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Chery S18D Service Manual

I. Removal, Installation & Maintenance of Front Bumper

 

                                                                                 

 

 

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 26

   

1. Preparations

 

                                                                                                                                             

 

 

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 26

   

2. Precautions

 

                                                                                                                                               

 

 

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 26

   

3. Removal Procedure

 

                                                                                                                                  

 

 

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 26

   

4. Installation Procedure

 

                                                                                                                              

 

 

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 27

   

II. Removal, Installation & Maintenance of Rear Bumper

 

                                                                                 

 

 

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 27

   

1. Preparations

 

                                                                                                                                             

 

 

............................................................................................................................................

 

 27

   

2. Precautions

 

                                                                                                                                               

 

 

..............................................................................................................................................

 

 27

   

3. Removal Procedure

 

                                                                                                                                  

 

 

.................................................................................................................................

 

 27

   

4. Installation Procedure

 

                                                                                                                              

 

 

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 28

   

Chapter V Removal and Installation of Outside Lamps

 

                                                                      

 

 

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 29

   

I. Preparations 

 

                                                                                                                                                     

 

 

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 29

   

II. Precautions

 

                                                                                                                                                      

 

 

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 29

   

III. Removal Procedure of Headlamp

 

                                                                                                                  

 

 

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 29

   

IV. Removal of Front Fog Lamp

 

                                                                                                                          

 

 

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 30

   

V. Removal of Rear Fog Lamp

 

                                                                                                                            

 

 

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 31

   

VI Removal of Tail Lamp

 

                                                                                                                                    

 

 

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 32

   

. Removal of License Lamp 

Ⅶ

 

                                                                                                                           

 

 

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 32

   

. Installation & Adjustment of Headlamp

Ⅷ

 

                                                                                                      

 

 

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 33

   

. Installation of Tail Lamp

Ⅸ

 

                                                                                                                                

 

 

...............................................................................................................................

 

 34

   

Chapter VI Removal and Installation of Vehicle Ceiling

 

                                                                      

 

 

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 35

   

I. Preparations

 

                                                                                                                                                      

 

 

.....................................................................................................................................................

 

 35

   

II. Precautions

 

                                                                                                                                                      

 

 

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 35

   

III. Removal and Installation of Sun Visor 

 

                                                                                                         

 

 

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 35

   

IV. Removal and Installation of Ceiling Armrest

 

                                                                                                

 

 

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 35

   

V. Removal and Installation of Front Ceiling Lamp

 

                                                                                           

 

 

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 36

   

VI. Removal and Installation of A-pillar Panel

 

                                                                                                   

 

 

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 36

   

VII. Removal and Installation of B-pillar Panel 

 

                                                                                                 

 

 

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 37

   

VIII. Removal and Installation of C-pillar Panel

 

                                                                                                

 

 

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 37

   

IX. Removal and Installation of Vehicle Ceiling

 

                                                                                                 

 

 

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 38

   

Chapter VII Removal and Installation of Instrument Panel & Instrument Panel Crossbeam

 

          

 

 

.........

 

 40

   

I. Removal of Instrument Panel

 

                                                                                                                           

 

 

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 40

   

1. Removal Procedure

 

                                                                                                                                  

 

 

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 40

   

2. Installation Procedure

 

                                                                                                                              

 

 

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 45

   

3. Methods for Clearing Instrument Maintenance Indicator

 

                                                                       

 

 

......................................................................

 

 45

   

II. Removal of Instrument Panel Cross Beam

 

                                                                                                     

 

 

....................................................................................................

 

 45

   

1. Removal Procedure

 

                                                                                                                                  

 

 

.................................................................................................................................

 

 45

   

2. Installation Procedure

 

                                                                                                                              

 

 

.............................................................................................................................

 

 47

   

Chapter VIII  Air Conditioning System

 

                                                                                                  

 

 

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 48

   

I. System Constitution

 

                                                                                                                                         

 

 

........................................................................................................................................

 

 48

   

II. Removal of Evaporator Assembly

 

                                                                                                                  

 

 

.................................................................................................................

 

 48

   

3

Summary of Contents for S18D

Page 1: ...Chery S18D Service Manual Body Accessories Dimensions After Sales Service Department of Chery Automobile Co Ltd...

Page 2: ...ions 8 3 Removal and Installation of the Seat belt of Front Seats 8 4 Removal and Installation of the Seat belt of Rear Seats 10 II Removal and Installation of Seats 11 1 Preparations 11 2 Removal of...

Page 3: ...tallation of Vehicle Ceiling 35 I Preparations 35 II Precautions 35 III Removal and Installation of Sun Visor 35 IV Removal and Installation of Ceiling Armrest 35 V Removal and Installation of Front C...

Page 4: ...of Mode Air Door Related Mechanism 52 6 Removal and Installation of Blend Air Door Related Mechanism 53 7 Removal and Installation of Int Ext Air Door Motor Related Mechanism 54 8 Removal and Installa...

Page 5: ...e washer fluid hose 3 1 2 Press down the water nozzle clip under the engine hood and then push it up while removing the noozle outward 3 2 Installation Procedure The installation procedures are revers...

Page 6: ...e engine hood lock assembly and remove the cable 5 2 Installation Procedure The installation procedures are reverse to those for removal 6 Removal Adjustment of Hood Cable 6 1 Removal Adjustment Proce...

Page 7: ...ence and remove the trunk lid interior trim board 2 2 Remove the fixing bolts of license plate lamp trim board with 10 socket wrench remove the license plate lamp trim board 2 3 Installaiton of trunk...

Page 8: ...torque 12 1N m 3 1 4 Remove the luggage boot lock 3 2 Installation Procedure The installation procedures are reverse to those for removal Installation precautions check if the lock cylinder has deform...

Page 9: ...shall not be throwed away 4 2 Installation Procedure The installation procedures are reverse to those for removal Note the clearance between the lock cylinder and door sheet metal 5 Removal of Rear W...

Page 10: ...posite to wiper motor steering shaft 6 Removal of Rear Wiper Motor 6 1 Removal Procedure 6 1 1 Remove the rear wiper blade and arm seat cover 6 1 2 Use a 10 socket wrench to loosen the nut above the m...

Page 11: ...S18D Service Manual 6 2 Installation Procedure The installation procedures are reverse to those for removal Notice to install the wiper seat sealing ring in place to avoid water leakage of rear windsh...

Page 12: ...seat belts clean and free of oil and check them for any damage 3 Removal and Installation of the Seat belt of Front Seats 3 1 Remove the front and rear door weather strip 3 2 Pry out the front doorsi...

Page 13: ...anel 3 6 Remove the pillar B upper panel 3 7 Remove the seat belt retractor assembly with 17 socket wrench Torque 50 10N m 3 8 Remove the seat belt guide plate with cross screwdriver 3 9 Remove the se...

Page 14: ...illar lower panel and front rear doorsill pressure plate shall be even and less than 1 mm 4 Removal and Installation of the Seat belt of Rear Seats 4 1 Remove the fixing screw of rear doorsill with cr...

Page 15: ...removal Note 1 Keep the seat belt clean and away from oil check if there is damage of seat belt adding screw thread sealant during the mounting of seat belt fixing bolt 2 The pillar panel shall be fit...

Page 16: ...to remove the seat bolts Torque 25 3N m 2 2 Pull out the seat connector and remove the seat 3 Removal of Rear Seats 3 1 Lift up the seat cushion and remove the fixing bolts of the rear seat cushion wi...

Page 17: ...moval Note keep the cleanness of vehicle interior trim parts during removal and installation avoid the trim parts surface scratch when moving the seat III Removal and Installation of Central Console 1...

Page 18: ...he gearshift handle in anti clockwise direction to remove it 2 5 Lift up the rear part of center console and pull the rear part to remove the center console 3 Installation Procedure The installation p...

Page 19: ...the upper lower panel of pillar B Refer the removal of seat belt 2 4 Pry out the footreast cover by slotted screwdriver 2 5 Remove the footrest with 10 socket wrench 2 6 Remove the pillar A lower pane...

Page 20: ...he vehicle and take out the harness connected with the seats and then press the vehicle carpet besides the middle passage tightly 3 2 Let the seat holes exposed 3 3 Spread the carpet under foot pedal...

Page 21: ...otection to prevent from accidents 2 2 Disconnect the battery to prevent damage for electrical equipments 2 3 To prevent glass from being damaged pay attention to take correct steps during removal and...

Page 22: ...move the five fixing screws of door inner panel with cross screwdriver two screws on panel front surface and three screws on panel side surface 3 6 Pry out the protective cover of door inner armrest g...

Page 23: ...out the exterior rear view mirror adjusting switch only driver side and window regulator control switch connector 3 10 Pry out the door inner panel from edge with the plastic screwdriver 3 11 Pull off...

Page 24: ...lator switch connector lower the window glass at a proper position and remove the two screws that fix the glass 3 15 Take out the glass carefully 3 16 Remove the five screws that fix the window regula...

Page 25: ...four fixing screws of the hinge that fix the vehicle door remove the door Torque 32 3 N m 4 Installation Procedure The installation procedures are reverse to those for removal Note The removal proced...

Page 26: ...ear door inner triangular block with plastic screwdriver 3 2 Pry out the protective cover of door inner armrest groove with slotted screwdriver expose the fixing screw 3 3 Remove the fixing screw of t...

Page 27: ...ice Manual 3 5 Remove the fixing screws of door panel on its front and side with cross screwdriver 3 6 Pry out the door inner panel from edge with the plastic screwdriver 3 7 Pull off the door inner h...

Page 28: ...he door outside handle fixing nuts with 10 socket wrench remove the door outside handle 3 11 Connect the battery and lower the window glass at a proper position let the glass fixing screws be exposed...

Page 29: ...indow regulator 3 13 Remove the fixing bolts of rear door and hinge with 10 socket wrench remove the rear door assembly Torque 32 3 N m 4 Installation Procedure The installation procedures are reverse...

Page 30: ...ons 2 1 Wear necessary appliance for labor protection to prevent from accidents 2 2 Try to avoid scratching the paint of the bumper during the removal operation 3 Removal Procedure 3 1 Open the Engine...

Page 31: ...Note the air intake grille can be replace directly without removing the lower bumper 4 Installation Procedure The installation procedures are reverse to those for removal II Removal Installation Maint...

Page 32: ...s of reverser radar and left right rear fog lamp Note notice to avoid the wiring harness being pulled by bumper when removing the wiring harness connector 3 6 Remove the rear bumper rod the rear bumpe...

Page 33: ...nt surface of the bumper when removing it 2 3 Pay attention not to scratch the headlamp surface during removal or placing it III Removal Procedure of Headlamp 3 1 Remove the headlamp wiring harness co...

Page 34: ...take out the high low beam bulb 3 8 Pull off the front position lamp wirning harness connector and remove the front position lamp bulb 3 9 Screw off the turn signal lamp holder by hand and can replace...

Page 35: ...d and turn the clip over to take out the high low beam bulb V Removal of Rear Fog Lamp 5 1 Remove the rear bumper see the removal and installation of rear bumper for details 5 2 Remove the rear fog la...

Page 36: ...ee nuts fixing tail lamp in luggage boot compartment with 10 socket wrench 6 3 Pull off the tail lamp wiring harness connector and remove the tail lamp assembly 6 4 Rotate the bulb seat anti clockwise...

Page 37: ...b holder 4 Low beam left right adjusting nut 5 Low beam lamp rear cover 6 Low beam lamp up down adjusting nut 8 3 Adjustment of Headlamp 8 3 1 Pay attention to law and regulations and verify the follo...

Page 38: ...tion procedures of tail lamp are reverse to those for removal 9 2 Function of tail lamp 9 2 1 Front view 1 Brake lamp position lamp one bulb has two filaments 2 Turn lamp 3 Reverse lamp 9 2 2 Rear vie...

Page 39: ...scratched III Removal and Installation of Sun Visor 1 Removal Procedure 1 1 Use a cross screwdriver to remove the screws on sun visor in left of the driver s cab and remove the sun visor 1 2 The remo...

Page 40: ...Align a slotted screwdriver with the groove along the ceiling lamp edge to pry it open Note Do not scratch part surface 1 2 Remove the three fixing screws of the front ceiling lamp 1 3 Disconnect the...

Page 41: ...anel 2 Installation Procedure The installation procedures are reverse to those for removal VII Removal and Installation of B pillar Panel 1 Removal Procedure 1 1 Remove the B pillar lower panel See Re...

Page 42: ...1 1 Remove the left right sun visors and their fixing seat See Removal and Installation of Sun Visor 1 2 Remove the front ceiling lamp Refer to removal and installation of front ceiling lamp 1 3 Remo...

Page 43: ...Chery S18D Service Manual 1 7 Remove the vehicle ceiling 2 Installation Procedure The installation procedures are reverse to those for removal 39...

Page 44: ...ch cross screwdriver slotted screwdriver and etc 1 Removal Procedure 1 1 Remove the center console See the removal and installation of center console 1 2 Remove the three fixing screws of instrument p...

Page 45: ...1 5 Remove the two fixing screws connecting the dashboard and instrument panel body with cross screwdriver 1 6 Pry out the dashboard body with slotted screwdriver 1 7 Pull off the harness connector o...

Page 46: ...le 1 10 Pry out the central control panel shield with slotted screwdriver 1 11 Pull off the A C regulating switch harness and central control panel switch harness Note during installation notice the c...

Page 47: ...dio cassette player 1 14 Loosen the two bolts besides the name car box with 10 socket wrench 1 15 Pry out the speaker shield with slotted screwdriver 1 16 Remove the speaker body with slotted screwdri...

Page 48: ...ket wrench 1 19 Remove the panel on two sides of instrument panel body 1 20 Remove the fixing screws on two sides of instrument panel body with cross screwdriver 1 21 Remove the fixing bolt between bo...

Page 49: ...indscreen or affects its installation and the clearance shall be even The clearances between the instrument panel and either sides of the vehicle body should be consistent and meet the requirements fo...

Page 50: ...nd engine wiring harness 1 5 Remove the connectors of A C wiring harness and ceiling wiring harness remove all ground points of instrument panel wiring harness 1 6 Remove the fixing bolt of anti theft...

Page 51: ...panel cross beam top cover and vehicle body with 10 socket wrench Torque 25 2N m 1 10 Remove the four bolts on the lower fixing points of middle support on instrument panel cross beam with 10 socket w...

Page 52: ...s Tools cross screwdriver clamp pliers socket wrench and etc Auxiliary material refrigerant antifreeze sponge rubber strip 2 Removal and Installation Procedures 2 1 Use coolant recycling machine to re...

Page 53: ...s to remove the inlet outlet water pipes of the evaporator and pull out the pipes Note Coolant will flow out from the water pipe pay attention to recycle the coolant 2 6 Loosen off the 3 fixing nuts t...

Page 54: ...for removal III Removal and Installation of Evaporator Interior 1 Preparation of Tools Cross screwdriver slotted screwdriver inner spline wrench and etc 2 Removal and Installation of Blower 2 1 Remov...

Page 55: ...ss screwdriver to remove the fixing screws on speed regulation module 3 1 3 Pull out the speed regulation module 3 2 Installation Procedure The installation procedures are reverse to those for removal...

Page 56: ...sponge seal around the housing is disposable 4 2 Installation Procedure The installation procedures are reverse to those for removal After the installation the system should be evacuated proper press...

Page 57: ...e the control motor 5 2 Installation Procedure The installation procedures are reverse to those for removal 6 Removal and Installation of Blend Air Door Related Mechanism 6 1 Removal Procedure 6 1 1 P...

Page 58: ...rse to those for removal 7 Removal and Installation of Int Ext Air Door Motor Related Mechanism 7 1 Removal Procedure 7 1 1 Pull out the motor connector 7 1 2 Remove the fixing screws of control motor...

Page 59: ...orator top cover 8 1 4 Remove the evaporator core 8 2 Installation of evaporator assembly The installation procedures are reverse to those for removal After the installation the system should be evacu...

Page 60: ...pointed and the clamping force of the electrodes should be increased and when doing gas shielded welding the welding current should be further intensified Do not weld the air conditioning parts or tr...

Page 61: ...f inside plates outside plates glass guide rails window frame reinforcing plates lock mounting plates hinges reinforcing plates impact bar assemblies and so on The figure below is a typical structure...

Page 62: ...nce Generally speaking the causes of door panel damages are related to the following 4 aspects structure design defects manufacturing defects chemical erosion and physical damage And the most common d...

Page 63: ...irons or spoon shaped irons tommy bars flat punches and so on can be used for primary repairs For enclosed metal panels or parts that are difficult to access from the backs other tools can be used fo...

Page 64: ...ron to distribute the impact of the hammer over a larger area 3 Restore the dent with a dent smoother The dent smoother is applied to the inner side of the metal panel and it is used for the dents tha...

Page 65: ...ea Wavy edge Heating position Triangle heatin Fig 11 Stretched area Spot heating Fig 1 0 3 Cooling contracting way When the flame is taken away proper cooling ways should be chosen according to the st...

Page 66: ...prying tool and heat the dead wrinkles one by one with a welding torch at the same time Finally all dead wrinkles are pried up and eased and converted into live wrinkle 3 Beat and smooth the live wri...

Page 67: ...1 0 5 4 1 0 0 7 Rear side windshield and ceiling 4 5 1 8 Rear door outside handle and rear door 2 0 5 0 9 Rear side windshield and back door 4 5 5 10 Tail lamp and fender 2 0 5 11 Rear bumper and fend...

Page 68: ...2 Left Rear Axonometric Drawing No Clearance position Clearance value mm Flatness value mm 1 Rear bumper and tail lamp 2 1 2 Back door and tail lamp 5 0 5 0 7 0 5 1 0 3 Rear fog lamp and rear bumper...

Page 69: ...B Front bumper cross beam installation hole 820 C D Headlamp installation hole 624 E F Headlamp installation hole 1323 7 G H Headlamp installation hole 1283 2 I J Engine right mounting bracket hole 13...

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