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Chery A21 2005, Service Manual, Page: 426 / 475

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Chery A21 2005 Service Manual Download Page 426

CHERY A21 SERVICE MANUAL

MECHANISM OF 2.0NALC ENGINE

37

3)

Mount the upper bearing of connecting
rod and the connecting rod together.

Note: the gap on bushing should be orderly
with that of connecting rod.

4)

Spread the engine transmission oil in the
engine  cylinder,  clasp  the  piston  ring
with  special  tool,  tap  the  piston  head
with  wooden  handle  and  encase  the
piston connecting rod assembly.

Note: the end of connecting rod with a point
should face the cylinder and consists with the
arrowhead on the top side of piston.

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Summary of Contents for A21 2005

Page 1: ...Position 0N ACC ST2 ACC AM2 IG2 AM1 START AND CHARGE SYSTEM CIRCUIT DIAGRAM NO 03 01 A21 2005 Starter Relay Ignition Switch Generator Starter Relay ACC 1 Relay ACC 2 I gnition S witch Relay Storage Baterry To instrument 16 ...

Page 2: ...A21 2005 NO 03 02 CIRCUIT DIAGRAM ABS SYSTEM To Brake Switch ABS Control Left Front Wheel Sensor Right Front Wheel Sensor Left Rear Wheel Sensor Right Rear Wheel Sensor ...

Page 3: ...ure Switch Cycling Motor Mode Damper Motor Incorporated Damper Motor Outer Temperature Sensor To Instrument 7 To W iper M otor 2 Governor Resistor Inner Temperature Sensor WaterT emperature S ensor Sunlight Sensor To D iagnostic C onnector 7 To D efrost S witch 2 A C Control ...

Page 4: ... CIRCUIT DIAGRAM AUDIO SYSTEM Audio System Left Rear Speaker Right Rear Speaker Left Front Speaker Right Front Speaker Left Front Door Speaker Right Front Door Speaker Antenna Steering Wheel Shortcut Key Front ISU PP3 3 ...

Page 5: ...Passenger Side Airbag To Instrument 17 Front Passenger Airbag Lock Switch Left Front Pretensioner Seat Belt Driver Side Airbag Front Passenger Side Airbag Left Impact Sensor Right Impact Sensor Right Front Pretensioner Seat Belt To Diagnostic Connector 7 To Instrument 24 To ISU PE2 16 ...

Page 6: ...sure Switch Fuel Level Sensor To Airbag Control 47 Brake Fluid Level Sensor To Speed Sensor 2 To Front ISU PE1 2 To Sunroof Module 3 To Diagnostic Connector 7 To Generator Terminal 1 To Automatic A C Module J Brake Shoe Lining Alarm Switch Brake Shoe Lining Alarm Switch Brake Shoe Lining Alarm Switch Brake Shoe Lining Alarm Switch ...

Page 7: ...sor Knock Sensor To ABS6 To Front ISU PE2 22 Vortex Control Valve Exhaust Timing Solenoid Valve Air Flowmeter Electronic Throttle Valve Camshaft Phaser Carbon Canister Solenoid Valve Intake Timing Solenoid Valve Oil Temperature Sensor To Instrument 27 To A C Pressure Switch 3 Compressor Relay Oil Pump Relay Oil Pump Clutch Switch Power Steering Switch To Electronic Control Headlamp Switch 6 To Ant...

Page 8: ...of Left Rear Door To Front ISU A30 High Mounted Stop Lamp Trunk Lock Actuator Left Turn Light Regulator Motor of Right Rear Door Rear Windshield Glass Heater resistor Left Backup Lamp License Lamp Left Position Lamp Left Rear Regulator Motor Left Probe Contact Switch of Right Rear Door Right Position Lamp Right Rear Fog Lamp Right Turn Signal Lamp Right Backup Lamp Middle P robe Right P robe ...

Page 9: ...t Lamp Adjusting Switch CIRCUIT DIAGRAM Left Front Position Lamp Right Front Position Lamp Rear Ceiling Light Rear Fog Lamp Switch Front Fog Lamp Switch Contact Switch of Left Front Door Contact Switch of Right Front Door Front Fog Lamp Right Front T urn Signal Lamp Right Side Turn Signal Lamp Left Front Turn Signal Lamp Left Side T urn Signal Lamp Regulator Motor of Right Front Door Regulator Mot...

Page 10: ...1 A21 ENGINE PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 11: ...amshaft 16 valves controllable burning rate CBR and variable valve timing VVT Cylinder diameter mm 81 Piston stroke 77 5 Displacement 1 597 Compression ratio 10 5 Rated Power net power 87 Revolution at rated power RPM 6200 Maximum torque Nm 275 Revolution at max torque RPM 4300 Minimum fuel consumption rate 275 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 12: ... TOOL Camshaft Timing Tool Crankshaft Timing Tool Flywheel Tool Guide Sleeve Of Crankshaft Oil Seal Guide Sleeve Of Camshaft Oil Seal Hydraulic Hoist PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 13: ...NE TIMING CALIBRATION 1 Dismantle dynamo belt Use wrench to clamp the tension pulley bolt screw it counterclockwise and dismantle the generator bolt Position of Engine Cylinder Block Number Engine Oil Dipstick PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 14: ...ight mounting bracket 3 Dismantle crankshaft pulley Shift the car into the 5th gear step on the brake and dismantle the fixed bolt of crankshaft pulley 4 Dismantle the timing belt cover Dismantle the upper cover and lower cover of timing belt respectively Upper Cover Lower Cover PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 15: ...ortions of timing belt If any one shown in the figure occurs you should replace with new spare parts 1 Chap of back side rubber 2 Chap of dedendum chap of separated cord fabric 3 Wearing gear missing and incomplete gear of cord fabric 4 Abnormal wearing of belt flank Air Intake Camshaft Pulley Exhaust Camshaft Pulley Idler Coolant Pump Belt Crankshaft Timing Timing Belt Tension Pulley Chap Chap We...

Page 16: ... the rubber may be damaged due to expansion you should replace the belt 5 Dismantle the valve chamber cover Loosen the fixed bolt of valve chamber cover and lift down the valve chamber cover 6 Camshaft phase alignment Rotate the camshaft and clamp the camshaft tool into the eccentric groove of camshaft sensor signal pulley Abnormal Wearing Gear Missing Belt Core Desquamation Camshaft Tool PDF crea...

Page 17: ...8 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 18: ...e timing belt in the position shown in the figure use allen wrench to rotate the tension pulley in order to strain the belt fasten the tension pulley bolt And fasten the fixed bolt of air intake and exhaust camshaft pulleys and the camshafts Torque 120 5Nm 9 Lift down the special timing calibration tools and then fasten the valve chamber cover timing belt cover the right engine mounting bracket of...

Page 19: ...e all the anti freezing solution 3 Dismantle the airflow lines between the throttle valve case and the air flow meter dismantle the a lead connector of air flow meter b lead connector of ignition coil c lead connector of canister solenoid valve 4 Remove the d the wire harness plug of water temperature sensor and e wire harness plug of air intake and exhaust camshaft position sensor b a c e d PDF c...

Page 20: ... 7 Remove l CBR solenoid valve plugs and m oil temperature sensor plugs 8 Loosen n generator positive pole output pull out o exciting current harness plugs as well as the plugs of relevant parts of the A C compressor steering booster pump oxygen sensor and A C high low voltage switch Loosen the fixed bolt of starter harness to confirm the plugs of all parts are completely separated f i k j h g m l...

Page 21: ...anger from the top and dismantle the two hexagonal flange bolts of front suspension bracket 11 Dismantle the hexagonal flange bolts of girder under the car body 12 Remove the hexagonal flange bolts of rear suspension cushion assembly of engine p q PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 22: ...olts of right suspension cushion and dismantle the right suspension cushion assembly and bracket 16 Dismantle the hexagonal flange bolts of left suspension cushion in order to ensure no connection between the engine and car body Lift down the crane carefully and shift out the power assembly PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 23: ...ear so you can dismantle the belt 1 3 Installation steps The installing steps are reverse to those for removal 2 Replacement of Generator Assembly 2 1 Needed tools and auxiliary materials Allen wrench ratchet wheel 13 sleeve 10 open end wrench 2 2 Process of removal 1 Dismantle the negative pole harness of battery 2 Dismantle the bolts connecting the generator and harness and take out the harness ...

Page 24: ...erator 3 Replacement of Air Conditioner Compressor 3 1 Needed tools and auxiliary materials Small ratchet wheel ratchet rod 10 sleeve big ratchet wheel 13 sleeve crosshead screwdriver allen wrench coolant R134a gauze A C pressure gauge 3 2 Process of removal 1 Release Refrigerant for A C compressor Screw off the nuts in the test pressure port of high pressure pipe and use screwdriver to press down...

Page 25: ...C compressor and fixed bracket 6 Loosen the bolt II connecting the A C compressor and fixed bracket 7 Use allen wrench to dismantle the bolts connecting the A C compressor and pipes Note After removing the A C pipes you should use clean gauze to block up the mouth of A C pipes in order to prevent outer substances from falling into the A C pipes 8 Dismantle the three fixed bolts of A C fixed bracke...

Page 26: ...ess plugs of power steering switch use17 open end wrench and vice clamp to loosen the connecting bolts of oil pipe and clips and discharge the power steering oil 2 Dismantle the dynamo belt Detailed removal methods are shown in the displacement of dynamo belt 3 Dismantle the bolt connecting power steering oil pump and bracket 4 otate the steering pump pulley to make the fixed bolt exposed and then...

Page 27: ...idler wheel 5 3 Installation steps Installation steps is opposite to the Process of removal 6 Replacement of Air Intake Flow Sensor 6 1 Needed tools Ratchet wheel ratchet rod 10 sleeve and slot head screwdriver 6 2 Process of removal 1 Pull out the plugs connecting the sensor and wire harness and use slot head screwdriver to loosen the clamp at the connection point of air intake hose and air clean...

Page 28: ...e filter case and take out the filter paper 7 3 Installation steps Installation steps are opposite to the process of removal 8 Replacement of Ignition Coil 8 1 Needed tools Ratchet wheel ratchet rod 10 sleeve 8 2 Process of removal 1 Put the ignition switch key at the OFF position and pull out the ignition coil plug 2 Remove the high voltage cable from the ignition coil PDF created with pdfFactory...

Page 29: ...ignition coil 2 Pull out the connection end of high voltage cable and sparking plug and dismantle the high voltage cable Note If the spare parts of high voltage cable corresponding to various cylinders are ordered you can replace the high voltage cable of single cylinder otherwise you must replace the assembly 9 2 Installation steps The installing steps are reverse to those for removal PDF created...

Page 30: ...for removal 11 Replacement of Camshaft Position Sensor 11 1 Needed tools Allen wrench 11 2 Process of removal 1 Put the ignition key at the position of OFF and shut off the sensor plug 2 Use allen wrench to loosen the sensor fixed bolt 11 3 Installation steps The installing steps are reverse to those for removal Installation precautions In the case of installation you should apply a layer of oil o...

Page 31: ...bstances entering into the cylinder block 2 Loosen the two bolts connecting the starter and transmission 3 Take out the starter and remove the electric plugs of it 12 3 Installation The installing steps are reverse to those for removal 13 Replacement of Oil Filter 13 1 Needed tools and auxiliary materials Special tools for oil replacement engine oil 13 2 Removal Use special tool to clamp the oil f...

Page 32: ...y 3 Hexagonal Flange Bolt 4 Throttle Valve Assembly 5 Gasket Throttle Body Assembly 6 Oil Injector Assembly 7 Fuel Delivery Pipe Assembly 8 CBR Position Sensor 9 Bracket Actuator 10 Actuator 11 Rocker 2 CBR System 12 Rocker 1 CBR System 4 8 7 6 2 12 10 1 3 5 9 11 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 33: ...sembly 11 First Bearing Cap Assembly 12 Front Camshaft Oil Seal 13 Exhaust Camshaft Assembly 14 Rocker Assembly 15 Hydraulic Tappet Assembly 16 Stud Bolt 9 Bars 17 Cylinder Head Gasket 18 Temperature Sensor 19 Engine Hanger 20 Cylinder head Bolt 21 CBR Cylinder head Assembly 11 15 14 13 8 9 10 17 7 18 1 5 4 3 2 6 12 16 19 20 21 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 34: ... the oil injector plug 3 Loosen the electric plug of CBR control valve and dismantle the bolts connecting the engine oil dipstick and intake manifold 4 Loosen the clamp at the connection end of air intake hose and valve body 5 Dismantle the connecting bolts of valve body and take out the valve body 6 Loosen the joint of oil intake pipe 7 Dismantle the fixed nut of intake manifold and remove the in...

Page 35: ...t a set of sleeve tools and one adjustable wrench special timing tool a set of allen wrenches 2 2 2 Removal 1 Dismantle the dynamo belt detailed methods are shown in the removal of dynamo belt 2 Dismantle the timing belt detailed method are shown in the replacement of engine timing belt and timing calibration 3 Dismantle the engine valve chamber cover 4 Clamp the engine timing special tool the cam...

Page 36: ...second third fourth and fifth camshaft bearing caps are marked with I1 I2 I3 I4 E1 E2 E3 E4 which stands for the corresponding bearing cap of 1 2 3 4 cylinder respectively 8 Take out the camshaft and hydraulic tappet 9 Dismantle the valve spring Use special tool to dismantle the valve spring 10 Use special valve oil seal tool to dismantle the old valve oil seal PDF created with pdfFactory Pro tria...

Page 37: ...camshaft Use micrometer caliper to measure the diameter of camshaft Standard value mm Limit value mm Diameter 0 15 0 20 Replace with the new camshaft if the measured value exceeds the limit value 3 Check the camshaft Use micrometer caliper to measure the length of camshaft Standard value mm Limit value mm Intake camshaft 0 15 0 20 Exhaust camshaft 0 15 0 20 Replace with the new camshaft if the mea...

Page 38: ...ue and the clearance If they exceed the specified limit values the value or guide shall be replaced more necessarily D Check the contact bandwidth of valve E Check the valve seat insert Valve Guide Outer Diameter Of Valve Stem Inner Diameter Of Valve Guide Measuring Point Measuring Point Contact Position Should Be At The Center Of Slope Edge Thickness PDF created with pdfFactory Pro trial version ...

Page 39: ...p 2nd and 3rd cylinders in the other group When the piston runs tothe top dead center of 1st and 4th pistons you should dismantle the valve springs of the 1st and 4th cylinders replace the valve oil seal and mount valve springs immediately When the piston runs to the top dead center of2nd and 3rd cylinders you should replace the valve oil seal Thus you can prevent the valve from falling into the c...

Page 40: ...sically there is only a gap on the top right corner The mixing of oil mist and air mainly depends on the eddy flow of air intake provided by tangential air duct thus improving the combustion status When the engine operates at high speed CBR control valve shall cut off the vacuum condition of vacuum actuator thanks to the spring functions the sliding plate shall return to the position illustrated i...

Page 41: ... engine oil system and can be regulated by solenoid valve and control loop When the engine operates at different rotation speeds there are different angles between the camshaft and sprocket which facilitates the air intake valve to open and close at different times in an effort to achieve variable valve timing On the other hand when the engine operates at different rotation speeds abundant and app...

Page 42: ...amshaft Phaser Assembly 3 Oil Pump Assembly 4 Engine Piston 5 Engine ECU 6 Crankshaft Position Sensor 7 Camshaft Position Sensor 8 Camshaft SECTION III SHORT ENGINE I STRUCTURE DIAGRAM PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 43: ...l Filter 8 Oil Cooler 9 Oil Filter Seat 10 Connecting Rod Bolt 11 Connecting Rod Bearing Cap 12 Oil Pump 13 Bolt 14 Gasket 15 Crankshaft Timing belt pulley 16 Gasket 17 Bolt 18 Crankshaft Pulley 19 Bolt 20 Bolt 21 Coolant pump 22 Coolant Pump Gasket PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 44: ...35 23 Crankshaft Main Bearing Bolt 24 Frame Bolt 25 Frame 26 O Type Ring 27 Crankshaft 28 Cylinder Block PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 45: ... the oil discharge bolt of oil pan to discharge the engine oil Note Engine oil should be stored in special container And Pay attention to environment protection 2 Use 10 open end wrench and 10 sleeve to dismantle the fixed bolt of oil pan 18 M7 25 3 7 40 and 4 M7 95 3 Use 17 sleeve wrench to dismantle the bolts 2 pieces black connecting the oil pan and transmission housing PDF created with pdfFact...

Page 46: ...Do not scuff the frame surface 1 2 2 Installation 1 Apply Le Tai 5910 Glue onto the connection surface of engine frame edges and oil pan to close up the oil pan and then mount fixed bolts for oil pan Note Spread glue to the inner of hole for installing bolt on the oil pan 2 Fasten the bolt Firstly fasten it slightly to press fit and then fasten it up to the specified torque Fastening method for bo...

Page 47: ...cess of removal 1 Dismantle oil pan removal method is shown in the replacement of oil pan 2 Use 10 sleeve wrench to dismantle the bolts 8 pieces connecting the oil strainer and engine frame 3 Pull out the oil strainer carefully 2 2 2 Installation 1 Spin the nozzle of engine oil strainer into the frame carefully 2 Mount the 8 bolts for the strainer and fasten them Note All bolts should be pasted wi...

Page 48: ...mantle the timing belt detailed methods are shown in the section of timing belt assembly in the replacement of timing belt 2 Dismantle the oil pan detailed methods are shown in the section of replacement of oil pan 3 Dismantle the cylinder head detailed methods are shown in the removal of cylinder head 4 Dismantle the oil strainer detailed methods are shown in the replacement of oil strainer 5 Loo...

Page 49: ...rk carefully in order to avoid hurting person 3 2 2 Inspection I Check the piston 1 Check the piston diameter Use micrometer caliper to carry out measurement at the position 11mm away from the lower part of piston skirt section a and along the vertical direction of piston pin Cylinder No Standard Size Wearing Limit 1 80 46 0 009 2 80 46 0 009 3 80 46 0 009 4 80 46 0 009 Please replace the piston w...

Page 50: ...ot Standard value mm Wearing limit mm First ring 0 04 0 08 Second ring 0 01 0 025 If the measured clearance exceeds wearing limit please replace it with new piston 3 Check the end clearance of piston ring a Put the piston ring at the position 45mm below the top surface of cylinder aperture and push the piston ring into cylinder with piston PDF created with pdfFactory Pro trial version www pdffacto...

Page 51: ... caliper to measure the outer edges of the part shown in the following figure and select the maximum value as the diameter size of piston pin b Use inner micrometer caliper to measure the outer edges of the parts of the piston pin hole shown in the following figure and select the minimum value as the diameter size of piston pin hole PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 52: ...oundness and cylindericity after two measurements Standard value Wearing limit Diameter Roundness Cylindericity b Check the radial clearance of connecting rod bearing Use clearance gauge to measure the radial clearance of connecting rod bearing Firstly clean the connecting rod journal and connecting rod bearing and then put the clearance gauge onto the journal and fasten the bearing bush to specif...

Page 53: ...model of the same manufacturer Standard value Wearing limit clearance 0 15 0 50 6 Check the flatness of the cylinder block surface a Clean the cylinder block surface b Use ruler and feeler gauge to check whether the cylinder block surface is warped or not C If the warping amount is excessive please rectify it If it exceeds the limit please replace the cylinder block The maximum summation of the pe...

Page 54: ...nto the piston pin and in the piston pin hole and use piston pin to connect the piston with the connecting rod and then mount the piston pin circlip 2 Mount piston ring Mount all the rings onto the piston according to the sequence the bushing ring of oil control ring upper and lower blades second air ring first air ring Observe the piston ring direction when mounting various rings those with TOP o...

Page 55: ...nnecting rod assembly Note The end of the connecting rod with points should point at the 1st engine cylinder and be consistent with the direction of arrow at the piston top surface 5 Mount the connecting rod lower bearing and connecting rod cap together and apply engine lubricant onto the bearing Note The bearing notch should be in alignment with the connecting rod notch 6 Latch on the connecting ...

Page 56: ...ench engine lubricant special tools for assembly oil seal 4 2 Process of replacement 4 2 1 Process of removal 1 Dismantle the timing belt detailed Process of removals are shown in the replacement of timing belt Standard value mm Limit value mm Clearance 0 15 0 50 2 Shift the car into the 5th gear and step on the brake use torque wrench to dismantle the bolts connecting the timing belt pulley and c...

Page 57: ...irt and stain on the oil seal seat ring and apply a layer of lubricant onto the seat ring 2 Apply a layer of engine lubricant onto the oil seal lip 3 Fit the lubricant applied new oil seal into special tool 4 Press the oil seal into the oil seal seat ring carefully and use hammer to knock it to the specified position PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 58: ...d bolt of oil pump and remove the oil pump Torque 8 3NM 4 Pry out the oil seal 5 Clean the seat ring of oil pump 5 2 2 Installation 1 Apply oil onto the oil pump gasket 2 Mount the oil pump into the seat ring of oil pump Note The bulging portion of oil pump should point downward When the position is not correct the bolt cannot be screwed in 3 Mount oil seal 4 Mount other components 6 Replacement o...

Page 59: ...l seal Note Avoid scuffing the oil seal seat ring 6 2 Installation 1 Clean the oil seal seat ring Use clean gauze to suck some engine oil to clean up the foreign substances in the oil seal seat ring 2 Apply a layer of oil onto the front oil seal lip of crankshaft equally Fit the oil seal onto the special tool and then press it into the oil seal seat ring 3 Install flywheel and clutch pressure plat...

Page 60: ...A C compressor power steering pump and bracket detailed methods are shown in the replacement of engine accessories 5 Dismantle the engine cylinder head assembly detailed methods are shown in the replacement of cylinder head 6 Dismantle the clutch pressure plate flywheel and timing belt pulley 7 Dismantle the oil pan and oil strainer detailed methods are shown in the replacement of oil span and str...

Page 61: ... bag of plastic gauge to measure the width of the widest portion of flattened plastic wire and get the clearance value Standard value Limit value Clearance 0 022 0 058 If the clearance value exceeds the limit value please replace the bearing bushing Note When replacing the bearing bushing you must replace the whole group of bearing bushings 2 Measure the axial clearance of crankshaft After mountin...

Page 62: ...crankshaft fixed bolts The fastening sequence is illustrated in the figure Torque 4 Mount the bolts onto the frame periphery and fasten them Torque 5 Mount oil strainer oil pan front and rear oil seals of crankshaft and oil pump 6 Mount engine accessories lift and install the engine onto the car mount water pipe and insert all electrical plugs PDF created with pdfFactory Pro trial version www pdff...

Page 63: ...e external surface from being scuffed Note Make sure that not spoil the paint coat or inner or outer trim parts when separating the glass Place a plastic piece between the piano wire and the instrument panel to prevent the instrument panel from being scuffed when disassembling the glass Figure 148 3 Pull the piano wire around the glass and cut off the bonding agent to take out the glass Note Leave...

Page 64: ... Even if the entire bonding agent has been cleared you should also clean the body surface and do not touch the glass surface after cleaning Figure 150 2 Remove the stopper with a knife Figure 151 3 Clear the bonding agent adhered to the glass with a scraper and clean the glass with washer fluid Note Do not touch the glass after cleaning Figure 152 Bonding Agent Stopper PDF created with pdfFactory ...

Page 65: ...ece Figure 153 5 Position the glass Place the glass at the proper position Make reference marks on the glass and the body Remove the glass Figure 154 6 Clean the contact surface of the glass Clear the black dirt around peripheral contact face of the glass with washer fluid Note Do not touch the glass surface after cleaning Figure 155 PDF created with pdfFactory Pro trial version www pdffactory com...

Page 66: ...ore than 3 minutes Do not apply the primer on the bonding agent Do not reserve the opened primer M for later use Figure 157 9 Apply a layer of primer G on the contact surface of the glass Apply a layer of primer G on the edges and the contact surface of the glass with a brush or sponge Wipe the primer off with a clean rag before it dries Note Let the primer coat dry for more than 3 minutes Do not ...

Page 67: ...ost crystal with 75 grams hardener completely on a glass board or similar with a scraper Figure 159 11 Applying the bonding agent Cut off the pot tip and fill the bonding agent into the pot Place the pot into the sealant gun Apply the bonding agent on the glass as shown in the figure Figure 160 12 Installing the glass Tip Make sure that the water resistant piece adhered to the panel of the body as...

Page 68: ...e excessive or over flown bonding agent with a scraper Clamp the glass until the bonding agent is harden Check for water leakage and repair it Perform the leakage test after the hardening period Seal the leakage part with sealant Figure 163 13 Install the upper moulding of the windshield Install the upper moulding on the body and tap it lightly to fasten it Install the outer moulding Figure 164 2 ...

Page 69: ...ding with a scraper as shown in the figure Tip Entangle the tip of the scraper with adhesive tape before starts Figure 166 3 Remove the glass of the rear window Pull the piano wire through between the body and the glass from inside of the vehicle Tie both ends of the piano wire with wood block or similar Tip Use adhesive tape on the outside to prevent the external surface from being scuffed Figure...

Page 70: ...oulding Place the moulding around the glass and fit it manually Tip Be sure to remove the glass of the rear window first before fitting the moulding Figure 169 2 Clean and finish the contact surface of the body and cut off the rough parts on the body Tip Leave bonding agent as much as possible on the body and clean the cut surface of the bonding agent with a rag soaked with washer fluid Tip Even i...

Page 71: ...ot touch the glass after cleaning Figure 171 4 Position the glass Place the glass at proper position Make reference marks on the glass and the body Remove the glass Figure 172 5 Clean the contact surface of the glass Clear the black dirt around peripheral contact face of the glass with washer fluid Note Do not touch the glass surface after cleaning Figure 173 PDF created with pdfFactory Pro trial ...

Page 72: ... the primer coat dry for more than 3 minutes Do not apply the primer on the bonding agent Do not reserve the opened primer G for later use in bonding agent mixing Note Make sure that the moulding is installed within the application period of the bonding agent and the bonding agent should be mixed within 5 minutes Figure 175 8 Completely clean the glass board and putty knife with solvent Completely...

Page 73: ...o from the edge Figure 178 Apply the bonding agent on the edges of the glass with a scraper Clear the excessive or over flown bonding agent with a scraper Clamp the glass until the bonding agent is harden 11 Check for water leakage and repair it Perform the leakage test after the hardening period Seal the leakage part with sealant Fit the outer lower moulding of the rear window fit the moulding on...

Page 74: ...Chery Service Manual for A520 Body Dimension and Accessories 12 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 75: ...STRUCTURAL DIAGRAM 1 Sun roof frame 2 Windshield frame 3 Sun roof central bracket 4 Sun roof back bracket 5 Rear roof frame 6 Car lining 7 Sun roof track 8 Sun roof module 9 Sun roof motor 10 Sun roof deflector 11 Sun roof glass 12 Guiding gutter 13 Sun visor PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 76: ...OOF GLASS 3 1 Disassembling the sun roof glass 1 Turn on the power switch to lift up the sun roof in full tilt 2 Push the inner trim strip SIDE COVER INNER LH RH backwards to make it off 3 Slowly unscrew the four screws and bolts fixing the glass Be sure not to make the glass off 4 Simply take off the glass PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 77: ...alling the sun roof glass 1 Turn on the power switch to operate the sliding mechanism without glass to the full open position and then place the glass in the middle of the support bar of the sliding mechanism PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 78: ...y forward 5 Turn on the power switch to test if the on off operation of the sun roof is normal Note check and adjust the height start up noise collision of the glass 6 Turn on the power supply switch to lift up the glass to the full open position again and then stick the inner trim strip to the support bar of the sliding mechanism 7 Test the on off operation starting and running operation as well ...

Page 79: ...ight 3 Draw out the sun visor backwards 4 2 Installation The installing steps are reverse to those for removal 5 REPLACING THE SUN ROOF MOTOR 5 1 Disassembling the sun roof motor 1 Turn on the power to run the sun roof to the full close position before disassembling i e the initial position of the sun roof 2 Remove the roof interior trim ceiling light See Service Manual for the Body Accessories fo...

Page 80: ... steps are reverse to those for removal 6 REPLACING THE SUN ROOF CONTROL MODULE 6 1 Disassembling the sun roof control module 1 Turn on the power to run the sun roof to the full close position before disassembling i e the initial position of the sun roof 2 Remove the roof interior trim ceiling light See Service Manual for the Body Accessories for detailed disassembling methods 3 Disconnect the pow...

Page 81: ...and install or replace the trim strip Abnormal starting and running Foreign material on the slide rail Inspect and clear the foreign material The sun visor runs off the slide rail or the broken trim strip rubs the slide rail Adjust and install the sun visor again and re install the trim strip also replace the broken parts Anti stick A T S function fails to work normally Check for collision between...

Page 82: ...Manual for A520 Body Dimension and Accessories 8 the roof hole is too big or the height of the glass is incorrect glasses and their relative positions PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 83: ... SCU controller could also normally start and restore its initial position 9 DETAILED SOLUTIONS FOR THE PROBLEMS 9 1 The sun roof loses its initial position Definition When the sun roof could not be opened or closed normally or closed to the normal position as well as the sun roof could not perform its original movement course When the failure of sun roof is like this its movement procedure of it ...

Page 84: ... roof hole check if the sun roof motor produces abnormal sounds check if the mouldings damage and rub the rail and then determine the reasons producing abnormal sounds Solutions 1 Refer to the procedures in replacing the sun roof glass to re install the sun roof glass and make sure the clearance between the sun roof glass and the roof hole is in its normal range 2 Replacing the motor producing abn...

Page 85: ...nt the metal clips of the pillar trim panel should be installed in place without any looseness The trim panel should be in good fitting with the roof and the weather strip Figure 93 2 Disassemble the scuff plate of the front door Figure 94 3 Disassemble the pedal pad for the left foot Figure 95 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 86: ...y is 80 The tightening torque for the catch bolt is 50 5N m The tightening torque for the fixing bolt of the slider track assembly is 50 5N m The tightening torque for the fixing bolt of the guide ring is 50 5N m The support for guiding should be fixed reliably with the tightening torque for the screw of which is 1 5 0 5 N m The tightening torque for the fixing bolt of the end piece is 50 5N m The...

Page 87: ...elt retractor assembly is 90 The tightening torque for all fasteners of this assembly is 50 5N m and the fasteners should be applied with the thread fastening glue before installing The belts could extend and shrink easily and could not slack after the latch is fastened with the lock striker The catch bolts of the middle seat belt should be applied with thread fastening glue and the tightening tor...

Page 88: ... and Accessories 4 8 Remove the two bolts and slider track Figure 102 9 Remove the weather strip Figure 103 10 The inner harness connector on the left rear door as shown Figure 104 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 89: ...n and Accessories 5 11 From here outwards to pull out the harness Figure 105 12 Remove C pillar trim panel Figure 106 13 Remove the weather strip from the left rear door Figure 107 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 90: ...nt The tightening force for the screw should be proper and make sure that the sun visor could work normally without any looseness The sun visor could move freely when working normally without any noise and being stuck Figure 109 16 Remove the fixing base Assembly requirement The fixing base could seize the sun visor properly so as to prevent the sun visor from breaking away when being used Figure ...

Page 91: ... bulb in the right sun visor with a flat head screwdriver Figure 111 18 Pry out the lamp house remove the screws pull out the harness and then detach the indoor front ceiling light Figure 112 19 Pry out the indoor rear ceiling light Figure 113 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 92: ...e roof The roof edge should be in good fitting with the weather strip of the door opening and the luggage compartment and exposure of the roof corner and non tight edge holding down are not allowed The roof corners are not allowed to raise outside and depress so as to prevent the weather strip layer from non flat fitting The roof edges should be in good fitting with the arcs of the upper trim pane...

Page 93: ... 4 Check the thickness of brake lining The standard thickness of front brake lining is19 3mm and the operating limit is 9mm The residual thickness of brake pad thickness limit should be not less than 1mm coated plate 5mm noise insulator 0 6m The standard thickness of rear brake lining is 16mm with its operating limit of 8 mm The residual thickness of brake pad thickness limit should be not less th...

Page 94: ...n the 4 clamp nuts for 1 2 folds and then screw off the nuts Do not scuff the bolt Torque 110 10 N m 2 Use 13 box end wrench to screw off the nut connecting the brake oil pipe and the brake caliper and discharge the brake fluid Note Since the brake fluid is poisonous you must keep your skin away from it Torque 11 14 N m 3 Use 13 box end wrench to loosen the bolts 2 pieces connecting the brake cali...

Page 95: ...please replace it in pair No matter whatever happens you are not allowed to use hammer or similar tools to hit the brake disc If necessary you can use rubber hammer to knock on the brake disc body 6 Take out the rear brake disc Check the thickness of brake disc and replace the brake disc when its thickness is less than the specified minimum thickness 7 Use bearing puller to pull out the wheel hub ...

Page 96: ...ke down the handbrake shoe 10 Use 15 socket wrench to loosen the fixed bolts 4 pieces of brake backing plate and dismount the brake backing plate Torque 7 14N m 2 2 Mounting of the rear brake assembly Mount the rear brake assembly according to the reverse sequence of dismounting 2 3 Disassembly of rear brake caliper 1 Use 17 box end wrench to dismount the connecting bolts of brake caliper Torque 2...

Page 97: ...o replace it with new brake lining Check the specified minimum thickness of brake lining and clean it Do not paint lubricant onto the backing plate of brake pad Note When replacing brake lining please replace it in pair 4 Dismount the dust seal ring and check its damage If necessary you should replace it Clean the contact surface of brake piston and paint a thin layer of noise silencing paste onto...

Page 98: ...ssembly SECTION III DISASSEMBLY AND ASSEMBLY OF FRONT WHEEL BRAKE Needed tools ratchet ratchet rod 8 13 15 20 sleeves 13 14 17 30 box end wrenches vice clamp and torque spanner 3 1 Assembly diagram of front wheel brake 3 2 Disassembly sequence of front wheel brake 1 Use torque wrench or carry on wrenches to unbolt the tire clamp nut and dismount the tire Torque 110 10 N m PDF created with pdfFacto...

Page 99: ... brake fluid from splashing onto your clothes or skin when dismounting the brake hose Torque 4 Screw off the nuts and bolts mentioned in the 2nd and 3rd steps remove the brake caliper from the steering knuckle and isolate the brake caliper from the brake hose Note Since brake fluid is poisonous you should prevent the brake fluid from splashing onto your clothes or skin when dismounting the brake h...

Page 100: ...e disc please replace it in pair Torque 7 9 N m 7 Use 3 arm hub puller to pull out the wheel hub Dismount the fastening bolt of splash shield and remove the splash shield 8 Use torque wrench and 18 sleeve to dismount the bolts connecting the steering knuckle and control arm Torque 110 5N m 9 Use torque wrench and 17 sleeve to dismount the bolts 3 pieces that connect the ABS wheel speed sensor unit...

Page 101: ...y of front wheel brake The assembly sequence is opposite to disassembly sequence 3 4 disassembly of front wheel brake caliper 1 Remove the thickness monitoring harness of friction wafer from the bracket 2 Use a 13 and a 15 open end wrench to dismount the fastening bolt of brake caliper bracket Torque 22 23N m PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 102: ...e cylinder 3 5 Assembly of brake caliper The assembly sequence is opposite to disassembly sequence SECTION IV REPLACEMENT OF HANDBRAKE CONTROL CABLE Needed tools flat tip screwdriver ratchet wrench ratchet rod 10 13 sleeves carry on wrenches torque wrench and vice clamp 4 1 Disassembly sequence 1 Use screwdriver to pry out the edges of central armrest box and dismount the central armrest box 2 Use...

Page 103: ...brake cable from the cable connection 5 Uplift the backseats and uncover the carpet Note When uncovering the carpet if the scuff plate stands in the way you should dismantle the scuff plate firstly 6 Unbolt the clamp nuts connecting the brake cable bracket and floor plate and remove the brake cable from the bracket PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 104: ...ount the return spring under the drum brake and remove the push rod as illustrated in the figure 8 Take out the brake cable from brake arm 9 Uplift the car and use flat tip screwdriver to pry out the brake cable from the brake backing plate 10 Use ratchet wrench and 15 sleeve to dismount the bolts as shown in the following figure and then pull out the brake cable PDF created with pdfFactory Pro tr...

Page 105: ...oosen the parking brake handle Heavily step on the brake pedal once Pull up the parking brake handle for 4 gears Fasten the adjusting nut until the two wheels cannot be rotated by hand After finishing the above mentioned sequences you should loosen the parking brake and check whether the two rear wheels can rotate freely Otherwise repeat the above mentioned steps Adjust Nut PDF created with pdfFac...

Page 106: ... central armrest box and dismount the central armrest box 2 Use ratchet wrench and 10 sleeve to dismount the handbrake fastening bolts 3 pieces 3 Take out the brake cable from the cable connection 4 Use cross head screwdriver to dismount the earth screw of handbrake circuit and then unbolt the handbrake 5 2 Assembly sequence Assembly sequence is opposite to disassembly sequence PDF created with pd...

Page 107: ...er to pump out the brake oil Note Since the brake oil has strong corrosiveness you should prevent the brake oil from splashing on your skin and lacquer finish 3 Use clamp pliers to dismount the fastening clamp at the oil inlet pipe of clutch cylinder and remove the oil inlet pipe of clutch 4 Use 10 and 13 open end wrench to loosen the brake pipeline of brake master cylinder PDF created with pdfFac...

Page 108: ...rench to dismount the fixing nut each at both left and right side of brake master cylinder and take out the brake master cylinder 6 2 Assembly sequence Assembly sequence is opposite to disassembly sequence SECTION VII REPLACEMENT OF BRAKE PEDAL AND VACUUM BOOSTER Needed tools ratchet wrench ratchet rod 13 sleeve vice clamp 10 12 open end wrenches and clamp pliers 7 1 Disassembly sequence 1 Disasse...

Page 109: ...mount the four fixed bolts of the brake pedal bracket and the two bolts connecting the brake pedal and car body 6 Take out the brake pedal and vacuum booster Note The internal components of booster cannot be repaired and the booster case cannot be dismantled The dismantling of booster case shall result in permanent deformation and improper capacity of thrust augmentation PDF created with pdfFactor...

Page 110: ... CHASSIS 18 7 Loosen adjusting bolt to regulate the brake pedal to standard height 7 2 Assembly sequence The assembly sequence is opposite to disassembly sequence PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 111: ...ing the car for a long time 7 Prevent the wheel speed sensor and sensor gear ring from being polluted by oil stain or other dirties Otherwise the wheel speed sensor shall generate inaccurate wheel speed signal which shall further impose influence on the accuracy of system control and even lead to system failure Furthermore you are prohibited to knock the rotation speed sensor otherwise sensor dega...

Page 112: ...reem entbetw eenyou rcom panyandT RW Th isisnottobetransm itted reproduced usedo rd isclos man nercon trarytotheterm softheagreem en t HCU440V A BS Mo to r LF Iso L F Du mp R F Iso RF D ump ABSWarningLam p Discrete M aster Cylinder Brake Fluid Reservoir IGN Brake Pedal Bra ke Switch LF LR RF W heelspee d Sensor W heelspeed Sensor Brake Booster INSTRUM ENTCLUSTER Bra keWarning Lam p ABSWarning L am...

Page 113: ...y You d better use clean gauze to block up the oil inlet of ABS while dismounting the pipeline 3 Use ratchet wrench and 10 sleeve to dismount the bolts connecting ABS assembly and bracket and take out ABS assembly 8 4 Assembly sequence The assembly sequence is opposite to the disassembly sequence Note Turn on the power supply after completing installation and connect diagnosis instruments to the s...

Page 114: ...rake hydraulic systems If the brake hose or brake is broken on certain wheel you should only discharge the air from the wheel clamp If brake pipe or hose is broken at any joint of mater cylinder and brake you should only discharge the air from the brake systems related to the broken pipe or hose 9 1 Air discharge of brake system 1 Uplift and support the car properly 2 Install the transparent plast...

Page 115: ... should meet the standards stipulated by the Department of Transportation DOT only DOT4 can be used and should not be mixed with other types of brake fluid 2 Brake fluid has relatively strong water absorptivity It should be put into the original sealed container when being recycled 3 Brake fluid has relatively strong corrosiveness If it splashes onto your skin you should instantly use wet cleaning...

Page 116: ...sistent with each other Front measuring point Measure the height from the ground to the central point of the bolt connecting the lower control arm assembly and the front steering knuckle The height of the vehicle body at the left wheel side should be as basically same as that of the vehicle body at the right wheel side Rear measuring point Check the height from the ground to the central point of t...

Page 117: ...on damper can operate normally 1 Check whether there is oil leakage 2 Check whether there is wearing in the assembly bushings 3 Check the damping force of vibration damper and replace the vibration damper if it disqualifies Note The oil tank is semi filled the cooling water in the water tank and the engine oil reach up to the specified height and the tire jack and other tools are in specified posi...

Page 118: ...re pressure Lower down vehicle speed Tire alignment b Too high tire pressure No tire alignment Measure adjust tire pressure Tire alignment c Improper toe in Regulate toe in d Improper camber angle or caster angle Suspension system failure Imbalanced tire Out of round brake drum or butterfly disk Other mechanical problems No tire alignment Regulate repair or replace axle and suspension system compo...

Page 119: ...se special tools to generate 200N 400N air pressure so as to make the alignment ring pass the aperture of the wheel In this way the tire valve is installed soapy water can be allowed to replace glycerin 2 Before assembling tire you should apply glycerin or soapy water to the rim edge At the same time you should pay attention to that when there is dub marks on rim you should put the homogeneity tes...

Page 120: ...e four wheels and regulate the pressure front wheel is 230Kpa while rear wheel is 210Kpa It is shown in the right figure 7 Air leakage Check whether there is air leakage on the tire valve It is shown in the right figure 8 Check the unevenness of rim 1 Uplift the car and securely support it 2 Fix a micrometer guage Φ10 furnished with cylindrical contact fingers on the edge of rim and measure its un...

Page 121: ...nd install appropriate balance weights on the inner and outer edges of rim as per the requirement The final total unevenness degree should be less than 100g cm that is each balance weight on the inner and outer edges of rim is about 5g Note Not more than one balance weight can be furnished on each side of each wheel with its maximum weight not exceeding 40g During the process of assembly you shoul...

Page 122: ...CHERY A520 SERVICE MANUAL CHASSIS 41 11 Wheel disassembly Disassembly sequence 1 Dismount the fastening bolt of wheel PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 123: ...After the initial driving of 100km the bolts of the installed wheels and tire assembly should be fastened once to ensure the fastening torque The inspection on the fastening torque of wheel bolts is one of the daily maintenance works 2 When fastening fixing nuts you should adopt cross method The fasten degrees of all fixing nuts should be similar and wheels can rotate freely Finally when tightly f...

Page 124: ... Toe in adjustment can be done by use of optical test instrument or mechanical toe in regulator Wheel aligner or alignment tester should be installed on the wheels Installation should be carried out according to the concrete instructions of the equipment manufacturers 1 To meet the requirement of test instruments you should make preparations for the wheel alignment and use the steering wheel limit...

Page 125: ...ts reinstall the rubber sleeve clamp and check whether the locknut is fastened and the sheath is at the proper position 4 After the front wheel toe in is well adjusted you should check whether the steering wheel is horizontal or not Otherwise you should loosen the locknuts of steering wheel to regulate it to the horizontal position and fasten the locknuts to meet the torque requirement 30 3Nm PDF ...

Page 126: ...ng The increasing of positive caster angle shall improve the stability of steering wheel but the force shall become stronger in the case of steering while the decreasing of positive caster angle shall lower down the stability of steering wheel but the force shall become weaker in the case of steering The degree of caster angle shall not impose influence on the tire wearing which is used to stabili...

Page 127: ... reasons the connecting bolt of independent suspension and steering knuckle can be used to rectify the camber angle 1 Prior to rectification you should firstly inspect visual inspection whether the driving components are damaged and replace the damaged components 2 If the front wheel camber angle is found to exceed the deviation you should loosen the connecting bolt of front vibration damper and s...

Page 128: ...ent tester should be installed on the wheels Installation should be carried out according to the concrete instructions of the equipment manufacturers 1 If the rear wheel toe in is found not to meet relevant requirements you can loosen the adjusting bolt 14 and adjusting nut 12 of the lower control arm as the figure illustrated Note prevent the nut from shedding out of the slot 2 Screw the eccentri...

Page 129: ...control arm and prevent the nut from shedding out of the slot 2 Loosen to alter the value of rear wheel camber angle until it complies with relevant requirements and then fasten the nut 4 to specified torque 100 120N m The left and right sides are the same Eccentric Adjusting Bolt 16 Adjusting Nut 4 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 130: ...e Fasten Adjust Replace Replace Circular vibration of the steering wheel Excessive deflexion of tire and rim Loose wheel nut or axle head Unbalanced tire Asymmetric tire wearing Deficient tire pressure Damage or wearing of front wheel bearing Failure of Steering system Failure of suspension system Replace Fasten Adjust Check Adjust Replace Check Check Steering wheel deflecting to single side Impro...

Page 131: ...ension system Improper wheel alignment parameters Adjust Check Check Check Bad alignment return of steering wheel Deficient tire pressure Failure of steering system Failure of suspension system Improper front wheel kingpin caster angle Adjust Check Check Adjust PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 132: ...tly connects with vehicle body The rubber cushion can insulate some noise and can damp the vibration passed from the road Accordingly the upper part of strut is fixed on the vehicle body and moves slightly However the lower part of strut shall rotate simultaneously with the wheels and bounces up and down thus the strut shall be influenced by the side force in the process of operation The middle pa...

Page 133: ...ion damper and spring Bolt mounting torque 50 10Nm Assembly sequence 1 Assemble the front vibration damper according to the disassembly sequence 2 Precautions After assembly all bolts must be fastened to reach up to specified torque Please check four wheel alignment after assembly II DISASSEMBLY AND ASSEMBLY OF CONTROL ARM Disassembly sequence Take the right control arm for example 1 Dismount tire...

Page 134: ... and right sides are the same 4 Dismount the bolts connecting the control arm and under frame and remove the control arm Mounting torque 180 15N m The left and right sides are the same Prevent the control arm from dropping when loosening the bolts Assembly sequence 1 Assemble the control arm according to the disassembly sequence 2 After assembly the bolts must be fastened to reach up to specified ...

Page 135: ... have the same disassembly process 1 Dismount tire Mounting torque 110 10Nm 2 Dismount the plug of wheel speed sensor and plug of the brake disk thickness alarm 3 Dismount the brake oil pipe and avoid the loss of brake oil 4 Dismount the bolts connecting the steering tie rod and the steering knuckle Mounting torque 35 3N m PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 136: ...uence Assemble the steering knuckle in the reverse sequence of disassembly Precautions Supplement the brake oil in the braking system and carry out air release adjustment Check and regulate toe in value Fasten the torque IV DISASSEMBLY AND ASSEMBLY OF THE ENGINE SIDE MEMBER Disassembly sequence 1 Dismount the two bolts connecting the side member and vehicle body Mounting torque 100 120 Nm PDF crea...

Page 137: ...dropping when loosening the bolts 4 Dismount the side member Assembly sequence 1 Assemble the side member according to the reverse sequence of disassembly 2 After assembly the side member must be fastened to reach up to specified torque V DISASSEMBLY AND ASSEMBLY OF UNDERFRAME AND STABILIZER BAR Disassembly sequence 1 Dismount the clip connecting the steering column and steering device as well as ...

Page 138: ...der frame and control arm the left and right sides are the same Mounting torque 180 15Nm 4 Dismount the bolts connecting the stabilizer bar and control arm the left and right sides are the same Mounting torque 50 3Nm 5 Dismount the bolts connecting the under frame control arm and vehicle body the left and right sides are the same Mounting torque 180 15Nm PDF created with pdfFactory Pro trial versi...

Page 139: ...y disassembly and assembly we suggest you dismount the rear suspension bolts shown in the right figure Mounting torque of the four assembling bolts 70 5N m Mounting torque of rear suspensions 60 5N m 8 Dismount the under frame stabilizer bar and the assembly of steering device and tie rod Note If the under frame is not dismounted the stabilizer bar cannot be removed from the car PDF created with p...

Page 140: ...torque of 50 3m The top and bottom surfaces of the connection joint of stabilizer bar end and lower control arm have a rubber pad 3 respectively and there is a metal sleeve 4 between the second and third rubber pads of either end of stabilizer bar It is to be noted that all the rubber pads 3 are the same but the top and bottom sides of each rubber pad are different of which one side has a sulfurat...

Page 141: ...ut 1 8 Nut 1 14 Nut 13 Clip 1 16 Bolt 15 Bolt 5 Bolt 6 Sleeve 1 10 Bolt 1 11 Bolt 9 Nut 1 12 Rubber Support 21 Antiroll Bar 22 Engine Side Member 17 Front Sliding Pole 18 Steering Knuckle 19Control Arm 20 Under frame 23 Bolt 1 24 Nut 7 Rubber Cushion PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 142: ...The left and right sides are the same Use nut 24 to connect the strut assembly 17 with the vehicle body to specified torque of 50 10 Nm The left and right sides are the same Use bolt 1 nut 2 to connect the strut assembly 17 with the steering knuckle 18 up to the specified fastening torque of 110 5Nm The left and right sides are the same Use nut9 bolt 10 and bolt 11 to connect the under frame assem...

Page 143: ...ear lower control arm by use of rubber hinge while the upper part directly connects with vehicle body through rubber cushion The rubber cushion can not only isolate a portion of noise but can also damp the vibration passing from the road As a result the upper part of strut is fixed onto the vehicle body and moves slightly However the lower part of strut shall bounces up and down simultaneously wit...

Page 144: ...ed View of Rear Trailing Arm Assembly Rear Upper Control Arm Assembly Bolt Guide Bar Assembly Rear Lower Control Arm Assembly Assembling Bolt Bolt Nut Left Rear Trailing Arm Gasket PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 145: ...e lower part of strut assembly due to the influence of the spring force Therefore you should firstly dismount the bolts connecting the rear lower control arm and vehicle body in order to reduce the bearing force of coil spring Mounting torque 100 120Nm 3 Dismount the bolts connecting rear strut and lower oscillating arm Mounting torque 80 5 Nm 4 Remove the rear strut assembly Assembly sequence 1 A...

Page 146: ... spring seat Check whether the limit gear block is damaged Check whether the limit gasket of suspending spring is worn cracked or deformed Replace defective spare parts Note When laying aside vibration damper you should abide by the following procedure 2 Disposal 1 Stretch the vibration damper lever as long as possible 2 Drill a hole to discharge the gas from vibration damper cylinder Note The dis...

Page 147: ...g torque 100 120Nm 2 Dismount the bolts connecting the upper control arm and rear trailing arm Mounting torque 90 100Nm 3 Take down the upper control arm Assembly sequence 1 Assemble the rear upper control arm according to the disassembly sequence 2 Precautions After assembly all bolts must be fastened up to specified torques PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 148: ...he control arm and rear vibration damper Mounting torque 80 5Nm 3 Dismount the bolts connecting the control arm and rear trailing arm Mounting torque 90 100Nm 4 Dismount the lower control arm assembly Assembly sequence 1 Assemble the rear lower control arm according to the disassembly sequence 2 Precautions After assembly all bolts must be fastened up to specified torques PDF created with pdfFacto...

Page 149: ... the bolts connecting guide bar and rear trailing arm assembly Mounting torque 90 100Nm 4 Dismount the bolts connecting guide bar and vehicle body Mounting torque 100 120Nm Assembly sequence 1 Assemble the guide bar according to the disassembly sequence 2 Precautions After mounting all bolts must be fastened up to specified torques PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 150: ...control arm 17 and trailing arm2 The left and right sides are the same and the fastening torque is90 100 m N Do not fasten the bolt and nut at this time Use nut 8 2 pieces to connect the rear strut 9 and vehicle body The left and right sides are the same and the fastening torque is 50 10 m N Use bolt 1 to connect the trailing arm and vehicle body the vehicle body has one weld nut and include the w...

Page 151: ...le body The left and right sides are the same and the fastening torque is 100 120 m N Do not fasten the bolt and nut at this time Use bolt 15 gasket 6 and nut 7 to connect the guide bar and vehicle body The left and right sides are the same and the fastening torque is 100 120 m N Do not fasten the bolt and nut at this time Use adjusting bolt 14 gasket 13 and nut 12 to connect the rear lower contro...

Page 152: ...Chery Service Manual for A520 Body Dimension and Accessories 1 CHAPTER NINE BODY DIMENSION Dimension of the beam Unit mm PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 153: ...Chery Service Manual for A520 Body Dimension and Accessories 2 Assembly dimension of the body Side view PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 154: ...ies 3 The clearance between the front fender and the headlamp at B1 B1 1 5 1 The clearance between the front fender and the front bumper at B2 B2 Headlamp Front Fender Front Bumper Front Fender PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 155: ...learance between the front fender and the front bumper at B3 B3 The allowable installation deviation between the front fender and the front bumper at F1 Front Bumper Front Fender Front Fender Front Bumper PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 156: ... clearance between the front fender and the side panel at B4 B4 3 2 0 5 The clearance between the front fender and the front door at B5 B5 4 5 1 Front Fender Side Panel Side Panel Front Fender Front Door PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 157: ...between the side panel and the front door frame at B7 B7 4 5 The clearance between the front door frame and the rear door frame at B8 B8 4 5 1 Side Panel Front Door Frame Front Door Frame Side Panel Rear Door Frame PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 158: ...e clearance between the front door and the rear door at B9 B9 4 5 1 The clearance between the rear door frame and the side panel at B10 B10 4 5 Side Panel Front Door Rear Door Side Panel Rear Door Frame PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 159: ... the rear trim panel of the rear door and the side panel at B12 B12 4 The clearance between the rear door and the side panel at B13 B13 4 5 Rear Door Frame Side Panel Rear Trim Panel of the Rear Door Rear Door Side Panel PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 160: ... between the rear door and the side panel at B14 B14 4 5 1 The clearance between the fuel filler opening cover and the side panel at B15 B15 3 1 Rear Door Side Panel Side Panel Fuel Filler Opening Cover Peripheral PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 161: ... rear bumper and the side panel at B16 B16 0 1 The clearance between the rear bumper and the side panel at B17 B17 0 0 5 Side Panel Rear Bumper Side Panel Rear Bumper From m to n From n to p and the value descends from 1 to 0 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 162: ...he tail light at B19 B19 1 0 5 The clearance between the side panel and the tail light at B20 B20 1 0 5 The clearance between the rear bumper and the tail light at B21 B21 1 7 Tail Light Side Panel Tail Light Side Panel Tail Light Rear Bumper PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 163: ...earance between the front fender and the fender apron at B22 B22 2 5 1 The clearance between the front door and the fender apron at B23 B23 6 3 1 Front Fender Fender Apron Fender Apron Front Door Side Panel PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 164: ...e clearance between the rear door and the fender apron at B24 B24 6 4 1 The clearance between the fender apron and the side panel at B25 B25 3 1 Rear Door Side Panel Fender Apron Side Panel Fender Apron PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 165: ...y Dimension and Accessories 14 The allowable installation deviation between the rear bumper and the side panel on rear fender at F2 Side Panel on Rear Fender Rear Bumper PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 166: ...Chery Service Manual for A520 Body Dimension and Accessories 15 Top view PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 167: ...earance between the luggage compartment cover and the side panel on rear fender at A3 A3 4 1 Parallelism Headlamp Engine Hood Side Panel on Rear Fender Luggage From d to e and descend from 6 7 1 to 0 5 1 0 5 1 from e to f Engine Hood Front Fender From o to o and the value increased from to From b to c and the value increased from 0 8 1 to 2 4 1 PDF created with pdfFactory Pro trial version www pdf...

Page 168: ...learance between the headlamp and the engine hood at F3 The clearance between the tail light and the luggage compartment cover at F4 Tail Light Luggage 0 5 1 From f to g From g to h and descend from 0 5 1 to 0 1 Engine Hood Front Fender Headlamp Luggage Side Panel on Rear Fender Tail Light PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 169: ...for A520 Body Dimension and Accessories 18 Rear view The clearance between the rear bumper and the luggage compartment cover at C1 C1 8 2 Luggage Rear Bumper PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 170: ...nd the luggage compartment cover at C2 C2 4 The clearance between the tail light and the luggage compartment cover at C3 C3 4 1 Luggage Rear Bumper 4 From j to k From j to l and increase from 4 to 8 2 Luggage Tail Light 3 3 0 5 from i to j PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 171: ... and the luggage compartment cover at C4 C4 4 1 The clearance between the rear bumper and the tail light at C5 C5 3 1 Luggage Tail Light 0 0 5 From h to i Tail Light Rear Bumper 3 1 From i to r From r to m and increase from 3 1 to 1 5 1 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 172: ...ion and Accessories 21 The allowable installation deviation between the rear bumper and the luggage compartment cover at F5 Front view Luggage Compartment Tail Light Rear Bumper PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 173: ...earance between the engine hood and the air inlet grille at D1 D1 is 4 5 1 while the clearance between the front bumper and the air inlet grille is 1 0 5 Engine Hood Air Inlet Grille Front Bumper Peripheral PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 174: ...t grille at D2 D2 1 5 1 The clearance between the front bumper and the air inlet grille at D3 D3 1 5 0 5 The clearance between the headlamp and the front bumper at D4 D4 4 1 Air Inlet Grille Front Bumper Air Inlet Grille Front Bumper Front Bumper Headlamp PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 175: ...he clearance between the headlamp and the front bumper at D5 D5 4 1 The clearance between the front fog light and the front bumper at D6 D6 Headlamp Front Bumper Front Bumper Front Fog Light Peripheral PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 176: ...f the engine 11 Bb Mounting hole for the fender 7 g Hole for the headlamp 7 Cc Via hole for the shock absorber 115 h Hole for the headlamp 7 Dd Mounting hole for the fender 7 i Mounting hole for the lights 7 e Mounting hole for the battery carrier 9 J Hole for the bumper 9 E Support hole for the right mounting bracket of the engine 11 K Hole for the condenser 8X12 PDF created with pdfFactory Pro t...

Page 177: ...int Place of Rear Windshield Cross Beam and Side Panel on Rear Fender Joint Place of Top Cover and Side Panel on Rear Fender Joint Place of Top Cover and Side Panel Joint Place of Front Windshield Lower Cross Beam and Front Fender PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 178: ...of the body while lowercase English letter indicates the right of the body View from the rear of the vehicle Mark Name Diameter Mark Name Diameter Aa Mounting hole for the upper hinge of the front door 11 Ff Support point for the front door Bb Mounting hole for the lower hinge of 11 Gg Front upper corner point of the rear door PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 179: ...of the front door guide rail of the side panel Hh Rear upper corner point of the rear door guide rail of the side panel Dd Mounting hole for the upper hinge of the rear door 11 Ii Support point of the rear door Ee Mounting hole for the lower hinge of the rear door 11 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 180: ...TER ONE FRONT ACCESSORIES 3 CHAPTER TWO TRUNK LID 10 CHAPTER THREE DOOR 14 CHAPTER FOUR INTERIOR TRIM 27 CHAPTER FIVE SUN ROOF 33 CHAPTER SIX INSTRUMENT PANEL 39 CHAPTER SEVEN DISASSEMBLY MANUAL FOR EVAPORATOR 48 CHAPTER EIGHT WINDSHIELD 54 CHAPTER NINE BODY DIMENSION 63 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 181: ...Hood 2 Windscreen Wiper Arm 3 Front Windscreen 4 Tail Light Assembly 5 Air Inlet Grille Assembly 6 Front Bumper Assembly 7 Left Front Headlamp Assembly 8 Left Front Door 9 Right Front Door 10 Rear Bumper Assembly 1 2 3 4 5 6 7 8 9 10 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 182: ...lling steps are reverse to those for removal 4 Adjusting the engine hood Replace the centering bolt with a washer accompanied bolt The centering bolt is the fixing bolt for the engine hood hinge which must be replaced before adjusting the engine hood Adjust the engine hood in front back and vertical directions Unscrew the hinge bolts on the engine hood sides to adjust the engine hood Adjust the en...

Page 183: ... screws on the air inlet grille to dismount the air inlet grille Figure 5 2 Remove the upper fastening bolts on the front bumper Figure 6 3 Remove the lower fastening bolts each at left and right and two bottom connecting bolts on the front bumper Figure 7 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 184: ...ve the front bumper Figure 8 III DISASSEMBLING THE HEADLAMP 1 To remove the headlamp remove the four bolts and pull out the connecting harness A Side Light 12V 5W B Headlamp Lower Beam 12V 55W C Turn Light 12V 5W D Headlamp High Beam 12V 55W Figure 9 2 Remove the lamp holder cover Figure 10 C A B D PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 185: ...arness to back out the high beam bulb counter clockwise Figure 11 4 Pull out the harness open the circlip and then back out the lower beam bulb counter clockwise Figure 12 5 Pull out the side light directly Figure 13 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 186: ...igure 14 IV DISASSEMBLING THE WIPER WASHING SYSTEM 1 Remove the lower trim panel of the front windscreen Figure 15 2 To remove the wiper motor unplug the electrical connector of the wiper motor and remove the fastening bolts Figure 16 Motor Connector PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 187: ... Accessories 8 3 To remove the wiper arm remove the bolts Figure 17 4 Remove the lower trim panel of the front windscreen Figure 18 5 To remove the wiper link remove the bolts Figure 19 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 188: ...ension and Accessories 9 6 Remove the bolts as shown Figure 20 7 Then remove the two bolts as shown to remove the washer fluid pot Figure 21 8 Remove the washer pump Figure 22 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 189: ... 10 V DISASSEMBLING THE FENDER 1 Remove the fastening bolts Figure 23 2 Remove the screws on the fender apron Figure 24 3 Move the trim panel and remove the fastening bolts on the fender Figure 25 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 190: ...strument desk see Disassembling the instrument desk 2 Remove the lining of the left fender see Disassembling the fender 3 Remove the engine hood lock to loosen and take out the engine hood control cable Assembly requirements Adjust the front engine hood lock to make sure that the front engine hood peripheral clearance is uniform 9 1 mm with equal height at top and bottom The tightening torque of t...

Page 191: ...Chery Service Manual for A520 Body Dimension and Accessories 12 hood lock is 14 2N m PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 192: ...e license plate light with a flat head screwdriver Figure 29 2 To pull out the harness from inside the luggage compartment unplug the harness plug Figure 30 3 Detach the connecting link and then unscrew the tightening screws of the lock actuator with a club screwdriver Figure 31 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 193: ...r side enclosure is uniform 5 0 5 mm The upper and lower height is basically uniform with a φ0 5 mm allowable deviation The tightening torque for the lock striker is 9 1N m Figure 32 5 Unscrew the bolts with a wrench remove the luggage compartment lock and then remove the latch Figure 33 6 Pry out the harness clip with a screwdriver 7 Remove the four bolts 2 at left and right to detach the luggage...

Page 194: ... All parts should be installed in place and in perfect joint with the body The luggage compartment carpet clip should be just placed into the room of the rear trim panel of the luggage compartment The two sides of the carpet should be tightly stuck to the folds of the left right trim of the luggage compartment wheel house and should be in perfect joint with the rear floor of the body after fitting...

Page 195: ...NG THE REAR BUMPER 1 Remove the three fastening screws to remove the rear cover of the trim panel Figure 38 2 Remove rear bump fastening screws and bolts to remove the rear cover of the trim panel Figure 39 Figure 40 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 196: ...he right figure 2 Note that the joint of the luggage compartment weather strip should be placed at the place where the luggage compartment lock locates Every corner should be fitted in place and no folds are allowed The hardness of the weather strip should be proper without great variation as the temperature changes Figure 42 V REMOVING THE SPARE TIRE Lift the luggage compartment floor mat up to t...

Page 197: ...Chery Service Manual for A520 Body Dimension and Accessories 18 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 198: ... tools for disassembling Cross screwdriver vice flat screwdriver 8 socket ratchet gear and ratchet rod 3 Disassembling and installing the evaporator 3 1 Replacing the blower 3 1 1 Disassembling the blower 1 Disconnect the wire connector of the blower motor 2 Remove the mounting bolts for the blower motor PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 199: ...se to those for removal 3 2 Replacing the heater water tank 3 2 1 Disassembling the heater water tank 1 Remove the bolts and clips as shown in the figure 2 Pull out the heater water tank 3 2 2 Installation procedures The installing steps are reverse to those for removal PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 200: ...assembly 1 Remove the fastening bolts for the expansion valve and the evaporator core assembly with an Allen wrench 2 Remove the three screws at the joint position of the blower and the evaporator housing 3 Remove the two screws on the rear vent air duct to detach the rear air duct PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 201: ...and then take out the evaporator core assembly 3 3 2 Installing the evaporator core assembly The installing steps are reverse to those for removal 3 4 Replacing the speed regulating resistor of the blower fan 3 4 1 Disassembling the blower fan speed regulating resistor module 1 Unplug the plug connecting to the speed regulating resistor module PDF created with pdfFactory Pro trial version www pdff...

Page 202: ...ng with the motor and remove the fastening screws connecting the motor with the bracket 3 3 5 2 Installation procedures The installing steps are reverse to those for removal Note After installs the motor connect the electrical connector turn the ignition switch to ACC position turn on the air conditioner AC and turn the AC temperature adjusting knob to HOTTEST or COLDEST and close the AC panel unt...

Page 203: ...e status and then adjust the pull rod to a proper position to connect with the motor 3 7 Replacing the inner and outer cycling servo motor 3 7 1 Disassembling procedures Remove the pull rod connecting with the motor and remove the fastening screws connecting the motor with the bracket 3 3 7 2 Installation procedures The installing steps are reverse to those for removal Note After installs the moto...

Page 204: ...sassembling procedures Disconnect the plug in unit of the sensor harness remove the connecting screw that attach the hose to the housing and remove the hose replace it 3 8 2 Installation procedures The installing steps are reverse to those for removal PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 205: ...h 2 Combination Instrument 3 Vent of Air Conditioning 4 Air Bag for Front Passenger Side 5 Steering Wheel Assembly 6 Air Bag Assembly 7 Ashtray 8 Air Conditioner Control Panel 9 CD Player Assembly 10 Glove Box Assembly 5 7 8 9 10 2 4 3 1 3 6 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 206: ...nition switch Press down and hold the Mode switch turn on the ignition switch and release the Mode switch touch the Mode switch and the Clock switch simultaneously in 30 seconds with a touch time less than 2 seconds to clear the mileages maintenance identification Figure 118 3 Unscrew the fastening screws each at left and right to remove the steering wheel cover Figure 119 PDF created with pdfFact...

Page 207: ...itch Remove the wiper switch with the same method Figure 120 5 Unscrew the fastening bolts with internal spline to remove the air bag assembly Figure 121 6 Unplug the spiral cable connector remove the steering wheel to take out the spiral cable Figure 122 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 208: ...cessories 4 7 Remove the right blanking cover assembly Figure 123 8 Remove the left lower trim panel assembly of the instrument panel Figure 124 9 Remove the glove box assembly Figure 125 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 209: ...Body Dimension and Accessories 5 10 Remove the trim strip Figure 126 11 Unscrew the fixing bolts Figure 127 12 Remove the bezel of the central control panel Figure 128 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 210: ...e CD player and then pull out the harness Figure 129 14 Remove the fastening screw take out the air conditioner control panel and then pull out the harness Figure 130 15 Unscrew the fastening screw to take out the ashtray assembly Figure 131 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 211: ...y Service Manual for A520 Body Dimension and Accessories 7 16 Remove the fastening screws and bolts as shown Figure 132 Figure 133 Figure 134 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 212: ...s 8 17 Remove the bolts as shown to remove the instrument panel Figure 135 18 Unscrew the fastening bolts as shown Figure 136 19 Remove the fixing bolts at two sides to remove the beam Figure 137 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 213: ...e refrigerant remove the fastening bolts on the expansion valve with an internal hexagonal socket to remove the expansion valve Remove the two clamps with pliers to remove the water pipe Note receive the coolant Figure 139 22 Remove the air outlet unit Figure 140 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 214: ... A520 Body Dimension and Accessories 10 23 Detach the evaporator assembly after removes the fastening bolts and the ground wire Figure 141 Figure 142 Figure 143 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 215: ...cessories 11 Figure 144 24 Detach the evaporator assembly after removes the fastening bolts and the ground wire Figure 145 25 Remove the engine compartment shock pad Figure 146 Ground Wire PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 216: ...ove the outside rear view mirror after detaches the door trim panel Assembly requirements Make sure that the clearance between the rear view mirror rand and the door outside trim panel is uniform when fitting The tightening torque for the screw is 5 0 5N m The rear view mirror could be freely flexibly and reliably adjusted after installation The plug in unit of the rear view mirror should be fixed...

Page 217: ...8 6 Remove the fixing bolts on the left front door trim panel in figure 49 and 50 to detach the door trim panel Assembly requirements Measures should be taken to prevent blurring the working area for cleaning when disassembling and installing It is of great importance to keep clean during these jobs The fit clearance between the door trim panel and the inner door panel should be uniform Figure 49 ...

Page 218: ... 3 Figure 50 7 Remove the protective film from the left front door Figure 51 8 Remove the set screw of inside door handle to loosen the inside control cable and the inner retention cable Figure 52 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 219: ...ower the glass to a proper position remove the fixing bolts move the glass to the bottom of door and then take out the glass slantways Assembly requirements The glass should has a uniform upper and lower left and right clearances to ensure an good fitting with the peripheral rubber strip The sealing of the glass should be good without any leakage during the rain test Figure 55 PDF created with pdf...

Page 220: ...e of the fixing bolt or nut should be 7 1 N m Make sure that the glass could rise and fall smoothly and easily without any swinging flapping and shocking after installation and adjustment Electric requirement Time of rise fall not more than 5s Figure 57 14 Unscrew the fastening screws from the left front door rear glass guide rail Figure 58 PDF created with pdfFactory Pro trial version www pdffact...

Page 221: ...ld be applied at the middle of the fixing bolts of the side door lock The tightening torque for the bolt is 9 1N m The tightening torque for the inside door handle assembly screw is 1 5 0 15N m while the value for the bolts of the outside door handle assembly is 9 1N m The side door should fit tightly with its handle with reliable sealing Be sure to position the fastener the tightening torque of w...

Page 222: ... is as shown in the figure A Locking cable B Opening out control cable C Link the opening out push rod D Link the latch pull rod Figure 62 19 Unscrew the door handle bolt 1 Figure 63 20 Unscrew the bolt 2 Figure 64 A C B D PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 223: ...of the door check Figure 66 23 Remove the weather strip from the door opening During installation every corner should be fitted in place and no folds are allowed The joint of weather strip should be placed in the lower middle of the door opening The weather strip should have a proper rigidity and should not interfere with the opening and closing of the door after the lock and hinge have been adjus...

Page 224: ...25 The inner harness of the door could be taken out from outside Figure 69 II DISASSEMBLING THE REAR DOOR See left front door for considerations during disassembling the parts 1 Remove the trim strip from the left rear door Figure 70 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 225: ...crews to detach the inner and outer trim panels of the triangle glass Figure 71 3 Unscrew the screw to detach the bezel for the inside door handle Figure 72 4 Unscrew the screw to detach the arm rest cover Figure 73 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 226: ...ories 11 5 Pry out the window regulator switch to pull out the harness Figure 74 6 The door trim panel could be removed Figure 75 7 Remove the protective film from the left rear door Figure 76 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 227: ...andle to detach the handle Figure 77 9 Remove the fixing bolts from the trim panel bracket Figure 78 10 Lower the glass to a proper position remove the set screws move the glass to the bottom of the door and then take out the glass slantways Figure 79 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 228: ...fastening screws for the glass guide rail Figure 80 12 Remove the top screws to detach the glass rear guide rail and the triangle glass Figure 81 13 Remove the top fastening bolts from the window regulator Figure 82 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 229: ... from the window regulator Figure 83 15 Remove the lock fastening screws with an internal spline socket Figure 84 16 Loosen the opening out pull rod from the door handle pull out the harness and then detach the lock Figure 85 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 230: ...Dimension and Accessories 15 17 Remove the door handle bolt 1 Figure 86 18 Remove the door handle bolt 2 to take out the handle Figure 87 18 Remove the door check Figure 88 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 231: ...520 Body Dimension and Accessories 16 19 Remove the weather strip from the door opening Figure 89 20 Pull out the inner harness of the door from outside Figure 90 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 232: ...or to unscrew the four fixing bolts from the upper and lower hinges and then remove the hinges Figure 91 II ADJUSTING THE REAR DOOR Adjust the rear door in front back and vertical directions Unscrew the body hinge bolts to adjust the door with special tools for maintenance Adjust the door in left right and vertical directions Unscrew the side hinge bolts for the door to adjust the door REPLACING T...

Page 233: ...circumstance but also other chassis components should be carried out visual inspection to see whether there is curve or bull crack II INSTRUCTION ON POWER STEERING PUMP Power steering pump is a vane pump which shall provide hydraulic pressure to the system Power steering pump consists of components as follows Drive shaft Steering pump body Steering pump ring Pressure plate Thrust plate Flow contro...

Page 234: ...ponents shall play the functions except for steering The depicted functions shall be achieved by the steering column components as follows 1 Steering column Steering column absorbs energy When frontal collision occurs the steering column shall retract in order to reduce the probability of hurt to the driver 2 Ignition switch and steering lock on the steering column The ignition switch and steering...

Page 235: ...eering gear 35 3 2 Tie rod end And Steering Knuckle 75 5 4 Secure Steering gear And Subframe 75 5 2 Secure Steering gear And Subframe 25 3 2 Secure Steering oil reservoir 25 3 1 Secure clamping sleeve 25 3 1 Secure Steering Oil Pump 180 15 2 Subframe Front And Vehicle Body Connections 80 90 2 Subframe Rear And Vehicle Body Connections 80 90 2 Ball Pin Of Control Arm And Steering Knuckle 25 2 4 Sta...

Page 236: ...G SHAFT 1 Loosen the fastening bolts of universal connector II DISMOUNT SUBFRAME ASSEMBLY 1 Discharge the power steering system Refer to steering system fluid 2 Disassemble the power steering system pipeline 3 Hoist the vehicle and dismount the two front wheels 4 Loosen the fixed nuts of left and right tie rod ends PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 237: ...ixed bolts at the both ends of left and right lower links 6 Loosen the ball bolts on the left and right lower links 7 Loosen the fixed bolts of subframe 8 Lossen the fixed bolts of subframe PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 238: ...of transmission s rear mountings 10 Dismount the frame assembly III DISMOUNT THE STEERING GEAR ASSEMBLY FROM THE SUBFRAME 1 Dismount the fuel pipes of steering gear Loosen the fixed bolts of pipe clamp PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 239: ...ting the stabilizer bar to the lower link Note Before disassembly please pay attention to observing the relative positions of all washers and rubber cushions in order to carry out installation smoothly Loosen the fixed rubber sleeve bolts of stabilizer bar Dismount the stabilizer bar assembly 3 Dismount the rear mounting bracket of engine PDF created with pdfFactory Pro trial version www pdffactor...

Page 240: ...31 4 Dismount thermal shield 5 Remove the fixed bolts of steering gear Remove the steering mechanism assembly Assembly The installing steps are reverse to those for removal PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 241: ...e liquid level of the steering fluid in the liquid reserve bank Shut down the engine and check the liquid level The steering fluid shall approach to the Max position when the operating temperature is about 80 C LIQUID DISCHARGE 1 Uplift the front part of the vehicle in the air in order to ensure that the front wheels can rotate freely that the power steering oil return pipe can be dismounted from ...

Page 242: ...uid from the power steering liquid reservoir 3 Remove the power steering oil return pipe from the power steering liquid reservoir 4 Put the power steering oil return pipe into the large container that contains the discharged power steering fluid 5 Start up the engine and make it under idle operation and instruct the assistant to fill power steering fluid into the power steering liquid reservoir 6 ...

Page 243: ...automatic transmission fuel The process for checking power steering oil is very simple you only need to inspect this steering oil reservoir but you should remember that the oil level is in close connection with the oil temperature When the oil temperature is relatively high the oil level shall approach to the MAX position On the contrary when the oil cools down the oil level may approach to the MI...

Page 244: ...uation in the requiring steering force Normalized value 25N Allowed fluctuation less than 5 9N 3 If the measured force exceeds the normalized value please inspect and regulate in accordance with the steering heaviness specified in the troubleshooting Precautions in System Utilization 1 Do not confuse the power steering fluid and the brake fluid otherwise the system shall malfunctions 2 When the st...

Page 245: ...therefore you are not allowed to drive your car when the liquid level is very low or there is no hydraulic oil in the liquid reservoir driving at this time shall not only do serious damage to the steering oil pump and other spare parts but may also lead to the malfunction of the steering system PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 246: ... mechanism is extremely low 8 Repair the power steering mechanism and regulate the system pressure 1 The tire pressure of steering wheel is deficient 1 Inflate the tire until it reaches to the normalized value 2 Front wheel alignment distortion 2 Check and regulate front wheel alignment UnsuitableBad Wheel Alignment 3 The gears of steering gear are improperly regulated or damaged 3 Regulate the st...

Page 247: ...sm is air filled 3 Discharge the air from the power steering mechanism 4 Hydraulic oil emulsion or thickening 4 Replace hydraulic oil 5 Abrasion and damage of redirector gear 5 Replace the redirector gear PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 248: ......

Page 249: ...Electric Equipment Position of Trunk Electric Equipment Starting and Charging System ECU System ABS System Airbag System Auto A C System Manual A C System Front ISU System Rear ISU System Instrument System Wiper System Power Rear View Mirror System Power Window of Front Door Power Door Lock System Electric Seat System Seat Heater System Audio System Sun roof Cigarette Lighter System Circuit of the...

Page 250: ... points and Main Modules 3 PIN Definition Explanation G4 ABS G5 G2 ECU G9 G8 G6 G1 G3 G10 G11 G7 The PIN definition of the circuit theory diagram For instance as follows D8 D 7 D6 D5 D4 D3 D2 D1 A8 A7 A6 A5 A 4 A3 A2 A1 C 12 C11 C10 C9 C8 C7 C6 C5 C4 C3 C2 C1 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1 Ins trument harness and indoor harness front Connector Connector detailed explication Connector detai...

Page 251: ... points and Main Modules 3 PIN Definition Explanation G4 ABS G5 G2 ECU G9 G8 G6 G1 G3 G10 G11 G7 The PIN definition of the circuit theory diagram For instance as follows D8 D 7 D6 D5 D4 D3 D2 D1 A8 A7 A6 A5 A 4 A3 A2 A1 C 12 C11 C10 C9 C8 C7 C6 C5 C4 C3 C2 C1 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1 Ins trument harness and indoor harness front Connector Connector detailed explication Connector detai...

Page 252: ... D PP5 is port E PP6 is port F Rear ISU PE1 is port A PP3 is port B PP5 is port C PP6 is port D 9 Note This circuit diagram is mainly designed to provide ref rence for model 2 0 1 6 automatic basic configuration type As limited time is likely to give rise to international e 10 Notes to plug in unit For example Front ground front Left 13 means the No 13 terminal for front ground harness and front L...

Page 253: ...itch Power ground 1 CAN communication Non continuance powe r Diagnose K wire EOBD inspect lamp 5V power 2 5V power 1 Ant i theft equipment Clutch switch Engine speed sensor B A C switch Sensor ground 3 Sensor ground 2 Power turn switch Headlamp switch Sensor ground Air flow sensor Electric throttle position Phase sensor Power ground 2 Engine coolant temperature sensor Accelerate pedal position sen...

Page 254: ...4 S J 7 15 9 10 Front Rear A H J S 1 2 3 4 5 6 7 8 9 11 12 13 14 15 16 D8 D7 D6 D5 D4 D3 D2 D1 C12 C11 C10 C9 C8 C7 C6 C5 C4 C3 C2 C1 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1 A8 A7 A6 A5 A4 A3 A2 A1 D08 C12 B12 A8 D1 C1 B1 A1 Front Ground Instrument Front Ground Instrument A H 1 2 3 4 5 6 8 9 10 11 12 13 14 S J Front Ground Left 1 A H 1 2 3 4 5 6 8 11 12 13 14 S J 7 15 16 Front Ground Left 2 Front G...

Page 255: ...erator Electric throttle Fuel injector High pressure wire Knock sensor Camsha ft p osition se nsor Ignition coil Air flow meter Position of wiper motor Positive of power Negative of power Front left headlamp Positive fuse box Battery F R high beam F R low beam Side Light 12V 5W Tur n Light 12V 5W Headlamp High Beam 12V 55W Headlamp Lower Beam 12V 55W Front right headlamp 7 Only for 2 0L engine ...

Page 256: ...left door lock ear F L door window regulator assembly Front left door Rear left door R R door window regulator assembly Rear right door lock Front right door lock Front right door Rear right door F R door window regulator assembly R L door window regulator assembly 8 ...

Page 257: ... frontwards and backward s sliding dynamotor The upwards and downwards adjusti ng dynamotor of th e seat front part Position of instrument electric equipment Combination instrument Horn switch Key hole illumination lamp Electric rear view mirror Tr unk Switch Headlamp adjusting Switch Electric seat Mirror for make up Rear window heating Switch Warning lamp switch Assembly Front fog lamp Swi tch R ...

Page 258: ...nk electric equipment Rear left lamp Rear Reproducer Rear ISU High mounted brake lamp Rear right lamp Rear Fog Light Bulbs 12V 21W Tail Lamp Assembly Bra ke Lamp Side Light Bulbs 12V 21W 5W Turn Light Back up Light 10 ...

Page 259: ...ACC2 relay both get electricity The contact point close 30th live wire 87 pin of ACC1 relay 30 pin of ACC1 relay ACC1 wire get electricity 30th live wire 87 pin of ACC2 relay 30 pin of ACC2 relay ACC2 wire get electricity 3 When the ignition switch is at the ON position the 1 3 5 pin of ignition switch is connected and ACC1 and ACC2 wire both get electricity the 2 6 pin of ignition switch connecte...

Page 260: ...of the AC generator increases with the augment of excitation current And decreases with the fall of the current When the battery voltage the voltage of the S end of AC generator reaches the adjusting voltage the exci ation current is cut off And when the start and t battery voltage is less than the adjusting voltage the voltage adjustor controls the excitation current to adjust the output voltage ...

Page 261: ...is Within the Positive Fuse Box This Fuse Wire is Within the Positive Fuse Box Fan Control Module Fuel Pump Relay ECU A2 9 FB5 5A ECU A2 12 FB15 7 5A SB1 30A 86 30 87 85 P B P Br O 13 12 14 59 5 P P ECU A2 6 1 3 2 2 3 1 O B L W B Y 2 58 21 L W W B ECU A2 1 ECU A1 16 ECU A2 8 TO Front ISUPE2 22 EMS Relay Fuse Box K8 Fuse Box K10 Fuse Box K16 Fuse Box Plug In Unit K10 Fuse Box Plug In Unit K9 Front ...

Page 262: ...he ME7 9 7 electric control system the constitution is shown as figure 9 2 9 2 ME7 9 7 Electric Control System Constitution Figure Air intake pressure temperature sensor Carbon canister control Valve Throttle valve Accelarate pedal position sensor Electric fuel pump Crankshaft position sensor Coolant tempe rature sensor Rear oxygen sensor Front catalyst Front oxygen sensor Spark plug Fuel distribu...

Page 263: ...ut voltage of 5th pin if it is over 1 025V then the sensor will be disqualification If it is primarily diagnosed as the sensor s trouble connect the emission analyzer and check the performance in the two working condition Trouble analysis Troubleshoot Static state test zero flux test Dynamic test ECU receives and deals with the engine state signals which is inputted by each sensor and drive each a...

Page 264: ...ultimeter at the DC volt position connecting the two pens to the 3rd 1st pin of sensor confirm that there is a reference voltage of 12V Start the engine then check whether the 2nd pin signal is normal by using the oscillograph the 1st pin connect to screen the 2nd 3rd pin supply signal to ECU and connect to the 15th 34th pin respectively 15 34 B P Crankshaft Position Sensor ECU Crankshaft position...

Page 265: ...to detect the content of oxygen in the exhaust the transmits a signal to ECU according to the information ECU will make the fuel closed loop control so that the engine can work in the best Condition and make the CO HC NOx compound transformed and depurated mostly by the three way catalytic converter 5 Knock sensor There are 3 pins on the sensor the 1st 2nd pin connect to the 19th 20th pin of ECU t...

Page 266: ...vehicle speed signal it connect to the 59th pin of engine ECU 60 75 Br B V W 2 3 4 1 High Low pressure Switch To The Air Conditioner Module B19 AC Switch ECU 8 Vehicle speed sensor Figure9 12 Vehicle speed sensor and its circuit 9 A C pressure switch Figure9 13 A C pressure switch and its circuit 10 Clutch pedal switch 74 Sb B ECU A1 7 Clutch Pedal Switch ECU The 1st pin of clutch pedal switch is ...

Page 267: ...orce It is forbidden to try the short circuit test way to test the ignition function so as to avoid the damage to electric controller Remove the plug set the multimeter at the OHM position connecting two pens to the two pins of primary winding respectively When it is 20 the resistance is 0 42 0 58Ω and the secondary winding is 11 2 14 8kΩ Refer to table 20 Fault description Troubleshoot Fault anal...

Page 268: ...or unit erode Remove the plug set the multimeter at the ohm position connecting the two pens to the two pins of fuel pump test the inner resistance it is not 0 or that s to say it is not short circuit or open circuit state Connect the plug connect the fuel pressure gauge at the oil intake pipe start the engine check whether the fuel pump work if it is not work check the pin to see whether there is...

Page 269: ... volume of cleaning air flow from charcoal canister to air intake main pipe The adsorbing capability of carbon canister is limited if the oil steam adsorbed in the carbon canister can t be consumpt the oil will volatilize to outside and pollute the air 5 Cooling fan control module ECU Controls the running of fan according to the engine coolant temperature and A C requirement signal it controls the...

Page 270: ...th pin of ABS control unit connect to the brake switch signal the 16th 45th pin of ABS control unit connects to ground The 3rd pin of ABS control unit connect to CAN H wire and connects to the 30th pin of combination instrument 62nd pin of engine ECU respectively The18th pin of ABS control unit connects to CAN L wire and connects to the 29th pin of combination instrument 81st pin of engine ECU res...

Page 271: ...and SRS fault warning lamp When the ignition switch is set at the position of ON or ST the voltage of battery supply to the 25th pin of SRS control module via FB4 fuse The 2nd 1st pin of the airbag module are connectted to the front driver side airbag via helix cable the 17th 16th pin of airbag module are connectted to the driver side airbag directly the front passenger side airbag connect to the ...

Page 272: ...rnal Temperature Sensor Fr ont Gr oun d F ron t En gineCompartment D Sunlight Sensor Instrument Air Conditioner 2 Instrument Air Conditioner 15 Instrument Front Ground 15 Instrument F ron t Ground b6 To Instrument 7 To Wiper Switch 9 Instrument Air Conditioner 14 Instr ume nt F ront Gro und B10 Instrum ent A ir Co nd itio ne r 1 2 Ins trume nt A ir Con di tioner 1 Internal Temperature Sensor A 9 A...

Page 273: ...ltage of the the front ground front engine compartment D end of the wiring harness the normal value is 5V if not that s to say there is something wrong with the wiring harness or A C computer The A15 pin of A C controller connects the inner temperature sensor The inner temperature sensor is one of the important sensors of auto A C It will influence the air temperature of the wind outlet port wind ...

Page 274: ... panel drive the connecting bar shift lever of wind direction adjusting control mechanism by controlling the mode wind door servo motor different shift lever control the open and close of different wind door and thereby realize the control of air supplies The ACC1 line supplies power to the blower relay coil the blower relay coil get electricity and the contact closed the voltage of the 30th line ...

Page 275: ...nt Ground Front Engine Compartment 10 High Beam Relay Br W L12 Instrument FrontGround 9 G4 G7 To Ins trument 11 FB22 7 5A Sb Sb Lg P7 P5 G W W P11 Low Beam Relay L11 Instr um ent Front Ground 9 2 Gr R R P L Instrument Front G round G Instrument Front Ground A2 G Y Br B Front Ground Instrument B11 To Automa tic Air Co nditio ne r Instru ment Air Conditi oner 8 3 1 W L W W L W 4 1 W L W 4 1 Front Gr...

Page 276: ...led by switch 7 Key not pull out warning 8 Warning and anti theft 9 CAN BUS data transfer with instrument engine ABS computer Front Ground Left 2 8 Front Ground Right 5 Front Rear Windshield Warmer Switch Front ISU 30 15 ACC1 ACC2 31 ILLUM ON OFF ON O FF C14 A23 C6 B14 B30 F10 7 5A FB29 80A E R R P L Instrument FrontGround G Instrument FrontGround A2 9 9 10 O W Keyhole Light Clove Box Switch Front...

Page 277: ...n then The voltage of 30th line fuse Fb22 low beam relay coil the A17 pin of front ISU when the low beam relay coil get electricity the contact point will close The voltage of 30th line line after the low beam relay contact point get into three lines one line via the FB27 F L low beam and F L lamp adjusting motor the 2nd line supply power to headlamp adjusting switch the 3rd line via the FB14 F R ...

Page 278: ...2 6 R φ L ToInstrument 15 11 11 11 11 Terminal F unct ion Main Light Switc B eam C hange S wit c h Tu rn On T he H eadlamp St eer ing Sw it c h 触点功率 W Clea ranc e Lamp Hea d Lamp Low Beam High Beam O v ert a k ing B19 G W G W Br B B4 Br W B28 L W L W B1 Lg W B12 O B O B Lg W Left low beam Right low beam Right high beam Left high beam Figure14 5 Headlamp Circuit F L low beam F L high beam Installa...

Page 279: ...ompartment 13 Front Right Fog Light Front Left Fog Light Front ISU C14 4 5 6 2 F10 7 5A F1 25A C7 C8 R Rear Windshield Warmer Switch 3 1 W L W A22 A18B29 A24 A12 B13 Rear Fog Light Switch Front Fog Light Switch W L W W L W Front Ground Instrument B7 Front Ground Instrument B8 L R G L L G R P P 30 15 ACC1 ACC2 31 ILLUM A10 A13 B32 G Y Br B L To Instru ment 13 4 5 6 2 3 1 4 5 6 2 3 1 Figure14 6 ILLU...

Page 280: ...s plug at the time Test the resistance between the 62nd and 81st pin of A5 engine control unit this is the resistance value of the data trasmission end port the prescriptive value is 123Ω if it is not so please replace the engine control unit DTC logical decision Signal waveform test Maintain way of the CAN data transmission system A25 A26 CAN H CAN L 29 30 81 62 ECU Front ISU Anti Theft Horn Horn...

Page 281: ...ar Ground Rear Right Door6 7 7 7 To front ISU A29 Tofront ISU A30 L10 To the Front ISU Pe1 11 and Instrument Combination Switch 2 Y L W Gr Gr O B B4 B1 B13 B5 A 4 A19 A10 A12 A11 A13 B3 B12 A7 C1 A16 FR1 25A FR2 30A H BRIDGE D1 B19 B20 B8 B9 H BRIDGE B11 A9 A8 Rear ISU Br G Y B V W O G W Lg Br G W Lg B R A22 A6 L R Y L W Br B L Br FR3 15A O B B16 Br B15 FR4 15A Gr Gr L Br L G FR5 15A Y Gr Y Rear C...

Page 282: ... pin of rear ISU the 13th pin is The reverse warning system start to self check when the ignition switch is turned on if the If the control unit finds trouble in the system during the self check procedure the buzzer will generate a 5s continuous sound When put into the reverse gear and if the vehicle is 1 5m away from the roadblock the buzzer will start to warning The sound frequency will increase...

Page 283: ...nnectted rear is connectted rear reversing rear reversing 1st pin of reversing is connectted rear rear 3 Brake lamp and reversing lamp circuit FB31 50A C1 R 31 B4 B1 B13 Rear ISU Br B L Br FR3 15A B16 Br B15 FR4 15A Gr Gr L Br L G FR5 15A Y Gr Y Rear Combination Light System Gr O B B5 O B 30 Figure15 4 L a R ing L C Brake amp nd evers amp ircuit Rear fog lamp High mounted brake lamp Installa ti on...

Page 284: ...U A2 6 11 13 12 17 16 27 18 7 32 3 5 30 29 9 2 26 24 15 To Combination Instrument Instrument Front Ground 13 To Brake Shoe Thickness Sensor To ECU 59 To Handbrake Instrument Air Conditioner 1 To Air Conditioner Control Panel Module 10 Instrument FrontGround 2 Front Ground Roof 4 To Sunroof Module 3 To Dynamo To Air Bag Module 10 Fuse BoxL Plug In Unit 10 Fuse Box G Plug In Unit 4 Fuse Box G Plug I...

Page 285: ...spew water then When the wiper switch is at the position of INT the 4th 5th pin are connectted 6th 7th pin are connectted when the wiper switch input intermission signal to the front ISU via A15pin the inner relay of front ISU will electrify for 0 5s After 0 5s The ACC2 power supply wire the 1st pin of wiper Motor the 3rd pin of wiper Motor the C18 pin of front ISU the C17 pin of front ISU the 5th...

Page 286: ...or 8th pin ground The rear left view mirror will move right then The working principle of the right rear view mirror is the same with the left Choose the R button on the control switch panel when press the UP button the 7th and 6th pin of rear view mirror switch are connectted the 5th and 8th pin are connectted when press the DOWN button the 7th and 5th pin of the rear view mirror are connectted t...

Page 287: ... Ground Left 2 15 Front G round Left 2 12 FrontGround Left 2 14 Front Ground Left2 4 Front Ground Left2 2 Instrument Front Ground C7 Front Ground Left Door 2 1 Front Front Ground Left Door 2 14 Front Instrument Front Ground C7 Instrument FrontGround C7 Instrument Front Ground C9 Front Ground Right Door C Front Figure19 1 Power Window of Front Door Power Door Lock System Diagram M 1 2 P L L B31 B15...

Page 288: ...the remote controller when pull out the ignition key from the lock core the four doors will be locked immediately Then the anti theft system will get into the activation or release state If one door is not closed well then use the remote controller to lock all the four doors will be locked or unlocked right away front the The vehicle door control set is at the driver seat side When the driver open...

Page 289: ...liding motor the 4th pin of seat s adjusting switch the REAR contact point of seat s adjusting switch the 2nd pin of seat s adjusting switch the ground point near the hand brake Negative of battery then the front part of seat will move backwards 1 Upwards and downwards of seat front part 2 Forwards and backwards of seat Electric Seat System Circuit Analysis 3 Upwards and downwards of seat rear par...

Page 290: ...in of front right seat heating switch contact point of front right seat heating switch 4th pin of front right seat heating switch 1st pin of front right seat heating set 3rd pin of front right seat heating set ground The positive pole of battery FB32 fuse in positive pole fuse box 2nd pin of the front right seat heating set go through the heating wire and relay contact point in the front right sea...

Page 291: ...nectted to the 2nd 3rd pin of acoustics 30 15 ACC1 AC C2 31 ILLUM 8 9 Rear Right horn Lg B V Instrument Front Ground C4 Front Ground Rear Ground 5 Instrument Front Ground C3 Front Ground Rear Ground 13 _ 30 15 ACC1 ACC2 31 ILLUM FB23 15A 16 G 6 ToDiagnosis Port 16 Instrument Front Ground A3 L 11 Instrument Front Ground D4 Front Ground Rear Ground 1 Am plifier Rear Windshield Antenna Br Amplifier F...

Page 292: ...nectted to the 2nd 3rd pin of acoustics 30 15 ACC1 AC C2 31 ILLUM 8 9 Rear Right horn Lg B V Instrument Front Ground C4 Front Ground Rear Ground 5 Instrument Front Ground C3 Front Ground Rear Ground 13 _ 30 15 ACC1 ACC2 31 ILLUM FB23 15A 16 G 6 ToDiagnosis Port 16 Instrument Front Ground A3 L 11 Instrument Front Ground D4 Front Ground Rear Ground 1 Am plifier Rear Windshield Antenna Br Amplifier F...

Page 293: ... cigarette lighter via the 30A fuse Fb6 When press down the lighter switch the lighter gain the electricity and heating thread work the indicator lamp light on The two ends of the cigarette lighter parallel are connectted to the outer power Figure23 1 Circuit Diagram Sun roof Cigarette Lighter System FB6 30A C1 11 15 ACC1 ACC2 31 ILLUM 31 30 Front Ground Instrument D5 External Power Supply Plug In...

Page 294: ...E6 E12 G1 7 P3 L18 G16 C6 G3 G2 G1 K1 G12 L4 L3 L2 L1 G21 G22 G10 G9 L5 FB8 75A K18 Battery _ FB29 80A FB22 75A FB23 75A SB4 10A SB5 40A FB21 30A SB8 60A FB19 30A SB6 30A FB24 5A High beam relay 87 86 30 85 Low beam relay FB25 10A FB26 10A FB24 15A FB27 15A FB17 20A FB18 20A 86 87 30 85 ACC RELAY IGNITION RELAY 87 86 30 85 85 30 87 86 5A FB4 FB1 5A 75A FB2 5A FB5 L12 P7 P6 L11 P2 P11 G4 G7 G6 A1 A...

Page 295: ...andby Standby Standby Standby Front Engine Compartment Fuse Box Fron t eng in e compartmen t fuse bo x ABS B R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 Power rear view mirror Power of instrument front ISU and combin ation switch illumination the 15th wire Starter relay Reserve Right low beam Low beam relay High beam relay A C blower Left low beam Right high beam Left high b eam Transmissi on control unit ...

Page 296: ...tment Fuse Box Wiper ISU 2 The 15th pin of Ignition switch the G15 pin of Circuit of the Front Engine Compartment Fuse Box Ignition Relaycoil get electricity Voltage of battery fuse FB29 Ignition relay contact point and then supply to Fuse FB4 the L9 pin of Circuit of the Front Engine Compartment Fuse Box Airbag Module 8 Circuit of the Front Engine Compartment Fuse Box Circuit Analyse Voltage of b...

Page 297: ...ment Fuse Box Front Oxygen Sensor Warmer fuse FB9 the K17 pin of Circuit of the Front Engine Compartment Fuse Box Rear Oxygen Sensor Warmer The J10 pin of Circuit of the Front Engine Compartment Fuse Box EMS The J9 pin of Circuit of the Front Engine Compartment Fuse Box Electronic Fan Fuel Pump Relay the K10 pin of Circuit of the Front Engine Compartment Fuse Box EMS When Fuel Pump Relay get elect...

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Page 324: ...AM SHAFT POSITIONING SENSOR 19 3 7 ELECTRIC FUEL PUMP 20 3 8 ELECTROMAGNETIC INJECTOR 21 3 9 AIR FLOW SENSOR 22 3 10 DOUBLE SPARK IGNITION COIL 23 3 11 CARBON CANISTER SOLENOID VALVE 25 3 12 FUEL PRESSURE REGULATOR 26 3 13 ELECTRONIC THROTTLE VALVE AND ACCELERATOR 27 3 14 FAN CONTROL 28 3 15 AIR CONDITIONER CONTROL 29 4 ME7 SYSTEM TEST AND REPAIR ACCORDING TO TDC 30 4 1 ENGINE DTC DIAGNOSTIC TROUB...

Page 325: ...t idle speed is not steady or dying out when there is partial loading 61 10 Regular starts with high idle speed 62 11 Low engine speed or dying out exists when it is accelerated 63 12 React slowly when it is accelerated 64 13 The performance is poor when it is accelerated 65 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 326: ...om working properly Please leave the ignition switch at shut off position when you disconnect and connect the inserts otherwise it will damage the electric element It is must keep the ECU under 80 when you do the work of hot status simulation and other works which may cause the temperature increase The supplying oil pressure is high around 300kPa all the fuel pipe is made up of anti high pressure ...

Page 327: ...has been fixed well in advance by manufacturer so that it is not allowed to change it original position by the customer Do not exchange the anode and cathode of the accumulator to prevent damaging the electronic component This system uses cathode ground Do not disassemble accumulator cable when the engine is running Disassemble the cable of accumulator anode and cathode and ECU when there is weldi...

Page 328: ...the pressure in fuel system judge the status of fuel pump and fuel pressure regulator Tool name Pressure gauge for cylinder Function Inspect the pressure in every cylinder Tool name Fuel injector cleaner and analyzer function Analyze and clean the injector Tool name Vacuum meter function Inspect the pressure of intake manifold PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 329: ...l the intake air quantity fuel injection quantity and ignition advance angle The basic frame is shown in chart 2 1 Chart 2 1 compose of engine electronic control system In engine electronic control system the sensor is the input part used for measuring all kinds of physics signal temperature and pressure etc and change them to corresponding electronic signal the function of ECU is accepting the si...

Page 330: ...ition Sensor Fuel Distributing Pipe Speed Sensor Oxygen Sensor Canister Control Valve Knock Sensor Ignition Coil Canister Control Valve Ignition Coil Phase Sensor Phase Sensor Air intake temperature sensor Fuel Distribution Pipe Assembly Front Catalytic Converter Oxygen Sensor Oxygen Sensor Main Catalytic Converter Speed Sensor Knock Sensor Temperature Sensor UAES Parts Electric Fuel Pump Accelera...

Page 331: ... catalytic convert heating u Canister control u Idle speed control u Limping home 2 2 CONTROL SIGNAL ME7 9 7 SYSTEM INPUT OUTPUT SIGNAL The main sensor input signal of ECU of ME7 system l Air flow signal l Throttle valve corner signal l Coolant temperature signal l Engine speed signal l Phase signal l Knock sensor signal l Oxygen sensor signal l Speed signal l Air conditioner pressure signal The a...

Page 332: ... malfunction and contingency malfunction for example the malfunction is caused by short time cable braking or bad contact of the inserts according to its appeared frequency Chart 2 4 EFI System Malfunction Diagnosis Principle Chart 2 3 2 CONTROL STRATEGY OF FAILURE LAMP When there is no trouble The failure lamp is lighting and die out within 4 seconds after the ignition switch is ON Starting withi...

Page 333: ...agnosis Joint 2 3 4 READ MALFUNCTION INFORMATION BY WINK CODE Switch on ignition switch and use engine data K cable that is standard diagnosis joint 7 to ground use one lead connect pin of diagnosis joint 4 and pin of 7 more than 2 5 seconds if there are malfunction code in ECU malfunction memorizer the malfunction light wink code of engine now is P CODE value Such as P0203 winking type is wink 10...

Page 334: ...t 1 Oxygen sensor heating 42 Air intake temperature 2 Ignition coil 2 43 3 Ignition 44 Non persistent power 4 Oxygen sensor heating 45 Non persistent power 5 Ignition coil 1 46 Canister valve 6 Injection nozzle 4 cylinder No 2 47 Injection nozzle 3 cylinder No 4 7 Injection nozzle 2 cylinder No 3 48 8 Engine speed 49 9 Coolant temperature 50 Fan control 1 10 Fuel consuming 51 electronically 2 11 T...

Page 335: ... Cooling fan 28 69 Air conditioner relay 29 70 Fuel pump relay 30 71 Diagnosis K cable 31 EOBD inspection light 72 32 5V power supply 2 73 Anti theft device 33 5V power supply 1 74 Clutch switch 34 Engine speed sensor B 75 Air conditioner switch 35 Sensor 3 76 Power steering switch 36 Sensor 2 77 Headlamp switch 37 Air flow sensor 78 Sensor 38 Electronic throttle valve control 79 Phase sensor 39 E...

Page 336: ...vice notice 1 do not disassemble ECU at random during the service 2 disassemble accumulator 5 minutes prior to disassemble ECU 3 keep the disassembled ECU carefully 4 prohibit to connect any circuit to ECU connecting line l Simple measurement method 1 connect ECU joint Read engine malfunction record by K line 2 disassemble ECU joint Check the connecting line of ECU and pay more attention to check ...

Page 337: ...ead of the socket The maximum moment is 20Nm 4 Working principle This sensor is a thermistor of negative temperature coefficient NTC and its value will decrease with the coolant temperature increasing but the changes are not linearity There are several different resistance values at different temperature T Resistance value kΩ 10 8 62 10 28 20 2 37 2 63 80 0 299 0 345 5 Normal working temperature 3...

Page 338: ...or the casting iron using 25mm long bolt And the moment is 20 5Nm 4 Working principle Knock sensor is a kind of vibrating acceleration sensor and is assembled on cylinder block The sense organ of the sensor is a piezoelectric element The vibration of cylinder block is transferred to piezoelectric crystal by mass block inside of sensor The piezoelectricity crystalloid gets pressure from mass block ...

Page 339: ... to heating power cathode white No 3 connects to signal cathode gray No 4 connects to signal anode black 2 Installation position Assemble it on the top of exhaust pipe 3 Purpose The oxygen sensor checks the oxygen percent in exhaust gases and transfer the signal to ECU and ECU will control the fuel closed loop according to this information This will make engine working at its optimum conditions An...

Page 340: ...d a disassemble joint put digital multimeter to ohm shift connect meter pen to No 1 white and No 2 white pins of the sensor Normally the resistance value is 1 6Ω b Connect the joint and keep it at idle speed status When the oxygen sensor reaches to its working temperature 350 keep digital multimeter to DC volt shift and connect meter pen to No 3 gray and No 4 black pins of sensor Now the voltage s...

Page 341: ...eed and crank shaft top dead center information Speed sensor is made up of a permanent magnet and coil outside of magnet Pulse disc is a tooth disc with 60 teeth originally but there are two teeth opening Pulse disc is assembled on crank shaft and rotate with crankshaft When the tip of the tooth passed the end of inductive engine speed sensor the magnet pulse disc incises the magnetic line of forc...

Page 342: ...er 4 Working principle It is a Hall sensor 5 Working temperature 30 130 Working voltage 4 5 16V Trigger gap 0 1 1 8mm 6 Malfunction and diagnosis method l Malfunction can not start emission exceed standard fuel consume increased l Reason Man made l Simple measuring method connect the joint switch on ignition switch but do not start the engine put digital multimeter on DC volt connect two meter pen...

Page 343: ...ll of gasoline for coolant and greasing inside of the casing The accumulator provide power to electric fuel pump via fuel pump relay and the relay switches on electric fuel pump only when engine starting and running When the engine stops for some reason the pump will stop to run by itself 5 Working voltage 8 14V Working temperature 30 70 System pressure 300KPa 6 Malfunction and diagnosis method l ...

Page 344: ...essure if it is around 260kPa plug off the fuel pressure regulator vacuum pipe if it is around 300kPa 3 8 ELECTROMAGNETIC INJECTOR 1 Exterior drawing and pin There are two pins on each injector One of them is No 87 pin aside of casing marked with plus and connected to main relay output and another one connect with ECU No 27 6 7 47 pins 2 Installation position On the air intake manifold near the en...

Page 345: ...g and pin definition This sensor is 5 pins No 1 is intake temperature pressure signal No 2 is accumulator pressure No 3 is grounding No 4 is reference voltage 5V No 5 is intake airflow signal output 2 Installation position It is behind the air cleaner of the air intake tube 3 Purpose This sensor is hot cable airflow sensor which check the temperature and air intake flow entering to cylinder and pr...

Page 346: ...ring service 2 not to use high pressure air to impact sensing element 3 make sure there are no dust into air pipe when you change air cleaner and no unqualified air into air cleaner l Simple measuring method static measurement zero flow measurement No 3 grounding No 4 input 5V reference voltage No 2 input 14V rated voltage check No 5 output voltage if the output is bigger than 1 025V we can confir...

Page 347: ...k plug on both side of the secondary winding and the both spark plugs can ignite at the same time These two primaries connect and disconnect to power alternatively And correspondently these two secondary windings discharge alternatively 5 Working voltage 14V Working temperature 40 120 6 Malfunction and diagnosis method l Malfunction can not start l Reason current is too big and got burnt damaged b...

Page 348: ...control valve output by ECU but also to the pressure difference between canister valve intake and outlet When there is no electronic impulse the canister control valve will shut down 5 Working voltage 9 16V Working temperature 30 120 6 Malfunction and diagnosis method l Malfunction Function invalidation l Reason some particle coming to inside of valve causes erosion or poor sealing l Service notic...

Page 349: ...as not changed So the opening and closing of the valve is decided by the pressure difference of the fuel pressure from lower compartment and the air pressure from the upper compartment If the valve is closed at first then the fuel pressure increased causing the pressure difference between upper and lower compartments increased At last the film was raised up by the fuel pressure and valve is opened...

Page 350: ...put voltage signal l Electronic throttle valve pin definition Pin No 1 is motor anode Pin No 2 is potentiometer anode Pin No 3 is potentiometer cathode Pin No 4 is motor cathode Pin No 5 is signal output 1 Pin No 5 is signal output 2 2 Installation position Electronic throttle valve front end of intake manifold accelerator driver cockpit 3 Working principle The engine on time torque requirement wa...

Page 351: ...ken b Engine coolant temperature higher than 102 3 Conditions of fan continue to work after the engine stops working A Engine air intake temperature sensor is broken and delay 60 seconds B Engine coolant temperature sensor is broken and delay 60 seconds C Engine coolant temperature higher than 100 5 high speed delay 60 seconds D Temperature of intake air more than 70 5 delay 60 seconds 4 Malfuncti...

Page 352: ...rts b Cut off the air conditioner when temperature of intake air higher than 140 3 c Cut off air conditioner when the coolant temperature higher than 114 8 resume the air conditioning control after its lower than 11 8 d Cut off air conditioner when the engine speed is higher than 6520rpm or lower than 520rpm e Cut off air conditioner when the pressure inside of air conditioner high pressure pipe i...

Page 353: ...e trouble light will not light on 5 If it shows much lower of the voltage in some circuit in DTC explanation it refers to perhaps there is ground short circuit inside of this circuit If it shows much higher of the voltage in some circuit in DTC explanation it refers to perhaps there is power supply short circuit inside of this circuit If it shows circuit failure in DTC explanation it refers to per...

Page 354: ...0132 Much higher voltage of upstream oxygen sensor P0507 Rotating speed of idle speed is higher than target idle speed P0134 Signal failure of upstream oxygen sensor P0508 Idle speed regulator control circuit voltage is too low P0135 Heating circuit failure of upstream oxygen sensor P0509 Idle speed regulator control circuit voltage is too high P0171 Closed loop air fuel ratio control self adaptin...

Page 355: ...or quickly to complete open the displayed value should be reach up to 90kpa instantaneous No Replace the sensor DTC P0108 Much higher voltage of the air intake pressure sensor No Operating steps Result Follow up steps 1 Connect the diagnostic tester and commutator put the ignition switch to ON Next step Yes To step No 5 2 Observe air intake pressure item in data flow if it is about 101kpa specific...

Page 356: ... No 17 No 40 and sensor connector No 1 No 2 No Next step Yes Diagnosis help 6 Start the engine at idle speed Observe the value changes of diagnostic tester air intake temperature the value should increase with the increase of the engine intake air No Replace the sensor DTC P0113 Temperature is much higher indicated by the air intake temperature sensor No Operating steps Result Follow up steps 1 Co...

Page 357: ...ng multimeter between sensor connector No 1 and No 2 and check if it is corresponding to its temperature please reference the related section of this service manual No Replace sensor Yes To step 6 4 Take off the joint of coolant temperature sensor on the cable check the voltage between pin No 1 and pin No 2 by multimeter and observe if it is around 5V No Next step Yes Repair or replace cable 5 Che...

Page 358: ...ure is much lower of the air intake temperature sensor No Operating steps Result Follow up steps 1 Connect the diagnostic tester and commutator put the ignition switch to ON Next step Yes Next step 2 Observe throttle valve absolute opening item in data flow check the value if it is between 4 and 10 specific data is correlated to the vehicle type No To step No 5 Yes Next step 3 Step on the accelera...

Page 359: ... of sensor No Next step Yes Replace sensor 6 Check the voltage between pin No 1 and pin No 2 by multimeter and observe if it is around 5V No Diagnosis help DTC P0130 Unreasonable failure of the upstream oxygen sensor signal Notice below diagnosis process is fit for those without P0135 at the same time if there is P0135 failure please deal with P0135 failure at first and then check as below No Oper...

Page 360: ...with P0135 failure at first and then check as below No Operating steps Result Follow up steps 1 Connect the diagnostic tester and commutator put the ignition switch to ON Next step Yes Diagnosis help 2 Start the engine and leave it at idle speed until its coolant temperature reaches to the normal value Observe the value changes of oxygen sensor voltage item on diagnostic meter the displayed value ...

Page 361: ...2 Start the engine and leave it at idle speed until its coolant temperature reaches to the normal value Observe the value changes of oxygen sensor voltage item on diagnostic meter and the displayed value keeps around the value of 100mV at some working conditions No Diagnosis help Yes Repair or replace the cable 3 Connect the fuel pressure meter connection position is the front end of fuel distribu...

Page 362: ... 300kpa No Check and repair fuel system Yes Repair or replace cable 4 Check if there is short circuit to power supply between ECU pin No 36 No 18 and pin A opposite to oxygen sensor gray connecting line pin B opposite to oxygen sensor black connecting line of sensor joint No Next step Yes Repair according to diagnosis data 5 A check if the injector is leaking B check if the exhaust pipe is jammed ...

Page 363: ... 2 and power supply cathode and observe if it is around 3 7V No Next step Yes Repair or replace cable 6 Check if there is open circuit or short circuit to ground between 2nd cylinder injector joint pin No 2 and the ECU pin No 6 No Diagnosis help DTC P0203 The 3rd cylinder injector circuit failure No Operating steps Result Follow up steps 1 Connect the diagnostic tester and commutator put the ignit...

Page 364: ...or replace cable 6 Check if there is open circuit or short circuit to ground between 4th cylinder injector joint pin No 2 and the ECU pin No 47 No Diagnosis help DTC P0230 Fuel pump control circuit failure No Operating steps Result Follow up steps 1 Connect the diagnostic tester and commutator put the ignition switch to OFF Next step Yes To step No 4 2 Take off the fuel pump relay and put ignition...

Page 365: ...eck the resistance value by multimeter between speed sensor connector No 2and No 3 and observe if it is around 770 950MΩwhen it is 20 No Replace sensor Yes Repair or replace the cable 3 Check if there is open circuit or short circuit to ground or to power supply between circuit of speed sensor joint No 2 No 3 and ECU pin No 34 No 15 No Next step Yes Diagnosis help 4 Check the flywheel signal disc ...

Page 366: ...ck the camshaft signal disc if it is in good conditions No Replace signal disc DTC P0342 Much lower voltage of the phase sensor No Operating steps Result Follow up steps 1 Connect the diagnostic tester and commutator put the ignition switch to ON Next step Yes To step No 4 2 Take off the phase sensor joint from the cable check the voltage value by multimeter between phase sensor joint pin No 3 and...

Page 367: ... Diagnosis help 6 Check the camshaft signal disc if it is in good conditions No Replace signal disc DTC P0443 Canister control valve drive grade control circuit failure No Operating steps Result Follow up steps 1 Connect the diagnostic tester and commutator put the ignition switch to ON Next step Yes To step No 4 2 Take off the canister control valve joint from the cable check the voltage value by...

Page 368: ...ound between the circuit of canister joint pin No 2 and ECU pin No 46 No Diagnosis help DTC P0445 Much higher voltage of canister control valve drives grade control circuit No Operating steps Result Follow up steps 1 Connect the diagnostic tester and commutator put the ignition switch to ON Next step Yes To step No 4 2 Take off the canister control valve joint from the cable check the voltage valu...

Page 369: ...ioner condenser cooling fan relay control ends that is relay pin No 86 and power supply cathode No Next step Yes Repair or replace cable 5 Check if there is open circuit or short circuit to power supply or to ground between the circuit of relay control end pin No 86 and ECU pin No 50 No Diagnosis help DTC P0500 Unreasonable failure of speed signal No Operating steps Result Follow up steps 1 Connec...

Page 370: ...r is jammed G check if the exhaust system is not straightway No Replace speed sensor DTC P0507 Rotating speed of idle speed is higher than target idle speed No Operating steps Result Follow up steps 1 Connect the diagnostic tester and commutator put the ignition switch to OFF Next step Yes Next step 2 Check if the throttle valve adjusting screw accelerator cable and throttle valve working in good ...

Page 371: ... when it is 20 No Replace step motor Yes Repair or replace cable 3 Check using multimeter separately if there is short circuit to power supply between the circuits of idle speed regulator joint pin A B C D and ECU pin No 65 No 66 No 67 No 64 No Diagnosis help DTC P0511 Idle speed regulator control circuit failure No Operating steps Result Follow up steps 1 Connect the diagnostic tester and commuta...

Page 372: ...f the resistance is over big between the circuits of ECU pin No 44 No 45 No 63 and main relay pin No 87 No Next step Yes Next step 4 Start the engine and check if the entire generator recharging voltage is around 9 16V at the different engine speed No Replace generator Yes Diagnosis help 5 Check the engine cable harness contact position if it is in good conditions No Repair or replace cable DTC P0...

Page 373: ...lt Follow up steps 1 Connect the diagnostic tester and commutator put the ignition switch to OFF Next step Yes To step No 4 2 Take off air conditioner compressor relay put ignition switch to ON check the voltage value between relay power supply ends that relay pin No 30 No 85 and power cathode and observe if it is around 12V No Next step Yes Repair or replace cable 3 Check if there is open circuit...

Page 374: ...mpressor relay control ends that is relay pin No 86 and ECU pin No 70 No Diagnosis help DTC P0647 Much higher voltage of air conditioner compressor relay control circuit No Operating steps Result Follow up steps 1 Connect the diagnostic tester and commutator put the ignition switch to OFF Next step Yes To step No 4 2 Take off air conditioner compressor relay put ignition switch to ON check the vol...

Page 375: ...y inspection before start the diagnosing according to the engine failure phenomenon 1 Make sure the engine trouble light is working properly 2 Make sure that there is no failure information record checked by diagnostic meter 3 Make sure that the failure phenomenon exists according to the customers complaints and confirm the conditions causing the failure Then carry out the exterior inspection 1 Ch...

Page 376: ... Yes Next step 1 Check the voltage value between the two wiring terminals of the accumulator by multimeter check if it is around 8 12V when the engine is starting No Replace accumulator Yes Next step 2 Put the ignition switch at start position checking the anode terminal of starting motor by multimeter and observe the voltage if it is above 8V No Repair or replace cable Yes Repair or replace start...

Page 377: ...nnect EFI diagnostic meter observe engine speed data item and start the engine and check if there is rotation speed signal is output No Repair the sensor cable Yes Next step 3 Pull off one of the cylinder separating line and take off this cylinder injector joint and connect spark plug to it keep the spark electrode around 5mm away from engine body start the engine by starter and check if there is ...

Page 378: ...m away from engine body start the engine and check if there is blue and white high pressure fire No Repair the ignition system Yes Repair circuit or replace sensor 3 Take off the coolant temperature sensor joint and start the engine observe if the engine can be started successfully or serial connecting a 300Ωresistance at the joint of coolant temperature sensor observe if we can start the engine N...

Page 379: ...circuit or replace sensor 3 Take off the coolant temperature sensor joint and start the engine observe if the engine can be started successfully or serial connecting a 2500Ωresistance at the joint of coolant temperature sensor observe if we can start the engine No Next step Yes Clean throttle valve and idle speed air port 4 Step on the accelerator slightly and observe if it is easy to be started N...

Page 380: ...m away from engine body start the engine and check if there is blue and white high pressure fire No Check and repair ignition system Yes Next step 4 Check spark plugs in every cylinder and observe its type and clearance if it is accord with the regulation No Adjust or replace Yes Repair circuit or replace sensor 5 Take off the coolant temperature sensor joint and start the engine observe if the en...

Page 381: ...le valve and idle speed by pass if there is carbon deposition No Next step Yes Replace part 5 Disassemble the injector check the injector using the injector special cleaning analysis meter and observe if it is leaking or jammed No Next step Yes Change fuel 6 Check fuel conditions and check if the failure is appeared after the fuel refilling No Next step Yes Trouble shoot 7 Check pressure condition...

Page 382: ... deposition No Next step Yes Repair the line or replace sensor 4 Pull off coolant temperature sensor joint and start the engine observe the engine if it is idle speed unsteady during warming up the engine No Next step Yes Replace part 5 Disassemble the injector check the injector using the injector special cleaning analysis meter and observe if it is leaking or jammed or overflowing No Next step Y...

Page 383: ...osition No Next step Yes Repair the line or replace sensor 4 Pull off coolant temperature sensor joint and start the engine observe the engine if it is idle speed unsteady during warming up the engine No Next step Yes Replace part 5 Disassemble the injector check the injector using the injector special cleaning analysis meter and observe if it is leaking or jammed or overflowing No Next step Yes C...

Page 384: ...3 Connect EFI system adaptor break connecting line of ECU pin No 75 check the cable end if it is up level signal when the air conditioner is switched on No Repair air conditioning system Yes Next step 4 Check air conditioning system pressure check the compressor solenoid clutch and air conditioner compressor pump fuel conditions and check if it is working correctly No Repair the air conditioning s...

Page 385: ...rt 3 Disassemble the idle speed regulator and check the throttle valve and idle speed by pass port if there is carbon deposition No Next step Yes Repair line or replace sensor 4 Take off the coolant temperature sensor joint start the engine and observe if it has high idle speed No Next step Yes Next step 5 Check the engine ignition timing if it is accord with the regulations No Repair the ignition...

Page 386: ...or replace Yes Clean related part 4 Disassemble idle speed regulator and check throttle valve idle speed regulator and idle speed by pass port if there is carbon deposition No Next step Yes Next step 5 Inspect air intake pressure sensor throttle position sensor and its line if it is working correctly No Repair line or replace sensor Yes Replace fault part 6 Disassemble the injector check the injec...

Page 387: ...es Clean related part 4 Disassemble idle speed regulator and check throttle valve idle speed regulator and idle speed by pass port if there is carbon deposition No Next step Yes Next step 5 Inspect air intake pressure sensor throttle position sensor and its line if it is working correctly No Repair line or replace sensor Yes Replace fault part 6 Disassemble the injector check the injector using th...

Page 388: ...system Yes Next step 4 Pull off one of the cylinder separating line and connect spark plug to it keep the spark electrode around 5mm away from engine body start the engine and check the high pressure fire strength if it is regular No Repair ignition system Yes Next step 5 Check spark plugs in every cylinder and observe its type and clearance if it is accord with the regulation No Adjust or replace...

Page 389: ...xhaust pipe Yes Diagnosis help 12 Connect EFI system adaptor turn on the ignition switch check the power supply of pin No 12 13 44 45 and No 63 if it is in right conditions check pin armature of No 3 51 53 61 and No 80 if it is in right conditions No Repair corresponding line PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 390: ...AINTENANCE TOOLS 2 SECTION 1 TECHNOLOGY DATA INSTRUCTION 2 SECTION 2 SPECIAL TOOLS 5 SECTION 3 ENGINE NUMBER POSITION 6 SECTION 4 COLLATING METHOD OF ENGINE TIMING 7 CHAPTER 2 ENGINE BODY 9 SECTION 1 WHEEL TRAIN 9 SECTION 2 CYLINDER HEAD 14 SECTION 3 SHORT ENGINE 26 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 391: ...95 Rev at Rated Power r min 5500 Max Torque N M 180 Rev at Max Torque r mim 4000 Minimum Fuel Consumption Rate g Kw h 301 Cylinder Pressure Bar 10 0 2 Fuel Pressure Bar 4 Low Idle Speed 800 50r min High Idle Speed 2000r min Engine Oil Pressure Bar High Speed 4000r min High Pressure Circuit 2 3 A C Circuit Pressure Bar Low Pressure Circuit 12 16 Pressure Relief Valve Release Pressure to Outside 88 ...

Page 392: ...ake Valve 0 3 0 15 Fringe Thickness on Top of Valve Exhaust Valve 0 3 0 15 Intake Valve 5 98 0 008 Valve Stem Diameter Exhaust Valve 5 96 0 008 Intake Valve Seal Bandwidth Exhaust Valve Intake Valve 0 02 Gap Between Valve Stem And Guide Exhaust Valve 0 04 Intake Valve 65 Tilt Angle Exhaust Valve 68 Intake Valve 107 998 Valve Height Exhaust Valve 106 318 Free Height 47 7 Working Tension in Advance ...

Page 393: ...n Pin Hole Axial Clearance 0 076 0 265 Radical Clearance 0 0375 Coaxial Degree 0 05 Cylindricity 0 008 Crankshaft Mainshaft Diameter Roundness 0 005 Cylindricity Crankshaft Connecting Rod Journal Diameter Roundness Whole Height 218 0 05 Cylinder Hole Roundness Straightness Accuracy 0 008 0 01 Cylinder Upper Surface Planeness 0 04 Radial Clearance of Connecting Rod Bearing 0 016 0 051 Connectin g R...

Page 394: ...LC ENGINE 5 SECTION 2 SPECIAL TOOLS Camshaft Timing Tool Crankshaft Timing Tool Flywheel Tool Guide Sleeve of Crankshaft Oil Seal Guide Sleeve of Camshaft Oil Seal Hydraulic Hoist PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 395: ...ly remove the spark plug screw the pipe end of instrument instead of it and operate the engine by starter then take the maximum value in cylinder pressure gauge as cylinder pressure SECTION 3 ENGINE NUMBER POSITION Position of Engine Cylinder Block Number Engine Oil Dipstick PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 396: ... TIMING 1 Remove the upper cover of engine timing belt 2 Remove the lower cover of engine timing belt 3 Loosen the central bolt of timing belt tension pulley and remove the timing belt 4 Draw out the high voltage ignition cable PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 397: ...ft 7 Loosen the bolts of air intake and exhaust camshaft tension pulleys with torque wrench Note It is not to remove but loosen 8 Revolving the crankshaft you may rotate in the crankshaft tool so as to it cannot move in both direction Note Do it with patience and carefulness lest the crankshaft should be broken Camshaft Tool Crankshaft Tool PDF created with pdfFactory Pro trial version www pdffact...

Page 398: ...Torque value Nm Re screw angle 1 Bolt Lower Part Of Timing Front Cover 8 3 2 Bolt Upper Part Of Timing Front Cover 8 3 3 Bolt Upper Part Of Timing Front Cover 8 3 4 Lower Part Of Timing Front Cover 5 Upper Part Of Timing Front Cover 6 Washer Lower Part Of Timing Front Cover 7 Bolt Crankshaft Timing Gear 130 10 65 5 8 Washer Crankshaft Timing Gear 9 Crankshaft Timing Gear 10 Timing Belt 11 Water Pu...

Page 399: ...iary materials Allen wrench 10 13 sleeve ratchet wheel and ratchet rod 1 2 Removal 1 Loosen the five bolts on the upper cover with Allen wrench 2 Remove the upper cover of timing belt 3 Clip the flywheel with flywheel tool 4 Remove the crankshaft pulley with 13 sleeve Flywheel Tool PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 400: ...t the position of timing belt if any trail from crack or friction is found 1 4 Installation The installing steps are reverse to those for removal Note Install the lower cover first and then install the upper one 2 Replace timing belt 2 1 Needed tools and auxiliary materials Allen wrench 10 13 sleeve ratchet wheel and ratchet rod 2 2 Removal 1 Remove the upper and lower covers of timing belt see re...

Page 401: ...d fabric 3 Wearing gear missing and incomplete gear of cord fabric 4 Abnormal wearing of belt flank Replace the belt as any following situation occurs even though abrasion cannot be found directly 1 The water pump leaks water out and requires continuing infusion 2 If the belt is spotted with much oil stains and the rubber may be damaged due to expansion you should replace the belt Chap Chap Wearin...

Page 402: ...lley 3 3 Inspection 1 Check from appearance Check idler wheel tension pulley and contact belt pulley carefully for any damages such as sunken trace and sliding damage etc 2 Check performance Revolve tension pulley idler wheel and contact belt pulley respectively to insure that they can run freely without stagnancy Replace it with the spare part if any above problem is found 3 4 Installation 1 The ...

Page 403: ...GRAM 1 Gasket Intake Manifold 2 Intake Manifold Assembly 3 Hexagonal Flange Bolt 4 Throttle Valve Body Assembly 5 Gasket Throttle Valve Body Assembly 6 Oil injector Assembly 7 Fuel Distribution Pipe Assembly 8 Bracket 4 7 6 2 1 3 5 8 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 404: ...Control Valve Camshaft Phaser Assembly 11 First Bearing Cap Assembly 12 Front Camshaft Oil Seal 13 Exhaust Camshaft Assembly 14 Rocker Arm Assembly 15 Hydraulic Tappet Assembly 16 Stud Bolt 9 Bars 17 Cylinder Head Gasket 18 Temperature Sensor 19 Engine Hanger 20 Cylinder Head Bolt 21 Cylinder Head Assembly 11 15 14 13 8 9 10 17 7 18 1 5 4 3 2 6 12 16 19 20 21 PDF created with pdfFactory Pro trial ...

Page 405: ...ector 3 Remove the connecting bolt between engine oil dipstick and intake manifold 4 Remove the clamp between intake hose and throttle valve body 5 Remove the connecting bolt of throttle valve body and take out throttle valve body Note Because this throttle valve body is electronic do not force the middle vanes turning manually or with other objects 6 Loosen the joint of oil intake pipe 7 Remove t...

Page 406: ...transmission oil a set of sleeve tools an adjustable spanner special tools for timing and a set of Allen wrenches 2 2 2 Removal 1 Remove the dynamo belt see removal of dynamo belt for details 2 Remove the timing belt see replacement of engine timing belt and timing calibration for details 3 Remove the cover of engine valve chamber 4 Clamp the timing special tool into camshaft slot and fasten the b...

Page 407: ...ing caps of air intake and exhaust camshaft respectively and put them down in the sequence Note The second third fourth and fifth camshaft bearing caps are marked with I1 I2 I3 I4 E1 E2 E3 E4 which stands for the corresponding bearing cap of 1 2 3 4 cylinder respectively I refers to intake camshaft E refers to exhaust camshaft Torque PDF created with pdfFactory Pro trial version www pdffactory com...

Page 408: ... tools Picture is unavailable 10 Remove the used valve oil seal with special tools Picture is unavailable 2 2 3 Inspection 1 Check the valve spring Measure the free length the verticality and the length under special pressure with caliper Standard Value mm Free length 47 7 Length of 620N 32 Replace with the new valve spring if the measured value exceeds the limit value PDF created with pdfFactory ...

Page 409: ...ometer caliper Standard Value mm limit value mm Intake Cam 37 15 Exhaust Cam 37 05 Replace with the new camshaft if the measured value exceeds the limit value 4 Examine diameter of valve stem a Measure the diameter of valve stem with micrometer caliper See the picture for measuring points they are 26 52 and 78 mm from measure positions to bottom of valve Valve Guide External Diameter Of Valve Stem...

Page 410: ...he value exceeds the limit value d Examine the contact bandwidth of valve e Check the valve seat insert Standard Value IN 5 98 0 008 Outer Diameter of Valve stem mm EX 5 96 0 008 IN 5 4 0 1 Inner Diameter of Valve guide mm EX 5 4 0 1 IN 0 02 Clearance mm EX 0 04 IN 0 3 0 15 Thickness of Valve Top mm EX 0 3 0 15 IN 1 158 Seal Bandwidth mm EX 1 306 Measuring Point Contact Position Should be the Cent...

Page 411: ...camshaft if the value of axial clearance exceeds the normal value Standard Value Intake camshaft 0 015 0 02 Exhaust camshaft 0 015 0 02 6 Examine the planeness of cylinder a Clear the lower surface of cylinder head b With the help of ruler and feeler gauge check whether the lower surface of cylinder head is warped Measure it in the sequence of A C D E F G in the picture Standard Value Cylinder hea...

Page 412: ...alve spring of 1st and 4th cylinders replace their valve oil seal and mount the spring immediately And put the piston to the upper point of 2nd and 3rd cylinders in order to replace the other valve oil seal Those steps prevent from that the valve falls into cylinder and the unanticipated trouble occurs 2 Wipe the engine transmission oil on the opening of oil seal when mounting the valve oil seal 3...

Page 413: ...mostat in the boiling water and use it with thermometer Then observe the temperatures when the thermostat is turning on and fully opened Temperature value Regular unlocking temperature 87 fully opened temperature 104 Replace the new thermostat if the measured value is abnormal 2 3 5 Installation The installing steps are reverse to those for removal Note Fill in the engine coolant with fixed quanti...

Page 414: ...4 Connecting Rod Lower Bearing 5 Pad 6 Bolt 7 Oil Filter 8 Oil Cooler 9 Oil Filter Seat 10 Connecting Rod Bolt 11 Connecting Rod Bearing Cap 12 Oil Pump 13 Bolt 14 Gasket 15 Crankshaft Timing belt pulley 16 Gasket 17 Bolt 18 Crankshaft Pulley 19 Bolt 20 Bolt 21 Coolant pump 22 Coolant Pump Gasket PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 415: ...SERVICE MANUAL MECHANISM OF 2 0NALC ENGINE 26 23 Crankshaft Main Bearing Bolt 24 Frame Bolt 25 Frame 26 O Type Ring 27 Crankshaft 28 Cylinder Block PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 416: ...removal 1 Loosen the oil discharge bolt of oil pan to discharge the engine oil Note Engine oil should be stored in special container And Pay attention to environment protection 2 Remove the fastening bolt of oil pan with 10 open end wrench and 10 sleeve 18 bars of M7 25 3 bars of M7 40 4 bars of M7 95 3 Remove the connecting bolt 2 bars black between oil pan and transmission housing with 17 sleeve...

Page 417: ... right angled tool to get rid of old Le Tai glue Note Do not lacerate the frame surface 1 2 2 Installation 1 Spread Le Tai 5910 glue on the connection surfaces of frame and oil pan close the oil pan and fasten the fastening bolt of oil pan Note Spread glue to the inner of hole for installing bolt on the oil pan 2 Screw the bolt Screw to combine enough at first then to get specified Torque See the ...

Page 418: ...replace oil pan for details 2 Remove the connecting bolt between engine oil strainer and frame with 10 sleeve wrench total 8 bars 3 Draw out the engine oil strainer carefully 2 2 2 Installation 1 Spin the nozzle of engine oil strainer into the frame carefully 2 Mount the 8 bolts for the strainer and fasten them Note the bolts should be mounted with Le Tai 243 glue Torque 8 3Nm 3 Install oil pan Se...

Page 419: ...rocess of replacement 3 2 1 Process of removal 1 Dismantle the timing belt see dismantle the timing belt in the section of replacement of engine timing belt for details 2 Remove the oil pan see REPLACE OIL PAN for details 3 Remove the cylinder head see removal of cylinder head for details 4 Dismantle the engine oil strainer see the replacement of engine oil strainer for details 5 Loosen the big bo...

Page 420: ...on the retainer ring may hurt people in the process of removal 3 2 2 Inspection I Check piston 1 Examine the diameter of piston Measure the diameter along the vertical direction to piston pin and at the place 11mm under piston skirt with micrometer caliper Cylinder No Standard Size 1 83 46 0 009 2 83 46 0 009 3 83 46 0 009 4 83 46 0 009 Replace with the new one if the part cannot be worn and torn ...

Page 421: ...m 1st Ring 0 04 0 08 2nd Ring 0 01 0 025 Replace with the new one if the examined clearance cannot be worn and torn any longer 3 Inspect the end clearance of piston ring a Put the piston ring at the position 45mm below the top surface of cylinder aperture and push the piston ring into cylinder with piston b Measure the opening with feeler gauge Replace with the new piston if the examined clearance...

Page 422: ... the diameter of piston pin b Measure the diameter of piston pin hole around with micrometer guage for inside diameter as the following picture and take the minimum value as the diameter of pin hole Replace with the new piston and pin if the examined clearance exceeds the limit Standard Size Diameter of piston pin 21 0 005 0 Diameter of piston pin hole 21 008 0 002 0 PDF created with pdfFactory Pr...

Page 423: ...aximum bore Minimum bore 2 As the picture measure the bores of 3 planes along both A direction and B direction respectively Get the maximum and the minimum from 6 values and then subtract the half of Minimum from the Maximum to get cylindricity b Inspect the radial clearance of connecting rod bearing Inspect the radial clearance of connecting rod bearing with clearance gauge Clean up the connectin...

Page 424: ...the connecting rod bearing by observing the sign on the first balance weight at the front end of crankshaft see picture unavailable 6 Inspect the planeness of cylinder block surface a Clean the upper surface of cylinder block b Check with ruler and feeler gauge whether the surface of cylinder block is warped Measure it in the sequence of A C D E F G in the picture C Revise it if the warping amount...

Page 425: ...ues and then subtract the half of Minimum from the Maximum to get cylindricity 3 2 3 Installation 1 Spread oil on the piston pin and in the piston pin hole connect the piston and connecting rod with piston pin and mount the piston pin circlip 2 Mount the piston ring Mount the rings on the piston in the sequence of oil ring expander upper and lower segments 2nd air ring and 1st air ring Pay attenti...

Page 426: ...onnecting rod 4 Spread the engine transmission oil in the engine cylinder clasp the piston ring with special tool tap the piston head with wooden handle and encase the piston connecting rod assembly Note the end of connecting rod with a point should face the cylinder and consists with the arrowhead on the top side of piston PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 427: ...micrometer guage or feeler gauge Standard Value mm Clearance 0 15 0 50 8 Mount the engine oil strainer 9 Mount the oil pan 10 Mount the cylinder head 11 Mount the timing belt during timing adjusting 4 Replace front oil seal of crankshaft 4 1 Needed tools and auxiliary materials Ratchet wheel and ratchet rod 13 15 17 22 sleeve 13 open end wrench allen wrench engine transmission oil and guide sleeve...

Page 428: ...age the oil seal seat ring 4 2 2 Installation 1 Clean the oil seal seat ring and spread transmission oil on the seat ring 2 Spread transmission oil at the seal lip 3 Enclose the guide sleeve of crankshaft oil seal special tool with that oil seal 4 Press the oil seal into oil seal seat ring and knock it to right position with hammer 5 Replacement of oil pump 5 1 Needed tools and auxiliary materials...

Page 429: ...ould be put downwards because the wrong position can not make the bolt be screwed in 3 Mount the oil seal 4 Mount the other parts 6 Replacement of crankshaft rear oil seal 6 1 Needed tools and auxiliary materials A set of big sleeves a right angled screwdriver a small hoist and engine oil 6 2 Process of Removal 1 Suspend the engine assembly from vehicle See suspending of engine assembly for detail...

Page 430: ... and then mount the engine on the vehicle Torque 25 5N M then screw 30 5 7 Replace crankshaft and thrust washer 7 1 Needed tools and auxiliary materials A set of open end wrenches a set of sleeve tools a small hoist Le Tai glue Engine oil feeler gauge feeler gauge micrometer gauge 7 2 Process of Removal 1 Suspend the engine assembly from vehicle See suspending of engine assembly for details 2 Drai...

Page 431: ...d strainer for details 8 Remove the piston connecting rod assemblies for 4 cylinders and Put them in order Note You d better stick the number on each piston connecting rod assembly to prevent from wrong mounting 9 Dismantle engine oil pump assembly 10 Dismantle the frame assembly under cylinder block and remove the crankshaft and thrust washer 7 3 Inspection 1 radial clearance of crankshaft a Clea...

Page 432: ...asured clearance value exceeds the limit value Note Replace the whole group when replacing bearing bushing Selecting method of main bearing bushing By observing the sign on cylinder see the picture we could see 5 As which correspond to bearing bushings respectively There two kinds of signs on this vehicle A and B corresponding to two kinds bushing red one and blue one the color can be recognized o...

Page 433: ...unt the crankshaft correctly and then mount the thrust washer 3 Mount the cylinder frame and screw down the crankshaft fastening bolt See the picture for the screwing sequence Screwing way and Torque A Pre fasten the bolt according to the sequence in the picture B Screw the bolt as the sequence on the picture to 45 5 N m C Screw 180 5 4 Mount and screw down the bolt of frame periphery Torque 23N m...

Page 434: ... wrench coolant 8 2 Removal 1 Remove the engine timing belt see engine timing calibration for details 2 Loosen the engine water exhaust pipe and exhaust coolant 3 Removal the coolant pump 8 3 Installation The installing steps are reverse to those for removal Infuse enough coolant after installation Note Do not splash the coolant on the timing belt and skin PDF created with pdfFactory Pro trial ver...

Page 435: ...CHERY A520 SERVICE MANUAL QR519 TRANSMISSION 1 QR519 TRANSMISSION SERVICE MANUAL PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 436: ...IV TECHNICAL PARAMETERS 6 V TIGHTENING TORQUE FOR ASSEMBLY 7 VI DISASSEMBLY PROCEDURE NOTICE 8 VII STRUCTURAL DISASSEMBLY DIAGRAM 17 VIII TRANSMISSION ASSEMBLY NOTICE 37 IX AIR EXHAUST METHOD OF HYDRAULIC CLUTCH 37 X USE OPERATION METHOD NOTICE 38 XI COMMON FAULTS TROUBLESHOOTING 39 XII LIST OF WEARING PARTS 40 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 437: ...OUTSIDE VIEW AND FUNCTIONAL DIAGRAM OF ASSEMBLY Gear Shift Mechanism Assembly Rear Cover Assembly Transmission Housing Assembly Quick Coupler For Release Bearing Clutch Housing Assembly PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 438: ...CHERY A520 SERVICE MANUAL QR519 TRANSMISSION 4 Lifting Eye Drain Plug Blanking Cover Differential Oil Seal Blanking Cover For Odometer PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 439: ...ing 8 3rd Driving Gear 9 Input Shaft 10 Clutch 11 Crankshaft 12 Engine 13 Idler Gear Shaft 14 Idler Gear 15 1st Driven Gear 16 1st Synchronizer Ring 17 Axle Shaft 18 Side Gear 19 Planetary Gear 20 Final Drive Driven Gear 21 1st 2nd Synchronizer 22 2nd Synchronizer Ring 23 2nd Driven Gear 24 3rd Driven Gear 25 Output Shaft 26 4th Driven Gear 27 5th Driven Gear 28 2nd Driving Gear 29 1st Driving Gea...

Page 440: ... 1st gear 39 11 3 546 2nd gear 43 21 2 048 3rd gear 35 26 1 346 4th gear 36 35 0 972 5th gear 38 31 0 816 Gear ratio Z2 Z1 Reverse gear 40 12 3 333 Transmission oil type API 75W 90 GL 4 gear oil Transmission oil volume 2 1L Rated torque 190 N m Rated speed 5500 r min Rated power 95 KW Center distance 72 mm Number of teeth 18 Modulus 1 0583 Pressure angle 37 5 o Major diameter φ20 10 25 0 Input sha...

Page 441: ... nut for 5th driven gear M16X1 5 6h 88 9 108 5 Friction ball blanking cover for 5th shift fork M10X1 6h 5 8 8 8 Bolt for connecting rear cover and transmission housing M6 6h 6 9 9 8 Clutch release lever bolt M8X35 29 4 49 Bolt for connecting gearshift mechanism and transmission housings M8X1 25 6h 14 7 21 5 Bolt for connecting gear selector arm and its bracket M8X75 14 7 21 5 Backup lamp switch as...

Page 442: ... oil drain plug and then rotate the transmission to drain the transmission oil as possible as you can Figure 1 2 Undo the clip for fastening the release bearing it is unnecessary to take it off Figure 2 3 Disassemble the hydraulic release bearing seat and the quick coupler for release bearing Figure 3 Clip PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 443: ...mbly as shown in the figure Figure 4 5 Disassemble the release bearing bolts and remove the release bearing Figure 5 6 Screw off the rear cover bolts and remove the rear cover Figure 6 Air Exhaust Switch PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 444: ... off the tight nut for the 5th driven gear counterclockwise Note alternatively you can engage the 5th gear and put a thin copper bar or any other low hardness metal bar between the 5th driving and driven gears and then use a torque wrench to screw off the tight nut for the 5th driven gear counterclockwise Figure 8 9 Similarly use the torque wrench to screw off the tight nut for the 5th driving gea...

Page 445: ...th the punch engage the reverse gear and take out the 5th reverse shift fork Figure 10 11 Remove the 5th synchronizer along with the 5th driving and driven gears Figure 11 12 Remove the needle roller bearing Figure 12 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 446: ...gonal socket wrench and remove the bearing retainer Figure 13 14 Take out the adjusting washer for rear output shaft bearing by using a caliper Figure 14 15 Similarly take out the adjusting washer for rear input shaft bearing Figure 15 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 447: ...nism housing bolts Figure 16 17 Screw off the shifting finger locating base Figure 17 18 Remove the backup lamp switch now you can directly pull the control mechanism assembly out of the transmission housing Figure 18 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 448: ...h shift fork locating base 3 The 1st 2nd shift fork locating base Note the bolt to the 1st 2nd shift fork locating base is relatively long Figure 19 20 Screw off the idler gear shaft fixing screw with the hexagonal socket wrench Figure 20 21 Screw off the transmission housing bolts Figure 21 3 2 1 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 449: ...he transmission housing so as to suspend the transmission assembly and then use the copper bar to hit the input and output shafts and remove the transmission housing as well as the 5th collar Figure 23 24 Remove the reverse idler gear assembly Figure 24 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 450: ...e 25 26 Remove the split baffle ring with a caliper Figure 26 27 Take hold of the input shaft assembly output shaft assembly 1st 2nd shift fork 3rd 4th shift fork and 5th reverse fork shaft together with your hands and take them out finally take out the differential assembly Figure 27 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 451: ...gear assembly 6 3rd driving gear 7 3rd 4th synchronizer cone 8 Synchronizer ring 3rd 4th synchronizer 9 3rd 4th synchronizer assembly 10 Steel wire spring for 3rd 4th synchronizer 11 Guide block for 3rd 4th synchronizer 12 Gear sleeve for 3rd 4th synchronizer 13 4th gear needle roller bearing 14 4th driving gear assembly 15 Gear hub for 3rd 4th synchronizer 16 4th driving gear 17 4th collar PDF cr...

Page 452: ...ear or lockup of the needle roller bearing s outer diameter portion to be mounted Check whether there is any damage or wear of the spline Check the needle roller bearing whether the input shaft and gears are correctly assembled whether the gears can rotate smoothly and whether there is any part looseness or noise Check the 3rd and 4th driving gears Check whether there is any damage or wear on toot...

Page 453: ... Figure 31 Check whether there is any damage or wear on the gear tooth surfaces of the synchronizer ring whether there is any damage or wear on the inner diameter surface of the synchronizer s conical portion and whether the screw thread is damaged due to crushing 4 Press the synchronizer rings in turn onto their respective gears conical surfaces and check the values of the clearance A The standar...

Page 454: ...zer Cone Ring 7 1st 2nd Synchronizer Ring Outer 8 1st 2nd Synchronizer Ring Inner 9 1st 2nd Synchronizer Assembly 10 Guide Block for 1st 2nd Synchronizer 11 Spring 1st 2nd Synchronizer 12 Gear Hub 1st 2nd Synchronizer 13 Ball 1st 2nd Synchronizer Guide Block 14 Gear Sleeve 1st 2nd Synchronizer 15 Snap Ring 1st 2nd Synchronizer Gear Hub 16 2nd Driven Gear 17 3rd Driven Gear 18 3rd 4th Driven Shaft ...

Page 455: ...he front end of output shaft Figure 34 NOTICE FOR INSTALLATION 1 Clean all the components 2 In the same way as for the input shaft successively check the following items output shaft needle roller bearing 1st driven gear 2nd driven gear and 1st 2nd synchronizer gear sleeve and hub 3 Check the outer synchronizer ring inner synchronizer ring and synchronizer cone ring Check whether there is any dama...

Page 456: ...it is necessary to change the outer synchronizer ring inner synchronizer ring or synchronizer cone ring you shall use a new complete set of these components for substitution INSTALLATION The procedure to assemble the output shaft assembly is opposite to its disassembly procedure PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 457: ... TRANSMISSION 23 IDLER GEAR ASSEMBLY 1 2 3 5 4 Figure 36 1 Reverse Idler Gear 2 Bushing Reverse Idler Gear 3 Idler Gear Assembly 4 Idler Gear Gasket 5 Idler Gear Shaft PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 458: ... Reverse Locating Base 2 Spring for Reverse Locating Base 3 Ball for Reverse Locating Base 4 Reverse Shift Arm Bracket 5 Reverse Shift Arm 6 Pin Shaft Reverse Shift Arm Bracket 7 Drive Pin Idler Gear 8 Reverse Locating Base 9 Reverse Shift Fork Mechanism Assembly PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 459: ...NUAL QR519 TRANSMISSION 25 1ST 2ND SHIFT FORK ASSAMBLY 1 2 3 4 Figure 38 1 1st 2nd Shift Fork 2 1st 2nd Fork Shaft 3 Spring Pin 4 1st 2nd Shift Fork Assembly PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 460: ...39 1 3rd 4th Fork Shaft 2 3rd 4th Fork Bracket 3 Spring Pin 4 3rd 4th Shift Fork 5 Split Baffle Ring 6 Reverse Pin 7 Interlock Pin 8 5th Reverse Fork Shaft 9 3rd 4th 5th and Reverse Fork Shaft Components 10 5th Reverse Shift Fork 11 Spring Pin for Fork Shaft PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 461: ...SION 27 1 30 GEAR SELECTION SHIFT MECHANISM ASSEMBLY 9 8 7 6 5 4 3 11 10 2 1 36 12 13 14 15 16 17 18 21 22 24 25 26 27 28 29 31 32 33 34 35 23 19 20 37 38 39 41 42 40 Figure 40 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 462: ...Selector Lever Assembly 22 Boot Gear Selection Shift Shaft 23 Oil Seal Gear Selection Shift Shaft 24 Air Duct Cap 25 Air Duct 26 Gear Selection Shift Mechanism Housing 27 Linear Bearing 28 5th Reverse Return Spring Retainer 29 Bottom Base For 5th Reverse Return Spring 30 5th Reverse Return Spring 31 Reverse Lock Plate Bracket 32 Bolts Reverse Lock Mechanism 33 Reverse Lock Plate 34 Torsion Spring ...

Page 463: ...ntroller housing Smear the transmission oil onto the oil seal lip Transmission oil Use hypoid gear oil complying with the API classification GL 4 or above SAE 75W 85W Figure 41 MOUNTING THE AIR VENT 1 Smear sealant onto its inserted portion Specified sealant Mobilux EP2 Figure 42 Linear Bearing Air Duct PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 464: ...ear 3 Front Rear Differential Bearing 4 Spherical Washer Planetary Gear 5 Planetary Gear Shaft 6 Adjusting Washer Side Gear 7 Fixing Pin Planetary Gear 8 Side Gear 9 Planetary Gear 10 Driving Gear Odometer 11 Bolts Final Drive Driven Gear and Differential Housing 12 Differential Assembly 4 5 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 465: ... Engage two planetary gears with side gears behind the spherical washers on the backs of the planetary gears When rotating any of these gears you shall put it into appropriate place 3 Insert the planetary gear shaft Figure 44 Figure 45 4 Measure the clearances between side gear and planetary gear Standard value 0 025 0 150 mm 5 If any measured clearance does not measure up please select and instal...

Page 466: ...L QR519 TRANSMISSION 32 FIXING THE LOCK PIN Install the fixing pin to the place as shown in Figure 43 Figure 47 Differential Housing Fixing pin Planet gear shaft PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 467: ... 48 1 Clutch Housing 2 Collar 161410 3 Oil Drain Channel 4 Fixing Pin 5 Front Rear Differential Bearing Outer Ring 6 Oil Seal Differential 7 Magnet 8 Front Output Shaft Bearing Outer Ring 9 Oil Seal Input Shaft 10 Clutch Housing Assembly PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 468: ...CHERY A520 SERVICE MANUAL QR519 TRANSMISSION 34 TRANSMISSION HOUSING ASSEMBLY 1 2 3 4 5 6 7 6 3 11 10 9 8 12 Figure 49 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 469: ... Limiting Plug 9 Fixing Pin Gearshift Housing 10 Linear Bearing 11 Oil Receiving Tube 12 Transmission Housing Assembly NOTICE FOR INSTALLATION Installation of linear bearing Press the linear bearing in so as for it to be aligned with the housing surface and make sure that the model number is inscribed in the position as shown in Figure 46 Figure 50 PDF created with pdfFactory Pro trial version www...

Page 470: ...SION 36 REAR COVER ASSEMBLY 4 3 2 1 5 Figure 51 1 Rear Cover 2 Oil Drain Tube for Input Shaft 3 Reverse Synchronizer Cone 4 Screw Reverse Synchronizer Cone 5 Rear Cover Assembly PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 471: ...ar bearing retainer and their tightening torque is 10 5N m 4 When installing the input shaft oil seal and differential oil seal you shall smear lubricating grease onto their lips and use a special tool to press them into the transmission housing sufficiently IX AIR EXHAUST METHOD OF HYDRAULIC CLUTCH QR519MHA transmission adopts full hydraulic clutch mechanism and thus its air exhaust can be easily...

Page 472: ...o start the engine by using synchronizer to force into gear in the condition of flameout neutral gear otherwise the service life of the synchronizers will be reduced 5 No flap i e rapid push and release is allowed for gear shifting and you shall hold the shift lever all the time during the procedure so as to considerably reduce the sliding friction time of synchronizer locking ring as well as thei...

Page 473: ...n junction surface s damage due to knocking Check and repair Oil leakage Damaged differential bearing Replacement Improper clutch adjustment and incomplete release Adjustment Improper gearshift transmission system adjustment or movement obstruction occurring Check and adjust Difficult to implement gear shift Synchronizer ring s fails to work Replacement Worn synchronizer gear sleeve s or tooth con...

Page 474: ...for 1st 2nd gears 2 11 Synchronizer ring for 3rd 4th 5th gears 3 12 Seal gasket for clutch and transmission housings 1 13 Seal gasket for gearshift mechanism and transmission housings 1 14 Snap ring for 3rd 4th synchronizer 1 15 Snap ring for 1st 2nd synchronizer 1 16 Snap ring for 5th synchronizer 1 17 Snap ring for reverse fork shaft 1 18 Interlock plate snap ring 3 19 Dust proof oil seal for re...

Page 475: ...ing the time limit it is liable to mistakes or omissions Please contact with Service Technology Dep of sales company if any unconformity is found TEL 0553 5922392 FAX 0553 5840795 1 NO of relay circuit 30 Coming from storage battery 15 Controling by ignition switch ACC Ignition switch radio set 31 Ground 58b Luminous regulating line ...

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