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Chery A1 2009, Service Manual, Page: 1078 / 1080

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Chery A1 2009 Service Manual Download Page 1078

K

Knock Sensor, 1.3L Engine Controls . . . . . . . . . . . . . . 3-170

L

Left-Front View, Body Exterior . . . . . . . . . . . . . . . . . 15-157

License Plate Lamp, Body Exterior . . . . . . . . . . . . . . 15-210

Liquid Line, System Plumbing . . . . . . . . . . . . . . . . . . 13-41

Lower Console, Body Interior . . . . . . . . . . . . . . . . . . 15-74

Luggage Rack, Body Exterior . . . . . . . . . . . . . . . . . . 15-217

Luggage Rack, Body Exterior . . . . . . . . . . . . . . . . . . . . .217

M

Manifold Absolute Pressure Sensor,

1.3L Engine Controls . . . . . . . . . . . . . . . . . . . . . . . 3-174

Manual Temperature Control . . . . . . . . . . . . . . . . . . . . 13-1

Manual Temperature Control Module,

Manual Temperature Control . . . . . . . . . . . . . . . . . . 13-10

Manual Transaxle, 5-Speed Manual Transaxle . . . . . . . . . 8-10

Master Cylinder, Base Brakes . . . . . . . . . . . . . . . . . . . 12-9

Mirrors, Body Exterior . . . . . . . . . . . . . . . . . . . . . . 15-221

Muffler, Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . 7-6

N

Negative Battery Cable, Starting System . . . . . . . . . . . . . 5-9

O

Oil Filter, 1.3L Engine Mechanical . . . . . . . . . . . . . . . . 2-49

Oil Pan, 1.3L Engine Mechanical . . . . . . . . . . . . . . . . . 2-50

Oil Pump, 1.3L Engine Mechanical . . . . . . . . . . . . . . . . 2-51

Oil Strainer, 1.3L Engine Mechanical . . . . . . . . . . . . . . 2-52

On-Vehicle Service, 1.3L Engine Controls . . . . . . . . . . 3-169

On-Vehicle Service, 1.3L Engine Mechanical . . . . . . . . . 2-16

On-Vehicle Service, 5-Speed Manual Transaxle . . . . . . . . 8-10

On-Vehicle Service, Air Distribution . . . . . . . . . . . . . . 13-23

On-Vehicle Service, Airbag System . . . . . . . . . . . . . . . 14-36

On-Vehicle Service, Alignment . . . . . . . . . . . . . . . . . . 10-44

On-Vehicle Service, Antilock Brakes . . . . . . . . . . . . . . 12-75

On-Vehicle Service, Automated Manual

Transaxle (AMT) Control System . . . . . . . . . . . . . . . 8-102

On-Vehicle Service, Base Brakes . . . . . . . . . . . . . . . . . 12-8

On-Vehicle Service, Body Exterior . . . . . . . . . . . . . . . 15-236

On-Vehicle Service, Body Interior . . . . . 15-148, 15-67, 15-87

On-Vehicle Service, Charging System . . . . . . . . . . . . . . 5-15

On-Vehicle Service, Cooling System . . . . . . . . . . . . . . . . 6-8

On-Vehicle Service, Evaporative Emissions . . . . . . . . . . 3-211

On-Vehicle Service, Exhaust System . . . . . . . . . . . . . . . . 7-5

On-Vehicle Service, Front Axle . . . . . . . . . . . . . . . . . . . 9-5

On-Vehicle Service, Front Suspension . . . . . . . . . . . . . . 10-6

On-Vehicle Service, Fuel Delivery System . . . . . . . . . . . 4-11

On-Vehicle Service, Ignition Control . . . . . . . . . . . . . . 3-204

On-Vehicle Service, Manual Temperature Control . . . . . 13-10

On-Vehicle Service, Parking Brake . . . . . . . . . . . . . . . 12-85

On-Vehicle Service, Power Steering Pump . . . . . . . . . . 11-40

On-Vehicle Service, Rear Axle . . . . . . . . . . . . . . . . . . . 9-12

On-Vehicle Service, Rear Suspension . . . . . . . . . . . . . 10-31

On-Vehicle Service, Seat Belt System . . . . . . . . . . . . . 14-41

On-Vehicle Service, Starting System . . . . . . . . . . . . . . . . 5-6

On-Vehicle Service, Steering Column . . . . . . . . . . . . . 11-12

On-Vehicle Service, Steering Gear . . . . . . . . . . . . . . . 11-23

On-Vehicle Service, Steering System . . . . . . . . . . . . . . 11-6

On-Vehicle Service, System Controls . . . . . . . . . . . . . 13-18

On-Vehicle Service, System Plumbing . . . . . . . . . . . . . 13-33

On-Vehicle Service, Wheels and Tires . . . . . . . . . . . . . 10-48

Output Shaft, 5-Speed Manual Transaxle . . . . . . . . . . . . 8-29

Outside Mirror, Body Exterior . . . . . . . . . . . . . . . . . . 15-224

Oxygen Sensor, 1.3L Engine Controls . . . . . . . . . . . . . 3-170

P

Paint Codes, Body Exterior . . . . . . . . . . . . . . . . . . . 15-226

Paint, Body Exterior . . . . . . . . . . . . . . . . . . . . . . . . 15-226

Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-80

Parking Brake Cable, Parking Brake . . . . . . . . . . . . . . 12-85

Parking Brake Lever, Parking Brake . . . . . . . . . . . . . . 12-85

Parking Sonar, Body Exterior . . . . . . . . . . . . . . . . . . 15-227

Passenger Grab Handle, Body Interior . . . . . . . . . . . . 15-15

Pedal Pad, Body Interior . . . . . . . . . . . . . . . . . . . . . . 15-16

Pistons, 1.3L Engine Mechanical . . . . . . . . . . . . . . . . . 2-56

Positive Battery Cable, Starting System . . . . . . . . . . . . . 5-9

Power Brake Booster, Base Brakes . . . . . . . . . . . . . . . 12-10

Power Lock Motor, Body Interior . . . . . . . . . . . . . . . . 15-28

Power Outlet, Body Interior . . . . . . . . . . . . . . . 15-96, 15-98

Power Steering Filling and Flushing,

Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6

Power Steering Fluid Reservoir,

Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . 11-42

INDEX

AI-4

Summary of Contents for A1 2009

Page 1: ...ations and contents of this manual without obligation or advance notice All rights reserved No part of this book may be reproduced or used in any form or by any means electronic or mechanical includin...

Page 2: ...ns 01 2 VEHICLE SERVICE PREPARATION 01 3 Preparation For Vehicle Service 01 3 Tools and Testing Equipment 01 3 Special Tools 01 3 Disconnection of the Negative Battery Cable 01 4 PROPER SERVICE PRACTI...

Page 3: ...ation instructions Integrated torque specifications Integrated illustrations Component specifications Diagnostic Procedures The diagnostic procedures are divided into the following two groups Diagnost...

Page 4: ...Tools and Testing Equipment Be sure that all necessary tools and measuring equipment are available before starting any work Inspect the vehicle and reference any needed ser vice information before sta...

Page 5: ...nd then wait two minutes to allow the backup supply of the air bag diagnostic monitor unit to deplete its stored power Disconnecting the battery cable deletes the memo ries of the clock audio and DTCs...

Page 6: ...foreign material from entering Component Disassembly If the disassembly procedure is complex requiring many parts to be disassembled make sure that all parts are disassembled in a way that will not a...

Page 7: ...ressed air can cause dirt and other particles to fly out causing injury to the eyes Wear protective eye wear whenever using compressed air Component Reassembly Standard values such as torques and cert...

Page 8: ...moving components of parts Apply specified oil or grease at the prescribed loca tions such as oil seals before reassembly Adjustments Use suitable gauges and testers when making adjustments Rubber Par...

Page 9: ...namometer Place a fan preferably a vehicle speed proportional type in front of the vehicle Connect an exhaust gas ventilation unit WARNING Exhaust gases can injure or kill They contain carbon monoxide...

Page 10: ...VEHICLE IDENTIFICATION NUMBER VIN 01 10 VIN Location 01 10 VIN Identification Codes 01 11 INTERNATIONAL SYMBOLS 01 13 International Symbols 01 13 FASTENER USAGE 01 14 Fastener Usage 01 14 01 01 9 Cher...

Page 11: ...The VIN is printed on a plastic tag attached to the top right corner of the upper instrument panel The VIN is also found on the vehicle certification VC label Vehicle Identification Number VIN Tag Loc...

Page 12: ...ry Automobile Co Ltd Digit 4 The fourth digit of the VIN code represents the brand of the vehicle The brand 9Chery9 is represented by the letter 9D9 Digit 5 The fifth digit of the VIN code represents...

Page 13: ...the front row Digit 9 The ninth digit of the VIN code is the check digit It is to check accuracy of VIN record and is made out through computation after confirming the other six teen digits of the VI...

Page 14: ...Display Symbols 1 High Beam 2 Fog Lamps 3 Headlamp Parking Lamps Panel Lamps 4 Turn Signals 5 Hazard Warning 6 Windshield Washer 7 Windshield Wiper 8 Windshield Wiper and Washer 9 Windshield Defroste...

Page 15: ...onal injury or death Fasteners and torque specification references in this Service Manual are identified in metric format During any maintenance or repair procedure it is important to salvage all fast...

Page 16: ...01 16 Performing Efficient Electrical Circuit Diagnosis and Troubleshooting 01 16 Electrical Circuit Simulation Tests 01 16 Precautions For Handling Control Modules and Electrical Components 01 18 Ho...

Page 17: ...service If possible re create the conditions present at the time of the incident Doing so may help avoid a No Trouble Found Diagnosis The following illustrates tests to simulate the conditions enviro...

Page 18: ...an electrical component is heat sensitive heat the component with a heat gun or equivalent CAUTION Do not heat components above 60 C 140 F If the incident occurs while heat testing the component repla...

Page 19: ...g components Do not apply excessive force when disconnecting a connector If a connector is installed by tightening bolts loosen mounting bolt then remove it by hand When connecting components Before i...

Page 20: ...een the wire and connec tor may result Probing From Terminal Side Female Terminal Do not insert any object into the female connector that is bigger than the male terminal Male Terminal Carefully probe...

Page 21: ...ELECTRICAL SCHEMATICS 01 21 Connector Symbols 01 21 Option Splices 01 22 Electrical Schematic Example 01 23 HOW TO LOCATE ELECTRICAL SCHEMATICS IN THE SERVICE MANUAL 01 25 Electrical Schematic Index 0...

Page 22: ...wn from the harness side are enclosed by a double line and followed by the direction mark Most of the connector symbols in the electrical schematics are shown from the terminal side In electrical sche...

Page 23: ...Option Splices Option splices are shown with solid squared boxes with identification numbers inside HOW TO READ ELECTRICAL SCHEMATICS BESMW010002T 01 22 Chery Automobile Co Ltd...

Page 24: ...Electrical Schematic Example HOW TO READ ELECTRICAL SCHEMATICS BESMW010001T 01 01 23 Chery Automobile Co Ltd...

Page 25: ...nding on vehicle application 11 Option abbreviation This represents that the circuit is optional depending on vehicle application 12 Ground GND This represents the ground connection See Ground Distrib...

Page 26: ...e 03 Electronic Engine Controls Engine Control Module ECM Engine Coolant Temperature Sensor Knock Sensor Upstream Oxygen Sensor Downstream Oxygen Sensor Crankshaft Position Sensor Camshaft Position Se...

Page 27: ...e None 10 Suspension None 11 Steering Power Steering Switch 12 Brakes Antilock Brake System ABS Module Wheel Speed Sensors Brake Switch Parking Brake Switch Brake Fluid Level Switch Brake Pad Wear Sen...

Page 28: ...n List TERM ABBREVIATION Antilock Brake System ABS Accelerator Sensor AES Accelerator Pedal Position Sensor APPS Automated Manual Transaxle AMT Body Control Module BCM Brake Pressure Sensor BPS Camsha...

Page 29: ...trol Module ICM Knock Sensor KS Manifold Absolute Pressure Sensor MAP Sensor Malfunction Indicator Lamp MIL Oil Pressure Switch OPS Output Shaft Speed Sensor OSS Sensor Positive Crankcase Ventilation...

Page 30: ...moval Installation 02 29 Engine Mounts 02 31 Removal Installation Left Mount 02 31 Removal Installation Right Mount 02 31 Removal Installation Front Mount 02 32 Removal Installation Rear Mount 02 32 E...

Page 31: ...mbly 02 68 Camshaft 02 69 Specifications 02 69 Disassembly 02 70 Inspection 02 70 Assembly 02 72 Valve Valve Guides 02 73 Specifications 02 73 Disassembly 02 73 Inspection 02 74 Assembly 02 75 Valve S...

Page 32: ...at is located on the crankshaft The piston assembly is an aluminum piston with a cast iron connecting rod The aluminum cylinder head contains double overhead camshafts with four valves per cylinder Th...

Page 33: ...n Journals 46 01 mm Diameter Of Crankshaft Rod Journals 44 485 44 495 mm Out Of Round Maximum Of Crankshaft Main Journals Less than 0 008 mm Axial Clearance Of Crankshaft 0 02 0 30 mm Radial Clearance...

Page 34: ...ust Valve 68 Valve Height Intake Valve 107 998 mm Exhaust Valve 106 318 mm Torque Specifications CAUTION When torquing a fastener in two steps DO NOT use a torque wrench for the second step DESCRIPTIO...

Page 35: ...el Bolt 1st Step Tighten the bolt to 15 5 N m 2nd Step Tighten the bolt an additional 30 5 Idler Pulley Bolt 40 5 Intake Camshaft Timing Belt Pulley Bolt 120 5 Intake Manifold Bolts 8 3 Intake Manifol...

Page 36: ...Mount Bolt Remover CH 20001 Camshaft Seal Installer CH 20002 Crankshaft Holder CH 20003 Valve Spring Compressor Adaptor CH 20004 Rear Crankshaft Oil Seal Installer CH 20005 GENERAL INFORMATION 02 02...

Page 37: ...kshaft Oil Seal Guide CH 20006 Front Crankshaft Seal Installer CH 20007 Front Crankshaft Seal Guide CH 20008 Flywheel Fixture CH 20009 Camshaft Holder CH 20010 GENERAL INFORMATION 02 8 Chery Automobil...

Page 38: ...al Installer CH 20011 Valve Stem Seal Installer Guide CH 20012 Valve Seal Remover CH 20013 Valve Keeper Installer CH 20017 Valve Spring Compressor CH 20018 GENERAL INFORMATION 02 02 9 Chery Automobile...

Page 39: ...n journals the oil is routed through cross drilled passages in the crankshaft to lubricate the con necting rod bearings Controlled leakage through the crankshaft main bearings and connecting rod beari...

Page 40: ...nger 10 Flange Bolt 11 Flange Bolt 12 Oil Filter Seat 13 Oil Filter Connector 14 Oil Filter 15 Dowel Pin 16 Oil Pan Bolt 17 Oil Pan Bolt 18 Oil Pan Bolt 19 Oil Pan 20 O Ring 21 O Ring 22 Oil Pump Stra...

Page 41: ...ger Inlet Oil Passage if equipped 6 To Cylinder Head 7 Oil Return Passage 8 To Front Bearing Cap 9 To Middle Bearing Cap 10 Oil Dipstick 11 To Crankcase 12 Crankcase Pipe 13 Oil Filter Bracket 14 Oil...

Page 42: ...ifold manifold gasket and vacuum hoses 4 Test and replace if necessary Refer to Appropriate Diagnostic Information Engine Loss Of Power 1 Dirty or incorrectly gapped spark plugs 2 Contamination in fue...

Page 43: ...7 Misaligned connecting rods 8 Connecting rod nuts loose 1 Check engine oil level 2 Check engine oil level Inspect oil pump relief valve and spring 3 Change oil to correct viscosity 4 Measure bearings...

Page 44: ...ence Disconnect fuel injector electrical connectors Be sure throttle blade is fully open during the compression check Insert compression pressure adaptor or the equivalent into each spark plug hole in...

Page 45: ...Inspect the drive belt only when the engine is stopped 1 Loosen the power steering pump adjustment bolt 1 1 A C Compressor Belt 2 Power Steering Pump 3 A C Compressor 4 Crankshaft Pulley 5 Generator...

Page 46: ...ve the generator belt 6 Installation is in the reverse order of removal Installation Notes Use a deflection gauge and adjust the drive belt tension to 95 N m with a limit deflection of 5 mm NOTE Measu...

Page 47: ...the air cleaner element 1 3 Install a new air cleaner element 4 Installation is in the reverse order of removal Air Cleaner Housing Removal Installation 1 Remove the two retaining bolts 1 on the air...

Page 48: ...manifold hose 5 Remove the two air cleaner housing retaining bolts 1 Tighten Air cleaner housing bolts to 10 5 N m 6 Remove the air cleaner housing 7 Installation is in the reverse order of removal Cy...

Page 49: ...nifold hose 4 Remove the intake manifold hose 5 Disconnect the manifold air pressure MAP sensor electrical connector 6 Remove the MAP sensor retaining bolt 1 and remove the MAP sensor 7 Remove the fou...

Page 50: ...or return hose clamp 1 and remove the fuel vapor return hose from the throttle body 10 Disconnect the Camshaft Position CMP sensor electrical connector 11 Remove the CMP sensor retaining bolt 1 and re...

Page 51: ...amshaft Removal Installation NOTE The following special tools are required to perform the repair procedure CH 20002 Camshaft Seal Installer CH 20010 Camshaft Holder 1 Remove the accessory drive belt S...

Page 52: ...timing belt pulley bolts 1 Tighten Camshaft timing belt pulley bolt to 120 5 N m 5 Remove the six rear timing cover bolts Tighten Rear timing cover bolts to 10 2 N m ON VEHICLE SERVICE PZSM020041 BES...

Page 53: ...m shaft seals 9 Installation is in the reverse order of removal Installation Notes Identify and separate the intake camshaft and the exhaust camshaft the intake camshaft is identified by the gear on t...

Page 54: ...shaft seal in the required location and depth Install the intake and exhaust camshaft bearing caps in the proper order Slowly tighten bolts to the specified torque Follow the torque sequence as shown...

Page 55: ...02 Engine 3 Remove the camshafts See Camshaft Removal Installation in Section 02 Engine 4 Remove intake manifold See Intake Manifold Removal Installation in Section 02 Engine 5 Remove exhaust manifol...

Page 56: ...ds are not damaged The cylinder head bolts should not be reused The new bolts should be examined before use If the bolts are stretched the bolts should be replaced Position the new cylinder head gaske...

Page 57: ...ools are required to perform the repair procedure CH 20007 Front Crankshaft Seal Installer CH 20008 Front Crankshaft Seal Guide 1 Remove the accessory drive belt See Accessory Drive Belt Removal Insta...

Page 58: ...tes Use the front crankshaft seal installer CH 20007 1 to install the new seal Lubricate the new front seal with engine oil prior to assembly Rear Crankshaft Oil Seal Removal Installation NOTE The fol...

Page 59: ...sing a suitable tool 6 Installation is in the reverse order of removal Installation Notes When installing seal lubricate seal guide with clean engine oil Position the seal over the rear crankshaft sea...

Page 60: ...oval Installation in Section 02 Engine 4 Remove the four battery tray retaining bolts 1 5 Remove the three left transaxle mount bolts 2 and the three left transaxle mount bracket bolts 1 Tighten Engin...

Page 61: ...e mount bolts 1 and the four front engine mount bracket bolts 2 Tighten Engine front mount bolt to 80 5 N m 3 Installation is in the reverse order of removal Removal Installation Rear Mount NOTE The f...

Page 62: ...6 Cooling WARNING Always allow the engine to cool before opening the cooling system Do not loosen the coolant pressure relief cap when the engine is operating or the cooling system is hot The cooling...

Page 63: ...e sensor Camshaft position sensor Ignition coil Four fuel injectors Intake manifold air pressure sensor Carbon canister solenoid valve Crankshaft position sensor Throttle body control A C compressor O...

Page 64: ...he vacuum line 1 from the brake booster 17 Remove the dipstick 18 Remove the transaxle shift cable 1 19 Remove the shift cable clamp 1 from the shift cable bracket ON VEHICLE SERVICE PZSM020004 PZSM02...

Page 65: ...eld bolts to 20 5 N m 22 Disconnect the upstream and downstream oxygen sensor connectors 23 Remove the three catalytic converter to exhaust manifold bolts 1 Tighten Catalytic converter to exhaust mani...

Page 66: ...removing the A C lines plug the A C lines to prevent any debris from entering the A C system 28 Raise and support the vehicle 29 Drain the engine oil 30 Remove the exhaust pipe assembly See Exhaust P...

Page 67: ...move the two front engine mount bolts 1 and the four front engine mount bracket bolts 2 Tighten Engine front mount bolt to 80 5 N m 35 Remove the rear engine mount bolt 1 and the three rear engine mou...

Page 68: ...mount bolt to 65 5 N m 38 Verify all components between the engine and vehicle are disconnected 39 Remove the front sub frame See Front Sub Frame Removal Installation in Section 10 Suspension 40 Hois...

Page 69: ...system Do not loosen the coolant pressure relief cap when the engine is operating or the cooling system is hot The cooling system is under pressure steam and hot liquid can come out forcefully when th...

Page 70: ...lts 1 and bracket bolts 2 Tighten Engine right mount bolts to 65 5 N m 7 Remove the accessory drive belt See Accessory Drive Belt Removal Installation in Section 02 Engine 8 Remove the six crankshaft...

Page 71: ...cover See Cylinder Head Cover Removal Installation in Section 02 Engine 12 Remove the plug in the cylinder block 13 Using special tool CH 20003 1 install the crank shaft holder 1 into the cylinder blo...

Page 72: ...belt 3 NOTE When removing the timing belt pay attention to the operating direction of the timing belt Refer to the oper ating direction of the engine crankshaft and the arrow head direction on the ti...

Page 73: ...hield 3 Remove the three bolts 1 securing the exhaust manifold to the catalytic converter assembly Tighten Exhaust manifold to the catalytic con verter bolts to 60 5 N m 4 Disconnect the catalytic con...

Page 74: ...card the exhaust manifold gasket 1 7 Installation is in the reverse order of removal Installation Notes Clean all surfaces of manifold and cylinder head ON VEHICLE SERVICE LTSM020169 02 02 45 Chery Au...

Page 75: ...spark plug wires 1 and set them aside 3 Remove the clamps 1 between the intake mani fold and the air cleaner housing 4 Remove the PCV return hose clamp 1 on the intake manifold hose 5 Remove the air...

Page 76: ...Remove the MAP sensor retaining bolt 1 and then remove the MAP sensor 8 Remove the intake manifold bracket retaining bolts 1 9 Remove the fuel vapor return hose 1 from the throttle body ON VEHICLE SE...

Page 77: ...12 Remove the A C compressor belt 13 Remove the steering pump See Steering Pump Removal Installation in Section 11 Steering 14 Remove the A C compressor See A C Compressor Removal Installation In Sect...

Page 78: ...rfaces of manifold and cylinder head Install new O rings on the fuel injectors Oil Filter Removal Installation NOTE The following special tools are required to perform the repair procedure CH 10003 Oi...

Page 79: ...r of removal Installation Notes Lubricate the oil filter gasket ring with clean engine oil Clean all surfaces and verify the oil filter does not leak Oil Pan Removal Installation 1 Remove the oil dips...

Page 80: ...the six crankshaft vibration damper retain ing bolts 1 Tighten Crankshaft vibration damper bolts to 25 5 N m and an additional 30 5 3 Remove the engine timing belt See Engine Timing Belt Removal Inst...

Page 81: ...rotate the oil pump Replace the oil pump gasket Oil Strainer Removal Installation 1 Raise and support the vehicle 2 Remove the oil pan See Oil Pan Removal Installation in Section 02 Engine 3 Remove th...

Page 82: ...3 Cylinder Bore Specifications DESCRIPTION SPECIFICATION mm Surface Distortion Limit 0 15 Inner Diameter Standard 73 005 0 005 Out Of Round Less than 0 008 Taper Less than 0 01 Disassembly 1 Remove th...

Page 83: ...assembly 1 out through the top of the cylinder block 7 Remove the connecting rod bearings See Con necting Rod Removal Installation in Section 02 Engine CAUTION When removing the connecting rod side be...

Page 84: ...e replaced and new pistons and rings fitted Measure the cylinder bore at three levels in directions X and Y Top measurement should be 10 mm down and bottom measurement should be 10 mm up from bottom o...

Page 85: ...ifications Piston Ring Groove DESCRIPTION SPECIFICATION First Ring 0 035 0 08 mm Second Ring 0 025 0 07 mm Clearance Specifications Piston Ring End Gap DESCRIPTION SPECIFICATION LIMIT First Ring End G...

Page 86: ...rom piston Clean ring grooves of any carbon deposits CAUTION Before removing the piston rings 1 check the piston ring side clearance Be careful to mark the location of the piston rings if they are to...

Page 87: ...uitable tool Connecting Rod Piston Disassembly Remove the piston from the connecting rod Inspection Check the piston diameter PISTON DIAMETER All Pistons 72 965 0 009 mm ENGINE UNIT REPAIR BESM020049...

Page 88: ...0 035 0 08 mm Second Ring 0 025 0 07 mm Check piston ring end gap clearance Wipe the cylinder bore clean Insert ring and push down with piston to ensure it is square in the bore The ring end gap meas...

Page 89: ...mall end PISTON PIN CLEARANCE Piston and Piston Pin 0 013 0 018 mm Assembly 1 Install the piston to the connecting rod Assemble the components in their original positions 2 Using a piston ring expande...

Page 90: ...arance 0 023 0 058 mm Connecting Rod Axial Clearance 0 15 0 4 mm Disassembly 1 Remove the connecting rod cap bolts 2 Remove the connecting rod bearing cap 3 Using a hammer handle or similar tool push...

Page 91: ...bly NOTE The rod bolts should not be reused 1 Before installing the NEW rod bolts the threads and under the bolt head should be oiled with clean engine oil 2 Install each bolt finger tight then altern...

Page 92: ...iameter of Crankshaft Rod Journals 44 485 44 495 Out of Round Maximum of Crankshaft Main Journals 0 008 Axial Clearance of Crankshaft 0 02 0 30 Radial Clearance of Crankshaft 0 0035 0 034 Coaxality Cr...

Page 93: ...led in the same position and direction Inspection Inspect the crankshaft rod and main journals for the fol lowing The crankshaft main journals should be checked for excessive wear roundness and scorin...

Page 94: ...cap Measure the oil clearance with the plastic gauge Standard oil clearance of crankshaft rod and main journals should be 0 02 mm Limits of oil clearance of crankshaft rod and main journals should be...

Page 95: ...aust Valve Deflection 0 04 Spring Height 49 0 Disassembly NOTE The following special tools are required to perform the repair procedure CH 20018 Valve Spring Compressor CH 20013 Valve Seal Remover CH...

Page 96: ...iner 2 and valve spring 3 5 Push the valve stem from the cylinder head and remove the valve 4 6 Using special tool CH 20013 1 remove the valve oil seal 7 Remove the valve guide if necessary 8 Remove t...

Page 97: ...ve freely in their bores and that they have been rotating Check the valve guide height Assembly 1 Install new valve guide if necessary 2 Install new valve seat if necessary 3 Using special tool CH 200...

Page 98: ...mshaft Specifications Camshaft Specifications DESCRIPTION SPECIFICATION mm Intake Cam Lobe Height 37 11 Exhaust Cam Lobe Height 37 09 Journal 1 Outer Diameter 31 934 31 95 Journal 2 3 4 5 Outer Diamet...

Page 99: ...OTE The camshaft bearing caps are marked for identification 3 Remove the camshafts and then remove the cam shaft seals Inspection Measure the camshaft cam lobe height If wear is beyond the limit repla...

Page 100: ...DIAMETER OF CAMSHAFT BEARING Cam Bearing 1 Inner Diameter 32 32 025 mm Cam Bearing 2 3 4 5 Inner Diameter 24 24 021 mm Calculation of camshaft journal clearance Journal clearance inner diameter of ca...

Page 101: ...afts in place NOTE The camshaft holder will prevent the camshafts from rotating in either direction 2 Installation is in the reverse order of removal Installation Notes Install the intake and exhaust...

Page 102: ...ust Valve 5 4 0 1 Fringe Thickness On Top Of Valve Intake Valve 0 3 0 15 Exhaust Valve 0 3 0 15 Valve Tilt Angle Intake Valve 65 Exhaust Valve 68 Valve Height Intake Valve 107 998 Exhaust Valve 106 31...

Page 103: ...pect the valves for the following Clean all valves thoroughly and discard burned warped and cracked valves Check valve seats and valve faces for damage When reconditioning valves follow the specificat...

Page 104: ...flection VALVE DEFLECTION LIMIT DIAL GAUGE READING Intake Valve 0 02 mm Exhaust Valve 0 04 mm If it exceeds the limit check valve to valve guide clearance Measure valve stem diameter and valve guide i...

Page 105: ...press the valve springs 6 Install the valve keepers 7 Strike the valve stem lightly with a plastic hammer after installation to verify proper assembly Valve Springs Specifications Valve Spring Specifi...

Page 106: ...0011 Valve Seal Installer CH 20012 Valve Stem Seal Installer Guide CH 20017 Valve Keeper Installer 1 Using the special tool CH 20018 1 compress the valve springs 2 Remove the valve keeper 1 and the va...

Page 107: ...GHT Spring Free Length 49 mm Spring Height At 620 Newtons Of Pressure 32 0 mm If it is not within specifications replace the valve spring Assembly 1 Install the valve springs 2 Install the valve sprin...

Page 108: ...Pressure Or Barometric Pressure Low Input P0108 Manifold Absolute Pressure Or Barometric Pressure High Input 03 52 P0112 Intake Air Temperature Circuit Low Input 03 57 P0113 Intake Air Temperature Cir...

Page 109: ...171 Removal Installation Upstream Oxygen Sensor 03 171 Removal Installation Downstream Oxygen Sensor 03 171 Crankshaft Position Sensor 03 172 Description 03 172 Operation 03 172 Removal Installation...

Page 110: ...ition Coil A C Compressor Cooling Fan Oxygen Sensor Heater Upstream Downstream Operation The ECM monitors components and circuits and tests them in various ways depending on the hardware function and...

Page 111: ...ure gauge indicates too high The temperature gauge indicates too low The cooling fan operates continuously on high speed The high temperature warning lamp will flash when the IP indicates low temperat...

Page 112: ...gine operation Replace 15 IAT Intake air temperature will be equal to the coolant temperature Replace 16 Cooling Fan High engine temperature Poor air conditioner performance Replace 17 Accelerator Sen...

Page 113: ...Special Tools Diagnostic Scan Tool X 431 Engine Analyzer KES 200 Digital Multimeter Fluke 15B 17B GENERAL INFORMATION 03 6 Chery Automobile Co Ltd...

Page 114: ...Compression Gauge Fuel Pressure Gauge GENERAL INFORMATION 03 03 7 Chery Automobile Co Ltd...

Page 115: ...Electronic Control Systems On Chery A1 Series 7 Fiat 3 Pin Connector To Diagnose Vehicles With Fiat 3 Pin Diagnostic Connector ITEM NAME FUNCTION 8 Smart OBDII 16 Pin Connector To Diagnose Other Syste...

Page 116: ...Electrical Schematics Electronic Engine Controls Page 1 of 11 GENERAL INFORMATION PZSMW030024T 03 03 9 Chery Automobile Co Ltd...

Page 117: ...Electronic Engine Controls Page 2 of 11 GENERAL INFORMATION PZSMW030029T 03 10 Chery Automobile Co Ltd...

Page 118: ...Electronic Engine Controls Page 3 of 11 GENERAL INFORMATION PZSMW030020T 03 03 11 Chery Automobile Co Ltd...

Page 119: ...Electronic Engine Controls Page 4 of 11 GENERAL INFORMATION PZSMW030021T 03 12 Chery Automobile Co Ltd...

Page 120: ...Electronic Engine Controls Page 5 of 11 GENERAL INFORMATION PZSMW030022T 03 03 13 Chery Automobile Co Ltd...

Page 121: ...Electronic Engine Controls Page 6 of 11 GENERAL INFORMATION PZSMW030023T 03 14 Chery Automobile Co Ltd...

Page 122: ...Electronic Engine Controls Page 7 of 11 GENERAL INFORMATION PZSMW030028T 03 03 15 Chery Automobile Co Ltd...

Page 123: ...Electronic Engine Controls Page 8 of 11 GENERAL INFORMATION PZSMW030025T 03 16 Chery Automobile Co Ltd...

Page 124: ...Electronic Engine Controls Page 9 of 11 GENERAL INFORMATION PZSMW030026T 03 03 17 Chery Automobile Co Ltd...

Page 125: ...Electronic Engine Controls Page 10 of 11 GENERAL INFORMATION PZSMW030027T 03 18 Chery Automobile Co Ltd...

Page 126: ...Electronic Engine Controls Page 11 of 11 GENERAL INFORMATION PZSMW030030T 03 03 19 Chery Automobile Co Ltd...

Page 127: ...Sensor 1 60 20 Knock Sensor 2 61 GND Power 21 Brake Switch 62 CAN H 22 A C Temperature Sensor 63 Switched Supply Voltage 23 64 Electronic Throttle Control Actuator 24 65 Electronic Throttle Control A...

Page 128: ...move the Engine Control Module ECM from the troubled vehicle and install in a new vehicle and test If the DTC cannot be deleted the ECM is malfunctioning If the DTC can be deleted return the ECM to th...

Page 129: ...ctronic Throttle Control Actuator self learning condition If the self learning procedure fails the engine cannot be started or the EPC lamp will be lit If this condition occurs the self learning proce...

Page 130: ...sor 1 No Activity Detected P0136 O2 Sensor Circuit Bank 1 Sensor 2 Malfunction P0137 O2 Sensor Circuit Bank 1 Sensor 2 Low Voltage P0138 O2 Sensor Circuit Bank 1 Sensor 2 High Voltage P0140 O2 Sensor...

Page 131: ...Vehicle Speed Sensor Range Performance P0506 Idle Control System RPM Lower than Expected P0507 Idle Control System RPM Higher than Expected P0508 Idle Air Control System Circuit Low P0509 Idle Air Con...

Page 132: ...ontrolled Computer and Auxiliary Outputs P1614 Manufacture Controlled Computer and Auxiliary Outputs P1651 Manufacture Controlled Computer and Auxiliary Outputs P2106 Throttle Actuator Control System...

Page 133: ...Power Supply and Ground Circuit Test Power Supply and Ground Circuit DIAGNOSIS TESTING PZSMW030001T 03 26 Chery Automobile Co Ltd...

Page 134: ...Voltage Voltage 11 14 V 13 Ignition Switch Ignition switch ON Voltage 11 14 V Ignition switch OFF Approximately 0 V 14 EMS Relay Main Relay Ignition switch OFF More than a few seconds after turning i...

Page 135: ...DIAGNOSIS TESTING PZSMW030002T 03 28 Chery Automobile Co Ltd...

Page 136: ...ew data stream If the data stream is not detected the condition is current Go to Diagnostic Procedure Step 1 If the data stream is detected the condition is intermittent See Diagnostic Help and Interm...

Page 137: ...en or short between ECM connector E 601 terminal 12 and battery 5 CHECK GROUND CONNECTIONS Turn ignition switch off Loosen and retighten ground screws on the body See Ground Inspection in Section 03 E...

Page 138: ...63 and ground harness side Turn the ignition switch on battery voltage should exist Turn the ignition switch off battery voltage will exist for a few seconds then drop to approxi mately 0 V Is the ch...

Page 139: ...relay terminal in the front fuse and relay box A 040 Continuity should exist Check the main relay Check terminal 15 in connectors A 101 E 701 Check harness for a short to ground or short to power Is t...

Page 140: ...Diagnostic Trouble Code DTC Tests P0016 Camshaft Position Crankshaft Position Correlation Error DIAGNOSIS TESTING PZSMW030011T 03 03 33 Chery Automobile Co Ltd...

Page 141: ...DIAGNOSIS TESTING PZSMW030004T 03 34 Chery Automobile Co Ltd...

Page 142: ...DLC use the most current software available Turn ignition switch on With the scan tool record and erase stored DTCs in the ECM Start the engine and warm it to normal operating temperature With the sc...

Page 143: ...es Go to step 5 No Go to the next step 4 DETECT MALFUNCTIONING PART Check the following for a possible malfunction Fuse EF5 Main relay Front fuse and relay box K A 040 Harness for an open or short bet...

Page 144: ...e 11 V should exist Is the check result normal Yes Go to the next step No Repair or replace circuit for an open short to power or short to ground in harness or connectors If circuit is normal go to th...

Page 145: ...CMP SENSOR RESISTANCE Check resistance between the following CMP sensor terminals component side CMP SENSOR RESISTANCE TERMINAL NO RESISTANCE V 25 C 1 2 Except 0 or 1 3 2 3 Is the check result normal...

Page 146: ...he CKP output signal normal Yes Go to step 16 No Go to the next step 11 CHECK CKP SENSOR Remove the CKP sensor 1 Inspect and clean the CKP sensor and mounting area for any condition that would result...

Page 147: ...ECK THE CAMSHAFT AND CAMSHAFT SIGNAL PLATE Remove the cylinder head cover and timing belt cover See Timing Belt Removal Installation in Section 02 Engine Check the installed clearance See CMP Sensor R...

Page 148: ...einstall the CKP sensor No Go to the next step 15 CHECK THE ENGINE BASE TIMING Check for timing belt misalignment Is the timing belt misaligned Yes Align the engine timing belt See Timing Belt Removal...

Page 149: ...P0031 O2 Sensor 1 Heater Control Circuit Low P0032 O2 Sensor 1 Heater Control Circuit High DIAGNOSIS TESTING PZSMW030012T 03 42 Chery Automobile Co Ltd...

Page 150: ...Confirmation Procedure Before performing the following procedure confirm that battery voltage is more than 12 V Turn ignition switch off Connect the X 431 scan tool to the Data Link Connector DLC use...

Page 151: ...rness or connections 2 CHECK O2 SENSOR ELECTRICAL CONNECTOR Disconnect the O2 sensor 1 electrical connector E 004 Inspect the electrical connector for damage Is the electrical connector OK Yes Go to t...

Page 152: ...OR SHORT Turn ignition switch off Disconnect the ECM connector Check continuity between ECM terminal and O2 sensor terminal O2 SENSOR HEATER CONTROL CIRCUIT COMPONENT TERMINAL ECM 48 Upstream Oxygen S...

Page 153: ...7 CHECK DTC With the X 431 scan tool read ECM DTCs Refer to 9DTC Confirmation Procedure9 Is DTC P0031 or P0032 still present Yes Replace the ECM NOTE The Immobilizer control module must be matched to...

Page 154: ...P0105 Manifold Absolute Pressure Barometric Pressure Circuit P0106 Manifold Absolute Pressure Or Barometric Pressure Range Performance DIAGNOSIS TESTING PZSMW030007T 03 03 47 Chery Automobile Co Ltd...

Page 155: ...absolute pressure or barometric pressure range performance MAP sensor Harness or connectors ECM DTC Confirmation Procedure Before performing the following procedure confirm that battery voltage is mor...

Page 156: ...r replace ground connections 2 CHECK MAP SENSOR ELECTRICAL CONNECTOR Disconnect the MAP sensor 1 electrical connector Inspect the electrical connector for damage Is the electrical connector OK Yes Go...

Page 157: ...ect the MAP sensor electrical connector E 001 Check the continuity between terminal 1 in MAP sensor connector E 033 and terminal 17 in ECM connector E 601 Continuity should exist Is the check result n...

Page 158: ...nsor for blockage or damage and clean the pressure port of the sensor Is the check result normal Yes Replace the MAP sensor with a known good MAP sensor Select view DTC on the X 431 screen If DTC P010...

Page 159: ...P0107 Manifold Absolute Pressure Or Barometric Pressure Low Input P0108 Manifold Absolute Pressure Or Barometric Pressure High Input DIAGNOSIS TESTING PZSMW030007T 03 52 Chery Automobile Co Ltd...

Page 160: ...output is above maximum acceptable range for a few seconds continuously MAP sensor Harness or connectors ECM DTC Confirmation Procedure Before performing the following procedure confirm that battery...

Page 161: ...place ground harness or connections 2 CHECK MAP SENSOR ELECTRICAL CONNECTOR Disconnect the MAP sensor 1 electrical connector Inspect the electrical connector for damage Is the electrical connector OK...

Page 162: ...601 Check the continuity between MAP sensor terminal 1 and ECM terminal 17 Continuity should exist Is the check result normal Yes Go to the next step No Repair or replace the circuit for an open high...

Page 163: ...Visually check the sensor for blockage or damage and clean the pressure port of the sensor Is the check result normal Yes Replace the MAP sensor with a known good MAP sensor Select view DTC on the X 4...

Page 164: ...P0112 Intake Air Temperature Circuit Low Input DIAGNOSIS TESTING PZSMW030007T 03 03 57 Chery Automobile Co Ltd...

Page 165: ...With the scan tool record and erase stored DTCs in the ECM Start the engine and warm it to normal operating temperature With the scan tool select view DTCs in the ECM If the DTC is detected the condi...

Page 166: ...minal 2 and ground in the MAP IAT sensor connector E 003 terminal side 5 V should exist Is the check result normal Yes Go to Step 5 No Go to the next step 4 DETECT MALFUNCTIONING PART Turn ignition sw...

Page 167: ...sor Ignition switch ON IAT 36 C 1 88 V Is the check result normal Yes Go to the next step No Replace the MAP IAT sensor 6 CHECK DTC With the X 431 scan tool read ECM DTCs Refer to 9DTC Confirmation Pr...

Page 168: ...P0113 Intake Air Temperature Circuit High Input DIAGNOSIS TESTING PZSMW030007T 03 03 61 Chery Automobile Co Ltd...

Page 169: ...h the scan tool record and erase stored DTCs in the ECM Start the engine and warm it to normal operating temperature With the scan tool select view DTCs in the ECM If the DTC is detected the condition...

Page 170: ...ensor connector E 033 terminal side 5 V should exist Is the check result normal Yes Go to the next step No Repair circuit for an open or short to power in harness or connectors If circuit is normal go...

Page 171: ...ENSOR OUTPUT SIGNAL REFERENCE DATA IAT SENSOR TERMINAL NO ITEM CONDITION DATA DC VOLTAGE 2 IAT sensor Ignition switch ON IAT 36 C 1 88 V Is the check result normal Yes Go to the next step No Replace t...

Page 172: ...P0117 Engine Coolant Temperature Circuit Low Input DIAGNOSIS TESTING PZSMW030006T 03 03 65 Chery Automobile Co Ltd...

Page 173: ...rase stored DTCs in the ECM Start the engine and warm it to normal operating temperature With the scan tool select view DTCs in the ECM If the DTC is detected the condition is current Go to Diagnostic...

Page 174: ...lace the electrical connector as necessary 3 CHECK THE ENGINE ECT SENSOR SIGNAL CIRCUIT FOR A SHORT Turn ignition switch on Check the ECT sensor reference voltage between sensor terminal 2 and ground...

Page 175: ...or connectors 5 CHECK ECT SENSOR Check resistance between the ECT sensor terminals 1 and 2 component side ECT RESISTANCE REFERENCE DATA ECT C RESISTANCE KV 10 C 8 62 10 28 20 C 2 37 2 63 80 C 0 299 0...

Page 176: ...ace the ECM NOTE The Immobilizer control module must be matched to the new ECM See ECM Removal Instal lation in Section 03 Electronic Engine Controls No The system is now operating properly Reassemble...

Page 177: ...P0118 Engine Coolant Temperature Circuit High Input DIAGNOSIS TESTING PZSMW030006T 03 70 Chery Automobile Co Ltd...

Page 178: ...urn ignition switch on With the scan tool record and erase stored DTCs in the ECM Start the engine and warm it to normal operating temperature With the scan tool select view DTCs in the ECM If the DTC...

Page 179: ...ference voltage between sensor terminal 2 and ground in sensor connector E 019 terminal side 5 V should exist Is the check result normal Yes Go to the next step No Repair or replace the harness for an...

Page 180: ...uld exist Check harness for a short to power Is the check result normal Yes Go to the next step No Repair or replace the circuit for an open or short to power in harness or connectors 5 CHECK ECT SENS...

Page 181: ...94 V Is the check result normal Yes Go to the next step No Replace ECT sensor 6 CHECK DTC With the X 431 scan tool read ECM DTCs Refer to 9DTC Confirmation Procedure9 Is DTC P0118 still present Yes R...

Page 182: ...P0122 Throttle Position Sensor A Circuit Low Input P0123 Throttle Position Sensor A Circuit High Input DIAGNOSIS TESTING PZSMW030003T 03 03 75 Chery Automobile Co Ltd...

Page 183: ...c Logic Self diagnosis detection logic DTC NO DTC DEFINITION DTC DETECTION CONDITION DTC SET CONDITION POSSIBLE CAUSE P0122 Throttle position sensor A circuit low input Ignition switch ON or after eng...

Page 184: ...Vehicle Wiring Harness Layout ECM Control Harness in Section 16 Wiring Are the ground connections OK Yes Go to the next step No Repair or replace ground harness or connections 2 CHECK TPS ELECTRICAL C...

Page 185: ...harness for an open a short to ground or a short to power between TPS connector terminal 2 and ECM connector E 601 terminal 78 Is the check result normal Yes Go to the next step No Repair or replace...

Page 186: ...ased 4 24 V Engine stopped Accelerator pedal Fully depressed 0 72 V 54 Electronic throttle control actuator Engine stopped Accelerator pedal Fully released 0 74 V Engine stopped Accelerator pedal Full...

Page 187: ...s Replace the ECM NOTE The Immobilizer control module must be matched to the new ECM See ECM Removal Instal lation in Section 03 Electronic Engine Controls No The system is now operating properly Reas...

Page 188: ...P0132 O2 Sensor Circuit 1 High Voltage DIAGNOSIS TESTING PZSMW030012T 03 03 81 Chery Automobile Co Ltd...

Page 189: ...dure confirm that battery voltage is more than 12 V Turn ignition switch off Connect the X 431 scan tool to the Data Link Connector DLC use the most current software available Turn ignition switch on...

Page 190: ...ICAL CONNECTOR Disconnect the upstream O2 sensor 1 electrical connector Inspect the electrical connector for damage Is the electrical connector OK Yes Go to the next step No Repair or replace the elec...

Page 191: ...llowing Start engine and warm it up to normal operating temperature 90 C Turn ignition switch off Start engine and maintain the engine speed between 3 500 RPM and 4 000 RPM for at least 1 minute Let e...

Page 192: ...ace the ECM NOTE The Immobilizer control module must be matched to the new ECM See ECM Removal Instal lation in Section 03 Electronic Engine Controls No The system is now operating properly Reassemble...

Page 193: ...P0171 Fuel Trim System Too Lean DIAGNOSIS TESTING PZSMW030007T 03 86 Chery Automobile Co Ltd...

Page 194: ...DIAGNOSIS TESTING PZSMW030009T 03 03 87 Chery Automobile Co Ltd...

Page 195: ...oo lean Engine is running The amount of mixture ratio compensation is too large The mixture ratio is too lean Intake air leaks MAP sensor MAF sensor Fuel injector Exhaust gas leaks Incorrect fuel pres...

Page 196: ...LEAK Allow engine to idle Listen for intake air leak after the MAP sensor Check PCV hose connector Is the check result normal Yes Go to the next step No Repair or replace as necessary 3 CHECK ECM CONT...

Page 197: ...TERMINAL 36 3 18 4 Continuity should exist Check harness for a short to ground Is the check result normal Yes Go to the next step No Repair or replace the circuit for an open or short to ground in ha...

Page 198: ...rocedure in Section 04 Fuel Delivery Install fuel pressure gauge 2 and check the fuel pressure See Fuel Pressure Test in Section 04 Fuel Delivery Observe the following fuel pressures when testing FUEL...

Page 199: ...at each test produces a momentary drop in engine speed Is the check result normal Yes Go to step 14 No Go to the next step 10 CHECK FUNCTION OF INJECTOR Listen to each injector for an operating sound...

Page 200: ...CTOR POWER SUPPLY CIRCUIT AND CONTROL CIRCUIT Turn ignition switch off Disconnect the ECM electrical connector Check continuity between the following terminals FUEL INJECTOR CIRCUIT INJECTOR NO ECM TE...

Page 201: ...ear the vehicle Remove fuel delivery rail with injectors See Fuel Injector Rail Removal Installation in Section 04 Fuel Deliv ery NOTE Be careful not to drop the fuel injectors when removing the fuel...

Page 202: ...lace the ECM NOTE The Immobilizer control module must be matched to the new ECM See ECM Removal Instal lation in Section 03 Electronic Engine Controls No The system is now operating properly Reassembl...

Page 203: ...P0172 Fuel Trim System Too Rich DIAGNOSIS TESTING PZSMW030007T 03 96 Chery Automobile Co Ltd...

Page 204: ...DIAGNOSIS TESTING PZSMW030009T 03 03 97 Chery Automobile Co Ltd...

Page 205: ...ratio compensation is too large The mixture ratio is too rich MAP sensor MAF sensor Fuel injector Exhaust gas leaks Incorrect fuel pressure Upstream O2 sensor ECM DTC Confirmation Procedure Before pe...

Page 206: ...ITEM CONDITION DATA Injector pulse Engine Temp Warm up 78 C Transaxle Position N Air Conditioner Off Engine load No load Idle Approximately 2 5 ms Is the check result normal Yes Go to step 5 No Go to...

Page 207: ...ace circuit for an open or short to power in harness or connectors 5 CHECK FUEL PRESSURE Release the fuel system pressure See Fuel Pres sure Relief Procedure in Section 04 Fuel Delivery Install fuel p...

Page 208: ...ute Pressure MAP sensor Engine Running Engine running Idle Press accelerator pedal slowly Approximately 1 3 V Engine running 2000 RPM Approximately 1 5 V Press accelerator pedal quickly Up to Approxim...

Page 209: ...cal connector OK Yes Go to the next step No Repair or replace the electrical connector as necessary 11 CHECK INJECTOR CONTROL CIRCUIT Disconnect the ECM electrical connector Check harness for short to...

Page 210: ...with injectors See Fuel Injector Rail Removal Installation in Section 04 Fuel Deliv ery NOTE Be careful not to drop the fuel injectors when removing the fuel delivery rail Keep fuel hose and all inje...

Page 211: ...place the ECM NOTE The Immobilizer control module must be matched to the new ECM See ECM Removal Instal lation in Section 03 Electronic Engine Controls No The system is now operating properly Reassemb...

Page 212: ...P0201 Cylinder 1 Injector Circuit P0202 Cylinder 2 Injector Circuit P0203 Cylinder 3 Injector Circuit P0204 Cylinder 4 Injector Circuit DIAGNOSIS TESTING PZSMW030009T 03 03 105 Chery Automobile Co Ltd...

Page 213: ...With the scan tool record and erase stored DTCs in the ECM Start the engine and warm it to normal operating temperature With the scan tool select view DTCs in the ECM If the DTC is detected the condit...

Page 214: ...result normal Yes Go to step 10 No Go to step 5 4 CHECK FUNCTION OF INJECTOR Listen to each injector for operating sound Operating sound should exist Is the check result normal Yes Go to step 10 No G...

Page 215: ...nd between injector and fuse Is the check result normal Yes With X 431 check the system If OK go to the next step No Repair or replace malfunctioning part s 8 CHECK INJECTOR CONTROL CIRCUITS FOR OPEN...

Page 216: ...1 2 4 1 2 Is the check result normal Yes Go to the next step No Replace injector 11 CHECK INJECTOR OPERATION Connect the ECM electrical connector Connect injector connector Check injector voltage und...

Page 217: ...ent Yes Replace the ECM NOTE The Immobilizer control module must be matched to the new ECM See ECM Removal Instal lation in Section 03 Electronic Engine Controls No The system is now operating properl...

Page 218: ...P0221 Throttle Position Sensor B Performance DIAGNOSIS TESTING PZSMW030003T 03 03 111 Chery Automobile Co Ltd...

Page 219: ...DIAGNOSIS TESTING PZSMW030008T 03 112 Chery Automobile Co Ltd...

Page 220: ...rd Diagnostic Logic Self diagnosis detection logic DTC NO DTC DEFINITION DTC DETECTION CONDITION DTC SET CONDITION POSSIBLE CAUSE P0221 Throttle Position Sensor TPS B performance Ignition switch on or...

Page 221: ...2 mounting positions See Vehicle Wiring Harness Layout ECM Control Harness in Section 16 Wiring Are the ground connections OK Yes Go to the next step No Repair or replace ground harness or connections...

Page 222: ...r or replace circuit for an open If the circuit is normal go to the next step 5 CHECK TPS POWER SUPPLY CIRCUIT Check harness for short to power and short to ground between the following terminals TPS...

Page 223: ...released 0 36 0 37 V Engine stopped Accelerator pedal Fully depressed 1 97 V Is the check result normal Yes Go to step 11 No Replace the Accelerator Pedal Assembly See Accelerator Pedal Position Sens...

Page 224: ...s 6 TPS1 and ground terminal 5 TPS2 and ground under the following conditions TPS TERMINAL TPS TERMINAL NO ITEM CONDITION VOLTAGE DC VOLTAGE 5 Throttle Position Sensor 2 TPS2 Ignition switch ON Engine...

Page 225: ...place the ECM NOTE The Immobilizer control module must be matched to the new ECM See ECM Removal Instal lation in Section 03 Electronic Engine Controls No The system is now operating properly Reassemb...

Page 226: ...P0321 Distributor Engine Speed In Phase Circuit Performance DIAGNOSIS TESTING PZSMW030004T 03 03 119 Chery Automobile Co Ltd...

Page 227: ...scan tool record and erase stored DTCs in the ECM Start the engine and warm it to normal operating temperature With the scan tool select view DTCs in the ECM If the DTC is detected the condition is cu...

Page 228: ...voltage between CKP sensor terminal 2 and ground in connector E 006 terminal side Approximately 3 V should exist Is the check result normal Yes Go to step 5 No Go to the next step 4 DETECT MALFUNCTION...

Page 229: ...AL Is the CKP output signal normal Yes Go to step 9 No Go to the next step 6 CHECK CKP SENSOR Check the sensor as follows Remove the sensor mounting bolt Remove the sensor Visually check the sensor fo...

Page 230: ...exist Is the check result normal Yes Go to the next step No Reinstall CKP sensor 8 CHECK GEAR TEETH Visually check for any chipped signal plate gear teeth Is the check result normal Yes Go to the nex...

Page 231: ...P0324 Knock Control System Error P0327 Knock Sensor 1 Circuit Low Input P0328 Knock Sensor 1 Circuit High Input DIAGNOSIS TESTING PZSMW030005T 03 124 Chery Automobile Co Ltd...

Page 232: ...ink Connector DLC use the most current software available Turn ignition switch on With the scan tool record and erase stored DTCs in the ECM Start the engine and warm it to normal operating temperatur...

Page 233: ...Check the resistance between knock sensor connector E 017 terminal 1 and terminal 2 The resistance should be above 1 MV Is the check result normal Yes Go to the next step No Replace the knock sensor...

Page 234: ...signal in connector 1 Set digital multimeter on voltage range Using the test methods below test the knock sensor circuit as follows KNOCK SENSOR OUTPUT SIGNAL KNOCK SENSOR TERMINAL NO TEST METHOD 1 2...

Page 235: ...Yes Replace the ECM NOTE The Immobilizer control module must be matched to the new ECM See ECM Removal Instal lation in Section 03 Electronic Engine Controls No The system is now operating properly R...

Page 236: ...Sensor Circuit P0341 Camshaft Position Sensor Performance P0342 Camshaft Position Sensor Circuit Low Input P0343 Camshaft Position Sensor Circuit High Input DIAGNOSIS TESTING PZSMW030011T 03 03 129 C...

Page 237: ...DLC use the most current software available Turn ignition switch on With the scan tool record and erase stored DTCs in the ECM Start the engine and warm it to normal operating temperature With the sc...

Page 238: ...heck the following for a possible malfunction Fuse EF5 Main relay Front fuse and relay box A 040 Harness for open or short between CMP sensor terminal 1 and fuse EF5 Harness for open or short between...

Page 239: ...hort to ground in harness or connectors If circuit is normal go to the next step 7 CHECK CMP SENSOR SIGNAL Connect CMP sensor electrical connector Check signal voltage between CMP sensor terminal 2 an...

Page 240: ...nown good CMP sensor Monitor the CMP sensor signal on the KES 200 screen If the CMP sensor signals are normal the system is OK If the CMP sensor signals are still irregular or missing go to step 9 No...

Page 241: ...he camshaft or replace camshaft 11 CHECK DTC With the X 431 scan tool read ECM DTCs Refer to 9DTC Confirmation Procedure9 Is DTC P0343 still present Yes Replace the ECM NOTE The Immobilizer control mo...

Page 242: ...P0444 Evaporative Emission System Purge Control Valve Circuit Open DIAGNOSIS TESTING PZSMW030015T 03 03 135 Chery Automobile Co Ltd...

Page 243: ...rase stored DTCs in the ECM Start the engine and warm it to normal operating temperature With the scan tool select view DTCs in the ECM If the DTC is detected the condition is current Go to Diagnostic...

Page 244: ...No Go to the next step 3 CHECK EVAP CANISTER CONTROL VALVE ELECTRICAL CONNECTOR Disconnect the EVAP canister control valve 1 electrical connector Inspect the electrical connector for damage Is the el...

Page 245: ...terminal side Approximately 3 6 V should exist Is the check result normal Yes Go to the next step No Repair or replace circuit for an open in harness or connectors If harness is normal go to the next...

Page 246: ...ace the ECM NOTE The Immobilizer control module must be matched to the new ECM See ECM Removal Instal lation in Section 03 Electronic Engine Controls No The system is now operating properly Reassemble...

Page 247: ...tion switch off Connect the X 431 scan tool to the Data Link Connector DLC use the most current software available Turn ignition switch on With the scan tool record and erase stored DTCs in the ECM St...

Page 248: ...h the X 431 scan tool read ECM DTCs Refer to 9DTC Confirmation Procedure9 Is DTC P0506 still present Yes Replace the ECM NOTE The Immobilizer control module must be matched to the new ECM See ECM Remo...

Page 249: ...P0562 System Voltage Low Voltage P0563 System Voltage High Voltage DIAGNOSIS TESTING PZSMW030001T 03 142 Chery Automobile Co Ltd...

Page 250: ...DIAGNOSIS TESTING PZSMW030002T 03 03 143 Chery Automobile Co Ltd...

Page 251: ...on is current Go to Diagnostic Procedure Step 1 If the DTC is not detected the DTC condition is intermittent See Diagnostic Help and Intermittent DTC Trou bleshooting in Section 03 Electronic Engine C...

Page 252: ...ttery positive and negative terminals Is the voltage less than 9 V Yes Check the charging system No Go to the next step 4 CHECK THE BATTERY Raise the speed over 1000 RPM for a few minutes Turn ignitio...

Page 253: ...step 7 CHECK DTC With the X 431 scan tool read ECM DTCs Refer to 9DTC Confirmation Procedure9 Is DTC P0562 or P0563 still present Yes Replace the ECM NOTE The Immobilizer control module must be matche...

Page 254: ...he DTC is not detected the DTC condition is intermittent See Diagnostic Help and Intermittent DTC Trou bleshooting in Section 03 Electronic Engine Controls for more information NOTE While performing e...

Page 255: ...and road test to verify the customers complaint is repaired 4 CHECK DTC With the X 431 scan tool read ECM DTCs Refer to 9DTC Confirmation Procedure9 Is the check result normal Yes The system is now o...

Page 256: ...w DTCs in the ECM If the DTC is detected the condition is current Go to Diagnostic Procedure Step 1 If the DTC is not detected the DTC condition is intermittent See Diagnostic Help and Intermittent DT...

Page 257: ...system is now operating properly Reassemble the vehicle and road test to verify the customers complaint is repaired No Replace the ECM NOTE The Immobilizer control module must be matched to the new E...

Page 258: ...P0645 A C Clutch Relay Circuit DIAGNOSIS TESTING PZSMW030013T 03 03 151 Chery Automobile Co Ltd...

Page 259: ...N DTC SET CONDITION POSSIBLE CAUSE P0645 A C clutch relay circuit Engine is running ECM detected that the input signal is out of the acceptable range Fuse A C compressor relay Harness or connectors EC...

Page 260: ...EN Turn ignition switch on Turn A C switch off Check A C compressor relay control circuit between ECM terminal 69 and ground in the ECM electrical connector E 601 harness side 12 V should exist Is the...

Page 261: ...lace the ECM NOTE The Immobilizer control module must be matched to the new ECM See ECM Removal Instal lation in Section 03 Electronic Engine Controls No The system is now operating properly Reassembl...

Page 262: ...P1545 Throttle Position Control Performance DIAGNOSIS TESTING PZSMW030003T 03 03 155 Chery Automobile Co Ltd...

Page 263: ...DIAGNOSIS TESTING PZSMW030008T 03 156 Chery Automobile Co Ltd...

Page 264: ...rd Diagnostic Logic Self diagnosis detection logic DTC NO DTC DEFINITION DTC DETECTION CONDITION DTC SET CONDITION POSSIBLE CAUSE P1545 Throttle position control performance Ignition switch ON or afte...

Page 265: ...Wiring Harness Layout ECM Control Harness in Section 16 Wiring Are the ground connections OK Yes Go to the next step No Repair or replace ground harness or connections 2 CHECK THROTTLE POSITION SENSO...

Page 266: ...etween the following terminals TPS POWER SUPPLY CIRCUIT ECM TERMINAL TPS APPS TERMINAL 32 or 73 TPS terminal 3 32 or 73 APP sensor terminal 3 33 APP sensor terminal 6 Is the check result normal Yes Go...

Page 267: ...le valve position learning 7 CHECK THE TPS SIGNAL CIRCUIT FOR AN OPEN OR SHORT Turn ignition switch off Disconnect the ECM electrical connector Check continuity between the electronic throttle control...

Page 268: ...d Accelerator pedal Fully released 0 74 V Engine Stopped Accelerator pedal Fully depressed 4 62 V Is the check result normal Yes Go to the next step No Replace the electronic throttle control actuator...

Page 269: ...P2138 Pedal Position Sensor Performance DIAGNOSIS TESTING PZSMW030008T 03 162 Chery Automobile Co Ltd...

Page 270: ...DIAGNOSIS TESTING PZSMW030003T 03 03 163 Chery Automobile Co Ltd...

Page 271: ...ed Rationally incorrect voltage is sent to ECM compared with the signals from APPS1 and APPS2 Accelerator pedal position sensor 1 and 2 Harness or connectors Electronic throttle control actuator TPS1...

Page 272: ...LERATOR PEDAL POSITION SENSOR 1 APPS1 POWER SUPPLY CIRCUIT Disconnect the APPS1 electrical connector C 301 1 Inspect the electrical connector for damage Is the electrical connector OK Yes Go to the ne...

Page 273: ...r C 301 terminal side Approximately 5 V should exist Is the check result normal Yes Go to step 7 No Go to the next step 6 DETECT MALFUNCTIONING PART Check the following for a possible malfunction Harn...

Page 274: ...control actuator TPS1 Engine Stopped Accelerator pedal Fully released 0 74 V Engine Stopped Accelerator pedal Fully depressed 4 62 V Is the check result normal Yes Go to the next step No Repair or re...

Page 275: ...dal Fully released 0 72 0 74 V Engine Stopped Accelerator pedal Fully depressed 3 95 V 40 Accelerator pedal position sensor 2 APPS2 Engine Stopped Accelerator pedal Fully released 0 36 0 37 V Engine S...

Page 276: ...oolant pressure relief cap when the engine is operating or the cooling system is hot The cooling system is under pressure steam and hot liquid can come out forcefully when the cap is loosened slightly...

Page 277: ...three way catalyst The oxygen sensors continually monitor the oxygen level in the exhaust gas The sensor is made of ceramic zirconia The zirconia generates voltage from approximately 1 volt in richer...

Page 278: ...ream Oxygen Sensor 1 Disconnect the negative battery cable 2 Disconnect the oxygen sensor electrical connector CAUTION Remove the oxygen sensor after the exhaust pipe has cooled 3 Remove the upstream...

Page 279: ...ry cable 2 Disconnect the CKP sensor electrical connector 3 Remove the CKP sensor retaining bolt 1 and remove the CKP sensor Tighten CKP sensor retaining bolt to 10 N m 4 Installation is in the revers...

Page 280: ...e vehicle speed sensor generates a signal that the Engine Control Module ECM utilizes to perform engine and transaxle functions Removal Installation 1 Disconnect the negative battery cable 2 Disconnec...

Page 281: ...te Pressure Sensor Description The Manifold Absolute Pressure MAP sensor is mounted to the front of the engine Operation The MAP sensor monitors the pressure in the intake manifold The pressure in the...

Page 282: ...e throttle valve and actuates the throttle valve motor based on inputs from the APP sensor Removal Installation 1 Disconnect the negative battery cable 2 Remove the instrument panel lower trim panel 3...

Page 283: ...al connector 4 Remove four electronic throttle control actuator mounting bolts Tighten Electronic throttle control actuator bolts to 10 N m 5 Remove the throttle control actuator carefully 6 Installat...

Page 284: ...n Notes NOTE The Immobilizer control module must be matched to the new ECM before the engine will start Matching Immobilizer Control Module to new Engine Control Module ECM Perform the following to ma...

Page 285: ...Test List 03 179 Engine Cranks Normal But Will Not Start 03 180 Engine Will Not Crank 03 182 Hard Start Long Crank Erratic Start Erratic Crank 03 184 Fast Idle 03 187 Lack Loss Of Power 03 188 Back Fi...

Page 286: ...ve conditions first before continuing with symptom diagnostics Diagnostic Help Confirm there are no current engine DTCs Confirm that the failure exists and the customer complaint can be verified Inspe...

Page 287: ...to the next step No Repair as necessary Verify the symptom no longer exists 2 CHECK DTC Turn the ignition switch on With the X 431 scan tool select view DTC Are there any DTCs present Yes Check for c...

Page 288: ...on test on the engine Is engine compression correct Yes Verify test results If OK see Symptom Diagnostic Tests list to repair any additional symptoms No Check for cause ELECTRONIC ENGINE CONTROLS ENGI...

Page 289: ...s a clicking sound heard from the starter relay when the ignition key is turned to START Yes Go to the next step No Go to step 5 3 CHECK STARTING SYSTEM Check the starter starter ground starter relay...

Page 290: ...rting system primary circuits as follows Starter relay Ignition switch Are components systems OK Yes Ensure customer s concern has been resolved No Repair as necessary ELECTRONIC ENGINE CONTROLS ENGIN...

Page 291: ...tool select view DTC and data stream in ECM Are there any DTCs present Yes Check for cause of DTC See Diagnostic Trouble Code DTC List in Section 03 Electronic Engine Controls No Go to the next step 3...

Page 292: ...ound repair or replace fuel filter pressure regulator or fuel pump assembly 5 CHECK EXHAUST SYSTEM Check the exhaust system for restrictions Is there a restriction in the exhaust system Yes Repair as...

Page 293: ...P system See Evaporative Emissions in Section 03 Electronic Engine Controls and refer to EVAP control circuit relative to the DTC No Go to the next step 9 CHECK INTAKE AIR SYSTEM Check for MAP MAF sen...

Page 294: ...inary checks Vacuum leaks Throttle plate and linkage Intake air tube leaks Correct sealing of intake manifold and components attached to intake air tube Are all checks OK Yes Go to the next step No Re...

Page 295: ...symptom no longer exists 2 CHECK ECM DTC Turn ignition switch on With the X 431 scan tool read the DTC Are there any DTCs present Yes Check for causes See Diagnostic Trouble Code DTC index Engine Con...

Page 296: ...on Spark plug wires Spark plugs 5 CHECK INTAKE AIR SYSTEM Check for MAP MAF sensor Is there any contamination Yes Clean or replace the sensor No Go to the next step 6 CHECK EXHAUST SYSTEM Check the ex...

Page 297: ...e loads or over RPM limiting functions enabled Clutch Charging system Ignition base timing if not previously checked If the base timing is not correct align the engine timing belt See Engine Timing Be...

Page 298: ...SECONDARY IGNITION SYSTEM Perform the following to test the secondary ignition system Disconnect the injector fuse Remove any of the 4 spark plugs Connect the spark plug to spark plug wire Ground the...

Page 299: ...pressure See Fuel Pressure Test in Section 04 Fuel Delivery Is fuel pressure correct Yes Go to the next step No If the fuel pressure is greater than 400 kPa 4 bar Replace the fuel pressure regulator...

Page 300: ...t the following preliminary checks Fuel quality Vacuum lines check for damage and correct routing Intake air system check for damaged tubes and dirty air filter Vehicle wiring disconnected corroded da...

Page 301: ...No Go to the next step 4 CHECK ECM DTC Turn the ignition switch on With the X 431 scan tool read the DTC Are there any DTCs present Yes Repair as necessary No Go to the next step 5 CHECK THE ELECTRONI...

Page 302: ...ssure Relief Procedure in Section 04 Fuel Delivery Check fuel system pressure See Fuel Pressure Test in Section 04 Fuel Delivery Is fuel pressure correct Yes Go to the next step No If the fuel pressur...

Page 303: ...ENGINE CYLINDER COMPRESSION Check engine cylinder compression Compression should not be less than 1 000 kPa and not vary more than 25 percent from cylinder to cylinder Is engine compression correct Y...

Page 304: ...diagnosis Inspect the following components Clean the carbon deposit on intake and exhaust valves Valve stem Spark plugs and combustion chamber Does the engine idle rough Yes Repair as necessary No Go...

Page 305: ...eck fuel system pressure See Fuel Pressure Test in Section 04 Fuel Delivery Is fuel pressure correct Yes Go to the next step No If the fuel pressure is greater than 400 kPa 4 bar Replace the fuel pres...

Page 306: ...E Remove Positive Crankcase Ventilation PCV valve and shake it Does PCV valve rattle Yes Install PCV valve go to the next step No Replace the PCV valve 4 CHECK PCV SYSTEM Start engine and bring to nor...

Page 307: ...03 201 Special Tools 03 202 Electrical Schematics 03 203 ON VEHICLE SERVICE 03 204 Ignition Coil 03 204 Description 03 204 Operation 03 204 Removal Installation 03 204 Spark Plug Wire 03 205 Removal I...

Page 308: ...ylinders When the ignition coil discharges two spark plugs fire at the same time The Engine Control Module ECM uses inputs from the Crankshaft Position CKP Sensor to determine the Top Dead Center TDC...

Page 309: ...Special Tools Diagnostic Scan Tool X 431 Engine Analyzer KES 200 GENERAL INFORMATION 03 202 Chery Automobile Co Ltd...

Page 310: ...Electrical Schematics Ignition Control System Page 1 of 1 GENERAL INFORMATION PZSMW030016T 03 03 203 Chery Automobile Co Ltd...

Page 311: ...is connected to battery power current will flow causing a strong magnetic field to form When the primary wire is disconnected the magnetic field will collapse into the secondary winding causing a ver...

Page 312: ...e spark plug wire 1 from the spark plug then pull the spark plug wire straight up away from the engine 4 Remove the spark plug wires 1 Cylinder Number 1 2 3 4 Length mm 690 525 450 380 Resistance kV m...

Page 313: ...raight up away from the engine 3 Remove the spark plug Tighten Spark plug to 30 N m 4 Inspect the spark plug condition 5 Installation is in the reverse order of removal Installation Notes Verify the p...

Page 314: ...Tools 03 209 Electrical Schematics 03 210 ON VEHICLE SERVICE 03 211 Vapor Canister Control Valve 03 211 Description 03 211 Operation 03 211 Removal Installation 03 211 Vapor Canister 03 212 Descripti...

Page 315: ...ion The ECM will only energize the vapor canister control valve solenoid when the engine is at operating temperature but will de energize it during periods of deceleration When de energized no vapors...

Page 316: ...Special Tools Diagnostic Scan Tool X 431 Engine Analyzer KES 200 GENERAL INFORMATION 03 03 209 Chery Automobile Co Ltd...

Page 317: ...Electrical Schematics Canister Control Valve Page 1 of 1 GENERAL INFORMATION PZSMW030015T 03 210 Chery Automobile Co Ltd...

Page 318: ...ol valve When the Main Relay is energized the vapor canister control valve switches from closed to open The ECM controls the frequency at which the vapor canister control valve operates in order to ac...

Page 319: ...ontrol valve The ECM purges the canister at predetermined intervals and engine conditions Diagnosis Testing 1 Disconnect the air intake hose and plug the air intake hole 2 Apply air pressure into the...

Page 320: ...g Fuel System Pressure 04 11 Fuel Pump 04 11 Description 04 11 Operation 04 11 Removal Installation 04 11 Fuel Pump Inspection 04 13 Fuel Filter 04 14 Description 04 14 Operation 04 14 Removal Install...

Page 321: ...obilizer control module sig nals the ECM to activate the fuel system If the ECM does not receive the proper signal from the Immobilizer control module the ECM will not allow the fuel system to operate...

Page 322: ...ow to each cylinder The fuel injectors are opened and closed constantly during engine operation The amount of fuel is controlled by the length of time the fuel injector is held open The fuel injectors...

Page 323: ...Special Tools Digital Multimeter Fluke 15B 17B Fuel Pressure Gauge Fuel Pump Remover CH 20032 Service Jack GENERAL INFORMATION 04 4 Chery Automobile Co Ltd...

Page 324: ...Electrical Schematics Fuel Delivery System Page 1 of 4 GENERAL INFORMATION PZSMW040001T 04 04 5 Chery Automobile Co Ltd...

Page 325: ...Fuel Delivery System Page 2 of 4 GENERAL INFORMATION PZSMW040002T 04 6 Chery Automobile Co Ltd...

Page 326: ...Fuel Delivery System Page 3 of 4 GENERAL INFORMATION PZSMW040003T 04 04 7 Chery Automobile Co Ltd...

Page 327: ...Fuel Delivery System Page 4 of 4 GENERAL INFORMATION PZSMW040004T 04 8 Chery Automobile Co Ltd...

Page 328: ...e fuel rail inlet 1 2 Start and warm the engine and note pressure gauge reading Fuel pressure should be 350 kPa 3 5 bar at idle 3 If engine runs but pressure is below 350 kPa 3 5 bar check the followi...

Page 329: ...ystem Replace fuel tank Cannot Refill Fuel Tank Excessive Pressure in Fuel Tank When Cap is Removed Sticking or damaged fuel tank fill vent valve hose or lines Inspect repair vent hose and lines repla...

Page 330: ...n switch is turned ON When the relay is activated it provides voltage to the fuel pump When the ECM receives an engine speed signal from the Crankshaft Position CKP sensor and a signal from the Immobi...

Page 331: ...he fuel pump on its side and drain the fuel from the fuel pump and remove the fuel pump from the vehicle 9 Cover the opening in the fuel tank while the fuel pump is removed CAUTION To avoid foreign ma...

Page 332: ...pump resistance Connect a digital multimeter to terminals 2 and 3 If the result is not as specified replace the fuel pump 2 Check the fuel pump operation Use the following table to test fuel pump oper...

Page 333: ...entilated areas and avoid ignition sources Never smoke while servicing the vehicle This may result in personal injury or death 1 Release the fuel system pressure See Fuel Pressure Relief Procedure in...

Page 334: ...tilated areas and avoid ignition sources Never smoke while servicing the vehicle This may result in personal injury or death 1 Release the fuel system pressure See Fuel Pressure Relief Procedure in Se...

Page 335: ...control injector pulse width operation to obtain optimum performance NOTE Clean injectors regularly with an approved method Removal Installation WARNING Release fuel system pressure before servicing...

Page 336: ...w O ring seals on the fuel injector sealing surfaces To ease the installation of the fuel injectors use a small amount of engine oil between the injectors and the fuel rail Use care to match the corre...

Page 337: ...m the tank to the entire fuel system Removal Installation WARNING Release the fuel system pressure before servicing any fuel system components Service vehicles in well venti lated areas and avoid igni...

Page 338: ...k hoses 1 7 Disconnect the vapor canister line 1 8 Disconnect the fuel line 2 9 Raise and support the vehicle 10 Using a service jack support the fuel tank ON VEHICLE SERVICE PZSM040009 PZSM040005 04...

Page 339: ...ve the four retaining bolts 1 from the fuel tank straps 12 Remove the fuel tank from the vehicle 13 Installation is in the reverse order of removal ON VEHICLE SERVICE PZSM040006 04 20 Chery Automobile...

Page 340: ...STING 05 5 Starter Motor Bench Test 05 5 Starter Solenoid Test 05 5 ON VEHICLE SERVICE 05 6 Battery 05 6 Description 05 6 Operation 05 6 Removal Installation 05 6 Battery Tray 05 7 Removal Installatio...

Page 341: ...ct operation of starting charging systems all components used in these 3 systems must per form within specifications When attempting to diagnose any of these systems it is important that you keep thei...

Page 342: ...Special Tools Digital Multimeter Fluke 15B 17B GENERAL INFORMATION 05 05 3 Chery Automobile Co Ltd...

Page 343: ...Electrical Schematics Starting System Page 1 of 1 GENERAL INFORMATION PZSMW050001T 05 4 Chery Automobile Co Ltd...

Page 344: ...mbly 5 Adjust the carbon pile load of the tester to obtain the free running test voltage 6 Note the reading on the ammeter and compare this reading to the free running test maximum amperage draw 7 If...

Page 345: ...ore electrical energy in a chemical form When an electrical load is applied to the ter minals of the battery an electrochemical reaction occurs This reaction causes the battery to discharge electrical...

Page 346: ...battery 4 Installation is in the reverse order of removal Battery Tray Removal Installation 1 Loosen the negative and positive battery cable retaining nuts 1 and disconnect the cables ON VEHICLE SERVI...

Page 347: ...emove the four bolts 1 from the battery tray 4 Lift the battery tray out of the engine compartment and remove from the vehicle 5 Installation is in the reverse order of removal ON VEHICLE SERVICE PZSM...

Page 348: ...der of removal Starter Motor Assembly Description The starter motor is mounted with two bolts to the transaxle housing and is located on the side of the engine The starter motor incorporates several f...

Page 349: ...2 Engine 4 Remove the starter battery B terminal nut 2 Tighten Starter B terminal nut to 10 N m 5 Remove the starter solenoid connector 3 6 Remove the two starter mounting bolts 1 connect ing the star...

Page 350: ...Operation 05 12 Specifications 05 12 Special Tools 05 12 Electrical Schematics 05 13 DIAGNOSIS TESTING 05 14 Generator Noise 05 14 ON VEHICLE SERVICE 05 15 Generator 05 15 Removal Installation 05 15...

Page 351: ...field induces a current into the windings of the stator coil The Y type stator winding connections deliver the induced AC current to 3 positive and 3 negative diodes for recti fication From the diodes...

Page 352: ...Electrical Schematics Charging System Page 1 of 1 GENERAL INFORMATION PZSMW050002T 05 05 13 Chery Automobile Co Ltd...

Page 353: ...ator may be caused by the following Worn loose or defective bearings Loose or defective drive pulley Incorrect worn damaged or misadjusted drive belt Loose mounting bolts Misaligned drive pulley Defec...

Page 354: ...Generator mounting bolts to 30 N m 7 Remove the generator from the engine 8 Installation is in the reverse order of removal Installation Note After the generator is installed adjust the drive belt te...

Page 355: ...HICLE SERVICE 06 8 Cooling System Draining and Filling 06 8 Cooling System Draining Procedure 06 8 Cooling System Filling Procedure 06 9 Thermostat 06 9 Description 06 9 Operation 06 9 Removal Install...

Page 356: ...ps Coolant temperature sensor Heater core Operation The primary purpose of a cooling system is to maintain engine temperature in a range that will provide satisfactory engine performance and emission...

Page 357: ...Electrical Schematics Cooling System Page 1 of 3 GENERAL INFORMATION PZSMW060001T 06 06 3 Chery Automobile Co Ltd...

Page 358: ...Cooling System Page 2 of 3 GENERAL INFORMATION PZSMW060002T 06 4 Chery Automobile Co Ltd...

Page 359: ...Cooling System Page 3 of 3 GENERAL INFORMATION PZSMW060003T 06 06 5 Chery Automobile Co Ltd...

Page 360: ...epair as necessary 5 If no leaks are found and the pressure drops the pressure relief cap may be leaking Install a new pressure relief cap and retest the system 6 If no leaks are found after a new pre...

Page 361: ...lant flow restriction Add coolant as needed Repair engine coolant leak Bleed air from cooling system Ensure pressure relief cap is installed correctly Remove restriction from the A C condenser radiato...

Page 362: ...one turn counterclockwise Step back while the pressure is released from the cooling system When you are certain all the pressure has been released using a cloth turn and remove the pressure relief cap...

Page 363: ...coolant flow to the radiator The thermostat opens when the engine coolant temperature is approximately 90 C At this temperature engine coolant is allowed to flow to the radiator The thermostat provide...

Page 364: ...ll opening temperature of the thermostat is 104 C 3 Verify the thermostat closes 5 C lower than the opening temperature 4 If the thermostat fails any of the inspection steps replace the thermostat Coo...

Page 365: ...greater strength as well as sufficient heat transfer capabilities to keep the engine coolant within operating temperatures Operation The radiator functions as a heat exchanger using air flow across t...

Page 366: ...en fans The radiator fan assembly includes two electric motors two five blade fans and a support shroud that is attached to the radiator The radiator fans are serviced as an assembly Operation The rad...

Page 367: ...cedure in Section 06 Cooling System 3 Disconnect the upper radiator hose 2 from the radiator 4 Loosen the clip 4 from the coolant return hose 5 Disconnect the cooling fan electrical connector 3 and th...

Page 368: ...tage is applied 3 If the test results are not as specified replace the fan motor MEASURING CONDITION OPERATION INSPECTION DIAGRAM Battery positive to terminal 1 Battery negative to terminal 3 Turns sm...

Page 369: ...Specifications 07 3 DIAGNOSIS AND TESTING 07 4 Exhaust System Diagnostic Chart 07 4 ON VEHICLE SERVICE 07 5 Exhaust Pipe Assembly 07 5 Removal Installation 07 5 Muffler 07 6 Removal Installation 07 6...

Page 370: ...tem leaks should be repaired immediately Never operate the engine in enclosed areas Failure to follow these instructions may result in personal injury Operation In order to reduce vehicle emissions r...

Page 371: ...Specifications Torque Specifications DESCRIPTION TORQUE N m Catalytic Converter Mounting Nuts 60 5 Exhaust Flange Bolts 60 5 GENERAL INFORMATION 07 07 3 Chery Automobile Co Ltd...

Page 372: ...mps to specified torque at leaking joints Replace muffler assembly Replace exhaust pipe Tighten connection attaching nuts Replace exhaust manifold Tighten exhaust manifold to cylinder head stud nuts o...

Page 373: ...talytic converter The temperature of the converter rises to a high level after a short period of engine oper ation 1 Remove the heat shield retaining bolt 1 2 Remove the exhaust manifold See Exhaust M...

Page 374: ...ter The temperature of the converter rises to a high level after a short period of engine oper ating time 1 Raise and support the vehicle 2 Remove the two pipes connecting bolts 1 Tighten Exhaust bolt...

Page 375: ...yst s ability to store oxygen is somewhat related to proper operation oxygen storage can be used as an indicator of cat alyst performance CAUTION Unleaded gasoline must be used in order to avoid damag...

Page 376: ...port isolators 2 Tighten Catalytic converter mounting bolts to 60 5 N m 9 Remove the catalytic converter 10 Clean exhaust pipe ends and ensure all exhaust components fit properly 11 Discard broken or...

Page 377: ...e 08 10 Removal Installation 08 10 Gear Selector Shifter Assembly 08 15 Removal Installation 08 15 TRANSAXLE UNIT REPAIR 08 19 Transaxle 08 19 Specifications 08 19 Disassembly 08 19 Assembly 08 23 Inp...

Page 378: ...s synchronized in all gear ranges includ ing reverse The transaxle consists of three major sub assemblies Input shaft Output shaft Differential assembly The transaxle shift system consists of the foll...

Page 379: ...QR513 Internal View 1 Transaxle Housing 2 Clutch Housing 3 Input Shaft 4 Output Shaft 5 Differential GENERAL INFORMATION PZSM080007 08 08 3 Chery Automobile Co Ltd...

Page 380: ...aft The synchronizer sleeve engages the third gear clutch teeth engaging the gear to the input shaft and allowing power to transmit through the output shaft to the differential 4th Gear Engine power i...

Page 381: ...Gear Synchronizer 7 3rd Driving Gear 8 2nd Driving Gear 9 Reverse Driving Gear 10 1st Driving Gear 11 Idler Gear Shaft 12 Clutch 13 Crankshaft 14 Idler Gear 15 Differential Driving Gear 16 1st Driven...

Page 382: ...t 25 2 Reverse Lamp Switch Assembly 20 2 Clutch Release Fork Bolt 20 2 Gear Shift Mechanism Assembly Bolt 32 2 5 Reverse Lock Mechanism Bolt 18 2 Engine To Transaxle Bolts 70 5 Gear Ratio Specificatio...

Page 383: ...Special Tools Clutch Pressure Plate Installer CH 20014 Flywheel Fixture CH 20009 Differential Seal Installer CH 30002 GENERAL INFORMATION 08 08 7 Chery Automobile Co Ltd...

Page 384: ...Bearing Remover MB 998801 Bearing Remover MB 998917 GENERAL INFORMATION 08 8 Chery Automobile Co Ltd...

Page 385: ...le lubricant is usually the result of leaks or inaccurate fluid level check or refill method Vehi cle must be level to accurately check fluid level Leakage is evident by the presence of oil around the...

Page 386: ...move the air intake pipe retaining bolts 1 Tighten Air intake pipe bolts to 8 3 N m 3 Remove the clamps 1 on each side of the intake manifold hose 4 Remove the clamp 1 on the intake manifold hose 5 Re...

Page 387: ...ttery and battery tray See Battery Removal Installation in Section 05 Starting Charging 9 Remove the two shift cables 1 from the transaxle 10 Remove the shift cable clamp 1 from the shift cable bracke...

Page 388: ...n 05 Starting Charging 15 Remove both front axle shafts See Front Axle Shaft Removal Installation in Section 09 Axle 16 Support the engine using an engine support fixture or suitable jack 17 Raise the...

Page 389: ...it aside 21 Remove the left transaxle mount bolts 1 and bracket bolts 2 22 Remove the transaxle front mount bolts 1 and bracket bolts 2 Tighten Transaxle front mount bolts to 80 5 N m ON VEHICLE SERV...

Page 390: ...t the transaxle with a suitable jack while removing the transaxle 27 Installation is in the reverse order of removal Installation Notes When installing the transaxle be careful to avoid interference b...

Page 391: ...Remove the retaining bolts 1 from the air intake pipe Tighten Air intake pipe bolts to 8 3 N m 4 Remove the clamps 1 on each side of the intake manifold hose 1 Gearshift Arm Bracket Bolts 2 Reverse Ge...

Page 392: ...hten Air intake pipe bolts to 10 5 N m 8 Remove the air cleaner housing 9 Remove the battery and battery tray retaining bolts 1 See Battery Removal Installation in Section 05 Starting Charging 10 Remo...

Page 393: ...andle to clear lower console upon removal 15 Remove the lower console See Lower Console Removal Installation in Section 15 Body 16 Remove the crossover cable and the selector cable 1 from the gearshif...

Page 394: ...etaining bolts 2 19 Remove the gear selector shift cable assembly 20 Installation is in the reverse order of removal NOTE Selector cables can be adjusted with the adjustment bolt 1 ON VEHICLE SERVICE...

Page 395: ...everse Idler Shaft to Case Bolt 38 2 5 Reverse Fork Mechanism Bolt 25 2 Reverse Lamp Switch Assembly 20 2 Gear Shift Mechanism Assembly Bolts 25 2 5 Reverse Lock Mechanism Bolt 18 2 Disassembly 1 Remo...

Page 396: ...d remove the release fork 3 5 Remove the release bearing 1 6 Engage the transaxle to neutral position 7 Remove the backup lamp switch 1 Tighten Backup lamp switch to 20 2 N m 8 Remove the idle gear sh...

Page 397: ...ate the gearshift mechanism assembly 1 from transaxle housing 12 Remove the three locating seat retaining bolts 1 of the 3rd 4th fork shaft reverse fork shaft and the 1st 2nd fork shaft Tighten Fork s...

Page 398: ...m 14 Remove the four interior connecting bolts 1 for clutch housing and transaxle housing Tighten Clutch housing and transaxle housing bolt to 25 2 N m 15 Using a copper bar tap the transaxle housing...

Page 399: ...e gear from idle gear shaft and take off the idle gear gasket 19 Remove the input shaft output shaft and fork mechanism together 20 Separate the 3rd 4th gear shift fork and shift fork rail 5th reverse...

Page 400: ...ifications Clearance Specifications SYNCHRONIZER RING VALUE OF A mm WEARING LIMIT mm 1st 2nd Gear 1 10 1 17 0 05 3rd 4th Gear 1 35 1 90 0 05 5th Gear 1 10 1 17 0 05 TRANSAXLE UNIT REPAIR 08 24 Chery A...

Page 401: ...Disassembly TRANSAXLE UNIT REPAIR PZSM080020 08 08 25 Chery Automobile Co Ltd...

Page 402: ...8 Remove the 4th driving gear 9 Remove the 3rd and 4th needle roller bearing 10 Remove 3rd 4th gear synchronizer 11 Using snap ring pliers remove the front snap ring 1 Front Input Shaft Bearing 2 Rear...

Page 403: ...the following Any damage abnormal wear or lockup of the needle roller bearings Any damage or wear of the spline Correct gears for the transaxle assembly Smooth rotation of gears Any part looseness or...

Page 404: ...damage or wear on the inner diameter surface of the synchronizer s conical portion and whether the screw thread is damaged due to crushing 7 Press the synchronizer rings onto their respective gears c...

Page 405: ...Output Shaft Disassembly TRANSAXLE UNIT REPAIR PZSM080021 08 08 29 Chery Automobile Co Ltd...

Page 406: ...n gear 6 Remove the 2nd driven gear 1 Front Bearing Of Output Shaft 2 Output Shaft 3 1st 2nd Needle Roller Bearing 4 1st Driven Gear 5 1st 2nd Gear Synchronizer Ring 6 1st 2nd Gear Synchronizer Assemb...

Page 407: ...nspection 1 Clean all components 2 Inspect the following components for wear Output shaft Needle roller bearing 1st driven gear 2nd driven gear 1st 2nd synchronizer gear sleeve Synchronizer ring Damag...

Page 408: ...everse idle gear from idle gear shaft and take off the idle gear gasket Assembly 1 Assemble in the reverse order of disassembly Reverse Shift Fork Disassembly 1 Remove the reverse shift arm bracket re...

Page 409: ...the shift fork assembly 2 Use a suitable tool to remove the shift fork spring pin from the shift fork and the shift fork shaft 3 Remove the shift fork shaft 1 from the shift fork 2 TRANSAXLE UNIT REP...

Page 410: ...ft fork assembly 1 3rd 4th Shift Fork Shaft 2 Spring Pin 3 Spring Pin 4 3rd 4th Shift Fork 5 Split Baffle Ring 6 Reverse Shaft 7 Interlock Pin 8 5th Reverse Shift Fork Shaft 9 5th Reverse Shift Fork 1...

Page 411: ...fle ring 5 4 Separate the 3rd 4th shift fork shaft 1 and 3rd 4th shift fork 4 5 Separate the reverse shaft 6 6 Remove the interlock pin 7 and spring pin 10 7 Separate the 5th reverse shift fork shaft...

Page 412: ...Description 08 37 Operation 08 38 Specifications 08 38 Special Tools 08 38 DIFFERENTIAL UNIT REPAIR 08 39 Differential Carrier 08 39 Removal Installation 08 39 Disassembly 08 39 Inspection 08 40 Assem...

Page 413: ...ential pinion shaft lock pin that extends through the end of the differential pinion shaft and the differential case The differential assembly consists of the following components Differential case pa...

Page 414: ...rough the pinion mate and side gears The side gears are connected to the axle shafts Specifications Clearance Specifications DESCRIPTION CLEARANCE mm Clearance between side gear and planetary gear 0 0...

Page 415: ...the differential assembly Disassembly 1 Mount the differential in a vice 2 Remove the eight drive gear bolts 1 1 Front Rear Differential Bearing 2 Final Drive Driven Gear 3 Differential Housing 4 Bolt...

Page 416: ...washers Side gears Spherical washers Planetary gears Planetary gear shaft Assembly Installation of the adjusting washers side gears spherical washers planetary gears and the planetary gear shaft Inst...

Page 417: ...SIDE GEAR CLEARANCE Standard 0 025 0 150 mm Adjusting Washer 0 93 1 00 mm If any measured clearance is not within specifications select and install the appropriate adjusting washer s and then measure...

Page 418: ...8 43 Specifications 08 43 Special Tools 08 44 CLUTCH ASSEMBLY SERVICE 08 45 Clutch and Pressure Plate 08 45 Removal Installation 08 45 Clutch Release Mechanism 08 47 Removal Installation 08 47 Clutch...

Page 419: ...the clutch Depressing the clutch pedal causes the release to advance and push on the tips of the tapering fingers of the diaphragm spring When this happens the diaphragm spring pulls the pressure plat...

Page 420: ...Special Tools Flywheel Fixture CH 2009 Clutch Pressure Plate Installer CH 20014 GENERAL INFORMATION 08 44 Chery Automobile Co Ltd...

Page 421: ...pecial tool CH 20043 1 hold the flywheel 3 Remove the clutch pressure plate bolts 1 Tighten Clutch pressure plate bolts to 30 5 N m 4 Remove the modular clutch assembly 5 Remove the flywheel to cranks...

Page 422: ...surface as shown in the figure If the depth of any hole comes to the limit replace friction lining assembly Standard 1 2 mm Limit 0 5 mm Check clutch pressure plate diaphragm spring for irregular wear...

Page 423: ...elease the return torsion spring 5 Tighten Release arm bolt to 20 2 N m 3 Remove the release shaft assembly 4 and remove the release fork 3 4 Remove the release bearing 1 5 Installation is in the reve...

Page 424: ...1 Tighten Clutch cable retaining bolt to 10 2 N m 3 Remove the clutch cable 1 to the release shaft arm assembly 4 Remove the clutch cable 5 Installation is in the reverse order of removal CLUTCH ASSEM...

Page 425: ...Self Learning Test 08 62 Step 3 Road Test 08 62 Diagnostic Trouble Code DTC List 08 63 Automated Manual Transaxle DTC List 08 63 Diagnostic Trouble Code DTC Tests 08 65 P0560 Battery Voltage Too Low 0...

Page 426: ...l hydraulic system is controlled by the AMT control module and Engine Control Module ECM The gear position is determined by the gearshift lever Automatic Mode The AMT control module performs gear chan...

Page 427: ...ssure Refilling AMT Hydraulic Fluid Perform the following procedure when refilling the AMT hydraulic reservoir with the approved fluid WARNING Do not refill the AMT hydraulic fluid until the internal...

Page 428: ...Special Tools Diagnostic Scan Tool X 431 Engine Analyzer KES 200 Digital Multimeter Fluke 15B 17B CAN BUS Diagnostic Connector GENERAL INFORMATION 08 52 Chery Automobile Co Ltd...

Page 429: ...Electrical Schematic AMT Control System Page 1 of 6 GENERAL INFORMATION PZSMW080001T 08 08 53 Chery Automobile Co Ltd...

Page 430: ...AMT Control System Page 2 of 6 GENERAL INFORMATION PZSMW080002T 08 54 Chery Automobile Co Ltd...

Page 431: ...AMT Control System Page 3 of 6 GENERAL INFORMATION PZSMW080003T 08 08 55 Chery Automobile Co Ltd...

Page 432: ...AMT Control System Page 4 of 6 GENERAL INFORMATION PZSMW080004T 08 56 Chery Automobile Co Ltd...

Page 433: ...AMT Control System Page 5 of 6 GENERAL INFORMATION PZSMW080005T 08 08 57 Chery Automobile Co Ltd...

Page 434: ...AMT Control System Page 6 of 6 GENERAL INFORMATION PZSMW080006T 08 58 Chery Automobile Co Ltd...

Page 435: ...nsor Ground 20 60 21 61 22 62 23 63 24 64 25 65 External Sensor Ground 26 Gear Selection Lever Bit 0 66 External Sensor Ground 27 Battery 67 Gear Selection Lever Bit 1 28 Ignition Switch 68 Gear Selec...

Page 436: ...a for any condition that would result in an incorrect signal such as dam age or foreign material A data recorder and or oscilloscope should be used to help diagnose intermittent conditions Remove the...

Page 437: ...rs the following inputs Vehicle speed sensor AMT input sensor The AMT control module controls the following outputs Three proportion solenoids Two conversion switches Two pressure pumps Engine starter...

Page 438: ...e 5 Repeat the procedure at least 3 times until the MIL lamp engine fault lamp in instrument cluster stops flashing and is turned off 6 Turn the ignition switch OFF for 1 minute to store the self lear...

Page 439: ...0805 Clutch Position Sensor Circle The Primary P0806 Clutch Position Sensor P0807 Clutch Position Sensor Wrong Value P0810 Clutch Position Sensor Conditioner Custom Faster P0817 KI 15 P081A Cranking E...

Page 440: ...P2906 Generated Engine Torque From CAN P2907 Engine Maximum Torque From CAN P2908 Clutch Error P2909 Gearbox Error P290A Gear Position Sensor Error P290D Shift Electro Valves For Low Rank P290E Shift...

Page 441: ...Diagnostic Trouble Code DTC Tests P0560 Battery Voltage Too Low DIAGNOSIS TESTING PZSMW080007T 08 08 65 Chery Automobile Co Ltd...

Page 442: ...DIAGNOSIS TESTING PZSMW080008T 08 66 Chery Automobile Co Ltd...

Page 443: ...software available Turn the ignition switch on With the scan tool record and erase stored DTCs in the Automated Manual Transaxle AMT control module Turn ignition switch off and then turn the ignition...

Page 444: ...Layout Engine Control Harness in Section 16 Wiring Is the ground connection OK Yes Go to the next step No Repair or replace ground connection 2 CHECK AMT CONTROL MODULE ELECTRICAL CONNECTOR Disconnec...

Page 445: ...tor E 603 and terminal 1 2 in the AMT control module electrical connector E 602 terminal side AMT CONTROL MODULE CONNECTOR TERMINAL VOLTAGE 76 and 1 2 Less than 9 V Is the voltage less than 9 V Yes Go...

Page 446: ...continuity between the AMT control module connector terminal 25 and the battery positive terminal Continuity should exist Is the check result normal Yes Go to the next step No Check fuse Check the ele...

Page 447: ...Turn ignition switch off Connect the X 431 scan tool to the Data Link Connector DLC use the most current software available Turn ignition switch on With the scan tool record and erase stored DTCs in t...

Page 448: ...or an open high resistance or short circuits Is the check result normal Yes Go to the next step No Repair the circuit for an open or shorts as necessary 3 CHECK DTC With the X 431 scan tool read AMT c...

Page 449: ...P0715 Clutch Speed DIAGNOSIS TESTING PZSMW080009T 08 08 73 Chery Automobile Co Ltd...

Page 450: ...f Connect the X 431 scan tool to the Data Link Connector DLC use the most current software available Turn ignition switch on with the scan tool view and erase stored DTCs in the Automated Manual Trans...

Page 451: ...conditions that caused this DTC to set are not present at this time See Diagnostic Help in Section 08 Transaxle No Go to the next step 2 CHECK CLUTCH SPEED SENSOR ELECTRICAL CONNECTOR Stop the vehicl...

Page 452: ...off Disconnect the AMT control module electrical connector Check the continuity between the clutch speed sensor terminal 1 and the AMT control module electrical connec tor terminal 38 CLUTCH SPEED SEN...

Page 453: ...result normal Yes Go to step 9 No Go to the next step 6 CHECK CLUTCH SPEED SENSOR Loosen the sensor mounting bolt Remove the sensor Visually inspect the sensor for any missing chipped or damaged comp...

Page 454: ...ition such as shifting from 1st gear to reverse gear and shifting from reverse gear to neutral gear This condition would lead to a difference in speed between the engine speed and clutch speed Is the...

Page 455: ...P0904 Gear Position Sensor DIAGNOSIS TESTING PZSMW080012T 08 08 79 Chery Automobile Co Ltd...

Page 456: ...C use the most current software available Turn ignition switch on with the scan tool view and erase stored DTCs in the Automated Manual Transaxle AMT control module Start the engine and warm it to nor...

Page 457: ...tor the value of 9GEAR POSITION9 GEAR CONDITION DISPLAY VALUE 1st Vehicle is driving OK 2nd 3rd 4th 5th Is the check result normal Yes The conditions that caused this DTC to set are not present at thi...

Page 458: ...h position sensor 7 Gear solenoid valve 8 Shift solenoid valve Is the electrical connector OK Yes Go to the next step No Repair or replace the electrical connector as necessary 3 CHECK GEAR POSITION S...

Page 459: ...sition sensor connector P 008 and terminal 39 of the AMT control module connector E 602 terminal side Continuity should exist Check the signal circuit for a short to ground and short to power supply I...

Page 460: ...9 Is the check result normal Yes The system is now operating properly Reassemble the vehicle and road test to verify the customers complaint is repaired No Replace the AMT control module See AMT Contr...

Page 461: ...P0914 Shift Position Sensor DIAGNOSIS TESTING PZSMW080012T 08 08 85 Chery Automobile Co Ltd...

Page 462: ...LC use the most current software available Turn ignition switch on with the scan tool view and erase stored DTCs in the Automated Manual Transaxle AMT control module Start the engine and warm it to no...

Page 463: ...tor the value of 9SHIFT POSITION9 GEAR CONDITION DISPLAY VALUE 1st Vehicle is driving OK 2nd 3rd 4th 5th Is the check result normal Yes The conditions that caused this DTC to set are not present at th...

Page 464: ...h position sensor 7 Gear solenoid valve 8 Shift solenoid valve Is the electrical connector OK Yes Go to the next step No Repair or replace the electrical connector as necessary 3 CHECK SHIFT POSITION...

Page 465: ...sition sensor connector P 007 and terminal 51 of the AMT control module connector E 602 terminal side Continuity should exist Check the signal circuit for a short to ground and short to power supply I...

Page 466: ...9 Is the check result normal Yes The system is now operating properly Reassemble the vehicle and road test to verify the customers complaint is repaired No Replace the AMT control module See AMT Contr...

Page 467: ...P0932 Hydraulic Pressure Sensor DIAGNOSIS TESTING PZSMW080011T 08 08 91 Chery Automobile Co Ltd...

Page 468: ...ore performing the following procedure confirm that battery voltage is more than 12 V Connect the X 431 scan tool to the Data Link Connector DLC use the most current software available Turn ignition s...

Page 469: ...is DTC to set are not present at this time See Diagnostic Help in Section 08 Transaxle No Go to the next step 2 CHECK HYDRAULIC PRESSURE SENSOR ELECTRICAL CONNECTOR Stop the vehicle and turn ignition...

Page 470: ...uity between the following terminals SYSTEM PRESSURE SENSOR TERMINAL AMT CONTROL MODULE CONNECTOR TERMINAL CONTINUITY 1 66 Yes Check the harness for a short to power and a short to ground Is the check...

Page 471: ...eplace the hydraulic pressure sensor 7 CHECK DTC With the X 431 scan tool read AMT control module DTCs Refer to 9DTC Confirmation Procedure9 Is DTC P0932 still present Yes Replace the AMT control modu...

Page 472: ...P2904 Clutch Error DIAGNOSIS TESTING PZSMW080010T 08 96 Chery Automobile Co Ltd...

Page 473: ...ool to the Data Link Connector DLC use the most current software available After connection press POWER key to start X 431 Turn ignition switch on with the scan tool view and erase stored DTCs in the...

Page 474: ...M CONDITION CURRENT VALUE Clutch Vehicle is driving OK Is the check result normal Yes The conditions that caused this DTC to set are not present at this time See Diagnostic Help in Section 08 Transaxl...

Page 475: ...connector OK Yes Go to the next step No Repair or replace the electrical connector as necessary 4 CHECK CLUTCH SOLENOID VALVE RESISTANCE Check the clutch solenoid resistance as shown in the following...

Page 476: ...een AMT connector and clutch solenoid valve connector Is the check result normal Yes Go to the next step No Repair or replace the circuit for an open short to power or short to ground 7 CHECK CLUTCH S...

Page 477: ...Is the check result normal Yes The system is now operating properly Reassemble the vehicle and road test to verify the customers complaint is repaired No Replace the AMT control module See AMT control...

Page 478: ...l 1 Disconnect the negative battery cable 2 Disconnect the following electrical connectors Clutch Solenoid Valve Shift Gear Solenoid Valve Selector Gear Solenoid Valve Gear Position Sensor Shift Posit...

Page 479: ...s 1 Tighten Control shaft cover retaining bolts to 44 2 N m 6 Remove the two clutch control actuator retaining bolts 1 Tighten Clutch control actuator retaining bolts to 24 2 N m ON VEHICLE SERVICE PZ...

Page 480: ...draulic actuator assembly Installation Notes During assembly ensure that the clutch cable is installed in a loose state with the distance between clutch cable control actuator to clutch control arm at...

Page 481: ...aining bolts to 10 2 N m 5 Remove the gearshift mechanism from the bracket Automated Manual Transaxle AMT Control Module Removal Installation 1 Disconnect the negative battery cable 2 Remove the lower...

Page 482: ...IAGNOSIS TESTING 09 4 Vehicle Inspection 09 4 Noise Or Vibration On Turns 09 4 Clunking Noise During Acceleration 09 4 Shudder Or Vibration During Acceleration 09 4 Vibration At High Speeds 09 4 ON VE...

Page 483: ...CV joint has a splined end and is attached to the transaxle and is retained with a snap ring The outer joint has a splined connection to the wheel hub and is retained with a lock nut For further infor...

Page 484: ...nds of the axle shafts Specifications Torque Specifications DESCRIPTION TORQUE N m Axle Shaft Hub Nut 135 Brake Caliper Adapter To Steering Knuckle Bolts 110 Brake Caliper To Adapter Bolts 40 Dust Shi...

Page 485: ...the CV seal boot is damaged this will result in the loss and or contamination of the joint grease resulting in inad equate lubrication of the joint Clunking Noise During Acceleration This noise may be...

Page 486: ...nuts to 110 N m 3 Remove the front axle hub nut from the front knuckle Tighten Front axle hub nut to 135 N m 4 Remove the front brake rotor See Brake Rotor Removal Installation in Section 12 Brakes 5...

Page 487: ...et the wheel speed sensor aside Tighten Wheel speed sensor bolt to 15 2 N m 4 Remove the axle shaft hub nut from the front knuckle Tighten Axle shaft hub nut to 135 N m 5 Remove the front brake calipe...

Page 488: ...to an excessive angle Also be careful not to excessively extend the slide joint 12 Remove the outer axle shaft from the steering knuckle 13 Remove the inner axle shaft from the transaxle 14 Remove the...

Page 489: ...cription 09 9 Operation 09 10 Specifications 09 10 DIAGNOSIS TESTING 09 11 Vehicle Inspection 09 11 Vibration At High Speeds 09 11 ON VEHICLE SERVICE 09 12 Rear Hub and Bearing 09 12 Removal Installat...

Page 490: ...tions independent of each other This independent action offers improved isolation from the effects of jounce and rebound The rear axle consists of the following components Wheel hub Wheel studs Wheel...

Page 491: ...peration in Section 10 Sus pension Operation The rear axle utilizes a sealed wheel bearing housed in the rear knuckle assembly Specifications Torque Specifications DESCRIPTION TORQUE N m Rear Axle Hub...

Page 492: ...y damage or excessive runout Check the rear bearing for runout Check for any noise from the rear bearing while driving the vehicle Vibration At High Speeds This problem could be a result of Foreign ma...

Page 493: ...re and wheel assembly Tighten Wheel mounting nuts to 110 N m 3 Remove the rear axle hub nut cover 4 Remove the rear axle hub nut 1 Tighten Rear axle hub nut to 135 N m 5 Remove the rear brake drum 2 6...

Page 494: ...ol Arm 10 9 Description 10 9 Operation 10 9 Removal Installation 10 9 Front Stabilizer Bar 10 11 Removal Installation 10 11 Front Stabilizer Bar Link 10 12 Removal Installation 10 12 Front Strut Rod 1...

Page 495: ...y a coil spring The strut assembly supports the weight of the vehicle and is also the pivot point for the steering knuckle This system uses a lower control arm and ball joint for the lower pivot point...

Page 496: ...corporates a strut assembly that takes the place of the upper arm and ball joint The strut performs the function of a shock absorber and is encom passed by a coil spring Specifications Torque Specific...

Page 497: ...Special Tools Ball Joint Separator CH 10002 GENERAL INFORMATION 10 4 Chery Automobile Co Ltd...

Page 498: ...orrect tire pressure Incorrect front or rear wheel toe in Worn wheel bearings Worn control arm bushings Excessive friction in strut upper bearing Inflate tires to recommended pressure Correct front or...

Page 499: ...ot a repairable com ponent of the front suspension It must be replaced if damaged in anyway If it is determined that the steering knuckle is bent when servicing the vehicle no attempt should be made t...

Page 500: ...Remove the wheel speed sensor retaining bolt 1 and set the wheel speed sensor aside Tighten Wheel speed sensor bolt to 15 2 N m 7 Remove the nut 1 attaching the outer tie rod end to the steering knuc...

Page 501: ...Using special tool CH 10002 separate the ball joint from the steering knuckle 11 While holding the bolt heads stationary remove the two nuts 1 from the bolts attaching the strut assembly to the steeri...

Page 502: ...etween the steering knuckle and the vehicle sub frame The lower control arm uses a lower ball joint on the outer end and two sub frame mounts on the inner end Operation The front lower control arm sup...

Page 503: ...pinch bolt to 110 10 N m 4 Remove the lower control arm to the stabilizer bar link nut 1 Tighten Lower control arm to the stabilizer bar link nut to 110 10 N m 5 Remove the two lower control arm to th...

Page 504: ...joint if defective replace the ball joint 9 Install the lower control arm is in the reverse order of removal Installation Notes After installation each bolt must be tightened to the required tightenin...

Page 505: ...l mounting nuts and the wheel assembly Tighten Wheel mounting nuts to 110 N m 3 Remove the stabilizer bar link nuts 1 attaching the stabilizer bar to stabilizer bar link Tighten Stabilizer bar link nu...

Page 506: ...3 Remove the two strut rod bolts 1 attaching the strut rod to lower control arm Tighten Strut rod bolts to 75 5 N m 4 Remove the strut rod nut 1 attaching the strut rod to sub frame Tighten Strut rod...

Page 507: ...int The bottom of the strut mounts directly to the steering knuckle using two attaching bolts and nuts going through the strut clevis bracket and steering knuckle The top of the strut mounts directly...

Page 508: ...the vehicle should be equal If the strut shock absorber functions properly the vehicle will recoil several times and then stop recoiling after the pushing force is removed Removal Installation CAUTION...

Page 509: ...cle 8 Installation is in the reverse order of removal Front Coil Spring Description A coil over front strut assembly supports each front coil spring The top of the strut assembly mounts to the strut t...

Page 510: ...e coil spring is held under pressure The coil spring must be compressed removing spring tension from the upper mount and bearing before the strut rod nut is removed 2 Position the strut assembly in th...

Page 511: ...the engine and transaxle assembly 1 Raise and support the vehicle 2 Remove the wheel mounting nuts and the wheel assembly Tighten Wheel mounting nuts to 110 N m 3 Support the engine using an engine su...

Page 512: ...taining bolt 1 and set it aside Tighten Vehicle speed sensor bolts to 10 1 N m 9 On each side of the steering gear remove the nut 1 attaching the outer tie rod end to the steering knuckle Tighten Oute...

Page 513: ...ckle pinch bolt to 110 10 N m 12 Raise and support the vehicle 13 Remove the A C pipe bracket retaining bolts 1 on the sub frame See Suction Line Removal Instal lation in 13 Heating And Air Conditioni...

Page 514: ...1 from the steering gear Tighten High pressure line to steering gear 25 5 N m Tighten Low pressure line to steering gear 25 5 N m 16 Remove the steering gear retaining bolts 1 to the sub frame Tighten...

Page 515: ...location of the sub frame must be marked on the body of the vehicle Do this so the sub frame can be relocated upon reinstallation against the body of vehicle in the same location as before removal If...

Page 516: ...erly compressed The coil spring is held under pressure The coil spring must be compressed removing spring tension from the upper mount and bearing before the strut rod nut is removed 3 If the spring c...

Page 517: ...evidence of fluid running from the upper end of the fluid reservoir actual leakage will be a stream of fluid running down the side of the reservoir tube and dripping off lower end of unit Inspect the...

Page 518: ...ry parts prior to reassembly 1 Cushion Pad 2 Dust Boot 3 Cushion Block 4 Upper Spring Seat 5 Upper Spring Mount 2 Mount the new strut assembly into the fixture 3 Insert the coil spring into the spring...

Page 519: ...m spring holder 1 the end of the spring should be indexed in the spring pocket 8 Install the upper spring holder with the index posi tion of 180 angle between the punched hole and the spring strut mou...

Page 520: ...0 ON VEHICLE SERVICE 10 31 Trailing Arm 10 31 Removal Installation 10 31 Rear Shock Absorber 10 33 Description 10 33 Operation 10 33 Removal Installation 10 33 Rear Coil Spring 10 33 Description 10 33...

Page 521: ...ted using equipment designed to lift a vehicle by the rear axle If this type of hoisting equipment is used damage to rear suspension components will occur 1 Rear Spring Cushion 2 Rear Bumper Block 3 R...

Page 522: ...The rear suspension utilizes an rigid axle suspension It incorporates a cross stay to enhance vehicle stability Specifications Torque Specifications DESCRIPTION TORQUE N m Strut Assembly Lower Mountin...

Page 523: ...xle for loose bearings Check the rear axle hub for any damage or excessive runout Vibration At High Speed This problem could be a result of Foreign material mud etc packed on the backside of the wheel...

Page 524: ...the wheel mounting nuts and the wheel assembly Tighten Wheel mounting nuts to 110 N m 3 Remove the rear coil spring See Rear Coil Spring Removal Installation in Section 10 Suspension 4 Remove the two...

Page 525: ...olt 1 from the rear trailing arm Tighten Rear trailing arm bracket retaining bolts to 110 10 N m 7 Remove the rear trailing arm assembly 8 Separated the rear trailing arm to the trailing arm bracket b...

Page 526: ...he vehicle body nut to 110 10 N m 4 Remove the bolt 2 connecting the rear shock absorber to rear axle Tighten Rear shock absorber to the rear axle bolt to 110 10 N m 5 Lower the jack and remove the re...

Page 527: ...110 10 N m 4 Release the jack slowly 5 Remove the coil spring 1 6 Installation is in the reverse order of removal Rear Cross Stay Removal Installation 1 Raise and support the vehicle 2 Remove the whee...

Page 528: ...el mounting nuts and the wheel assembly Tighten Wheel mounting nuts to 110 N m 3 Use a jack to support the rear axle 4 Remove the parking brake cable See Parking Brake Cable Removal Installation in Se...

Page 529: ...Rear Shock Absorber Removal Installation in Section 10 Suspension 8 Remove the rear coil spring 1 See Rear Coil Spring Removal Installation in Section 10 Suspen sion ON VEHICLE SERVICE PZSM100034 PZS...

Page 530: ...e brake shoes See Parking Brake Cable Removal Installation in Sec tion 12 Brakes 11 Remove the rear trailing arm See Trailing Arm Removal Installation in Section 10 Suspension 12 Lower the jack and re...

Page 531: ...s 10 40 DIAGNOSIS TESTING 10 42 Vehicle Inspection 10 42 Tire Wear 10 42 Tire Wear Chart 10 42 Alignment Troubleshooting Chart 10 43 ON VEHICLE SERVICE 10 44 Front Wheel Alignment 10 44 Front Axle Toe...

Page 532: ...be the same size as standard equipment Vehicle height is checked with the fuel tank full of fuel and no passenger or luggage compartment load Vehicle height is not adjustable If the measurement is not...

Page 533: ...on an alignment rack 2 Install all required alignment equipment on the vehicle per the alignment equipment manufacturer s instructions On this vehicle a four wheel alignment is recommended 3 Read the...

Page 534: ...ACCEPTABLE RANGE Camber 52 1 40 to 2 Caster 3 24 3 54 to 2 54 Toe Individual 6 0 to 12 Rear Axle Alignment Specifications REAR WHEEL ALIGNMENT PREFERRED SETTING ACCEPTABLE RANGE Camber 0 30 to 30 Toe...

Page 535: ...ts 7 Scalloped Wear 2 Effect 1 Excessive Tire Wear 2 Excessive Tire Wear 3 Tire Damage 4 Vehicle Pulls 2 Excessive Tire Wear 6 Poor Traction 7 Excessive Tire Wear 3 Cause 8 Under Inflation Or Lack Of...

Page 536: ...re of steering system Fasten wheel nut Adjust the tire pressure Check the wheel alignment and then adjust Repair or install new suspension component as necessary Steering Wheel Deflecting To Single Si...

Page 537: ...ed reinstall the clamp where the boot meets the inner tie rod 4 Remove the alignment equipment 5 Lower vehicle and jounce the front and rear of the vehicle Front Camber Adjustment NOTE The front axle...

Page 538: ...ut Of Round Inspection 10 47 ON VEHICLE SERVICE 10 48 Tire Replacement Repair 10 48 Description 10 48 Replacement Procedure 10 48 Repair Procedure 10 48 Wheel Assembly 10 49 Description 10 49 Removal...

Page 539: ...driving habits which will shorten the life of any tire are Rapid acceleration Severe application of brakes High speed driving Taking turns at excessive speeds Striking curbs and other obstacles Opera...

Page 540: ...use wear on the shoulders of tire Over inflation will cause wear at the center of tire Excessive camber causes the tire to run at an angle to the road One side of tread is then worn more than the othe...

Page 541: ...s of vehicle control The use of oversize tires may cause interference with vehicle components Under extremes of suspension and steering travel interference with vehicle components may cause tire damag...

Page 542: ...e is equipped with wheel center caps that cover the wheel nuts remove the cap with an appropriate removal tool utilizing the notch located between the wheel and the outer edge of the cap NOTE Use care...

Page 543: ...its maximum weight not exceeding 40g CAUTION Use caution not to damage wheel weights dur ing tire and wheel installation 5 Install the wheel assembly and install the wheel mounting nuts Tighten Wheel...

Page 544: ...m Directional Tires Some vehicles may be fitted with special high performance tires having a directional tread pattern These tires are designed to improve traction on wet pavement To obtain the full...

Page 545: ...NFORMATION 11 2 Description 11 2 Operation 11 3 Specifications 11 3 Special Tools 11 3 DIAGNOSIS TESTING 11 4 Power Steering Troubleshooting Chart 11 4 Power Steering Fluid Troubleshooting Chart 11 5...

Page 546: ...e pump is connected to the steering by the pressure and return lines The steering gear used is a rack and pinion type gear 1 Power Steering Fluid Reservoir 2 Power Steering Fluid Pressure Hose Bracket...

Page 547: ...ng control of the vehicle can be maintained if power steering assist is lost However under this condi tion steering effort is significantly increased WARNING Power steering fluid engine parts and exha...

Page 548: ...he specified pressure Verify belt tension Replace belt auto tensioner and belt if necessary Check the outer tie rod ends Steering Wheel Does Not Return To Center Position Tire s not properly inflated...

Page 549: ...ut and inspect O ring If damaged or missing replace O ring Clean joints and reinspect for leaks Clean fluid from around suspect areas Run vehicle and inspect for leaks Look inside reservoir to see if...

Page 550: ...d a few minutes and repeat the procedure Flushing 1 Raise and support the vehicle 2 Remove the steering fluid reservoir release cap 3 Siphon out the contaminated power steering fluid from the power st...

Page 551: ...use pump damage 2 Perform the following to inspect the power steering fluid reservoir level Park the vehicle on a level surface Start the engine Turn the steering wheel several times to heat the power...

Page 552: ...le Inspection 11 11 Loose Steering Vehicle Leads Drifts Troubleshooting Chart 11 11 ON VEHICLE SERVICE 11 12 Steering Wheel 11 12 Removal Installation 11 12 Inspection Steering System 11 13 Steering C...

Page 553: ...the steering gear The steering column shaft then connects the steering column to the steering gear The tilt function of the steering column is controlled by a mechanical lever on the underside of the...

Page 554: ...Special Tools Steering Wheel Puller GENERAL INFORMATION 11 10 Chery Automobile Co Ltd...

Page 555: ...ECTION Excessive Play In Steering Wheel Worn or loose suspension or steering components Worn or loose wheel bearings Steering gear mounting Gear out of adjustment Worn or loose steering coupler Repair...

Page 556: ...traight ahead position 2 Disconnect the negative battery cable 3 Remove the driver airbag See Driver Airbag Removal Installation in Section 14 Restraints 4 Disconnect the spiral cable electrical conne...

Page 557: ...he engine off If free play exceeds standard value remove steering gear housing and inspect the gross torque of pinion gear Static Steering Force Inspection Park the vehicle on a level surface and turn...

Page 558: ...returns over 70 the steering wheel return function can be considered good NOTE When rapidly turning the steering wheel there will be a sense of heavy however this does not indicate a problem with the...

Page 559: ...may result in acci dental deployment of the airbag and possible personal injury See Airbag System Disarming Procedure in Sec tion 14 Restraints NOTE To help maintain alignment of the spiral cable con...

Page 560: ...al connector 9 Remove the two multi function switch wiper and washer switch assembly retaining bolts 1 Tighten Multi function switch wiper and washer switch assembly bolts to 7 2 N m 10 Remove the mul...

Page 561: ...olumn Tighten Steering column upper mounting bolts to 25 3 N m 13 Remove the two lower mounting bolts 1 from the steering column Tighten Steering column lower mounting bolts to 25 3 N m ON VEHICLE SER...

Page 562: ...joint and replace if necessary Check the steering column seal cover The distance to the groove button should be less than 1 00 mm replace if necessary Verify the airbag system is operating properly af...

Page 563: ...ghten Upper end cap bolts to 12 2 N m 3 Using snap ring pliers remove the outer snap ring 1 4 Remove the retainer and spring 5 Remove the upper end cap of steering column 6 Assembly is in the reverse...

Page 564: ...22 Binding and Sticking Troubleshooting Chart 11 22 Insufficient Assist Poor Return To Center Troubleshooting Chart 11 22 ON VEHICLE SERVICE 11 23 Steering Gear LHD 11 23 Removal Installation 11 23 St...

Page 565: ...teering wheel turns the pinion The rack is a long flat bar with teeth on one side The rack teeth mesh with the teeth on the pinion Rotation of the pinion moves the rack from left to right and right to...

Page 566: ...rt CONDITION POSSIBLE CAUSES CORRECTION Hard Turning Or Momentary Increase In Turning Effort Tire pressure Low fluid level Loose belt Lack of lubrication Low pump pressure or flow Internal gear leak B...

Page 567: ...G Prolonged and repeated contact with power steering fluid will damage skin If steering fluid is spilled on your skin wash it off immediately with water 2 Raise and support the vehicle 3 Remove the fr...

Page 568: ...e steering wheel from lock to lock until all power steering fluid has been removed from the system 6 Stop the engine 7 Use a service jack to support the engine 8 Remove the intermediate shaft coupling...

Page 569: ...Exhaust Pipe Removal Installation in Section 07 Exhaust 12 Remove the vehicle speed sensor retaining bolt 1 and set it aside Tighten Vehicle speed sensor bolt to 10 1 N m 13 Remove the pinch bolt 1 f...

Page 570: ...uter tie rod ends from both steering knuckles 16 Remove the steering gear pressure lines clamp 1 17 Remove the high pressure line nut 2 and the low pressure line nut 1 from the steering gear Tighten H...

Page 571: ...ng 19 Remove the front engine mount bolts 1 and the front engine mount bracket bolts 2 Tighten Front engine mount bolt to 80 5 N m 20 Remove the rear engine mount bolts 1 and the rear engine mount bra...

Page 572: ...slowly lower the sub frame enough to access the intermediate shaft coupling at the steering gear pinion shaft 23 Remove the steering gear retaining bolts 1 Tighten Steering gear retaining bolts to 10...

Page 573: ...power steering fluid will damage skin If steering fluid is spilled on your skin wash it off immediately with water 2 Raise and support the vehicle 3 Remove the front wheel mounting nuts and the wheel...

Page 574: ...e steering wheel from lock to lock until all power steering fluid has been removed from the system 6 Stop the engine 7 Use a service jack to support the engine 8 Remove the intermediate shaft coupling...

Page 575: ...Exhaust Pipe Removal Installation in Section 07 Exhaust 12 Remove the vehicle speed sensor retaining bolt 1 and set it aside Tighten Vehicle speed sensor bolt to 10 1 N m 13 Remove the pinch bolt 1 f...

Page 576: ...uter tie rod ends from both steering knuckles 16 Remove the steering gear pressure lines clamp 1 17 Remove the high pressure line nut 2 and the low pressure line nut 1 from the steering gear Tighten H...

Page 577: ...ng 19 Remove the front engine mount bolts 1 and the front engine mount bracket bolts 2 Tighten Front engine mount bolt to 80 5 N m 20 Remove the rear engine mount bolts 1 and the rear engine mount bra...

Page 578: ...ear retaining bolts 1 Tighten Steering gear retaining bolts to 100 10 N m 24 Remove the steering gear assembly 25 Installation is in the reverse order of the removal Tie Rod Removal Installation NOTE...

Page 579: ...ck NOTE When removing the outer tie rod end count the number of revolutions when removing This will aid in installation getting the toe setting close to where it needs to be when setting the final toe...

Page 580: ...ering tie rod end Standard value 0 98 3 92 N m 2 When the starting torque is less than the standard value inspect the ball joint for excessive play or wear problem If there is no problem found the bal...

Page 581: ...39 Insufficient Assist Poor Return To Center Troubleshooting Chart 11 39 ON VEHICLE SERVICE 11 40 Power Steering Pump 11 40 Removal Installation 11 40 Power Steering Fluid Reservoir 11 42 Removal Ins...

Page 582: ...rapped between the pump vanes and moved to the high pressure side of the pump creating a flow of fluid The restriction of this flow by the steering gear creates the pressure that provides the steering...

Page 583: ...line clamp O ring missing or damaged on hose fitting Low fluid level Air leak between pump and reservoir Replace clamp Replace O ring Fill to proper level Repair if necessary Scrubbing Or Knocking Wro...

Page 584: ...ise and support the vehicle 3 Remove the return hose clamps 1 from the power steering fluid reservoir and insert the end of the hose into a container 4 Start the engine and turn the steering wheel fro...

Page 585: ...power steering pump drive belt adjust ment bolt 1 7 Loosen the two bolts 1 on the steering pump bracket 8 Remove the A C compressor belt ON VEHICLE SERVICE PZSM020005 PZSM020050 11 11 41 Chery Automo...

Page 586: ...ighten Power steering pump bolts to 20 5 N m 11 Remove the steering pump from the engine bracket 12 Installation is in the reverse order of removal Installation Notes Fill the power steering fluid res...

Page 587: ...d reservoir fitting 3 Slide the hose off the end of the reservoir fitting 4 Installation is in the reverse order of removal Installation Notes Fill the power steering reservoir to the proper level Che...

Page 588: ...ing bolts 4 Remove the power steering pressure hose clamp 1 5 Loosen the lower bolt and remove the retaining bolt 1 on the pressure pipe bracket Tighten Pressure pipe bolt to 20 5 N m 6 Remove the pre...

Page 589: ...as possible from the power steering fluid reservoir 2 Loosen the clamps 1 and remove the return hose from the power steering fluid reservoir 3 Remove the clamp 1 from the power steering return hose ON...

Page 590: ...remove the retaining bolt 1 on the return line bracket Tighten Return line bolt to 20 5 N m 7 Remove the return line 8 Installation is in the reverse order of removal Installation Notes Fill the powe...

Page 591: ...peration 12 9 Removal Installation 12 10 Power Brake Booster 12 10 Description 12 10 Operation 12 10 Removal Installation 12 10 Front Brake Caliper 12 11 Description 12 11 Operation 12 11 Removal Inst...

Page 592: ...aliper be careful to avoid damaging the brake rotor and caliper and scratching or nicking the brake shoe lining Operation Applying the brake pedal uses lever action to push a rod into the brake booste...

Page 593: ...sc Brake Caliper Guide Pin Bolts Front 23 Disc Brake Caliper Bleeder Screw 10 Fluid Reservoir Mounting Screw 11 Master Cylinder Mounting Nuts 23 Parking Brake Lever Mounting Nuts 9 12 Rear Hub and Bea...

Page 594: ...Special Tools Dial Indicator Brake Measuring Gauge Digital Multimeter Fluke 15B 17B GENERAL INFORMATION 12 4 Chery Automobile Co Ltd...

Page 595: ...Electrical Schematics Brake System Page 1 of 1 GENERAL INFORMATION PZSMW120010T 12 12 5 Chery Automobile Co Ltd...

Page 596: ...flushed if the fluid is separated into layers or contains a substance other than brake fluid The system seals cups hoses master cylinder and HCU will also have to be replaced after flush ing Use clea...

Page 597: ...rake lines Bleed brakes Pedal Pulsates Surges During Braking Disc brake rotor has excessive thickness variation Isolate condition as rear or front Resurface or replace brake rotors as necessary Pedal...

Page 598: ...level periodically during the bleeding procedure and add brake fluid as required NOTE Do not pump the brake pedal at any time while having a bleeder screw open during the bleeding process This will on...

Page 599: ...gh fresh brake fluid to submerge the end of the hose 1 Turn the ignition switch off 2 Open the bleeder screw at least one full turn or more to obtain a steady stream of brake fluid 3 After approximate...

Page 600: ...m 8 Disconnect the brake fluid level switch electrical connector 2 from the master cylinder brake fluid reservoir 9 Slide the master cylinder straight out of the power brake booster 10 Installation is...

Page 601: ...irections This means pressure exerted against the caliper piston and within the caliper bore will be equal Fluid pressure applied to the pistons is transmitted directly to the inboard brake pad This f...

Page 602: ...hes or skin during the removal of the brake hose 5 Remove the front caliper guide bolts 1 Tighten Front caliper guide bolts to 23 N m 6 If necessary remove the brake caliper bracket mounting bolts 3 7...

Page 603: ...brake drum and remove the brake drum from the axle hub 6 Remove the rear hub and bearing nut Tighten Rear hub and bearing nut to 250 10 N m 7 Remove the parking brake cable 5 8 Remove the upper return...

Page 604: ...pection Excessive runout or wobble in a rotor can increase pedal travel due to piston knock back This increases guide pin sleeve wear due to the tendency of the caliper to follow the rotor wobble Brak...

Page 605: ...to contact the rotor braking surface approxi mately 10 mm from the outer edge of the rotor 3 Slowly rotate the brake rotor 3 checking lateral runout marking the low and high spots Record these measure...

Page 606: ...e the inside diameter of the brake drum Place the brake measuring gauge over the brake shoes at their widest point Using the adjuster wheel adjust the brake shoes until the linings on both brake shoes...

Page 607: ...e and make several stops to wear off any foreign material on the brakes and to seat the brake pads After installation and before moving the vehicle pump the brake pedal several times to set the pads t...

Page 608: ...n 1 Raise and support the vehicle 2 Remove the wheel mounting nuts and the tire and wheel assembly Tighten Wheel mounting nuts to 110 N m 3 Remove the two brake drum mounting screws 1 from the brake d...

Page 609: ...ake Shoes Inspect the rear brake shoes linings for proper alignment Inspect the rear brake shoe linings for proper contact across the entire width of the lining Inspect the rear brake shoe linings for...

Page 610: ...ical connector 4 Remove the stop lamp switch 5 Remove the pin 2 from the brake booster rod 6 Remove the nuts 1 attaching the brake pedal and power brake booster to the dash panel Tighten Brake pedal P...

Page 611: ...ce face or hands near caliper and piston if using compressed air pressure to remove piston Do not use high pressure 1 Place a wooden block 1 in the caliper 2 Apply low pressure compressed air to the c...

Page 612: ...sing a soft brass wire brush or a rough shop towel Do not clean piston with a polishing or emery cloth because this will damage the chrome plated surface Replace the piston if the chrome plated surfac...

Page 613: ...ton seal Bleed the brakes as necessary Perform the following procedure to assemble the brake caliper 1 Lubricate the caliper piston piston seals and piston bore with clean brake fluid 2 Install the ne...

Page 614: ...ore by hand or with the handle of a hammer in the direc tion shown NOTE Apply a small amount of air pressure into the caliper to help during assembly CAUTION When assembling the force applied to the p...

Page 615: ...t Front Wheel Speed Sensor Circuit Open or Shorted 12 47 C1205 Right Front Wheel Speed Sensor Gap Error 12 51 C1206 Left Rear Wheel Speed Sensor Circuit Open or Shorted 12 55 C1208 Left Rear Wheel Spe...

Page 616: ...stopped without locking the wheels retains directional stability and some steering capability This allows the driver to retain greater control of the vehicle during braking Operation ABS Braking ABS o...

Page 617: ...operation the brake pedal may vibrate lightly and a mechanical noise may be heard This is normal Stopping distance may be longer than that of vehicles without ABS when vehicle drives on rough gravel...

Page 618: ...Electrical Schematics Antilock Brake System Page 1 of 3 GENERAL INFORMATION PZSMW120001T 12 28 Chery Automobile Co Ltd...

Page 619: ...Antilock Brake System Page 2 of 3 GENERAL INFORMATION PZSMW120002T 12 12 29 Chery Automobile Co Ltd...

Page 620: ...Antilock Brake System Page 3 of 3 GENERAL INFORMATION PZSMW120003T 12 30 Chery Automobile Co Ltd...

Page 621: ...d Sensor 15 3 16 ABS Lamp 4 Ignition Switch 17 5 Left Rear Wheel Speed Sensor 18 Brake Switch 6 Left Rear Wheel Speed Sensor 19 Right Front Wheel Speed Sensor 7 Diagnostic Link K 20 Right Front Wheel...

Page 622: ...the wiggle test Look for broken bent pushed out or corroded terminals Inspect the sensor and mounting area for any condition that would result in an incorrect signal such as dam age foreign material A...

Page 623: ...Wheel Speed Sensor or Sensor Ring C1205 Right Front Wheel Speed Sensor Gap Error C1206 Left Rear Wheel Speed Sensor Circuit Open or Shorted C1207 Left Rear Wheel Speed Sensor or Sensor Ring C1208 Lef...

Page 624: ...Diagnostic Trouble Code DTC Tests C1101 Battery Voltage High C1102 Battery Voltage Low DIAGNOSIS TESTING PZSMW120004T 12 34 Chery Automobile Co Ltd...

Page 625: ...DIAGNOSIS TESTING PZSMW120005T 12 12 35 Chery Automobile Co Ltd...

Page 626: ...m and DTC If the DTC is detected the DTC condition is current Go to Diagnostic Procedure Step 1 If the DTC is not detected the DTC condition is intermittent See Diagnostic Help and Intermittent DTC Tr...

Page 627: ...e at the battery positive and negative terminals Is the voltage less than 9 4 V Yes Check the charging system No Go to the next step 4 CHECK THE BATTERY Maintain the engine speed to over 1000 RPM for...

Page 628: ...o the next step 7 CHECK DTC With the X 431 scan tool read the ABS module DTCs Refer to 9DTC Confirmation Procedure9 Is DTC C1101 or DTC C1102 still present Yes Replace the ABS module See ABS Module Re...

Page 629: ...C1200 Left Front Wheel Speed Sensor Circuit Open or Shorted DIAGNOSIS TESTING PZSMW120006T 12 12 39 Chery Automobile Co Ltd...

Page 630: ...for fault setting conditions to be met With the scan tool select View ABS Data Stream and DTC If the DTC is detected the DTC condition is current Go to Diagnostic Procedure Step 1 If the DTC is not d...

Page 631: ...nce voltage between ter minal 2 of the wheel speed sensor connector A 019 terminal side and ground Voltage should exist less than 1 0 V Is the proper voltage present Yes Go to the next step No Repair...

Page 632: ...exist Is the check result normal Yes Go to the next step No Repair or replace the circuit for a short to ground 7 CHECK LEFT FRONT WHEEL SPEED SENSOR GROUND CIRCUIT FOR A SHORT TO VOLTAGE Check the v...

Page 633: ...C1202 Left Front Wheel Speed Sensor Gap Error DIAGNOSIS TESTING PZSMW120006T 12 12 43 Chery Automobile Co Ltd...

Page 634: ...nition switch from off to on Start the engine and warm it to normal operating temperature Turn the ignition switch off and wait for a few seconds Start the engine With the scan tool connected to the D...

Page 635: ...Right Front Wheel Speed Left Rear Wheel Speed Right Rear Wheel Speed With the scan tool read active DTCs in the ABS module Is DTC C1202 present and the Left Front Wheel Speed signal abnormal Yes Go to...

Page 636: ...ing for excessive runout or clearance before replacing the wheel bearing assembly Replace the Left Front wheel bearing assembly See Front Hub and Bearing Removal Installation in Section 09 Driveline A...

Page 637: ...C1203 Right Front Wheel Speed Sensor Circuit Open or Shorted DIAGNOSIS TESTING PZSMW120007T 12 12 47 Chery Automobile Co Ltd...

Page 638: ...h for fault setting conditions to be met With the scan tool select View ABS Data Stream and DTC If the DTC is detected the DTC condition is current Go to Diagnostic Procedure Step 1 If the DTC is not...

Page 639: ...nce voltage between ter minal 2 of the wheel speed sensor connector A 020 terminal side and ground Voltage should exist less than 1 0 V Is the proper voltage present Yes Go to the next step No Repair...

Page 640: ...t exist Is the check result normal Yes Go to the next step No Repair or replace the circuit for a short to ground 7 CHECK RIGHT FRONT WHEEL SPEED SENSOR GROUND CIRCUIT FOR A SHORT TO VOLTAGE Check the...

Page 641: ...C1205 Right Front Wheel Speed Sensor Gap Error DIAGNOSIS TESTING PZSMW120007T 12 12 51 Chery Automobile Co Ltd...

Page 642: ...the ignition switch from off to on Start engine and warm it to normal operating temperature Turn ignition switch off and wait for a few seconds Start the engine With the scan tool connected to the DLC...

Page 643: ...heel Speed Right Front Wheel Speed Left Rear Wheel Speed Right Rear Wheel Speed With the scan tool read active DTCs in the ABS module Is DTC C1205 present and the Right Front Wheel Speed signal abnorm...

Page 644: ...l bearing for excessive runout or clearance before replacing the wheel bearing assembly Replace the Right Front wheel bearing assembly See Front Hub and Bearing Removal Installation in Section 09 Driv...

Page 645: ...C1206 Left Rear Wheel Speed Sensor Circuit Open or Shorted DIAGNOSIS TESTING PZSMW120008T 12 12 55 Chery Automobile Co Ltd...

Page 646: ...for fault setting conditions to be met With the scan tool select View ABS Data Stream and DTC If the DTC is detected the DTC condition is current Go to Diagnostic Procedure Step 1 If the DTC is not de...

Page 647: ...as necessary 3 CHECK LEFT REAR WHEEL SPEED SENSOR REFERENCE SIGNAL CIRCUIT Turn ignition switch on Measure the sensor reference voltage between ter minal 2 of the wheel speed sensor connector B 021 te...

Page 648: ...module connector A 025 and terminal 1 of the Left Rear wheel speed sensor connector A 021 terminal side Continuity should exist Is the check result normal Yes Go to the next step No Repair or replace...

Page 649: ...o to the next step No Repair or replace the circuit for a short to battery 8 CHECK DTC With the X 431 scan tool read the ABS module DTCs Refer to 9DTC Confirmation Procedure9 Is DTC C1206 present Yes...

Page 650: ...C1208 Left Rear Wheel Speed Sensor Gap Error DIAGNOSIS TESTING PZSMW120008T 12 60 Chery Automobile Co Ltd...

Page 651: ...gnition switch from off to on Start engine and warm it to normal operating temperature Turn ignition switch off and wait for a few seconds Start the engine With the scan tool connected to the DLC driv...

Page 652: ...he vehicle over 40 km h 25 mph Left Front Wheel Speed Right Front Wheel Speed Left Rear Wheel Speed Right Rear Wheel Speed With the scan tool read active DTCs in the ABS module Is the DTC C1208 presen...

Page 653: ...g for excessive runout or clearance before replacing the wheel bearing assembly Replace the Left Rear wheel bearing assembly See Front Hub and Bearing Removal Installation in Section 09 Driveline Axle...

Page 654: ...C1209 Right Rear Wheel Speed Sensor Circuit Open or Shorted DIAGNOSIS TESTING PZSMW120009T 12 64 Chery Automobile Co Ltd...

Page 655: ...or fault setting conditions to be met With the scan tool select View ABS Data Stream and DTC If the DTC is detected the DTC condition is current Go to Diagnostic Procedure Step 1 If the DTC is not det...

Page 656: ...r as necessary 3 CHECK RIGHT REAR WHEEL SPEED SENSOR REFERENCE SIGNAL CIRCUIT Turn ignition switch on Measure the sensor reference voltage between ter minal 2 of the wheel speed sensor connector B 022...

Page 657: ...module connector A 025 and terminal 1 of the Right Rear wheel speed sensor connector A 022 terminal side Continuity should exist Is the check result normal Yes Go to the next step No Repair or replace...

Page 658: ...Go to the next step No Repair or replace the circuit for a short to battery 8 CHECK DTC With the X 431 scan tool read the ABS module DTCs Refer to 9DTC Confirmation Procedure9 Is DTC C1209 present Ye...

Page 659: ...C1211 Right Rear Wheel Speed Sensor Gap Error DIAGNOSIS TESTING PZSMW120009T 12 12 69 Chery Automobile Co Ltd...

Page 660: ...e ignition switch from off to on Start engine and warm it to normal operating temperature Turn ignition switch off and wait for a few seconds Start the engine With the scan tool connected to the DLC d...

Page 661: ...Wheel Speed Right Front Wheel Speed Left Rear Wheel Speed Right Rear Wheel Speed With the scan tool read active DTCs in the ABS module Is DTC C1211 present and the Right Rear Wheel Speed signal abnor...

Page 662: ...el bearing for excessive runout or clearance before replacing the wheel bearing assembly Replace the Right Rear wheel bearing assembly See Rear Hub and Bearing Removal Installation in Section 09 Drive...

Page 663: ...BS Data Stream and DTC If the DTC is detected the DTC condition is current Go to Diagnostic Procedure Step 1 If the DTC is not detected the DTC condition is intermittent See Diagnostic Help and Interm...

Page 664: ...edure9 Is DTC C1604 still present Yes Replace the ABS module See ABS Module Removal Installation in Section 12 Brakes No The system is now operating properly Reassemble the vehicle and road test to ve...

Page 665: ...of brake fluid while bleeding the system An empty reservoir will allow additional air into the brake system Check the fluid level frequently and add fluid as needed The following wheel circuit sequenc...

Page 666: ...ll be trapped in the system Re bleed the brakes as necessary 9 Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct Pressure Bleeding Instructions NOTE Follow p...

Page 667: ...es 2 at the hydraulic con trol unit Tighten Brake tube nuts to 10 N m 5 Disconnect the ABS module electrical connector 1 6 Remove the mounting bolts 3 attaching the HCU mounting bracket to vehicle Tig...

Page 668: ...Rear Wheel Speed Sensor Removal Installation 1 Disconnect the negative battery cable 2 Raise and support the vehicle 3 Remove the wheel mounting nuts and the tire and wheel assembly Tighten Wheel moun...

Page 669: ...5 Remove the rear wheel speed sensor 1 6 Installation is in the reverse order of removal ON VEHICLE SERVICE VISM080033 12 12 79 Chery Automobile Co Ltd...

Page 670: ...81 Electrical Schematics 12 82 DIAGNOSIS TESTING 12 83 Parking Brake Warning Light 12 83 Parking Brake Operation 12 83 Parking Brake Adjustment 12 83 ON VEHICLE SERVICE 12 85 Parking Brake Lever 12 8...

Page 671: ...tensioner is built into the equalizer mounted on the end of the lever s output cable There is an individual parking brake cable for each rear wheel that joins a parking brake cable equalizer attached...

Page 672: ...Electrical Schematics Parking Brake System Page 1 of 1 GENERAL INFORMATION PZSMW120011T 12 82 Chery Automobile Co Ltd...

Page 673: ...e not secured to lever Rear cable not attached to actuator Rear cable seized Parking brake lever not seated Parking brake lever bind Parking Brake Adjustment Adjust the parking brake only if the parki...

Page 674: ...hat the parking brake shoes are working properly 8 With the parking brake lever in the released down position attempt to rotate the rear rotors by hand to ensure that the parking brake shoes are not d...

Page 675: ...e parking brake cable equalizer 8 Disconnect the electrical connector 3 from the parking brake switch 9 Remove the bolts 1 attaching the parking brake lever to the vehicle Tighten Parking brake lever...

Page 676: ...g brake cable Tighten Parking brake cable bracket bolts to 9 12 N m 6 Remove the lower console See Lower Console Removal Installation in Section 15 Body Accessories 7 Release and lower the parking bra...

Page 677: ...rom the underside of the vehicle body NOTE Remove the parking brake cable at another side in accordance with the same method 13 Installation is in the reverse order of removal Installation Notes After...

Page 678: ...RAL INFORMATION 13 2 Description 13 2 Operation 13 3 Specifications 13 4 Special Tools 13 4 Electrical Schematics 13 5 DIAGNOSIS TESTING 13 7 A C System Performance 13 7 Heater Performance 13 9 ON VEH...

Page 679: ...iver can choose the following functions from the HVAC control panel The inside temperature The speed of the blower Five different modes of operation A C compressor clutch operation Recirculation door...

Page 680: ...nings clear of debris because leaf particles and other debris that is small enough to pass through the cowl plenum screen can accumulate within the HVAC housing The A C compressor can be engaged by pr...

Page 681: ...fications AMBIENT TEMPERATURE A C HIGH SIDE PRESSURE A C LOW SIDE PRESSURE 15 5 C 8 4 11 9 kgf cm2 120 170 psi 1 9 2 1 kgf cm2 28 31 psi 21 1 C 10 5 17 5 kgf cm2 150 250 psi 1 9 2 1 kgf cm2 28 31 psi...

Page 682: ...Electrical Schematics Climate Control System Page 1 of 2 GENERAL INFORMATION PZSMW130001T 13 13 5 Chery Automobile Co Ltd...

Page 683: ...Climate Control System Page 2 of 2 GENERAL INFORMATION PZSMW130002T 13 6 Chery Automobile Co Ltd...

Page 684: ...ycle depending upon the ambient temperature and humidity 7 With the compressor clutch engaged record the discharge air temperature and the compressor discharge pres sure 8 Compare the discharge air te...

Page 685: ...ation and sealing Correct if required Replace if faulty The Low Side Pressure Is Normal Or Slightly Low And The High Side Pressure Is Too Low Low refrigerant system charge Refrigerant flow through the...

Page 686: ...s Compare the test thermometer reading to the heater performance chart HEATER PERFORMANCE Ambient Air Temperature 15 5 C 60 F 21 1 C 70 F 26 6 C 80 F 32 2 C 90 F Minimum Air Temperature at Floor Outle...

Page 687: ...ICLE SERVICE Manual Temperature Control Module Removal Installation 1 Disconnect the negative battery cable 2 Open the upper storage box and remove the two screws 1 PZSM150179 13 10 Chery Automobile C...

Page 688: ...3 Remove the upper storage box 1 4 Remove the two upper cover retaining screws 1 5 Using a trim stick pry the lower cover ON VEHICLE SERVICE PZSM150180 PZSM150181 13 13 11 Chery Automobile Co Ltd...

Page 689: ...the center instrument panel cover 1 7 Disconnect the hazard warning switch electrical connector 8 Remove the HVAC control panel cover 1 ON VEHICLE SERVICE PZSM150182 PZSM150184 13 12 Chery Automobile...

Page 690: ...rior to servicing the blower motor resistor wait five minutes to allow the blower motor resistors to cool before per forming diagnosis or service Failure to take this precaution can result in possible...

Page 691: ...two screws 1 attaching the blower motor resistor to the HVAC housing 4 Remove the blower motor resistor 5 Installation is in the reverse order of removal ON VEHICLE SERVICE PZSM130012 13 14 Chery Auto...

Page 692: ...16 Operation 13 16 Specifications 13 16 Special Tools 13 16 DIAGNOSIS TESTING 13 17 Mechanical Problems 13 17 Temperature Control 13 17 ON VEHICLE SERVICE 13 18 Recirculation Door Actuator 13 18 Remo...

Page 693: ...e box for more information on the suggested oper ation and use of these controls Operation The HVAC control panel is located on the instrument panel above the radio The HVAC control panel contains the...

Page 694: ...perly An air bound system Temperature Control If the heater outlet air temperature cannot be adjusted with the temperature control knob s on the HVAC control panel the following could require service...

Page 695: ...r actuator screws to 2 N m 6 Remove the plastic clip from the recirculation door actuator 7 Remove the recirculation door actuator 8 Installation is in the reverse order of removal Installation Notes...

Page 696: ...3 21 DIAGNOSIS TESTING 13 22 Blower Motor Electrical Troubleshooting 13 22 Blower Motor Noise 13 22 Blower Motor Vibration 13 22 ON VEHICLE SERVICE 13 23 HVAC Housing 13 23 Removal Installation 13 23...

Page 697: ...e of the system The mode door cable operates the mode air doors which direct the flow of the conditioned air out the various air outlets depending on the mode selected When equipped with A C the recir...

Page 698: ...Special Tools Digital Multimeter Fluke 15B 17B GENERAL INFORMATION 13 13 21 Chery Automobile Co Ltd...

Page 699: ...se To determine if the blower motor is the source of the noise simply switch the blower motor from Off to On To verify that the blower motor is the source of the noise unplug the blower motor wire har...

Page 700: ...steam and hot liquid can come out forcefully when the cap is loosened slightly Failure to follow these instructions may result in serious personal injury 2 Drain the cooling system See Cooling System...

Page 701: ...ove the mode door and the blend door cable clamps 1 and remove the two cables 8 Remove the steering assembly mounting bolts and nuts 1 ON VEHICLE SERVICE PZSM130021 PZSM130023 13 24 Chery Automobile C...

Page 702: ...ly 11 Remove the eight HVAC housing assembly retain ing nuts 1 12 Remove the inlet and outlet A C pressure line snap rings from the evaporator and remove the A C pressure lines 13 Remove the HVAC hous...

Page 703: ...tor can be accessed for service from underneath the instrument panel The blower motor and blower motor wheel are factory balanced as an assembly and cannot be adjusted or repaired and must be replaced...

Page 704: ...ttom of the left side of the instru ment panel 3 Push down on the clip 1 and remove the blower assembly clockwise 4 Remove the blower motor 5 Installation is in the reverse order of removal ON VEHICLE...

Page 705: ...34 A C System Recharge 13 34 A C Compressor 13 35 Description 13 35 Operation 13 35 Removal Installation 13 35 Evaporator 13 37 Description 13 37 Operation 13 37 Removal Installation 13 37 Condenser...

Page 706: ...system contains refrigerant under high pressure Repairs should only be performed by qualified service personnel Serious or fatal injury may result from improper service procedures WARNING If accident...

Page 707: ...A C Refrigerant Charge Specifications DESCRIPTION CAPACITY g R 134a Refrigerant 500 10 Special Tools Refrigerant Recovery Recycling Station GENERAL INFORMATION 13 30 Chery Automobile Co Ltd...

Page 708: ...hub is broken or if the compressor shaft does not rotate smoothly 8 Check the compressor hub and pulley and bearing assembly Ensure that the hub and pulley are properly aligned and that the pulley be...

Page 709: ...Refrigerant System Low 1 Position the vehicle in a wind free work area This will aid in detecting small leaks 2 Operate the heating A C system with the engine at idle under the following conditions f...

Page 710: ...A C System Evacuation and Recharge Connecting Refrigerant Recovery Recycling Station WARNING The A C system is under high pressure use caution when servicing the A C system PZSM130026 13 13 33 Chery...

Page 711: ...cuate the refrigerant system 1 With the engine OFF connect a suitable charging station refrigerant recovery machine or a manifold gauge set with vacuum pump and refrigerant recovery equipment Do not o...

Page 712: ...ressor damage NOTE The compressor drive hub and the pulley and bearing assembly cannot be serviced separately from the A C com pressor In the event of drive hub or pulley and bearing assembly damage o...

Page 713: ...ystem leak 1 Evacuate the A C system See A C System Evacuation and Recharge in Section 13 Heating and Air Condition ing 2 Remove the power steering pump See Power Steering Pump Removal Installation in...

Page 714: ...and outlets However air passing over the evaporator coil fins will only be condi tioned when the compressor is engaged and circulating refrigerant through the evaporator coil tubes Operation Refriger...

Page 715: ...ff to remove the evaporator shield NOTE The sponge seal around the housing must be replaced when servicing the evaporator The seal is not reusable 6 Remove the evaporator assembly 7 Remove the expansi...

Page 716: ...ir flow Also any factory installed air seals or shrouds must be properly reinstalled following radiator or condenser service Removal Installation 1 Disconnect the negative battery cable 2 Evacuate the...

Page 717: ...Accumulators are used on systems that use an orifice tube to meter refrigerants into the evaporator Operation The primary function of the accumulator is to isolate the compressor from any damaging liq...

Page 718: ...d line connects the A C condenser to the A C evaporator Operation The high pressure A C liquid line is the refrigerant line that carries refrigerant from the A C condenser to the A C accumulator Air c...

Page 719: ...fied O rings as they are made of a special material for the R 134a system Use only refrigerant oil of the type recommended for the A C compressor in the vehicle Recharge the A C system See A C System...

Page 720: ...essure line assembly to the A C evaporator 4 Remove the A C pressure line clamp retaining bolt from the engine body 5 Disconnect the A C pressure switch 6 Remove the retaining nut 1 on the accumulator...

Page 721: ...ater core before it is distributed through the heating A C system ducts and outlets One end of the heater core is fitted with a tank that includes the fittings for the heater core tubes The heater cor...

Page 722: ...workbench See HVAC housing removal installation in Section 13 Heating Air Conditioning 6 Remove the mode door and the blend door cable retaining clamps 1 and remove the two cables 7 Loosen the two he...

Page 723: ...ed when servicing the heater core The seal is not reusable 10 Pry the clips off and remove the air conditioner cover plate assembly 11 Remove the heater core 12 Installation is in the reverse order of...

Page 724: ...ol Module DTC List 14 9 Diagnostic Trouble Code DTC Tests 14 11 B1200 ECU Internal Errors 14 11 B1400 Power Supply Under Volt 14 16 B1241 Front Driver Airbag I STAGE Open Circuit or Over Upper Limit o...

Page 725: ...m safety benefit from the supplemental restraint system The supplemental restraint system electrical circuits are continuously monitored and controlled by a microprocessor and software contained withi...

Page 726: ...eneral Airbag Special Load Tool Resistor Harness For Driver s and Passenger s Front Airbag General Airbag Special Load Tool Dummy Resistor For Driver s and Passenger s Front Airbag and Seat Belt Pre T...

Page 727: ...Electrical Schematics Airbag Control System Page 1 of 3 GENERAL INFORMATION PZSMW140001T 14 4 Chery Automobile Co Ltd...

Page 728: ...Airbag Control System Page 2 of 3 GENERAL INFORMATION PZSMW140003T 14 14 5 Chery Automobile Co Ltd...

Page 729: ...Airbag Control System Page 3 of 3 GENERAL INFORMATION PZSMW140002T 14 6 Chery Automobile Co Ltd...

Page 730: ...nger Seat Belt Pretensioner Lo 28 4 Front Passenger Seat Belt Pretensioner Hi 29 5 Ignition Switch 30 6 GND 31 7 Airbag Lamp 32 8 33 9 Diagnostic Link K 34 10 Driver Airbag Lo 35 11 Driver Airbag Hi 3...

Page 731: ...ed vehicle and install in a new vehicle and test If the DTC cannot be deleted the RCM is malfunctioning If the DTC can be deleted return the RCM to the origi nal vehicle Ground Inspection Ground conne...

Page 732: ...enger Airbag I STAGE Short Circuit Or Below Lower Limit Or Ground Lost B1245 Front Passenger Airbag I STAGE Open Circuit or Over upper limit Or Vbatt voltage lost B1254 Front Driver Pretensioner Short...

Page 733: ...ger Headbag Short Circuit Or Below Lower Limit Or Ground Lost B1277 Front Passenger Headbag Open Circuit Or Over Upper Limit Or Vbatt Voltage Lost B1292 Front Driver Side Impact Sensor Defective Signa...

Page 734: ...Diagnostic Trouble Code DTC Tests B1200 ECU Internal Errors DIAGNOSIS TESTING PZSMW140004T 14 14 11 Chery Automobile Co Ltd...

Page 735: ...DIAGNOSIS TESTING PZSMW140005T 14 12 Chery Automobile Co Ltd...

Page 736: ...sly this indicates that there are history DTCs in the system Use the Scan Tool to erase the DTCs If any other condition occurs use the Scan Tool to erase the history DTCs first then check the warning...

Page 737: ...RCM ELECTRICAL CONNECTOR Turn ignition switch off Disconnect the Restraints Control Module RCM electrical connector 1 Inspect the electrical connector for damage Is the electrical connector OK Yes Go...

Page 738: ...firmation Procedure9 Is DTC B1200 still present Yes Replace the Restraints Control Module RCM No The system is now operating properly Reassemble the vehicle and road test to verify the customers compl...

Page 739: ...B1400 Power Supply Under Volt DIAGNOSIS TESTING PZSMW140004T 14 16 Chery Automobile Co Ltd...

Page 740: ...DIAGNOSIS TESTING PZSMW140005T 14 14 17 Chery Automobile Co Ltd...

Page 741: ...rging cranking DTCs before proceeding If the warning lamp goes out immediately after the warning lamp flashed for 6 7 seconds this indicates that the system is OK If the warning lamp is on for 6 7 sec...

Page 742: ...OL MODULE RCM ELECTRICAL CONNECTOR Turn ignition switch off Disconnect the Restraints Control Module RCM electrical connector 1 Inspect the electrical connector for damage Is the electrical connector...

Page 743: ...approximately 9 0 V Is the check result normal Yes Go to step 6 No Charge or replace the battery 6 CHECK RESTRAINTS CONTROL MODULE RCM SUPPLY CIRCUIT Turn ignition switch off Disconnect the battery p...

Page 744: ...B1241 Front Driver Airbag I STAGE Open Circuit or Over Upper Limit or Vbatt Voltage Lost DIAGNOSIS TESTING PZSMW140008T 14 14 21 Chery Automobile Co Ltd...

Page 745: ...e Diagnostic Help and Intermittent DTC Trou bleshooting in Section 14 Restraints for more information Diagnostic Guide Lines Observe the following guide lines while diagnosing this DTC Troubleshoot an...

Page 746: ...ide of the vehicle harness in place of the driver airbag WARNING To avoid serious or fatal injury the driver airbag should not be checked with a multimeter NOTE If the airbag special load tool is not...

Page 747: ...d serious or fatal injury turn the ignition switch off disconnect the negative battery cable and wait two minutes before proceeding Disconnect the spiral cable connector J 005 NOTE Check connectors Cl...

Page 748: ...s 4 CHECK DRIVER AIRBAG CONTROL CIRCUITS WARNING To avoid serious or fatal injury turn the ignition switch off disconnect the negative battery cable and wait two minutes before proceeding Check the co...

Page 749: ...s a guide inspect the following Inspect the wiring and connectors of the related airbag system wiring and connectors Look for any chafed pierced pinched or partially broken wires Look for broken bent...

Page 750: ...B1245 Front Passenger Airbag I STAGE Open Circuit or Over Upper Limit or Vbatt Voltage Lost DIAGNOSIS TESTING PZSMW140009T 14 14 27 Chery Automobile Co Ltd...

Page 751: ...See Diagnostic Help and Intermittent DTC Trou bleshooting in Section 14 Restraints for more information Diagnostic Guide Lines Observe the following guide lines while diagnosing this DTC Troubleshoot...

Page 752: ...harness in place of the passenger airbag Connect the negative battery cable WARNING To avoid serious or fatal injury the passenger airbag should not be checked by a multimeter NOTE If the airbag spec...

Page 753: ...RCUITS Disconnect the airbag special load tool or disconnect the known good driver airbag WARNING To avoid serious or fatal injury turn the ignition switch off disconnect the negative battery cable an...

Page 754: ...he electrical schematic as a guide inspect the following Inspect the wiring and connectors of the related airbag system Look for any chafed pierced pinched or partially broken wires Look for broken be...

Page 755: ...B2214 Warning Lamp Short to Ground DIAGNOSIS TESTING PZSMW140010T 14 32 Chery Automobile Co Ltd...

Page 756: ...e Diagnostic Help and Intermittent DTC Trou bleshooting in Section 14 Restraints for more information Diagnostic Guide Lines Observe the following guide lines while diagnosing this DTC Troubleshoot an...

Page 757: ...he ignition switch ON Yes Go to the next step No Go to step 4 3 CHECK RESTRAINTS CONTROL MODULE RCM ELECTRICAL CONNECTOR Turn ignition switch off Disconnect the Restraints Control Module RCM electrica...

Page 758: ...y fuse and relay box C 020 for an open or short to ground 5 CHECK CONNECTORS NOTE Diagnose and repair all active codes before diagnosing stored codes See Restraints Control Module DTC List in Section...

Page 759: ...bstitutes Anytime a new fastener is needed replace with the correct fasteners provided in the service package or fasteners listed in the parts books 1 Turn the ignition off 2 Disconnect and isolate th...

Page 760: ...charge before beginning any airbag system or component service Failure to do so may result in accidental airbag development serious or fatal injury See Airbag System Disarming Procedure in Section 14...

Page 761: ...ure to do so may result in accidental airbag development serious or fatal injury See Airbag System Disarming Procedure in Section 14 Restraints 2 Remove the lower console See Lower Console Removal Ins...

Page 762: ...0 Specifications 14 40 ON VEHICLE SERVICE 14 41 Front Seat Belt and Pre Tensioner 14 41 Removal Installation 14 41 Adjustable Shoulder Belt Anchor 14 43 Removal Installation 14 43 Rear Seat Belt and T...

Page 763: ...eferred to as a supplemental restraint system because they were designed and are intended to enhance the protection for the occupants of the vehicle only when used in conjunction with the seat belts S...

Page 764: ...E SERVICE Front Seat Belt and Pre Tensioner Removal Installation 1 Remove the seat belt upper mounting bolt 1 2 Remove the seat belt lower mounting bolt 2 PZSM140014 14 14 41 Chery Automobile Co Ltd p...

Page 765: ...the front seat belt pre tensioner retaining bolt 1 Tighten Front seat belt retaining bolt to 50 N m 5 Remove the front seat belt and pre tensioner 6 Installation is in the reverse order of removal ON...

Page 766: ...houlder Belt Anchor Removal Installation 1 Remove the B pillar lower trim panel 1 2 Remove the front seat belt bracket retaining screws 1 ON VEHICLE SERVICE PZSM140015 PZSM140017 14 14 43 Chery Automo...

Page 767: ...adjustable shoulder belt anchor mounting bolts 1 Tighten Adjustable shoulder belt anchor bolts to 50 N m 5 Remove the adjustable shoulder belt anchor 6 Installation is in the reverse order of the rem...

Page 768: ...Rear Seat Removal Installation in Section 15 Body Accessories 2 Remove the rear seat belt mounting bolts 1 Tighten Rear seat belt mounting bolts to 50 N m 3 Remove the two side seat belt mounting bolt...

Page 769: ...n 15 Body Accessories 5 Remove the rear seat tensioner mounting bolt 1 Tighten Rear seat belt tensioner mounting bolt to 50 N m 6 Remove the tensioner 7 Installation is in the reverse order of the rem...

Page 770: ...Description 15 20 Operation 15 20 Electrical Schematics 15 21 DOOR LOCKS 15 24 Description 15 24 Operation 15 24 Electrical Schematics 15 25 Power Lock Motor 15 28 Removal Installation 15 28 Door Lock...

Page 771: ...15 114 Operation 15 114 Front Seat 15 114 Removal Installation 15 114 Rear Seat 15 115 Removal Installation 15 115 IMMOBILIZER CONTROL MODULE 15 118 Description 15 118 Operation 15 118 Electrical Sche...

Page 772: ...nt The system uses an ignition switched source of battery current so that the system will operate when the ignition switch is in the LOCK ACC ON positions The radio will also operate for up to one hou...

Page 773: ...Electrical Schematics Audio System Page 1 of 2 AUDIO SYSTEM PZSMW150034T 15 4 Chery Automobile Co Ltd...

Page 774: ...Audio System Page 2 of 2 AUDIO SYSTEM PZSMW150037T 15 15 5 Chery Automobile Co Ltd...

Page 775: ...n 1 Disconnect the negative battery cable 2 Open the storage box over the console and remove the two retaining screws 1 3 Using a trim stick remove the storage box 1 AUDIO SYSTEM PZSM150179 PZSM150180...

Page 776: ...retaining screws 1 5 Using a trim stick pry the lower cover 6 Remove the center instrument panel cover 1 7 Disconnect the emergency switch electrical connector AUDIO SYSTEM PZSM150181 PZSM150182 15 1...

Page 777: ...screws 1 10 Disconnect the two electrical connectors behind the HVAC control panel 11 Remove the two control cables from the HVAC control panel 12 Remove the HVAC control panel 13 Remove the two uppe...

Page 778: ...nstallation 1 Disconnect the negative battery cable 2 Remove the headliner See Headliner Removal Installation in Section 15 Body Accessories 3 Disconnect the antenna electrical connector 4 4 Disconnec...

Page 779: ...anel 1 to release the retaining clips 2 Remove the A pillar trim panel 3 Installation is in the reverse order of removal Installation Notes The A pillar trim panel clips should be installed to allow t...

Page 780: ...Remove the seat belt upper mounting bolt 1 2 Remove the seat belt lower mounting bolt 2 3 Using a trim stick pry the B pillar trim panel 1 to release the retaining clips BODY INTERIOR TRIM PZSM140014...

Page 781: ...nt seat belt bracket retaining screws 1 5 Using a trim stick remove B pillar upper trim panel 1 6 Installation is in the reverse order of removal BODY INTERIOR TRIM PZSM140017 PZSM140012 15 12 Chery A...

Page 782: ...lation 1 Remove the two side seat belt mounting bolts 1 2 Disconnect the rear speaker electrical connector 2 3 Remove the three rear speaker retaining screws 1 BODY INTERIOR TRIM PZSM140018 PZSM150107...

Page 783: ...1 6 Remove the two rear hatch kick plates 7 Remove the C pillar lower trim panel retaining clips 1 8 Remove the C pillar lower trim panel and discon nect the rear hatch lamp electrical connector 1 BO...

Page 784: ...the passenger grab handle 4 Installation is in the reverse order of removal Scuff Plate Removal Installation 1 Remove the two scuff plate retaining screws 1 2 Grasp the scuff plate and gently pull it...

Page 785: ...hten the sun visor mounting screws Tighten the sun visor mounting screws at the sun visor hinge just enough to allow for free movement of the sun visor Headliner Removal Installation 1 Remove the pass...

Page 786: ...f and not interfere with the view of the front wind shield The headliner corners should fit tight to the roof and not be visible outside the car The headliner should fit tight with the weatherstrip ar...

Page 787: ...Automated Manual Transaxle AMT Control Module Operation Control modules on the Controller Area Network CAN network transmit signals using the CAN communication con trol circuit Data exchange between m...

Page 788: ...Electrical Schematics CAN Vehicle Communications Page 1 of 1 CAN VEHICLE COMMUNICATIONS PZSMW151010T 15 15 19 Chery Automobile Co Ltd...

Page 789: ...inputs from various sensors and switches to activate the chime The sensors and switches are located throughout the vehicle The following conditions will cause the chime to operate Turn signal on Hazar...

Page 790: ...Electrical Schematics Chime Page 1 of 3 CHIME PZSMW150039T 15 15 21 Chery Automobile Co Ltd...

Page 791: ...Chime Page 2 of 3 CHIME PZSMW150041T 15 22 Chery Automobile Co Ltd...

Page 792: ...Chime Page 3 of 3 CHIME PZSMW150044T 15 15 23 Chery Automobile Co Ltd...

Page 793: ...switch is located on the front door trim panel The power door locks can also be operated by the Remote Keyless Entry RKE trans mitter Operation The power lock system receives non switched battery curr...

Page 794: ...Electrical Schematics Power Door Lock System Page 1 of 3 DOOR LOCKS PZSMW150021T 15 15 25 Chery Automobile Co Ltd...

Page 795: ...Power Door Lock System Page 2 of 3 DOOR LOCKS PZSMW150022T 15 26 Chery Automobile Co Ltd...

Page 796: ...Power Door Lock System Page 3 of 3 DOOR LOCKS PZSMW150023T 15 15 27 Chery Automobile Co Ltd...

Page 797: ...urn the ignition switch off 2 Using a trim stick remove the outside mirror switch panel 1 from the door trim panel 3 Disconnect the outside mirror switch electrical con nector 1 DOOR LOCKS PZSM150120...

Page 798: ...4 Using a trim stick remove the power window switch assembly 1 5 Disconnect the power window switch electrical con nector 1 DOOR LOCKS PZSM150126 PZSM150073 15 15 29 Chery Automobile Co Ltd...

Page 799: ...6 Using a trim stick remove the inside door handle panel retaining screw cover 1 7 Remove the inside door handle panel retaining screw 1 DOOR LOCKS PZSM150122 PZSM150123 15 30 Chery Automobile Co Ltd...

Page 800: ...8 Using a trim stick remove the inside door handle panel 1 9 Loosen the inside door handle panel control cable 1 DOOR LOCKS PZSM150125 PZSM150130 15 15 31 Chery Automobile Co Ltd...

Page 801: ...Remove the small storage compartment retaining screw 1 on the door trim panel 11 Using a trim stick remove the small storage com partment 1 DOOR LOCKS PZSM150127 PZSM150128 15 32 Chery Automobile Co L...

Page 802: ...1 13 Disconnect the door switch electrical connector 1 14 Remove the four retaining screws 1 from the door trim panel 15 Remove the door trim panel DOOR LOCKS PZSM150124 PZSM150145 PZSM150129 15 15 3...

Page 803: ...nuts 1 and remove the outside mirror electrical connector Tighten Outside mirror mounting nuts to 7 1 N m 17 Remove the two door trim panel mounting bracket retaining screws 1 DOOR LOCKS PZSM150134 PZ...

Page 804: ...the protective film 1 from the front door 19 Remove the power lock motor retaining screws 1 Tighten Power lock motor retaining screws to 8 1 N m DOOR LOCKS PZSM150133 PZSM150143 15 15 35 Chery Automob...

Page 805: ...ng the following table apply battery voltage to the specified connector terminals 2 Verify that the door lock assembly locks and unlocks when voltage is applied to the specific terminals 3 If the test...

Page 806: ...the vehicle The following components are inputs to the BCM Key switch Rear window defogger switch Hazard lamp switch Front power window switches Power door lock switches Door ajar switches Front fog...

Page 807: ...Electrical Schematics Body Control Module Page 1 of 4 BODY CONTROL MODULE BCM PZSMW150051T 15 38 Chery Automobile Co Ltd...

Page 808: ...Body Control Module Page 2 of 4 BODY CONTROL MODULE BCM PZSMW150052T 15 15 39 Chery Automobile Co Ltd...

Page 809: ...Body Control Module Page 3 of 4 BODY CONTROL MODULE BCM PZSMW150053T 15 40 Chery Automobile Co Ltd...

Page 810: ...Body Control Module Page 4 of 4 BODY CONTROL MODULE BCM PZSMW150055T 15 15 41 Chery Automobile Co Ltd...

Page 811: ...t Front Window Up Output 11 Left Rear Window Down Input 32 Right Front Window Down Output 12 Right Rear Window Up Input 33 Right Rear Window Up Output 13 Left Front Window Down Input 34 Right Rear Win...

Page 812: ...such as dam age or foreign material A data recorder and or oscilloscope should be used to help diagnose intermittent conditions Remove the BCM module from the troubled vehicle and install in a new ve...

Page 813: ...l Circuit Low Current B1306 Central Unlock Control Circuit High Current B1307 Central Unlock Control Circuit Stuck On B1310 FL Window Up Control Circuit Low Current B1312 FL Window Up Control Circuit...

Page 814: ...Diagnostic Trouble Code DTC Tests B1000 Left Turn Lights Control Circuit Low Current DIAGNOSIS TESTING PZSMW150064T 15 15 45 Chery Automobile Co Ltd...

Page 815: ...e Before performing the following procedure confirm that battery voltage is more than 12 V Turn ignition switch off Connect the X 431 scan tool to the Data Link Connector DLC use the most current soft...

Page 816: ...nstall the bulbs go to the next step No Replace the LH turn signal bulb s as necessary 1 High Beam Lamp Bulb Front Position Lamp Bulb 12 V 65 W 12 V 5 W 2 Low Beam Lamp Bulb 12 V 55 W 3 Front Turn Sig...

Page 817: ...No Repair or replace the circuit for an open in harness or connectors between BCM and LH turn signal lamp 3 CHECK THE LH TURN SIGNAL LAMPS GROUND CIRCUIT Turn ignition switch off Disconnect the front...

Page 818: ...CM DTCs Refer to 9DTC Confirmation Procedure9 Is DTC B1000 present Yes Replace BCM No The system is now operating properly Reassemble the vehicle and verify the customers complaint is repaired DIAGNOS...

Page 819: ...B1004 Right Turn Lights Control Circuit Low Current DIAGNOSIS TESTING PZSMW150063T 15 50 Chery Automobile Co Ltd...

Page 820: ...e Before performing the following procedure confirm that battery voltage is more than 12 V Turn ignition switch off Connect the X 431 scan tool to the Data Link Connector DLC use the most current soft...

Page 821: ...nstall the bulbs go to the next step No Replace the RH turn signal bulb s as necessary 1 High Beam Lamp Bulb Front Position Lamp Bulb 12 V 65 W 12 V 5 W 2 Low Beam Lamp Bulb 12 V 55 W 3 Front Turn Sig...

Page 822: ...p No Repair or replace the circuit for an open in harness or connectors between BCM and RH turn signal lamp 3 CHECK THE RH TURN SIGNAL LAMPS GROUND CIRCUIT Turn ignition switch off Disconnect the fron...

Page 823: ...Refer to 9DTC Confirmation Procedure9 Is DTC B1004 still present Yes Replace BCM No The system is now operating properly Reassemble the vehicle and road test to verify the customers complaint is repai...

Page 824: ...B1100 Dome Light Control Circuit Low Voltage DIAGNOSIS TESTING PZSMW150066T 15 15 55 Chery Automobile Co Ltd...

Page 825: ...tion switch on with the scan tool view and erase stored DTCs in the BCM Turn ignition switch off Turn the front dome lamp switch to DOOR position and close all the doors Press the unlock button on the...

Page 826: ...tion switch on Check voltage between the front dome lamp harness connector B 008 terminal 1 and ground FRONT DOME LAMP TERMINAL GROUND 1 12 V should exist Is the check result normal Yes Go to the next...

Page 827: ...xist Is the check result normal Yes Go to the next step No Repair or replace the control circuit for an open or high resistance in harness or connectors 5 CHECK DTC Reconnect all previously disconnect...

Page 828: ...B1301 Central Lock Control Circuit Low Current DIAGNOSIS TESTING PZSMW150062T 15 15 59 Chery Automobile Co Ltd...

Page 829: ...ing procedure confirm that battery voltage is more than 12 V Turn ignition switch off Connect the X 431 scan tool to the Data Link Connector DLC use the most current software available Turn ignition s...

Page 830: ...ctor D 006 G 006 H 003 or I 003 terminal 3 and ground while operating the center lock switch in the lock position CENTRAL LOCK ACTUATOR TERMINAL GROUND 3 12 V should exist Is the check result normal Y...

Page 831: ...rn circuit between BCM connector B 002 terminal 28 and door lock actuator connectors for an open or high resistance 3 CHECK CENTRAL LOCK ACTUATORS Remove and check the LF RF LR and RR central lock act...

Page 832: ...B1310 FL Window Up Control Circuit Low Current DIAGNOSIS TESTING PZSMW150058T 15 15 63 Chery Automobile Co Ltd...

Page 833: ...ng procedure confirm that battery voltage is more than 12 V Turn ignition switch off Connect the X 431 scan tool to the Data Link Connector DLC use the most current software available Turn ignition sw...

Page 834: ...ector D 002 terminal 2 and ground while operating the left front power window switch in the up position FRONT LH POWER WINDOW MOTOR TERMINAL GROUND 2 12 V should exist Is the check result normal Yes G...

Page 835: ...No Replace the LH front power window motor 3 CHECK DTC With the X 431 scan tool read the BCM DTCs Refer to 9DTC Confirmation Procedure9 Is DTC B1310 present Yes Replace the BCM No The system is now o...

Page 836: ...y cable 2 Remove the left front seat See Front Seat Removal Installation in Section 15 Body Accessories 3 Remove the two BCM retaining bolts 1 4 Disconnect the BCM electrical connector 5 Remove the BC...

Page 837: ...cable 2 Remove the instrument cluster See Instrument Cluster Removal Installation in Section 15 Body Accesso ries 3 Remove the retaining bolt 1 4 Remove the driver airbag See Driver Airbag Removal In...

Page 838: ...e lower console See Lower Console Removal Installation in Section 15 Body Accessories 10 Remove the CD player See CD Player Removal Installation in Section 15 Body Accessories 11 Remove the HVAC contr...

Page 839: ...ontrol switch electrical con nectors 1 and remove the dimmer control switch 15 Remove the following harnesses from the main harness Body harness Front end module harness Engine control harness A C har...

Page 840: ...6 Remove the wiper switch and high beam switch 17 Remove the glove box assembly and the passen ger side airbag retaining bolts 1 INSTRUMENT PANEL PZSM150117 PZSM150189 15 15 71 Chery Automobile Co Ltd...

Page 841: ...ument panel cover assembly and remove the retaining screw 1 21 Remove the right instrument panel cover assembly and remove the retaining screw 22 Remove the A pillar panel See A Pillar Panel Removal I...

Page 842: ...ning bolt 1 24 Remove the right instrument panel side retaining bolt 25 Remove the hood release lever 1 26 Remove the retaining bolt 2 27 Remove the instrument panel assembly INSTRUMENT PANEL PZSM1502...

Page 843: ...electrical connectors 1 29 Installation is in the reverse order of removal Lower Console Removal Installation 1 Remove the lower console panel retaining screws 1 INSTRUMENT PANEL PZSM150208 PZSM15017...

Page 844: ...2 Remove the shield 1 from the hand brake 3 Remove the shield 1 from the gearshift selector INSTRUMENT PANEL PZSM150171 PZSM150172 15 15 75 Chery Automobile Co Ltd...

Page 845: ...e gear selector shield upward by hand the shield and the lower console are attached with clips and no retaining screws are used 6 Remove the lower console 7 Installation is in the reverse order of rem...

Page 846: ...ture as determined by the Engine Control Module ECM indicating engine coolant temperature Fuel Gauge The IC displays the amount of fuel in the fuel tank as determined by the fuel level sensor 1 Door O...

Page 847: ...cifications DESCRIPTION TORQUE N m Instrument Cluster Bezel Fasteners 2 Instrument Cluster Fasteners 9 Special Tools Diagnostic Scan Tool X 431 Digital Multimeter Fluke 15B 17B INSTRUMENT CLUSTER 15 7...

Page 848: ...Electrical Schematics Instrument Cluster Page 1 of 6 INSTRUMENT CLUSTER PZSMW150012T 15 15 79 Chery Automobile Co Ltd...

Page 849: ...Instrument Cluster Page 2 of 6 INSTRUMENT CLUSTER PZSMW150018T 15 80 Chery Automobile Co Ltd...

Page 850: ...Instrument Cluster Page 3 of 6 INSTRUMENT CLUSTER PZSMW150013T 15 15 81 Chery Automobile Co Ltd...

Page 851: ...Instrument Cluster Page 4 of 6 INSTRUMENT CLUSTER PZSMW150014T 15 82 Chery Automobile Co Ltd...

Page 852: ...Instrument Cluster Page 5 of 6 INSTRUMENT CLUSTER PZSMW150015T 15 15 83 Chery Automobile Co Ltd...

Page 853: ...Instrument Cluster Page 6 of 6 INSTRUMENT CLUSTER PZSMW150016T 15 84 Chery Automobile Co Ltd...

Page 854: ...GND Power 19 Seat Belt Buckle Switch LH 4 20 5 GND Sensor 21 Fuel Level Input 6 22 7 Speed Output 23 8 Reserve 24 9 Oil Pressure Switch 25 10 26 Brake Fluid Level Input 11 Continuous Supply Voltage 2...

Page 855: ...area for any condition that would result in an incorrect signal such as dam age or foreign material Ground Inspection Ground connections are very important to the proper operation of electrical and el...

Page 856: ...nstallation 1 Disconnect the negative battery cable 2 Remove the steering wheel See Steering Wheel Removal Installation in Section 11 Steering 3 Remove the two instrument cluster cover retaining screw...

Page 857: ...he retaining screws 1 around the cluster 6 Disconnect the instrument cluster electrical connector 7 Remove the instrument cluster 8 Installation is in the reverse order of removal ON VEHICLE SERVICE P...

Page 858: ...h Combination Lamp Switch Hazard Switch Console Power Socket Illumination Audio Unit Door Mirror Remote Control Switch Main Power Window Switch Front Power Window Switch Rear Power Window Switch Rear...

Page 859: ...Electrical Schematics Interior Lamps Page 1 of 5 INTERIOR LAMPS PZSMW150045T 15 90 Chery Automobile Co Ltd...

Page 860: ...Interior Lamps Page 2 of 5 INTERIOR LAMPS PZSMW150046T 15 15 91 Chery Automobile Co Ltd...

Page 861: ...Interior Lamps Page 3 of 5 INTERIOR LAMPS PZSMW150048T 15 92 Chery Automobile Co Ltd...

Page 862: ...Interior Lamps Page 4 of 5 INTERIOR LAMPS PZSMW150049T 15 15 93 Chery Automobile Co Ltd...

Page 863: ...Interior Lamps Page 5 of 5 INTERIOR LAMPS PZSMW150050T 15 94 Chery Automobile Co Ltd...

Page 864: ...2 Using a trim tool remove the lamp cover 3 Remove the lamp retaining screws 1 4 Disconnect the electrical connector 1 5 Remove the front dome lamp assembly 6 Installation is in the reverse order of r...

Page 865: ...cigarette lighter The other is located on the right trim panel near the front passenger area CAUTION This power outlet is designed for 12V 120W only Do not use any type of accessory above this rating...

Page 866: ...Electrical Schematics Power Outlet Page 1 of 1 POWER OUTLET PZSMW150031T 15 15 97 Chery Automobile Co Ltd...

Page 867: ...Body Accessories 3 Remove the two power outlet panel retaining screws 1 4 Remove the power outlet panel 5 Remove the four power outlet retaining screws 1 6 Disconnect the power outlet electrical conne...

Page 868: ...window switches on the driver s door trim panel passenger door and rear doors and the power window motors Operation The front and rear power window motors are a permanent magnet type A battery positiv...

Page 869: ...Electrical Schematics Power Window System Page 1 of 3 POWER WINDOWS PZSMW150024T 15 100 Chery Automobile Co Ltd...

Page 870: ...Power Window System Page 2 of 3 POWER WINDOWS PZSMW150025T 15 15 101 Chery Automobile Co Ltd...

Page 871: ...Power Window System Page 3 of 3 POWER WINDOWS PZSMW150026T 15 102 Chery Automobile Co Ltd...

Page 872: ...sembly 1 on the left front door 3 Disconnect the power window switch electrical con nector 1 4 Remove the power window switch assembly 5 Installation is in the reverse order of removal Power Window Mo...

Page 873: ...el 1 from the door trim panel 3 Disconnect the outside mirror switch electrical con nector 1 4 Using a trim stick remove the power window switch assembly 1 on the left front door POWER WINDOWS PZSM150...

Page 874: ...onnect the power window switch electrical con nector 1 6 Using a trim stick remove the inside door handle panel retaining screw cover 1 POWER WINDOWS PZSM150073 PZSM150122 15 15 105 Chery Automobile C...

Page 875: ...7 Remove the inside door handle panel retaining screw 1 8 Remove the inside door handle panel 1 POWER WINDOWS PZSM150123 PZSM150125 15 106 Chery Automobile Co Ltd...

Page 876: ...Loosen the inside door handle panel control cable 1 10 Remove the small storage compartment retaining screw 1 on the door trim panel POWER WINDOWS PZSM150130 PZSM150127 15 15 107 Chery Automobile Co L...

Page 877: ...11 Using a trim stick remove the small storage com partment 1 12 Remove the door switch 1 POWER WINDOWS PZSM150128 PZSM150124 15 108 Chery Automobile Co Ltd...

Page 878: ...panel retaining screws 1 15 Remove the door trim panel 16 Remove the outside mirror retaining nuts 1 and remove the outside mirror electrical connector Tighten Outside mirror retaining nuts to 7 1 N m...

Page 879: ...17 Remove the two door trim panel mounting bracket retaining screws 1 18 Remove the protective film 1 from the front door POWER WINDOWS PZSM150131 PZSM150133 15 110 Chery Automobile Co Ltd...

Page 880: ...19 Lower the glass to a proper position remove the two glass retaining screws 1 20 Remove the window glass 1 POWER WINDOWS PZSM150137 PZSM150139 15 15 111 Chery Automobile Co Ltd...

Page 881: ...trical connector 1 22 Remove the two guide rail mounting nuts 2 23 Remove the three window regulator retaining nuts 1 Tighten Window regulator retaining nuts to 9 1 N m POWER WINDOWS PZSM150138 PZSM15...

Page 882: ...or terminals 2 Verify that the motor operates smoothly when voltage is applied in each direction 3 If the test results are not as specified replace the motor MEASURING CONDITION OPERATIONAL DIRECTION...

Page 883: ...an be adjusted to control eight different seating positions Front Seat Removal Installation NOTE The removal installation of the left seat is shown the right seat is similar 1 Move the seat to the fur...

Page 884: ...nt seat 6 Installation is in the reverse order of removal Rear Seat Removal Installation 1 Remove the rear seat cushion retaining bolts 1 Tighten Rear seat cushion retaining bolts to 25 3 N m SEATS PZ...

Page 885: ...two left side rear seat mounting bolts 1 Tighten Left rear seat mounting bolts to 25 3 N m 5 Remove the two right side rear seat mounting bolts Tighten Right rear seat mounting bolts to 25 3 N m 6 Ope...

Page 886: ...wo middle bolts 1 from the rear seat Tighten Rear seat middle mounting bolts to 25 3 N m 9 Remove the rear seats 10 Installation is in the reverse order of removal SEATS PZSM150106 15 15 117 Chery Aut...

Page 887: ...t key is inserted into the ignition switch Operation When an incorrect key is inserted into the ignition switch the Immobilizer Coil senses the incorrect key and sends a signal to the Immobilizer cont...

Page 888: ...Electrical Schematics Immobilizer Control Module Page 1 of 1 IMMOBILIZER CONTROL MODULE PZSMW150035T 15 15 119 Chery Automobile Co Ltd...

Page 889: ...le PIN CIRCUIT IDENTIFICATION PIN CIRCUIT IDENTIFICATION 1 Continuous Supply Voltage 7 Diagnostic Link K 2 GND 8 W Line 3 9 Coil GND 4 Ignition Switch 10 Coil ANT B 5 R Line 11 Coil ANT A 6 IMMOBILIZE...

Page 890: ...shed out or corroded terminals Inspect the sensor and mounting area for any condition that would result in an incorrect signal such as dam age or foreign material A data recorder and or oscilloscope s...

Page 891: ...t DWA Line Malfunction B3048 DWA Line Short Circuit To Battery B3050 Relay External Line Short Circuit To Ground Or Open Circuit Relay External Line Malfunction B3053 Relay External Line Short Circuit...

Page 892: ...Diagnostic Trouble Code DTC Tests B1000 ECU Defect Internal Errors DIAGNOSIS TESTING PZSMW150035T 15 15 123 Chery Automobile Co Ltd...

Page 893: ...nostic Procedure Step 1 If the DTC is not detected the DTC condition is intermittent See Diagnostic Help and Intermittent DTC Trou bleshooting in Section 15 Body Accessories for more information NOTE...

Page 894: ...or replace the electrical connector as necessary 4 CHECK IMMOBILIZER CONTROL MODULE POWER SUPPLY Connect the negative battery cable Turn ignition switch on Check voltage between the Immobilizer contr...

Page 895: ...ng Continuity should exist Check harness for short to ground Continuity between Immobilizer control module power supply and ground should not exist Is the check result normal Yes Go to the step 7 No C...

Page 896: ...L TERMINAL IMMOBILIZER COIL TERMINAL CONTINUITY 9 10 No 11 10 Is the check result normal Yes Go to the next step No Replace the Immobilizer coil 8 CHECK DTC With the X 431 scan tool read the Immobiliz...

Page 897: ...B3042 W Line Short Circuit To Ground B3043 W Line Short Circuit To Battery Immobilizer Control Module DIAGNOSIS TESTING PZSMW150035T 15 128 Chery Automobile Co Ltd...

Page 898: ...the Immobilizer control module If the DTC is detected the condition is current Go to Diagnostic Procedure Step 1 If the DTC is not detected the DTC condition is intermittent See Diagnostic Help and I...

Page 899: ...ff Disconnect the Immobilizer control module electrical connector C 025 C 026 1 Inspect the electrical connector for damage Is the electrical connector OK Yes Go to the next step No Repair or replace...

Page 900: ...1 scan tool view the DTCs in the Immobilizer control module Is DTC B3042 or B3043 present again Yes Go to the next step No The system is now operating properly The DTC was caused by the Immobilizer co...

Page 901: ...Relay External Line Short Circuit To Ground Or Open Circuit Relay External Line Malfunction B3053 Relay External Line Short Circuit To Battery DIAGNOSIS TESTING PZSMW150035T 15 132 Chery Automobile C...

Page 902: ...switch on with the scan tool view and erase stored DTCs in Immobilizer control module Try to start the engine Turn ignition switch off and wait a few seconds then turn ignition switch on With the scan...

Page 903: ...for damage Is the electrical connector OK Yes Go to the next step No Repair or replace the electrical connector as necessary 4 CHECK IMMOBILIZER CONTROL MODULE POWER SUPPLY Turn ignition switch on Ch...

Page 904: ...uld not exist Is the check result normal Yes Go to the step 7 No Check fuse F2 10A fuse 13 10A and fuse SF1 30A Verify the fuse is OK If not OK refer to the wiring diagram to identify the possible cau...

Page 905: ...mponents 8 REPLACE AND MATCH THE IMMOBILIZER CONTROL MODULE With the X 431 scan tool view active DTCs in the Immobilizer control module Refer to 9DTC Confirmation Procedure9 Is DTC B3050 or B3053 stil...

Page 906: ...B3055 No Transponder Modulation Or No Transponder B3056 No Transponder Fixed Code Programmed DIAGNOSIS TESTING PZSMW150035T 15 15 137 Chery Automobile Co Ltd...

Page 907: ...tool view active DTCs in the Immobilizer control module If the DTC is detected the condition is current Go to Diagnostic Procedure Step 1 If the DTC is not detected the DTC condition is intermittent...

Page 908: ...OK Yes Go to the next step No Repair or replace the electrical connector as necessary 4 CHECK IMMOBILIZER COIL Check the resistance between the Immobilizer coil connector C 026 terminal 9 and terminal...

Page 909: ...nd terminal 10 IMMOBILIZER COIL TERMINAL IMMOBILIZER COIL TERMINAL CONTINUITY 9 10 No 11 10 Continuity should not exist Is the check result normal Yes Go to the next step No Replace the Immobilizer co...

Page 910: ...the electrical schematic as a guide inspect the related wiring and connectors of the Immobilizer control module Verify that there is good terminal contact in the related connectors Try to start the en...

Page 911: ...programmed Transponder Fixed Code Received B3061 Disturbed Or No Challenge Response Transponder Communication B3077 Read Only Transponder Detected DIAGNOSIS TESTING PZSMW150035T 15 142 Chery Automobil...

Page 912: ...th the scan tool view and erase stored DTCs in Immobilizer control module Try to start the engine Turn the ignition switch off and wait a few seconds then turn the ignition switch on With the scan too...

Page 913: ...Immobilizer control module Verify that there is good terminal contact in the related connectors 3 CHECK IMMOBILIZER CONTROL MODULE ELECTRICAL CONNECTOR Turn ignition switch off Disconnect the Immobil...

Page 914: ...l 10 Check the resistance between the Immobilizer coil connector C 026 terminal 11 and terminal 10 IMMOBILIZER COIL TERMINAL IMMOBILIZER COIL TERMINAL CONTINUITY 9 10 None 11 10 Is the check result no...

Page 915: ...sent Yes Go to the next step No No problem found at this time This concern may have been caused by an unprogrammed transponder Erase all codes before returning the vehicle to the customer 7 REPLACE AN...

Page 916: ...inspect the related wiring and connectors of the ECM Verify that there is good terminal contact in the related connectors Attempt to start the engine With the X 431 scan tool view active DTCs in the I...

Page 917: ...ontrol module retaining bolt 1 3 Disconnect the Immobilizer control module electri cal connectors 2 4 Remove the Immobilizer control module 5 Installation is in the reverse order of removal Installati...

Page 918: ...o the Immobilizer control module With the X 431 scan tool choose A1 series Choose 9immobilize9 Choose 9input code9 Input the safety code Click the small keyboard Click 9OK9 Choose 9Immobilizer adapt9...

Page 919: ...ration Is the check result normal Yes Go to the next step No Repair or replace the ignition lock cylinder key switch 3 PERFORM THE RKE TRANSMITTER MATCH PROCEDURE Close all the doors Insert the igniti...

Page 920: ...the key from the ignition switch Press the lock button on the RKE transmitter for less than 2 seconds Try to operate the RKE transmitter Does the RKE transmitter operate properly Yes Then click OK to...

Page 921: ...ion 15 195 Electrical Schematics 15 196 Front Combination Lamp Assembly 15 205 Removal Installation 15 205 Headlamp Adjustment Procedure 15 206 Rear Combination Lamp Assembly 15 207 Removal Installati...

Page 922: ...5 239 Description 15 239 Electrical Schematics 15 240 Front Windshield 15 241 Removal 15 241 Installation 15 241 Rear Window 15 243 Removal 15 243 Installation 15 243 WIPERS AND WASHERS 15 246 Descrip...

Page 923: ...efore taking measurements for underbody alignment Monitor the upper body structure for excessive stress or movement while making any corrections to the under body structure Remove all the necessary gl...

Page 924: ...hood and headlamp at 2 2 5 1 mm 1 Front Compartment Cover 3 Inner Layer Of Front Compartment Cover 2 Latch Supporting Plate 4 Front Compartment Cover Seal Strip 1 Headlamp 2 Front compartment cover 3...

Page 925: ...r inlet grid at 3 3 1 1 mm Clearance between the front windshield and the vehicle roof at 4 4 6 1 mm 1 Air Inlet Grille 2 Headlamp 1 Front Windscreen 2 Vehicle Roof BODY DIMENSIONS PZSM150004 PZSM1500...

Page 926: ...t View Body Left Front Dimensions Units mm Clearance between front bumper and front fender at 5 5 0 0 5 mm 1 Front Bumper 2 Front Fender BODY DIMENSIONS PZSM150006 PZSM150007 15 15 157 Chery Automobil...

Page 927: ...nder and A pillar side wall at 7 7 3 mm Clearance between front fender and front vehicle doors at 8 8 4 1 mm 1 Front Compartment Cover 2 Front Fender 1 A pillar 2 Front Fender 1 Front Fender 2 Front D...

Page 928: ...front vehicle doors and vehicle roof 10 10 4 1 mm Clearance between front door and rear door at 11 11 4 1 mm 1 Vehicle Roof 2 A Pillar 3 Front Door 1 Vehicle Roof 2 Front Door 1 Front Door 2 Rear Door...

Page 929: ...door and rear door at 12 12 4 1 mm Clearance between rear door and rear fender side wall at 13 13 4 1 mm 1 Front Door 2 Rear Door 1 Rear Door 2 Rear Fender BODY DIMENSIONS PZSM150014 PZSM150015 15 160...

Page 930: ...rance between rear door and C pillar at 15 15 4 1 mm Clearance between rear windshield and C pillar at 16 16 5 1 mm 1 C Pillar 2 Rear Hatch 1 Rear Door 2 C Pillar 1 Rear Windscreen 2 C Pillar BODY DIM...

Page 931: ...rear bumper and rear fender at 19 19 0 0 5 mm Clearance between front fender and sill decorative board side wall at 20 20 2 1 mm 1 Rear Fender 2 Gas Tank Cover 1 Rear Fender 2 Rear Bumper 1 Rear Fende...

Page 932: ...etween front door and sill decorative board side wall at 21 21 6 1 mm Back View Body Back Dimensions 1 Front Fender 2 Sill Decorative Board BODY DIMENSIONS PZSM150022 PZSM150023 15 15 163 Chery Automo...

Page 933: ...window and trunk door at 23 23 4 1 mm Clearance between trunk door and rear bumper at 24 24 21 1 mm 1 Vehicle Roof 2 Trunk Door 3 Rear Windscreen 1 Rear Windscreen 2 Trunk Door 1 Trunk Door 2 Rear Bu...

Page 934: ...rear fender side wall at 26 26 4 1 mm Clearance between tail lamp and rear bumper at 27 27 2 1 mm 1 Rear Fender 2 Tail Lamp 3 Rear Windscreen 1 Rear Fender 2 Tail Lamp 3 Rear Fender 1 Tail Lamp 2 Rea...

Page 935: ...Front Bumper Cross Beam Mounting Hole F 11 C D E F Headlight Mounting Hole F 7 G H Engine Right Suspension Bracket Mounting Hole F 13 NO NAME DIAMETER I J Installation Of Fender F 8 K L Shock Absorbe...

Page 936: ...Body Openings Body Opening Dimensions BODY DIMENSIONS PZSM150031 15 15 167 Chery Automobile Co Ltd...

Page 937: ...Windshield Windshield Dimensions Units mm BODY DIMENSIONS PZSM150032 15 168 Chery Automobile Co Ltd...

Page 938: ...he front combination lamp See Front Combination Lamp Removal Installation in Section 15 Body Accessories 3 Remove the bumper retaining clips 2 under the combination lamp and the two bumper side retain...

Page 939: ...rs 1 7 Remove the lower bumper retaining bolts Tighten Lower bumper retaining bolts to 11 1 N m 8 Lower the vehicle and remove the front bumper 9 Disconnect the front fog lamp left and right 10 Instal...

Page 940: ...Dust shield connecting bolts to 5 0 5 N m 2 Remove the four left and right bumper retaining bolts 3 Raise the vehicle and remove the bumper lower connecting retainers 1 4 Lower the vehicle and remove...

Page 941: ...5 Remove the rear bumper 1 6 Remove the parking sonar 1 BUMPERS PZSM150113 PZSM150114 15 172 Chery Automobile Co Ltd...

Page 942: ...parking sonar and remove the sonar sensor 1 8 Disconnect the license plate lamp electrical con nector 1 9 Installation is in the reverse order of removal BUMPERS PZSM150116 PZSM150115 15 15 173 Chery...

Page 943: ...ng bolts to 63 5 N m 4 Remove the front door 5 Installation is in the reverse order of removal Installation Notes Adjust the door in the left right and vertical directions Disassembly 1 Turn the ignit...

Page 944: ...ing a trim stick remove the power window switch assembly 1 on the left front door 5 Disconnect the power window switch electrical con nector 1 DOORS PZSM150126 PZSM150073 15 15 175 Chery Automobile Co...

Page 945: ...6 Using a trim stick remove the inside door handle retaining screw cover 1 7 Remove the inside door handle retaining screw 1 DOORS PZSM150122 PZSM150123 15 176 Chery Automobile Co Ltd...

Page 946: ...8 Remove the inside door handle 1 9 Loosen the inside door handle control cable 1 DOORS PZSM150125 PZSM150130 15 15 177 Chery Automobile Co Ltd...

Page 947: ...0 Remove the small storage compartment retaining screw 1 on the door trim panel 11 Using a trim stick remove the small storage com partment 1 DOORS PZSM150127 PZSM150128 15 178 Chery Automobile Co Ltd...

Page 948: ...switch 1 13 Disconnect the door switch electrical connector 1 14 Remove the door trim panel four retaining screws 1 15 Remove the door trim panel DOORS PZSM150124 PZSM150145 PZSM150129 15 15 179 Chery...

Page 949: ...g nuts 1 and remove the outside mirror electrical connector Tighten Outside mirror retaining nuts to 7 1 N m 17 Remove the two door trim panel mounting bracket retaining screws 1 DOORS PZSM150134 PZSM...

Page 950: ...18 Remove the protective film 1 from the front door 19 Remove the front speaker retaining screws 1 DOORS PZSM150133 PZSM150132 15 15 181 Chery Automobile Co Ltd...

Page 951: ...ect the speaker electrical connector 1 21 Remove the speaker 22 Lower the door glass to a proper position remove the two door glass retaining screws 1 DOORS PZSM150135 PZSM150137 15 182 Chery Automobi...

Page 952: ...23 Remove the door glass 1 24 Disconnect the window motor electrical connector 1 DOORS PZSM150139 PZSM150138 15 15 183 Chery Automobile Co Ltd...

Page 953: ...nting nuts 2 26 Remove the three window regulator retaining nuts 1 Tighten Window regulator retaining nuts to 9 1 N m 27 Remove the window regulator and guide rail assembly DOORS PZSM150136 PZSM150140...

Page 954: ...motor retaining bolts to 8 1 N m 29 Disconnect the power lock motor electrical connec tor 1 30 Disconnect the door lock motor connecting rod to the outside door handle 31 Remove the power door lock m...

Page 955: ...ling the power window assembly it should be checked The time for the glass to travel from the lowest position to the highest position should be about 7 seconds If the time is too long recheck the oper...

Page 956: ...and then remove the hinges Rear Door Removal Installation 1 Turn the ignition switch off 2 Disconnect the inner electrical harness connector 2 on the rear door 3 Remove the four rear door mounting bo...

Page 957: ...1 2 Remove the power window switch 2 and discon nect the electrical connector 3 Remove the small storage compartment 1 retain ing screw on the door trim panel and remove the small storage compartment...

Page 958: ...4 Remove the inner door handle panel retaining screw cover 1 5 Remove the inner door handle retaining screw 1 DOORS PZSM150149 PZSM150150 15 15 189 Chery Automobile Co Ltd...

Page 959: ...ndle 8 Remove the door trim panel CAUTION While servicing the door panels care should be taken to maintain a clean work environment 9 Remove the two door mounting bracket retaining screws 1 and remove...

Page 960: ...the electrical connector from the win dow regulator 3 14 Remove the three window regulator retaining nuts 1 Tighten Window regulator retaining nuts to 9 1 N m 15 Remove the two window guide rail retai...

Page 961: ...17 Remove the power lock motor retaining screws 1 18 Disconnect the power lock motor electrical connec tor 1 19 Remove the power lock motor DOORS PZSM150157 PZSM150155 15 192 Chery Automobile Co Ltd...

Page 962: ...e door check bolts 2 Support the door 3 Remove the retaining bolts from the upper and lower hinges and then remove the hinges Rear Hatch Removal Installation 1 Disconnect the negative battery cable 2...

Page 963: ...he four bolts 1 two on the left and two on the right to remove the rear hatch Tighten Rear hatch bolts to 20 1 N m 8 Disconnect the rear hatch electrical connector 3 9 Remove the rear hatch 10 Install...

Page 964: ...ON posi tion voltage is applied to the RH or LH turn signal circuit Hazard Lamps When the hazard switch is in the ON position voltage is applied to all the turn signal lamps Fog Lamps When the front...

Page 965: ...Electrical Schematics Headlamp System Page 1 of 2 EXTERIOR LAMPS PZSMW150001T 15 196 Chery Automobile Co Ltd...

Page 966: ...Headlamp System Page 2 of 2 EXTERIOR LAMPS PZSMW150002T 15 15 197 Chery Automobile Co Ltd...

Page 967: ...Parking License Plate and Tail Lamps Page 1 of 2 EXTERIOR LAMPS PZSMW150003T 15 198 Chery Automobile Co Ltd...

Page 968: ...Parking License Plate and Tail Lamps Page 2 of 2 EXTERIOR LAMPS PZSMW150004T 15 15 199 Chery Automobile Co Ltd...

Page 969: ...Fog Lamps Page 1 of 1 EXTERIOR LAMPS PZSMW150005T 15 200 Chery Automobile Co Ltd...

Page 970: ...Turn Signal and Hazard Warning Lamps Page 1 of 2 EXTERIOR LAMPS PZSMW150007T 15 15 201 Chery Automobile Co Ltd...

Page 971: ...Turn Signal and Hazard Warning Lamps Page 2 of 2 EXTERIOR LAMPS PZSMW150008T 15 202 Chery Automobile Co Ltd...

Page 972: ...Stop Lamp Page 1 of 1 EXTERIOR LAMPS PZSMW150006T 15 15 203 Chery Automobile Co Ltd...

Page 973: ...Backup Lamps Page 1 of 1 EXTERIOR LAMPS PZSMW030062T 15 204 Chery Automobile Co Ltd...

Page 974: ...the hood 2 Disconnect the front combination lamp assembly electrical connector 3 Remove the grille retaining screws 1 4 Remove the three front combination lamp assem bly retaining bolts 1 EXTERIOR LA...

Page 975: ...hicle should be parked on a level surface The headlights are clean The headlights are working properly 2 Park the vehicle on a level surface approximately 10 meters from the vertical wall or screen di...

Page 976: ...moval Installation 1 Open the rear hatch 2 Removal the two rear combination lamp retaining screws 1 3 Disconnect the rear combination lamp electrical connector 1 EXTERIOR LAMPS PZSM150078 PZSM150111 1...

Page 977: ...Removal Installation 1 Disconnect the negative battery cable 2 Remove the three front fog lamp retaining screws 1 1 Rear Turn Signal Lamp Bulb 12 V 21 W 2 Stop Lamp 12 V 21 W 3 Rear Position Lamp Bul...

Page 978: ...rn the ignition switch off 2 Open the rear hatch 3 Remove the high mounted stop lamp cover 1 4 Remove the high mounted stop lamp mounting screws 1 5 Disconnect the high mounted stop lamp electrical co...

Page 979: ...p electrical con nector 2 4 Replace the bulb 5 Installation is in the reverse order of removal License Plate Lamp Removal Installation 1 Using a plastic trim stick remove the license plate lamp 1 2 Di...

Page 980: ...nstallation in Section 15 Body Accessories 2 Remove the bolts connecting the fender and the dust shield 3 Remove the bolts 1 on the fender apron 4 Remove the bolts connecting the fender to the body 5...

Page 981: ...uel Door Removal Installation 1 Open the fuel door 2 Remove the two fuel door retaining bolts 1 3 Remove the fuel door 4 Installation is in the reverse order of removal PZSM150092 15 212 Chery Automob...

Page 982: ...le Removal Installation 1 Open the hood 2 Remove the grille retaining screws 1 3 Remove the grille from the vehicle 4 Installation is in the reverse order of removal PZSM150081 15 15 213 Chery Automob...

Page 983: ...HOOD Hood Removal Installation 1 Loosen the windshield washer hose and then remove the spray nozzle 1 2 Remove the washer hose 1 PZSM150119 PZSM150070 15 214 Chery Automobile Co Ltd...

Page 984: ...er of removal Hood Release Cable Removal Installation 1 Remove the left fender inner lining See Fender Removal Installation in Section 15 Body Accessories 2 Remove the hood lock retaining screws 1 and...

Page 985: ...lease lever retaining bolt 2 4 Remove the hood release lever 1 5 Remove the hood release cable from the hood release lever 6 Installation is in the reverse order of removal HOOD PZSM150207 15 216 Cher...

Page 986: ...Rack Removal Installation 1 Remove the luggage rack bolt covers and then remove the mounting bolts 1 2 Remove the luggage rack 3 Installation is in the reverse order of removal PZSM150088 15 15 217 Ch...

Page 987: ...orn The horns are located under the headlamp in the front bumper Horn Switch The horn switch is located under the driver airbag Operation The horns operate on voltage supplied by the horn relay in the...

Page 988: ...Electrical Schematics Horn Page 1 of 1 HORN PZSMW150030T 15 15 219 Chery Automobile Co Ltd...

Page 989: ...nnect the negative battery cable 2 Disconnect the horn electrical connectors 2 3 Remove the horn retaining bolts 1 and remove the horns 4 Installation is in the reverse order of removal HORN PZSM15019...

Page 990: ...Right Left directions The heated mirror system is controlled by Body Control Module BCM When there is water vapor on the mirrors the heated mirrors will eliminate the water vapor Operation Use the mir...

Page 991: ...Electrical Schematics Power Mirrors Page 1 of 2 MIRRORS PZSMW150033T 15 222 Chery Automobile Co Ltd...

Page 992: ...Power Mirrors Page 2 of 2 MIRRORS PZSMW150038T 15 15 223 Chery Automobile Co Ltd...

Page 993: ...urn the ignition switch off 2 Using a trim stick remove the outside mirror switch panel 1 from the door trim panel 3 Disconnect the outside mirror switch electrical con nector 1 MIRRORS PZSM150120 PZS...

Page 994: ...ighten Outside mirror retaining nuts to 7 1 N m 5 Remove the outside mirror 6 Installation is in the reverse order of removal Installation Notes If replacing the outside mirror lens remove the lens an...

Page 995: ...PAINT Paint Codes Specification NO COLOR ITEM CODE 1 Jade Blue GE 2 Indicolite Gold DY 3 Dark Iron Gray GH 4 Cuprite Red NA 5 Aegean Blue HU 6 Azure Blue VC 15 226 Chery Automobile Co Ltd...

Page 996: ...und continuously Operation With power and ground supplied transaxle gear selector lever in 9R9 position the rear sonar sensor will detect obsta cles within 1 5 m of the rear sonar sensors The sensor s...

Page 997: ...Electrical Schematics Parking Sonar Page 1 of 1 PARKING SONAR PZSMW150067T 15 228 Chery Automobile Co Ltd...

Page 998: ...emoval Installation 1 Disconnect the negative battery cable 2 Remove the rear bumper 1 See Rear Bumper Removal Installation in Section 15 Body Accessories PARKING SONAR PZSM150113 15 15 229 Chery Auto...

Page 999: ...emove the parking sonar 1 4 Disconnect the parking sonar and remove the sonar sensor 1 5 Installation is in the reverse order of removal PARKING SONAR PZSM150114 PZSM150116 15 230 Chery Automobile Co...

Page 1000: ...nel Removal Installation in Section 15 Body Accesso ries 2 Remove the sonar module retaining bolts 1 3 Disconnect the sonar module electrical connector 4 Remove the sonar module 5 Installation is in t...

Page 1001: ...SUNROOF Description BESM150008 15 232 Chery Automobile Co Ltd...

Page 1002: ...10 Sunroof Glass 11 Guiding Gutter 12 Sun Visor 13 Operation The sunroof control module monitors the sunroof switch input The sunroof control module controls the output of the sunroof motor to move t...

Page 1003: ...Electrical Schematics Sunroof Page 1 of 1 SUNROOF PZSMW150065T 15 234 Chery Automobile Co Ltd...

Page 1004: ...will need to be initialized 2 Sunroof Mechanical Failure If after the sunroof has been used for a period of time and can not be closed in position there is a gap between mechanical components The time...

Page 1005: ...full tilt position 2 Disconnect the negative battery cable 3 Push the inner trim strip left and right inner side cover rearwards to remove 4 Remove the headliner See Headliner Removal Installation in...

Page 1006: ...Remove the sunroof module electrical connector 2 8 Remove the ten sunroof retaining bolts 1 9 Remove the sunroof assembly 10 Installation is in the reverse order of removal ON VEHICLE SERVICE PZSM1502...

Page 1007: ...l Installation in Section 15 Body Accessories 3 Remove the front bumper See Front Bumper Removal Installation in Section 15 Body Accessories 4 Remove the horns See Horn Removal Installation in Section...

Page 1008: ...STATIONARY GLASS Description The stationary glass is comprised of the following Front Windshield Rear Window Rear Window Defogger 15 15 239 Chery Automobile Co Ltd...

Page 1009: ...Electrical Schematics Rear Window Defogger Page 1 of 1 STATIONARY GLASS PZSMW150027T 15 240 Chery Automobile Co Ltd...

Page 1010: ...ass 3 Pull the piano wire around the glass and cut off the bonding agent to remove the glass NOTE Leave as much bonding agent as possible on the body when removing the bonding portion of the glass Ins...

Page 1011: ...rush NOTE Allow the primer coat to dry for a minimum of 3 minutes Do not apply the primer to the bonding agent Do not save the opened primer M for later use 9 Apply a layer of primer G on the contact...

Page 1012: ...ll the upper windshield molding on the body and tap it lightly to fasten it Install the outer windshield molding Rear Window Removal 1 Open the rear hatch 2 Remove the rear hatch trim panel 3 Remove t...

Page 1013: ...primer M for later use 8 Apply a layer of primer G on the contact surface of the glass Apply a layer of primer G on the edges and the contact surface of the glass with a brush or sponge Wipe the exce...

Page 1014: ...g agent with a scraper 14 Clamp the glass until the bonding agent has hard ened 15 Check for water leakage Perform the leakage test after the hardening period Seal any leaks with the proper sealant 16...

Page 1015: ...per Arm Wiper Link Washer Bottle Washer Motor Operation The wiper system is controlled by the wiper and washer switch The wiper and washer system operate with the ignition switch is in the ON position...

Page 1016: ...Electrical Schematics Wiper and Washer System Page 1 of 2 WIPERS AND WASHERS PZSMW150032T 15 15 247 Chery Automobile Co Ltd...

Page 1017: ...Wiper and Washer System Page 2 of 2 WIPERS AND WASHERS PZSMW150036T 15 248 Chery Automobile Co Ltd...

Page 1018: ...he wiper motor electrical connector 3 Remove the front wiper motor 4 Installation is in the reverse order of removal Rear Wiper Motor Removal Installation 1 Remove the rear wiper arm retaining nut 1 2...

Page 1019: ...3 Remove the rear hatch trim panel 1 4 Disconnect the rear wiper motor electrical connec tor 1 WIPERS AND WASHERS PZSM150146 PZSM150147 15 250 Chery Automobile Co Ltd...

Page 1020: ...reverse order of removal Front Wiper Arm Removal Installation 1 Remove the two protective covers 1 from the wiper arm retaining nuts 2 Remove the two wiper arm retaining nuts 2 3 Remove the two wiper...

Page 1021: ...1 Remove the rear wiper arm retaining nut 1 2 Remove the rear wiper arm 3 Installation is in the reverse order of removal Front Wiper Linkage Removal Installation 1 Remove the front wiper motor retai...

Page 1022: ...s 2 4 Remove the two wiper arms 5 Remove the lower trim panel retaining screws 1 of front windshield 6 Remove the retaining bolts 1 from the linkage 7 Remove the wiper linkage 8 Installation is in the...

Page 1023: ...ody Accessories 2 Disconnect the washer hose and the washer pump electrical connector 2 3 Remove the retaining bolts 1 as shown to remove the washer bottle 4 Remove the washer bottle 5 Remove the wash...

Page 1024: ...move the steering wheel See Steering Wheel Removal Installation in Section 11 Steering 3 Disconnect the wiper switch electrical connector 4 Remove the wiper switch 5 Installation is in the reverse ord...

Page 1025: ...al Symbols 16 3 ELECTRICAL TROUBLESHOOTING 16 5 Troubleshooting Wiring Problems 16 5 Testing For Voltage 16 5 Testing For Continuity 16 5 Testing For A Short To Ground 16 5 Intermittent and Poor Conne...

Page 1026: ...electrical schematics are designed to provide information regarding the vehicles wiring content In order to effectively use the electrical schematics to diagnose and repair Chery vehicles it is import...

Page 1027: ...used throughout the electrical schematics These symbols are consistent with those being used around the world See How to Read Electrical Schematics in Section 01 General Information GENERAL INFORMATI...

Page 1028: ...nal depending on vehicle application 11 Option abbreviation This represents that the circuit is optional depending on vehicle application 12 Ground GND This represents the ground connection See Ground...

Page 1029: ...isconnect the battery 2 Connect one lead of the ohmmeter to one side of the circuit being tested 3 Connect the other lead to the other end of the circuit being tested low or no resistance means good c...

Page 1030: ...r source line to a body ground This may cause burning or other damage to wiring harnesses or electronic components Voltmeter The DC voltmeter is used to measure circuit volt age A voltmeter with a ran...

Page 1031: ...tween two points in a circuit and to check for continuity and short circuits CAUTION Do not connect the ohmmeter to any circuit where voltage is applied This will damage the ohmmeter ELECTRICAL TROUBL...

Page 1032: ...ether NOTE Do not use acid core solder when making wiring repairs 5 Solder the connection together using a soldering iron and rosin core type solder only 6 Center the heat shrink tubing over the joint...

Page 1033: ...ative battery cable Sensors Switches and Relays Handle sensors switches and relays carefully Do not drop them or strike them against other objects Connectors Disconnecting Connectors When disconnectin...

Page 1034: ...cking Connector When locking connectors listen for a click indicat ing they are securely locked Connector Terminals Pull lightly on individual wires to check that they are secured in the terminal ELEC...

Page 1035: ...e 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 termin...

Page 1036: ...VEHICLE POWER DISTRIBUTION GENERAL INFORMATION 16 13 Description 16 13 Operation 16 13 ELECTRICAL SCHEMATICS 16 14 Electrical Schematics 16 14 16 12 Chery Automobile Co Ltd...

Page 1037: ...perate all vehicle electrical and electronic systems The following components are used for power distribution Battery Body Fuse and Relay Box Front Fuse and Relay Box Ignition Switch Fuses Circuit Bre...

Page 1038: ...include all wiring information detailed on the power side of all vehicle circuits This is helpful when attempting to troubleshoot a specific electrical failure and shows connector pin out infor matio...

Page 1039: ...Power Distribution Page 2 of 7 ELECTRICAL SCHEMATICS PZSMW160017T 16 16 15 Chery Automobile Co Ltd...

Page 1040: ...Power Distribution Page 3 of 7 ELECTRICAL SCHEMATICS PZSMW160018T 16 16 Chery Automobile Co Ltd...

Page 1041: ...Power Distribution Page 4 of 7 ELECTRICAL SCHEMATICS PZSMW160019T 16 16 17 Chery Automobile Co Ltd...

Page 1042: ...Power Distribution Page 5 of 7 ELECTRICAL SCHEMATICS PZSMW160020T 16 18 Chery Automobile Co Ltd...

Page 1043: ...Power Distribution Page 6 of 7 ELECTRICAL SCHEMATICS PZSMW160021T 16 16 19 Chery Automobile Co Ltd...

Page 1044: ...Power Distribution Page 7 of 7 ELECTRICAL SCHEMATICS PZSMW160022T 16 20 Chery Automobile Co Ltd...

Page 1045: ...VEHICLE GROUND DISTRIBUTION GENERAL INFORMATION 16 22 Description 16 22 Operation 16 22 ELECTRICAL SCHEMATICS 16 23 Electrical Schematics 16 23 16 16 21 Chery Automobile Co Ltd...

Page 1046: ...centralized and convenient ground locations for the entire vehi cle electrical system Operation The ground distribution system provides a grounding path for all electrical and electronic engine trans...

Page 1047: ...nclude all wiring information detailed on the ground side of all vehicle circuits This is helpful when attempting to troubleshoot a specific electrical failure and shows connector pin out infor mation...

Page 1048: ...Ground Distribution Page 2 of 5 ELECTRICAL SCHEMATICS PZSMW160015T 16 24 Chery Automobile Co Ltd...

Page 1049: ...Ground Distribution Page 3 of 5 ELECTRICAL SCHEMATICS PZSMW160023T 16 16 25 Chery Automobile Co Ltd...

Page 1050: ...Ground Distribution Page 4 of 5 ELECTRICAL SCHEMATICS PZSMW160012T 16 26 Chery Automobile Co Ltd...

Page 1051: ...Ground Distribution Page 5 of 5 ELECTRICAL SCHEMATICS PZSMW160013T 16 16 27 Chery Automobile Co Ltd...

Page 1052: ...FORMATION 16 29 Description 16 29 Operation 16 29 Front Fuse and Relay Box 16 29 Description 16 29 Operation 16 29 Overview 16 30 Body Fuse and Relay Box 16 31 Description 16 31 Operation 16 31 Overvi...

Page 1053: ...circuit that must be corrected Front Fuse and Relay Box Description The front fuse and relay box houses many of the fuses and relays for the vehicles electrical system The front fuse and relay box is...

Page 1054: ...Overview Front Fuse and Relay Box GENERAL INFORMATION PZSMW160004T 16 30 Chery Automobile Co Ltd...

Page 1055: ...side of the interior of the cabin and under the instrument panel which is mounted on the cross beam of the instrument panel All the fuses and relays cannot be serviced it must be replaced as a unit O...

Page 1056: ...Overview Body Fuse and Relay Box GENERAL INFORMATION PZSMW160009T 16 32 Chery Automobile Co Ltd...

Page 1057: ...5 Vehicle Harness Layout 16 35 Engine Control Harness 16 36 Engine Room Harness 16 38 Main Harness 16 40 Body Harness 16 42 Front Door LH Harness 16 44 Front Door RH Harness 16 45 Rear Door RH Harness...

Page 1058: ...rness Back Door Harness Restraints Harness Body SUB Harness and Parking Sonar Harness Operation Use the wiring harness diagrams in each harness section for component ground and splice identification R...

Page 1059: ...VEHICLE HARNESS ROUTING MAPS Vehicle Harness Layout Vehicle Harness Layout Page 1 of 1 PZSMW160001T 16 16 35 Chery Automobile Co Ltd...

Page 1060: ...Engine Control Harness VEHICLE HARNESS ROUTING MAPS PZSMW160003T 16 36 Chery Automobile Co Ltd...

Page 1061: ...up Lamp Switch C4 E 022 B 2 Canister Control Valve D4 E 027 B 6 Electronic Throttle Control Actuator D3 E 030 B 1 Battery D5 E 031 B 1 Starter Motor C3 E 032 B 1 Generator D2 E 033 B 4 Manifold Absolu...

Page 1062: ...Engine Room Harness VEHICLE HARNESS ROUTING MAPS PZSMW160024T 16 38 Chery Automobile Co Ltd...

Page 1063: ...Speed Sensor LH Front D4 A 020 B 2 Wheel Speed Sensor RH Front D5 A 021 B 2 Side Turn Signal Lamp LH E5 A 022 B 2 Side Turn Signal Lamp RH E1 A 023 B 2 A C Pressure Switch D2 A 025 B 25 ABS Hydraulic...

Page 1064: ...Main Harness VEHICLE HARNESS ROUTING MAPS PZSMW160002T 16 40 Chery Automobile Co Ltd...

Page 1065: ...019 B 6 Dimmer Control Switch D2 C 020 Body Fuse and Relay Box C1 C 022 G 16 Data Link Connector E5 C 024 B 2 Clutch Pedal Switch C2 C 025 B 8 Immobilizer Control Module E1 C 030 Blower Relay D1 C 03...

Page 1066: ...Body Harness VEHICLE HARNESS ROUTING MAPS PZSMW160030T 16 42 Chery Automobile Co Ltd...

Page 1067: ...034 W 2 Trunk Lamp D5 B 042 w 1 Front Door Unlock Switch LH C4 B 043 w 1 Rear Door Unlock Switch LH C4 B 044 B 4 Front Door Unlock Switch RH D2 B 045 W 18 Rear Door Unlock Switch RH D3 B 050 W 14 Sun...

Page 1068: ...wer Window Motor LH D 003 B 3 Outside Mirror LH D 004 B 2 Front Speaker LH D 005 B 10 Outside Mirror Remote Control Switch D 006 B 4 Front Door Lock Assembly LH D 007 W 2 Security Lamp D 101 W 14 To B...

Page 1069: ...witch RH G 002 W 2 Front Power Window Motor RH G 003 B 3 Outside Mirror RH G 004 B 2 Front Speaker RH G 006 W 4 Front Door Lock Assembly RH G 100 W 10 To B 108 G 101 W 6 To B 107 VEHICLE HARNESS ROUTI...

Page 1070: ...Harness I 001 W 10 Rear Power Window Switch LH I 002 B 2 Rear Power Window Motor LH I 003 B 4 Rear Door Lock Assembly LH I 100 B 10 To B 103 VEHICLE HARNESS ROUTING MAPS PZSMW160007T 16 46 Chery Autom...

Page 1071: ...arness H 001 W 10 Rear Power Window Switch RH H 002 B 2 Rear Power Window Motor RH H 003 B 4 Rear Door Lock Assembly RH H 100 B 10 To B 109 VEHICLE HARNESS ROUTING MAPS PZSMW160008T 16 16 47 Chery Aut...

Page 1072: ...4 Back Door Lock Assembly Rear Wiper Motor L 100 GR 4 Back Door Lock Assembly To B 110 L 103 B1 To L 401 L 201 W 2 Ground L 301 B 2 Rear Window Defogger L 302 W 2 Rear Window Defogger L 401 W 14 To B...

Page 1073: ...001 W 25 Restraints Control Module J 002 G 2 Front Passenger Airbag J 003 G 2 Driver Airbag J 005 B 2 Spiral Cable J 100 W 6 To C 101 J 201 Ground VEHICLE HARNESS ROUTING MAPS PZSMW160011T 16 16 49 Ch...

Page 1074: ...cense Plate Lamp LH B 302 W 2 License Plate Lamp RH B 401 W 2 To B 111 R 001 W 7 Sonar Module R 002 W 8 Sonar Module R 003 B 2 Rear Sonar LH R 004 B 2 Rear Sonar RH R 101 W 2 To B 120 VEHICLE HARNESS...

Page 1075: ...8 Brake Pedal Base Brakes 12 20 Bumpers Body Exterior 15 169 C C Pillar Trim Panel Body Interior 15 13 Camshaft Position Sensor 1 3L Engine Controls 3 172 Camshaft 1 3L Engine Mechanical 2 22 2 69 CAN...

Page 1076: ...16 6 Electrical Troubleshooting Wiring Information 16 5 Electronic Throttle Control Actuator 1 3L Engine Controls 3 175 Engine Assembly 1 3L Engine Mechanical 2 33 Engine Block 1 3L Engine Mechanical...

Page 1077: ...ontrol 13 2 General Information Parking Brake 12 81 General Information Power Steering Pump 11 38 General Information Rear Axle 9 9 General Information Rear Suspension 10 28 General Information Seat B...

Page 1078: ...Cooling System 6 8 On Vehicle Service Evaporative Emissions 3 211 On Vehicle Service Exhaust System 7 5 On Vehicle Service Front Axle 9 5 On Vehicle Service Front Suspension 10 6 On Vehicle Service Fu...

Page 1079: ...dy Exterior 15 249 Recirculation Door Actuator System Controls 13 18 Remote Keyless Entry RKE Inoperative Body Interior 15 150 Restraints Control Module RCM Airbag System 14 38 Reverse Shift Fork 5 Sp...

Page 1080: ...cle Identification Number VIN Vehicle Information 1 10 Vehicle Information 1 9 Vehicle Power Distribution 16 12 Vehicle Service Preparation Service Information 1 3 Vehicle Speed Sensor 1 3L Engine Con...

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