolant will cause your skin to be damaged partially if it drops up the skin of the skin.
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
Coolant shortage treatment
If it is found that there is the coolant shortage during checking the failure, it is
recommended to add the coolant. The reason is: there is the difference between the pressure
values indicated by the different pressure gauges, so it is difficult to add the coolant with
accurate quantity in accordance with the pressure reading. If the coolant added is excessive
or insufficient, it may cause a series of negative effects, such as: to damage the coolant
recycling parts, or, to reduce the refrigeration effect. Thus, if it is found that the coolant is
insufficient, it is recommended to completely drain off the coolant from the coolant
circulating pipes, and then add the specified quantity of coolant.
Compressor oil treatment
For this model of vehicle, it is recommended to use the SP10 model compressor oil;
otherwise it may be available to regulate the compressor.
Take care not to spray the compressor oil on the surface of the vehicle during the
maintenance operation. Thus, if this case occurs, immediately wipe and clean it, otherwise
the compressor oil will damage the paintwork on the surface of the vehicle.
Engine oil shall absorb the moisture.
U-22
TECHNICAL DATA
TECHNICAL DATE TD-2
ENGINE TD-2
LUBRICATION SYSTEM TD-10
COOLING SYSTEM TD-11
ENGINE ELECTRICAL FUEL INJECTION SYSTEM TD-12
CLUTCH TD-13
MANUAL TRANSAXLE TD-14
HEATER AND AIR CONDITIONER SYSTEMS TD-15
BRAKING SYSTEM TD-16
SUSPENSION TD-17
TD-1
TECHNICAL DATA
ENGINE
TD-2
Size of Hydraulic Tappet:
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
Valve Stem Size And Fit Clearance
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
Size of Valve Guide And Valve Guide Bore
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
The Diameter of Piston Skirt
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
The Diameter of The Piston Pin
Diameter of 480M piston pin bore (unit: mm) Diameter of 480E piston pin bore (unit: mm)
TD-7
Size of Piston Ring
TD-8
Diameter of Main Journal And Size of Main Bearing Shell
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
LUBRICATION SYSTEM
Coolant Mixing Ratio 50% glycol +50% soft water (volume ratio)
TD-10
COOLING SYSTEM
Diameter: 280mm
Number of blades: 6
TD-11
ENGINE ELECTRICAL FUEL INJECTION SYSTEM
TD-12
UAES M7 Electronic Fuel Injection System:
CLUTCH
Item Specification
Clutch Pedal stroke mm 150~165
d l
Clutch Run out limit mm 0.25
TD-13
MANUAL TRANSAXLE
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
HEATER AND AIR CONDITIONER SYSTEMS
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
CONTROL SYSTEM
Clearance (mm) 0.4~0.8
Magnetic clutch
Mass (kg) 2.2
TD-15
BRAKING SYSTEM
Brake power distribution ratio Front wheel 65%, rear wheel 35%
TD-16
SUSPENSION
Suspension
Item Specification
Secondary Spare
Item Front Wheel Rear Wheel Spare Wheel
Wheel
TD-17
SPECIAL TOOLS
ENGINE ST-2
ST-1
SPECIAL TOOLS
ENGINE
ST-2
SN Tool Number Name
ST-3
SN Tool Number Name
ST-4
MANUAL TRANSMISSION
ST-5
SN
N Tool Number Name
ST-6
SN Tool Number Name
ST-7
SN Tool Number Name
ST-8
SN Tool Number Name
ST-9
SN Tool Number Name
ST-10