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Chery A11 2003, Repair Manual, Page: 160 / 784

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Chery A11 2003 Repair Manual Download Page 160

CAC Gasoline Engine Maintenance And Servicing Manual 

16 

 

Engine maintenance

：

 

Daily maintenance 

——

 Check lubricant level 

                         

——

 Check coolant level 

                 

           

——

 Check bolt for loosing 

                                 

——

 Check for leaking (oil, water, air) 

        Per8000km 

——

 Replace engine oil and oil filter 

                                 

——

 Clean air filter

，

check air intake tube for cracking 

                 

           

——

 Check PCV valve 

                         

——

 Check spark plugs 

        Per16000km 

——

 Check accessories drive belt 

                         

——

 Check timing belt and tension pulley 

                           

——

 Check radiator and hoses for leaking 

        Per30000km 

——

 Replace fuel filter 

        Per32000km 

——

 Replace spark plug 

                           

——

 Check high-tension wire 

        Per45000km 

——

 Check lambda sensor function 

        Per48000km       

——

 Replace corrosion preventive coolant and clean cooling system 

                         

——

 Replace air filter 

        Per64000km 

——

 Replace timing belt 

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Summary of Contents for A11 2003

Page 1: ...front compartment harness shortening the current path Comparing with old wiring harness main changes in wiring harness and electrical devices are as follows Interior harness front compartment harness...

Page 2: ...No 1 Central Electrical Box Fuse And Relay Position 2 Pages No 2 Central Electrical Box Connector Position And Function 3 Pages No 3 Circuit Manual Explanation 2 Pages No 4 Circuit 23 Pages No 5 ET Ve...

Page 3: ...ght Sound Headlight Switch Rear Window Heater Gauge Wiper A C Horn Fog light Brake Light Thermo Switch Glass Lifter Central Locking Cigar Lighter Emergency Warning Indicator Gauge Anti Theft Unit Powe...

Page 4: ...Switch Fog Light Wiper Ceiling lamp Luggage Compartment Lamp Sound Brake Light Cigar Lighter A C Clutch Horn Gauge Relay Block Fuses Position II At Right side of Front Compartment Radiator Fan Control...

Page 5: ...CIRCUIT Central Electrical Box Connector Position Central Electrical Box Connector Position FRONT SIDE VIEW BACK SIDE VIEW 1...

Page 6: ...ic Power 15 12 13 Combination Instrument Power Positive 30 14 Brake Switch 138 247 134 132 114 192 B 01 02 03 04 A C Relay Blower Interior Circulate Solenoid Switch 51 C 01 Horn Switch 02 Fog Lamp Rel...

Page 7: ...4 05 Combination Instrument Positive 15 06 Sunroof Cab Freight Calculator 30 07 Ground 08 09 Rear View Mirror Lifter Module Position Select Box 15 10 Ignition Switch 15 11 Central Locking Controller G...

Page 8: ...No 3 CIRCUIT CIRCUIT MANUAL EXPLANATION 1...

Page 9: ...rom right side on previous page going to left side on next page 4 Central Electrical Box Main Circuit Board Pins No It will be helpful for locating main circuit board circuit such as E 8 indicates the...

Page 10: ...ront Fog Light Cigar Lighter A C Panel Indicator 08 Rear Window Heating System Dual Pitch Horn Compressor Magnetic Clutch 09 Wiper Horn Button Washer 10 Headlight Front Position Light Light Relay 11 T...

Page 11: ...Beside Central Electrical Box 2 Body Ground Near Battery 3 Engine Ground Point Located Beside Transmission TQ4 2 Holes Match Connector A Battery B Starter Motor C Alternator C1 Voltage Regulator D Ign...

Page 12: ...69 Throttle Position Sensor G19 Air Intake Pressure Sensor N30 Active Carbon Canister Solenoid G28 Crankshaft Position Sensor G39 Oxygen Sensor G35 System Fuse S36 Oil Pump Fuse A Battery Positive J17...

Page 13: ...Blue yellow red black 2a...

Page 14: ...r S42 Knock Sensor S12 Crankshaft Position Sensor L99 Power Relay FS 35 System Fuse FS 36 ECU Power Fuse FS 37 Oxygen Sensor Fuse A Battery Positive L01 04 Fuel Injector L05 Ignition Coil Q Spark Plug...

Page 15: ...CIRCUIT 2 2b...

Page 16: ...wer switch F18 thermo switch N23 blower in line speed regulator resistance V2 blower V7 fan motor J32 A C relay J69 Cooling fan high speed relay J70 Cooling fan low speed relay J5 A C blower relay in...

Page 17: ...M Brown V Green A Blue H Grey Z Purple G Yellow E35 A C unit switch E36 Interior circulation switch K84 A C operating illumination switch 7 8 Main circuit ground N63 Interior circulation solenoid TK...

Page 18: ...N V GREEN A BLUE H GREY Z PURPLE G YELLOW G2 Coolant temperature sensor 9 ground on engine cylinder F22 Oil pressure switch low pressure 10 ground connection in headlight wiring harness F9 Manual brak...

Page 19: ...D M BROWN V GREEN A BLUE H GREY Z PURPLE G YELLO R radio R2 front left speaker T8 8 holes connector R3 front right speaker T1 single hole connector R4 right rear speaker R5 left rear speaker R6 left f...

Page 20: ...nsor K5 manual brake warning light G25 coolant temperature sensor K6 engine self check indicator G30 RPM sensor K7 oil pressure warning light G35 preset fluid level compare meter K8 engine overheat wa...

Page 21: ...N BLACK R RED M BROWN V GREEN A BLUE H GREY Z PURPLE G YELLOW L16 A C Control Panel Indicator L22 Left Front Fog Light 11 Ground In headlight wiring harness L23 Right Front Fog Light F66 Coolant Leve...

Page 22: ...BROWN V GREEN A BLUE H GREY Z PURPLE G YELLOW J1 Idle Up Relay in electrical box J3 Dual Pitch Horn J39 Rear Window Heating Switch Illumination Light K10 Rear Window Heating Indicator E15 Rear Window...

Page 23: ...IRCUIT WIPER HORN BUTTON WASHER B WHITE N BLACK R RED M BROWN V GREEN A BLUE H GREY Z PURPLE G YELLOW E22 wiper switch H horn button J31 intermittent wiper relay S5 fuse 15A V wiper motor V5 washer 10...

Page 24: ...gh Beam Headlight Fuse 10A S28 Left Low Beam Headlight Fuse 10A S29 Left Position Light Fuse 10A S30 Left High Beam Headlight Fuse 10A S31 Right Low Beam Headlight Fuse 10A S32 Right Position Light Fu...

Page 25: ...AY B WHITE N BLACK R RED M BROWN V GREEN A BLUE H GREY Z PURPLE G YELLOW E2 Turn Light Switch E3 Emergency Warning Light Switch E4 Dimmer and Turn Light Switch E19 Parking Light Switch J2 Emergency Wa...

Page 26: ...T1 single hole connector 14 ground in rear light F18 brake light switch M9 left brake light L15 left taillight M10 right brake light L20 right taillight M501 right side turn light M2 rear right posit...

Page 27: ...T LIGHT SWITCH B WHITE N BLACK R RED M BROWN V GREEN A BLUE H GREY Z PURPLE G YELLOW E1 Light Switch E20 Panel indicator instruments illumination light variable resistance L9 Panel indicator S3 Fuse 1...

Page 28: ...ring F4 Back Light Switch T3 3 Holes Connector J4 Fog Lamp Relay in electrical box T3a 3 Holes Connector K17 Rear Fog Lamp Indicator T2 2 Holes Connector L1 Rear Fog Lamp T1 Single Hole Connector L40...

Page 29: ...EEN A BLUE H GREY Z PURPLE G YELLOW 16 Ground Located Beside Central Electrical Box 15 Ground at headlight T1 Single Hole Connector E102 Headlight Height Adjustment Switch L54 Light Adjustment Illumin...

Page 30: ...uch Switch TAa 2 Holes Connector on left side of luggage compartment F3 Right Front Door Touch Switch W1 Rear Interior Ceiling Lamp F5 Luggage Compartment Illumination Light Switch W3 Luggage Compartm...

Page 31: ...ctor left A pillar Side TK2 12 Holes Connector right A pillar Side Ty 2 Holes Connector Left C pillar side 17 Ground Point Beside Central Electrical C Central Locking Control Unit in left front door V...

Page 32: ...X1 Left Adjust X2 Right Adjust Y1 Up Adjust Y2 Down Adjust V17 Left Mirror Control Motor V25 Right Mirror Control Motor Z4 Left Mirror Defogger Z5 Right Mirror Defogger TK1 12 Holes Connector left A...

Page 33: ...BS Solenoid 18 Ground point at ground carrier on central electrical box VG4 ABS Hydraulic Pump G44 Right Rear Wheel RPM Sensor G45 Left Front Wheel RPM Sensor G46 Left Rear Wheel RPM Sensor G47 Right...

Page 34: ...YELLOW G Window Glass Lifter Module E40 Left Front Window Lifter Switch E81 Right Front Window Lifter Switch V14 Left Front Window Lifter Motor V15 Right Front Window Lifter Motor 19 Beside Central E...

Page 35: ...B Pillar Side TA2 4 Holes Connector Glass Right B Pillar Side E39 Rear Window Glass Lifter Lock Out Switch E52 Left Rear Dorr Upper Window Lifter Switch E54 Right Rear Dorr Upper Window Lifter Switch...

Page 36: ...irectly completed at front compartment harness shortening the current path Comparing with old wiring harness main changes in wiring harness and electrical devices are as follows Interior harness front...

Page 37: ...Function TOTAL CONTENT No 1 Central Electrical Box Fuse And Relay Position 2 Pages No 2 Central Electrical Box Connector Position And Function 3 Pages No 3 Circuit Manual Explanation 2 Pages No 4 Cir...

Page 38: ...CIRCUIT Central Electrical Box Connector Position 3...

Page 39: ...CIRCUIT Central Electrical Box Connector Pin And Function 4...

Page 40: ...CIRCUIT Central Electrical Box Connector Position Central Electrical Box Connector Position FRONT SIDE VIEW BACK SIDE VIEW Central Electrical Box Connector Pin and Function 5...

Page 41: ...tive 30 14 Brake Switch 138 247 134 132 114 192 B 01 02 03 04 A C Relay Blower Interior Circulate Solenoid Switch 51 C 01 Horn Switch 02 Fog Lamp Relay Positive 03 Fog Lamp Switch 04 Horn Relay Signal...

Page 42: ...sitive 15 06 Sunroof Cab Freight Calculator 30 07 Ground 08 09 Rear View Mirror Lifter Module Position Select Box 15 10 Ignition Switch 15 11 Central Locking Controller Glass Lifter Module 30 12 Ignit...

Page 43: ...CIRCUIT CIRCUIT MANUAL EXPLANATION...

Page 44: ...rom right side on previous page going to left side on next page 4 Central Electrical Box Main Circuit Board Pins No It will be helpful for locating main circuit board circuit such as E 8 indicates the...

Page 45: ...ront Fog Light Cigar Lighter A C Panel Indicator 08 Rear Window Heating System Dual Pitch Horn Compressor Magnetic Clutch 09 Wiper Horn Button Washer 10 Headlight Front Position Light Light Relay 11 T...

Page 46: ...sor G69 Throttle Position Sensor G19 Air Intake Pressure Sensor N30 Active Carbon Canister Solenoid G28 Crankshaft Position Sensor G39 Oxygen Sensor G35 System Fuse S36 Oil Pump Fuse A Battery Positiv...

Page 47: ...CIRCUIT...

Page 48: ...sor S42 Knock Sensor S12 Crankshaft Position Sensor L99 Power Relay FS 35 System Fuse FS 36 ECU Power Fuse FS 37 Oxygen Sensor Fuse A Battery Positive L01 04 Fuel Injector L05 Ignition Coil Q Spark Pl...

Page 49: ...CIRCUIT...

Page 50: ...ower switch F18 thermo switch N23 blower in line speed regulator resistance V2 blower V7 fan motor J32 A C relay J69 Cooling fan high speed relay J70 Cooling fan low speed relay J5 A C blower relay in...

Page 51: ...d M Brown V Green A Blue H Grey Z Purple G Yellow E35 A C unit switch E36 Interior circulation switch K84 A C operating illumination switch 7 8 Main circuit ground N63 Interior circulation solenoid TK...

Page 52: ...WN V GREEN A BLUE H GREY Z PURPLE G YELLOW G2 Coolant temperature sensor 9 ground on engine cylinder F22 Oil pressure switch low pressure 10 ground connection in headlight wiring harness F9 Manual bra...

Page 53: ...ED M BROWN V GREEN A BLUE H GREY Z PURPLE G YELLO R radio R2 front left speaker T8 8 holes connector R3 front right speaker T1 single hole connector R4 right rear speaker R5 left rear speaker R6 left...

Page 54: ...ensor K5 manual brake warning light G25 coolant temperature sensor K6 engine self check indicator G30 RPM sensor K7 oil pressure warning light G35 preset fluid level compare meter K8 engine overheat w...

Page 55: ...E N BLACK R RED M BROWN V GREEN A BLUE H GREY Z PURPLE G YELLOW L16 A C Control Panel Indicator L22 Left Front Fog Light 11 Ground In headlight wiring harness L23 Right Front Fog Light F66 Coolant Lev...

Page 56: ...BROWN V GREEN A BLUE H GREY Z PURPLE G YELLOW J1 Idle Up Relay in electrical box J3 Dual Pitch Horn J39 Rear Window Heating Switch Illumination Light K10 Rear Window Heating Indicator E15 Rear Window...

Page 57: ...CIRCUIT WIPER HORN BUTTON WASHER B WHITE N BLACK R RED M BROWN V GREEN A BLUE H GREY Z PURPLE G YELLOW E22 wiper switch H horn button J31 intermittent wiper relay S5 fuse 15A V wiper motor V5 washer...

Page 58: ...igh Beam Headlight Fuse 10A S28 Left Low Beam Headlight Fuse 10A S29 Left Position Light Fuse 10A S30 Left High Beam Headlight Fuse 10A S31 Right Low Beam Headlight Fuse 10A S32 Right Position Light F...

Page 59: ...ELAY B WHITE N BLACK R RED M BROWN V GREEN A BLUE H GREY Z PURPLE G YELLOW E2 Turn Light Switch E3 Emergency Warning Light Switch E4 Dimmer and Turn Light Switch E19 Parking Light Switch J2 Emergency...

Page 60: ...or T1 single hole connector 14 ground in rear light F18 brake light switch M9 left brake light L15 left taillight M10 right brake light L20 right taillight M501 right side turn light M2 rear right pos...

Page 61: ...UIT LIGHT SWITCH B WHITE N BLACK R RED M BROWN V GREEN A BLUE H GREY Z PURPLE G YELLOW E1 Light Switch E20 Panel indicator instruments illumination light variable resistance L9 Panel indicator S3 Fuse...

Page 62: ...iring F4 Back Light Switch T3 3 Holes Connector J4 Fog Lamp Relay in electrical box T3a 3 Holes Connector K17 Rear Fog Lamp Indicator T2 2 Holes Connector L1 Rear Fog Lamp T1 Single Hole Connector L40...

Page 63: ...REEN A BLUE H GREY Z PURPLE G YELLOW 16 Ground Located Beside Central Electrical Box 15 Ground at headlight T1 Single Hole Connector E102 Headlight Height Adjustment Switch L54 Light Adjustment Illumi...

Page 64: ...Touch Switch TAa 2 Holes Connector on left side of luggage compartment F3 Right Front Door Touch Switch W1 Rear Interior Ceiling Lamp F5 Luggage Compartment Illumination Light Switch W3 Luggage Compar...

Page 65: ...nector left A pillar Side TK2 12 Holes Connector right A pillar Side Ty 2 Holes Connector Left C pillar side 17 Ground Point Beside Central Electrical C Central Locking Control Unit in left front door...

Page 66: ...h X1 Left Adjust X2 Right Adjust Y1 Up Adjust Y2 Down Adjust V17 Left Mirror Control Motor V25 Right Mirror Control Motor Z4 Left Mirror Defogger Z5 Right Mirror Defogger TK1 12 Holes Connector left A...

Page 67: ...ABS Solenoid 18 Ground point at ground carrier on central electrical box VG4 ABS Hydraulic Pump G44 Right Rear Wheel RPM Sensor G45 Left Front Wheel RPM Sensor G46 Left Rear Wheel RPM Sensor G47 Righ...

Page 68: ...G YELLOW G Window Glass Lifter Module E40 Left Front Window Lifter Switch E81 Right Front Window Lifter Switch V14 Left Front Window Lifter Motor V15 Right Front Window Lifter Motor 19 Beside Central...

Page 69: ...t B Pillar Side TA2 4 Holes Connector Glass Right B Pillar Side E39 Rear Window Glass Lifter Lock Out Switch E52 Left Rear Dorr Upper Window Lifter Switch E54 Right Rear Dorr Upper Window Lifter Switc...

Page 70: ...Automatic closing with engine stopping and clamping prevention functions are available Maximized sliding and tilting range 10 sage green tempered glass may prevent 99 9 UV radiation and 96 heat High...

Page 71: ...Maintenance Manual for Chery Windcloud Sunroof 2 Components Page 2 of 37...

Page 72: ...ealing strip 2 2 Upper frame A plastic frame which supports mechanism group and glass plate and helps to produce excellent sealing 2 3 Mechanism group One of the major parts of sunroof installed in up...

Page 73: ...of in a quick manner 3 2 Opening shutting sunroof 3 2 1 Lightly press buttons for a period of time less than 0 1 second sunroof will automatically fully open or shut 3 2 2 Lightly press buttons for a...

Page 74: ...r adjustment 3 4 Presetting two memory positions 3 4 1 First open sunroof to a desired position by pressing button then press and hold button for a period of time longer than 3 seconds When a beep sou...

Page 75: ...ds after vehicle power is turned off two beep sounds will be given by sunroof and it begins to shut off automatically Pressing buttons before sunroof is fully shut will cancel automatic shutting At th...

Page 76: ...indcloud Sunroof 3 6 2 If any obstacle occurs during automatic shutting sunroof will fully reopen and repeat trying to shut until the obstacle is removed Pressing and holding button will cancel anti c...

Page 77: ...module motor assembly 4 1 1 Open sunroof 4 1 2 Turn off ignition switch and press and hold control button to prevent sunroof from automatically shutting 4 1 3 Take off the control panel cover plate 4...

Page 78: ...l buttons 4 1 6 Move the fixing clip toward computer case unplug the connection between motor and SCU then detach the fixing hook between SCU and motor to separate motor and SCU for replacement 4 1 7...

Page 79: ...to the engagement between motor driving shaft and gear 4 1 10 Fix interior decorative frame push it up in the direction shown in the figure with clip aligned with clip slot Add an under laying strip i...

Page 80: ...assembling procedure 4 2 1 Open sunroof 4 2 2 Turn off ignition switch and press and hold control button to prevent sunroof from automatically shutting 4 2 3 Take off the control panel cover plate 4 2...

Page 81: ...ction shown in the figure Take care not to damage control buttons 4 2 6 Unplug wire harness connecting SCU and remove the four fixing bolts to take off motor and SCU 4 2 7 Remove frame fixing bolts 4...

Page 82: ...3cm at the position shown in the figure 4 2 11 Insert the upper frame assembly into the opening in vehicle roof 4 2 12 Install interior fixing frame with the front end higher than rear about 45 inclin...

Page 83: ...ement between motor driving shaft and gear Finally tighten the silver bolts from the middle of rear part to both sides 4 2 14 Install motor and SCU in the reverse order in step 6 4 2 15 Fix interior d...

Page 84: ...Maintenance Manual for Chery Windcloud Sunroof 4 2 17 Fix control panel cover plate Page 15 of 37...

Page 85: ...driving base with a screwdriver as shown in the figure then take out lock pin the same with the other side 4 3 3 Turn the glass plate fixing pin clockwise to a 90 position with a minus screwdriver and...

Page 86: ...ure 4 3 5 Slide a new glass plate into mechanism group with both sides being parallel 4 3 6 Fix glass plate fixing pin and turn it to a 90 position 4 3 7 Push the fixing pin to its position 4 4 Replac...

Page 87: ...with the other side 4 4 3 Turn the glass plate fixing pin clockwise to a 90 position with a minus screwdriver and take it off the same with the other side 4 4 4 Carefully pull the glass plate out of...

Page 88: ...y two layers under glass plate holding piece 4 4 8 Place the new rubber sealing strip on the upper frame with the concaved center of sealing strip aligned with the center of glass plate holding piece...

Page 89: ...strip into the slot Make sure the sealing strip is installed in position 4 4 11 Slide the glass plate into mechanism group with both sides being parallel 4 4 12 Fix glass plate fixing pin and turn it...

Page 90: ...Remove excessive silica gel 4 4 15 Wait for at least 2 hours before operating sunroof 4 5 Replacing sunshade 4 5 1 Open sunroof 4 5 2 Turn off ignition switch and press and hold control button to prev...

Page 91: ...anel cover plate 4 5 4 Remove the two fixing bolts in front part of interior decorative frame 4 5 5 Remove the interior decorative frame pull it down in the direction shown in the figure Take care not...

Page 92: ...rocedure 4 5 7 Install the right guiding device and rear support of sunshade 4 5 8 Roll up sunshade and reel the string on right guiding roller 4 5 9 Insert the string into sliding fixing cap and guid...

Page 93: ...tring on left guiding roller 4 5 12 Insert the string into sliding fixing cap and guiding device 4 5 13 Insert guiding device into left side and insert sunshade end into rear support then tighten the...

Page 94: ...x interior decorative frame push it up in the direction shown in the figure with clip aligned with clip slot Add an under laying strip if necessary 4 5 16 Tighten fixing bolts of interior decorative f...

Page 95: ...cedure 4 6 1 Fully open sunroof 4 6 2 Detach the glass plate lock pin from fixed driving base with a screwdriver as shown in the figure then take out lock pin the same with the other side 4 6 3 Turn t...

Page 96: ...dcloud Sunroof 4 6 4 Carefully pull the glass plate out of mechanism group with both sides being parallel 4 6 5 Remove gear cover and gear 4 6 6 Remove four fixing bolts 4 6 7 Separate mechanism group...

Page 97: ...4 6 9 Take off horseshoe locating cap and horseshoe locating piece 4 6 10 Incline mechanism group and remove locking pin from the hinge and pull out hinge Shake it horizontally when pulling out if gr...

Page 98: ...ud Sunroof 4 6 12 Push out guiding lock rod as shown in the figure 4 6 13 Take out lock rod from the rail Assembling procedure 4 6 14 Insert a new guiding lock rod into the rail 4 6 15 Install guiding...

Page 99: ...indcloud Sunroof 4 6 16 Disconnect front raiser and rail slider then take out rail slider 4 6 17 Check the new rail slider 4 6 18 Install in the reverse order in step 16 4 6 19 Install in the reverse...

Page 100: ...Chery Windcloud Sunroof 4 6 20 Install in the reverse order in step 10 4 6 21 Install in the reverse order in step 9 4 6 22 Install in the reverse order in step 8 4 6 23 Install in the reverse order i...

Page 101: ...tep 6 4 6 25 Pull the chain to fully shut sunroof must be fully shut make sure that the hinge is not stuck in mechanism group 4 6 26 Fix chain gear and gear cover Note that gear shall be centered 4 6...

Page 102: ...Maintenance Manual for Chery Windcloud Sunroof 4 6 28 Fix glass plate fixing pin and turn it to a 90 position 4 6 29 Push the fixing pin to its position Page 33 of 37...

Page 103: ...er cut or maintenance of sunroof module In case of sunroof malfunction try to reprogram to resume its functions 4 7 1 Programming turn on ignition switch 4 7 2 Press button to fully shut sunroof then...

Page 104: ...a highly elastic wearproof rubber seal ring to ensure water resistance Make sure that the seal ring is dust free without debris Please clean the seal ring with wet sponge with a frequency of once per...

Page 105: ...is ranining or sunroof is being cleaned 5 2 2 Please wait for at least 5 minutes after the rain or car cleaning before opening sunroof 5 2 3 Never stretch your head or hands out of sunroof 5 2 4 Make...

Page 106: ...unshade with sunroof being open during high speed running 5 2 6 In case electric control of sunroof dose not work or automatic shutting and sensoring failure first check sunroof fuse If the fuse is no...

Page 107: ...Drawing of Transmission AQ015 1...

Page 108: ...Gear 4 32 31 1 032 32 31 1 032 Gear 5 34 40 0 850 34 40 0 850 Reverse gear 38 12 3 167 38 12 3 167 Speedometer 16 7 2 286 16 7 2 286 Volume of lubricant 2 0L 2 0L Type of lubricant Transmission oil G...

Page 109: ...nsmission 4 Input shaft 5 Output shaft 6 Differential gear Transmission Ratio I gear 1 II gear2 III gear 3 IV gear 4 V gear 5 R reverse gear A Master drive T transmission of speedometer The arrow in t...

Page 110: ...nce between the lips of oil seal with grease After installation check the volume of lubricant of transmission add lubricant if necessary Snap Ring Never expand the snap ring too much against distortio...

Page 111: ...In odder to assure normal volume of lubricant for the 5 gear transmission AQ015 attention must be paid to the following points 1 Since the exterior of transmission is sealed there is no need to check...

Page 112: ...Assembly Sketch of Transmission 1 Clutch housing 2 Differential gear 3 Input shaft 4 Output shaft 5 Gear 1 6 Reverse gear 7 Gear 2 8 Gear 3 9 Gear 4 10 Gear 5 11 Transmission housing 12 Rear housing 6...

Page 113: ...tening screw CQ1500865 2 pieces with torque at 25 Nm 3 Draining plug 4 Rear housing of transmission 5 Gear 5 synchronizer assembly 6 Gear 5 driven gear snap ring 7 Gear 5 driven gear 8 Gear 5 fork loc...

Page 114: ...ring 5 Screw plug cap of shifting gear 6 Big spreader spring of shifting gear 7 Shifting gear assembly 8 Shifting locking seat assembly 9 Spread spring damping ring 10 Output flange 11 Disk shape was...

Page 115: ...bearing seat 14 Closing ring of gear 1 needle roller bearing 15 Intermediate bearing seat of output shaft 16 Differential gear assembly 17 Damping ring 18 Spreader spring damping ring 19 Output flang...

Page 116: ...as indicated by arrow Drain out the oil completely Unscrew the joint bolt of rear housing and transmission housing dismantle the rear housing assembly and take out the separate bearing of clutch and g...

Page 117: ...the stoppers of reverse gear shaft as indicated by arrow Shift to gear 5 and reverse gear Slide the synchronizer down as indicated by arrow 1 and shift to gear 5 Move the first fork down as indicated...

Page 118: ...If necessary with special tool Unscrew the fastening bolts of fore and rear housing of transmission remove the transmission housing and the gaskets of fore and rear housings Take down the snap ring o...

Page 119: ...input shaft with special tool gear 1 synch ring gear 1 driven gear needle roller gear and take out gasket Remove snap ring B of gear 3 driven gear from the output shaft then gear 3 driven gear remove...

Page 120: ...contacted with bearing seat B When mounting gear 1 and gear 2 synch ring never confuse them gear 1 synch ring is not moly coated and has no teeth in three places Mount the needle roller bearings sync...

Page 121: ...le of clutch housing When mounting idler shaft Value X should be equal Mount the fork assy onto their correct positions 1 Gear 1 and gear 2 fork 2 Gear 3 and gear 4 fork 3 Gear 5 fork guide board and...

Page 122: ...ing may deviate from their due positions and fall out thus they must be reinstalled Before mounting the shifting shaft put transmission at neutral position Insert the shifting shaft and big spreader s...

Page 123: ...e locking plate of gear 5 fork Put on seal washers of rear housing and then mount the rear housing assy Apply a coat of grease onto the top of separating jogger of clutch and insert it Shift the gears...

Page 124: ...seal assy separate shaft 4 Rear housing transmission 5 Fastening screw CQ1500885 6 Fastening screw of rear housing CQ1500865 7 Separate shaft of clutch 8 Release spring 9 Separate pawl of clutch 10 Re...

Page 125: ...ip of separate finger pull out the separate shaft of clutch and take out the finger and spring The separate shaft of clutch can be taken down Use deift punch to flush down the oil seal assy of separat...

Page 126: ...shaft Dismantlement and assembly of needle roller bearing of output shaft Dismantlement When changing the bearing of shifting shaft it is needed to take out the shaft Remove oil seal put the special t...

Page 127: ...the position until snap ring 2 is removed Assembly the procedures are reverse to the above Note be sure that the fork system is at neutral position The torque of screw plug is 50Nm The torque of shift...

Page 128: ...emble the transmission assy Dismantlement and assembly of cone bearing They are intermediate bearings and meant to the differential bearings that are respectively installed on the clutch housing and t...

Page 129: ...r bearing baffle 12 Gear 4 driving gear 13 Gear 4 synch ring 14 Snap ring 15 Gear 3 and gear 4 synchronizer assy 16 Gear 3 and gear 4 tooth bush 17 Gear 3 and gear 4 tooth drum 18 Guide block 19 Wire...

Page 130: ...driven gear and its bush 12 Gear 2 synch ring 13 Gear 1 and gear 2 synchronizer assy 14 Wire spring 15 Gear 1 and gear 2 tooth bush 16 Gear 1 and gear 2 tooth drum 17 Guide block 18 Gear 1 synch ring...

Page 131: ...t After replacing any one of clutch housing output shaft intermediate bearing seat of output shaft intermediate bearing of output shaft and fore bearing of output shaft the thickness of adjusting shim...

Page 132: ...housing differential bearing and differential housing the thickness of adjusting shim of output shaft needs readjustment Unscrew the bolts of bearing baffle and take down the output shaft Fully press...

Page 133: ...accuracy of measurement Calculate the thickness of adjusting shim to be installed When pre tightening the bearing here the thickness of adjusting shim should be 0 40mm If the micrometer reads 0 90mm t...

Page 134: ...seal 10 Minor half axle 11 Needle roller bearing 12 Outer loop of needle roller bearing 13 Adjusting shim 14 Differential housing 15 Snap ring of output flange 16 Disk shape washer of output flange 17...

Page 135: ...ge remove the driving shaft and fix it at given position As indicated in figure fix M8 bolt onto the flange with special tool rotate the shaft of the special tool with wrench to remove the output flan...

Page 136: ...ecial tool as indicated in figure When mounting disk shape washer check it to see whether it is at its due position When mounting snap ring ensure it is in the groove Mount a new flange blind cover Co...

Page 137: ...The thickness of connecting rod bushing standard 47 89 47 91 1 480 1 487 undersize 0 025 47 89 47 91 1 492 1 499 undersize 0 25 47 64 47 66 1 605 1 612 undersize 0 5 47 39 47 41 1 730 1 737 undersize...

Page 138: ...mm Crankshaft thrust washers are two pieces They are only installed on the front and back thrust surface of cylinder block Before installation apply the engine oil on the surface with oil groove of th...

Page 139: ...ing the main bearing bolt engine oil should be applied on the joint surface of head end The main bearing bolt and stud should be screwed by hand first and tightened to 90 100Nm The max rotating torque...

Page 140: ...ter connector From the main oil passage oil lubricates the main bearing through the bore in the cylinder body and lubricates the connecting rod bearing through oil passage in the crankshaft There is a...

Page 141: ...naerobic sealant on the joint place between flange surface of oil pan of cylinder body and oil pump case and carrier of real oil seal Put the new rubber seal gasket on the cylinder body and have the t...

Page 142: ...torque 17 0 23 0Nm screw M8 screw M6 20 oil collector Tightening torque 8 0 12 0Nm with spring plate screws 2 Installation Install a new sealing gasket of oil collector on the flange face of oil pump...

Page 143: ...Loosen six M6 30 hexagonal flange surface bolts Remove the bolts as the figure indicates Remove oil pump with oil seal assembly Pry out the front oil seal of crankshaft by screwdriver or chisel Note D...

Page 144: ...een inner rotor and outer rotor of oil pump The radial clearance between inner rotor and outer rotor of oil pump should be 0 05 0 18mm Check the end play of rotor The end play of rotor should be 0 014...

Page 145: ...CAC Gasoline Engine Maintenance And Servicing Manual 3 ANHUI CHERY AUTOMOBILE CO LTD CAC478 480 GASOLINE ENGINE Instruction Book on Using and Maintenance PDF pdfFactory Pro www fineprint com cn...

Page 146: ...t oil seal removal and installation 23 8 Valve mechanism and cylinder head removal check and installation 24 9 Piston and connecting rod assembly removal and installation 33 10 Flywheel assembly and r...

Page 147: ...c control fuel injection system and multipoint electric control fuel injection system of the above engines are developed though the joint effort with Italy M M Corp With advanced product performance r...

Page 148: ...CAC Gasoline Engine Maintenance And Servicing Manual 4 Carburetor engine left view Carburetor engine frontal PDF pdfFactory Pro www fineprint com cn...

Page 149: ...CAC Gasoline Engine Maintenance And Servicing Manual 5 Carburetor engine right view Carburetor engine back view PDF pdfFactory Pro www fineprint com cn...

Page 150: ...CAC Gasoline Engine Maintenance And Servicing Manual 6 Carburetor engine overlook view Carburetor flywheel rear side jointing size illustration PDF pdfFactory Pro www fineprint com cn...

Page 151: ...CAC Gasoline Engine Maintenance And Servicing Manual 7 EI engine left view EI engine front end PDF pdfFactory Pro www fineprint com cn...

Page 152: ...CAC Gasoline Engine Maintenance And Servicing Manual 8 EI engine right view EI engine back view PDF pdfFactory Pro www fineprint com cn...

Page 153: ...CAC Gasoline Engine Maintenance And Servicing Manual 9 EI engine overlook view 3 locating pin holes EI engine flywheel rear end jointing size PDF pdfFactory Pro www fineprint com cn...

Page 154: ...CAC Gasoline Engine Maintenance And Servicing Manual 10 Carburetor engine exploded view PDF pdfFactory Pro www fineprint com cn...

Page 155: ...timing belt 4 camshaft assembly 14 upper lower timing gear cap assembly 5 fuel pump assembly 15 water pump assembly 6 air intake manifold assembly 16 camshaft timing gear 7 fuel pressure switch 17 ten...

Page 156: ...arburetor Single point electric control fuel injection Combustion chamber shape Wedge type Hemisphere type Hemisphere type Cylinders Working Order 1 3 4 2 Direction of crankshaft rotation Clockwise Vi...

Page 157: ...L 3 86 New oil filter Oil pump pressure regulator starts to open pressure kPa 440 20 Engine oil filter by pass valve starts to open pressure kPa 78 118 Coolant 50 Glycol 50 Soft water Rate by volume C...

Page 158: ...nder block is lubricated by oil spray from connecting rod bearing bore drill Connecting rod bolts of 12 9 grade 7 Crankshaft 4 balance weight Ductalloy Normalizing treatment 8 Bearing bushing Connecti...

Page 159: ...Push rod Made from low alloy steel Carbonization quench treatment Only applied for carburetor engine 26 Water pump Centrifugal type Cast iron impeller Aluminum alloy case Driven by timing belt throug...

Page 160: ...intake tube for cracking Check PCV valve Check spark plugs Per16000km Check accessories drive belt Check timing belt and tension pulley Check radiator and hoses for leaking Per30000km Replace fuel fil...

Page 161: ...Replace air filter core and clean case Check accessory driving belts Check radiator and hoses for leaking Replace spark plugs Replace timing belt Replace fuel filter Check high tension wires Check lam...

Page 162: ...aligns with the mark on the front end of cylinder head If not aligned rotate crankshaft one turn aligning the TDC mark on the camshaft gear with the TDC mark on the front end of cylinder head engine s...

Page 163: ...stall lower timing gear cover and seal gasket on crankshaft finger screw in 2 bolts and tighten to 9 0 11Nm Clean upper timing gear cover Mount new seal gasket with shot nail or glue on lower timing g...

Page 164: ...o bolts and finger screw in Block flywheel ring gear with screwdriver preventing crankshaft from turning Tighten bolts to 100 115Nm 4 Valve cover and seal gasket removal and installation Removal Remov...

Page 165: ...am showed Step 1 Tighten to 4 0 6 0Nm Step 2 Tighten to 8 0 10 0Nm 5 Timing belt removal installation and adjustment Removal Rotate crankshaft to no 1 cylinder compression TDC Loosen 2 tension pulley...

Page 166: ...th gear teeth grooves Recheck both gears there should be no movement Loosen 2 tension pulley mounting bolts push tension pulley right to the extreme viewed from the direction of pulley tighten 2 tensi...

Page 167: ...hould be positioned at no 1 cylinder compression TDC Install belt tension pulley finger screw in 2 mounting bolts then tighten to 16 20Nm 2 Camshaft gear Removal Rotate crankshaft to no 1 cylinder com...

Page 168: ...should be 1 392 1 739mm Install shim with curved face side forward Install crankshaft gear with boss side forward and then press crankshaft gear onto boss using a assistant pulley and pulley bolt 7 Ca...

Page 169: ...ud 8 Tightening torque 18 23Nm Upper Valve spring seat 8 Valve spring 8 Valve oil seal spring seat assy 8 Assembly before valve oil seal spring and valve installation Rocker arm seat washer 8 hydrauli...

Page 170: ...tapped hole or fluid pressure resulting from bolts screwing may possibly results in cylinder block cracking Rotate crankshaft until no 1 cylinder piston is 20mm or so under the deck of cylinder block...

Page 171: ...ting torque angle torque wrench or line plotting methods may be applied 3 Rocker arm mechanism and hydraulic lifting rod removal and installation Rocker arm mechanism removal Loosen rocker arm nuts re...

Page 172: ...cker arm support then finger screw in new nut tighten to 25 29Nm Note Before installing each rocker arm and tightening nut appropriate hydraulic lifting rod should be at the lowest position Hydraulic...

Page 173: ...of cylinder head don t damage the camshaft hole in Cylinder head Inspection Check camshaft cam and journal for wear if worn out replace it If camshaft end play exceeds specification replace thrust wa...

Page 174: ...tening torque is 9 13Nm Check camshaft end play end play should be as specified When the hydraulic lifting rod of oversize 0 25 is applied camshaft must be selected or the hydraulic lifting rod may be...

Page 175: ...ression locking pieces may be taken out After locking piece is taken out remove compression tools by unbolting slowly Remove valve spring seat and valve spring take out valve oil seal spring seat asse...

Page 176: ...nto the top of valve guide apply engine oil on the intake and exhaust valve guide edge where the valve seals are installed for preventing valve lock piece groove from damaging oil seal lip You may pro...

Page 177: ...0 01 0 01 44 763 0 025 0 oversize 0 5 44 377 0 01 0 01 44 263 0 025 0 oversize 1 0 44 877 0 01 0 01 44 763 0 025 0 0 079 0 124 Diameter of intake valve seat Diameter of the cylinder head valve seat h...

Page 178: ...piston ring and piston pin together Cleaning and inspection Clean and remove the carbon deposits from the piston piston ring and piston pin Clean and remove the carbon deposits from the upper cylinde...

Page 179: ...play in the piston groove unit mm 478 dia of piston skirt mm 488 dia of piston skirt mm 480E dia of piston skirt mm 1 77 19 77 20 79 91 79 92 79 915 79 925 2 77 20 77 21 79 92 79 93 79 925 89 935 3 77...

Page 180: ...CAC Gasoline Engine Maintenance And Servicing Manual 36 Measure the crosshead end bore of the connecting rod 20 589 0 02 0 PDF pdfFactory Pro www fineprint com cn...

Page 181: ...ecting rod and the left side of rod cap viewed from the front Be sure not to be deformed on the connecting side during printing The dimension of piston ring 478 piston ring 480 piston ring Paint marke...

Page 182: ...and carrier assembly of real crankshaft oil seal 1 The removal and installation of flywheel assembly removal Remove six M10 bolts and replace bolts Remove flywheel Check if there is crack in the surf...

Page 183: ...e jaw Align rear oil seal carrier hole with the part number side of oil seal outward press oil seal into rear oil seal carrier with vise The magnitude of interference for real oil seal and carrier hol...

Page 184: ...ush and pull crankshaft Loosen main bearing bolt and stud start with the middle bearing cap take out the bolt and stud remove main bearing cap and the other shell of main bearing bushings The other sh...

Page 185: ...7 89 47 91 1 480 1 487 undersize 0 025 47 89 47 91 1 492 1 499 undersize 0 25 47 64 47 66 1 605 1 612 undersize 0 5 47 39 47 41 1 730 1 737 undersize 0 75 47 14 47 16 1 855 1 862 undersize 1 0 46 89 4...

Page 186: ...l groove towards the cylinder body and the surface with oil groove towards crankshaft During installing crankshaft engine oil should be applied main journal connecting rod journal thrust surface and b...

Page 187: ...ngine oil should be applied on the joint surface of head end The main bearing bolt and stud should be screwed by hand first and tightened to 90 100Nm The max rotating torque of the crankshaft with pis...

Page 188: ...aust side in the connecting rod body The oil sprays out from this small oil port to lubricate the piston pin and cylinder bore Oil pressure sensor 8 is located near the oil filter It is connected with...

Page 189: ...nd carrier of real oil seal Put the new rubber seal gasket on the cylinder body and have the two sides of sealing gasket enter into the grooves of carrier of real oil seal and oil pump Install the oil...

Page 190: ...ge face of oil pump and then install oil collector assembly Screw two bolts with gasket by hand Screw the oil collector carrier into the cylinder body with M8 bolt At the same time hitch the carrier i...

Page 191: ...ve the bolts as the figure indicates Remove oil pump with oil seal assembly Pry out the front oil seal of crankshaft by screwdriver or chisel Note Don t damage the front oil seal bore Remove seven M6...

Page 192: ...ial clearance between inner rotor and outer rotor of oil pump should be 0 05 0 18mm Check the end play of rotor The end play of rotor should be 0 014 0 100mm Remove horizontal hexagonal socket head pl...

Page 193: ...of cylinder block Install the oil pump into the front end of crankshaft center the inner bore of inner rotor Before installation Screw six mounting bolts by hand Check and adjust the roughness of low...

Page 194: ...f oil filter and screw into the connector Tightening torque is 12 17Nm Or screw into oil filter by hand once rubber sealing gasket contacts cylinder block tighten another 3 4 1 turns Apply Lotite 243...

Page 195: ...relief valve in the thermostat seat opens The coolant enters the expansion tank from overflow tube After the system is cooled the coolant comes back to the inlet of water pump from expansion tank The...

Page 196: ...CAC Gasoline Engine Maintenance And Servicing Manual 52 wide opening temperature 89 102 Grade 91 Operating voltage 12V PDF pdfFactory Pro www fineprint com cn...

Page 197: ...clean d If radiator is too dirty it may be washed from the reverse direction Connect the hose connected to the water supply to the water outlet of thermostat seat to wash the engine until the water c...

Page 198: ...the front end of cylinder block Remove water pump assembly Remove sealing gasket of water pump Installation Install new sealing gasket of water pump on the water pump Install the water pump assembly i...

Page 199: ...ree M6 40 bolts and remove them Remove thermostat seat with thermostat assembly Pry out spring clip by chisel or screwdriver Take out the thermostat Take out sealing gasket Remove sealing gasket of th...

Page 200: ...er temperature sensor Removal Remove the water temperature sensor at the exhaust side under the rear lug Assembly Before installation apply the lotite sealant 243 onto the bolt threads finger screw in...

Page 201: ...of Engine 2 480M The Intake System of Engine 480M includes air filter Intake Hose Guide Cover Throttle Valve Intake Manifold Intake air preheating hose of Positive Crankcase Ventilation PCV and so on...

Page 202: ...f the Carburetor Engine 2 Description for the Intake Manifold Assembly of Engine 480M The Intake Manifold Assembly includes Water Hose Vacuum Fitting Water Temperature Gauge Sensor and Electric Heater...

Page 203: ...ater parameters Voltage 15V Initial current 75A Cold resistance 0 2 0 4 temperature after 12 second energizing 60 temperature after 180 second energizing 135 3 3 Removal and assembly for the intake ma...

Page 204: ...in 8 M8 studs of same length and tighten them with two nuts Assemble the new exhaust manifold sealing gasket Install the exhaust manifold Put the washers onto the studs and tighten lock nuts with han...

Page 205: ...of oil baffle assembly and valve chamber cover assembly 2 Description for PCV system of 480M engine 2 1 Description of PCV system The PCV system is a closed system The leaking air of piston goes to t...

Page 206: ...h speed or low speed conditions 17 Fuel supply system of the carburetor engine 1 Fuel supply system of the carburetor engine 1 1 Description of the fuel supply system The fuel in the tank flows into o...

Page 207: ...eters Pierburg 2E3 carburetor CAC478 CAC480 Larger throat pipe diameter 20 24 22 26 Mixing chamber size 28 30 28 30 Installation Use studs nuts and washers to connect the transition flange with intake...

Page 208: ...tor in the throttle valve body the redundant fuel returns to the fuel tank The vapor from the fuel tank goes into the charcoal canister by fuel vapor pipe and is sucked into air intake pipe though the...

Page 209: ...rness will be burn away while the alternator is under working condition it is not allowed to disconnect the alternator connector B from battery or the voltage caused will damage the transistor or othe...

Page 210: ...ed output 0 95kW Speed range 1000 1800r min Voltage 12V Type QDY1258 SD6RA78 the flywheel gear ring for vehicle and the one for independent engine assembly are different and also the starter gear modu...

Page 211: ...y more attention to keep the wire bayonet clip clean Make sure there s no oil fouling and water Or the voltage drop is too high and the engine doesn t work 3 Spark plug Type K7RTC Tighten torque 17 0...

Page 212: ...CAC Gasoline Engine Maintenance And Servicing Manual 68 PDF pdfFactory Pro www fineprint com cn...

Page 213: ...istributor flange with the mark on cylinder head Tighten two bolts to 5 0 7 0Nm 6 High tension ignition wire assembly The high tension ignition wire assembly is mounted on the cylinder wire bracket wh...

Page 214: ...C Gasoline Engine Maintenance And Servicing Manual 70 7 Ignition coil assembly 8 Connector wiring harness assembly ng assembly Ignition coil assembly Fig 132 type PDF pdfFactory Pro www fineprint com...

Page 215: ...discharged engine run slowly recharge or replace battery 4 Battery wire connector is loosed or corroded reconnects or replace battery 5 Ignition parts is damp or damaged replace ignition parts 6 Ignit...

Page 216: ...Vacuum leakage in intake manifold replace sealing gasket or replace connecting pipe 3 carburetor float position not proper check carburetor float or needle valve 4 mail measuring orifice blocked chec...

Page 217: ...ust ignition timing 8 Hydraulic valve lifter damaged replace Hydraulic valve lifting rod 9 low or unstable cylinder compression pressure check and service 10 PCV hose loose leaking or damaged connect...

Page 218: ...replace fuel pump 4 Fuel Tank ventilation pipe blocked or fuel hose blocked dredge the hose 5 Throttle valve not widely open adjust 6 Choke not widely open or auto choke damaged adjust or service 12...

Page 219: ...use Correction 1 Engine oil level too low or not correct fill in engine oil or apply correct engine oil 2 Oil pressure warning light woks abnormally replace Oil pressure warning light 3 Engine tempera...

Page 220: ...check and replace b Valve mechanism or camshaft worn out check and service c Timing belt or tension pulley worn out replace d Abnormal accessories ie alternator or water pump check service and replac...

Page 221: ...nuously leaks mechanism parts 6 Fuel pipe leaks correct fuel pipe connector leakage 7 cylinder compression pressure decreases check engine 8 Incorrect ignition timing adjust ignition timing 9 Too low...

Page 222: ...io is important for catalyst converter to work normally The aim having the catalyst converter installed is to reduce harmful exhaust emission The sensor analyzing oxygen content in exhaust gas continu...

Page 223: ...ignal and use output circuit to control the following control fuel injector switch on time for calculating fuel feed control by pass air volume and ignition advance for stepper motor compensating to c...

Page 224: ...vicing Manual 80 Throttle valve position sensor TDC RPM sensor Absolute pressure sensor High pressure ignition coil Oil injector Fuel pump Engine idle actuator Fuel vapor recirculate solenoid Engine P...

Page 225: ...Throttle valve is installed on intake manifold Throttle valve casting are consisted of upper and lower bodies Upper body cap is for arranging fuel passages and the lower body is for controlling engine...

Page 226: ...el will clean and cool injector during recirculation working procedure of Fuel pressure regulator Spring 2 applies pressure on the diaphragm 7 connected to sealing valve 6 keeping cavum closed between...

Page 227: ...ely controlled by time and not related to TDC signal ECU has a basic current control circuit to control fuel injector The circuit produces the maximal current signal at the first control order speed u...

Page 228: ...ipe throttle valve position sensor PF2C figure 140 shows the position sensor case structure also the relationship between output characteristic output signal and throttle valve opening ange Sensor com...

Page 229: ...displayed on the screen is 2 14 If the parameter is above 14 you should check throttle cable and make sure it s correct not very tight Or it needs to be adjusted again Notice Don t adjust the potenti...

Page 230: ...d fuel and equipped with a check valve and a pressure override valve vibration pressure is 2 6bar It is installed inside the fuel tank and equipped with a fuel filter Fuel pump supplies the fuel to fu...

Page 231: ...he teeth 60 2 in the flywheel see figure 143 engine speed may be calculated accurately by the signal impulses produced by the 58 teeth which are arranged equally with a interval of 6 The RPM sensor po...

Page 232: ...at three different teeth with a equal interval of 120 The value should be 2 0 6mm A speed sensor signal B ECU power signal C current circle for primary coil circuit a ignition advance angle relative...

Page 233: ...he intake air volume When the pressure signal is P 97mmHg or P 783mm Hg if the throttle valve position sensor doesn t fail the operation comeback will be performed according to the throttle valve angl...

Page 234: ...rature and air temperature one filter restricts the change of two continuous TDCs Under a specified condition ignition advance will be compensated dynamically Base ignition advance value as a function...

Page 235: ...nclosed by ceramic zirconia body 1 with thin platinum plate at one end The latter one is inserted in a protecting boot and installed in a metallic body 3 The protective casing works for the further pr...

Page 236: ...p operates CHECK UP1 performs to stop engine and recycle oil circuit Injection system ECU may adjust automatically therefore it may compensate for the system failure caused by the engine degradation A...

Page 237: ...s the combustion caused by the fuel will damage the converter sometimes a few second stay of the fuel in the converter may result in irremediable damage Therefore it is very necessary to insure the ig...

Page 238: ...e engine stopped the temperature in the fuel tank will rise Since the vehicle doesn t move the dynamic ventilation is not enough and the pressure in the fuel tank will rise When the fuel tank is full...

Page 239: ...or recirculation solenoid valve is designed to regulate the vapor volume from the charcoal canister controlled by ECU When the solenoid valve is deenergized the valve closes Its operation is controlle...

Page 240: ...r the normal condition When the mechanism is stricken by the ball resulting in the position variation it will vary from the closed circuit NC to the opened circuit NO and cut off the ground wire of fu...

Page 241: ...dual relays A ECU B fuel pump 3 sensor 11 fuel pump 4 fuel injector 12 fuel vapor recirculation solenoid 5 2 ignition coil cylinder 2 3 13 ECU 6 ignition switch 14 main ground wire of engine 7 25A sys...

Page 242: ...CAC Gasoline Engine Maintenance And Servicing Manual 98 Fig 158 PDF pdfFactory Pro www fineprint com cn...

Page 243: ...A C fuse U front cable junction box ECU I 0 function 1 primary signal for ignition coil 2 B phrase idling actuator signal 3 D phrase idling actuator signal 4 protect relay signal 5 without connection...

Page 244: ...ut 31 intake air temperature sensor signal input 32 absolute pressure sensor signal input 33 without connection line 34 main ground wire of engine 35 ignition switch 12V power supply input A C I O may...

Page 245: ...ECU connector connection of injection system Fig 160 system fuse ECU fuse ignition coil of cylinder 1 4 ignition coil of cylinder 2 3 fuel vapor solenoid sensor sensor fuel injector step motor throttl...

Page 246: ...rculation solenoid 10 absolute pressure sensor 19 sensor connector 11 intake air temperature sensor self diagnosis system the information is stored permanently even when the power is cut off the follo...

Page 247: ...al matches the signal from ECU again If the actuator or the corresponding signal channel fails the above program is also applied When a failure is detected and the corresponding substitute value is ap...

Page 248: ...from the filter during operating use an appropriate container to collect the fuel drained The fuel filter must be replaced every 30 000km Note The filter must not be installed reversely it must be rep...

Page 249: ...rottle valve cable adjustment Adjust the throttle cable according to the following Loosen two lock nuts 2 hexagonal lever 3 is retained in the protective sleeve tighten or loosen hexagonal lever 3 to...

Page 250: ...wave 1 throttle valve body 30MM4 1 check the throttle valve cable for proper adjustment smooth movement 2 if the throttle valve cable is correctly adjusted and may move smoothly remove it Check the t...

Page 251: ...CAC Gasoline Engine Maintenance And Servicing Manual 107 PDF pdfFactory Pro www fineprint com cn...

Page 252: ...rature via a comparison circuit inside Failure diagnosis The monitor circuit inside ECU detects sensor circuit troubles such as open circuit short circuit and sensor damages etc In case ECU detects an...

Page 253: ...le potentiometer ECU adopts Up Us votage ratio to avoid change in output signal due to fluctuation in engine voltage Failure diagnosis ECU monitors throttle angle and detects sensor failure when outpu...

Page 254: ...In this case ECU controls ignition and fuel injection according to set water temperature for failure mode at the same time the fan is running at high speed mode normal fan control for system with fan...

Page 255: ...ilure Knocking control data processing circuit failure Cylinder detecting signal is unreliable After failure mark of knock sensor being set knocking closed loop control is shut down reducing a safety...

Page 256: ...on various sensors actuators power amplification circuits and sensing circuits In case any of the following situations occurs failure mark of the oxygen sensor is set Accumulator voltage is unreliabl...

Page 257: ...nsor Providing sensors with power supply 5V 100mA closed loop control with self adaptation Controlling carbon canister control valve Air conditioning switch Engine fault indicating lamp Fuel quantitat...

Page 258: ...e speed stepper motor C 18 Not in use 58 Idle speed stepper motor D 19 Not in use 59 Ignition coil control 1 4 20 Oxygen sensor 60 Throttle position sensor power 5V 21 High speed fan request 61 Not in...

Page 259: ...Fuel temperature has fairly big impact on fuel pump performance in case of longstanding operation under high temperature condition when fuel temperature is higher than a certain value the pressure of...

Page 260: ...ts in failure of normal startup of vehicle after long term idling In this case please check carefully to see if the injector cements and check atomization as well Failure diagnosis EFI system of A11 d...

Page 261: ...ic field is formed to keep permanent magnet rotor rotating in a certain direction Failure diagnosis ECU can monitor short circuit open circuit status of two coils in idle speed stepper motor and light...

Page 262: ...rs in ignition coil there is no failure code the only way is to check the resistance of ignition coil to determine if the said coil is in working order Under normal conditions the thermal value of wor...

Page 263: ...o the said valve on one hand while related to pressure difference between its inlet outlet on the other hand In case there is no electric impulse carbon canister control valve will shut down ECU contr...

Page 264: ...jector Installation requirement connect fuel inlet outlet pipes with rubber pipes and fasten them down with hoops The size of hoops used shall match that of rubber pipes so as to ensure air tight conn...

Page 265: ...ional speed sensor of magnetic pulse type with coils winding around a slug inside signal wheel rotating at high speed and cutting magnetic lines of force induced electromotive force is generated in co...

Page 266: ...time stipulated for the first time ECU collects it as a stable failure and stores it as constant failure if such failure disappears ECU stores it as random failure and nonexistent if such failure is...

Page 267: ...or connecting the said connector and three pin plug of the scanner so as to enter engine diagnostic system 8 Clearance of Failure Information Record After elimination of failure failure information re...

Page 268: ...cuit occurs No Go to next step Yes Diagnosis Instruction 5 Start engine and idle it Slowly step down accelerating pedal to dead position and observe value of Intake Pressure on scanner and it does not...

Page 269: ...ion sensor Step Operation Result Solution 1 Connect scanner and commutator and then turn ignition switch to ON Go to next step Yes Go to next step 2 Check Throttle Absolute Opening in data stream to s...

Page 270: ...and Pin 2 of sensor connector Pin 76 of ECU and Pin 3 of sensor connector to see if open or short circuit occurs No Go to next step Yes Replace sensor 6 Check the voltage between Pin 1 and Pin 2 of s...

Page 271: ...in B of sensor connector two thin wires on ECU wire harness the two thick wires are heating coils to see if they are short circuit to power No Diagnosis Instruction Failure signal error of upstream ox...

Page 272: ...ensor of sensor connector to see if open or short circuit to power ground occurs No Diagnosis Instruction Failure self adaptation of air fuel ratio closed loop control exceeds upper limit Step Operati...

Page 273: ...let pipe of fuel system and observe fuel pressure under all working conditions to see if it is around 350kPa No Check and repair fuel system Yes Repair or replace wire harness 4 Check respectively the...

Page 274: ...lt Solution 1 Connect scanner and commutator and then turn ignition switch to ON Go to next step Yes Go to Step 4 2 Unplug Cylinder 2 injector connector from wire harness check the voltage between Pin...

Page 275: ...a multimeter to see if it is around 3 7V No Go to next step Yes Repair or replace wire harness 6 Check the connection between Pin 2 of Cylinder 3 injector connector and Pin 78 of ECU to see if open sh...

Page 276: ...e harness 3 Check power supply terminal circuit of relay to see if open circuit or short circuit to ground occurs No Go to Step 2 Yes Replace fuel pump relay 4 Check the voltage between Pin 85 of fuel...

Page 277: ...wire harness 3 Check repectively the connections between Pin 2 of engine speed sensor and Pin 53 of ECU Pin 3 of engine speed sensor and Pin 67 to see if open short circuit to power ground occurs No G...

Page 278: ...trol valve Yes Diagnosis Instruction 5 Check the voltage between Pin 2 of carbon canister control valve connector and cathode of power supply with a multimeter to see if it is around 3 7V No Go to nex...

Page 279: ...ntrol valve connector from wire harness check the voltage between Pin 1 of connector and cathode of power supply with a multimeter to see if it is around 12V No Go to next step Yes Repair or replace w...

Page 280: ...C Check system exhaust for blockage No Diagnosis Instruction Failure higher idling speed than target value Step Operation Result Solution 1 Connect scanner and commutator and then turn ignition switch...

Page 281: ...o ON Go to next step Yes Go to next step 2 Unplug idle speed regulator connector check respectively the resistances between Pin A and Pin D Pin B and Pin C of the regulator with a multimeter too see i...

Page 282: ...intains within 9 16V No Replace generator Yes Diagnosis Instruction 5 Check ground point of engine wire harness to see if it is normal No Repair or replace wire harness Failure too low system voltage...

Page 283: ...if it isin good condition No Repair or replace wire harness Failure non programmed check code error of ECU Step Operation Result Solution 1 Connect scanner and commutator and then turn ignition switc...

Page 284: ...in 41 of ECU to see if open circuit occurs No Diagnosis Instruction Failure too low control circuit voltage of air conditioner compressor relay Step Operation Result Solution 1 Connect scanner and com...

Page 285: ...d 3 7V No Go to next step Yes Repair or replace wire harness 5 Check the connection between Pin 86 of relay control terminal of air conditioner compressor relay and Pin 41 of ECU to see if short circu...

Page 286: ...see if blockage occurs Check intake pipe to see if it is squashed or damaged Check the sealing surface between throttle body and intake manifold to see if it is in good condition Check high voltage wi...

Page 287: ...iginition switch at ON check the voltage on terminal to ignition switch connected to starting motor push pull coil with a multimeter to see if it is higher than 8V No Repair or replace ignition switc...

Page 288: ...e harness to see if it is damaged No Go to next step Yes Go to next step 6 Check ignition coil to see if it is in normal condition No Replace Yes Go to next step 7 Check socket connector of crankshaft...

Page 289: ...mmutator between ECU and wire harness and then check Pin 15 47 and 29 of ECU to see if there is voltage on them Check the anode power wire connecting these pins and the grounding wire connecting Pin 2...

Page 290: ...and fuel pipe 5 Check if fuel leakage occurs in injector and fuel pipe No Go to next step Yes Check coolant temperature and lines 6 Unplug water temperature sensor connector and make engine start Che...

Page 291: ...eplace injector Yes Replace fuel 8 Replace fuel and check if fuel is deteriorated or contains water No Go to step 14 Yes Go to next step 9 Check if fuel pressure is lower than 350kPa No Go to step 13...

Page 292: ...emperature reaches normal value No Replace ECU Yes Go to next step 17 Check if cylinder compression pressure of engine is normal No Troubleshooting Yes Repair or replace 18 Check if intake manifold ab...

Page 293: ...le has carbon deposit No Replace Yes Go to next step 5 After successful starting check to see if intake manifold pressure is between 35 55kPa during idling No Eliminate intake system air leakage failu...

Page 294: ...fuel return and check if fuel pressure is formed rapidly No Repair replace injector or fuel pipe Yes Repair or replace fuel inlet pipe 15 Check if leakage or clogging occurs in fuel inlet pipe No Rep...

Page 295: ...next step 6 Check to see if the high voltage line resistance of each cylinder is in good order No Replace Yes Replace 7 Check if ignition coil is damaged No Go to next step Yes Go to next step 8 Chec...

Page 296: ...manifold pressure and intake air temperature sensor is blocked up No Go to next step Yes Go to next step 19 Make engine run at idle speed when coolant temperature reaches the point where closed loop c...

Page 297: ...switch on ignition switch and then connect commutator between ECU and wire harness to check the voltages of intake air temperature and water temperature sensor as well as ECU s 54 62 pins served as 4...

Page 298: ...t fuel pressure gauge valve Strap the 30 and 87 pins of fuel pump relay to make fuel pump work and then check if fuel pressure is at about 350kPa No Go to step 9 Yes Go to step 8 6 Provide 12V voltage...

Page 299: ...15 Pull out coolant temperature sensor to see if engine is in working order No Go to next step Yes Go to next step 16 Check if cylinder compression pressure of engine is normal No Troubleshooting Yes...

Page 300: ...repair air conditioner circuit Yes Go to next step 3 Check if pressure of air conditioning system electromagnetic clutch of compressor and air conditioning pump are in good order No Repair or replace...

Page 301: ...re sensor output oxygen sensor output electronic ground ignition switch pins as well as 57 58 64 and 65 pins output to idle speed actuator are in good order No Repair or replace wire harness Yes Go to...

Page 302: ...position step down on the brake pedal to see if idling speed is too high No Go to step 6 Yes Repair or replace vacuum booster 5 Clamp vacuum booster tube to see if idling speed turns normal No Go to n...

Page 303: ...hen check if fuel pressure is at about 350kPa No Go to step 10 Yes Go to step 9 7 Provide 12V voltage directly from accumulator to injector with special connector and check if injector is working in g...

Page 304: ...between ECU and wire harness to check the voltages of output signal terminal ground terminal and 76 60 pins served as 4 5 5V sensor power of ECU throttle position sensor to see if they are in good ord...

Page 305: ...rap the 30 and 87 pins of fuel pump relay to make fuel pump work and then check if fuel pressure is at about 350kPa No Go to step 11 Yes Go to step 10 8 Provide 12V voltage directly from accumulator t...

Page 306: ...terminal ECU sensor signal ground terminal as well as ECU32 33 pins as 4 5 5V sensor power to see if they are in good order No Repair or replace wire harness Yes Go to next step 6 Make engine run at...

Page 307: ...CU 15 Air conditioning system failure Yes Go to next step 1 Check if there is enough refrigerant in system and if air conditioning belt air conditioning clutch and pressure switch are working in good...

Page 308: ...tions on fuel supply system maintenance When disassembling and assembling fuel pump on the fuel tank filled or partly filled with fuel pay attention to the following Before operation device well enoug...

Page 309: ...FI System Caution the ECU plug of A series engine is liable to have problem of interior looseness in case such problem occurs while line sensors and control unit are all normal ECU wire harness shall...

Page 310: ...ce value decreasing with the increasing of intake air temperature And engine ECU monitors the variation of intake air temperature via a comparison circuit inside Failure diagnosis Short circuit occurs...

Page 311: ...y inside ECU instead output input signal ratio is tested thus preventing from signal fluctuation due to voltage fluctuation 2 Failure diagnosis Throttle position sensor signal above measuring range Th...

Page 312: ...r open circuit occurs in water temperature sensor line Limiting data 2 5 5 K Installation hint tightening torque is 15Nm in maximum Hints the vehicle is equipped with 2 water temperature sensors one i...

Page 313: ...l data processing circuit failure Cylinder detecting signal is unreliable After failure mark of knock sensor being set knocking closed loop control is shut down reduceing a safety angle from the ignit...

Page 314: ...the oxygen sensor is set Accumulator voltage is unreliable Manifold absolute pressure signal is unreliable Engine coolant temperature signal is unreliable Injector driver stage failure After oxygen s...

Page 315: ...r the control of EFI system Installation to be fixed by the support of bracket under pilot trench of front windshield Pay attention to waterproofing ECU Functions Multipoint group injection Controllin...

Page 316: ...Crankshaft position sensor signal negative Serial communication interface Bootstrap LPT Standard 5V power output Main power Sensor ground Idle stepper motor 1B Idle stepper motor 1A Compressor relay G...

Page 317: ...ting especially for engines using CNG and LPG Fuel temperature has fairly big impact on fuel pump performance in case of longstanding operation under high temperature condition when fuel temperature i...

Page 318: ...er long term idling In this case please check carefully to see if the injector cements Failure diagnosis EFI system of A11 does not apply failure diagnosis to injector itself but to injector driver st...

Page 319: ...ontrols valve opening Failure diagnosis ECU can monitor short circuit open circuit status of two coils in idle speed stepper motor and lighten engine failure lamp when such failure occurs then engine...

Page 320: ...there is no failure code the only way is to check the resistance of ignition coil to determine if the said coil is in working order Under normal conditions the thermal value of working ignition coil i...

Page 321: ...uel distributing pipe and injector Installation requirement connect fuel inlet outlet pipes with rubber pipes and fasten them down wtih hoops The size of hoops used shall match that of rubber pipes so...

Page 322: ...ead center to be used in engine ignition fuel injection and timing system Composition principle MOTOROLA system introduces rotational speed sensor of magnetic induction coil type and generates alterna...

Page 323: ...continuance of an identified failure exceeds the stabilization time stipulated for the first time ECU collects it as a stable failure and stores it as constant failure if such failure disappears ECU s...

Page 324: ...lication of scanner and data flow during the operational process of engine is also readible through the scanner which is favourable for troubleshooting of engine system Earth signal wire of engine dia...

Page 325: ...und or accumulator anode and may be even mechanical failure Failure is an internal error its external exhibition is various symptoms If a symptom is found first check with scanner or according to flas...

Page 326: ...emperature sensor Lo Excessive intake air temperature Use default intake air temperature value 3221 17 Intake air temperature sensor Hi Lo Intake air temperature out of limit Use default intake air te...

Page 327: ...output Short Short circuit occurs in air conditioning signal to ground Nil 1232 65 Air conditioning output Open Air conditioning signal open circuit Nil 2232 66 Air conditioning output Short Short cir...

Page 328: ...ngine power No Cause of failure Troubleshooting 1 Electric fuel pump defect Check and fasten connections check electric fuel pump and replace when necessary 2 Fuel filter or pipeline clogging Check if...

Page 329: ...rs Use scanner to check throttle opening the angle is between 2 14 when throttle is shut down 1 Throttle valve casing Abnormal throttle opening If throttle angle is normal check to see if the contact...

Page 330: ...engine Engine before stalling shall have be idling for a period of time to decrease temperature in a smooth way so as to reduce thermal impact strength and benefit the extension of service life of ope...

Page 331: ...disconnecting any electrical equipment so as to avoid damage on electronic component caused by induced electromotive force which is generated in circuit Failure Diagnosis for EFI System Generally the...

Page 332: ...44 2 4 Removing central seat brake C and oil pump 45 2 5 Removing clutch B and 2nd gear one way overrun clutch 48 2 6 Removing clutch A 49 2 7 Removing clutch E 51 2 8 Removing output shaft and 1st ge...

Page 333: ...es or 50 000 km mileage all clutches and brakes must be replaced 3 If the clutch is bumped it is absolutely necessary to use appropriate cleaning agent to clean torque converter oil cooler and oil coo...

Page 334: ...The manual of 4HP14 A T removing and installing CHERY AUTOMOBILE CO LTD 1 4HP14 A T assembly discription 1 1 4HP14 A T assembly explode view 2...

Page 335: ...The manual of 4HP14 A T removing installing CHERY AUTOMOBILE CO LTD 1 2 4HP14 A T power transfer schematic 3...

Page 336: ...earence between lock cam and shift cam Measure the distance X from shift cam to housing surface with measuring tool Determine thickness of washer by following formula S mm X mm 0 1 mm S washer thickne...

Page 337: ...0 288 and 5P 95 000 289 Turn over the transmission body by 180o stall main rear output gear and mounting bolts stall parking mechanism and retain gear shifter OTE Keeping brake rotor downward because...

Page 338: ...with torque wrench Only after both gears installed correctly can the parking plunger be removed easily Turn gear with an appropriate bolt repeatly as shown on fig Install parking plunger select stop...

Page 339: ...T removing installing CHERY AUTOMOBILE CO LTD Making marks on bolts and gears as shown on figure Turn screw 12 mm counterclockwise from marking position Using appropriate tool tamp mounting bolt flang...

Page 340: ...ess gasket and sub rear output gear and tighten bolt by hand To maintain the clearance select the thickest washer in alternative dimensions After Applying park gear tighten sub rear output gear lockin...

Page 341: ...lling CHERY AUTOMOBILE CO LTD Set the indicator to zero 1 Turn the screw until the needle moves 2 Turn the gear till needle to zero position Loosen transmisson lower mount carrier 5P 95 000 288 then t...

Page 342: ...75 Maximun washer thickness provided in table X Measured reading 0 06 Selected clearance select range is from 0 05 to 0 10 For example S 1 75 0 46 0 06 S 1 75 0 4 S 1 35mm Measured readings X 0 46mm...

Page 343: ...ickness adjustment Install 2 2mm thickness snap ring Use measuring unit with dial indicator Put the indicator right on pointer must be at zero position Lift up clutch read the readings Clearance shoul...

Page 344: ...ance washer thickness Install adjusting washer 2 0mm thickness and flanged thrust washer Install clutch brake oil pump and other middle units And retain with bolts Tighten torque is 10Nm While install...

Page 345: ...When measuring the indicator must be positively placed and the pointer is set to zero positon As shown on fig pull up the handle read out the measured result Clearance should be within 0 1mm 0 3mm The...

Page 346: ...all adjustor 5P 95 000 286 and tighten to 7Nm pressing bearing and outer race As shown on fig turn the housing clockwise tighten to 7Nm and repeat the above procedures As shown on fig using depth gaug...

Page 347: ...ing top For example Distance B 8 65mmm Pretension washer thickness is within 0 1mm to 0 15mm Washer thickness is determined by following formula Dimension A dimension B washer thickness S For example...

Page 348: ...cating rod of brake band Adjusting bolt tighten torque is 10Nm Tool 6 socket spanner NOTE While tightening the brake band place the locating rod to proper installation position Make marks on bolts and...

Page 349: ...nstalling CHERY AUTOMOBILE CO LTD 1 3 7 Adjusting throttle cable Pull the throttle cable to the most length Measure as shown on figure And the measuring value cannot be more than 39mm otherwise it wil...

Page 350: ...g and installing CHERY AUTOMOBILE CO LTD 1 4 Special tools No Figure Code and Application 1 A Tp operating bracket of 5 x 46 000 244 2 Torque converter driver installer 5 x 56 000 090 3 Bearing inner...

Page 351: ...de and Application 4 Removing and installing socket Rolle x 1000 1 5 Removing and installing socket 5 x 46 000 232 used for inner racer of roller bearing on driven shaft and 1st gear one way overrunni...

Page 352: ...P14 A T removing and installing CHERY AUTOMOBILE CO LTD No Figure Code and Application 7 Piston C assembling tool 5 x 46 000 295 8 Diaphragm spring compression device 5 x 46 167 9 Clutch B drum hook 5...

Page 353: ...CHERY AUTOMOBILE CO LTD No Figure C ode and Application 10 5 46 000 146 Clutch B diaphragm spring compression device B 5 x 46 000 146 11 Diaphragm spring compression device 5 x 46 000 148 12 Output sh...

Page 354: ...CHERY AUTOMOBILE CO LTD No Figure Code and Application 13 1st one way overrun clutch snap ring remover 5 x 46 000 243 14 Output shaft gear and differential bearing inner race remover 5 x 46 000 297 15...

Page 355: ...4HP14 A T removing installing CHERY AUTOMOBILE CO LTD Figure Code and Application 16 Bearing outer race puller Puller 21 7 17 Bearing outer race puller 22 2 18 Shift shaft oil seal installing tool 5 x...

Page 356: ...and installing CHERY AUTOMOBILE CO LTD No Figure Code and Application 19 Dowel pin drift of shift shaft 5 46 000 119 20 Oil sealing installing socket 5 46 000 161 21 Driven shaft bearing inner race c...

Page 357: ...UTOMOBILE CO LTD No Figure Code and Application 22 Oil pump sealing installing tool 5 x 46 000 299 23 Output shaft output gear and differential bearing inner race compression tool 5 x 46 000 300 24 Cl...

Page 358: ...installing CHERY AUTOMOBILE CO LTD No Figure Code and Application 25 Differential oil sealing assembling tool 5 46 000 111 26 Speedmeter drive gear case oil sealing intalling socket 5 46 000 180 27 P...

Page 359: ...T removing installing CHERY AUTOMOBILE CO LTD No Figure Code and Application 28 Shift shaft clearence adjuster 5P 95 001 287 29 Input shaft mounting carrier 5P 95 000 288 30 Output shaft mounting car...

Page 360: ...emoving and installing CHERY AUTOMOBILE CO LTD No Figure Code and Application 31 Shaft shaft position adjuster 5P 95 001 285 32 Output gear clearence test tool 5P 01 001 518 33 Middle seat clearence t...

Page 361: ...The manual of 4HP14 A T removing installing CHERY AUTOMOBILE CO LTD No Figure Code and Application 34 Differential adjuster 5P 95 000 286 29...

Page 362: ...governor Torx bix 27 10 Connecting bolt side cover and transmission case Torx bix 27 10 Mounting bolt oil pump body Torx bix 27 10 Connecting bolt central seat and transmission case Torx bix 27 10 Lo...

Page 363: ...bnormal sound from transmission when turning High fluid level Air bubble occurs in transmission causing power consumption High fluid temperature when operating in high speed Oil evaporates into atmosp...

Page 364: ...sembly with 5 x 46 000 244 braket and drain oil Remove converter carrier Remove torque converter with special tool 5 x 56 000 090 NOTE when removing torque converter prevent oil leaking as possible an...

Page 365: ...alve plate mounting bolts with 10 big size bolt head Tool 27 quincunx socket spanner Turn over transmission by 90 degree remove 17 mounting bolts on the converter housing Tool 13 socket spanner Remove...

Page 366: ...ILE CO LTD Remove differential and drive gear of the speedmeter Remove central seat oil pump and brake C assembly Tool 27 quincunx socket spanner NOTE During disassembling hold transmission firmly Rem...

Page 367: ...OMOBILE CO LTD Loosen C type brake band Remove clutch A clutch B and 2nd gear one way overrunning clutch as an assembly Separate clutch A clutch B and one way overrunning clutch Slightly remove the te...

Page 368: ...T removing and installing CHERY AUTOMOBILE CO LTD Remove clutch E and input shaft Remove center shaft clutch E support and thrust bearing together Remove sun gear shaft clutch A support and thrust bea...

Page 369: ...The manual of 4HP14 A T removing installing CHERY AUTOMOBILE CO LTD Remove sun gear drive drum and thrust bearing Remove the sun gear As shown on fig remove planetery mechanism 37...

Page 370: ...all locator 5P 95 000 289 on output shaft top and fix it on the transmission housing Install locator on the driven shaft and fix it on the housing with bolts Turn over transmission by 180 Remove 11 co...

Page 371: ...e apply stop shift using appropriate tool loosen rear sub output gear mounting bolt After removing main rear and sub rear output gear with appropriate tool new transmission rear output gear can be rem...

Page 372: ...46 000 297 and 2 cotter spanners remove rolling bearing inner race in direction shown figure Turn over transmission by 180o remove 2 holding units Then remove driven shaft with governor still remaine...

Page 373: ...removing installing CHERY AUTOMOBILE CO LTD Remove output gear and rear gear ring as an assembly Remove slice gear C refers to sub gear without wheel Release parking position remove governor cover an...

Page 374: ...A T removing and installing CHERY AUTOMOBILE CO LTD Turn over the transmission by 90o remove protect plate Using removing installing socket 5 x 46 000 155 remove groove nut Remove 1st gear one way ov...

Page 375: ...ll an installer 5 x 46 000 295 with screw mechanism push brake band hydraulic cylinder head inwards Remove snap ring with 2 screwdrivers Take off brake band hydraulic cylinder cap and brake band pisto...

Page 376: ...stalling CHERY AUTOMOBILE CO LTD Screw adjuster bolt out after loosening locking nut Pull out brake band locator rod 2 3 Removing brake band D Turn over transmission by 90o As shown on figure remover...

Page 377: ...pring Insert air gun into oil inlet and remove piston D using HP gas 2 4 Removing central seat brake C assembly and oil pump Press down the diaphragm spring of the brake C with special tool 5 x 46 000...

Page 378: ...emoving and installing CHERY AUTOMOBILE CO LTD Insert air gun into oil inlet hole removing piston C using HP gas Remove snap ring with screwdriver Remove central seat snap ring First step loosen pump...

Page 379: ...out snap ring of the center seat with 2 hooks Loosen connecting bolt separate central seat from pump body Only plastic hammer can be used to remove If removing in proper working process piston ring an...

Page 380: ...UTOMOBILE CO LTD 2 5 Removing clutch B and 2nd one way overrun clutch Remove cotter snap ring and clutch B assembly Press pressure plate with special tool 5 x 46 000 146 then remove snap ring and thru...

Page 381: ...OMOBILE CO LTD Insert the air gun into oil inlet hole remove pistion B using HP gas One way overrun clutch can not be further disassembled 2 6 Removing clutch A Using appropriate snap ring plier remov...

Page 382: ...D Remove the snap ring clutch A assembly and diaphragm spring in order Using special tool 5 x 46 000 167 press piston with flow guiding flange then remove snap ring with appropriate tool Insert air gu...

Page 383: ...4HP14 A T removing installing CHERY AUTOMOBILE CO LTD Knock piston gently and remove piston A and the diaphragm spring 2 7 Removing clutch E Take out thrust washer Remove cotter snap ring and clutch...

Page 384: ...diaphragm spring with the special tool 5 46 000 148 and then take off retainer Remove shim spring Insert air gun and remove piston E using HP gas 2 8 Removing output shaft and 1st gear one way overrun...

Page 385: ...move rolling bearing using special tool 5 46 000 296 Remove cotter snap ring place whole one way overrun clutch into remover installer 5 46 000 232 Remove cotter snap ring with installing sleeve 5 46...

Page 386: ...ughly disassembled Clutch inner ring outer gear ring and free wheel 2 9 Removing governor and speedometer Loosen four mounting bolts and separate the governor case from the hub sleeve NOTE If the case...

Page 387: ...Press down spring with screwdriver remove locking piece spring and piston 2 After removing components are as shown in figure There are only two pistons Loosen connecting bolts on the governor hub sle...

Page 388: ...osition and then take them out For new type structure remove two differential side shafts and then take out two side gears For convenience of inspecting scratch on side gears move the two side gears t...

Page 389: ...OBILE CO LTD Remove hex bolts in the speed meter drive gear case Tool 13 sleeve Loosen mounting bolts in the speedometer sensing rotor and carrier Take out the speedometer sensing rotor and carrier an...

Page 390: ...sealing ring using appropriate drift The bearing outer race may be removed with the sleeve Remove the differential taper rolling bearing outer race in same method 2 10 Removing transmission housing a...

Page 391: ...BILE CO LTD Loosen mounting bolts and remove the mounting carrier Take out two dowel pins on throttle cam throttle cam and return spring Loosen two mounting bolts and remove pawl spring Tool 27 socket...

Page 392: ...4 A T removing and installing CHERY AUTOMOBILE CO LTD Removing parking plunger brake plate spring and lock cam Take out the brake rotor dowel pin With appropriate drift remove elastic pin and then rem...

Page 393: ...LE CO LTD Remove shift cam and adjusting gasket Remove dowel pin using appropriate drift Take out pawl and retracting spring Removing bolts and sealing ring Remove bearing outer race with special tool...

Page 394: ...f 4HP14 A T removing and installing CHERY AUTOMOBILE CO LTD Remove driven shaft bearing and outer race with same method Remove differential and shift shaft sealing ring Loosen back light switch Tool 2...

Page 395: ...The manual of 4HP14 A T removing installing CHERY AUTOMOBILE CO LTD Remove all locking bolt and clean housing 63...

Page 396: ...d installing CHERY AUTOMOBILE CO LTD 3 Assembling 3 1 Assembling transmission housing and parking system If necessary install lug 01 250 and fix with hex bolts Tool 13 socket Torque 23Nm When assembli...

Page 397: ...ns Torque Nm 01022 Locking bolt M14 1 5 40 01020 Sealing ring A14 18 01270 Locking bolt M10 1 15 01260 Sealing ring A10 14 Installing back light switch 01 112 with use new sealing washer 01 116 Tool 2...

Page 398: ...0 and 09 040 into the housing Install driven bearing outer race properly and adjust its position in the housing Otherwise the mounting bolt can not be aligned with threaded holes Install two bearing o...

Page 399: ...MOBILE CO LTD Press differential oil sealing 09 130 into location with installing sleeve 5 46 000 299 Install shift shaft oil sealing 06 010 with special spindle drift 5 46 000 187 Knock rolling pin 0...

Page 400: ...5P 89 001 995 Install pawl spring dowel pin 06 040 and then install the pawl spring Keep pawl spring close to the adjusting piece and then fix with two bolts 06 050 Tool 27 inner socket spanner Torqu...

Page 401: ...06 110 with the lock spring 24 010 Locking cam must be installed on brake rotor Install the whole mechanism on the dowel pin and connect the brake rotor and lock cam with spring Shift cam and lock ca...

Page 402: ...lled between the cam and the housing Therefore brake rotor must be removed and pull shift shaft out enough as necessary Install shift shaft elastic pin 06 090 with special tool 5 46 000 119 and a hamm...

Page 403: ...BILE CO LTD Install pawl 24 040 on dowel pin and then install dowel pin to stop Connect return spring and the pawl and push the spring outward Install the parking plunger 24 030 As shown on figure pla...

Page 404: ...The manual of 4HP14 A T removing and installing CHERY AUTOMOBILE CO LTD 3 2 Installing band brake C Install O ring 31 340 on groove on brake band plunger 31 330 end Oil O ring before installing 72...

Page 405: ...screw bolt into housing half or so Installing piston C Place washer 31 400 thick on piston plunger 31 390 then install elastic washer 31 404 thin NOTE Both washers are of U shape When installing conc...

Page 406: ...on piston After oiling O ring mount whole piston into the housing Place 2 O rings 31 470 on brake fluid hydraulic cylinder cap and apply oil or Vaseline and then install cylinder cap Press cylinder c...

Page 407: ...The manual of 4HP14 A T removing installing CHERY AUTOMOBILE CO LTD After bending brake band with pressure install it into housing and adjust position between the brake band and two plungers 75...

Page 408: ...oving and installing CHERY AUTOMOBILE CO LTD 3 3 Assembling brake D and 1st one way overrun clutch Install O rings 17 020 and 17 030 in piston 17 010 and apply lubricant Build piston into the housing...

Page 409: ...CO LTD Install diaphragm spring 17 040and thrust washer 17 090 Install one way overrun clutch 17 130 into the clutch outer gear ring USE CARE to right tooth match and push clutch downwards to stop Ins...

Page 410: ...half or so and then turn clockwise to location Place clutch on special tool 5 46 000 232 and install snap ring 17 100 with installing drift pin 5 46 000 243 Install 1st gear one way overrun clutch int...

Page 411: ...Nm As shown on figure using appropriate drift tamp tooth ring into groove on grooved nut enhancing locking Turn over housing by 90 check clutch operating condition Clockwise turn clutch confirm clutch...

Page 412: ...The manual of 4HP14 A T removing and installing CHERY AUTOMOBILE CO LTD 3 4 Assembling governor driven shaft Insert piston 33 040 into the governor case 33 030 and fix with lock sheet 33 050 80...

Page 413: ...with lock sheet 33 090 Governor units are shown on right figure The piston may not be divided into three sections Install driven shaft into governor for adjusting governor position much easier Fix the...

Page 414: ...with bolts Install two snap rings 33 020 and let them interlocked Install O ring 33 022 into the governor hub Tool 27 inner socket spanner Torque 10Nm Install the governor shroud 33 110 After applying...

Page 415: ...ing CHERY AUTOMOBILE CO LTD Press bearing inner race 09 080 into driven shaft 5 46 000 070 with special tool 5 46 000 182 Install one end of the driven shaft into the governor Install a mounting carri...

Page 416: ...anual of 4HP14 A T removing and installing CHERY AUTOMOBILE CO LTD 3 5 Assembling planetary mechanism and rear output gear Install drive wheel drum 17 170 into 2nd gear one way overrun clutch outer ra...

Page 417: ...MOBILE CO LTD Press rolling bearing inner race 14 050 into output shaft 14 010 with installing socket 5 46 000 300 onnect output shaft with front gear ring 32 040 and fix with snap ring 32 050 Install...

Page 418: ...y 180 Press bearing inner race 14 050 onto rear main output gear 09 010 using installing socket 5 46 000 300 and then press bearing inner race 09 040 onto rear sub output gear 09 020 with same method...

Page 419: ...rear onto driven shaft Tighten bolt 09 030 NOTE The whole output gear mechanism needs adjusting by procedures in section 1 4 2 in page 5 2 Lubricating gasket 09 210 and then install it Install side c...

Page 420: ...UTOMOBILE CO LTD Install washer 14 020 thrust bearing 14 030 and thrust washer14 040 Install snap ring 32 020 into groove of planetary carrier and suddenly press both ends of the snap ring for self lo...

Page 421: ...CHERY AUTOMOBILE CO LTD Install the sun gear 32 030 in the planetary mechanism Install drive wheel drum 30 310 and make it engaged with the sun gear Install washer 02 190 thrust bearing 02 180 and th...

Page 422: ...ment condition If the installation is right drive drum shall turn towards the sun gear Install thrust washer 30 170 thrust bearing 30 180 and washer 30 190 onto intermediate shaft 30 160 and then inst...

Page 423: ...The manual of 4HP14 A T removing installing CHERY AUTOMOBILE CO LTD 3 6 Installing input shaft and clutch E assembly After applying lubricant or petrolatum to O ring install it into piston E 30 050 91...

Page 424: ...body of engine input shaft 30 010 Install two U washers 30 080 on the top of the piston with installing tool 5 46 000 148 and fix with snap ring 30 090 Install the whole clutch E assembly Install oute...

Page 425: ...friction plate and sheet steel is changed the outer diameter of the retainer ring shall be changed accordingly Install snap ring 30 130 Install washer 30 020 and 30 030 into input shaft and make them...

Page 426: ...The manual of 4HP14 A T removing and installing CHERY AUTOMOBILE CO LTD 3 7 Assembling clutch A assembly Install 2 O ring 02 068 and on piston and apply lubricant to piston 94...

Page 427: ...ILE CO LTD Install piston A into cylinder A02 050 Install diaphragm spring 02 090 with its convex surface upwards Install O ring 02 096 into piston 02 092 and lubricate O ring Install piston 02 092 In...

Page 428: ...tall outer teeth sheet steel 02 120 and friction plate 02 130 alternately Install retainer ring 02 140 and fix with snap ring 01 150 NOTE Adjust as per procedures in section 1 4 3 page 5 8 Install two...

Page 429: ...a snap ring pliers NOTE The worm must be fixed with the snap ring otherwise there may exists axial clearance Install the clutch assembly into the housing shake clutch A to seat clutch NOTE The thickn...

Page 430: ...l of 4HP14 A T removing and installing CHERY AUTOMOBILE CO LTD 3 8 Assembling clutch B and 2nd gear one way overrun clutch After applying lubricant to O ring install O ring 31 220 into clutch drum B 3...

Page 431: ...ILE CO LTD Install lubricated O ring 31 230 into piston B 31 210 Install piston B into the clutch drum and install one pressure ring on the piston Install diaphragm spring 31 290 with special tool and...

Page 432: ...install friction plate 31 260 and outer teeth sheet steel 31 250 alternately Install retainer ring 31 270 and snap ring 31 280 onto assembly top Install clutch B assembly Shake clutch B to make its i...

Page 433: ...ral Position D 1st gear idle Position D 1st gear forced upshift Position D 2nd gear idle Position D 2nd gear forced upshift Position D 3rd gear idle Position D 3rd gear forced upshift Position D 3rd g...

Page 434: ...c transmission assembly s service Vehicle Service Transmission fluid level inspection Oil changing Oil feed filter screen and gasket Housing gap sealing Gearshift cable adjustment Air throttle cable r...

Page 435: ...Clutch A and brake D control valve plate Bottom valve plate Main valve plate Transmission assembly Brief introduction of automatic transmission structure and working principle Brief introduction of t...

Page 436: ...Transmission oil grade Dexron DD or Dexron M Fluid pressure Position P N D 3 2 1 7 10kg cm Idle Position R back gear 10 12kg cm2 Position D 10 13kg cm Stall Position R 10 12kg cm Fluid level Service F...

Page 437: ...n shift actuator s working principle P R N D 3 2 1 Control handle position Parki ng Back Neutr al 1 2 3 4 1 2 3 1 2 1 A Drive clutch B 2nd gear clutch Clutch E Direct clutch C 2nd gear brake C 2nd 4th...

Page 438: ...ssion plate s connecting bolt 40 71 Bottom valve plate interior compression plate s connecting bolt 6 71 Neutral start switch s connecting nut 8 30 Shift cable s connecting nut 6 53 Shift cable s adju...

Page 439: ...nger KA 000 088 KA 0888 Differential adjuster J2936 1 Bearing inner racer remover KA 002 111 KA 111 Bearing assembler KA 001 023 KA 232 Bolt remover KA 000 155 KA 155 Grooved nut remover socket KA 001...

Page 440: ...ring assembler KA 000 288 KA 288 Driven shaft locator KA 001 483 KA 483 Gap detector KA 000 298 KA298 Bearing inner racer remover KA 001 655 KA 655 Main back output gear gap detector KA 001 715 04 KA...

Page 441: ...CHERY AUTOMOBILE CO LTD Automatic Transmission Fault Diagnosis Manual DIAGRAM 1 9...

Page 442: ...CHERY AUTOMOBILE CO LTD Automatic Transmission Fault Diagnosis Manual DIAGRAM 2 10...

Page 443: ...CHERY AUTOMOBILE CO LTD Automatic Transmission Fault Diagnosis Manual DIAGRAM 3 11...

Page 444: ...CHERY AUTOMOBILE CO LTD Automatic Transmission Fault Diagnosis Manual DIAGRAM 4 12...

Page 445: ...CHERY AUTOMOBILE CO LTD Automatic Transmission Fault Diagnosis Manual DIAGRAM 5 13...

Page 446: ...CHERY AUTOMOBILE CO LTD Automatic Transmission Fault Diagnosis Manual DIAGRAM 6 14...

Page 447: ...CHERY AUTOMOBILE CO LTD Automatic Transmission Fault Diagnosis Manual DIAGRAM 7 15...

Page 448: ...CHERY AUTOMOBILE CO LTD Automatic Transmission Fault Diagnosis Manual DIAGRAM 8 16...

Page 449: ...CHERY AUTOMOBILE CO LTD Automatic Transmission Fault Diagnosis Manual DIAGRAM 9 17...

Page 450: ...CHERY AUTOMOBILE CO LTD Automatic Transmission Fault Diagnosis Manual DIAGRAM 10 18...

Page 451: ...CHERY AUTOMOBILE CO LTD Automatic Transmission Fault Diagnosis Manual DIAGRAM 11 19...

Page 452: ...CHERY AUTOMOBILE CO LTD Automatic Transmission Fault Diagnosis Manual DIAGRAM 12 20...

Page 453: ...CHERY AUTOMOBILE CO LTD Automatic Transmission Fault Diagnosis Manual DIAGRAM 13 21...

Page 454: ...CHERY AUTOMOBILE CO LTD Automatic Transmission Fault Diagnosis Manual DIAGRAM 14 22...

Page 455: ...CHERY AUTOMOBILE CO LTD Automatic Transmission Fault Diagnosis Manual DIAGRAM 15 23...

Page 456: ...CHERY AUTOMOBILE CO LTD Automatic Transmission Fault Diagnosis Manual DIAGRAM 16 24...

Page 457: ...CHERY AUTOMOBILE CO LTD Automatic Transmission Fault Diagnosis Manual DIAGRAM 17 25...

Page 458: ...CHERY AUTOMOBILE CO LTD Automatic Transmission Fault Diagnosis Manual DIAGRAM 18 26...

Page 459: ...CHERY AUTOMOBILE CO LTD Automatic Transmission Fault Diagnosis Manual DIAGRAM 19 27...

Page 460: ...CHERY AUTOMOBILE CO LTD Automatic Transmission Fault Diagnosis Manual DIAGRAM 20 28...

Page 461: ...CHERY AUTOMOBILE CO LTD Automatic Transmission Fault Diagnosis Manual DIAGRAM 21 29...

Page 462: ...CHERY AUTOMOBILE CO LTD Automatic Transmission Fault Diagnosis Manual DIAGRAM 22 30...

Page 463: ...CHERY AUTOMOBILE CO LTD Automatic Transmission Fault Diagnosis Manual DIAGRAM 23 31...

Page 464: ...Automati bly 4HP14 Automatic transmission appearance vie c transmission assem sketch w 1 Differential out 2 Side cover pan 4 Neutral start switc 5 Shift shaft 6 Air vent 7 Air throttle cable 8 Brake...

Page 465: ...converter 11 2 M 3 D 3 A 4 S 15 8 Planetary gear me 16 18 10 Auxiliary back output gear 2 Intermediate seat and brake C assembly Brake D 3 Output shaft 1 ain output gear 4 Differential 1 iaphragm spr...

Page 466: ...te The parking interlock has b When nece parking interlock sys a normal friction ssary replace the tem Adjust pawl spring The parking gear uld not engage or is disengaged A When neces l spring co bnor...

Page 467: ...The back light is not on Neutral start switch fault Replace the neutral start switch trol handle is at Position N osis Actions Fault analysis when the con Fault description Fault diagn The engine coul...

Page 468: ...governor s bushing is stuck Replace the governor s connection mechanism Replace 1st 2nd gearshift valve inside the bottom valve plate and 2nd 3rd gearshift valve spindle and spring inside the main val...

Page 469: ...rottle cable s bushing has too high friction Replace the throttle cable Throttle cable is difficult to operate The governor s hydraulic valve is obstructed Replace the valve plate assembly Replace clu...

Page 470: ...Similarly dete Item P N D 3 2 1 7 10kg cm 995 1421psi Oil pressure Idle R 10 12kg cm 1421 1706psi D 10 13kg cm 1421 1848psi Stall R 10 12kg cm 2274 2843psi Stall test Note The stall test should not l...

Page 471: ...ion inspection General inspection method 1 inspect whether the transmission leaks or not 2 the suspected part of leaking 3 4 5 f the engine and find the point of leaking 6 repair Powder inspection met...

Page 472: ...the side cover s connecting bolt transmis The side cover s gasket is damaged Replace the side cover gasket It leaks at brake C and the aulic cylinder head Defective O ring on the cylinder head Replac...

Page 473: ...ve the oil pan and gasket Remove the oil feed filter screen s back cover oil feed filter screen and gasket powder cermet powder from the clutch s surface rubble parti matters from the engine coolant o...

Page 474: ...hen blow dry ote The epoxy resin grouting agent will hurt skin and eyes Please operate as instructed by ckaging label provided by the manufacturer Mix enough epoxy resin grouting agent as specified Af...

Page 475: ...olt Pull the gear shifter arm to the limit i e position P hift cable and Fix the gearshift cable with the adjusting bolt and nut Install the gearshift box gear position display board Install the batte...

Page 476: ...mbly procedure Remove the battery Remove the cable ends from the air throttle s swing arm 3 ehicle n and gasket Remove the valve plate assembly Rotate the air throttle cable and remove the cable ends...

Page 477: ...tall the air throttle cable 2 Install the air throttle cable on the air throttle s swing arm Lift the vehicle Rotate the cam by certain degree and install the cable Install the control valve plate t L...

Page 478: ...re Lift the vehicle oil pan and gasket valve plate throttle cable 5 wl spring for cam 6 1 adjusting turnbuckl Permissible gap 0 1mm Check the distance between t idle po adjusting turnbuckle when WO Di...

Page 479: ...awl spring The tightening torque for the pawl spring s positioning bolt 3 Install the air throttle cable 4 late Dis cedure ry s negative 2 utral start switch s wiring harness 1 2 10Nm Install the cont...

Page 480: ...etween the neutral start switch and the case Remove the neutral start switch ssembly procedure Install the neutral start switch and fix it on the case with the connecting nut Tightening torque 40Nm Co...

Page 481: ...all the electromagnetic interlock and fix it with a bolt Tightening torque 8Nm Connect the electromagnetic interlock s electric terminal battery s Oil feed pipe isassembly procedure Remove the battery...

Page 482: ...and the oil pan ssembly procedure pe and fix it Install the connecting bolt at upper raulic fl Remove the oil feed pipe A 1 Install the oil feed pi with a fixing nut Tightening torque 15Nm 2 part of t...

Page 483: ...peed sensor isassembly procedure Remove the battery s negative ed the and remove Remove the O ring on the vehicle speed sensor D 1 terminal 2 Lift the vehicle 3 Remove the vehicle spe sensor s termina...

Page 484: ...sis Manual Assembly procedure Install O ring on the vehicle speed sensor Install the vehicle speed sensor and fix it with the dowel pin Install the terminal on the vehicle y s negative 1 1 2 speed sen...

Page 485: ...sket Check whether there is me particles and foreign matters in en make necessary repair ssembly procedure Install a new gasket Install the oil pan and fix it ty of e Check the fluid level D 1 2 N sur...

Page 486: ...lts Tightening torque 10Nm Fill hydraulic fluid into the transmission Lower the vehicle dometer drive gear case isassembly procedure Take off the vehicle speed sensor s terminal Loosen the connecting...

Page 487: ...out the odometer s drive gear ssembly procedure Install the odometer s drive gear ing bolt Ti Put on the vehicle speed sensor s terminal Connect the battery s negative terminal A 1 2 Install the odome...

Page 488: ...g isassembly procedure Lift the vehicle Remove the two front 3 atic transmission 4 il sealing Remove the left drive shaft s haft s D 1 2 wheels Take off the drive shaft on the autom Remove the right d...

Page 489: ...d right drive shafts Install two front wheels Lower the vehicle Oil cooling pipe isassembly procedure Remove the battery Place a oil box under the vehicle to collect the oil Remove the clip connecting...

Page 490: ...een the cooling pipe and the cooler Loosen the terminals between the cooling pipe and the transmission Remove the cooling pipe and the cooling guide pipe ssembly procedure Install the cooling pipe and...

Page 491: ...nnecting the cooling guide pipe and the case The clip s tightening torque Install the clip connecting the co the n l in and in 7 Tightening torque 22Nm 4 35Nm 5 oling guide pipe and cooler The clip s...

Page 492: ...sion Fault Diagnosis Manual 60 Lef 2 Remove the coolant tank s lift the t back suspension Tool J 28467 B engine hanger Disassembly procedure 1 Remove the battery Remove the coolant tank 3 top cover 4...

Page 493: ...ft back tr 7 R suspension ssembly procedure Install the upper left suspension Install the bolt connecting the left suspension and the transmission Tightening torque 58Nm emove the bolt connecting the...

Page 494: ...agnosis Manual 3 Install the bolt connecting the left suspension and the cushion anger Install the coolant tank The tightening torque on the coolant tank s fixing bolt 25Nm 4 Remove the engine h 5 Ins...

Page 495: ...ic terminal 3 Remove the cooling fan 4 Remove the bolt co the front suspension and the front cross member Remove the bolt conn the front suspension and the transmissi Assembly procedure Install the bo...

Page 496: ...n the bolt connecting the transmission s left and back suspension and the transmission Lift the vehicle Remove the two front wheels Remove the transmission s drive shaft spension Rotate the targeted w...

Page 497: ...vehicle 24 e lower part of the converter case and the engine Remove the front suspension Remove the transmission assembly 1 ion assembly while being supported with a jack Install the bolt connecting...

Page 498: ...rque 45Nm 8 front suspension Plug on the vehicle speed sensor s terminals Install the transmission s drive shaft Install two front wheels Lower the vehicle Install the left back suspension Remove the...

Page 499: ...mbly procedure Remove the transmission assembly from the whole vehicle Remove the torque converter After the oil is drained fix the transmission on a rack Face the side with oil pan upwards Remove the...

Page 500: ...is Manual 8 Turn the transmission by 90 degree and face the converter case upwards Loosen the bolt connecting the converter case with the housing 10 Take off the converter case and its gasket Take off...

Page 501: ...O LTD Automatic Transmission Fault Diagnosis Manual 12 Loosen the bolt connecting the middle seat with the housing Take out the middle seat oil pump and brake C Take out the adjusting washer and thrus...

Page 502: ...t Diagnosis Manual 15 Loosen the lock nut Rotate the adjusting bolt counterclockwise Loosen the brake band C 16 R e clutch A clutch B You will see that the clutch A is separated from clutch B emove th...

Page 503: ...utomatic Transmission Fault Diagnosis Manual 18 Take out brake C Please don t bend the brake band arbitrarily Take out the input shaft and clutch E assembly Take out the middle shaft clutch E rack and...

Page 504: ...AUTOMOBILE CO LTD Automatic Transmission Fault Diagnosis Manual 21 Take out the sun gear shaft and rack A washer and thrust bearing Take out the drive drum and thrust bearing Take out the sun gear 22...

Page 505: ...m and needle bearing Fix the driven shaft with the special tool of KA 000 288 Turn the transmission by 90 degree to the direction as shown by the figure Loosen the bolt connecting the d Locate the shi...

Page 506: ...Transmission Fault Diagnosis Manual 29 Pry the output gear lock bolt s flange edge to flat Loosen the main back output gear s lock bolt with the special tool of KA 001 023 0 Take off the lock bolt an...

Page 507: ...smission Fault Diagnosis Manual 32 Loosen the auxiliary back output gear s lock bolt with the special tool of KA 001 023 Take off the lock bolt and auxiliary back output gear Take out the output shaft...

Page 508: ...nosis Manual 35 Remove the driven shaft s locator of KA 288 Take off the driven shaft Loosen the parking position Take out the governor s shroud and the governor itself ry the space washer for 1st gea...

Page 509: ...ssion Fault Diagnosis Manual 39 Loosen 1st gear one way overrun clutch s grooved nut with the special tool of KA 000 155 Take off the grooved nut and 1st gear one way overrun gear s outer racer Take o...

Page 510: ...smission Fault Diagnosis Manual 42 Turn the transmission by 90 degree as shown by the figure Remove brake D s snap ring Take off the brake D assembly and diaphragm spring se high pressure gas to remov...

Page 511: ...9 Remove the lock bolt on the driven shaft bearing s outer racer Use the dedicated tool of J29369 1 to remove the driven shaft bearing s outer racer Apply the same method in removing the main back out...

Page 512: ...and C ssembly procedure Remove the transmission assembly from the whole vehicle Remove brake C from the transmission Remove the snap ring on the Take out cylinder head and piston C Remove the snap rin...

Page 513: ...AUTOMOBILE CO LTD Automatic Transmission Fault Diagnosis Manual 6 Separate piston C piston rod and two disk washers Remove O ring on the piston 8 Lo adjusting nut 7 osen the pretension for the brake b...

Page 514: ...BILE CO LTD Automatic Transmission Fault Diagnosis Manual 9 Take out the carrier rod on the brake band C Remove the O ring on carrier rod of brake band C ssembly procedure Put an O ring on brake band...

Page 515: ...e adjusting bolt is screwed in by half ote Two disk washers have assembled so that the sunk de faces each other br 3 e der Put a new O ring on piston C Then put piston C on the piston push rod and fix...

Page 516: ...ault Diagnosis Manual 5 Put a spring on the piston push rod The plug piston C assembly into the housing Install the hydraulic cylinder head Install the snap ring Install the brake band C bled 6 7 8 9...

Page 517: ...y procedure automatic 2 and oil pump from the transmission Remove the positioning snap ring on brake C Take out brake C assembly Press down the diaphragm spring with KA 000 914 of diaphragm spring com...

Page 518: ...D Automatic Transmission Fault Diagnosis Manual 6 Take out the diaphragm spring compression ring and retaining ring Plug the air gun into the oil feed Take out plug C 7 hole and remove piston C with h...

Page 519: ...positioning snap ring on the middle ring and the middle ring itself If necessary O ring on the middle ring could be removed Separate the oil pump If the two are engaged too a plastic hammer 10 Loosen...

Page 520: ...agnosis Manual 12 88 Spring hydraulic valve spindle and valve cap on the middle seat Take out the annulus gear and pinion of the oil pump Ass 1 In oil pump s annulus gear and pinion Face the side of t...

Page 521: ...2 Install the spring hydraulic valve spindle and valve cap Install the middle seat Please seat should be aligned with the spring Install the bolt connecting the middle seat with the oil pump 3 pay at...

Page 522: ...AUTOMOBILE CO LTD Automatic Transmission Fault Diagnosis Manual 5 Install the middle ring and fix it with a snap ring Install diaphragm spring ri 6 Install piston C 7 compression ring and retaining n...

Page 523: ...of KA 000 914 diaphragm spring compressor to press down the diaphragm spring bly 11 le seat brake C and oil pump Install the assembled transmission on the vehicle and install the fixing snap ring 9 In...

Page 524: ...rocedure smission whole vehicle Remove clutch A clutch B and 2nd gear one way overrun clutch from the transmission Separate clutch A clutch B and 2nd gear one way overrun clutch ng on clutch B Press d...

Page 525: ...lt Diagnosis Manual 6 Take out the adjusting washer and snap ring Take out the diaphragm Plug the air gun into the oil feed hole and remove piston B with high pressure air 7 Remove KA 000 914 of diaph...

Page 526: ...Y AUTOMOBILE CO LTD Automatic Transmission Fault Diagnosis Manual 10 94 Take out piston B Replace O ring if necessary Replace O ring on clutch B ssembly procedure Install piston B 11 drum if necessary...

Page 527: ...Transmission Fault Diagnosis Manual 2 Install diaphragm spring and compression ring gm spring compressor to press down the compression ring 3 Use the special tool of KA 000 914 diaphra 4 Install the...

Page 528: ...lutch B assembly Install clutch B assembly Assemble clutch A clutch B ity Install clutch A clutch B and 2nd gear one way overrun clutch assembly Install the assembled transmission assembly on the vehi...

Page 529: ...3 aphragm spring compressor sassembly procedure Remove the automatic 2 3 ing on clutch A s worm shaft Remove the worm shaft 5 mbly s snap ring and clutch A assembly Sp di Di 1 transmission assembly fr...

Page 530: ...ault Diagnosis Manual 6 98 Press down piston A and remove the snap ring Introduce in compressed air to remove piston A assembly Knock lightly piston A ta ton A and 7 from the oil feed hole 8 assembly...

Page 531: ...BILE CO LTD Automatic Transmission Fault Diagnosis Manual 9 Replace O ring on the booster piston if necessary ssembly procedure 10 Replace O ring on piston A A 1 Install diaphragm spring on the booste...

Page 532: ...ion Fault Diagnosis Manual 2 Install piston A on the booster piston Install the booster piston into tool of down the booster piston and install the snap ring 3 clutch A drum 4 Use the special KA 000 9...

Page 533: ...ch A assembly s Check the gap between clutch dial indicator on 8 m and read If the reading exceeds this scope select the snap ring with different thickness 6 positioning snap ring 7 A assembly As show...

Page 534: ...procedure Remove the automatic transmission assembly from the vehicle Remove clutch E from the automatic transmission Take out the input shaft s adjusting washer Install the s worm shaft 12 Install c...

Page 535: ...Diagnosis Manual 4 Remove the snap ring and clutch E assembly Use the special tool of g 7 In m 5 KA 001 715 04 bearin remover to press down piston E 6 Take out the retaining ring and diaphragm spring...

Page 536: ...c Transmission Fault Diagnosis Manual 8 Take out piston E Replace O ring on piston E if necessary 1 Put the piston E on the input shaft 3 and 9 Assembly procedure 2 Press down piston E Install the ret...

Page 537: ...bly from the vehicle Remove the output shaft and 1st gear one way overrun clutch from the automatic transmission Remove the snap ring on the output shaft Separate the output shaft from the gear ring 5...

Page 538: ...ission Fault Diagnosis Manual 5 Remove the tapered roller bearing from the output shaft with the special tool of KA 000 060 bearing remover Remove the retaining ring and Remove 1st gear one way 6 snap...

Page 539: ...clutch s inner racer Separate the clutch drum from the clutch s inner racer ssembly procedure Install the one way overrun correctly Press down the clutch drum Install the snap ring on the one way ove...

Page 540: ...he snap ring on the output shaft Install the output ring and one way overrun clutch into the housing Install the assembled transmission on the vehicle D S rem Remove the automatic 5 Install the snap r...

Page 541: ...r from the automatic transmission assembly Take off the governor s shield 4 L e ce on the th ssembly procedure Press fit the tapered roller bearing on the driven shaft 2 3 oosen the connecting bolt on...

Page 542: ...the spring and two adjusting valve spindles on the governor s case Then fix them with lock pieces Install the centrifugal bock on the governor s drum and fix it with a bolt tightening torque 10Nm Con...

Page 543: ...assembler KA 002 298 bearing ter racer remover isassembly and assembly ocedure isassembly procedure Remove the automatic transmission assembly from the vehicle Remove the converter case from the autom...

Page 544: ...Install the outer racer of the input shaft s tapered roller bearing with KA 002 111 bearing outer racer assembler Install the converter case on the transmission on the Spe A 000 060 bearing remover A...

Page 545: ...lt Diagnosis Manual transmission from the vehicle from the transmission e dowel pin on the planetary gear shaft ear shaft 2 Remove the differential 3 Remove th 4 Remove the planetary g 5 Take out the...

Page 546: ...Diagnosis Manual Remove the tapered roller bearing from the differential with KA 001 060 Remove the outer racer of the differential bearing on the housing Ass 1 In er racer of the differential bearing...

Page 547: ...ferential s tapered roller bearing with KA 000 300 bearing assembler Install the side shaft gear and planetary gear After installation the central lines of two side shaft gears must be aligned Otherwi...

Page 548: ...assembly procedure Remove the automatic transmission assembly from the vehicle Remove the main back output gear from the automatic transmission assembly Remove the tapered roller bearing with KA 000 0...

Page 549: ...le Remove the oil pan from the automatic transmission Remove the control valve plate assembly Remove the side cover and 5 Take out parking connecting rod and parking cam 7 Special tool A 000 187 oil s...

Page 550: ...ult Diagnosis Manual ke out shift shaft shift cam adjusting washer and brake disk s pintle Pry the sunk part at the flange of the lock nut on the main back output gear to flat 10 8 Ta 9 Loosen the loc...

Page 551: ...LE CO LTD Automatic Transmission Fault Diagnosis Manual 11 Take off the oil guide groove 12 on Remove the shift shaft s ring Press out the dowel pintle the parking pawl Take out the pawl and return sp...

Page 552: ...al Assembly procedure Install the shift shaft s O ring Push in the dowel pintle on the parking pawl about half of its length Put on the return spring and parking pawl 3 P p sp 1 2 ush the dowel pintle...

Page 553: ...sis Manual hift shaft it Install the pawl spring and fix it with a bolt Tightening torque 10Nm Parking cam and brake disk Connect the pawl spring 4 Push in the shift shaft by half of its length Put on...

Page 554: ...ix the parking cam Check the gap between the shift cam and house Deduct the reading by 0 10mm to get the depth of the adjusting washer required Remove the pawl spring and brake disk Push part of the s...

Page 555: ...ERY AUTOMOBILE CO LTD Automatic Transmission Fault Diagnosis Manual Engage the parking cam with the shift cam correctly 13 11 12 Install the parking carrier rod Install the plastic oil guide groove 12...

Page 556: ...over and gasket Install the control valve plate 18 n gasket and the oil pan Install the assemb transmission assembly on the vehicle ontrol valve plate assembly isassembly procedure Remove the transmis...

Page 557: ...LTD Automatic Transmission Fault Diagnosis Manual 5 Loosen the connecting bolt on th bottom v 125 e alve plate Take off the Remove the bottom cover 7 top baffle from the middle valve plate bottom valv...

Page 558: ...is Manual Take out the valve ball an small 8 d tab at lower side of the middle valve plate Turn over the middle valve plate Remove the control valve plate for clutch A and brake D 11 ate if necessary...

Page 559: ...cuit board together with the top baffle from the middle valve plate Turn over the oil circuit board and top baffle Put them on the worktable Take out the vent valve ball lock piece and throttle metal...

Page 560: ...ock pin and valve ball from the oil circuit board ssembly procedure ote Ensure that each throttle etal tab is installed to its correct sition Install lock pin valve ball and throttle metal tab to thei...

Page 561: ...throttle metal tab on top side of the main valve plate Turn over the top baffle and oil circuit board together and put them on the main valve plate Install the lock piece on clutch A and clutch D s c...

Page 562: ...Diagnosis Manual Turn over the main valve plate Install the shift valve ball and throttle metal tab on bottom side of the main valve plate Install the bottom baffle Install the bottom valve cover and...

Page 563: ...nd fix it with a bolt tightening torque 8Nm nstall oil feed filter screen and gasket mission 11 12 I 13 Install oil feed filter screen and fix it with bolts tightening torque 8Nm 14 Install the contro...

Page 564: ...ate assembly from the transmission l valve plate from the valve plate Remove the manual shift valve Take out the pressure regulator and spring Remove the side compression plate on the valve plate Disa...

Page 565: ...utomatic Transmission Fault Diagnosis Manual Take out brake D control valve spindle and spring Take out clutch A control valve spindle and spring Assembly procedure 1 Install clutch A control valve sp...

Page 566: ...atic Transmission Fault Diagnosis Manual Brake D control valve spindle 2 and spring Install clutch A and brake D control valve plate s side compression plate tightening torque 8Nm Install the pressure...

Page 567: ...smission assembly on the vehicle ottom valve plate isassembly procedure ote Take care that the spring will p out when removing the main s compression plate Remove the transmission assembly from the ve...

Page 568: ...AUTOMOBILE CO LTD Automatic Transmission Fault Diagnosis Manual Take out 2nd gear lock valve and spring Take out the control valve and limit spring Take out the position 3 slide valve and spring 6 7...

Page 569: ...s Manual Take out 4th 3rd 2nd downshift valve and spring Loosen the fixing bolt on the bottom valve plate s inner side compression plate to take off the bottom valve plate s compression plate and gask...

Page 570: ...ERY AUTOMOBILE CO LTD Automatic Transmission Fault Diagnosis Manual ssembly procedure st 2nd shift valve Install 2nd 3rd 4th upshift valve and spring Take out 1st 2nd shift valv 12 e A 1 Install 1 2 1...

Page 571: ...ansmission Fault Diagnosis Manual Bottom valve plate s inner side compression plate and gasket Fix them with bolts Tightening torque 8Nm Install 4th 3rd 2nd downshift valve and spring 5 Install positi...

Page 572: ...RY AUTOMOBILE CO LTD Automatic Transmission Fault Diagnosis Manual Install the control valve and limit spring Install 2nd gear lock valve and spring 6 7 8 Install 1st 2nd shift slide valve and spring...

Page 573: ...all the assembled transmission on the vehicle isassembly procedure ote Take care that the spring will mp out when removing the ma lve plate s compression plate Remove the automatic transmission assemb...

Page 574: ...LTD Automatic Transmission Fault Diagnosis Manual ake out 2nd 3rd shift valv 6 T e 7 T alve and interior and exterior springs 8 e valve and its interior and exterior springs ake out the delay v Take o...

Page 575: ...ch E s slide valve and its interior and exterior springs and its interior and exterior springs Loosen the connecting bolt on te and take off the control valve compression plate 10 Take out main oil ci...

Page 576: ...OBILE CO LTD Automatic Transmission Fault Diagnosis Manual Take out 4th 3rd shift slide valve and spring Take out 3rd 4th shift slide valve and spring Take out 4th 3rd kickdown valve and its spring 12...

Page 577: ...ault Diagnosis Manual Take out the pressure regulator and its spring Take out 1st gear and back gear lock valve and spring 17 8 Take out 2nd 3rd shift control valve and its spring 15 16 Take out 1st 2...

Page 578: ...iagnosis Manual Take out 3rd 4th shift slide valve and 19 its spring ssembly procedure Install 3rd 4th shift slide valve and its spring Install 1st 2nd 3rd shift control valve and its spring Install 2...

Page 579: ...E CO LTD Automatic Transmission Fault Diagnosis Manual 4 147 Install 1st gear and back gear s lock valve and its spring Install the pressure regulator and its spring 5 6 Install 4th 3rd kickdown valve...

Page 580: ...Fault Diagnosis Manual 7 Install 3rd 4th shift slide valve and Install 4th 3rd shift slide valve and its spring Install the main valve plate s control valve compression plate and fix it with bolts The...

Page 581: ...nosis Manual 149 Install the main oil circuit s pressure regulator and its interior and exterior springs Install clutch E s control valve and its interior and exterior springs Install the brake valve...

Page 582: ...HERY AUTOMOBILE CO LTD Automatic Transmission Fault Diagnosis Manual 13 Install the delay valve and its interior and exterior springs Install 2nd 3rd shift valve rd 4th shift valve 14 15 Install 3 150...

Page 583: ...ed transmission assembly on the vehicle ransmission assembly ecial tools A 002 008 differential regulator KA A 001 483 gap detector A 001 655 main back output gear p detector ssembly procedure Install...

Page 584: ...gree and face the side of driven shaft upwards ote Preheat the transmission the i outp Turn over the case by 90 degree and face the parking lock mechanism upwards Install 1st gear one way overrun 4 In...

Page 585: ...protection ring s square teeth and lock it on the grooved nut Turn over the transmission by 90 degree as shown by the figure Install the diaphragm spring and brake D assembly 9 Install the protection...

Page 586: ...nsmission Fault Diagnosis Manual Install the positioning 13 snap ring on brake D assembly 15 16 14 Turn over the transmission by 90 degree as shown by the figure Install the governor and its protectio...

Page 587: ...BILE CO LTD Automatic Transmission Fault Diagnosis Manual 17 Fix the driven shaft with the special tool of KA 000 288 Pull the shift gear to the parking position Adjust the position of brake D assembl...

Page 588: ...k gasket Then fix them with bolts Install the main back output 23 k output gear upwards Tighten the lock bolt of the main and auxiliary output gear Torque 10Nm Take off the parking carrier rod and tur...

Page 589: ...ge into deformed sha 157 27 Tu 12 fl pes so that it sinks into the sunk pit on the gear Tighten the auxiliary back output gear with a tightening torque of 150Nm 28 Install the output gear gap detector...

Page 590: ...ollowing formula 1 75mm Xmm 0 06mm The 1 75mm 0 46mm 0 06mm 355mm in accordance with this formula mong which 1 75mm and 0 06mm are all adjusting coefficients Remove the gauge Replace the washer on aux...

Page 591: ...Automatic Transmission Fault Diagnosis Manual 40 159 Install the planetary gear Install the sun gear into the Install the drive drum so that the inner racer engages with the sun gear mechanism 41 plan...

Page 592: ...n disk washer into the drive drum Install the sun gear shaft ote Correct installation of the sun ar The drive drum could only tate towards the sun gear at one rection Put the washer thrust bearing and...

Page 593: ...ut the washer and thrust bearing on top of the middle shaft 47 I ro nuously when with clutch E case and sun gear shaft rack that are integrated with the input shaft ble clutch A and clutch B together...

Page 594: ...utomatic Transmission Fault Diagnosis Manual 49 Install clutch A and clutch B assembly into the transmission 50 Install the brake band C 51 Install the positioning ring on top of washer of 2nd gear on...

Page 595: ...Diagnosis Manual 52 Install the oil pump assembly and fix it with bolts The torque m Install the axial gap detector Put the adjusting washer and thrust washer onto the input shaft 53 on the bolt conn...

Page 596: ...en 0 1mm to 0 3mm Otherwise select the washer with different depth and adjust the gap into permissible scope Install the differential assembly ote Remove the cases for the lve plate assembly and odome...

Page 597: ...installing the bearing Verify the torque again 60 Measure the distance from the bearing s outer racer to the case plane with a depth 9 Rotate the drive drum 165 gauge 61 Measure with a depth gauge the...

Page 598: ...e brake band with a tightening torque of 10Nm Note Rotate clutch B drum while tightening the brake band to ensure that it is installed to the correct position 65 Turn the adjusting bolt counterclockwi...

Page 599: ...late s fixing bolt The bolt s tightening Install the oil pan and oil pan 70 Install the torque converter to ensure that the converter is installed to its correct 71 67 Install the control valve plate...

Page 600: ...full of hy connection between the drive and driven pieces hence no friction inside the converter Brief introduction of automatic transmission s structur Brief introduction of the automat 4HP14 is an a...

Page 601: ...the engine s output shock and the shock arising from road bumps at 3rd and 4th gear to the minimum due to mechanical connection at 3rd and 4th gear The torque shock absorber is connected with the engi...

Page 602: ...ntrol brake band in order to lock the sun gear Since there is no friction the brake band could be used continuously He ent is not necessary converter worm gear and worm and sun gear shaft The planetar...

Page 603: ...front sun gear and brings along the output shaft through the gear ring 6 Back gear s power transfer route Clutch A engages The worm is connected with the front sun gear through the brake drum Clutch...

Page 604: ...side the converter 5 Governor The governor simulates the engine s output torque and controls the oil circuit pressure in the shift elements at each gear When gear shifted the governor s oil pressure i...

Page 605: ...oses or opens the valve chamber in accordance with the oil pressure control valve spindle s moving The time when the shift moves from position 1 to 2 is related with the linear governor and throttle o...

Page 606: ...valve controls the pressure on 2nd 3rd shift valve s oil circuit and maintains it at position 3 until the planetary gear engages at 3rd gear Since the transmission could not jump directly from clutch...

Page 607: ...closes the oil inlet somewhat until the oil pressure of the governor is balanced with the centrifugal force on the slide valve Condition II Since the centrifugal block integrated with the slide valve...

Page 608: ...t 18 7 electric injection theory diagram 19 8 ECU pin definition 21 Part 2 M M Multi port electric injection engine systems 1 system description 23 2 operation 23 3 fuel injection system control strat...

Page 609: ...rules are as follows Electric injection type Motor model No Gear box type Ex factory No MOT SQR480EB MT SQR480EB EB MOT SQR480EC AT SQR480EC EC M M SQR480ED MT SQR480ED ED Note due to the difference...

Page 610: ...el injection system is installed on Chery sedan with following differences EI Engine Transmission Factory Number MOT SQR 480EB MT SQR480EB EB MOT SQR 480EC AT SQR480EC EC M M SQR 480ED MT SQR480ED ED...

Page 611: ...Part MOT multi port electric fuel injection engine system...

Page 612: ...ressure sensor temperature sensor throttle valve body air intake hose and manifold and idle adjuster valve and idle adjuster screw for idle adjusting Electric Control System Consists of sensor ECU and...

Page 613: ...5 16 Operating current Ampere 0 01 0 1 Operating temperatu re Centigrade 40 85 Humidity RH 20 85 Vibrating frequency HZ 1000 ECU operation ambient temperature range is 40 85 therefore before baking v...

Page 614: ...120 100 9 5 12261 60 671 125 88 3 0 9399 65 559 130 77 5 5 7263 70 469 135 68 3 10 5658 75 395 140 60 3 15 4441 80 334 145 53 4 20 3511 85 283 150 47 5 b voltmeter method Install the sensor on the mot...

Page 615: ...When temperature is 800 impedance is 25 0 10 When temperature is 40 heater impedance is 12 2 10...

Page 616: ...nsor fault A medium reading maintained indicates a possible oxygen sensor fault Remove oxygen sensor from engine Connect a digital voltmeter lead to sensor and combust sensor sensitive element on prop...

Page 617: ...6 3ms Secondary peak value current 74mA 7 I firing delayed time 3 6ms 3 Coil number ratio 83 1 Testing method Ohmmeter method referring to above chart and check ignition coil resistance Ignition wire...

Page 618: ...Remove TPS connector Depress throttle slowly and monitor resistance Measuring resistance at wide open throttle WOT resistance is 5K 20 at WOT Verify resistance change smoothly when throttle closed...

Page 619: ...system 2 2 1 fuel filter a DO NOT install fuel filter at an opposite direction otherwise a new one should be installed even it has been used for a short time There is an arrow marked on fuel filter ho...

Page 620: ...3 1 Throttle valve body 1 Idle step motor 2 Throttle position sensor Throttle valve Joint connecting to water outlet elbow Joint throttle valve water outlet Preheating water hose outlet pipe 2 3 1 1...

Page 621: ...Sensing Method When ignition switch is turned on short time vibration should be felt 2 3 2 Air Intake Temperature AIT Pressure Sensor AIT pressure sensor has 4 leads votage supply wire pin B22 pressu...

Page 622: ...CU sensor operates by abve engine air intake temperate resistance chart Remove air intake temperature sensor and heat sensor in water refer to diagram 4 3 Sensor has a corresponding resistance with di...

Page 623: ...function under following conditions which should be avoided Burned under high temperature The ideal temperature for a high purge ratio and long life time is s 400 800 A higher temperature will cause...

Page 624: ...gine is battery voltage and to avoid ECU damaging for over voltage any other external voltage supply such as fast charging starter voltage stabilizing power CAN NOT be used to start engine 3 2 4 ECU s...

Page 625: ...t Check 1 ignition wire 2 ignition coil 3 spark check fuel pipe pressure and fuel injector ECU power wire diagnostic Measure ECU voltage with a digital voltmeter Pin A16 is positive and pin B16 is neg...

Page 626: ...ession pressure and air valve gap 1 fuel injector leakage or short 2 fuel injector wire short 3 over fuel injection Check fuel supply 1 if fuel tank is empty 2 fuel supply pipe fuel pressure When igni...

Page 627: ...check spark plug and spark plug gap Plug gap 8mm NOTE if necessary check compression pressure and air valve gap 1 replace spark plug 2 cylinder compression pressure 3 air valve gap Throttle valve pos...

Page 628: ...es Determine fault sources upon diagnostic codes Check air intake system Vacuum leakage 1 hose connection 2 throttle valve body intake air valve 3 intake manifold installation Check throttle position...

Page 629: ...or mentioned above check following components Engine coolant temperature sensor fault check engine coolant temperature sensor and wire repair or replace as necessary Air intake temperature sensor faul...

Page 630: ...gle of throttle valve ensuring a correct total steps 2 If there exists carbon or tar deposits please remove it Note If reliable tool for testing total idle steps is not available DO NOT adjust initial...

Page 631: ...Ignition system fault check Fuel circuit pressure fuel injector and fuel pump check Engine compression pressure check...

Page 632: ...injection ECU wiring harness ECU module connector ECU module connector B black A11 372466ba ECU power fuse black Fuel pump fuse black Diagnos fuel pump d A C central connector Grou Spa Oxygen sensor p...

Page 633: ...Engine Theory Diagram Step INJECTOR 1 black Throttle osition sensor INJECTO Senso INJECTOR Water temperatu Central Gr Central Ignition coil INJECTOR 4 black...

Page 634: ...ry Negative Sensor Rotational Rotationa Shiel S A A C High low H Compress A C Ox Oxygen 5V Throttle Absolute Air intake Water Throttle S Water Ig Igni Igni Ignit fuel fuel injector 1 fuel fuel injecto...

Page 635: ...he italic parts means functions under development Groun Rotational speed signal tachomet h l d vehicle speed signal input Cooling fan relay Cool ing fan relay Cooling fan relay 2 Cooling fan relay 2 K...

Page 636: ...l Injector Control Output 10 Cylinder2 fuel Injector Control Output 11 Brake Signal Output Input 12 not used not used 13 not used not used 14 A C Pressure Signal Output 15 not used not used 16 Power I...

Page 637: ...Sensor Input 8 Vehicle Speed Input 9 Fuel Pump Output 10 Water Temperature Sensor Signal Input 11 A C Demand Signal Input 12 not used Output 13 TXD Output 14 RXD Output 15 not used Output 16 B 17 Thr...

Page 638: ...Part II M M MULTI PORT ELECTRIC INJECTION ENGINE SYSTEM...

Page 639: ...ch 10 system relay 11 A C compressor 12 Carbon canister solenoid 13 Fuse 14 Active carbon canister 15 Anti theft unit 16 Absolute pressure and temperature sensor 17 Crankshaft speed and position senso...

Page 640: ...ECU control With rising of coolant temperature idle speed decrease to normal speed gradually When engine idles if A C is turned on ECU will increase idle speed by 100rpm 3 Accelarating During accelera...

Page 641: ...of oxygen sensor during operation These differences will be stored permanentlyallowing system and components to be correct gradually as a new one This function contains automatic conformance check and...

Page 642: ...el filter Fuel filter is located outside of fuel tank The fuel filter consists of housing and low filter core of high filtering quality Due to fuel injector is excessively sensitiveto foreign material...

Page 643: ...ntrol logic of fuel injector is phase sequence control Four fuel injectors is controlled according to four cylinders air intake sequence opening in power stroke till intake stroke start Fuel injectors...

Page 644: ...Idle step motor Idle step motor is used for controlling idle speed directly fixed on throttle valve body consists of one step motor and screw worm retard unit which change the rotational movement of l...

Page 645: ...r signal knocking sensor signal Air charge efficiency is calculated upon managed intake manifold absolute pressure intake air temperature engine speed and throttle position by which air charge volume...

Page 646: ...t speed and position sensor with inner composition of watered magnet round cylinder and coil Crankshaft speed and position sensor are fixed on transmission housing corresponding with sensor signal gea...

Page 647: ...the exhaust front pipe before 3 way catalyst converter Oxygen sensor mainly consists of a ceramics shell made of zirconium oxidize on which the internal external surface of closed side is coated with...

Page 648: ...Protecting tube 3 outer metal shell of sensor 4 heating resistor a signal positive exposed to air b signal negative exposed to exhaust gas The oxygen sensor is heated oxygen sensor which can enter ope...

Page 649: ...onditions ECU dynamically compensate basic ignition advance angle upon engine rotational speed and air intake manifold absolute pressure to obtain optimum ignition advance angle Under a very low engin...

Page 650: ...venting fuel from evaporating and fuel vapor recycle system By this system fuel vapor formed in fuel tank and fuel feed system is combusted in engine combustion chamber after filtering prevent fuel va...

Page 651: ...ne warming up ECU will send a square wave signal to carbon canister Carbon canister on and off is regulated by cycle ratio of signal itself Therefore ECU may control fuel vapor quantity input to intak...

Page 652: ...alien frequencies radar anti theft system is an electric device connecting with engine control system prevent vehicle from disoperation One of characteristics engine anti theft unit on and off need no...

Page 653: ...structure of anti theft ECU is as shown in fig 14...

Page 654: ...ning indicator begins to flicker indicating system is operating but engine will not be protected until the key is stored 5 Electronic Control Fuel Injection System Maintenance 1 Fuel ONLY high quality...

Page 655: ...blocking Fuel injectors shall be washed at least every one year Fuel injector O ring is life time component and can not be reused 6 3 way catalyst converter When ignition switch is at ON position or e...

Page 656: ...ts resistance under all conditions Voltmeter is often used to measure electronic controlled components voltage under all conditions and scan tester is used to determine if an electronic controlled com...

Page 657: ...tion Check if all connections good Check electric fuel pump replace as necessary 2 Blocked fuel filter or pipe Check if fuel filter and fuel pipe blocked clean or replace fuel pipe as necessary Insuff...

Page 658: ...sensor Check throttle opening Check if throttle position sensor operating parameter within specification Check if throttle cable installed correctly Move throttle and check if throttle stuch Check th...

Page 659: ...Wiring diagram...

Page 660: ...ed 8 ignition switch 20 Fan relay second stage speed 9 System failure warning indicator 21 diagnostic socket 10 speedometer 22 relay 11 air pressure temperature sensor 22 relay 12 throttle position se...

Page 661: ...sor irreplaceable code IPF2C Internal expanded view A Negative B Power supply 5V C signal Specification Effective electric power angle 90 2 Mechanical angle 105 4 Full mechanical travel 110 8 Temperat...

Page 662: ...VEHICLE CIRCUIT MANUAL 2002 VERSION Note The differences between ET VEHICLE CIRCUIT MANUAL and previous part are in pages No 1 2 14 15 and an added page No 23 Automatic Transmission Gear PDF pdfFacto...

Page 663: ...or 08 Rear Window Heating System Dual Tone Horn Compressor Magnetic Clutch 09 Wiper Horn Button Washer 10 Headlight Front Position Light Light Relay 11 Turn Light Parking Light Switch Emergency Warnin...

Page 664: ...A Battery T2 Back Light Switch B Starter Motor M1 Left Back Light C Alternator M2 Right Back Light C1 Voltage Regulator 1 Ground on ground carrier beside central electrical box D Ignition Switch 2 Bod...

Page 665: ...Step Motor KS Knock Sensor TW Crankshaft Position Sensor IC Ignition Coil Q Spark Plug IJ 1 4 Fuel Injector QS Oxygen Sensor BC Water Temperature Sensor TP Throttle Position Sensor TC Air Intake Tempe...

Page 666: ...A11 2002 CIRCUIT MANUAL 3 PDF pdfFactory Pro www fineprint com cn...

Page 667: ...ch F18 thermo switch N23 blower in line speed Regulator resistance V2 blower V7 fan motor J32 A C relay J69 Cooling fan high speed relay J70 Cooling fan low speed relay J5 A C blower relay in electric...

Page 668: ...V Green A Blue H Grey Z Purple G Yellow E35 A C unit switch F23 High pressure switch E36 Interior circulation switch F73 Low pressure switch K84 A C operating illumination light 7 8 Main circuit groun...

Page 669: ...A BLUE H GREY Z PURPLE G YELLOW G2 Coolant temperature gauge sensor 9 ground on engine cylinder F22 Oil pressure switch low pressure 10 ground connection in headlight wiring harness F9 Manual brake in...

Page 670: ...V GREEN A BLUE H GREY Z PURPLE G YELLOW R radio R1 antenna R2 front left speaker T8 8 holes connector R3 front right speaker T1 single hole connector R4 right rear speaker R5 left rear speaker R6 left...

Page 671: ...0 fuel sensor K2 left turn indicator K8 engine overheat warning light G25 coolant temperature sensor K3 right turn indicator G30 RPM sensor K4 engine charging indicator K5 manual brake warning light G...

Page 672: ...RED M BROWN V GREEN A BLUE H GREY Z PURPLE G YELLOW L16 A C Control Panel Indicator L28 Cigar Lighter Illumination Light L22 Left Front Fog Light U1 Cigar Lighter L23 Right Front Fog Light 11 Ground...

Page 673: ...REEN A BLUE H GREY Z PURPLE G YELLOW J1 Idle Up Relay in electrical box J3 dual tone Horn J39 Rear Window Heating Switch Illumination Light K10 Rear Window Heating Indicator E15 Rear Window Heater Swi...

Page 674: ...PER HORN BUTTON WASHER B WHITE N BLACK R RED M BROWN V GREEN A BLUE H GREY Z PURPLE G YELLOW E22 wiper switch H horn button J31 intermittent wiper relay S5 fuse 15A V wiper motor V5 washer PDF pdfFact...

Page 675: ...gh Beam Headlight Fuse 10A L2 Left Low Beam Headlight S28 Left Low Beam Headlight Fuse 10A L3 Right Low Beam Headlight S29 Left Position Light Fuse 10A L4 Right High Beam Headlight S30 Left High Beam...

Page 676: ...E N BLACK R RED M BROWN V GREEN A BLUE H GREY Z PURPLE G YELLOW E2 Turn Light Switch E3 Emergency Warning Light Switch E4 Dimmer and Turn Light Switch E19 Parking Light Switch J2 Emergency Warning Lig...

Page 677: ...connector L15 left taillight M10 right brake light T1 single hole connector L20 right taillight M501 right side turn light 14 Ground in rear light M2 rear right position light M701 left side turn ligh...

Page 678: ...ION LIGHT B WHITE N BLACK R RED M BROWN V GREEN A BLUE H GREY Z PURPLE G YELLOW E1 Light Switch E20 Panel indicator instruments illumination light variable resistance L9 Panel illumination light M Gea...

Page 679: ...T3 3 Holes Connector J4 Fog Lamp Relay in electrical box T3a 3 Holes Connector K17 Rear Fog Lamp Indicator T2 2 Holes Connector L1 Rear Fog Lamp T1 Single Hole Connector L40 Front Rear Fog Lamp Switch...

Page 680: ...adlight Height Adjustment Switch 16 Ground Located Beside Central Electrical Box L54 Light Adjustment Illumination Light 15 Ground at headlight V48 Left Front Headlight Adjustment Motor T1 Single Hole...

Page 681: ...h TAa 2 Holes Connector on left side of luggage compartment F3 Right Front Door Touch Switch W1 Interior Rear Ceiling Lamp F5 Luggage Compartment Illumination Light Switch W3 Luggage Compartment Light...

Page 682: ...Lock Control Motor TK1 12 Holes Connector left A pillar Side V29 Left Rear Door Lock Control Motor TK2 12 Holes Connector right A pillar Side V30 Right Rear Door Lock Control Motor Ty 2 Holes Connect...

Page 683: ...Mirror Defogger X1 Left Adjust Z5 Right Mirror Defogger X2 Right Adjust TK1 12 Holes Connector left A pillar side Y1 Up Adjust TK2 12 Holes Connector right A pillar side Y2 Down Adjust TZ 2 Holes Conn...

Page 684: ...Sensor A Battery S33 ABS Solenoid Valve Power Fuse N55 ABS Solenoid S34 ABS Hydraulic Pump Power Fuse VG4 ABS Hydraulic Pump TK Diagnosis Connector G44 Right Rear Wheel RPM Sensor 18 Ground point at...

Page 685: ...Window Glass Lifter Module 19 Beside Central Electrical Box E40 Left Front Window Lifter Switch TK1 12 Holes Connector Left B Pillar Side E81 Right Front Window Lifter Switch TK2 12 Holes Connector R...

Page 686: ...Rear Window Glass Lifter Motor E52 Left Rear Dorr Upper Window Lifter Switch V27 Right Rear Window Glass Lifter Motor E54 Right Rear Dorr Upper Window Lifter Switch TA1 4 Holes Connector Glass Left B...

Page 687: ...2002 CIRCUIT MANUAL 24 AUTOMATIC TRANSMISSION GEAR B WHITE N BLACK R RED M BROWN V GREEN A BLUE H GREY Z PURPLE G YELLOW K Gear Selector Switch H Gear Selector Box PDF pdfFactory Pro www fineprint com...

Page 688: ...Field and summer road and performance tests were carried out in China Xianfang Vehicle Test Feild Test results indicate Chery ABS system brake efficiency brake turning ability brake stability and sub...

Page 689: ...ng Fault Code 5 6 HCU Diagnostic 6 7 Quick Fault Repairing Index 7 7 1 Fault With Code Check Chart Index 7 7 2 Fault Without Code Check Chart Index 7 8 ABS ECU Socket 8 9 Electric Circuit 9 10 Fault W...

Page 690: ...16 1 Dry HCU 29 16 2 Oil Carried HECU 29 Attachment I ABS FAQ 31 Attachment II Precautions on using ABS 32...

Page 691: ...Chery SQR7160 series sedan ABS system fault diagnostic and repairing nostic Chart...

Page 692: ...r inquiry at ADDRESS Intermittent fault display with SP Continuous Fault Clearing fault code Recording fault code Go to INTERMITTENT FAULT DIAGNOSTIC PROCEDURE repair problem Go to FAULT W CODE DIAGNO...

Page 693: ...It is the sound of ABS system self check and is normal Sound when ABS operating 1 Sound of motor running in ABS hydraulic unit 2 Sound of brake pedal viabrating 3 When ABS operating creaking sound fr...

Page 694: ...on Introduction Function 01 condition information display Function 02 fault inquiry Function 03 hydraulic controlled unit diagnostic Function 04 filling fluid and bleeding Function 05 clearing fault c...

Page 695: ...ctor Slightly wiggle wiring harness Slightly shake sensor Slightly shake other moving parts wheel bearing Note Replace with a new part when wiring harness is broken for high tension especially for a t...

Page 696: ...t Code Enter 02 at FUNCTION SELECT press Q fault number will be displayed Then press fault code and related information of each fault will be listed 5 4 Clearing Fault Code Enter 05 at FUNCTION SELECT...

Page 697: ...V Rad blockiert Normal Open Valve POWER ON Normal Closed Valve 0V Wheel Block Wheel Block 05 EVL UBAT AVL UBAT Rad frei Normal Open Valve POWER ON Normal Closed Valve POWER ON Wheel can spin freely Wh...

Page 698: ...signal 7 P 18 7 2 Fault w o code check chart index Problem Sympton Check chart No Page No Igniton turned to ON position engine off ABS warning light is off 1 P 19 After engine running ABS warning lig...

Page 699: ...Chery SQR7160 series sedan ABS system fault diagnostic and repairing 8 ABS ECU SOCKET 8...

Page 700: ...AL CIRCUIT MK20 I EABS EDS And ASR Electrical Circuit PIN ECU Valve coil EDS Only for ABS Pin 8 9 21 25 4 8mm width Other pins 1 5mm width 9 Chery SQR7160 series sedan ABS system fault diagnostic and...

Page 701: ...d loose engine wiring hareness defective motor Note If battery is over discharged motor actuating will fail Check if battery voltage is normal before motor actuating test Perform motor actuating test...

Page 702: ...nstalled Short in sensor coil or harness short Big gap between sensor and gear ring Gear ring not installed Defective ABS ECU 456 Sensor installed correctly NO Reinstall the sensor Check sensor output...

Page 703: ...between sensor and gear ring or defective gear ring teeth sensor coil harness intermittent poor contact or short big or small air gap between sensor and gear ring damaged gear ring teeth big bearing g...

Page 704: ...sor signal circuit Check each wheel sensor OKAY Not okay Check appropriate sensor connector Not okay Okay Repair connector Does problem appear again No Go to INTERMITTENT FAULT DIAGNOSTIC YES Check el...

Page 705: ...t consistent with ABS harness pin code will be set Pin connection error in ABS harness ABS ECU programming error Check if ABS ECU software programming correct using scan tool Correct value 01901 for S...

Page 706: ...Replace fuse Not normal Check ABS electrical harness connector Not normal Repair connector Normal Retry Does problem reoccur NO YES Disconnect ABS electrical harness and ECU Turn ignition to ON posit...

Page 707: ...electromagnetic wave or micro prcrosser recognized an incrorrect input speed signal code is set high frequency electromagnetic wave interference damaged sensor or sensor harness defective ABS ECU No...

Page 708: ...okey OKAY Replace fuse socket Remove ABS ECU connector Ignition ON position Is warning light on YES NO Check if ABS warning light burned YES NO Replace Check if wire connecting ABS warning light contr...

Page 709: ...defective warning light control unit open ABS warning light control unit defective ABS ECU Note This code only applies to a condition under which there is communication between system and scan tool AB...

Page 710: ...iagnose If no code set perform following check Sensor not correctly installed Sensor wiring harness has problem damaged sensor damaged gear ring foreign material on sensor damaged wheel bearing damage...

Page 711: ...ormal NO Go to INTERMITTENT FAULT DIAGNOSIS YES Repair wiring harness or connector No normal Replace ABS ECU YES Remove ABS ECU Check if resistance between following terminals is within 1 0 1 3 KOhm L...

Page 712: ...heavily worn manual brake misadjusted Visually inspect if fitting leaking NOT NORMAL Tignten fitting to specified torque NORMAL NOT NORMAL Replace brake rotor Check if brake rotor worn NORMAL NOT NOR...

Page 713: ...vel using conventional methods Normally open valve problem can be checked by hydraulic unit diagnostic function test on scan tool booster problem normally open valve problem NORMAL NOT NORMAL Check no...

Page 714: ...vehicle Scan tool problem Repair it and check again Check ABS voltage supply fuse Replace fuse Is there information displayed on scan tool screen Remove ABS ECU connector Check ABS ECU terminal 13 an...

Page 715: ...Brake Pedal Not Depressed ON 8 18 0 0 0 5 V Brake Light Switch Function Brake Pedal Depressed ON 8 18 10 0 14 5 V Diagnostic Connector OFF Diagnostic Connector K and 7 0 0 0 5 LF Wheel Speed Sensor Re...

Page 716: ...s pedal When RF wheel can spin freely pedal does not desecent Normally open valve check ON Depress pedal When LR wheel can not spin pedal does not desecent Normally closed valve check LR wheel normall...

Page 717: ...6 Right Rear Wheel terminal 22 23 Output Voltage Using volt ohmmeter Front Wheel see front wheel speed sensor installing illustration Rear Wheel see rear wheel speed sensor installing illustration Usi...

Page 718: ...oving MK20 1 HECU off and remove battery negative lead edal 60mm and keep depressed with pedal Keep cleaness when servicing only can be used for cleaning Clean external surface u mineral oil Wipe off...

Page 719: ...Replacing Hydraulic Con pump motor wiring harness Remove 4 screws shown on illustration Removed screws cannot be reused Separate HCU and ECU Install a new HCU Retain ECU on HCU usin 3 1Nm Connect mot...

Page 720: ...ight should go on 1 7 second and then off Clear fault code memory and retrive again Ensure no codes in memory Finally perform vehicle drive test to confirm ABS function correctly pedal kic system doe...

Page 721: ...re HECU is a dry one after replacing HECU second circuit must be bleeded after filling and bleeding as per conventional brake system Operating procedures are as following using scan tool Filling and b...

Page 722: ...ight front brake caliper bleed screw press key Loosen brake pedal and loosen left and right front brake caliper bleed screw press key Repeat above procedures 7 times BLEEDING OVER displayed press key...

Page 723: ...ough solenoid valve repeatedly regulating How to tell if ABS is operating When ABS operating brake pedal vibrating will be felt and ECU operating sound will be heard Warning DO NOT be afraid at this m...

Page 724: ...O NOT drive an ABS installed vehicle more careless than a vehicle without ABS Even for an ABS installed vehicle a sharp cornering fast way changing way and other sharp steering operations are hazard a...

Page 725: ...cuit short circuit and sensor damages etc In case ECU detects any sensor output signal that goes beyond output characteristic curve the sensor is diagnosed as failed by ECU For example when intake pre...

Page 726: ...rottle axis with 5V power supply voltage US being applied to both ends of each contact resistor When throttle turns contact arms turn along with it and move on sliding contact resisters educing potent...

Page 727: ...orks in failure mode In this case ECU controls ignition and fuel injection according to set water temperature for failure mode at the same time the fan is running at high speed mode Limiting data 2 5...

Page 728: ...it failure Cylinder detecting signal is unreliable After failure mark of knock sensor being set knocking closed loop control is shut down reduceing a safety angle from the ignition advance angle store...

Page 729: ...ensing circuits In case any of the following situations occurs failure mark of the oxygen sensor is set Accumulator voltage is unreliable Manifold absolute pressure signal is unreliable Engine coolant...

Page 730: ...njection Controlling ignition Idle speed control Independent knocking control on cylinder by cylinder basis knock sensor KS 1 Providing sensors with power supply 5V 100mA Adopting cylinder detecting s...

Page 731: ...nput 57 Air conditioning compressor switch Input 17 Sensor ground 1 Ground 58 18 Oxygen sensor Input 59 Speed signal Input 19 Knock sensor A Input 60 20 Knock sensor B Input 61 Power ground 1 Ground 2...

Page 732: ...n system pressure and manifold pressure is determined by fuel pressure adjuster and is 350kPa in general Caution Fuel temperature has fairly big impact on fuel pump performance in case of longstanding...

Page 733: ...idle vehicle gasoline cementation in injector results in failure of normal startup of vehicle after long term idling In this case please check carefully to see if the injector cements Failure diagnosi...

Page 734: ...er of which fixed a nut All stator coils are electrified all the time Once the current direction of a coil is changed the rotor will rotate by an angle When all stator coils are changing their current...

Page 735: ...lure code the only way is to check the resistance of ignition coil to determine if the said coil is in working order Under normal conditions the thermal value of working ignition coil is fairly big ho...

Page 736: ...rence between its inlet outlet on the other hand In case there is no electric impulse carbon canister control valve will shut down ECU controls the said valve s current on time and indirectly controls...

Page 737: ...njector EV Installation requirement connect fuel inlet outlet pipes with rubber pipes and fasten them down wtih hoops The size of hoops used shall match that of rubber pipes so as to ensure air tight...

Page 738: ...ts it as a stable failure and stores it as constant failure if such failure disappears ECU stores it as random failure and nonexistent if such failure is identified again then still it is random failu...

Page 739: ...This system adopts K wire communication protocol and ISO 9141 2 standard diagnosing connector see figure 2 5 below The standard diagnosing connector is fixed on engine wire harness with Pin 4 7 and 16...

Page 740: ...h only the rough part of failure occurrence found For the reason causing a failure information may be electrical element breakdown for example sensor actuator or ECU may be wire having open circuit or...

Page 741: ...Diagnosis Instruction 5 Start engine and idle it Slowly step down accelerating pedal to dead position and observe value of Intake Pressure on scanner and it does not vary much quickly step down accele...

Page 742: ...peration Result Solution 1 Connect scanner and commutator and then turn ignition switch to ON Go to next step Yes Go to next step 2 Check Throttle Absolute Opening in data stream to see if it is 4 10...

Page 743: ...16 of ECU and Pin 3 of sensor connector to see if open or short circuit occurs No Go to next step Yes Replace sensor 6 Check the voltage between Pin 1 and Pin 2 of sensor connector with a multimeter t...

Page 744: ...900mV No Go to next step Yes Repair or replace wire harness 3 Check respectively the connections between Pin 36 of ECU and Pin A corresponding to gray wire of oxygen sensor of sensor connector Pin 18...

Page 745: ...next step Yes Repair or replace wire harness 5 Check respectively the connections between Pin 1 of ECU and Pin C corresponding to white wire of oxygen sensor of sensor connector Pin 87 of main relay a...

Page 746: ...only when failure codes of intake pressure sensor carbon canister control valve and oxygen sensor do not occur at the same time In case these failure codes occur concurrently please fix other failure...

Page 747: ...next step 4 Check the resistance between Pin 1 and Pin 2 of Cylinder 1 injector with a multimeter to see if it is around 11 16 at 20 No Replace injector Yes Diagnosis Instruction 5 Check the voltage b...

Page 748: ...ness check the voltage between Pin 1 of the connector and cathode of power supply with a multimeter to see if it is around 12V No Go to next step Yes Repair or replace wire harness 3 Check the connect...

Page 749: ...4 injector connector and Pin 47 of ECU to see if open short circuit to power ground occurs No Diagnosis Instruction Failure code P0230 control circuit error of fuel pump Step Operation Result Solution...

Page 750: ...f failure code P0325 occurs again No Check to see if it is random failure Failure code P0335 signal error of crankshaft position sensor Step Operation Result Solution 1 Connect scanner and commutator...

Page 751: ...nplug phase sensor connector from wire harness check the voltage between Connector 3 and Pin 1 of phase sensor with a multimeter to see if it is around 12V No Go to next step Yes Repair or replace wir...

Page 752: ...ess 6 Check the connection between Pin 2 of carbon canister control valve connector and Pin 46 of ECU to see if open circuit occurs No Diagnosis Instruction Failure code P0444 too low driver stage con...

Page 753: ...r control valve to see if open circuit or short circuit to ground occurs No Go to Step 2 Yes Go to next step 4 Check the resistance between Pin 1 and Pin 2 of carbon canister control valve with a mult...

Page 754: ...P0481 control circuit error in relay of Cooling Fan B of air conditioning condenser Step Operation Result Solution 1 Connect scanner and commutator and then turn ignition switch to OFF Go to next ste...

Page 755: ...or and Pin 59 of ECU to see if open circuit short circuit to power supply or to ground occurs No Diagnosis Instruction Failure code P0506 lower idling speed than target value Step Operation Result Sol...

Page 756: ...k injectors for leakage C Check fuel system pressure to see if it is too high No Diagnosis Instruction Failure code P0508 too low control circuit voltage of idle speed regulator Step Operation Result...

Page 757: ...ctor check respectively the resistances between Pin A and Pin D Pin B and Pin C of the regulator with a multimeter too see if they are around 53 5 3 at 20 No Replace stepper motor Yes Repair or replac...

Page 758: ...next step 4 Start engine check charging voltage of generator at different engine speeds to see if it maintains within 9 16V No Replace generator Yes Diagnosis Instruction 5 Check ground point of engin...

Page 759: ...ircuit error of air conditioner compressor relay Step Operation Result Solution 1 Connect scanner and commutator and then turn ignition switch to OFF Go to next step Yes Go to Step 4 2 Unplug air cond...

Page 760: ...s around 3 7V No Go to next step Yes Repair or replace wire harness 5 Check the connection between Pin 86 of relay control terminal of air conditioner compressor relay and Pin 70 of ECU to see if shor...

Page 761: ...r and then turn ignition switch to ON Go to next step Yes Go to next step 2 Test operation of engine fault indicating lamp using Actuator Operation Test function of scanner observe if it keeps off or...

Page 762: ...is within normal range 4 Confirm the existence of failure complained by vehicle owner and locate the specific failure Then appearance inspection Check ground point of wire harness to see if it is clea...

Page 763: ...pair terminal or change wire Yes Go to next step 3 Keep iginition switch at ON check the voltage on terminal to ignition switch connected to starting motor push pull coil with a multimeter to see if i...

Page 764: ...f camshaft to see if it is properly connected No Connect it Yes Go to next step 8 Turn ignition switch to ON and check fuel pump relay and fuel pump to see if they work normally No Check and repair fu...

Page 765: ...3 of ECU to see if there is voltage on them Check the anode power wire connecting these pins and the grounding wire connecting Pin 3 51 53 61 and 80 of ECU to see the connections are proper No Repair...

Page 766: ...Check if fuel leakage occurs in injector and fuel pipe No Go to next step Yes Check coolant temperature and lines 6 Unplug water temperature sensor connector and make engine start Check to see if the...

Page 767: ...ce fuel 8 Replace fuel and check if fuel is deteriorated or contains water No Go to step 14 Yes Go to next step 9 Check if fuel pressure is lower than 350kPa No Go to step 13 Yes Go to next step 10 Sh...

Page 768: ...nition advance angle Yes Go to next step 17 Check if cylinder compression pressure of engine is normal No Troubleshooting Yes Repair or replace 18 Check if intake manifold absolute pressure and intake...

Page 769: ...Go to next step 5 After successful starting check to see if intake manifold pressure is between 35 65kPa during idling No Eliminate intake system air leakage failure Yes Check throttle and idle speed...

Page 770: ...fuel return and check if fuel pressure is formed rapidly No Repair replace injector or fuel pipe Yes Repair or replace fuel inlet pipe 15 Check if leakage or clogging occurs in fuel inlet pipe No Rep...

Page 771: ...resistance of each cylinder is in good order No Replace Yes Replace 7 Check if ignition coil is damaged No Go to next step Yes Go to next step 8 Check if spark plug is in good order No Replace spark...

Page 772: ...e manifold pressure and intake air temperature sensor is blocked up No Go to next step Yes Go to next step 19 Make engine run at idle speed when coolant temperature reaches the point where closed loop...

Page 773: ...p 4 Shut down the engine and switch on ignition switch and then connect commutator between ECU and wire harness to check the voltages of intake air temperature and water temperature sensor as well as...

Page 774: ...alve connecting point may differ among models Strap the 30 and 87 pins of fuel pump relay to make fuel pump work and then check if fuel pressure is at about 350kPa No Go to step 9 Yes Go to step 8 6 P...

Page 775: ...advance angle Yes Replace coolant temperature sensor 15 Pull out coolant temperature sensor to see if engine is in working order No Go to next step Yes Go to next step 16 Check if cylinder compressio...

Page 776: ...ner circuit Yes Go to next step 3 Check if pressure of air conditioning system electromagnetic clutch of compressor and air conditioning pump are in good order No Repair or replace Yes Go to next step...

Page 777: ...e sensor output oxygen sensor output electronic ground ignition switch pins as well as 65 64 67 and 66 pins output to idle speed actuator are in good order No Repair or replace wire harness Yes Go to...

Page 778: ...wn on the brake pedal to see if idling speed is too high No Go to step 6 Yes Repair or replace vacuum booster 5 Clamp vacuum booster tube to see if idling speed turns normal No Go to next step Yes Rep...

Page 779: ...pressure is at about 350kPa No Go to step 10 Yes Go to step 9 7 Provide 12V voltage directly from accumulator to injector with special connector and check if injector is working in good order No Go to...

Page 780: ...re harness to check the voltages of output signal terminal ground terminal and 32 33 pins served as 4 5 5V sensor power of ECU throttle position sensor to see if they are in good order No Repair or re...

Page 781: ...ap the 30 and 87 pins of fuel pump relay to make fuel pump work and then check if fuel pressure is at about 350kPa No Go to step 11 Yes Go to step 10 8 Provide 12V voltage directly from accumulator to...

Page 782: ...terminal ECU sensor signal ground terminal as well as ECU32 33 pins as 4 5 5V sensor power to see if they are in good order No Repair or replace wire harness Yes Go to next step 6 Make engine run at...

Page 783: ...U 15 Air conditioning system failure Yes Go to next step 1 Check if there is enough refrigerant in system and if air conditioning belt air conditioning clutch and pressure switch are working in good c...

Page 784: ...pply system maintenance When disassembling and assembling fuel pump on the fuel tank filled or partly filled with fuel pay attention to the following Before operation device well enough to absorb leak...

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