Professional Documents
Culture Documents
CONTENT
Title
General Information
Engine
Lubrication System
Cooling System
Fuel and Emission Control System
Engine Electrical System
Clutch
Manual Transmission
Axles And Suspension System
Steering System
Braking System
Body
Body Electrical System
Air Conditioner System
Technical Data
Special Tools
Section
GI
B
D
E
F
G
H
J
M
N
P
S
T
U
TD
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
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
Electric current
Aampere
Electric power
Wwatt
Electric resistance
ohm
Electric voltage
Vvolt
Length
mmmillimeter
kPakilo pascal
Negative pressure
Positive pressure
Torque
Kg/cm2kg/square centimeter
N.mNewton meter
Lliter
Volume
mlmilliliter
ggram
Weight
Kg (kilogram)
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.
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.
CODE
V
H
A
N
M
COLOR
Green
Gray
Blue
Black
Brown
CODE
R
Z
B
G
COLOR
Red
Purple
White
Yellow
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
M/G
N/R
BLACK
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
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
1. LVV is the code of vehicles manufactured by Chery Automobile Co., Ltd.
2. The fourth digit of VIN code stands for the brand of the vehicle. The brand Chery is
represented by letter D.
GI-14
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.
YEAR
CODE
YEAR
CODE
YEAR
CODE
YEAR
CODE
1999
2002
2005
2008
2000
2003
2006
2009
2001
2004
2007
2010
9. The eleventh digit of VIN code stands for the assembly factory. The Chery Automobile
Co., Ltd is represented by the letter D.
10. The twelfth to the seventeenth digits of VIN code stand for production serial number.
GI-15
PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION TABLE
Appearance and interior
Defects of appearance and interior
Paint, galvanized components and interior trim
Carrying items, tools, spare tire, operation manual for jack and
keys
Remove anti-vibration cover for tires and body protective film
Engine
Lock and hinge of engine hood
Poles of battery
Electrolyte level
Main ground
Main fuse and spare parts
Oil level of engine
Coolant level and water quality
Power steering oil level
A/T oil level
Glass washing liquid level
Degree of tightness of timing belt (power steering, generator and
compressor)
Throttle control cable(A/T control cable) Close the engine hood
Operation and Control
Height and free distance of clutch pedal
Height and free distance of brake pedal
Acceleration pedal
Inspect the indoor fuse and spare parts
Turn ignition switch to position
Radio debug
Radio/Cassette/CD and antenna
Turn ignition switch to position
Inspection of all the alarming lamps, defects of dynamo,
hand-brake, oil pressure, brake, A/T gear display, ABS, SRS
AT startup protector
Start engine
The operation of battery and dynamo as well as the displays of
various alarming lamps
Idle speed
Operation of front washer
The operation of front wiper
Turn signal light
Side light and license plate light
Head lamp and high beam light (high beam indicator)
Switch of fog light
Brake light and backup light
Instrument light and light adjusting switch
Horn
Cigar lighter
Operation of sun roof
Fog-remover of rear windscreen and indicator
Performance of air condition under each gear (refrigeration and
amount of blast)
Cycle switch
Power rear view mirror
GI-16
SCHEDULE MAINTENANCE
SCHEDULE MAINTENANCE TABLE
MileageKm
Items
5000
15000
30000
Wiper and washing system: check performance, add washer fluid if necessary
Oil: Replace
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
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
LOCATION INDEX B-3
MECHANICAL LOCATION INDEX B-3
ENGINE TIMING B-4
TOP AND BOTTOM TIMING GEAR COVER ASSEMBLY B-4
TIMING BELT REMOVAL
B-4
B-5
B-1
B-2
LOCATION INDEX
MECHANICAL LOCATION INDEX
1
2
3
4
5
6
TIMING BELT
(SEE B-4 ENGINE TIMING)
VALVE MECHANISM COMPONENTS
(SEE B-9 VALVE CLEARANCE)
CYLINDER HEAD GASKET
(SEE B-19 CYLINDER HEAD GASKET REPLACEMENT)
FRONT OIL SEAL
(SEE B-21 FRONT OIL SEAL REPLACEMENT)
REAR OIL SEAL
(SEE B-23 REAR OIL SEAL REPLACEMENT)
CAMSHAFT
(SEE B-25 CAMSHAFT)
CRANKSHAFT
(SEE B-28 CRANKSHAFT, CRANKSHAFT THRUST SPACER, BEARING SHELL AND
MAIN BEARING CAP)
PISTON AND CONNECTING ROD
(SEE B-33 PISTON AND CONNECTING ROD ASSEMBLY)
B-3
ENGINE TIMING
TOP AND BOTTOM TIMING GEAR
COVER ASSEMBLY
Removal
Loosen and unscrew two bolts of the top timing
gear cover assembly.
Remove the top timing gear cover and gasket
assembly.
Remove the gasket from the top timing gear
cover.
Remove the crank pulley.
Loosen and unscrew the two bolts on the timing
gear cover.
Remove the timing gear cover and gasket
assembly.
Remove the gasket from the bottom timing gear
cover.
Installation
Clean the bottom timing gear cover and fix the
new gasket on the bottom timing gear cover with
glue. Install the bottom timing gear cover and
gasket assembly on the crank shaft, screw in two
bolts by hands and tighten them for a moment of
9.0~11N.m.
Clean the top timing gear cover and fix the new
gasket on the top timing gear cover with glue. Fix
the top timing gear cover and gasket assembly on
the cylinder head with two bolts for a tightening
moment of 9~11N.m.
B-4
B-5
Timing gear
Bush
Key
Bolt: M12*1.5*30
Tightening torque: 52~60Nm
Tension Pulley
Bolt: M8*25
Tightening torque: 16~20Nm
Key
Crankshaft Gear
B-6
B-7
B-8
VALVE CLEARANCE
VALVE MECHANISM COMPONENTS
B-9
Cupped gasket
Installation
Clean the junction face of the cylinder head
and the valve cover.
Push the wedge of the sheet gasket for the
valve cover into corresponding valve cover to
integrate them.
Install the combined valve cover and sheet
gasket assembly on the cylinder head.
Put 9 hexagonal-head long cylindrical end
bolts into the cupped gaskets and supports and
screw them into the cylinder head.
Tighten the bolts in 2 steps according to the
graphics and tightening order. First step:
tighten
them
to
the
moment
of
4.0-6.0Nm.Second step: tighten them to the
moment of 8.0-10.0Nm.
B-10
Gasket assembly
for valve cover
Valve Cover
Cupped
gasket
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.
Note: The corresponding hydraulic
tappet shall be in the Min.
position before each rocker
arm is installed and tightened
with nuts.
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
Fit clearance
(unit: mm)
Class
Standard
22.200~22.212
22.250.015
0.023~0.065
T25
22.454~22.466
22.500.015
0.023~0.065
B-12
CYLINDER
1
B-13
Intakemm
Class
Inner
Diameter of
Diameter of
valve stem
valve guide
Standard
Oversized
8.443 +00.018 8.4638.494
0.4
Exhaustmm
Clearance
0.02
0.069
Spring load
(N)
L1=37.084
422
L2=27.7
892.7
L3=27.0
945
Free Length
of Spring
(mm)
L0=47.2
B-14
Diameter
of valve
stem
Inner Diameter
Clearance
of valve guide
8.017 +00.018
8.0638.094
8.417 +00.018
8.4638.494
0.046
0.095
4430---4530
1.75---2.32mm
91 (0-030)
1.440.1
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.
Press the valve oil seal and spring seat assembly
into the upper end of the valve guide, apply some
motor oil on the guide opening or the edge of the
valve oil seal and wrap the glove of the valve cotter
by adhesive tape. After the valve is installed, take
away the adhesive tape.
Install the valve spring and valve spring seat,
compress the valve spring seat to the stroke that
enables the valve cotter groove to appear by special
compression device and install the cotter. Then
slowly release the compression device and remove
it.
After the whole valve cotter is installed, put the
cylinder head on a piece of wood and knock at the
small end of the valve stem by a plastic or copper
hammer to help the valve mechanism to be in place
better.
B-15
Class
Diameter of
intake
valve seat
ring (unit:
mm)
Diameter of
the seat ring
bore of
cylinder
head (mm)
Standard
43.877 +00..01
01
43.763 0+0.025
Oversized
0.5
Oversized
1.0
44.377 +00..01
01
44.263 0+0.025
44.877 +00..01
01
44.763 0+0.025
Interfer
ence
(mm)
0.079
0.124
Size of exhaust valve seat ring and cylinder head seat ring bore
Diameter of exhaust valve Diameter of cylinder head
Class
seat ring (mm)
seat ring bore (mm)
Standard
38.877 +00..01
01
38.263 0+0.025
Oversized
0.5
Oversized
1.0
UAESs
new
two-valve
Oversized
0.5
Oversized
1.0
39.377 +00..01
01
38.763 0+0.025
39.877 +00..01
01
39.263 0+0.025
38.377 +00..01
01
38.263 0+0.025
38.877 +00..01
01
38.763 0+0.025
39.377 +00..01
01
39.263 0+0.025
13.555 00.01
13.48113.519
Oversized
14.305 00.01
14.23114.269
Oversized
14.505 00.01
14.48114.519
B-16
Interference
(mm)
0.0790.124
0.0790.124
Interference
(unit: mm)
0.0260.07
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.
5. Remove the ignition coil connector.
6. Remove the spark plugs.
7. Connect a compression gauge into the spark plug
hole.
8. Fully depress the accelerator pedal and crank the
engine.
9. Note the maximum gauge reading.
10. Inspect each cylinder as above.
If the measured value is less than the limited value, or there is a cylinder whose
compression value varies from that of other cylinders, add a small amount of engine oil
through the spark plug hole. Then measure the compression pressure and perform the
respective operations for the following cases.
If the compression increases, the piston, the piston rings, or cylinder wall may be worn
and overhaul is required.
If the compression stays low, a valve may be stuck or improperly seated and overhaul is
required.
If the compression in adjacent cylinders stays low, the cylinder head gasket may be
damaged or the cylinder head distorted and overhaul is required.
B-17
B-18
B-19
B-20
A. Location Pin
B. Gasket
Installation
Clean the pulley and crankshaft journals and wipe
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
the crank shaft to rotate. Tighten the bolts for a
moment of 100-115N.m
B-21
Bolt: M12*35
Tightening torque: 100~115Nm
Pulley
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
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.
B-24
Seal
washer
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.
CAMSHAFT AND CAMSHAFT THRUST
SPACER
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
480
480E
38.602
37.559
37.586
37.559
B-26
1. Standard size
Number of cam shaft
journal
1
2
3
4
5
1
2
3
4
5
45.1245.14
45.3745.39
45.6245.64
45.8745.89
46.1246.14
45.16345.188
45.41345.438
45.66345.688
45.91345.938
45.16345.188
2. Oversized (0.38)
B-27
CRANKSHAFT
CRANKSHAFT, CRANKSHAFT THRUST
SPACER, BEARING SHELL AND MAIN
BEARING CAP
Removal
Check the axial clearance of the crank shaft before
removal.
Kiss the end side of the crank shaft with the
contacts of a dial gauge (less degree of shrinkage).
Push the crank shaft away from the contacts and
adjust the dial gauge to 0, then push the crank shaft
to the direction of contacts as possible with a0 stout
carrying pole. Check the reading of the dial gauge,
which shall be the axial clearance. The axial
clearance of a crank shaft is 0.092-0.303mm.
The leaf of a clearance gauge can be used to check
the axial clearance of a crank shaft if there is no
dial gauge, which shall be placed between the third
main bearing cap and crank shaft (push and pull the
crank shaft).
Loosen the bolts and studs of the main bearing
shell, (beginning from the middle bearing cap),
take out the bolts and the threaded rods to remove
the main bearing cap and the lower shell of the
main bearing shell. This lower shell shall still
remain in the main bearing cap.
Take the crank shaft out.
Remove the crank shaft thrust spaces (2 pieces)
from the cylinder block.
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
Class
Standard
Downsized
by 0.025
Downsized
by 0.25
Downsized
by 0.5
Downsized
by 0.75
Downsized
by1.0
Diameter of
connecting rod
journal
(unit: mm)
47.8947.91
Thickness of
connecting-rod
bearing shell
(unit: mm)
1.4801.487
47.8947.91
1.4921.499
47.6447.66
1.6051.612
47.3947.41
1.7301.737
47.1447.16
1.8551.862
47.8946.91
1.9801.987
B-29
Class
Standard
Oversized by 0.4
Downsized by 0.02
Downsized by 0.25
Downsized by 0.50
Downsized by 0.75
Downsized by 0.25
and oversized by
0.4
Downsized by 0.50
and oversized by
0.4
Downsized by 0.75
and oversized by
0.4
57.9858.00
57.9858.00
57.9858.00
57.7357.75
57.4857.50
57.2357.25
57.7357.75
62.6935+0.0065
2.4562.463
57.4857.50
62.6935+0.0065
2.5182.558
57.2357.25
62.6935+0.0065
2.7062.713
Diameter of main
journal (unit: mm)
Size of crank shaft thrust, thrust spacer and cylinder block thrust
Size of cylinder block thrust
(unit: mm)
Standard
24+0.03
Oversized
24+0.03
by 0.38
Class
Thickness of thrust
spacer (unit: mm)
2.326+0.025
29.205-29.255
2.516+0.025
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
B-32
B-33
Ex-factory
grouping
Ex-factory
repair
For
Maintenance
B-34
79.91-79.92
79.92-79.93
79.93-79.94
79.94-79.95
80.20-80.21
80.21-80.22
80.22-80.23
79.93-79.955
80.21-80.235
80.43-80.455
Diameter of 480E
piston skirt (unit: mm)
79.915-79.925
79.925-79.935
79.935-79.94
79.945-79.955
80.205-80.215
80.215-80.225
80.225-80.235
79.965-79.975
80.245-80.255
80.465-80.475
Diameter of UAESs
new two-valve piston
skirt (unit: mm)
79.915-79.925
79.925-79.935
79.935-79.94
79.945-79.955
80.205-80.215
80.215-80.225
80.225-80.235
80.435-80.455
B-35
2.0
0.610.025
0
-0.012
2.680.05
4.0 -0.015
-0.025
4.0
4.0
+0.03
+0.01
+0.03
+0.01
Fit clearance
(unit: mm)
0.050-0.082
0.050-0.082
0.01-0.23
0.025-0.055
First compression
ring
Second
compression ring
Sealing strip of
oil ring
Spring of oil ring
1.2-0.03-0.01
1.20.030.05
1.5-0.03-0.01
1.50.020.04
0.460.02
2.750.05
2.00.02
B-36
30.010.03
Installation
Piston weights and spare piston skirts are not
grouped, but the piston pin holes shall be
grouped. Before assembly, check the piston
crown marks. The marks of the four cylinders
must be same.
Heat the small end of the connecting rod to
230~400, apply SAE50 lube or glue type of
graphite oil, then press the piston pin into the
small end bore of the connecting rod and the
piston pin bore. One end of the piston pin can
be 0.7mmmaxhigher than the pin boss or
lower than the pin seat, and the other end shall
be in the pin boss.
Forward
pointing bump
B-37
No paint (Standard)
No paint (Standard)
B-38
LUBRICATION SYSTEM
DESCRIPTION OF LUBRICATION SYSTEM D-2
OIL PAN D-3
DISASSEMBLY/ASSEMBLY D-3
OIL FILLING D-5
OIL STRAINER ASSEMBLY D-5
DISASSEMBLY/ASSEMBLY D-5
OIL PUMP AND FRONT OIL SEAL D-6
DISASSEMBLY/ASSEMBLY D-6
OIL FILTER AND OIL PRESSURE SENSOR D-10
DISASSEMBLY/ASSEMBLY D-10
OIL PRESSURE TESTING PARAMETER LIST D-11
D-1
D-2
2. Oil Strainer
7. Oil Filter
3. Oil Pan
9. Camshaft
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
To fill the engine with 3.1 0.15L of oil
(SAE10W/30SF grade, or SAE5W/30SJ grade at
temperature lower than -18)
The oil surface shall be between max and
min on the dipstick.
D-5
Flat
D-6
D-7
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
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.,
or screw the oil filter manually and screw more
3/4-1 round when the rudder gasket reaches the
cylinder.
D-10
Serial
No.
Subject
Rev
r/min
200
Oil outputL/min
800
1962
>6
Oil outputL/min
3000
2943
>28
Opening Pressure of
Pressure Limit Valve: Kpa
(Kgf/cm2)
Seal
Pressure Kpa
(Kgf/cm2)
Judgment
Index
Achievement
Oil yield
starting
44020
Oil yield
starting
2000
6867.0
D-11
No oil
leakage on
each faying
face
4.49
0.2
Passed
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
DESCRIPTION OF COOLING SYSTEM
COMPONENTS OF 480 ENGINE COOLING SYSTEM
Engine cooling system is used to cool engine to
prevent the engine from overheating, ensuring the
normal operation of engine. It is composed of the
timing belt-driven water pump, transverse radiator,
water tank, water pipe, thermostat, temperature control
switch of electrically-driven fan and water temperature
sensor.
E-2
Hose
Hose
Expansion Tank
Hose
Hose
Engine
Water Pump Inlet
Hose
Hose Assembly
Thermo-Switch
Radiato
ENGINE COOLANT
Coolant Discharge:
To demount the pressure cap of expansion
reservoir;
To install a vessel under the radiator, demount
the radiator outlet hose under the radiator and
discharge the coolant.
Cooling System Cleaning:
To discharge coolant, mount the radiator outlet
hose;
To inject clean water up to the position of the
largest water surface of the expansion reservoir
from the expansion reservoir filler, and then close
the pressure cap;
To start up engine to make it operate at idle speed,
E-3
E-4
E-5
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
repaired, it should be replaced when seal ring or bearing
is worn and torn.
E-6
Gasket
Tightening Torque
THERMOSTAT
Disassembly:
To unscrew 3 M640 bolts and then demount the
bolts;
To demount thermostat chassis and thermostat
assembly.
E-7
Assembly:
To clamp the thermostat and then put the gasket
into the thermostat aperture.
To install thermostat (the side with spring facing
outward).
To embed spring clamp to ensure the clip within
the thermostat chassis slot;
To mount new gasket onto thermostat chassis;
To mount the thermostat chassis and thermostat
assembly into the aperture at the rear side of engine
cylinder head, and screw up the bolt by hand to
912N.m.
E-8
Resistance Value ()
-20
29,125
-10
16,660
9,790
+20
3,748
+25
3,000
+60
747
+80
377
+100
204
+120
117
COOLING FAN
Disassembly:
To disconnect the negative terminal of battery;
E-9
Assembly:
To assemble the cooling fan according to the
disassembly order (the tightening torque of
self-tapping screw is 1.8~2.2Nm)
E-10
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).
To demount the left and right wind boards by M10
sleeve.
E-12
Assembly:
To assemble the radiator according to the order
opposite of the disassembly order.
To install the 2 wind boards onto the radiator by
using self-tapping screws with their tightening
torque of 67Nm.
E-13
F-1
INTAKE-AIR SYSTEM
INTEGRAL INTAKE MANIFOLDS
Warning
When the engine and intake-air system are hot, they can badly burn. Turn off the
engine and wait until they are cool before removing the intake-air system.
Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage.
Always keep sparks and flames away from fuel.
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
2. Throttle Body
7.Fuel Injector
8. Oil Rail
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
2. By-pass Hose
3. Lock Pin
Qo.
Q.
4. Throttle Valve
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
1.Connector
2.Resistance Circuit
A Ground Signal
3.Throttle Body
B 5V Voltage
C Output Signal
Recovery:
If failure happens, the setting value is calculated through the readings of TDC (top dead
center)/ ESS (engine speed sensor) and absolute pressure sensor.
If there is a failure in the absolute pressure sensor signal, set throttle valve opening angle a
fixed value 50 degree. For the moment, adopting the methods like buffering, idling
adaptability and air fuel ratio adjustment all doesnt work.. Throttle signal cycle is also
malfunctioned when running automatic transmission.
F-5
Recovery:
When a failure in sensor circuit happens, manifolds pressure value will be estimated
according to the method of data-inserting arithmetic based on the rotate speed and related
throttle valve opening angle in a pressure-recovery recorder Then the value shall be modified
by coolant temperature and the air pressure.
Pins:
1. Grounded
2. Outputs Temperature Signal
3. 5V Power Source
4. Outputs Pressure Signal
F-6
solenoid/crankshaft
position
OIL-VAPOR SEPARATOR
A
1
2
B
E
D
1.Oil-vapor separator
2. Air cleaner
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
Exhaust system inspection
Start the engine and inspect each exhaust system component for exhaust gas leakage.
If leakage is found, repair or replace as necessary.
Exhaust system removal/installation
Warning
When the engine and exhaust system are hot, they can badly burn. Turn off the engine
and wait until they are cool before removing the exhaust system.
Exhaust assembly and oxygen sensor position
1. Oxygen Sensor
2. Catalytic Converter
3. Silencer
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.
re-cycle system.
Spark wear and efficiency of high voltage wire insulator.
If timing and positioning of TDC (top dead center)/rotate speed sensor is right or not.
Tappet clearance and engine compression ratio.
If supplied oil pressure is right or not.
F-10
CO%
HC (p.p.m.)
CO2 (%)
0.4 - 1
< 600
> 12
< 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
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.
Mount 3 M10 copper nuts with a tightening torque of 603Nm.
M8 bolts and 2 M8 flange plane nuts and lay sealing pad with a tightening torque of
303Nm. The nuts shall near the three-way catalyst converter.
Install back hose assembly on front hose assembly with a hose clamp.
Connect back hose assembly to the back hose hook with a hang block.
M8 bolts and 2 M8 flange plane nuts and lay sealing pad with a tightening torque of
303Nm.
Use one hang block connecting front hose of three-element catalytic converter to the
of back silencer.
Set 2 hooks to welding bolts and tighten them using 2 M8 lock nuts with a torque of
303Nm.
Connect back silencer to the body with 4 flying rings (hang block).
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.
Installation of exhaust hose bracket:
Install exhaust hose bracket.
Mount 4 M8 lock nuts and tighten them with a torque of 121Nm.
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
mouth.
Set up 3 fuel tank fixed belts and 5 M8 bolts.
Tighten 5 M8 bolts (tightening torque is 30
F-16
Caution
Fuel pipe can not be bent excessively.
After insert the quick release connector,
please pull and push the quick release
connector several times to confirm it
insert in position.
F-17
Caution
When adjusting degree of tightness of
accelerator cable you should ensure
that: Accelerator pedal doesnt need
any part of empty stroke at idle; when
throttle is full open, accelerator pedal
limiting screw assembly is effective
(accelerator pedal can step on
accelerator pedal limiting screw
assembly).
Adjusting of accelerator cable:
Range of free travel : 1.03.0mm
F-18
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
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.
1Complete the Before repair procedure
2Disconnect the negative battery cable.
3Remove the fuel injectors.
4Connect the fuel injector to the fuel injector tester.
5Measure the injection volume of each fuel injector using a graduated container.
F-21
Atomization
1Inspect atomization pattern.
If the atomization is faulty, replace the fuel injector.
2.Fuel Filter
7.Fuel Pump
3.Fuel Rail
4.Fuel Injector
5.Pressure Regulator
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
4.Safety Valve
F-23
Fuel rail
Fuel rail 1 is made of cast aluminum. Its function is distributing fuel to injector 2.
F-24
1.Fuel Rail
2.Fuel Injector
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).
1. O-ring
4. Coil
2. O-ring
5. Electric Terminal
F-25
Specification:
Voltage: 12V
Resistance: 13.8 ~ 15.2 10% on 23C
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
G-4
G-1
19
18
Diagnostic
connector
1
2
3
4
5
6
7
8
9
10
Engine ECU
Air pressure / temperature sensor
Engine speed sensor for top dead center
Throttle valve position sensor
Knock sensor
Coolant temperature sensor
Oxygen sensor ( signal)
Air condition request
Ignition coil and spark plugs
Instrument panel
G-2
11
12
13
14
15
16
17
18
19
Fuel injector
Oxygen sensor (heater)
Fuel pump
Carbon canister solenoid valve
Two step speed fan controller
Compressor relay control
Idling speed step motor
Diagnostic connection
Relay
Fuel pump
+12V)
Power supply
(15/54)
A/C relay
Idling speed step motor
Malfunction
indicator
Fuel injector
Ignition coil
Carbon canister
solenoid valve
Engine
ENGINE
Throttle valve
position sensor
Line K
Air pressure /
temperature sensor
Knock sensor
Cooling temperature
overheat alarm light
Decoder alarm light
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
G-5
G-6
TMAP
signal
G-7
5 Casing
6 Pressure bracket
3 PCB
7 Welded joint
4 Sensing element
8 Bonded joint
G-8
Pins:
1 sensor signal ground (ECU17#)
2 5V power (ECU32#)
3 sensor signal (ECU16#)
Troubleshooting: mainly check if there is short circuit
or open circuit on the connection between 3 lines on
sensor and ECU.
Check to see if there is short circuit, open circuit or
grounding between sensor wire harnesses.
Coolant Temperature Sensor TF-W
Purpose: this sensor is designed to provide coolant
temperature information. To provide engine ECU with
water temperature signal used for control of ignition
timing and fuel injection pulse width in startup, idle
speed and normal operation.
Composition and principle: this sensor is a
thermistor of negative temperature coefficient (NTC)
with resistance value decreasing with the increasing of
coolant temperature except linear relation. The said
thermistor is installed in a heat-conducting sleeve.
ECU monitors water temperature variation by
converting resistance value of thermistor into a
changing voltage through a bleeder circuit (inner
structure of ECU).
G-9
1.Knocking
block
2.Casing
3.Piezoelectric
ceramics
4.Contactor
5.Electric
connection
G-10
Oxygen Sensor
G-11
G-12
ECU
Connection point
Heated oxygen sensor
Ignition coil 2
Type
Output
Output
Pin
42
43
Ground
44
4
5
45
Ignition coil 1
Output
46
G-13
Connection point
A/C temperature sensor
Non-sustained power
supply
Non-sustained power
supply
Carbon canister Valve
Type
Input
Input
Input
Output
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Output
Output
Ground
Electronic ground 1
Ground
Input
Speed signal
Input
Power ground 1
Non-sustained power
supply
Phase angle sensor D of
step motor
Phase angle sensor A of
step motor
Phase angle sensor B of
step motor
Phase angle sensor C of
step motor
Ground
68
Output
69
70
71
72
73
74
75
76
Output
Output
I/O
A/C switch
Blaster switch
Input
Input
77
Headlight switch
Input
Input
Output
47
Output
48
Output
49
Input
Input
Output
Input
Input
Ground
Input
Input
Input
50
51
52
53
54
55
56
57
58
59
60
61
22
63
23
64
24
65
25
66
26
67
27
28
29
30
31
32
33
34
35
36
37
Fuel injector 1 (1
cylinder)
Inspection light
Output
Output
5V power supply 2
Output
5V power supply 1
Output
Engine rotary sensor B
Input
Sensor ground 3
Ground
Sensor ground connector
Ground
2
Air intake pressure
Input
sensor
38
39
40
Output
Output
Output
Output
78
79
Temperature sensor of
engine coolant
Temperature sensor of
air intake
Input
Input
80
Input
81
41
G-14
Ground
G-15
G-17
Pins:
Pin A is connected to the 29# pin of ECU;
Pin B is connected to the 4# pin of ECU;
Pin C is connected to the 26# pin of ECU;
Pin D is connected to the 21# pin of ECU.
Troubleshooting: Verify that the four circuits between
the step motor and the ECU are short or open. Verify
that the step motor is jammed. Verify that there is
circuit short or circuit open inside the step motor.
Ignition coil ZSK-ROV
Function: The ignition coil transforms the low voltage
of the primary winding into the high voltage of the
secondary winding. The spark plug generates the spark
through discharging and ignites the combustion gas
mixed with air and fuel.
Structure and working principle: The ignition coil is
comprised of the primary winding, the secondary
winding, the iron core, the shell and so on. If the
battery voltage applies on the primary winding, the
primary winding is charged. After the ECU cut off the
circuit of the primary winding the charging will be
stopped and the high voltage will be inducted in the
secondary winding.
Fault diagnosis: Because the ECU is not able to
conduct diagnosing for the ignition coil, there is no
diagnostic trouble code for the malfunction of the
ignition coil. Whether the ignition coil functions
properly can be judged only by inspecting the ignition
il
it
Th i iti
il
d
it
l t
G-18
External appearance of
G-19
G-20
G-21
G-22
G-23
Inspection
results
Operation procedure
Connect the diagnostic tester and adaptor,
and turn the ignition switch to ON
position.
Observe the air intake pressure in data
flow and verify that it is maintained at
101kPa (the exact value is determined by
the atmospheric pressure at that time).
Disconnect the connector of the air intake
pressure sensor on the wiring harness and
inspect with multimeter to verify that the
voltage between the 3# and 1# pins of the
connector is about 5V.
Verify that the circuits between the 17#,
33# and 37# pins of ECU and the 1#, 3#,
and 4# pins of the sensor connector are
short to ground.
Start up the engine, run at idle speed. Step
on the accelerator pedal slowly until the
nearly full opening, observe the air intake
pressure displayed on the diagnostic
tester and verify that the value is stable
without significant change; if step on the
accelerator pedal quickly until nearly full
opening, whether the value exceeds 90kPa
instantaneously.
Start up the engine, run at idle speed.
Observe
the
value
of
Coolant
temperature on the diagnostic tester to
verify that the indicated value is increased
along with the temperature increase of the
engine coolant.
G-24
Follow-up
procedure
Proceed to next
step.
Yes
Proceed to Step 5
No
Proceed to next
step.
Yes
Proceed to Step 5
No
Proceed to next
step.
Yes
No
Repair or replace
the wiring
harness.
Proceed to next
step.
Yes
Refer to diagnosis
help.
No
Replace the
sensor.
Yes
Refer to diagnosis
help.
No
Replace the
sensor.
Inspection
results
Operation procedure
Connect the diagnostic tester and
adaptor, and turn the ignition switch to
ON position.
Observe the coolant temperature in
data flow to verify that it matches to the
engine temperature (the exact value is
determined by the engine temperature at
that time).
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
temperature sensor on the wiring
harness, inspect with multimeter to
verify that the resistance between 1#
and 2# pins of the sensor matches to the
temperature (see the related part of this
maintenance manual for reference).
Disconnect the connector of the coolant
temperature sensor on the wiring
harness, inspect with multimeter to
verify that the voltage between 1# and
2# pins of this connector is about 5V.
Check whether the circuits between 39#
and 35# pins of ECU and the 1# and 2#
pins of the sensor connector are short to
ground.
Start up the engine, run at idle speed.
Observe the value of Coolant
temperature on the diagnostic tester to
verify that the indicated value is
increased along with the temperature
increase of the engine coolant.
G-25
Follow-up procedure
Proceed to next step.
Yes
Proceed to Step 6
No
Yes
No
Yes
Proceed to Step 6
No
Yes
No
Yes
Refer to diagnosis
help.
No
Inspection
results
Operation procedure
Connect the diagnostic tester and adaptor,
and turn the ignition switch to ON
position.
Observe the item of throttle absolute
opening in the data flow to verify that the
value is maintained within 4%-10% (the
exact value varies from individual auto
model.)
Step on the accelerator pedal slowly until
full opening, observe the absolute
opening of throttle in data flow and verify
that the value is increased to 85%-95%
with the increasing of the accelerator pedal
opening (the exact value varies from
individual auto model).
Repeat the step 3, observe the absolute
opening of throttle in data flow to verify
that there is jump during the change of the
value.
Disconnect the connector of the throttle
position sensor on the wiring harness to
verify that the circuits between 17#, 32#,
and 16# pins of ECU and 1#, 2#, and 3#
pins of the sensor connector are short to
ground.
Inspect with multimeter to verify that the
voltage between 1# and 2# pins of this
connector is about 5V.
G-26
Follow-up
procedure
Proceed to next
step.
Yes
Proceed to next
step.
No
Proceed to Step5
Yes
Proceed to next
step.
No
Proceed to Step 5
Yes
No
Proceed to next
step.
Yes
No
Proceed to next
step.
Yes
No
Inspection
results
Operation procedure
Connect the diagnostic tester and adaptor,
and turn the ignition switch to ON
position.
Observe the item of throttle absolute
opening in the data flow to verify that
the value is maintained within 4%-10%
(the exact value varies from individual
auto model.)
Step on the accelerator pedal slowly until
full opening, observe the absolute
opening of throttle in data flow and
verify that the value is increased to
85%-95% with the increasing of the
accelerator pedal opening (the exact value
varies from individual auto model).
Repeat the step 3, observe the absolute
opening of throttle in data flow to verify
that there is jump during the change of
the value.
Disconnect the connector of the throttle
position sensor on the wiring harness to
verify that the circuits between 17#, 32#,
and 16# pins of ECU and 1#, 2#, and 3#
pins of the sensor connector are open or
short to power supply.
Inspect with multimeter to verify that the
voltage between 1# and 2# pins of this
connector is about 5V.
G-27
Follow-up
procedure
Proceed to next
step.
Yes
Proceed to next
step.
No
Proceed to Step5
Yes
Proceed to next
step.
No
Proceed to Step5
Yes
No
Proceed to next
step.
Yes
No
Proceed to next
step.
Yes
No
Inspection
results
Operation procedure
Connect the diagnostic tester and adaptor,
and turn the ignition switch to ON
position.
Start up the engine, run at idle speed until
the temperature of coolant reaches the
normal value. Observe the value of
Oxygen sensor voltage on the diagnostic
tester to verify that the indicated value is
changed quickly within the range of
100mV 900mV.
Verify that the circuits between 36# and
18# pins of ECU and A# (corresponding to
grey connecting wire of the oxygen sensor)
and B# (corresponding to black connecting
wire of the oxygen sensor) pins of 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;
C. Verify that the clearance of spark plug is
excessive large;
D. Verify that the resistance of distributor
circuit is excessive large;
E. Verify that the air intake valve conduit is
worn out;
And etc.
G-28
Follow-up
procedure
Proceed to next
step.
Yes
Refer to diagnosis
help.
No
Proceed to next
step.
Yes
No
Proceed to next
step.
Yes
No
Refer to diagnosis
help.
Item
No.
1
Inspection
results
Operation procedure
Connect the diagnostic tester and adaptor,
and turn the ignition switch to ON
position.
Start up the engine, run at idle speed until
the temperature of coolant reaches the
normal value. Observe the value of
Oxygen sensor voltage on the
diagnostic tester to verify that the
indicated value is changed quickly within
the range of 100mV 900mV.
Verify that the circuits between 36# and
18# pins of ECU and A# (corresponding
to grey connecting wire of the oxygen
sensor) and B# (corresponding to black
connecting wire of the oxygen sensor)
pins of the sensor connector are short to
power supply.
G-29
Follow-up
procedure
Proceed to next
step.
Yes
Refer to diagnosis
help.
No
Proceed to next
step.
Yes
No
Refer to diagnosis
help.
Item
No.
1
Inspection
results
Operation procedure
Connect the diagnostic tester and adaptor,
and turn the ignition switch to ON
position.
Start up the engine, run at idle speed until
the temperature of coolant reaches the
normal value. Observe the value of
Oxygen sensor voltage on the diagnostic
tester to verify that the indicated value is
changed quickly within the range of
100mV 900mV.
Verify that the circuits between 36# and
18# pins of ECU and A# (corresponding to
the grey connecting wire of oxygen sensor)
and B# (corresponding to the black
connecting wire of oxygen sensor) pins of
the sensor connector are open.
G-30
Follow-up
procedure
Proceed to next
step.
Yes
Refer to diagnosis
help.
No
Proceed to next
step.
Yes
No
Refer to diagnosis
help.
Inspection
results
Operation procedure
Connect the diagnostic tester and adaptor,
and turn the ignition switch to ON
position.
Disconnect the connector of the oxygen
sensor on the wiring harness and inspect
with multimeter to verify that the voltage
between C# (corresponding to the white
connecting wire of the oxygen sensor)
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
resistance between C# (white) and D#
(white) pins of the oxygen sensor is
within 1~6 under 20.
G-31
Follow-up
procedure
Proceed to next
step.
Yes
Proceed to next
step.
No
Proceed to Step4
Yes
Proceed to next
step.
No
Yes
No
Yes
No
Refer to diagnosis
help.
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
No.
1
Inspection
results
Operation procedure
Connect the diagnostic tester and adaptor,
and turn the ignition switch to ON
position.
Start up the engine, run at idle speed until
the temperature of coolant reaches the
normal value.
Under the full load working condition,
observe the value of Oxygen sensor
voltage on the diagnostic tester to verify
that the indicated value is maintained at
100 mV without significant change for
long time under certain working
conditions.
Connect the fuel pressure gauge to the
feeding pipe of fuel supply system to
observe whether the fuel pressure is
maintained at 350kPa under full load
working condition.
Verify that the circuits between 36# and
18# pins of ECU and A# (corresponding to
the grey connecting wire of oxygen sensor)
and B# (corresponding to the black
connecting wire of oxygen sensor) pins of
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;
C. Verify that the clearance of spark plug is
excessive large;
D. Verify that the resistance of distributor
circuit is excessive large;
E. Verify that the valve clearance is
excessive large; and etc.
G-32
Follow-up
procedure
Proceed to next
step.
Yes
Proceed to next
step.
No
Refer to diagnosis
help.
Yes
Proceed to next
step.
No
Yes
No
Proceed to next
step.
Yes
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
No.
1
Inspection
results
Operation procedure
Connect the diagnostic tester and adaptor,
and turn the ignition switch to ON
position.
Start up the engine, run at idle speed until
the temperature of coolant reaches the
normal value.
Under the full load working condition
observe the value of Oxygen sensor
voltage to verify that the indicated value
is maintained at 900 mV without
significant change for long time under
certain working conditions.
Connect the fuel pressure gauge to the
feeding pipe of fuel supply system to
observe whether the fuel pressure is
maintained at 350kPa under full load
working condition.
Verify that the circuits between 36# and
18# pins of ECU and A# (corresponding
to the grey connecting wire of oxygen
sensor) and B# (corresponding to the
black connecting wire of oxygen sensor)
are short to power supply.
A. Verify that there is leakage in the fuel
injector;
B. Whether there is air leakage in
exhaust pipe;
C. Whether the ignition timing is correct;
D. Whether the air intake valve conduit
is worn out;
E. Whether the valve clearance is
excessive small;
And etc.
G-33
Follow-up
procedure
Proceed to next
step.
Yes
Proceed to next
step.
No
Refer to diagnosis
help.
Yes
Proceed to next
step.
No
Yes
No
Proceed to next
step.
Yes
No
Refer to diagnosis
help.
Inspection
results
Operation procedure
Connect the diagnostic tester and adaptor,
and turn the ignition switch to ON
position.
Disconnect the connector of the 1
cylinder fuel injector on the wiring
harness, and inspect with multimeter to
verify that the voltage between 1# pin of
this connector and the negative grid of
power supply is about 12V.
Verify that the circuit between 1# pin of
the connector of the 1 cylinder fuel
injector and the main relay is open, or
short to ground.
Inspect with multimeter to verify that the
resistance between 1# and 2# pins of the
1 cylinder fuel injector is within 11~16
under 20.
Inspect with multimeter to verify that the
voltage between the connector of the 1
cylinder fuel injector (2# pin) and the
negative grid of power supply is about
3.7V.
Verify that the circuit between the
connector of the 1 cylinder fuel injector
(2# pin) and 27# pin of ECU is open or
short to ground or power supply.
G-34
Follow-up procedure
Proceed to next step.
Yes
Proceed to Step 4
No
Yes
No
Yes
No
Yes
Refer to diagnosis
help.
No
Yes
No
Diagnostic trouble code: P0202 Circuit malfunction of the double cylinder fuel
injector
Item
No.
1
Inspection
results
Operation procedure
Connect the diagnostic tester and adaptor,
and turn the ignition switch to ON
position.
Disconnect the connector of the double
cylinder fuel injector on the wiring
harness, and inspect with multimeter to
verify that the voltage between 1# pin of
this connector and the negative grid of
power supply is about 12V.
Verify that the circuit between 1# pin of
the connector of the double cylinder fuel
injector and the main relay is open, or
short to ground.
Inspect with multimeter to verify that the
resistance between 1# and 2# pins of the
double cylinder fuel injector is within
11~16 under 20.
Inspect with multimeter to verify that the
voltage between the connector of the
double cylinder fuel injector (2# pin) and
the negative grid of power supply is about
3.7V.
Verify that the circuit between the
connector of the double cylinder fuel
injector (2# pin) and 6# pin of ECU is
open or short to ground or power supply.
G-35
Follow-up
procedure
Proceed to next
step.
Yes
Proceed to Step 4
No
Proceed to next
step.
Yes
No
Yes
No
Yes
No
Yes
No
Diagnostic trouble code: P0203 Circuit malfunction of the triple cylinder fuel
injector
Item
No.
1
Inspection
results
Operation procedure
Connect the diagnostic tester and adaptor,
and turn the ignition switch to ON
position.
Disconnect the connector of the triple
cylinder fuel injector on the wiring
harness, and inspect with multimeter to
verify that the voltage between 1# pin of
this connector and the negative grid of
power supply is about 12V.
Verify that the circuit between 1# pin of
the connector of the triple cylinder fuel
injector and the main relay is open or
short to ground.
Inspect with multimeter to verify that the
resistance between 1# and 2# pins of the
triple cylinder fuel injector is within
11~16 under 20.
Inspect with multimeter to verify that the
voltage between the connector of the
triple cylinder fuel injector (2# pin) and
the negative grid of power supply is about
3.7V.
Verify that the circuit between the
connector of the triple cylinder fuel
injector (2# pin) and 7# pin of ECU is
open or short to ground or power supply.
G-36
Follow-up
procedure
Proceed to next
step.
Yes
Proceed to Step 4
No
Proceed to next
step.
Yes
No
Yes
No
Yes
No
Yes
No
Repair or replace
the wiring harness.
Proceed to next
step.
Proceed to next
step.
Replace the fuel
injector.
Refer to diagnosis
help.
Proceed to next
step.
Repair or replace
the wiring harness.
Refer to diagnosis
help.
Inspection
results
Operation procedure
Connect the diagnostic tester and adaptor,
and turn the ignition switch to ON
position.
Disconnect the connector of the 4
cylinder fuel injector on the wiring
harness, and inspect with multimeter to
verify that the voltage between 1# pin of
this connector and the negative grid of
power supply is about 12V.
Verify that the circuit between 1# pin of
the connector of the 4 cylinder fuel
injector and the main relay is open or
short to ground.
Inspect with multimeter to verify that the
resistance between 1# and 2# pins of the
4 cylinder fuel injector is within 11~16
under 20.
Inspect with multimeter to verify that the
voltage between the connector of the 4
cylinder fuel injector (2# pin) and the
negative grid of power supply is about
3.7V.
Verify that the circuit between the
connector of the 4 cylinder fuel injector
(2# pin) and 47# pin of ECU is open or
short to ground or power supply.
G-37
Follow-up
procedure
Proceed to next
step.
Yes
Proceed to Step 4
No
Proceed to next
step.
Yes
No
Yes
No
Yes
No
Yes
No
Repair or replace
the wiring harness.
Proceed to next
step.
Proceed to next
step.
Replace the fuel
injector.
Refer to diagnosis
help.
Proceed to next
step.
Repair or replace
the wiring harness.
Refer to diagnosis
help.
Inspection
results
Operation procedure
Connect the diagnostic tester and adaptor,
and turn the ignition switch to OFF
position.
Pull out the relay of fuel pump, turn the
ignition switch to ON position, and
verify that the voltage between the power
supply terminal of fuel pump relay (i.e.
30# and 86# pin of the relay) and the
negative grid of power supply is about
12V.
Verify that the power supply circuit of the
relay is open or short to ground.
Inspect with multimeter to verify that the
voltage between the control terminal of
fuel pump relay (i.e. 85# pin of the relay)
and the negative grid of power supply is
about 3.7V.
Verify that the circuit between the control
terminal of the relay (i.e. 85# pin of the
relay) and 69# pin of ECU is open or short
to power supply or ground.
G-38
Follow-up
procedure
Proceed to next
step.
Yes
Proceed to Step4
No
Proceed to next
step.
Yes
No
Yes
No
Yes
No
Repair or replace
the wiring harness.
Proceed to Step2
Replace the fuel
pump relay.
Proceed to next
step.
Repair or replace
the wiring harness.
Refer to diagnosis
help.
Inspection
results
Operation procedure
Connect the diagnostic tester and adaptor,
and turn the ignition switch to OFF
position.
Disconnect the connector of knock sensor
on the wiring harness, inspect with
multimeter to verify that the resistance
between 1# pin and 2# pin of this sensor
is higher than 1M.
Verify that the circuits between 1# and 2#
pin of the knock sensor connector and
19# and 20# pins of ECU are open, or are
short to ground or power supply.
Replace the knock sensor complying with
the operation instructions, trial run and
make the rotary speed of engine exceed
2200 rpm. Verify that the diagnostic code
of P0325 appears again.
G-39
Follow-up
procedure
Proceed to next
step.
Yes
Proceed to next
step.
No
Yes
No
Yes
No
Repair or replace
the wiring harness.
Proceed to next
step.
Refer to diagnosis
help.
Verify that it is a
random
malfunction.
Inspection
results
Operation procedure
Connect the diagnostic tester and
adaptor, and turn the ignition switch to
OFF position.
Disconnect the connector of rotary
sensor on the wiring harness, inspect
with multimeter to verify that the
resistance between 2# pin and 3# pin of
this rotary sensor is about 770~950
under 20.
Verify that the circuits between 2# and
3# pin of the rotary sensor connector
and 34# and 15# pins of ECU are open,
or are short to ground or power supply.
Verify that the signal panel of flywheel
is in good condition.
G-40
Follow-up procedure
Proceed to next step.
Yes
No
Yes
No
Yes
No
Refer to diagnosis
help.
Replace the signal
panel.
Inspection
Follow-up procedure
results
Operation procedure
Connect the diagnostic tester and
adaptor, and turn the ignition switch to
OFF position.
Disconnect the connector of rotary
sensor on the wiring harness, inspect
with multimeter to verify that the
resistance between 2# pin and 3# pin of
this rotary sensor is about 770~950
under 20.
Verify that the circuits between 2# and
3# pin of the rotary sensor connector and
34# and 15# pins of ECU are open, or are
short to ground or power supply.
Verify that the signal panel of flywheel is
in good condition.
G-41
No
Yes
No
Yes
No
Refer to diagnosis
help.
Replace the signal
panel.
Inspection
results
Operation procedure
Connect the diagnostic tester and adaptor,
and turn the ignition switch to ON
position.
Disconnect the connector of phase angle
sensor on the wiring harness, inspect with
multimeter to verify that the voltage
between 1# pin and 3# pin of this phase
angle sensor connector is about 12V.
Verify that the circuit between 3# pin of
phase angle sensor and 87# pin of the main
relay is open or short to ground;
Verify that 1# pin of phase angle sensor is
grounded properly.
Verify that the voltage between 2# pin of
the phase angle sensor connector and the
negative grid of power supply is about 9.9V.
Verify that the circuit between 2# pin of the
phase angle sensor connector and 79# pin of
ECU is open, or is short to ground or power
supply.
Verify that the signal panel of camshaft is in
good condition.
G-42
Follow-up
procedure
Proceed to next
step.
Yes
Proceed to Step 4
No
Proceed to next
step.
Yes
No
Yes
No
Yes
No
Yes
No
Repair or replace
the wiring
harness.
Proceed to next
step.
Proceed to Step 6
Proceed to next
step.
Repair or replace
the wiring
harness.
Proceed to next
step.
Refer to diagnosis
help.
Replace the signal
panel.
Operation procedure
Connect the diagnostic tester and adaptor, and
turn the ignition switch to ON position.
Disconnect the connector of carbon canister
control valve on the wiring harness, inspect
with multimeter to verify that the voltage
between 1# pin of this connector and the
negative grid of power supply is about 12V.
Verify that the power supply circuit of carbon
canister control valve is open or short to
ground.
Inspect with multimeter to verify that the
resistance between 1# and 2# pins of carbon
canister control valve is within 22-30 under
20.
Inspect with multimeter to verify that the
voltage between 1# pin of carbon canister
control valve connector and the negative grid
of power supply is about 3.7V.
Verify that the circuit between 2# pin of
carbon canister control valve connector and
46# pin of ECU is open.
G-43
Inspection
results
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Follow-up
procedure
Proceed to next
step.
Proceed to Step
4
Proceed to next
step.
Repair or
replace the
wiring harness.
Proceed to Step
2
Proceed to next
step.
Replace the
control valve.
Refer to
diagnosis help.
Proceed to next
step.
Repair or
replace the
wiring harness.
Refer to
diagnosis help.
Inspection
results
Operation procedure
Connect the diagnostic tester and
adaptor, and turn the ignition switch to
ON position.
Disconnect the connector of carbon
canister control valve on the wiring
harness, inspect with multimeter to
verify that the voltage between 1# pin
of this connector and the negative grid
of power supply is about 12V.
Verify that the power supply circuit of
carbon canister control valve is open
or short to ground.
Inspect with multimeter to verify that
the resistance between 1# and 2# pins
of carbon canister control valve is
within 22-30 under 20.
Inspect with multimeter to verify that
the voltage between 1# pin of carbon
canister control valve connector and
the negative grid of power supply is
about 3.7V.
Verify that the circuit between 2# pin
of carbon canister control valve
connector and 46# pin of ECU is short
to ground.
G-44
Follow-up procedure
Proceed to next step.
Yes
Proceed to Step 4
No
Yes
No
Yes
No
Yes
Refer to diagnosis
help.
No
Yes
No
Inspection
results
Operation procedure
Connect the diagnostic tester and
adaptor, and turn the ignition switch to
ON position.
Disconnect the connector of carbon
canister control valve on the wiring
harness, inspect with multimeter to
verify that the voltage between 1# pin
of this connector and the negative grid
of power supply is about 12V.
Verify that the power supply circuit of
carbon canister control valve is open or
short to ground.
Inspect with multimeter to verify that
the resistance between 1# and 2# pins
of carbon canister control valve is
within 22-30 under 20.
Inspect with multimeter to verify that
the voltage between 1# pin of carbon
canister control valve connector and
the negative grid of power supply is
about 3.7V.
Verify that the circuit between 2# pin
of carbon canister control valve
connector and 46# pin of ECU is short
to power supply.
G-45
Follow-up procedure
Proceed to next step.
Yes
Proceed to Step 4
No
Yes
No
Yes
No
Yes
Refer to diagnosis
help.
No
Yes
No
Inspection
results
Operation procedure
Connect the diagnostic tester and
adaptor, and turn the ignition switch to
OFF position.
Pull out the relay of A/C condenser
fan, turn the ignition switch to ON
position and verify that the voltage
between the power supply terminal of
the relay (i.e. 30# and 85# pins of the
relay) and the negative grid of power
supply is about 12V.
Verify that the power supply circuit of
the relay of A/C condenser fan is open
or short to ground.
Inspect with multimeter to verify that
the voltage between the control
terminal of relay of A/C condenser fan
(i.e. 86# pin of the relay) and the
negative grid of power supply is about
3.7V.
Verify that the circuit between the
control terminal of relay (i.e. 86# pin
of the relay) and 50# pin of ECU is
open, or is short to power supply or to
ground.
G-46
Follow-up procedure
Proceed to next step.
Yes
Proceed to Step 4
No
No
Yes
No
Yes
No
Refer to diagnosis
help.
Yes
Inspection
results
Operation procedure
Connect the diagnostic tester and adaptor,
and turn the ignition switch to OFF
position.
Pull out the relay of A/C condenser fan,
turn the ignition switch to ON position
and verify that the voltage between the
power supply terminal of the relay (i.e.
30# and 85# pins of the relay) and the
negative grid of power supply is about
12V.
Verify that the power supply circuit of the
relay of A/C condenser fan is open or short
to ground.
Inspect with multimeter to verify that the
voltage between the control terminal of
relay of A/C condenser fan (i.e. 86# pin of
the relay) and the negative grid of power
supply is about 3.7V.
Verify that the circuit between the control
terminal of relay (i.e. 86# pin of the relay)
and 68# pin of ECU is open or is short to
power supply or to ground.
G-47
Follow-up
procedure
Proceed to next
step.
Yes
Proceed to Step 4
No
Proceed to next
step.
No
Repair or replace
the wiring harness.
Proceed to Step 2
Yes
No
Proceed to next
step.
Yes
Yes
No
Repair or replace
the wiring harness.
Refer to diagnosis
help.
Operation procedure
Inspection
results
Proceed to next
step.
Yes
No
Yes
G-48
Follow-up
procedure
No
Yes
No
Yes
No
Diagnostic trouble code: P0506 Idle speed lower than nominal idle speed
Item
No.
Operation procedure
Inspection
results
Proceed to next
step.
Yes
No
Yes
G-49
Follow-up
procedure
No
Yes
No
Proceed to next
step.
Carry out
necessary
Overhaul.
Proceed to next
step.
Carry out
necessary
Overhaul.
Carry out
necessary
Overhaul.
Refer to diagnosis
help.
Diagnostic trouble code: P0507 Idle speed higher than nominal idle speed
Item
No.
Operation procedure
Inspection
results
Proceed to next
step.
Yes
No
Yes
G-50
Follow-up
procedure
No
Yes
No
Proceed to next
step.
Carry out
necessary
Overhaul.
Proceed to next
step.
Carry out
necessary
Overhaul.
Carry out
necessary
Overhaul.
Refer to diagnosis
help.
Inspection
results
Operation procedure
Connect the diagnostic tester and adaptor,
and turn the ignition switch to ON
position.
Disconnect the connector of idle speed
regulator and inspect with multimeter to
verify that the resistances between pin A
and D, pin B and C are 535.3 under
20.
Verify that the circuits between pin A, B,
C, and D of idle speed regulator and 65#,
66#, 67#, and 64# pin of ECU are short to
ground.
G-51
Follow-up
procedure
Proceed to next
step
Yes
Proceed to next
step
No
Yes
No
Repair or replace
the wiring harness.
Refer to diagnosis
help.
Inspection
results
Operation procedure
Connect the diagnostic tester and
adaptor, and turn the ignition switch to
ON position.
Disconnect the connector of idle speed
regulator and inspect with multimeter to
verify that the resistances between pin A
and D, pin B and C are 535.3 under
20.
Verify that the circuits between pin A, B,
C, and D of idle speed regulator and 65#,
66#, 67#, and 64# pin of ECU are short
to power supply.
G-52
Follow-up procedure
Proceed to next step
Yes
No
Yes
No
Inspection
Follow-up procedure
results
Operation procedure
Connect the diagnostic tester and
adaptor, and turn the ignition switch to
ON position.
Disconnect the connector of idle speed
regulator and inspect with multimeter to
verify that the resistances between pin A
and D, pin B and C are 535.3 under
20.
Verify that the circuits between pin A, B,
C, and D of idle speed regulator and 65#,
66#, 67#, and 64# pin of ECU are open.
G-53
No
Yes
No
Operation procedure
Inspection
results
G-54
Follow-up
procedure
Proceed to next
step
Yes
No
Yes
No
Yes
No
Yes
No
Proceed to next
step.
Replace the battery.
Repair or replace
the wiring harness.
Proceed to next
step
Proceed to next
step
Replace the
generator.
Refer to diagnosis
help.
Repair or replace
the wiring harness.
Inspection
results
Operation procedure
Connect the diagnostic tester and
adaptor, and turn the ignition switch to
OFF position.
Inspect with multimeter to verify that
the voltage of battery is about 12V.
Verify that the resistances between the
44#, 45#, and 63# pins of ECU and 87#
pin of the main relay are excessive.
Start up the engine, and verify that the
charging voltage of generator is
maintained within 9-16V under different
speeds.
Verify that the earth point of engine
wiring harness is correct.
G-55
Follow-up procedure
Proceed to next step
Yes
No
Yes
No
Yes
No
Yes
No
Operation procedure
Inspection
results
G-56
Follow-up
procedure
Proceed to next
step
Yes
No
Yes
No
Yes
No
Proceed to next
step
Replace the
battery.
Proceed to next
step
Replace the
generator.
Refer to diagnosis
help.
Repair or replace
the wiring harness.
2
3
Inspection
results
Operation procedure
Connect the diagnostic tester and adaptor
and turn the ignition switch to ON
position.
Clear the diagnostic trouble code and
reconfirm that this malfunction is a steady
state malfunction.
Replace ECU.
Follow-up
procedure
Proceed to next
step
Yes
No
Proceed to next
step
Normal operation
End
2
3
Inspection
results
Operation procedure
Connect the diagnostic tester and adaptor
and turn the ignition switch to ON
position.
Clear the diagnostic trouble code and
reconfirm that this malfunction is a steady
state malfunction.
Replace ECU.
G-57
Follow-up
procedure
Proceed to next
step
Yes
No
Proceed to next
step
Normal operation
End
Inspection
results
Operation procedure
Connect the diagnostic tester and adaptor
and turn the ignition switch to OFF
position.
Pull out the A/C compressor relay, turn the
ignition switch to ON position and check
if the voltage between the power supply
terminal of relay (i.e. 30# and 85# pins of
the relay) and the negative grid of power
supply is about 12V.
Check if the power supply circuit of relay is
open or short to ground.
G-58
Follow-up
procedure
Proceed to next
step
Yes
Proceed to step 4
No
Proceed to next
step
Yes
No
Yes
No
Yes
No
Repair or replace
the wiring
harness.
Proceed to Step 2
Replace the relay.
Proceed to next
step
Repair or replace
the wiring
harness.
Refer to
diagnosis help.
Inspection
results
Operation procedure
Connect the diagnostic tester and adaptor
and turn the ignition switch to OFF
position.
Pull out the A/C compressor relay, turn
the ignition switch to ON position and
check if the voltage between the power
supply terminal of relay (i.e. 30# and 85#
pins of the relay) and the negative grid of
power supply is about 12V.
Check if the power supply circuit of relay
is open or short to ground.
Inspect with multimeter to check if the
voltage between the control terminal of
A/C compressor relay (i.e. 86# pin of the
relay) and the negative grid of power
supply is about 3.7V.
Check if the circuit between the control
terminal of A/C compressor relay (i.e. 86#
pin of the relay) and 70# pin of ECU is
short to ground.
G-59
Follow-up
procedure
Proceed to next step
Yes
Proceed to Step 4
No
No
Yes
Repair or replace
the wiring harness.
Proceed to Step 2
Replace the relay.
No
Yes
Yes
No
Repair or replace
the wiring harness.
Refer to diagnosis
help.
Inspection
results
Operation procedure
Connect the diagnostic tester and adaptor
and turn the ignition switch to OFF
position.
Pull out the A/C relay, turn the ignition
switch to ON position and check if the
voltage between the power supply
terminal of relay (i.e. 30# and 85# pins of
the relay) and the negative grid of power
supply is about 12V.
Check if the power supply circuit of relay
is open or short to ground.
Inspect with multimeter to check if the
voltage between the control terminal of
A/C compressor relay (i.e. 86# pin of the
relay) and the negative grid of power
supply is about 3.7V.
Check if the circuit between the control
terminal of A/C compressor relay (i.e.
86# pin of the relay) and 70# pin of ECU
is short to supply.
G-60
Follow-up
procedure
Proceed to next step
Yes
Proceed to Step 4
No
Proceed to next
step.
No
Yes
Repair or replace
the wiring harness
Proceed to Step 2
Replace the relay
No
Yes
Yes
No
Repair or replace
the wiring harness
Refer to diagnosis
help
Inspection
results
Operation procedure
Connect diagnostic tester and adaptor,
and turn the ignition switch to ON
position.
Check the action of engine malfunction
alarm light by using the actuator
action testing" function of diagnostic
tester and observe whether the light is
always on or off.
Verify that the supply circuit of engine
malfunction alarm light is open or short
to ground.
Check if the supply circuit between the
control terminal pin of engine
malfunction alarm light and 29# pin of
ECU is open, or is short to ground or
power supply.
G-61
Follow-up procedure
Proceed to next step
Yes
No
Normal operation
Yes
No
Yes
No
G-62
Operation procedure
Inspect with multimeter to see whether there
is a voltage of about 10-12.5V between two
battery terminals.
Turn the ignition switch to ON position.
Inspect with multimeter to see whether there
is a voltage of about 10-12.5V between the
terminals connecting the ignition switch and
the positive grid of the battery.
Keep the ignition switch at the startup
position and inspect with multimeter to see
whether that there is a voltage of more than
8V between the terminals connecting the
ignition switch and the starting motor
magnetic clutch.
Inspect with multimeter to see whether the
starting motor has any open or short-circuit.
G-63
Inspection
results
Yes
No
Follow-up procedure
Proceed to next step
Repair or replace the
battery
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
2) The engine can run but cannot successfully start up during starting
Item
No.
1
4
5
Operation procedure
Turn the ignition switch to ON position.
Inspect with the diagnostic tester to see
whether there is any malfunction information
record.
Disconnect the cylinder distribution wire and
connect it to the spark plugs, make a space of
5-10mm between the grid of the spark plug
and engine body. Then turn on the engine
with starting motor, verify that there is any
bluish-white high-voltage spark.
Verify that the resistance of the high voltage
cable is normal
Verify that the cylinder-distribution high
voltage cable and spark plug have any
damage.
Verify that the cylinder identification rotor
ring in distributor is loose or damaged.
10
11
G-64
Inspection
results
Follow-up procedure
Yes
No
Yes
Proceed to Step 8.
No
Yes
Yes
No
Yes
No
Yes
No
Yes
Yes
Replace
Proceed to next step.
Proceed to next step.
Replace
Proceed to next step.
Connect the connector
properly
Proceed to next step.
Service the fuel pump
circuit
Proceed to next step.
No
Yes
No
Yes
No
No
Yes
No
No
12
13
14
15
16
17
18
19
20
21
22
Yes
No
Yes
No
Yes
No
Yes
Yes
G-65
No
No
Yes
No
Yes
No
Yes
No
Yes
Repair
Proceed to next step.
Repair or replace
No
Yes
No
Yes
No
Operation procedure
Inspection
results
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
G-66
Yes
No
Yes
No
Follow-up
procedure
Fix the indicated
malfunction
Proceed to next
step.
Proceed to next
step.
Proceed to Step 9.
Proceed to next
step.
Repair the leakage
of fuel system
Replace the fuel
pressure regulator
Proceed to next
step.
Replace the fuel
injector and fuel
pipe
Proceed to next
step.
Inspect the coolant
temperature and
circuit
Proceed to next
step.
Proceed to next
step.
Repair or replace
the wiring harness
10
11
12
Yes
No
End
Replace the ECU
No
Repair or replace
Yes
Proceed to next
step.
No
Repair or replace
Yes
No
Yes
No
Yes
No
G-67
Proceed to next
step.
Repair or replace
fuel pump relay
and wire
Proceed to next
step.
Replace the fuel
pump
Replace the fuel
pump
Replace the ECU
2
3
7
8
9
10
11
12
Operation procedure
Turn the ignition switch to ON
position. Inspect with the diagnostic
tester to see whether there is any
malfunction information record.
Verify that the air filter is free of any
blockage.
After start up, verify that the air intake
manifold pressure is maintained between
35-65 kPa at idle speed.
Step on the throttle gently and observe
whether its easy to start up.
Connect the fuel manometer valve. Short
the 30# and 87# pins of the fuel pump
relay to operate the fuel pump in order to
verify that the fuel pressure is
maintained at about 350kPa.
Apply a voltage supply of 12V directly
between the battery and the fuel injector
with special connector, and verify that
the fuel injector functions normally.
After washing and cleaning the fuel
injector, verify that its function is
normal.
Replace the fuel and verify that the fuel
is deteriorated or contaminated by water.
Verify that the fuel pressure is lower
than 350kPa.
Close the fuel manometer valve.
Connect the ignition switch again to
re-operate the fuel pump in order to
verify that the fuel pressure can be
established.
Open the fuel manometer valve and
clamp the fuel return pipe with the fuel
tube clamp to stop the fuel return in
order to verify that the fuel pressure can
be established quickly.
Verify that the fuel inlet pipe has any
leakage or blockage.
G-68
Inspection
results
Follow-up procedure
Yes
No
Yes
No
Yes
Yes
No
Proceed to Step 9
Yes
Proceed to Step 8
No
Yes
Yes
No
Yes
No
Yes
No
No
Yes
No
Yes
No
Yes
No
13
14
15
16
17
18
19
Yes
No
Yes
G-69
No
Yes
No
Yes
No
Yes
No
Yes
Repair or replace
No
Yes
No
Operation procedure
Turn the ignition switch to ON
position. Inspect with the diagnostic
tester verify that there is any
malfunction information record.
Inspect with multimeter to see
whether the coolant temperature
sensor is normal. (Or connect a
1.5K resistance in series with
ECUs pin of 39# and 35# to replace
the function of the coolant
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
position and connect the adaptor
between ECU and the wiring harness.
Verify that the voltages at following
ECU pins are normal: 13# is at about
12V of battery voltage; 80# and 61#
are at zero.
Verify that the air filter is free of any
blockage.
After start up, verify that the air
intake
manifold
pressure
is
maintained between 35-65 kPa at idle
speed.
Step on the throttle gently to verify
that it is easy to be started up.
Disconnect the connector of idle
speed actuator before the temperature
of engine coolant reaches 35 in
order to observe whether the engine
speed is decreasing.
Connect the fuel manometer valve
(the connecting point will depend on
G-70
Inspection
results
Follow-up procedure
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
10
11
12
13
14
15
16
17
18
19
G-71
No
Proceed to Step 12
Yes
Proceed to Step 11
No
Yes
No
Yes
No
Yes
No
Yes
No
Proceed to Step 15
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
10
11
12
13
14
G-72
Yes
No
No
Yes
No
Yes
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
Yes
No
Yes
No
15
16
17
18
19
20
21
22
G-73
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
5
6
G-74
Yes
No
Yes
No
Yes
No
Yes
No
Service
Yes
Yes
No
Yes
No
No
G-75
Yes
No
Yes
No
Yes
No
Repair or replace.
Yes
No
Yes
No
Yes
No
3
4
7
8
9
10
11
Yes
No
Yes
No
Yes
No
Proceed to Step 9
Yes
Proceed to Step 8
No
Yes
Replace
Yes
No
Yes
No
Yes
No
Yes
G-76
Yes
No
Yes
No
No
13
No
Yes
No
Yes
No
Yes
14
15
Yes
16
17
18
19
G-77
No
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
G-78
Yes
No
2
3
7
8
10
11
G-79
Yes
No
Yes
No
Yes
Yes
No
Yes
No
Yes
No
Yes
Clean
No
Yes
No
Yes
No
No
Yes
No
Yes
12
No
Yes
No
G-80
12) Too high idle speed (the memory has to be restored after ECUs power-off)
8
9
10
11
G-81
Yes
No
Yes
No
Yes
Adjust or replace.
Proceed to next step.
Repair or replace.
No
Yes
No
Proceed to Step 6
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
8
9
10
11
12
G-82
Yes
No
Yes
No
Yes
Yes
No
Overhaul
Yes
No
Yes
No
Proceed to Step 10
Yes
Proceed to Step 9
No
Yes
Yes
No
Yes
No
Yes
No
No
No
Yes
No
13
14
15
16
G-83
Yes
No
Yes
No
Yes
No
Yes
No
9
10
11
G-84
Yes
No
Yes
No
Yes
Yes
Replace
Proceed to next step.
Overhaul according to
the idle speed
malfunction instruction
Proceed to next step.
No
Overhaul
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
No
Yes
No
Yes
No
12
13
14
15
16
Yes
No
Proceed to Step 14
Yes
G-85
Yes
No
Yes
No
No
Yes
No
10
G-86
Yes
Repair
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
11
12
13
14
15
16
17
18
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
G-87
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
CLUTCH INTRODUCTION
H-2
H-2
H-5
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).
1.Flywheel
2.Driven Disk
3.Snap Ring
4.Release Disk
5.BoltM10(1105N.m)
6.Intermediate Disk
7.Pressure Plate
8.Bolt (23~25N.m)
9.Clutch Pusher
H-2
3.Driven Disk
4.Pusher
6.Transmission Axle
1.Clip
7.Inner Pipe
13.Clip Ring
2.Cable Latch
3.Washer
4.Cable Cushion
5.Jacket Tie-in
6.Jacket
8.Cable
9.Dust Cover 10.Adjust Rod
11.Jam Nut
12.Adjust Bushing
14.Retainer
15.Washer
16.Rubber Cushion
17.Gasket
18. Butt End
H-3
H-4
L (adjustment travel)
Jam nut
Adjust
bushing
Rubber cushion
Bracket
2~3mm
travel
Transmission
release pusher
free
CLUTCH DISASSEMBLY
Disassemble the transmission.
H-5
CLUTCH OVERHAUL
Clutch friction disk: measure the dent depth of
rivet head, i.e. the distance between the rivet head
and the friction disk surface. In case it is found that
the depth reaches the using limit for any hole, the
friction disk shall be changed.
Standard value
Maintenance
1.5mm
0.5mm
0.06in
0.02in
Rivet head
Dent depth
Measure the clutch disc runout using a dial indicator.
If the runout is excessive, replace the clutch disc.
Runout
0.8mm
max
has
0.25mm
max
Flywheel:
Examine whether the connection surface of friction
disk exists abnormal wear or hot point; the change
or maintenance shall be conducted if necessary.
Measure the flatness of the flywheel with a straight
edge and a feeler gauge. If not as specified, replace
the clutch cover.
Maximum clearance
0.05mm
Service limit
0.15mm
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.
Pressure plate
assembly bolt
Torque
Nm
Kg-m
1b-ft
57-65
5.7-6.5
41.5-47.0
Nm
Kg-m
1b-ft
18-28
1.8-2.8
13.5-20.0
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
symptom
Cause
Treatment method
Slip of clutch
Uncompleted
segregation of
clutch
Vibration of
clutch
Clutch noise
Non-separation of
clutch
Lubricate
Change the input shaft
Change friction disk
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
J-26
DISASSEMBLY
J-26
J-27
J-28
J-1
J-30
J-38
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-2
J-43
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
4shift
1.032
1.032
5shift
0.850
0.850
Reverse gear
3.167
3.167
Speedometer
2.286
2.286
2.0L
2.0L
Mechanical
Mechanical
210mm
210mm
100mm
100mm
3.513
3.240
Ratio
J-3
Tyre disassembly.
J-4
J-5
J-6
J-7
J-8
J-9
1. Shift Housing, Fasten The Fixing Bolt By 20Nm 2. Tubular RivetTo Fix Reverse Gear Guide Rail
3. Reverse Gear Guide Rail
4. Self-Tapping ScrewTo Fix The Dashboard
5. Seal 6. Gasket
7. Ball Holder
8. Spacer
9. Ball
10. Spring
11. Spring Plunger
12. Bracket Plate
13. Locknut, 10Nm
14. Plastic Ring
15. Shift Lever With Positioning Eccentric RingBefore
Installation, Installation FinishedAssemble Bracket Plate, Spring And Ball, Fixed By Spring Plunger
16. BushingShift LeverInstallation, Make Sure That Do Not Press The Housing Open 17. Shield Plate
18. Selector Arm Assembly 19. Lock Washer
20. Gear Shift Arm 21. Selector RodBefore
Disassembly Press The Plastic Ball Clamp By Screw Driver
22. Shift Lever (Different End Angle:
Mark (Groove) Towards Selector Rod/ Gearshift Lever)
23. Gearshift Shaft 24. Gear Shift Arm
SubassemblyOnly One Position Can Assemble This Rod 25. Locknut 25Nm 26. Selector Lever
Press The Plastic Ball Clamp By Screw Driver Before Disassembly 27. Selector Rod Arm Subassembly
28. O Ring 29. Left Back Bracket 30. Gear Shift Shaft Subassembly 31. Hexagon Bolt With
Flange 35Nm 32. Gear Shift Shaft Bracket Sub-Assembly
33. Support Bushing
34. Shift Rod
J-10
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
too much bigger and difficult for gear shifting
then you need fine adjustment.
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
Eccentric Ring
Bolt
TRANSMISSION RESOLUTION
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
J-15
J-16
Shift to 5th
Prize up the 5th fork pad and turn left the 5th
fork bushing, take off the 5th fork assembly.
Special Tool
J-17
Special Tool
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.
J-19
Special Tool
J-20
Special Tool
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
Part No.
thicknessmm
015-1700381AA
2.8
015-170038AB
2.9
015-1700381AC
3.0
015-1700381AD
3.1
015-1700381AE
3.2
J-22
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
Main points:
Move the slip cap and fork slightly to eliminate the
free space when measuring the space a.
J-25
Special Tool
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
J-28
Assembly:
Lubricate the lip of oil seal and press oil seal
into transmission housing completely by a
special tool.
J-29
Special Tool
Disassembly:
It needs to take off the gearshift shaft and oil
seal as changing the gearshift shaft bearing.
Penetrate the special tool into gearshift shaft
housing, see the picture, and tap it slightly
until the gearshift shaft out from the other
side.
Assembly:
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.
J-30
Special Tool
Special Tool
Special Tool
Special Tool
Disassembly:
Remove the needle bearing by special tool,
see the picture.
Special Tool
Assembly:
Press the needle bearing to its right position
by special tool.
J-31
Special Tool
Special Tool
J-32
Assembly:
See the picture, assemble the input shaft
needle bearing by special tool, and make sure
press it to the right position.
J-33
Special Tool
Special Tool
Special Tool
Assembly:
See the picture, lubricate the lip of the oil seal
and press the oil seal to its right position by
special tool.
Special Tool
J-34
J-35
1. Rear housing 2. 5th Driven gear snap ring 3. 5th Driven gear 4. Transmission housing
5. Needle bearing 6. 4th Driven gear snap ring 7. 4th Driven gear 8. 3rd Driven gear
snap ring 9.3rd Driven gear 10. 2nd Driven gear 11. 2nd Driven gear and bushing 12. 2nd
Synchronizer ring 13. 1st-2nd Synchronizer assembly 14. Steel spring 15. 1st-2nd Gear
sleeve 16. 1st-2nd Hub 17. Gate 18. 1st Synchronizer ring 19. 1st Driven gear 20. 1st
Needle bearing snap ring 21. Adjustment shim 22. Front bearing external ring 23.
Clutch housing 24. Output shaft front bearing 25. Output shaft 26. Output shaft
intermediate shaft 27. Intermediate bearing pedestal 28. Bearing fixing bolt Output
shaft break down
J-36
ADJUSTMENT TABLE
Adjustment items:
During the repair of
transmission assembly, you
should think about to adjust
the output shaft or differential
assembly installing dimension
when you change any of the
below element.
In order to avoid the
ungrateful work we provide
the right table to you.
Changed parts
Transmission housing
Clutch housing
Differential cone bearing
Output shaft
Output shaft intermediate
bearing pedestal
Differential housing
Output shaft intermediate
bearing
Output shaft front bearing
J-37
Adjusted items
Output
Differential
shaft
No
Adjust
Adjust
Adjust
No
Adjust
Adjust
No
Adjust
No
No
Adjust
Adjust
No
Adjust
No
J-38
Special Tool
Special Tool
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
plate and bolt fasten by 40Nm moment.
Special Tool
Adjustment:
Press differential bearing external ring
completely by special tool.
Special Tool
Special Tool
Put a special tool on small axle shaft and put a dial indicator with magnetic base on the
benchmark. Set the dial indicator to zero when the pre fasten force is 1mm. Move the
differential assembly up and down from one side and record the indication of the indicator.
Notice: during measuring, do not roll the differential assembly otherwise it will influence the
accuracy.
Calculate the adjustment shim thickness:
For bearing pre fasten it needs thickness of the adjustment shim 0.40m; if the reading of the
dial indicator is 0.90mm, then the thickness of the adjustment shim should be
0.40mm+0.90mm=1.30mm.
Disassemble the connecting bolt of differential housing and clutch housing, take out
differential bearing external ring, and buildup the needed adjustment shim thickness by the
least shim, put it to its right position on clutch and press differential bearing external ring
completely. Assemble gasket and transmission housing, and fasten the fixing bolt by 25Nm
moment.
J-40
1, Final drive driven gear 2, Rivet 3, 11, Needle bearing 4,12, Needle bearing
external ring 5,13, Adjustment shim 6, Clutch housing 7, Rivet (may not use) 8,
Oil seal holder 9, Oil seal 10, Small axle shaft 14, Transmission housing 15,
Output flange snap ring 16, Output flange dish washer 17, Output flange 18,
Compression spring 19, Spring seat ring 20, Damper ring 21, Differential
housing 22, Knob gasket 23, Snap ring 24, Planet gear shaft 25, Planet gear snap
ring 26, Axle shaft gear and planet gear 27, Output flange cover
Break down of differential assembly
J-41
J-42
Special Tool
Special Tool
Assembly:
Use the right size oil seal and lubricate its lip.
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
Special Tool
Special Tool
M-2
M-22
M-1
kPa
Item
Front wheel
Rear wheel
Spare wheel
No-load/half-load
200
220
350
420
Full-load
210
260
420
420
M-2
Rim No.
185/60 R1482H
6J14
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.
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.
----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.
USUAL TROUBLES OF THE TIRE
Proper utilization of the tire
The tire is an important part of the wheel assy. Please pay attention to the following items
while using:
------The tire of the same manufacturer and the same No. should be used on the same vehicle.
------Do not install tires out of the specified types
------Make all the tires wear evenly. In order to remedy and lighten the uneven wear, besides
periodic checking and correcting the parameters of the wheel alignment, the rotation
should be also applied. The specific rotation way depends on the practical wearing status.
It is recommended to adopt the tire rotation at interval of 5000~8000km
Possible causes
Solutions
Adjust
Tire noise
Adjust
M-6
Degradation of tire
Insufficient tire pressure
Road noise or
vehicle vibration
Unbalance of tire
Deformation of rim or tire
Uneven wear of tire
Replace
Adjust
Adjust
Repair or
Replace
--
Unbalance of tire
Breach or wear of engine bearing
pad
Breach or wear of transmission
bracket rubber
Overbeating of tire and rim
Looseness of wheel bolt
Unbalance of tire
Circular vibration of
steering wheel
Unstable running
Replace
Lock
Adjust
Replace
Replace
Replace
Lock
Adjust
-Adjust
Replace
---
Adjust
--
--
--
--
Adjust
Repair or
Replace
Lock
M-7
---
Heavily steering of
steering wheel
Improper
returnability of
steering wheel
Adjust
--
Adjust
--
--
Adjust
--
--
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.
M-9
Value
-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
Car No.
Chery A15LHD
2010
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
-3020
Kingpin caster
13030
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
Chery A15LHD
010
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
M-14
M-15
M-16
M-18
M-20
M-21
M-22
M-23
M-24
3 Belleville washer
6 Bearing sleeve
8 Locating ring
11 Dust cover
17 Bowl washer
25Nm
12 Valve cap
21 Bolt
22 Nut 70 Nm
M-25
M-26
M-27
4.
5.
6.
7.
1.
2.
Abnormal wear
on tire
3.
4.
1.
2.
Oscillation of
vehicle
3.
4.
5.
6.
1.
Abnormal noise
of chassis
2.
3.
4.
Causes
Different tire pressure of both
sides
Half way releasing of front
braker
Invalidation of front spring or
housing
Inaccurate alignment of front
wheel
Invalidation of shock absorber
Invalidation of metal rubber
bushes of suspension
Deformation of vehicle chassis,
frame or control arm
Inaccurate alignment of wheel
Serious wear or loose of metal
bushes of suspension system
Looseness of steering link ball
joint
Looseness of front wheel
bearing
Low or different tire pressure
Inaccurate alignment of front
wheel
Invalidation of stabilizer bar
Unbalance of wheels
Looseness of hub bearing
Improper adjustment of steering
gear or serious wear of
components
Too small tightening torque of
chassis sub-frame bolt
Looseness of rear axle bracket
Abnormal noise of front and
rear shock absorber
Looseness of rear axle rubber
hinge bolt looses
M-28
Solutions
1.
2.
3.
4.
5.
6.
Adjust
Overhaul, adjust
Replace
Check, adjust
Replace
Check and replace the
damaged bushes
7. Replace or align
1.
2.
3.
4.
Check, adjust
Replace
Replace
Replace
1.
STEERING SYSTEM
INTRODUCTION OF STEERING SYSTEM N-2
INTRODUCTION OF STRUCTURE N-2
WORKING PRINCIPLE N-3
INTRODUCTION OF PERFORMANCE N-4
REMOVAL/INSTALLATION OF STEERING COLUMN N-5
REMOVAL/INSTALLATION AND CHECK OF STEERING GEAR N-6
REMOVAL/INSTALLATION AND REPAIR OF MAIN BODY OF STEERING
GEAR N-7
CHECK OF STEERING SYSTEM N-18
REGULAR INSPECTION N-18
CHECK OF THE SEAL OF POWER STEERING SYSTEM N-19
CHECK AND REPLACEMENT OF THE HYDRAULIC POWER OIL N-20
EXHUAST OF THE STEERING HYDRALIC SYSTEM N-20
CHECK OF THE OUTPUT PRESSURE OF POWER STEERING PUMP N-21
CHECK OF THE TENSION OF THE BELT N-21
DIAGNOSIS AND TROUBLESHOOTING OF POWER STEERING SYSTEM N-22
PRECAUTION OF STEERING SYSTEM MAINTENANCE N-26
N-1
Figure 1
The rack & pinion power steering gear is composed of three sections: control valve,
mechanical steering gear and servo cylinder. The control valve is widely utilized overseas due
to its advanced structure and high sensitivity. The mechanical steering gear is rack & pinion
pattern.
Contr ol Valve
The control valve is a normally open rotary valve and consisted of: torsion bar1, input shaft
2, valve bush 3 and other components. The hydraulic oil flows into the left and right oil
chambers through the pre-opened clearance of the input shaft 2 and the valve bush 3. The
structure is shown as Figure 2.
Mechanical Steering Mechanism
The mechanical steering mechanism is rack & pinion pattern and composed of three
sections: pinion shaft, steering rack piston assy and steering link.
Servo Cylinder
The servo cylinder has metallic hull, which is divided into right and left oil chambers by the
inner rack piston and connected with the two oil inlets of control valve.
N-2
1. Torsion Bar
2. Input Shaft
3. Valve Bush
Figure 2
To Left Chamber
Oil Inlet
Return oil inlet
To Right Chamber
WORKING PRINCIPLE
Middle Position
When the vehicle moves straight (the steering wheel does not turn), the hydraulic oil
which is supplied by the oil pump enters the oil inlet through the pre-opened
clearance of the rotary valve. 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
N-5
20
Description
Left pull rod outboard joint assy
Right pull rod outboard joint assy
Hexagon nut
Clamp
Rack shield
Single ear no-level clamp
Inner ball joint
Seal ring
Dust cover
Snap ring for hole
Oil seal
Bearing
Valve core assy
Bearing
Oil seal
Conical connector
Hull oil cylinder assy
N-7
Quantity
1
1
2
2
2
2
2
4
1
1
1
1
1
1
1
2
1
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
Conical connector
Left oil tube assy
Lock nut
Adjusting plug
Spring
Rack holder
Hexagon flange bolt
Bearing
Plug cap
Right oil tube assy
O rubber ring
Washer
Oil seal
Steering rack piston assy
Piston ring
O rubber ring
Housing
Stop collar
2
1
1
1
1
1
1
1
1
1
2
2
2
1
1
1
1
1
36.
Wire stopper
N-8
Specification
Quantity
Tightening Torque
N.m
Q1840812
20~30
Plug cap
M30X1.5
35~45
Lock nut
M32X1.5
40~50
M12X1
15~25
M12X1
70~90
M14X1.5
4.9~9.8
Illustration 5
N-9
Illustration 7
Illustration 8
Illustration 9
N-10
Illustration 11
Illustration 12
N-11
Illustration 13
Illustration 14
PrecautionDo not damage the rack 31. Apply the power steering oil on the new O
rubber ring 33, and then install it. Enlarge the piston 30 with finger.
PrecautionDo not enlarge the piston ring excessively. Install the new piston ring 32 on
the piston of the rack piston, apply power steering oil on it, press it tightly with finger.
Check the bearing of the rack hull assy
Refer to Illustration 15
Check (2) Examine if there is indention or
N-12
Illustration 16
Illustration 17
Valve core assy
Illustration 18
N-13
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 bearing 12, the upper oil seal 11 and the snap ring for hole 10.
Apply the 5242 sealant on 1/4 circle thread of the hexagon flange bolt 24 and screw it to the
specified position of the pinion shaft. The tightening torque is 20~30N.m
Screw the plug cap 26 1-2 threads, then apply proper quantities 5242 sealant onto the thread
of the plug cap and fix it into the hull. The torque is 35~45N.m.
N-15
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.
aCheck the clearance
Pull the steering tie rod to make it swing back and forth by hand to ensure that there is no
clearance between the rack and the pinion shaft.
Hint: It is not needed to adjust it if it is normal during the check.
b) Adjust the lock nut of the rack holder to eliminate the clearance
If there is the clearance, loosen the lock nut 18 and screw the adjusting plug 19 clockwise
until the clearance can not be felt between the rack 29 and the pinion shaft. Screw the
adjusting plug 19 back about 30~40 , and then apply the 5242 sealant on the lock nut 18 and
screw it with the tightening torque of 40~50N .m.
N-16
N-17
which can make the internal system pressure reach the maximum. Please pay attention to
the stay time.
Visual inspect if the steering flux control valve, rack seal, vane pump(power steering pump)
or oil tube connectors leakage. Replace the seal components, if necessary.
Check if the ATF oil of the oil reservoir is enough. If it is shortage, inspect if the seal of the
available, the ATF oil may flows into the bellow housing. Therefore, disassemble the
steering gear and replace all the seal rings.
Check if there is leakage in the oil tube connector. If necessary, find out the cause and
reconnect it.
Oil pump flow test
During inspection, turn the steering wheel to the limit position and apply enough force on
the wheel to ensure that the control valve of the steering gear can function normally.
When the engine is idling and the oil temperature range is 505, measure the flux of
the fuel pump and compare the reading of the flow meter with the specified value.
Next, adjust the rotating speed of the engine to three times as much as the idling speed and
repeat the test mentioned above. If the flux of the fuel pump can not return to the original
position immediately, it also shows that the oil pump works abnormally which could lead
to the instant failure or the discontinuity of the power. If the value of the internal leakage is
larger than 1.2L/min, the steering gear should be repaired.
Precaution: All the tests should be carried out when the engine is hot.
N-19
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
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 air enters the steering hydraulic loop.
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
components are bended, and friction force on every ball pin is too large.
The tire pressure is too low.
Front wheel alignment is not accurate.
The vehicle is overloaded seriously.
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
steering oil.
Check all the connectors of the steering hydraulic system to see if there is leakage of the
steering oil, and discharge the air penetrated into the oil tube.
Check the output pressure of the steering oil pump. Disassemble the pump when the
pressure is insufficient to determine if there is wear or serious internal leakage of the oil
pump; the badly leakage or clog of the pressurelimited valve and pressure regulator
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.
resistance of the steering gear, which does not enable the valve bush return in time.
The movement of the valve bush and valve core is clogged due to the unclean oil.
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
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
loud noise.
The performance of the steering control valve is poor.
The oil tube connector is loose or the oil tube is broken.
The oil-filter strainer is blocked or there are too much sediments in the hydraulic circuit.
rod or ball joint loose. These components should be checked. If necessary, tighten them or
replace the damaged one; if the vibration of the steering column shaft is obvious, replace
the steering column assy; if the steering gear is installed too loose, tighten it; lubricate the
connecting sections where are necessary. In addition, if the steering pump driving belt is
loose it will also make a sound of click. Therefore, the steering pump belt wheel should
be checked if it is loose. If necessary, screw tightly or replace it to clear up the noise
failure.
If there is sound of quack-quack when the vehicle turns, especially when the steering
wheel is turned from one limit position to another which may be caused by the sliding of
the power steering pump. Check the tension and the wear status of the driving belt, then
tighten or replace it depending on practical situation.
If there is sound of cluck from the steering pump when the vehicle turns, the reason
maybe the air bubbles in the oil which cause the pneumatic noise as the oil flows. First,
check the oil level. If it is too low, fill the oil reservoir with oil to the proper position to
check and eliminate the leakage failure. Then, check if the hose is broken, or the clamp is
loose which the air would enter the system. Replace the broken hose or the clamp, if
necessary. After confirming that the air entered the liquid of the power steering system,
discharge the air from the power steering system to eliminate the pneumatic noise. If there
is sound of hiss or scream from the steering pump, and there is no air leakage in the
hydraulic system, the tension of the driving belt is normal, it shows there is block in the oil
pipeline or the oil pump is overworn and damaged. Repair or replace it.
There is sound of hiss when the steering wheel is in limit position or turning slow in spot.
If the noise is extremely abnormal, the performance of the steering control valve may be
incompetent. The control valve should be replaced and compared to eliminate the failure.
N-25
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
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
the steering wheel to the left and right limit position (Do not keep the steering wheel stay at
the limit position more than 5 seconds), and continue to refuel the oil reservoir with the
hydraulic oil until the oil level do not decline and no air bubbles appear. The oil level
should reach the half height of the filter core.
N-26
Precaution: Keep the impurities away from the system when refueling.
Caution: Dead steering (i.e. turning the steering wheel to the limit position) is forbidden
during use. Even if necessary, do not keep the steering wheel stay at the limit
position more than 10 seconds. If the minimum turning radius tests in the
general assy test drive ground to detect the interference, it is also forbidden to
do so. When the steering wheel is turned to the limit position and the louder
noise comes from the power steering pump, you can turn the steering wheel
back a little until the noise disappears. It is forbidden to run the power steering
pump without oil. If the steering is suddenly heavy during use, park the vehicle
to check and repair.
N-27
BRAKE SYSTEM
INDUCTION TO BRAKE SYSTEM P-2
REGULAR BRAKE SYSTEM
P-3
P-2
4 Brake pedal
5 Brake pipeline
6 Rear drum brake
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.
Operation of brake
Check Valve
* 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.
1. Nut
2. Brake master
cylinder
3. Check valve
of vacuum hose
4. Vacuum
booster
5. Push rod fork
6. Lock nut
7. Brake pedal
8. Floor
9. Spring
locking piece
10. Pin
11. Push rod
-- Shut down the engine and step on the brake pedal several times to remove the vacuum
kept in the vacuum booster.
-- Press down the brake pedal by hand until the resistance is felt, in this case, the pressed
distance is the free travel of brake pedal, the required value of which is 3 to 6 mm.
-- In case the free travel is less than the required value, adjust the clearance between the
vacuum booster push rod and the master brake cylinder.
Caution: The free travel of brake pedal shall not be shortened due to the carpet laid on
the floor, otherwise the brake travel shortened may cause the brake
performance decrease, even disable the brake.
P-4
P-5
P-6
P-7
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.
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.
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
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
7 Bolt
8 Bolt
9 Left caliper housing
10 Piston
11 Piston gasket
12 Piston dust cover
Good water stability, i.e., its efficiency decrease is small after being soaked in water. The
brake lining of disc brake is with high unit pressure which is easy to squeeze out the water,
and, based on the centrifugal force, only the first or twice braking is required to resume the
original after water is squeezed out. And, for the drum brake, tenth braking or more is
required to resume the original.
* Lower possibility of forming the hot crack or hotspot under the high temperature than
that of the brake drum provided that the brake disc is not too thick.
* Smaller dimension and lighter weight than drum brake in case that their output moments
of braking force are the same.
* Extremely low thermal expansion in the thickness direction of brake disc, which isn't the
same as the thermal expansion of brake drum to make the clearance of brake increase
considerably and cause the too larger travel of brake pedal.
*
Easy and automatic clearance regulation, and simple maintenance and repair operation.
P-10
1. Stop dowel
2. Bolt
3. Brake wheel cylinder
4. Brake back plate
5. Rubber stop block
6. Shoe plate
7. Regulating plate
8. Push rod
9. Regulating plate spring
10. Brake shoe fixing spring
11. Lower return spring
12. Return spring
P-11
Installation:
P-12
P-13
MAINTENANCE OF SPRING
-- Check the breakage, deformation or elastics
weakening of the spring, and replace it, if any.
P-14
9 Support plate
10 Rivet
11 Lower return spring
12 Tension spring
13 Inspection hole
14 Compression spring
15 Clamping pin
16 Spring seat
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.
RELATED PARAMETERS OF VACUUM BOOSTER AND MASTER BRAKE
CYLINDER
A15LHD series vehicles braking equipment adopts the 228.6mm (9in) vacuum booster and
tandem type master brake cylinder, which realizes the booster effect using the vacuum
produced by the operating engine. The vacuum chamber of the booster connects to the air
intake pipe of engine via the vacuum hose and check valve.
The master brake cylinder adopts the tandem type master brake cylinder, which consists of
the cylinder body, piston, spring, spring seat, cup and etc. The master brake cylinder
connects with the front part of the booster using two bolts. A brake fluid reservoir is installed
on the upper part of master brake cylinder. Two working chambers (primary chamber and
secondary chamber) at the front and rear are connected serially in the master cylinders.
Main technical parameters of the A15LHD brake system are:
Master brake cylinder: 22.2 mm
Vacuum booster:
228.6 mm (9in)
54 mm
256 mm
P-16
P-17
5. Compensation rod
6. Nut (20Nm)
7. Parking brake cable
8. Parking brake dust cover assy.
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.
Adjustment of Parking Brake (as shown in the figure below)
P-18
Adjusting Nut
Adjusting Nut
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;
*
*
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
P-21
P-22
Begin
Connect the diagnostic tester under the Power
Off condition
Turn the key switch to ON
Select
Universal
Connection
OBD-16
Diagnostic
Communicate or
not?
Check it in accordance with
the Non-DTC Failure Check
Sheet
DTC
Random failure
Continuous failure
End
P-23
CH 02 Failure inquiry
CH 07 Controller coding
Press the Clear button on the instrument after the TDC readout.
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:
1J0907379
P ABS
20
001
Coding:
WSC:
01901
000001
P-25
IE
CAN
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.
*
Display code
Never occur before
No DTC
Occur before
Random DTC
Non-random DTC
Random and non-random
DTCs
Description of Failure
Diagnostic Details
65535
Damaged
01276
00283
00285
00290
00287
01044
00668
01130
Unreasonable signal
P-26
P-27
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.
Use a blower to heat the parts that you think it may be failed.
Use the cold spraying agent to check the cold welding phenomenon.
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
Possible Cause
* Power supply broken
circuit or earth
*
Motor harness
uncoupling
* Motor damaged
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
Abnormal
Replace the hydraulic control unit
Normal
Check the fuses and ABS
Abnormal
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
No
Refer to the Repair Details
of Random Failure
P-30
Possible Cause
*
Sensor neglected to be
installed
*
Sensor coil or harness short
circuited
*
Excessive air clearance
between the sensor and gear
ring
*
Gear ring neglected to be
installed
*
ABS ECU failure
No
Sensor is installed
Install it normally
normally or not?
Yes
Abnormal
Abnormal
Replace
Normal
bearing clearance
Abnormal
Replace
Abnormal
Check every sensor
P-31
Repair or replace
Speed sensor
3. The DTCs are 00283, 00285, 00290, 00287
[Description] When the vehicle speed > 20 km/h, the
DTCs will appear if the sensor signal exceeds
the tolerance range.
[Hint] It is very possible that the too feeble signals from
sensor are caused due to the intermittent poor
contact or short circuit between sensor coil or
harness, the gear ring damaged, or the excessive
air clearance between the sensor and gear ring.
Sensor is installed
Possible Cause
*
Abnormal
normally or not?
Install it normally
Correct
Abnormal
Check the sensor output voltage at
ABS pin 25# plug
Abnormal
Normal
Replace the ABS ECU
Replace
Normal
Check all wheel sensor gear
Abnormal
rings
Replace
Normal
Check wheel bearing
clearance
Normal
Check the harness between the
sensor and ABS ECU
P-32
Abnormal
Repair or replace
Speed sensor
4. The DTCs are 00283, 00285, 00290, 00287
[Description] The DTCs will appear when the
sensor has the recognizable open circuit,
short circuit and other failures.
[Hint] It may be caused due to the poor contact of
sensor, the short circuit of coil or harness,
or the failure of sensor signal processing
circuit in the ABS ECU.
Possible Cause
*
*
*
Check the
related sensor
connector
Abnormal
Normal
The
failure
No
reoccurs or not?
Yes
Check
the
electrical
wirbetween the ABS ECU
and sensores
Normal
Replace ABS ECU
P-33
Refer to the
Repair
Details
of
Random
Failure
Incorrect
Recoding (coding is 01901)
Abnormal
Repair harness
Supply terminal 30
6. The DTC is 00668
[Description] The DTCs will appear when the
supply terminal 30# provides the
voltage or over-high voltage.
Possible Cause
* ABS systems fuse broken
*
Too low or over-high battery
voltage
* ABS electrical harness connections
damaged
* ABS ECU damaged
Abnormal
Replace the fuse
Normal
Abnormal
Disconnect the connection of ABS
Abnormal
Repair the connections
Normal
Normal
Replace the ABS ECU
No
Yes
Check the battery voltage
Normal
Check sensor
Abnormal
Replace sensor
Normal
Possible Cause
*
P-35
Abnormal
Replace
Normal
Abnormal
Replace the fuse socket
Normal
Remove the ABS ECU connection
Abnormal
Ignition switch: ON
Yes
Replace
No
Yes
Abnormal
Abnormal
Replace the electrical harness
Normal
Yes
Check the connectors of warning
Normal No
Failure reoccurs or not
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.
Yes
Replace harness
No
Check the ABS warning lamp controller
Abnormal
Replace
Normal
Replace the ABS ECU
P-37
Possible Cause
*
Improper installation of
sensor
*
Sensor harness problem
*
Sensor damaged
*
Gear ring damaged
*
Sensor adhered with
foreign material
*
Wheel bearing damaged
*
ABS HCU (Hydraulic
Control Unit) damaged
*
ABS ECU (Electronic
Control Unit) damaged
No
Sensor is installed properly or not
Install it properly
Yes
Abnormal
Check the sensor output voltage
Abnormal
Check all sensors
Normal
Use the diagnostic tester to
Replace
Normal
Abnormal
Check all sensor gear rings
Abnormal
Replace
Abnormal
Normal
Abnormal
Check wheel bearing clearance
Repair or replace
Normal
Check ABS ECU socket and
Abnormal
Replace the connection
intermediate connector
Normal
No
Failure reoccurs or not
Normal
Remove the ABS ECU connector, and check
whether the resistances between the
following terminals of ABS ECU conform to
Abnormal
RR wheel: 19-20
RL wheel: 5-6
FR wheel: 22-23
ABS ECU
Normal
Replace the ABS ECU
P-38
Possible Cause
*
Brake fluid leakage
*
NC valve leakage
*
Air kept in the system
*
Serious brake disc
wear
*
Hand brake
adjustment improper
Abnormal
Visually inspect the leakage of hydraulic
Normal
Normal
Check
hand
brake
adjusting
Normal
Abnormal
Air bleeding check
Normal
Use the diagnostic tester HCU to
Abnormal
Possible Cause
*
*
Booster failure
NO valve failure
Abnormal
Normal
Use the traditional method available
for ABS vehicle to check the booster
P-39
No
Possible Cause
* The fuse broken
*
The diagnostic circuit
broken or the connection
uncoupled
* ABS ECU damaged
* Diagnostic tester failure
Yes
Check ABS supply fuse
Abnormal
Replace
Normal
Display it on the screen of diagnostic tester or not
No
Yes
Remove ABS ECUs connections, check the
Abnormal
Repair
the
diagnostic
No
Yes
Replace the ABS ECU
P-40
Check Item
Battery voltage (motor)
Battery voltage (solenoid
valve)
Supply insulating property
Earth insulating property
Supply voltage
Terminal
MK20I/E
25-8
Ignition
Position
OFF
8-4
8-24
8-4
ON
ECU not
connected
ON
OFF
Connect the
ECU
ON
Braking lamp switch
functional pedal not stepped
down
Braking lamp switch
functional pedal stepped
down
Resistance value of FL
wheel speed sensor
Resistance value of FR
wheel speed sensor
Resistance value of RL
wheel speed sensor
Resistance value of RR
wheel speed sensor
FL wheel sensor output
voltage
FR wheel sensor output
voltage
RR wheel sensor output
voltage
RR wheel sensor output
voltage
Sensor output voltage ratio
Unit
10.1-14.5
9-24
OFF
Standard Value
V
0.00-0.5
10.0-14.5
Warning lamp
extinguishes
Warning lamp
lights
Warning lamp
extinguishes
The warning lamp
lights and then
extinguishes after
lasting for 1.7 s
V
V
V
Visual
inspection
Visual
inspection
Visual
inspection
Visual
inspection
ON
8-18
0.0-0.5
ON
8-18
10.0-14.5
OFF
1-2
1.0-1.3
OFF
19-20
1.0-1.3
OFF
5-6
1.0-1.3
OFF
22-23
1.0-1.3
OFF
1-2
3.4-14.8
mV/HZ
OFF
19-20
3.4-14.8
mV/HZ
OFF
5-6
>12.2
mV/HZ
OFF
22-23
>12.2
mV/HZ
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
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
S-2
S-3
EXTERIOR ACCESSORIES
REMOVAL, INSTALLATION & ADJUSTMENT OF ENGINE HOOD
REMOVAL
------Brace engine hood to remove washer
nozzle of windshield.
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
S-5
OF
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
OF
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.
S-7
S-8
REMOVAL OF BRACKETS
----Loosen the bolts between bumper and its
brackets to remove the brackets.
----Install the bumper in the reverse order of
removal. Note that tightening torque for
the bolt between the brackets and floor
side member is 25Nm. Place the brackets
horizontally with ground.
S-9
REMOVAL OF BRACKETS
----Loosen the bolts between bumper and its
brackets to remove the brackets.
----Install the bumper in the reverse order
of removal. Note that tightening torque
for the bolt between the brackets and
floor cross member is 25Nm. Place the
brackets horizontally with ground.
S-10
S-11
S-12
S-13
INSTALLATION
------Install in the reverse order of removal.
S-14
S-15
S-16
REMOVAL &
INSTALLATON
OF
PASSENGER GRAB HANDLE
---- Remove lid on bottom end of inner grab
handle and fixed bolt with screwdriver.
---- Take out fixed bolt between the handle
and body to remove the grab handle.
---- Install in the reverse order of removal.
S-17
S-18
Attention:
Do not damage the clamps of the housing.
Remove the switch and cover at the two
sides of the instrument panel. Remove the
radio cover and the air condition cover.
S-19
S-20
S-21
S-22
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.
S-24
S-25
DISASSEMBLY AND
INTERIOR CEILING
ASSEMBLY
OF
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/ASSEMBLY OF CARPET
FOR PASSENGER COMPARTMENT
Disassembly:
Remove the fixed decoration between the seal
and the carpet. Loosen the fastening bolt
between the floor and the safety belts of
passenger seats. Remove the oil pan. Use a
plug extraction tool to remove the fastening
plug for the carpet
Assembly:
Assembly is the reverse of disassembly.
Remember that the tightening torque of safety
belt is 5010Nm.
S-28
S-29
DISASSEMBLY
REAR SEATS
AND
ASSEMBLY
OF
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
S-31
S-32
INSTALLATION
Install in the reverse order of removal.
ADJUSTMENT
----If adjust door lock striker erroneously,
which normally causes a failure in closing
the door, position of lock striker shall be
adjusted. The adjusting operation means
that the lock striker is to be loosened with
15mm spanner, and then move as per
requirement.
Tightening
torque
is
505Nm.
S-33
S-34
S-35
S-36
S-37
INSTALLATION
Install in the reverse order of removal.
NOTE
----Tightening torque for bolts or nuts of
window regulator is M=91N.m.
----Installation size for glass bracket is 105mm
as shown in the figure.
----Tighten the six screws of window regulator
only after the glass is fully raised till the top
and can run up and down smoothly.
----After installation and adjustment, the glass
should run up and down smoothly. Any
shaking, vibration or shock is not allowed.
The up or down movement of glass shall
be finished within 31S.
S-38
105
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
105
S-40
RECTIFICATION:
The car body and chassis are produced in the production line through low temperature
tempering, and cold state of casting technology.
Therefore, when part of the metal is damaged in the accident, similar technology must be
used to return to its shape and heating is strictly not allowed.
If it is too damaged to return the original shape the damaged part should be removed after
rectifying the surface of terminal.
PROCESS FOR ANTI-CORROSIVE PROTECTION LAYER
Surface Coating
Intermediate Coating
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
TEST DATA
A=40.5
B=6.51
C=40.5
D=6.51
S-43
E=40.5
F=7.51
G=40.5
OPENING
SIZE
OF
ENGINE
COMPARTMENT AND WINDSCREEN
Size Code
A1090
B1550
C628
D997
E731
STD Value
2mm
Part Measured
Front Mount
Installation Center
2mm
Diagonal Line
between
Fixing
Bolts of Fenders
2mm
Space between
Mount Installation
Center and Fender
2mm
Space between
Center of Fire Wall
and Fixing Bolts of
Fender
2mm
Opening of
Windscreen
S-44
Part Measured
Opening of Boot
Y-Directional
Distance of Boot
Y-Directional Space of
Installation Center
Positions
D
14592mm
Y-Directional Space of
Installation Positions
for Locking Columns
of Real Fender
S-45
BETWEEN
S-46
STD Value
Part Measured
3600.5mm
Z-Directional
Distance
of
Hinges with
Column B
C
D
E
F
STD Value
9381mm
Part Measured
Space between
Column B and the
Installation Position
of Locking Column
with Fender
9501mm
Space between
Column A and the
Installation Position
of Locking Column
with Column B
10082mm
Opening of Front
Door
12922mm
Opening of Front
Door
10742mm
Opening of Rear
Door
11402mm
Opening of Rear
Door
S-47
S-48
S-49
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
S-52
2
3
A
B
C
D
E
Applied Position
Material Model
AMV
AMV
AKR
AKD
AKD
162 000
168 000
303 P10
473 K20
466 000
S-53
A
B
A
A
C
C
D
E
S-54
Applied Position
Material Model
C
D
E
D
C
AMV
AMV
AKR
AKD
AKD
162 000
168 000
303
P10
473
K20
466
000
PVC
PVC
PVC
S-55
Structural Glue
Reinforced Glue
Multifunctional Putty Adhesive
Sealing Putty Adhesive
Electronic Welding Adhesive
S-56
10
Applied Positions
-Connecting Position between Body Control Lever
and Wheel House
-Connecting Position between Floor Board and Front
Instrument Panel
-Connecting Position between Floor Board, Shift
Lever and Center Reinforced Fitting (to be maintained
when necessary)
11
12
S-57
Material
Model
C
C
C
C
C
D
C
Applied Position
Material Model
13
14
15
16
A
B
C
D
E
AMV
AMV
AKR
AKD
AKD
A
C
D
E
D
C
S-58
Point A-a
Point B-b
Point C-c
Point D-d
Size Code
1
2
3
4
5
6
7
8
9
10
STD Value
10201mm
10901.5 mm
679 1mm
703lmm
2l241.5 mm
226l2mm
8801.5 mm
8751.5 mm
l3061.5 mm
10741.5 mm
Part Measured
Between A and a
Between A and b
Between B and b
Between A and B
Between B and C
Between B and c
Between C and c
Between C and D
Between C and d
Between D and d
S-59
STRUCTURE OF
GUARD PLATE
S-60
USING
S-61
THE
FRAMEWORK
OF
SPECIAL
S-62
SUNROOF
BRIEF INTRODUCTION OF SUNROOFS MODEL AND FUNCTION
The agate super 300 auto sunroof, which is a new generation product manufactured by
German Webster Auto Sunroof Manufacturing Company, is the new option sunroof of Chery
A15 sedan.
Function
Type
Sliding opening
250mm
Tilt height
52mm
Outline dimension
803370mm
Applicable type
SQR7160/SQR7162
S-63
PARTS OF SUNROOF
S-64
Name
Glass panel
Glass panel fastening device
Guide bolt
Mechanical devices left / right
Seal
Interior trim rim with gray sunshade
Interior trim rim with beige sunshade
Sunroof motor
Sunroof module
Cover of control buttons
Upper frame
Interior fastening frame
Wind strip
Sunshade assembly
Harness
Rack + pinion / cover
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
FUNCTION
OF
SUNROOF
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
4. PRESET POSITIONS
Firstly press the
button to open the sunroof
to a proper position, press the button (more
than 3seconds) continuously, after the sound of
CREAK is heard from the sunroof, this
position will be automatically memorized as
the preset position 1 of sunroof.
S-67
5. AUTOMATIC CLOSING
When the sunroof is opened to any position,
cut off the power supply of sedan, the sunroof
will make a sound of CREAK.
S-68
INSTRUCTIONS
OF
SUNROOF
MAINTENANCE
S-69
S-70
S-71
S-72
S-73
Assembly:
10. Apply silicon gel with a width of 3 cm on
the position indicated in the figure.
S-74
S-75
S-76
Assembly
5.Slide the new glass panel into the mechanical
devices in parallel.
S-77
REPLACEMENT OF SEAL
1. Fully open the sunroof.
S-78
Assembly:
7. As shown in the figure, apply silicon gel
with a diameter of 3mm on the inner side of
upper frame and apply double layers of
silicon gel under the fastening block of glass
panel.
S-79
S-80
S-81
REPALCEMENT OF SUNSHADE
1. Fully open the sunroof.
S-82
Assembly
7. Install the right guide device and the rear
supporter of sunshade.
S-83
S-84
Assembly:
14. Place the new guide lock in the guide rail.
S-85
S-86
S-87
S-88
S-89
PROGRAM DESCRIPTION
S-90
NOTES ON
USEAGE
MAINTENANCE
AND
1. MAINTENANCE OF SUNROOF
The glass panel is designed with the function
of heat and ultraviolet ray insulation. Please
clean with soft cloth and detergent, dont use
any sticky detergent. Please clean the sunshade
with soft cloth and detergent, dont use any
sticky detergent.
S-91
2. NOTES:
It is not allowed to open the sunroof while
raining or washing.
S-92
S-93
T-2
T-3
Inspection procedure:
Battery inspection
Battery
Inspect the battery according to the following procedure
Procedure
Inspection description
T-4
Results
Above 12.4V
Below 12.4V
Yes
Measures
Proceed to step 3
Proceed to next
step
Proceed to next
step
Replace the battery
Battery is normal
No
Below 12.4V
Above 12.4V
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
T-6
Overhaul of generator:
Inspect the accuracy of deflexion and
tension value of the driving belt, if it does
not comply with the requirement, then the
driving belts should be replaced.
Shut down all the electro-devices, turn the
ignition switch to start the engine, inspect
the rotation process of the engine to see
whether the rotation of generator is smooth
without any noise.
T-7
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
clutch.
Screw three bolts and tighten them(one
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
T-9
Technical parameters
Voltage valueV Current
value
A
11
Less than 90
T-10
LIGHTING SYSTEM
REMOVAL/INSTALLATION OF LIGHTINGS FOR THE COMPLETE CAR
1. Headlamp
Removal Disconnect the negative grid of
the battery
Remove the radiator grille, and use sleeve to
remove the four fixing bolts of the
headlamp.
Unplug the wiring harness connector behind
the headlamp holder.
Then place the headlamp
corresponding position.
on
the
Installation
Install the headlamp properly on the
corresponding position, and ensure that the
fixing hole position of the bolt is concentric
with the welded nut on the crossbeam of the
headlamp;
Use 4 bolts, spacers and 1 nut to locate the
position of the front headlamp, put down the
front hood, confirm and adjust position of
the headlamp (whether it is extruding or
intruding; the requirement is such that the
headlamp should be slightly extruded
beyond the front hood border. The arc shape
of the headlamp can be felt by hand), after
that tighten the fastener, with a tightening
torque of 1.50.2 N.m
Install the radiator grille, and pay attention
not to scratch the paint on the protection
bumper; ensure that the spacing between the
left and right fenders is symmetrical.
Connect the wiring harness plug to the lamp
holder socket.
2. Removal/Installation of the front fog lamp: (Disconnect the negative grid of the
battery)
Connect the corresponding connector to the wiring harness of the fog lamp;
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
T-14
Malfunction Diagnosis
1.All of bulbs have been damaged.
2.The fuse has been burned down.
Neither high beam or low
3.Headlamp switch is faulty.
beam light is working
4.The circuit is faulty.
Only one headlamp, that
is either the high beam or
low beam is working
Either side of the high
beam or low beam is not
working.
Troubleshooting
1.Replace the bulb.
2.Replace the fuse.
3.Inspect and replace the
headlamp switch.
4.Check the circuit.
1.The bulb has been damaged.
1.Replace the bulb.
2.The fuse has been burned down. 2.Replace the fuse.
3.The lamp holder or conducting 3.Check the lamp holder
wire is faulty.
or conducting wire.
1.The bulb has been damaged.
1.Replace the bulb.
2.The fuse has been burned down. 2.Replace the fuse.
3.The headlamp switch is faulty.
3.Check the headlamp
4.The conducting wire or the switch.
grounding is faulty.
4.Inspect the circuit.
1.The bulb has been damaged.
1.Replace the bulb.
2.The fuse has been broken.
2.Replace the fuse.
3.The headlamp switch is faulty.
3.Check the headlamp
4.The conducting wire or the switch.
grounding is faulty.
4.Check the circuit.
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
Troubleshooting
1. Replace the bulb.
2. Check the circuit.
1. Replace the bulb.
2. Replace the fuse.
3. Check the relay.
4. Check the switch.
5. Check the circuit.
1. Check the switch.
2. Check the circuit.
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.
Troubleshooting
1. Replace the bulb.
2. Check the circuit.
1. Replace the bulb.
2. Replace the fuse.
3. Check the switch.
4. Check the circuit.
Check the backup
lamp switch.
Malfunction Diagnosis
1 The bulb has been damaged.
One side of the brake
2. The conducting wire or grounding is
lamps is not working
faulty.
1. The bulb has been damaged.
2. The fuse has been burned down.
Neither of the brake
3. The brake lamp switch is faulty.
lamps is not working
4. The conducting wire or grounding is
faulty.
Brake
lamp
is Incorrect adjustment or damage to the switch
continuously working. of backup lamp.
T-16
Troubleshooting
1. Replace the bulb.
2. Check the circuit.
1. Replace the bulb.
2. Replace the fuse.
3. Check the brake
lamp switch.
4. Check the circuit.
Check the brake
lamp switch.
5.
COMMON
MALFUNCTIONS
TROUBLESHOOTING
Malfunction
symptom
OF
TURN
Malfunction Diagnosis
SIGNAL
LAMP
AND
Troubleshooting
1. Replace the bulb.
2. Replace the standard bulb.
3. Check and replace the
relay.
4. Check the circuit.
1. Replace the bulb.
2. Replace the fuse.
3. Check the relay.
4. Check the switch of turn
signal lamp.
5. Check the circuit.
T-17
IGNITION SYSTEM
SUMMARY OF IGNITION SYSTEM
The ignition system is integrated with the fuel injection system. It is an electronic system
equipped with built-in power supply module. It can provide various kinds of optimum
ignition angular values. This task is being carried out through referencing of the input
instantaneous physical parameter related with the engine working conditions. With the help
of a circuit analyzing microprocessor, it is capable of writing in the various optimum ignition
values into the program.
Circuit of ignition system
1. Knock sensor
2. Ignition coil
3. Rotary sensor
4. Ignition switch
5. Relay
6. Ignition / Fuel injection ECU
7. Fuse
When ECU is breaking off the current of the primary coil, the resulted induction effect of the
secondary coil causes the voltage to rise (as high as 30,000V at idling speed), at this moment
the breakdown voltage of the compression stroke stage in the cylinder is very high
(>10,000V), and the breakdown voltage of the exhaust stroke stage in the cylinder is very low
(approx. 500V). The spark plugs in the 1-4 cylinders and 2-3 cylinders are directly connected
to the terminals of the secondary coils through high voltage cables.
Note: Take extreme care not to reverse the connection of high voltage cable during
reinstallation.
T-18
T-19
T-20
Engine revolutionsRPM
Non- load
800-900
800-900
800-900
950-1050
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
Tachometer
Water
temperature
meter
Fuel meter
Combination
instrument
Odometer
Dual short-range
Odometer
Power module
Circuit board
Speed sensor
Fuel sensor
Warning switch for fuel level
Function
The indicator needle of speedometer is moving as
per the signal from speed sensor, indicating the
driving speed of the car.
The indicator needle of tachometer is moving as per
the signal from ignition, indicating the engine
rotation speed.
The indicator needle of water temperature meter is
moving as per the signal from sensor, indicating the
engine coolant temperature.
The indicator needle of fuel meter is moving as per
the signal from sensor, indicating the remaining
fuel quantity in the fuel tank.
The odometer, counting the cars gross traveling
distance as per the pulse signal from speed sensor,
may switch over within short distance.
The dual short-range odometer, counting the cars
traveling distance as per the pulse signal from the
speed sensor, and may be reset by the switch.
The regulator circuit installed in the power module
is supplying current to various components of the
instruments through fuse S21 10A.
This board is containing the circuitry systems of
various meters and measuring instruments, warning
lamps and indicator lamps, as well as warning
activating circuits for the engine oil level, odometer
and short-range odometer and the circuit system of
various indicator lamps.
Installed in gearbox, this sensor transmits the pulse
signal according to the output shaft rotation speed
to the combination instrument.
This sensor, which converts the engine coolant
temperature into resistance, transmits the relevant
signal to the combination instrument.
This sensor, which converts the residual fuel oil
level in the fuel tank into resistance, transmits the
relevant signal to the combination instrument.
When the fuel level drop down to the preset level,
the level sensor signal activates the circuit in the
fuel meter and switches on the warning lamp.
T-23
Brake switch
Courtesy lamp switch
Warning lamp
Indicator lamp
T-24
left turn
light
ABS
computer,
diagnosi
s
right turn
light,
air bag
seat belt
purple
and black
blue
engine
brown
and white
green and
red
rotary speed
signal
of
ECU
speed,
steering device
black
and
b
brown
and green
purple
and black
purple
and black
hand
brake
switch
/ brake
oil
fuel sensor
yellow
and blue
and yellow
water
temperature
signal of ECU
fuel
pressure
switch
light switch
white and
blue
gray
black
light relay
light relay
Multiplexer
voltage regulator
fuel sensor
lamp
digital clock
RPM sensor
T-25
Function
Socket
No connected
16
Function
Connecting to the terminal D+ of
generator
17
18
19
20
21
22
23
Door light
Seat belt warning lamp
Engine malfunction warning lamp
Connecting to the fuel meter sensor
Left-turn signal lamp
Water temperature signal of the ECU
Right-turn signal lamp
2
3
4
5
6
7
8
24
10
25
11
12
13
Terminal 15#
14
15
Diagnostic wire
T-26
26
27
Speedometer sensor
28
Night illumination
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.
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.
Capacity (L)
0
30
55
Resistance ()
283
89
36
Components
The
speedometer
does not
function or
have an
excessive
error.
The water
temperature
meter does
not function.
Malfunction
symptoms
Malfunction
reasons
(1) The Hall
Speed Sensor of
speedometer.
(2) The indicator
needle
of
speedometer
is
jammed.
(3) Output shaft
The
speedometer driving gear of
gearbox
is
does not
seriously
worn
function or
there is a large out or the gears
error between engagement
is
the indicated clearance
speed and the excessive.
The
actual speed. (4)
speedometer
is
damaged.
(5) The engine is
damaged.
(6)
The
connecting circuit
is faulty.
(1) The water
temperature meter
is damaged.
(2) The water
temperature
sensor
is
ineffective.
(3) The circuit of
water temperature
The indicator
meter is open.
needle of
(4) The voltage
water
regulator
is
temperature
damaged.
meter does
(5) The ECU is
not function
damaged.
after engine
starting.
T-30
Malfunction diagnosis
and troubleshooting
(1) If the speedometer does
not function, firstly inspect
the engagement of Hall
Speed Sensor and the drive
gear to verify that there is
any
malfunction.
If
everything is normal, then
remove and inspect the
speedometer.
(2) In the case of only
inaccurate
indication
malfunction, it is caused
usually by the damage of
the interior part of the
meter.
(3) Inspect the link
between the speed signal
and the ECU, and the
signal wire between engine
and instrument.
(1) Open the engine bonnet
and pull out the connector
of the water temperature
sensor. Inspect whether the
resistance
of
water
temperature sensor is
normal; if it is normal,
inspect the signal from
sensor to the ECU, and
signal from the ECU to
instrument.
(2) If the above circuits are
normal, connect it to the
connector of combination
instrument and turn on the
ignition switch. Inspect to
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
Remarks
The fuel
meter does
not function
The indicator
needle does
not move after
ignition
switch is
turned on.
T-31
Oil warning
lamp always
on
The warning
lamp for
engine oil
pressure is
always on
while driving.
(1) Malfunction
of low pressure
switch
(30KPa
switch).
(2) Low pressure
switch circuit is
short.
(3) Malfunction
of high pressure
switch (180kPa
switch).
(4) High-pressure
switch circuit is
open.
(5) Pressure in the
lubricating
oil
circulation
can
not reach the
specified
requirement.
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
Coolant
warning lamp
is always on.
The warning
lamp for
coolant is
always on
while driving,
whatever its
in cold
condition or
hot condition.
T-34
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.
Washer motor
Washer assemblywiper-4
T-36
The circuit schematic diagram of the front window wiper and washer of Chery sedan A15:
to horn relay
green
green
green
green
blown and blue
horn
button
and yellow
blown
wiper switch
wiper motor
blown
black and gray
The circuit schematic diagram of the front window wiper and washer.
T-37
Gear
Intermittent
wiper relay
(state of
conduction
between the
pins)
V5 washer
(state of
conduction
between the
pins)
Wiper motor
(state of
conduction
between the
pins)
53e
53
B+
53
B+
53b
53a
B+
53b
B+
Intermittent
gear
1/J
2/53m
B+
8/15
int
53a
B+
53
B+
Reset gear
5/53s
2/53m
B+
53
53e
B+
53
53e
53a
B+
Washing
gear
6/T
2/53m
8/15
B+
53a
53c
B+
53
B+
Low gear
5/53s
2/53m
B+
Wiper switch
(state of
conduction
between the
pins)
High gear
1
B+
Remarks
B+
(power
supply
positive
grid)
B+
(power
supply
positive
grid)
B+
(power
supply
positive
grid)
B+
(power
supply
positive
grid)
B+
(power
supply
positive
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.
Malfunction
reasons
(1) The power
supply circuit of
the wiper motor
is open.
(2) Poor contact
of the ignition
switch and the
wiper switch.
(3) There is an
open circuited
point in the
wiper motor.
T-39
Malfunction
diagnosis and
troubleshooting
(1) Check the circuit
of the wiper power to
see whether there is
any open circuit. If
there
is,
fix
it
immediately.
(2) Test the voltage of
each point of the
motor winding with
multimeter, and verify
that the motor circuit
is open. If it is open,
replace the motor.
Remarks
T-40
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.
The
slowly When
the
wiping
motor ignition switch
does
not is turned on, turn
function.
the wiper switch
to
(slowly
wiping) position,
the wiper motor
does not run.
The short-time
wiping of the
wiper
motor
does
not
function.
(1)There
is
malfunction in
the
wiper
switch.
(2) The wiper
switch fails to
When
the
ignition switch
is turned on, turn
the wiper switch
to (short time
wiping) position,
T-41
(1) There is
malfunction in
the
wiper
switch.
(2) There is
damage in the
speed reducer.
The
washer When
the
motor does not ignition switch
function.
is turned on, turn
the wiper switch
to the spray
position,
the
washer
motor
does
not
function.
T-42
contact
of
the
short-time wiping of
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.
(1) Check the 0
position contact of the
wiper switch. If it is
poor contact, replace
it.
(2) If the contact
works properly, check
the automatic stop
conducting
strip
installed on the back
of the worm output
shaft of the speed
reducer,
and
3
conducting
contacts
installed on the cover
of the speed reducer. If
they are defective,
replace them.
(1) Ignition switch.
(2) If the ignition
switch works properly,
then verify that the
wiper spray switch has
a poor contact or is
defective. If it has a
poor contact or is
defective, replace the
wiper switch.
(3) If the wiper spray
switch works properly,
verify that the circuit
of washer motor power
The
washer
functions,
but
the wiper does
not function.
When
the
ignition switch
is turned on, turn
the wiper switch
to the spraying
position,
the
washer
functions,
but
the wiper does
not function.
is open.
(4) If the circuit of the
motor power works
properly, replace the
washer motor.
The intermittent The washer functions,
controller of the but the wiper does not
wiper
is function, it is mainly
defective.
because a malfunction
in
the
wiper
intermittent controller
results a circuit open
to the wiper motor, so
the
wiper
cannot
function. Replace the
wiper
intermittent
controller.
T-43
The up/down operation of the window can be centrally controlled by the driver through
pushing buttons, and also can be controlled individually by the door switch to adjust the door
window opening. The mechanism transmission route is as follows: motor speed reducer
steel wire roller steel wire window supporting bracket window up/down. The
control module is installed under the left-hand rear seat, as shown in the figure (window-2).
T-44
T-45
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
PRINCIPLE OF SRS SYSTEM
When the vehicle collision happens, the collision
between the vehicles or between the vehicle and the
barrier is called the first collision. After the first
collision, the vehicle speed changes rapidly. The
driver and the passengers will move forward due to
the inertia, and will collide with the steering wheel,
windshield or instrument dashboard etc. This
collision is called the second collision. The main
reason that caused the drivers injury in the accident
is the second collision. In order to reduce or avoid
the drivers injury in the second collision, the vehicle
has installed with the passive protection devices of
seat belt and safety airbag. The airbag is an option
for the Chery sedan A15 RHD, and the airbag model
employed is Dongfangjiule.
The purpose of the airbag design is: During the short
period between the first and the second collisions
(50ms), quickly insert an airbag between the driver
and the interior structures of the car, as shown in the
Figure:
The drivers head and chest will press on the air
filled cushion. The air bag can absorb the kinetic
energy aroused by the inertia of the human body by
the damping effect of itself so as to protect the
personal safety.
The airbag system is a kind of safety device used
together with the seat belt.
The airbag can not replace the function of the seat
belt.
The driver must put on the seat belt at all time and
adjust the seat belt to a proper tension.
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
T-50
Accident sensor
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.
Turning mark
Fastening
mark
Scheme of the hairspring installation
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.
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.
SRS SYSTEM MAINTENANCE AND OPERATION
If it is required to inspect the vehicle protection supplementary system or inspect the accident
vehicle, the procedures below should be followed. If any malfunction is found, the
corresponding parts should be replaced by new ones.
1. MAINTENANCE OF SRS SYSTEM
Warning: When the ignition is turned off and at the same time the fuse is taken out, the sensor
and the diagnostic module (BCM) can provide the sufficient voltage for 1 minute to activate
the airbag. If the airbag is not disconnected, then do not start the maintenance work within 1
minute after turning off the power supply to BCM. If the airbag has been disconnected, then
the maintenance work can be carried out immediately without waiting for the 1 minute
electrical discharging time. The failure of shutting off the SRS system temporarily during the
maintenance will result in false ignition, physical injury and SRS system discarded.
(1) Turn off the airbag system
Adjust the steering wheel to the center position, turn the ignition switch to Lock position
and remove the key, remove the airbag fuse from the fuse box and wait for more than 1
minute for BCM capacitor discharging.
(2) Turn on the airbag system
Insert the airbag fuse into fuse box, turn the ignition switch to ON position, and inspect
whether the airbag indicator lamp is off after being on for 6 seconds. If the indicator lamp
does not function in this way, please refer to the Diagnosis and inspection of SRS system of
this manual.
Warning: When the ignition switch is turned on, keep away from the airbag as far as possible,
otherwise it may cause physical injury.
(3) Operation, installation and diagnosis
The airbag should be placed in an environment with the temperature not higher than
65(149). If the airbag drop from a height of more than 0.9 meter (3 feet), the airbag and
T-56
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
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
2. AIRBAG CONTROL MODULE (BCM)
Warning: Dealing with the BCM carefully during maintenance. Do not knock or shake the
BCM. Do not switch on the SRS circuit before installing the BCM on the vehicle. 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, it may cause a potential false activation and consequential injury.
Notes: If there is water entering into the vehicle due to leakage, passing through deep water,
flood or other reasons, the BCM and BCM connector may need to be replaced. Turn the
ignition switch to the OFF position; check the BCM area including the carpet etc. If there is
any obvious dipping or dipped mark, the leakage or dipped parts must be cleared, and at the
same time replace the BCM and BCM connector. The SRS system must be disconnected
before carrying out the operations above. Please refer to Disconnection of the airbag
system of this manual.
Removal procedure
Disconnect the SRS. Please refer to Disconnection of the airbag system of this manual.
Remove the decoration panel on the left and right sides of instrument panel.
Loosen the safety interlock of the BCM wiring harness connector.
Remove the BCM wiring harness connector.
Remove the BCM fastening bolts.
Remove the BCM.
Installation procedure
Install the BCM according to the arrow on the BCM, which points at the direction right ahead
of the vehicle.
Install the BCM fastening bolts.
Fasten the bolts with a torque of 8--12Nm.
Connect the BCM wiring harness connector.
T-62
T-63
T-64
Incorrect placement
T-65
Correct placement
T-66
Double
locking plate
Airbag connector
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
VDO INTERFACE FUNCTION
10. BAND
1. Preset key 1
RANDOM Start/stop of CD
2. Preset key 2
3. Preset key 3
SETUP
11. AST
DISC-
6. MUTE
Select forward
7. Volume adjustment
8. POWER:
Power switch
DISC+
9. Display
Backward selection
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
press the tuning button
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
song.
or
to select the song that you want, and start to play from the selected
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
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
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
No power supply
The player fails to function
and display.
The player functions but
without sound or with poor
sound effect.
Reasons/Troubleshooting
Connection malfunction. Please check the connection.
Check the fuse (player and vehicle) and the connector.
Adjust the volume of the player.
Check the sound balancing function.
Check the antenna and its connection.
T-75
U-1
Compressor
U-2
Condenser
Evaporator
Fan
Expansion
Valve
Drying
Bottle/Collector
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.
An individual type casing system with blower
1. Restrictor damper
9. To panel
2. Heater core
6. Recirculated air
3. Blower motor
7. Evaporator core
11. To defroster
4. Fresh air
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
U-6
Low
pressur
High
pressur
Low
pressur
High
pressur
1-Refrigerant tank
2-Unlock valve
3-Low-pressure manual valve
4-High-pressure manual valve
5-Low-pressure gauge
6-High-pressure gauge
7-Connect to low-pressure service valve hose
8-Connect to high-pressure service valve hose
9-A/C compressor
4- Needle Valve
(5) Chery
model-A15LHD
adopts
the
refrigerant R134a which cannot be
interchanged with R12. Also compressor
oils cannot be mixed. During the course of
handling, any tool that has touched certain
kind of refrigerant must not touch any other
kind of refrigerant.
U-7
3-Plate-shaped Nut
U-8
LOW-PRESSURE
SEVICE VALVE
HIGH-PRESSURE
SEVICE VALVE
REFRIGERATION DEVICE
RECYCLING
RECEIVER
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.
Low-pressure gauge
High-pressure gauge
Air return
Air exhaust
auxiliary valve
Vacuum pump
Oil cup
U-11
U-12
OIL BOTTLE
DRAINED
OIL
QUANTITY
WARNING:
(1) When the recycling receiver is required, take care to operate it according to the
2.
After the completion of recycling work, turn off the recycling receiver.
Remove the manifold pressure gauge kit from the service valve.
U-13
and
Related
U-14
Swash Plate
Number of cylinders
293
Travel (mm)
max
342
min
22
Displacement (cm/r)
max
1613
min
104
8000
allowable
(r/min)
7000
maximum
continuous
speed
Coolant
R134a
11515
22
12
48
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
U-17
the
U-18
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
compressor: 30Nm;
Inner hexagonal head bolt (M6) secured in
expansion valve: 7Nm;
To connect with condenser inlet pipe and tighten
nuts: 32 Nm;
To connect with condenser outlet pipe and tighten
nuts: 11.9 to 13 Nm;
U-19
the
the
the
the
U-20
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
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;
U-22
TECHNICAL DATA
TECHNICAL DATE TD-2
ENGINE TD-2
LUBRICATION SYSTEM TD-10
COOLING SYSTEM
TD-11
TD-1
TECHNICAL DATA
ENGINE
Model
480ED-1000010 Magneti
Marelli (new)
480ED-1000010EA UAES
(new)
Type
Four-cylinders In-Line,
four-stokes, water-cooled
Four-cylinders In-Line,
four-stokes, water-cooled
79.94
79.94
Stroke (mm)
79.52
79.52
Displacement (L)
1.596
1.596
Compression ratio
10:1
10:1
65/5500
65/5500
135/2500-4000
135/2500-4000
285
285
Fuel Supply
Ignition Order
1-3-4-2
1-3-4-2
Lubrication Type
88030
85050
0.5
0.5
Weightkg
115
115
615610680
615610680
105
105
26before TDC
26before TDC
55after BDC
55after BDC
66before TDC
66before TDC
Parameter
15after TDC
TD-2
15after TDC
Class
Standard
22.200~22.212
22.250.015
0.023~0.065
T25
22.454~22.466
22.500.015
0.023~0.065
Cam Height:
Engine model
480
38.602
37.586
480E
37.559
37.559
Standard Size
Number of cam shaft
journal
44.7444.76
44.78344.808
44.9945.01
45.03345.058
45.2445.26
45.28345.308
45.4945.51
45.53345.558
45.7445.76
45.78345.808
45.1245.14
45.16345.188
45.3745.39
45.41345.438
45.6245.64
45.66345.688
45.8745.89
45.91345.938
46.1246.14
45.16345.188
Oversized (0.38)
TD-3
Diameter of
valve stem
Standard
8.043 +00.018
Oversized
by 0.4
8.443 +00.018
Inner
Diameter of Clearance
valve guide
8.063~8.09
0.02
4
~
8.463~8.49
0.069
4
Diameter of
valve stem
Inner
Diameter of
valve guide
8.017 +00.018
8.063~8.094
8.417 +00.018
8.463~8.494
Clearance
0.046
~
0.095
Size of Intake Valve Seat Ring And Cylinder Head Seat Ring Bore
480 engine
43.877 +00..01
01
43.763 0+0.025
Oversized by 0.5
44.377 +00..01
01
44.263 0+0.025
Oversized by 1.0
44.877 +00..01
01
44.763 0+0.025
Class
Interference
(mm)
0.079~
0.124
Size of Exhaust Valve Seat Ring And Cylinder Head Seat Ring Bore
Diameter of exhaust
valve seat ring
(mm)
Diameter of cylinder
head seat ring bore
(mm)
38.877 +00..01
01
38.263 0+0.025
Oversized by 0.5
39.377 +00..01
01
38.763 0+0.025
Oversized by 1.0
39.877 +00..01
01
39.263 0+0.025
38.377 +00..01
01
38.263 0+0.025
Oversized by 0.5
38.877 +00..01
01
38.763 0+0.025
Oversized by 1.0
39.377 +00..01
01
39.263 0+0.025
Class
TD-4
Interference
(mm)
0.079~0.124
0.079~0.124
Standard
13.555 00.01
13.48113.519
Oversized
14.305 00.01
14.23114.269
Oversized
14.505 00.01
14.48114.519
Interference
(unit: mm)
0.0260.07
Ex-factory
grouping
Ex-factory repair
For
Maintenance
79.94-79.95
79.94-79.95
79.95-79.96
79.95-79.96
79.96-79.97
79.96-79.97
79.97-79.98
79.97-79.98
80.23-80.24
80.23-80.24
80.24-80.25
80.24-80.25
80.25-80.26
80.25-80.26
Standard
79.965-77.975
Standard
79.965-77.975
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
TD-5
Ex-factory
grouping
Ex-factory
repair
Spare parts
Diameter of 480E
piston skirt (unit:
mm)
Diameter of UMCs
new two-valve piston
skirt (unit: mm)
79.91-79.92
79.915-79.925
79.915-79.925
79.92-79.93
79.925-79.935
79.925-79.935
79.93-79.94
79.935-79.94
79.935-79.94
79.94-79.95
79.945-79.955
79.945-79.955
80.20-80.21
80.205-80.215
80.205-80.215
80.21-80.22
80.215-80.225
80.215-80.225
80.22-80.23
80.225-80.235
80.225-80.235
Standard
79.93-79.955
79.965-79.975
Oversized by
0.29
80.21-80.235
80.245-80.255
Oversized by
0.5
80.43-80.455
80.465-80.475
80.435-80.455
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
TD-6
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
Fit clearance
(unit: mm)
2.0
2.0
+0.06
+0.04
0.050-0.082
0.610.025
2.680.05
4.0 -0.015
-0.025
+0.03
+0.01
0.01-0.23
0
-0.012
4.0
4.0
+0.03
+0.01
0.050-0.082
0.025-0.055
1.2-0.03-0.01
1.20.030.05
1.5-0.03-0.01
1.50.020.04
0.460.02
2.750.05
2.00.02
TD-7
30.010.03
Size of gauge
No paint (Standard)
79.94
80.23
80.44
Diameter of connecting
rod journal (unit: mm)
Standard
47.89~47.91
1.480~1.487
Downsized by 0.025
47.89~47.91
1.492~1.499
Downsized by 0.25
47.64~47.66
1.605~1.612
Downsized by 0.5
47.39~47.41
1.730~1.737
Downsized by 0.75
47.14~47.16
1.855~1.862
Downsized by1.0
47.89~46.91
1.980~1.987
TD-8
Class
Standard
Oversized by 0.4
Downsized by
0.02
Downsized by
0.25
Downsized by
0.50
Downsized by
0.75
Downsized by
0.25 and
oversized by 0.4
Downsized by
0.50 and
oversized by 0.4
Downsized by
0.75 and
oversized by 0.4
57.98~58.00
57.98~58.00
57.98~58.00
62.2935+0.0065
2.141~2.148
57.73~57.75
62.2935+0.0065
2.256~2.263
57.48~57.50
62.2935+0.0065
2.381~2.388
57.23~57.25
62.2935+0.0065
2.506~2.513
57.73~57.75
62.6935+0.0065
2.456~2.463
57.48~57.50
62.6935+0.0065
2.518~2.558
57.23~57.25
62.6935+0.0065
2.706~2.713
Class
Standard
Oversized
by 0.38
Thickness of thrust
(unit: mm)
mm)
24+0.03
28.825-28.875
2.326+0.025
24+0.03
29.205-29.255
2.516+0.025
TD-9
LUBRICATION SYSTEM
Lubricant Spec. (at above -10C)
SAE10W/3050SG grade
Fuel Spec.
100Kpa
280Kpa
3.86
44020
78118
8589
99102
160
High-speed motor 2000200
Low-speed gear
Fan speed
(r/min)
High-speed motor2800200
High-speed gear
Low-speed motor2600200
TD-10
COOLING SYSTEM
Cooling System
Parameters
Overall system capacityL 8
Capacity of Coolant
Fan
Water pump
Gear ratio:
1.053: 1
Thermostat
Thermal switch
0.202m
Radiation area
8.93m
Opening temperature
Full open temperature
85-89
99-102
Switch-on temperature
Gear I 95 C
Switch-off temperature
Gear I84 C
Gear II 102 C
Gear II91 C
CTS
Resistance: 70
Temperature C: 15921.3
90
86.711
110
52.36.3
124
28.22.8
TD-11
Normal value
Minimal value
Maximal value
850
910
Water Temperature ()
>80
Accelerator is released 0
0.6
3.4ms
4.7ms
390mbar
340mbar
450mbar
14
13
15
Sinusoidal periodical
change
100mV
900mV
70
50
90
TD-12
Parameter name
Value
Unit
1415
85050
rpm
0.91.1
8595
1.52.8
In-take temperature
30-60
1.2-1.4
In-take pressure
40-50
KPa
20100
Step
34
ms
39
100-900
mv
0.35-0.50
CLUTCH
Item
Clutch
d l
Clutch
Clutch disc
Flywheel
Specification
Pedal stroke
mm
150~165
mm
0.25
Standard
mm
1.5
Service
mm
0.5
0.8
0.05
Service limit
0.15
TD-13
MANUAL TRANSAXLE
Gearbox
AQ015
Main
4.133
1st
3.455
2nd
2.056
3rd
1.370
4th
1.032
5th
0.850
Reverse
3.167
Speedometer
2.286
Gear ratio
2.0L
Type of oil
GL-4 SAE75
Operation method
Mechanical type
210mm
100mm
3.513
132.5 N.m
6300 r/min
TD-14
Specification
REFRIGERANT SYSTEM
Refrigerant
Type
R-134
Regular amount
(g)
85025
BASIC SYSTEM
Number of cylinders
Cylinder diameter
Stroke
A/C compressor
(mm)
(mm)
Displacement
(cm/r)
29.3
Max
34.2
Min
2.2
Max
161.3
Min
10.4
8000
(r/min)
7000
(cm)
11515
(V)
12
Rated power
(W)
48
(mm)
0.4~0.8
(kg)
2.2
CONTROL SYSTEM
Magnetic clutch
Clearance
Mass
TD-15
BRAKING SYSTEM
Brake master cylinder
22.2mm
Vacuum booster
228.6mm
3.9:1
16 mm
18 mm
256mm
13mm
10mm
0.03mm
19.3mm
7mm
200mm
201mm
17.46mm
200mm40mm5mm
Parking brake
TD-16
SUSPENSION
Suspension
Item
Front wheel
alignment
Specification
-3020
13030
010
1010
-13020
Item
Front Wheel
Rear Wheel
Spare Wheel
Secondary Spare
Wheel
No load/half load
200kPa
220kPa
350kPa
420kPa
Full load
210kPa
260kPa
420kPa
420kPa
Tire Model
185/60 R1482H
6J14
TD-17
SPECIAL TOOLS
SPECIAL TOOLS ST-2
ENGINE ST-2
MANUAL TRANSMISSION ST-5
ST-1
SPECIAL TOOLS
ENGINE
SN
Tool
Number
Name
WX-001
WX-002
WX-003
WX-004-1
ST-2
SN
Tool
Number
Name
WX-004-2
WX-005
WX-006
WX-007
WX-008
ST-3
SN
Tool
Number
Name
10
WX-009
11
WX-010
12
WX-011
13
WX-012
14
WX-013
ST-4
MANUAL TRANSMISSION
SN
Tool
Number
Name
GZ101
GZ210
GZ310
GZ401
Cover Installer
ST-5
SN
N
Tool
Number
Name
GZ530
GZ410
GZ434
GZ411
GZ413
ST-6
SN
Tool
Number
Name
10
GZ421
11
GZ427
12
GZ428
13
GZ430
14
GZ432
ST-7
SN
Tool
Number
Name
15
GZ511
16
GZ518
17
GZ523
18
GZ524
19
GZ526
ST-8
SN
Tool
Number
Name
20
GZ529
21
GZ541
22
GZ542
23
GZ544
24
GZ546
ST-9
SN
25
Tool
Number
Name
GZ550
ST-10