Chery A15 2006 2010, A15 2003, A15 2004, A15 2005 User Manual

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AIR CONDITIONER SYSTEM

AIR CONDITIONING SYSTEM OVERVIEW … … … … … … …… …… …… … U-2

REFILLING OF REFRIGERANT AND REFRIGERANT OIL … … … … … … … U-6

A/C SYSTEM COMPONENTS … … … … … … …… … … … … … …… ……… U-14

FAILURES AND SHOOTING ANALYSIS SHEET … … … … … … …… … … … U-20

PRECAUTIONS ON THE SECURITY OF A/C SYSTEM … … … … ……… …U-21

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Evaporator

A/C Control System

Warm air radiator

Condenser

d Circuit

Compressor

AIR CONDITIONING SYSTEM OVERVIEW

Based on its function, the Chery A15LHD air conditioning unit may be divided into such five basic components as the refrigeration system, heating system, ventilation system, control system and air purification system.

1. Refrigeration system It is available to cool the air inside the vehicle based on the refrigeration principle of vapor compression refrigerator. The temperature of evaporator as the cold source is lower than the dew-point temperature of air, so the refrigeration system also play the role of dehumidification and air purification. The refrigeration system of Chery's electronic fuel injection type engine adopts the coolant R134a. As shown in the figure, the refrigeration system mainly consist of the compressor, condenser, expansion valve, evaporator and etc. In the evaporator, the coolant fluid absorbs the heat from the air inside vehicle and is gasified to the low-pressure, low-temperature coolant vapor, and then is inhaled into the compressor.

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Condenser

Fan

The coolant vapor will be compressed by the compressor as the high-temperature, high-pressure gas which enters into the condenser. In the condenser, the coolant is cooled by the ambient air, and condensed into the fluid after emitting its heat outwards, then the moisture content is filtered and removed from the fluid via the fluid reservoir. The high-temperature, high-pressure coolant fluid is throttled down through the expansion valve (installed in the inlet pipe of evaporator) to reduce its pressure and temperature, and then the fluid enters into the evaporator. The low-temperature and low-pressure coolant fluid also absorb the heat from the inside of vehicle, and gasifies again to the low-temperature and low-pressure coolant vapor, and then is inhaled into the compressor. In such a manner, the coolant cycles recurrently to make the indoor temperature of vehicle reduce. The pipelines for coolant are shown in the figure below:

Compresso

Evaporator

Drying

Expansion

Valve

Bottle/Collector

2. Heating system It adopts the engine coolant as the heat source and introduces the coolant into the radiator located at the compartment to heat the indoor air via the blower, and, at the same time, it is also used to defrost and defog the front windscreen.Chery A15LHD’s air conditioning unit adopts the reheating mixed type unit, the heating system of which is used not only to individually heat the circulating air from the inside of vehicle or the fresh air from the outside, but also to firstly cool these two kinds of airs and then heat the whole or part to obtain the air temperature required. It is available to dehumidify the air, and also to filter the air so as to get the clean air with desired humidity.

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3. Ventilation system Apart from the cool and heat the air inside the vehicle, the centrifugal blower is also used to change and ventilate the air inside the vehicle. The ventilation system consists of the air filter, air inlet, air duct, vent and etc. The system introduces the fresh air from the outside of vehicle into the inside while the ventilation and discharge port extracts the vitiated air from the inside to the outside. Chery A15LHD adopts the natural ventilation and forced ventilation. The open/close fresh air inlet is controlled by the fresh/circulating air vacuum valve.

During the natural ventilation, the fresh air enters into the vehicle from the air inlet fixed under the front windscreen (positive pressure area), and gets into the trunk from the seat belt notch on the trunk cover, then passes across the vents (negative pressure area) on the body rear skirt, trunk lining, rear side beam and finally discharges to the atmosphere. Due to the movement of air in the rear body compartment, it plays a good role to defrost the rear windows. In addition, the whole process is conducted without pressure, so the air changing doesn’t create any noise and has nothing with the driving speed.

And during the forced ventilation, in case that the fresh air doesn’t pass through the heating radiator (the mixed gate closed) after the air is pressurized by the blower, the air will enter

into the vehicle via all air ducts, and then discharge along the same route as that of natural ventilation to the atmosphere.

An individual type casing system with blower

1. Restrictor damper 5. Fresh/recirculated air door 9. To panel

2. Heater core 6. Recirculated air 10. A/C defrost damper

3. Blower motor 7. Evaporator core 11. To defroster

4. Fresh air 8. Air mix damper 12. To bottom outlet

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Air-Conditioner Compressor

Air-Conditi

vaporator Assembly

on Harness

4. Control system The control system mainly consist of the electrical component, vacuum hose and control mechanism. On one side, it is available to control the temperature and pressure of refrigeration and heating system, and, on the other side, it is also used to control the temperature of air inside the vehicle, the blowing rate and direction.

5. Air purification system The air purification system mainly indicates the dust filter, which is used to filter the outside air inhaled, and continuously discharge the vitiated air generated inside the vehicle to make the air inside the vehicle clean and hygienic.

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REFILLING OF REFRIGERANT AND REFRIGERANT OIL

Caution:

· If there are some moist materials or other foreign materials circulating in the refrigeration system, the cooling performance of the refrigeration system will considerably decrease and generate the abnormal noise. So, after any refrigeration and circulation part is removed, the openings shall be immediately plugged to avoid the entrance of moist materials or other foreign materials.

· If the service reservoir is used to refill the refrigerant, it is very dangerous to open the valve located at engine high pressure side. During the operation, the pressure inside the service reservoir will rise, which may cause the explosion of the reservoir, what’s more, the metal fragment from explosion and the refrigerant sputtered will be serious harmful to the operators. Thus, it is recommended to pay more attention to the close of the high-pressure-side valve during the course of engine operation.

Low Low pressur

Charging the refrigerant

1-Refrigerant tank

2-Unlock valve

3-Low-pressure manual valve

4-High-pressure manual valve

5-Low-pressure gauge

6-High-pressure gauge

7-Connect to low-pressure service valve hose

8-Connect to high-pressure service valve hose

9-A/C compressor

High pressur

pressur

High pressur

Caution:

· Take care not to exceed the starndard value(s) specified in the technical specification during refilling the refrigerant into the refrigeration system. If exceeding the standard values, it will considerably reduce the efficiency of the A/C system, and even damage the refrigerant recirculation parts.

· In accordance with the regulation, the refrigerant shall be refilled from the high-pressure side at all time. If it is refilled from the low-pressure side, the valve leaf of A/C compressor will loosen and give off the abnormal noise.

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1. Precautions for Refrigerant Concerned

(1) To avoid the refrigerant contacting with

your skin, wear rubber gloves and safety goggles while handling the refrigerant.

(2) Handle the refrigerant concerned at a well

ventilated location. Since the refrigerant is a colorless gas at room temperature and its density is greater than that of air, the refrigerant will deposit in the maintenance location, which may easily cause the maintenance personnel choked.

(3) Do not allow the refrigerant to contact with

fire. Otherwise it may generate the toxic gas.

(4) The O-ring can be applied once only.

(5) Chery model-A15LHD adopts the

refrigerant R134a which cannot be interchanged with R12. Also compressor oils cannot be mixed. During the course of handling, any tool that has touched certain kind of refrigerant must not touch any other kind of refrigerant.

Refrigerant Tank Unlock Valve

1-Butterfly Handle

2-Refrigerant Tank Refilling Valve

3-Plate-shaped Nut

4- Needle Valve

5-Refilling Valve Joint

2. Method to Refill Refrigerant

If the 400g tanked refrigerant is required, a refrigerant tank unlock valve shall be applied (shown in the figure). The operation procedures are as follows:

(1) Before the unlock valve is installed on the

refrigerant tank, turn the butterfly handle 1 in the counterclockwise direction till the needle valve returns back completely.

(2) Turn the plate-shaped nut 3 in the

counterclockwise direction to lift it up to the highest position, and then tighten the valve and the dummy club at the center of refrigerant tank.

(3) Install the intermediate filling hose of

manifold pressure gauge on the joint 5, and then turn the plate-shaped nut in the

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RECEIVER

SEVICE VALVE

clockwise direction and tighten it by hand as possible.

(4) Turn the butterfly handle 1 in the

clockwise direction to make the valve needle 4 in its front end punch a small hole in the dummy club of refrigerant tank.

(5) Turn the butterfly handle 1 in the

counterclockwise direction, which the refrigerant will flow into the manifold pressure gauge along the charging hose.

(6) Then turn the butterfly handle 1 in the

clockwise direction to the lowest position, and it can close down the refrigerant tank again. However, do not detach the unlock valve, otherwise the refrigerant inside the tank will leak out.

3. Refrigerant Refilling Procedures

(1) Connect the manifold pressure gauge to

the refrigerant tank, shown in the picture below.

(2) Unscrew the handle of unlock valve 2 in

the counterclockwise direction to enable the refrigerant to enter the intermediate charging hose. In this case, do not open the handle valves in the both sides.

(3) Unscrew the nuts of intermediate hose of

manifold pressure gauge, and then tighten the nuts of intermediate hose after the air inside the intermediate hose are drained when you see the white refrigerant gas overflow and heard the “fizzle” sound.

(4) Turn on the high-pressure manual valve 4,

shown in the figure below, stand the refrigerant tank 1 upside down so as to let the refrigerant in liquid-state charge into the refrigeration system. In this case, do not switch on the A/C unit to prevent the refrigerant from returning back to the tank.

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LOW-PRESSURE SEVICE VALVE

HIGH-PRESSURE

REFRIGERATION DEVICE

RECYCLING

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200 g or more refrigerants shall be charged every time, and turn the compressor several times by hand after the completion of charging.

(5) Turn off the high-pressure manual valve 4,

shown in the figure below, and turn on the low-pressure manual valve 3 to let the refrigerant in gas-state charge into the refrigeration system. The refrigerant charged from the low-pressure manual valve must be gas-state. If it is liquid state, the liquid hammer phenomenon may appear to damage the compressor. Turn off the low-pressure manual valve when the reading of low-pressure gauge reaches

2.8X105 Pa.

Refrigerant Refilling

Regulated amount:R134a，850±25g

4. Leak Check of Refrigeration System

Three effective methods can be used to check the air tightness of refrigeration system: check with electronic leak detector, soap solution and halogen leak detector.

1) Check with Electronic Leak Detector

As shown in the figure, connect the power supply connector 2 of electronic leak detector 1 to the power supply, and move probe 3 slowly (30 mm/s), which should be placed 3 mm away from the check point. And if any alarming sound is emitted, it means there is a leak phenomenon occurred at that place.

2）Check with Soap Solution

Apply the soap solution to the possible leak position. Observe whether air bubbles appear. If there are air bubbles, it indicates a leaking accident occurs.

3）Check with Halogen Leak Detector

The inspection procedure is described below:

(1) Check the liquid propane capacity in the

1. Electronic leak detector.

2. Power supply connector.

3. Probe

If the leakage occurs at the joints

of refrigeration pipes, the relevant

O-rings shall be replaced.

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Vacuumizing and Charging the Refrigeration Oil

reservoir.

(2) Tighten the propane reservoir 16 to the

leak detector.

(3) Insert a lighting match into lighting device

9, and then slowly turn the adjusting handle 14 in the counterclockwise direction till the torch is lit.

(4) Adjust the flame to smallest. The smaller

the flame, the more sensitive to the leak of refrigerant.

(5)Move suck pipe 3 to the possible leak

position.

(6) Observe the change of flame color. The

flame has no color if there is no leakage. The flame is tint green if there is very small leakage or be blue if there is relatively big leakage, and it will become purple if there is too much leakage.

5. Methods of Refrigerant Oil Charging

There are two methods for refrigerant oil charging: direct charging method and vacuum inhaling method.

1）Direct charging

Remove the oil charging plug 1, and charge the specified model of refrigerant oil.

2）Vacuum inhaling

Vacuumize the refrigeration system to 30psi, and then start to charge the refrigerant oil, the procedures of which are as follows:

(1) Turn off the high-pressure manual valve,

and turn off the auxiliary valve.

(2) Remove the high-pressure side hose from

the manifold pressure gauge, and insert the hose into the oil cup.

(3) Turn off the auxiliary valve to inhale the

refrigerant oil into the refrigeration system from the oil cup.

Low-pressure gauge

Low-pressure manual valve

Vacuum pump

High-pressure gauge

High-pressure manual valve

Low-pressure side hose

auxiliary valve

High-pressure side hose

High-pressure pipe

Oil cup

Air return

Air exhaust

(4) When the refrigeration oils in the cup are

nearly evacuated, immediately turn off the

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auxiliary valve so as to prevent the air from being inhaled into the system.

(5) Connect the high-pressure side hose joint

to the manifold pressure gauge, turn on the high-pressure manual valve, and start up the vacuum pump to vacuumize the high-pressure side hose. And turn on the auxiliary valve to vacuumize for the system to 30psi, and then vacuumize 15 min again so as to remove the air entering into the system together with the oils. In this case, the refrigeration oils are in the high-pressure side, and the oils will return back to the compressor after the operation of the system.

3）Type & amount of refrigerant oil charged

Regulated amount: SP10 type, 150ml.

It is unnecessary to charge the refrigerant oil into the newly-mounted A/C system, and it is required to complement some refrigerant oil only when a certain part is needed to repair or when the vehicle is driven to a specified mileage.

The amount of implementing oil required when replacing parts is as follows: Evaporator and condenser: 30ml. Drier: 20ml. and pipe: 10ml.

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6. Methods of Refrigerant Vacuumizing

It is difficult to pump out the water from the refrigeration system when vacuumizing. But the vacuumizing can reduce the fluidization point of water after the vacuum is generated in the refrigeration system, which enables the water to boil at the lower temperature, and pump out it in the form of steam from the system. Conduct the leak check firstly before vacuumizing. If vacuumizing without the leak check, it is difficult to find out the leaking position after vaccumizing when there is a certain leakage phenomenon. The purpose of vacuumizing is to further check the air tightness of the refrigeration system under the vacuum condition, and prepare for the system’s refrigerant charging. Its procedures are as follows: (1) Connect the high-pressure gauge hose to

the high-pressure service valve joint of refrigerant tank, shown in the figure below, connect the low-pressure gauge hose to the low-pressure service valve joints on the pipe from the evaporator to the A/C compressor, and connect the intermediate hose to the interface of vacuum pump.

(2) Turn on the high- and low-pressure valves

of manifold pressure gauge, and start up the vacuum gauge.

(3) The vacuum pump works for at least 15

min to make the vacuum reading of low-pressure gauge below 30psi . If the vacuum reading can’t be obtained, turn off the manual valves at the high- and low-pressure sides, stop vacuumizing, and check the leaking position.

(4) Turn off the valves, and the gauge needle

doesn’t return back within 10 min, which it is called the vacuum leakage check method. If the vacuum down, it shows that there is a leaking position which can be found out by using a leakage detector.

(5) If the gauge needle doesn’t considerably

1- Connect to low-pressure service valve hose

2- Connect to high-pressure service valve hose

3-Low-pressure gauge

4-High-pressure gauge

5-Low-pressure manual valve

6-High-pressure manual valve

7-Vacuum pump

Low pressu

Vacuumizing

High pressure

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return back within 10 min, it indicates that the system is normal and the refrigerant can be charged into the system.

(6) Restart the vacuum pump, and turn on the

low-pressure valve of the manifold pressure gauge to continuously vacuumize 15 min. Then, turn off the low-pressure valve to stop vacuumizing, and prepare for charging the refrigerant.

7. Refrigerant Recycling Equipment Operation Guide Recycle the refrigerant from the refrigeration device

When the refrigerant is removed from the

OIL BOTTLE

refrigeration device under the following conditions, a recycling receiver shall be applied to recycle the refrigerant. Before the components on the refrigerant pipe are replaced.

DRAINED OIL QUANTITY

When moisture or air enters into the refrigerant pipe. When excessive refrigerants are charged into the system.

WARNING:

(1) When the recycling receiver is required, take care to operate it according to the

requirements of device manufacturer's instructions.

(2) After the completion of recycling work, measure the level of compressor oil recycled so

that the same quantity of oils are added to the refrigeration device in the future.

Operation guide for refrigerant recycling receiver

1. Install the manifold pressure gauge kit on the service valve.

2. Recycle the refrigerant from the refrigeration device.

(a) Connect the intermediate hose to the recycling receiver.

(b) Operate the recycling receiver.

1. After the completion of recycling work, turn off the recycling receiver.

2. Remove the manifold pressure gauge kit from the service valve.

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A/C SYSTEM COMPONENTS

1. Function description of A/C control panel

(1) Blower switch

(2) Temperature control switch

(3) Air-flow distribution switch

(4) A/C ON/OFF

(5) Internal circulation switch

2. Removal/Installation of A/C compressor

(1) Drain off the coolant (see the coolant

recycling procedure)

(2) Loosen the drive belt, and remove it

(3) Remove the air filter and generator

(4) Remove the refrigerator pipes, and pull out

the electromagnetic clutch connector

(5) Remove the two bolts (M10*110) (with

tightening torque of 45±5N·m) used to secure the compressor and its support.

(6) Install it in the reverse order of removal

Compressor Position and Related Performance Parameters:

Chery A15LHD with the electronic fuel injection type engine adopts the SD7V16 type compressor, the performance parameters of which are shown in the table below.

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Swash Plate

Number of cylinders 7

Cylinder diameter (mm) 29．3

Travel (mm)

max

min

Displacement (cm³/r)

max

min

Allowable maximum instantaneous speed

34．2

2．2

161．3

10．4

8000

(r/min)

allowable maximum continuous speed

7000

(r/min)

Coolant R134a

Refrigerant oil (cm3) 115±15

Electromagnetic clutch mass (kg) 2．2

Rated voltage (V) 12

Rated power (W) 48

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The compressor is driven by engine crankshaft pulley via the M belt. When the shift lever on the A/C control mechanism is shifted to the refrigeration position, the electromagnetic clutch of A/C compressor engages, and the compressor pulley make the main shaft and swash plate rotate and then pull the rocking plate to swing. The swinging of the rocking plate pushes the piston to move, which creates the air pumping effect to compress the low-temperature and low-pressure air-state coolant into the high-temperature and high-pressure air-state coolant.

The motion parts of compressor are lubricated using the sputtered refrigerant oil and the oil in coolant. During the operation of compressor, due to the rotation and swing of the swash plate, the refrigerant oil will be sputtered to anywhere. In addition, due to the intersolubility of coolant and oil, when the coolant flows into the compressor, it also carries a part of refrigerant oil which is available to lubricate the motion parts inside the compressor.

ADJUSTMENT OF ELECTROMAGNETIC CLUTCH

1. Use a thickness gauge to measure the clearance between the platen and A/C compressor pulley.

2. Check whether the clearance is in the range specified by the technical specification.

• If it is found that the result doesn’t conform to the requirement of technical specification,

remove the platen, and use one or several shims to adjust the clearance.

Clearance:

0.6mm±0.2mm

3. Removal/Inspection of condenser

(1). Drain off the coolant from the system (see the

coolant recycling procedure)

(2). Remove the front bumper and headlamp crossbeam

assy.

(3). Remove the fluid reservoir and the refrigeration

pipes connecting to the condenser.

Check the condenser:

(1) Check the crack, damage or oily fluid leakage.

·Replace the condenser if any failure above occurs.

(2) Check whether the fender position is blocked by dust or not.

·Clean it if blocked.

(3) Check the bent condition of fender position.

·Use a flat headed screwdriver to straighten the fender

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position if the bent is found.

Installation of Condenser

(1) Use some self-tapping screws to secure the

condenser and radiator, and assemble the related screw bush and spacer, with the tightening torque of 6±0.6N·m;

(2) Use the bolts (M6) and spacer to secure the

condenser support on the front crossbeam, with the tightening torque of 1.5±0.15N·m;

(3) Assemble the integrated condenser-radiator into the

related fixing holes;

(4) Use spacer, shim block and two nuts to fasten the

condenser and front crossbeam, where the tightening torque of nut is 1.5±0.15N·m.

The condenser is designated to cool the coolant vapor discharged from the compressor and condense the vapor to make it give off its heat and become to the coolant fluild.

Chery A15LHD adopts the serpentine condenser, as shown in the figure. The condenser is secured with engine radiator in a row, and there is an axial fan, which is driven by a DC motor, behind them to forcedly cool the condenser and radiator.

Introduction to the fluid reservoir:

Removal/Installation (see the Removal of Condenser)

Chery A15LHD’s fluid reservoir is located under the condenser (i.e., the outlet of condenser), the structure of which is shown in the figure.

In fact, the fluid reservoir is a pressure container used to store the coolant, and it is available to delivery the fluid-state coolant to the expansion valve at a specified flow rate. The filter screen of fluid reservoir is applied to filter the all kinds of foreign materials from the coolant. The drying agent silicon oxide with powerful water absorptivity is filled in the drying unit, which is used to absorb the water content in the coolant. In addition, a fusible plug is also installed on the reservoir. If the poor heat emission of condenser or other causes result the rapid rise of temperature and pressure of the

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refrigeration system, the fusible plug will metal so as to drain off the high-temperature and high-pressure coolant when the temperature and pressure inside the reservoir reach the specified value, which protects the refrigeration system.

4. Introduction to the expansion valve and pressure

switch

1) Expansion valve

Chery A15LHD adopts the traditional thermo-expansion valve, as shown in the figure, fixed on the inlet/outlet pipes of evaporator. The temperature sensor inside the expansion valve adjust the opening of ball valve in accordance with the temperature of coolant located at the evaporator outlet, the purpose of which is to control the flow rate of coolant.

2) Pressure switch

Chery A15LHD’s A/C pressure switch adopts the dual-pressure (high and low pressures) and four-wire pressure switch which is installed on the high pressure pipe located at the front end of expansion valve, with 50 PSI or more of low-pressure CLOSE operation and 220 PSI or more of high-pressure CLOSE operation

5. Removal/Installation and inspection of evaporator

(1) Drain off the coolant from the system (see the

coolant recycling procedure)

(2) Remove the expansion valve

(3) Remove the instrument panel (see the

Disassembly/Assembly of Instrument Panel)

(4) Remove the control panel trim plate, and 4

self-tapping screws used to secure the control panel and console. (tightening torque of 1.5±0.2N·m)

(5) Remove 1 bolt (M8*25) and 4 nuts secured with the

steering crossbeam and front side respectively (tightening torque of 3.5±0.2N·m) from the fixed evaporator.

(6) Remove the four bolts from the evaporator.

Inspection of evaporator:

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(1) Check the crack, damage or oily fluid leakage.

·Replace the evaporation unit if any failure above

occurs.

(2) Check the bent of fender.

·Use a flat headed screwdriver to straighten it if a bent

is found.

The Chery A15LHD adopts the tube-fin type evaporator which is installed in the air conditioning unit assy. under the instrument panel.

The function of evaporator is opposite to that of condenser. After expanded in the expansion valve, the coolant fluid absorbs the heat inside the vehicle from the evaporator, and evaporates to the coolant gas, then enters into the compressor to circulate.

Introduction to the evaporator temperature sensor (thermostat):

The evaporator temperature sensor used by the Chery A15LHD is the heat-sensitive tube mechanical type temperature regulator, which is closed when the working temperature is adjusted to 4 or more while ℃ disconnected when adjusted to 4 or below. Its ℃ installation position is just under the evaporator, as shown in the figure.

The tightening parameters of A/C pipe fasteners

Inner hexagonal head bolt (M10) secured in the compressor: 30N•m; Inner hexagonal head bolt (M6) secured in the expansion valve: 7N•m; To connect with condenser inlet pipe and tighten the nuts: 32 N•m;

To connect with condenser outlet pipe and tighten the nuts: 11.9 to 13 N•m;

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FAILURES AND SHOOTING ANALYSIS SHEET

1. Precautions on A/C system installation

(1) For the pipes fixed using the fixing nuts, two

wrenches must be applied to ensure that the pipes don't deform or break;

(2) Do not use the compressed air to clean the pipes,

and the nitrogen or coolant gas is available;

(3) Correctly assemble it, and check the tightening

torque of all connections as required;

(4) Check all parts to ensure that they aren’t damaged

and all adjacent parts don’t interfere each other;

(5) Conduct the leakage test to ensure there is no

leakage in the A/C system.

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PRECAUTIONS ON THE SECURITY OF A/C SYSTEM

Coolant treatment

1. The operator shall pay more attention to prevent the coolant fluid from spraying into

your eye or on your skin because the fluid-state coolant is very dangerous. Only one drop of coolant will cause your skin to be damaged partially if it drops up the skin of the skin. You must put on your grooves and protective goggles. When the coolant sprays into your eye or on your skin

(a) Use the cold water to clean those parts

(b) Do not wipe your eye or skin

It is recommended to use such equipment as the recovered, recycling, or reused equipment. If there is any emergency system failure, it is recommended that the equipment is placed on a ventilation treatment site before the implementation of the equipment maintenance service.

2. Do not dispose the coolant located at a closed place or near fire. If the coolant gas contacts

with sparks or the similar heat source (such as: cigarette or heater), it will generate the toxic gas.

Storage of coolant A6E851001039W02

1. The coolant shall be stored in the high-pressure resistance equipment, and take care to

slightly place the fluid reservoir to prevent the reservoir from being impacted by some sharp materials. Heating the coolant fluid reservoir or taking it near the fire will make it explode, and the metal fragment generated and the sputtered fluid-state coolant will cause the serious injury to people. It is recommended to store the coolant under the environment of 400C (1040F) below.

Safety Notices

1. Do not sit inside the vehicle which operates at the idle speed for a long time, and also do

not leave a child in the vehicle.

2. Switchover the air conditioner to the external circulation mode and inhale the fresh air

into the vehicle from the outside, and change the blower switch to the High-Speed position when the engine has operated in an unclosed environment for a long time.

3. Avoid the open of luggage boot cover during driving because the gas emitted from the

engine may enter into the vehicle. If the boot cover must be opened, please close all windows, and change the air conditioner to the external circulation mode to inhale the fresh air into the vehicle from the outside.

4. Do not open the high-pressure valve of manifold pressure gauge during the operation of

compressor. If the high-pressure valve is opened, the coolant will flow in the reverse direction and cause the fluid reservoir to be broken.

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Coolant shortage treatment

·If it is found that there is the coolant shortage during checking the failure, it is

recommended to add the coolant. The reason is: there is the difference between the pressure values indicated by the different pressure gauges, so it is difficult to add the coolant with accurate quantity in accordance with the pressure reading. If the coolant added is excessive or insufficient, it may cause a series of negative effects, such as: to damage the coolant recycling parts, or, to reduce the refrigeration effect. Thus, if it is found that the coolant is insufficient, it is recommended to completely drain off the coolant from the coolant circulating pipes, and then add the specified quantity of coolant.

Compressor oil treatment

·For this model of vehicle, it is recommended to use the SP10 model compressor oil;

otherwise it may be available to regulate the compressor.

·Take care not to spray the compressor oil on the surface of the vehicle during the maintenance operation. Thus, if this case occurs, immediately wipe and clean it, otherwise the compressor oil will damage the paintwork on the surface of the vehicle.

·Engine oil shall absorb the moisture.

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Relay

Layout Diagram Of Central Electrical Box

(Under The Steering Wheel)

A/C Clutch

ABS

Fuse

ABS

Fuse

Sunroof

Taxi

License Lamp

Ceiling Light

Trunk Lamp

Audio Equ ipment

Headlamp Switch

Rear W

indow Heating

Instr

ument

Wiper

A/C

Fog Lamp

Horn

Brake Lamp

Thermo

Sensitive Switch

Win do w R eg ul ato r

/Central Control Lock

Cigarette Lighter

Malfunction Alarm Lamp

Instrument

Back-Up Lamp

Mileage Sensor

Wiper Relay

Emergency

Alarm Relay

Burglar Alarm

Electric Rea rview Mirror

Fuse Layout Diagra

m Of Central Electrical Box

(Under The Steering Wheel)

A/C clutch

Sunroof, Taxi

License Lamp

Top LampTrunk Lamp

Fog Lamp

Window Regulator

Thermo

Sensitive Switch

Brake Lamp

Burglar Alarm

Window Regulation

Back-Up Lamp

mileage Sensor

Layout Diagram Of Relay

Fuse

Radiator Fan Control

(1)

Side Of Carwash Container

Low Speed

High

Speed

Low Speed

High

eed

Relay

Note: For Dual

Speed Fan, Use 50a Fuse For High Speed.

Layout Diagram (2)

Of Fuse In Relay Box

Right Of Front Engine Compartment

Fuse For Left High

Fuse For Left

low

Fuse For

Right High

Fuse For Right

Fuse For

Right Low

Low And High

Beam Lamp

Position Light

Beam Lamp

Position Lamp

Beam Lamp

Beam Of

Headlamp

Relay

A/C

Relay

Audio Equipment

Instrument Wiper A/C

Horn

Cigarette Lighter Malfunction Alarm Lamp

Headlamp Switch

Rear Window Heating

Instrument

CODE AND FUNCTION DESCRIPTION OF THE INSERTING PART

AND CONTACT IN THE CENTRAL ELECTRICAL BOX

Code of

inserting part

01. Sunroof, Taximeter (+15)

02. A/C signal input of ECU

03. ——

04. Trunk lamp, radio, taxi mark light

05. ——

06. ——

07. ——

08. ——

09. Rear window preheating switch, rearview mirror defroster

switch

10. ——

11. Light switch, interior illuminator, power supply for ABS

diagnosis (+15)

12. ——

13. Positive grid of power supply for combined instrument (+15)

14. Brake switch

Function of contact of inserting part Circuit serial No.

——

138

——

247

——

134

——

132

——

114

192

01. ——

02. ——

03. ——

04. ——

01. Horn switch

02. Fog lamp relay (Positive)

03. Fog lamp switch

04. Horn relay signal (30)

05. Dual-tone horn

06. Wiper motor (Positive)

07. Instrument panel indicator light, switch illuminator,

adjustable resistor of light switch

08. Back-up lamp switch

09. ——

10. ——

11. ——

12. Fog lamp relay (negative)

13. ——

14. ——

15. Thermo-sensitive switch, A/C high voltage switch

16. Positive grid of power supply for central electrical box (+30)

——

142

219

220

140

141

154

209

152

——

215

——

CODE AND FUNCTION DESCRIPTION OF THE INSERTING PART

AND CONTACT IN THE CENTRAL ELECTRICAL BOX

Code of

inserting part

Function of contact point of inserting part Circuit serial No.

17. ——

18. Wiper intermittent relay

19. License lamp

20. Mileage meter sensor

01. ——

02. Cigarette lighter

03. Turn signal switch, headlamp regulation switch

04. ——

05. Positive grid of combined instrument (+15)

06. Sunroof, Taximeter (+30)

07. Grounding wire

08. ——

09. Rearview mirror switch, regulation module, shift lever box

(+15)

10. Ignition switch (+15)

11. Central lock controller, window regulator module (+30)

12. Ignition switch, wiper switch (+15)

13. Positive grid of power supply for central electrical box (+30)

14. ——

15. ——

16. ——

——

149

210

——

129

175

——

116

——

272

260

——

248

01. ——

02. ——

03. ——

04. A/C compressor electromagnetic clutch

05. ——

06. ——

07. ——

08. Positive grid of power supply for central electrical box

(+30).

09. Ignition switch (+15)

10. Light switch

11. ——

12. Horn relay

13. ——

14. ——

——

137

——

207

——

139

——

Illustration Of This Circuit Diagram Book

NOTES ON COMPILATION

1. The circuit code on the main circuit board of the central electrical box

30: No fuse, positive grid is connected directly from the battery;

15: No fuse, the positive grid is connect to the ignition switch;

X: No fuse, the positive grid is connect to the ignition switch, and cut off in the starting process.

31: Dummy ground wire, this wire maybe exist or not.

Example: 30(E8) indicates that the positive grid wire of No.30 in the central electrical box is directly output from the battery and connected to the 8# pin of plug base E in the central electrical box, other symbols such as 30(C16), 15(D10), X(D12)…can be interpreted in the same way.

2. The segmentation of the main circuit board in the central electrical box

This segmentation of the main electrical circuit board includes fuses, relays and connectors.

3. Indicating the extension of the wire or circuit

The circumstances that the wire or circuit been extended are as follows:

——Located at right of the circuit diagram on previous page

——Located at left of the circuit diagram on next page

4. Symbol of the contact point (pin) on the main circuit board of central electrical box

Can be used as “help” in referring to the circuit diagram of main circuit board, example: E/8

indicates the 8thpin of the plug base E in the central electrical box.

5. Color of the wire and cross sectional area of the wire in square millimeters (color of the

wire may not match with the actual item, so the color indicated is only used for reference)

6. Symbol of connector

This symbol is usually marked on the component itself.

7. Name of the part or component (Description can be found at the bottom left in every page of

the electrical circuit diagram).

8. Number label for the extension of circuit or wire

The number in the square box indicates the corresponding circuit serial number with the extension

of the wire in the circuit.

9. Internal wire

For the purpose of searching internal circuit of the component. The circuit comprised of this wire

maybe exist or not.

10. Grounding point

Indicated by a numerical code enclosed in a circle, its connection points are indicated in every

electrical circuit diagram.

11. Circuit serial number

Used for searching components and connection points of the discontinuous wires.

12. Connection points used in the multi-socket plug base

Given the corresponding terminal number for the socket.

Battery, Ac Generator, Ignition Switch, Starting Motor

Headlamp Switch

Wiper Swit

TQ4

Double

socket plug in connector

B=White,

Black,

R=Red,

M=Brown,

V=Green,

A=Blue,

H=Grey,

Z=Viole t,

G=Ye l lo w

A Battery B Starting Motor C Ac Generator C1 Voltage Regulation D Ignition Switch

ch/2

!Grounding Point, ground bracket beside the central electrical box " Car body connection point, close to the battery. # Grounding point of the engine, located at the side of gearbox.

MPI System (UAES)

N01

Fuel Pump Relay

Master

Relay

Green

Blue

Brown

Charcoal

Valve

Oxygen

Sensor

B=White,

Black,

R=Red,

M=Brown,

V=Green,

A=Blue,

H=Grey,

Z=Viole t,

G=Ye l lo w

S35 System Fuse S36 Fuel Pump Fuse S37 Ecu Fuse A+ Positive Grid Of Battery

1~4 Cylinder Ignition Coils 2~3 Cylinder Ignition Coils

Q Spark Plug

-N04 Fuel Injector G Fuel Level Sensor G6 Fuel Pump

Canister Solenoid

Low

Speed Relay

Stepping Motor

Water Sensor

Air Intake Pressure /

Temperature Sensor

Throttle Position

Sen

sor

To High Speed Relay

Low

Speed Relay

To High Pressure Switch

To Headlamp Switch

To Air Blower Switch

To Odometer Sensor

Charcoal

Canister

Solenoid Valve

Oxygen

Sensor

Phase Angle

Sensor

Tachogenerator

Knock Sensor

Dia

gnosis Port

To Wate r

Tem pe rat ur e Me ter

Air Intake Manifold Ground

Ground Of Battery Negative Grid

Air Conditioner, Operation Mechanism, Cooling System

beside of

B=White,

Black,

R=Red,

M=Brown,

V=Green,

A=Blue,

H=Grey,

Z=Viole t,

G=Ye l lo w

A+ Positive grid of battery E9 Air blower switch F18 Thermal-sensitive switch

23 Air blower serial regulation resistor V2 Air blower V7 Fan motor J32 Grounding point, ground bracket the central electrical box J69 Cooling fan high speed relay J70 Cooling fan low speed relay

J5 Air blower relay for air conditioner (in the electrical box) J6 Rear window preheating relay (in the electrical box)

$ Grounding point, in the harness of the i protection sleeve % Grounding point, ground bracket beside of the central electrical box

A/C switch, Internal circulation solenoid valve

N63 Internal circulation solenoid valve

High and low voltage switch

B=White,

Black,

R=Red,

M=Brown,

V=Green,

A=Blue,

H=Grey,

Z=Viole t,

G=Ye l lo w

E35 A/C switch E36 Internal circulation switch K84 A/C operation illuminator

F38 External temperature switch F23 High voltage switch F73 Low voltage switch

&' Five-socket plug in connector TK Main circuit grounding wire

Oil pressure switch, Coolant temperature sensor,

Hand brake indicator light switch, Odometer sensor

B=White,

Black,

R=Red,

M=Brown,

V=Green,

A=Blue,

H=Grey,

Z=Viole t,

G=Ye l lo w

G2 Coolant temperature sensor

F22 Oil pressure switch (low voltage)

F9 Hand brake switch indicator light

F34 Brake oil level alarm switch

G40 Odometer sensor

()))*ounding point, engine cylinder block + Ground connection, in the headlamp harness

TQ1 Ten-socket plug in connector F34 Ten-socket plug in connector TS2

Radio and Six channel loudspeaker

B=White,

Black,

R=Red,

M=Brown,

V=Green,

A=Blue,

H=Grey,

Z=Viole t,

G=Ye l lo w

R Radio R2 Front left loudspeaker R3 Front Right loudspeaker R4 Rear right loudspeaker R5 Rear left loudspeaker R6 Front left loudspeaker R7 Front right loudspeaker R1 Antenna

T8 8 socket plug in connector T1 Single-socket plug in connector

Instrument Panel And MFA

B=White,

Black,

R=Red,

M=Brown,

V=Green,

A=Blue,

H=Grey,

Z=Viole t,

G=Ye l lo w

F10 Multi-channel converter F15 Stabilizer G20 Fuel sensor G25 Coolant temperature sensor G30 Rpm sensor G35 Preset level comparator J114 Control unit

J119 Multi-function display K1 Abs alarm light K2 Left-turn signal lamp K3 Right turn signal lamp K4 Generator charging alarm light K5 Engine self-inspection

indicator light

K6 Hand brake alarm light

Oil pressure alarm light Engine over-temperature alarm light Instrument panel illumination light Instrument panel illumination light Instrument panel illumination light Instrument panel illumination light Low beam lamp,position alarm light

K14 Single socket plug

in connector K15 Fuel alarm light Y1 Digital clock T1 High beam alarm light

Front Fog Lamp, Cigarette Lighter, A/C Panel Indicator Light

B=White,

Black,

R=Red,

M=Brown,

V=Green,

A=Blue,

H=Grey,

Z=Viole t,

G=Ye l lo w

A/C panel indictor light Front right fog lamp Front left fog lamp Coolant level switch Cigarette lighter indicator light Cigarette lighter

, Grounding point, in the headlamp harness

Compressor Magnetic Clutch, Dual-Tone Horn

N25

Rear win

dow

heater

Rear Window Heating System

B=White,

Black,

R=Red,

M=Brown,

V=Green,

A=Blue,

H=Grey,

Z=Viole t,

G=Ye l lo w

J1 Idle speed accelerating relay (in the electrical box) J3 Dual-tone horn relay (in the electrical box) L39 Rear window heating switch illuminator K10 Rear window heating switch E15 Rear window heating indicator lamp

Compressor magnetic clutch

H1(2) Dual-tone born

- Grounding connection point, in the harness of dual-tone horn

Wiper, Washer, Horn Button

Wa sh er

B=White,

Black,

R=Red,

M=Brown,

V=Green,

A=Blue,

H=Grey,

Z=Viole t,

G=Ye l lo w

E22 Wiper switch H Horn button J31 Intermittent wiper relay S5 Fuse 15A V Wiper motor

Front Headlamp, Light Relay, Front Position Light

B=White,

Black,

R=Red,

M=Brown,

V=Green,

A=Blue,

H=Grey,

Z=Viole t,

G=Ye l lo w

A+ Positive grid of battery L1 Left high beam lamp L2 Left low beam lamp L3 Right low beam lamp L4 Right high beam lamp M1 Right position lamp M3 Left position lamp

J55 Light relay S27 Right high beam lamp fuse 10A S28 Left low beam lamp fuse 10A S29 Left position lamp fuse 10A S30 left high beam lamp fuse 10A S31 Right low beam lamp fuse 10A S32 Right position lamp fuse 10A

. Grounding point, in the harness of headlamp

Turn Signal Lamp Switch, Emergency Alarm Relay

Parking Light Switch

B=White,

Black,

R=Red,

M=Brown,

V=Green,

A=Blue,

H=Grey,

Z=Viole t,

G=Ye l lo w

E2 Tur n signal lamp switch E3 Emergency alarm light switch E4 Light changing and turn signal lamp switch E19 Parking lamp switch J2 Emergency alarm light relay K6 Emergency alarm light S17 Fuse 10A

Tail Lamp, Stop Lamp, Side Lamp

lectronic fuel i

njection

B=White,

Black,

R=Red,

M=Brown,

V=Green,

A=Blue,

H=Grey,

Z=Viole t,

G=Ye l low

F18 Brake lamp switch L15 Right tail lamp L20 Left tail lamp M2 Rear left position lamp M4 Rear right position lamp M5 Rear left turn signal lamp M6 Front left turn signal lamp M7 Front right turn signal lamp M8 Rear right turn signal lamp

braking signal

M9 Left brake lamp M10 Right brake lamp M501 Right turn signal lamp M701 Left turn signal lamp

S20 Fuse S7 Fuse S8 Fuse T3 3-socket plug in connector T1 Single-socket plug in connector / Grounded in the rear lamp

Light Switch

B=White,

Black,

R=Red,

M=Brown,

V=Green,

A=Blue,

H=Grey,

Z=Viole t,

G=Ye l lo w

E1 Light switch E20 Panel indicator light/adjustable resistor for instrument illuminator L9 Panel indicator light

S3 Fuse 10A

Rear Fog Lamp, Backup Lamp

B=White,

Black,

R=Red,

M=Brown,

V=Green,

A=Blue,

H=Grey,

Z=Viole t,

G=Ye l lo w

E23 Front fog lamp switch J4 Fog lamp relay (in the electrical box) K17 Rear fog indication lamp L1 Rear fog lamp L40 Front and rear fog lamp switch illuminator S10 Fuse 15A S14 Fuse 10A E24 Rear fog lamp switch

T3 Three-socket plug in connector T3a Three-socket plug in connector T2 Two-socket plug in connector T1 Single-socket plug in connector T1a Single-socket plug in connector

Interior front and rear lamp, Trunk lamp, Door switch,

License lamp, Shadow shield light

B=White,

Black,

R=Red,

M=Brown,

V=Green,

A=Blue,

H=Grey,

Z=Viole t,

G=Ye l lo w

F2 Front left door switch F3 Right front door switch F5 Luggage boot light switch F10 Rear right door switch F11 Rear left door switch TB Two -socket plug in connector TD Four-socket plug in connector

TAa Tw o-socket plug in connector, left of luggage boot W1 License lamp W3 Trunk lamp W4 Shadow shield light W5 Delay on/off interior front ceiling light X Interior rear ceiling light

Central Door Lock

B=White,

Black,

R=Red,

M=Brown,

V=Green,

A=Blue,

H=Grey,

Z=Viole t,

G=Ye l lo w

C Central lock controller (in the front left door) V28 Front right door lock control motor V29 Rear left door lock control motor V30 Fuel tank lid control motor V31 Trunk lock control motor V32 Rear right door lock control motor

TB1 Four-socket plug in connector (left column B) TB2 Four-socket plug in connector (right column B) TK1 12-socket plug in connector (left column A) TK2 12-socket plug in connector (right column A) Ty Tw o-socket plug in connector (left column C) 0 Grounding point beside of the central electrical box

Electrical Rearview Mirror

B=White,

Black,

R=Red,

M=Brown,

V=Green,

A=Blue,

H=Grey,

Z=Viole t,

G=Ye l lo w

F77 Rearview mirror switch X1 Left adjustment X2 Down regulation Y1 Up regulation Y2 Right regulation V17 Left rearview mirror control motor V25 Right rearview mirror control motor

Z4 Left rearview mirror defroster Z5 Right rearview mirror defroster

TK1 12-socket plug in connector (left column A) TK2 12-socket plug in connector (right column A) TZ 2-socket plug in connector (at the side of central electrical box)

B=White,

N55 ABS solenoid valve

Black,

R=Red,

M=Brown,

V=Green,

A=Blue,

H=Grey,

Z=Viole t,

G=Ye l lo w

J104 ABS controller A Battery

VG4 ABS hydraulic pump G44 Rear right wheel RPM sensor G45 Front right wheel RPM sensor G46 Rear left wheel RPM sensor G47 Front left wheel RPM sensor S33 Power supply fuse of ABS solenoid valve S34 Power supply fuse of ABS hydraulic pump TK Diagnostic port

1 Grounding point, ground bracket at the side of central electrical box

Control Unit Of Electrical Window Regulator

B=White,

Black,

R=Red,

M=Brown,

V=Green,

A=Blue,

H=Grey,

Z=Viole t,

G=Ye l lo w

G Win do w regulator module E40 Front left window regulator switch E81 Front right window regulator motor V14 Motor of front right window regulator V15 Motor of front left window regulator

2 At the side of central electrical box TK1 12-socket plug in connector (right column b) TK2 12-socket plug in connector (left column b)

Control Switch Of Electrical Window Regulator

B=White,

Black,

R=Red,

M=Brown,

V=Green,

A=Blue,

H=Grey,

Z=Viole t,

G=Ye l lo w

E39 Rear window regulator lock switch E52 Rear left door window regulator switch E54 Rear right door window regulator switch E53 Rear right door window regulator switch E55 Rear left door window regulator switch

V26 Rear left door window regulator motor V27 Rear right door window regulator motor TA1 4 -socket plug in connector (right column b) TA2 4 -socket plug in connector (left column b)

Air Bag Control Module

Malfunction alarm light

Instrument air bag

B=White,

Black,

R=Red,

M=Brown,

V=Green,

A=Blue,

H=Grey,

Z=Viole t,

G=Ye l lo w

AXLE AND SUSPENSION SYSTEM

ALIGNMENT OF THE WHEEL … … … … … … …… … … … … … … … …M-2

BASIC INSPECTION BEFORE THE ALIGNMENT……………………… … …M-2

USUAL TROUBLE OF THE TIRE… … … … … …… … …… … … …… … …M-5

ALIGNMENT OF THE REAR WHEEL … … … … … … … ……… … … … … M-9

ALIGNMENT OF THE FRONT WHEEL… … … … … … ………… … ……M-10

FRONT SUSPENSION… … … … … … … … … …… … … … … … …… …M-13

REMOVAL AND INSTALLATION OF THE FRONT SUSPENSION………… …M-13

OVERHAUL OF THE FRONT SUSPENSION… … … … … … … ……… … …M-15

REMOVAL AND INSTALLATION OF THE FRONT WHEEL BEARING … … M-19

REAR SUSPENSION AND REAR AXLE… … … … … … … …… … …… … …M-22

REMOVAL / INSTALLATION OF THE REAR AXLE ASSY …… … … …… …M-22

REMOVAL / INSTALLATION OF THE REAR SHOCK ABSORBER ASSY … M-25

OVERHAUL OF THE FRONT AND REAR AXLE… … … … … … …… ……M-28

M-1

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AXLE AND SUSPENSION SYSTEM

ALIGNMENT OF THE WHEEL

It is easy to understand that the theory of the four wheels alignment related to the definitions and the functions of various angles. However, the corresponding theory can hardly be applied to the four wheels alignment tester and chassis maintenance due to the chassis structure of the vehicle body, which all the angles of the four wheels alignment bear on the mechanical structure of the chassis. For examples:

－－The camber will be changed as the toe-in varied. The wheels will be turned while

adjusting the toe-in, which results the camber changing. The larger the caster is, the more the camber changed.

－－The wheel setback will be changed as the caster adjusted. When the caster increases or

decreases, the upper fulcrum of the steering shaft can move forwards or backwards and the lowest fulcrum of the steering shaft (tire) is also movable. The front wheel moves forwards or backwards along with the caster increasing or decreasing so that the axle setback will be altered. The turn plate must have the function of sliding forwards and backwards in order to make the front wheel move forwards and backwards freely.

－－The toe-in will be changed as the camber varied and vice versa. Various suspension

structures have different ways to adjust the camber. If the upper or lower fulcrum is moved left or right, not only the camber but also the toe-in will be changed. As a result, even if the camber is properly adjusted, the stable driving status cannot be achieved because of the toe-in changing. Therefore, after eliminating of malfunction, another one will appear.

－－Changing the toe-in of the rear wheel influences that of each front wheels. The toe-in of

the rear wheel determines the thrust angle of the rear wheel. The method of thrust line positioning is adopted to determine the toe-in of the front wheel in all the advanced four wheels alignment testers.

Precaution: The front wheel must be adjusted first and then the rear wheel when processing the four wheels alignment. The sequence of the rear wheel adjustment is the camber first, the toe-in second and so on. And the sequence of the front wheel adjustment is the caster first, the camber second, the toe-in third and so on.

BASIC INSPECTION BEFORE THE ALIGNMENT

Check the tire pressure, tire No. and rim No.

----Check the tire pressure and adjust it to the specified pressure

Tire inflation pressure kPa

Item Front wheel

No-load/half-load

200 220 350 420

Rear wheel Spare wheel Mini spare wheel

Full-load 210 260 420 420

M-2

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----Rim and Tire

A15LHD wheel No.

Tire No. Rim No.

185/60 R14×82H 6J×14

Note:

The above tire-rim combination is suitable for the steel or aluminum alloy rim. Please do not use rims and tires of other models which may lead to improper consequence.

Preaution: Be sure to consult the relevant instruction if non-standard tires or rims (such as light weight alloy rims or wheels of winter tire)should be installed.

Positioning of the tire

Different working conditions between the front wheel and the rear wheel lead to the different wear status, which depends mainly on the road condition, the driving custom and so on. The front wheel wears faster than the rear one does. In order to prevent the tires from wearing in different degrees and to prolong the service life of the tires, it is necessary to check and rotate the tires, adjust the tire pressure, and examine the tightening degree of the wheel bolt at interval of 5000km.

------ Utilization of the cold-resistant tire

If using the cold-resistant tire, all the four tires must be replaced at same time. Please do not excess the top speed and must accord to the tire pressure limited by the tire manufacturer.

Precaution: Using the cold-resistant tire may affect the safety and the maneuverability of the vehicle. Standard tires in same size and No. should be utilized. Do not use the cold-resistant tire as long as the road condition is available.

------Snow chain

M-3

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Adjusting the snow chain of the tire should accord to the type of the road condition. Inspection must be applied before install the snow chain. Please refer to the instruction of the snow chain manufacturer when install the snow chain on the tire. Please remove the wheel house before install the snow chain which may score the wheel house. Install the snow chain firmly on the front tire. It is not recommended to fix the snow chain on the rear wheel. The snow chain should be retightened after 0.5~1.0km driving with it.

Precaution: Using the snow chain may affect the vehicle maneuverability, so the vehicle speed should not excess 50km/h (30mph) or the speed limited by the snow chain manufacturer(less than 50km/h). Please stop the car and tighten the snow chain immediately when hearing collision between the snow chain and the vehicle body or the chassis when using the snow chain. Abrupt turning, concussion and passing the chuckhole, the vehicle locking and braking should be avoided. The instruction of the snow chain manufacturer should be also complied. Improper utilization of the snow chain will cause interference between the snow chain and the vehicle body.

Installation of the tire

----Make sure that the opening of the valve is slippery and no burrs before installing the tire valve. Then apply glycerol onto the rubber surface of the tire valve or dip it briefly in the glycerol. Pull or press the locating ring of the tire valve with special purpose tool at the force of 200-400N in order to make it through the hole on the wheel, which means the installation is finished. (Suds are permitted to replace the glycerol.)

----Wipe glycerol or suds round the bead before installing the tire, and please note at the same time:

When there is a light point mark on the rim, please aim the uniformity test mark at the point.

When there is no light point mark on the rim, please aim the dynamic balance test mark at the position of the tire valve.

When there is no light point mark on the rim and no dynamic balance test mark but the static balance test mark on the tire, please aim the tire valve at the static balance test mark.

The instructions for the uniformity, dynamic balance and static balance test mark of the tire should be offered by the production department or the supplier in written form.

----Inflate the tires according to the specified pressure strictly. Please do not excess 10% of the rated pressure during inflating. The spare tire assy is assembled at the rated pressure of 3.5atm and is separately stored with the four tires installed on the vehicle. Please check and adjust the tire pressure before the four wheel alignment: front wheel 2.0±0.2atm, rear wheel 2.1±0.2atm.

----Screw the valve cap after inflating the tire and undergo the dynamic balance test. Set the

proper weight balance block onto the inside and outside brims of the rim as required. The

M-4

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final assy imbalance is expected to be less than 100g·cm, approximately equal to a 5g balance block on the inside and outside brims of the rim.

Precaution: No more than one balance block with 70g weight at most is allowed to set on each side of a wheel. Avoid over hitting on the balance block. If that happened, replace it immediately. Do not reuse the replaced balance block.

----During installing the wheel and the tire assy, pre-screw the wheel bolt on the rim by hand first, and then tighten the screws with the special purpose tools under the way of diagonal method, (the tightening torque is 100±10N·m). No impact wrench is allowed in order to avoid screwing too tight or loose. Do not use lubricating grease while installing the wheel bolt. (The wheel bolt should be tightened to maintain the tightening torque after the initial 100km driving since the new installation of the wheel and tire assy. The check of the tightening torque of the wheel bolt is one of the daily service items.)

----Decussating method is adopted to tighten the set nut. The tightening degrees should be similar so that the wheels can turn freely. The wheel should stand on the ground during the last tightening.

----Install the trim cover or place it as required. Clip trim cover should be installed into through beating by hand or prying by rubber tools.

USUAL TROUBLES OF THE TIRE

Proper utilization of the tire

The tire is an important part of the wheel assy. Please pay attention to the following items while using:

------The tire of the same manufacturer and the same No. should be used on the same vehicle.

------Do not install tires out of the specified types

------Make all the tires wear evenly. In order to remedy and lighten the uneven wear, besides

periodic checking and correcting the parameters of the wheel alignment, the rotation should be also applied. The specific rotation way depends on the practical wearing status. It is recommended to adopt the tire rotation at interval of 5000~8000km

Usual troubles of tires and trouble diagnosis

------Wear on shoulder of tire

The wear on shoulder of tire means the brim with burrs forming of the tire wears are more badly than other parts. The theoretical reason for the wear on shoulder of tire is that the tire rolls at the limit lateral runout angle.

Main reason: Frequently steering at high speed, improper adjusting the toe-in and the camber, or often driving on the vaulted or zigzag road.

M-5

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Maintenance: Adjusting the positioning angle of the front wheel

------Wear on center of tire

The wear on center of tire means the abnormal wear on the center surface of the tire. The theoretical reason for this kind of wear is that the diameter elongation at the center of the tire surface is larger than that on the shoulder of the tire.

Main reason: Overhigh tire pressure

Maintenance: Readjusting the tire pressure to make it within the range of the specified value.

------Serrated wear

The serrated wear means the wear on the surface of the tire strip in ladder shape. The theoretical reason for this kind of wear is the uneven deformation of the tread pattern of the tire contact patch.

Main reason: The toe-in and the camber are not conformed to the specified value

Maintenance: Adjusting the toe-in and the camber to make it within the specified value. Checking the tire pressure is within the specified range.

------Initial severe wear somewhere on the tire

The initial severe wear is the severe wear on the tread pattern of tire contact patch due to the wheel locking while emergent braking.

Main reason: Vehicle speed while emergent braking, road conditions, wheel load and the braking intensity

Maintenance: Avoiding emergent braking and taking precautionary measure as early as possible

------Nick and crack on the sidewall of tire

The main reason is the sharp things on the road or the little stones, nails and metal flakes embedded into the tread slot.

------Initial wear on half round of the tire or wear in different places of the shoulders on

both sides

The main reason is the gyration part is in unbalanced state, or the tire and wheel are eccentric, or the bearing is worn or loose and so on. The eccentricity or bend of the rim or the steering knuckle may also cause the wear.

Troubleshooting Guide

Trouble Possible causes Solutions

Serious wear of tire

Tire noise Improper tire pressure Adjust

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Improper tire pressure Adjust

M-6

Degradation of tire Replace

Road noise or

vehicle vibration

Up-and-down

shaking of steering

wheel

Circular vibration of

steering wheel

Insufficient tire pressure

Unbalance of tire

Deformation of rim or tire

Uneven wear of tire

Overbeating of tire and rim

Looseness of wheel nut

Unbalance of tire

Breach or wear of engine bearing

pad

Breach or wear of transmission

bracket rubber

Overbeating of tire and rim

Looseness of wheel bolt

Unbalance of tire

Uneven wear of tire

Insufficient tire pressure

Damage or wear of front wheel

bearing

Malfunction of steering system

Malfunction of suspension system

Adjust

Repair or

Replace

Lock

Adjust

Replace

Lock

Adjust

Replace

Improper tire pressure

Serious or uneven wear of tire

One side deflection

of steering wheel

Unstable running

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Malfunction of steering system

Malfunction of braking system

Malfunction of suspension system

Uneven tire pressure of both sides

Deformation of rim or tire

Looseness of wheel bolt

Malfunction of steering system

M-7

Adjust

Repair or

Replace

Lock

Malfunction of suspension system --

One side deflection

of braking

Heavily steering of

steering wheel

Improper

returnability of

steering wheel

Check whether the connection of the transmission rod of steering system is loose, deformed, etc.

Check the status of the ball joint and the rubber bush of front and rear suspension

Check whether the shock absorber works normally

Uneven tire pressure of both sides

Malfunction of braking system

Insufficient tire pressure

Malfunction of steering system

Malfunction of suspension system

Insufficient tire pressure

Malfunction of steering system

Malfunction of suspension system

Adjust

------Check whether the shock absorber leaks grease

------Check whether the bush wears out

------Check whether the shock absorber is improper through shaking the vehicle body up and

down by pressing the foreside and the tail of the vehicle

Pre-check before wheel alignment

------Check the status of the tire inflation. Adjust to the recommended pressure if necessary.

------Check the clearance of the front wheel bearing. Adjust it if necessary.

------Check the flop of the vehicle and the tire.

------Check whether the ball joint and the steering linkage are too loose.

------Check the shock absorber by shaking the vehicle.

Note:

The vehicle must be on the level ground with no-load.

No-load: Full gasoline in the oil reservoir, engine coolant and the oil filled at the specified

level; the spare tire, jack and tools in the pointed position.

M-8

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------Measure the height from the wheel center to the mudguard edge. The measured

rear wheel should be adjusted

difference from left and right should be not more than 10mm.

ALIGNMENT OF THE REAR WHEEL

It is recommended to utilize the four-wheel alignment tester with thrust line positioning method on this type of chassis.

Note: thrust line positioning is defined as adjusting the front wheel toe-in based on the rear wheel thrust line.

With the thrust line positioning, the adjustment of the rear wheel toe-in will influence the single front wheel toe-in, so during four-wheel alignment, the before the front wheel alignment.

Measure the vehicle height

------Rear measure point

From ground to the center of the joint bolt of the rear axle and the body (as the arrow shows)

Precaution: Check whether the height from left and right are same before processing the wheel alignment

------If there is a difference of the heights from

left and right, that means there are damaged or deformed components of the front and rear suspension.

Install the wheel alignment tester on wheel

------Please refer to the specific instruction of

manufacturer for the wheel alignment tester.

M-9

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Check the caster

Inspection angle Value

Rear wheel caster -1°30′±10′

Note: The rear wheel caster cannot be adjusted. If there is abnormal wear on the tire of the rear wheel, so check whether there are worn or deformed parts on the rear suspension

Check the rear wheel toe-in

Car No. Chery A15LHD

Rear wheel toe-in 20′±10′

Note: The rear wheel toe-in out of standard range may lead to wear on shoulder of tire on both sides. If the differences of the rear wheel toe-in both rear wheel are too much, the vehicle running direction may be affected. Therefore the rear wheel toe-in is a vital parameter of the alignment angles.

ALIGNMENT OF THE FRONT WHEEL

------Install the wheel alignment tester on the wheel

Please refer to the specific instruction of manufacturer.

------Check and adjust the wheel camber and the kingpin caster of the front wheel

according to the standard

Angle Value

Front wheel camber -30′±20′

Kingpin caster 1°30′±30′

Note: Adjust the caster before the camber

Kingpin caster

There is no need to adjust the kingpin caster for it is assured by the structure of design

M-10

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Influence of caster

The main function of the caster is to keep the vehicle running straight forward. If the caster is positive, the inside of the vehicle descends and the chassis ascends which increase the steering knuckle load when the front wheel turns. If the casters of two wheels are same, the vehicle will return forward after turning. Increasing the positive caster angle will enhance stability of the steering wheel while the steering force will be increased at the same time. Decreasing the positive caster may reduce stability of the steering wheel but lightens the steering force.

The angle of the caster could not make the wear on tire. It is used to stabilize the steering direction and to return automatically after steering. If the vehicle is equipped with a traditional manual steering wheel, the caster is small or even tends to negative, which makes the steering easy. If the vehicle is equipped with a power steering wheel, the caster is usually set to be large positive in order to offer the driver a better feeling. Increasing the positive caster will increase the steering force but enhances the stability of straight running.

Adjust the camber

Under normal condition, there is no need to adjust the camber after assembling the independent suspension and the wheel steering knuckle. Use the joint bolt of the independent suspension and the steering knuckle to calibrate the wheel camber if the camber is out of the tolerance range for other reasons.

----Check (visual inspection) whether there

are damaged parts in the steering system and replace the damaged ones before the calibration.

----If the front wheel camber is out of the

tolerance, loosen the joint bolt of the front shock absorber and the steering knuckle and move the wheel to calibrate.

----For the further calibration, use the

substitute bolt to adjust the wheel camber. Replace the M12 bolt with the M11 bolt. The camber is allowed to be adjusted within about ±1° shown as the illustration

M-11

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----The connection between the lower

control arm of the suspension and the steering knuckle is clearance fit. Loosen the joint bolt, move the wheel and adjust the camber.

Check the front wheel toe-in

Toe-in (general)

Car No. Chery A15LHD

Front wheel toe-in 0′±10′

Tightening torque of toe-in: 55±5N•m.

Adjust the toe-in

Optical tester or mechanical toe-in adjuster can be used to adjust the toe-in.

----According to the tester’s requirement, make the wheel alignment well before the

adjustment;

----Loosen the lock nut and the elastic cover snap ring of the right steering tie rod, and

then screw the toe-in adjusting rod till the length of the rod reaches the specified value.

----Tighten the lock nut and reinstall the elastic cover snap ring. Check whether the lock

nut is tightened enough and cover is in the correct position.

----After adjusting the front wheel toe-in, check whether the steering wheel is level. If not,

loosen the lock nut of steering wheel, and then adjust to the level position. The tightening torque of the steering wheel lock nut is 55±5N•m as required.

M-12

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FRONT SUSPENSION

The functions of axle and suspension system include receiving the torque generated by engine and passed via transmission system; producing the traction force between the road surface and the vehicle body through the adhesive force between the driving wheel and the ground in order to keep the whole vehicle steering normally; passing and bearing the counterforce on the wheel from different directions and relieving the impact and shake from the road to the vehicle body in order to ensure the stability and maneuverability of the whole vehicle. The front suspension is composed of the sub-frame, lateral stabilizer bar, control arm and etc.

REMOVAL AND INSTALLATION OF THE FRONT SUSPENSION

----Loosen the opening of the joint bracket of the front shock absorber assy and clip it to the bolt of the steering knuckle arm(tightening the lock nut to 80N•m), (shown as the picture)

----Remove the joint bolt of the control arm assy and the front steering knuckle with braker, and then release the front control arm assy.

Inspection of the control arm: check the situations of the damage crack and bend.

----Loosen the four bolts amounted on the sub-frame of the steering gear with tie rod assy (the specified tightening torque is 30N•m). (shown as the picture)

M-13

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----Suspend the engine and transmission assy, loosen the bolts at the two supporting points from the engine and transmission to the sub-frame.

Caution: The removal process is extremely dangerous which could cause serious damage or even death. Please make sure the power assy is well fixed.

----Loosen the lock nut of the left-right steering tie rod and the steering knuckle arm, knock from one side to pry the ball joint out of the steering knuckle arm (The tightening torque is specified as 35±3 N·m).

----Stand the front sub-frame by jack and loosen the four long-short bolts of the left

-right sub-frame with the cross beam. (The tightening torque is specified as 130±10 N·m).

Caution: The removal of the cross beam is extremely dangerous. The drop of cross beam components could cause serious damage or even death. Please make sure that the jack has supported fully the cross beam components before the removal.

M-14

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OVERHAUL OF THE FRONT SUSPENSION

front shock absorber assy

Installation of the front axle

Cherry adopts the divided steering drive axle as the front axle. The suspension is the model of shock absorber (also called MacPherson) independent suspension. The front suspension of A15RHD model has the functions of both driving and steering. The top of the suspension is connected with the vehicle body while the bottom with the steering knuckle. The wheel camber is adjusted through the joint bolt of the suspension the steering knuckle. The sub-frame enhances the stability and comfortability of the vehicle through the connection of the control arm ball pin and the hinge by adopting the elastic components.

Overhaul of the front suspension

----When overhaul the front suspension, please do not weld or remodel the support and guide devices of the front suspension.

----Use the special purpose tools to remove the joint bolts or nuts. Make sure the tightening torque fits the specified value.

Illustration. The installation of the

front strut assy

2-front dust cover

3-front bumper block4-slotted nut

40N•m

5-bearing and vibration isolator assy

6-front spring top tray

7-washer 8-front coil spring

----When install the sub-frame to the vehicle body, the sequence of tightening the joint bolts is the rear left bolt, the rear right bolt, the front left bolt and the front right bolt last.

----Check the position of steering wheel and measure the data of front wheel alignment after installation.

Overhaul of front shock absorber assy

----Structure of the front shock absorber

(shown as the illustration)

M-15

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Removal of the front shock absorber assy

Precaution: Before the procedure below, the careless pull may lead the disconnection of the harness if the ABS vehicle speed sensor is not removed first. Therefore, before the following procedure, remove the ABS vehicle speed sensor (the axle side) first and fix it in a proper position in order to keep the sensor untouched during the vehicle maintaining.

----Remove the wheel. Then loosen the joint bolt of the propeller shaft and the brake disc.

----Use the special socket wrench to remove the joint bolt of the shock absorber strut and the steering knuckle arm. (shown as the illustration)

----Use special purpose tools to remove and install the shock absorber coil spring. (shown as the illustration) During the removal, push down the vibration isolator assy of the coil spring by puller first, compress the coil spring, and then loosen the piston rod nut to release the tension of the coil spring.

Caution: The removal of the piston rod nut is extremely dangerous, because the shock absorber and the spring will burst out under tremendous pressure which could cause injury or even death. Please make sure the shock absorber is fixed properly before the removal of the piston rod nut.

Installation of the front shock absorber (refer to the installation illustration of the front strut assy)

Illustration. The installation of front

strut assy

1-Front shock absorber assy

2-Front dust cover

3-Front bumper block

4-Slotted nut 40N•m

5-Bearing and vibration isolator assy

6-Front spring top tray

7-Washer 8-Front coil spring

----Assemble the front cover dust 2 with the front bumper block 3, and then cover them onto the piston rod of the front shock absorber 1.

M-16

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----Set on the front coil spring 8 and compress it less than 200~220mm.

----Amount the washer 7, the front spring top tray 6, the bearing and vibration isolator assy 5 in sequence, and tighten the slotted nut 4 to the specified torque (40N•m), then loosen the compressing tools on the coil spring.

Precaution: Please note that the two ends of the

front coil spring should reach the corresponding

locating positions of the spring trays.

Inspection of the shock absorber: The methods for checking the shock absorber are as following:

----Method of hand pressing the vehicle body. Shake the vehicle body for times on the side of the shock absorber which required to be checked and feel whether it is available. After the pressing, the vehicle will shake 2-3 times and then stop, which means the shock absorber works well.

----Method of observation. The shock absorber should not leak oil at outside appearance. A little oil stain is normal. If there is serious leakage, the shock absorber should be replaced.

----Method of touch. After long time running, touch the exterior of the shock absorber to check whether it is hot. If not hot, the shock absorber is in trouble.

----Method of pulling and pressing. Place the piston rod of the shock absorber upwards, then pull and press it by hand for times and check:

a whether there is a force during pulling and

pressing which means the force is large while pulling up and small while pressing down.

b whether there is idle stoke during pulling and

M-17

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pressing which means there is a force in lower part and not abruptly in upper part while pulling; there is a force in lower part and not in upper part while pressing.

c whether the shock absorber is locked and

unable to pull.

d whether the piston rod of shock absorber is

severely loose.

Note: The above phenomenons indicate the

failures of the shock absorber.

Deal with the front shock absorber

Caution:

Whenever drilling on the shock absorber,

please wear the goggles. The air pressure in the shock absorber could probably blow the metal flakes into eyes or face.

----Clamp the shock absorber on flat ground or point the piston downwards to the clamped absorber.

----Drill a hole of 2-3mm diameter at a distance of 20-30mm to the bottom of the tube in order to emit the air of the tube.

----Turn the shock absorber to make the hole downwards.

----Move the piston rod up and down for times to concentrate the oil, then cut the tube at the end.

----Process the waste oil according to the waste disposal method.

Note:

The shock absorber air is nitrogen.

The shock absorber oil is mineral oil.

M-18

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REMOVAL AND INSTALLATION OF THE FRONT WHEEL BEARING

Removal:

----Remove the front brake disc and the dust plate, and then extrude the hub.

----Remove the spring retainer of both sides and extrude the wheel bearing. (shown as the illustration)

----Pull out the bearing inner race. Use the puller with hoop to pull the wheel bearing inner race out of the wheel hub. (shown as the illustration)

Inspection:

----After all the components are disassembled, please clean and check them, and replace them with new ones if necessary.

----If the working surface of the brake disc wears severely beyond the specified value (wearing limit: 10.0mm), please replace it with a new one.

Caution: Do not exceed the wearing limit.

----If the dust plate is severely deformed, please replace it with a new one.

----If the hub spline wears severely and looses, please replace it with a new one.

----If the spring retainer is not available, please replace it with a new one.

----If the wheel bearing is damaged, please replace it with a new one.

Installation and adjustment

----Set the outer spring retainer first, apply the lubricating grease onto the wheel bearing holder and then press the bearing down to the limit position, as shown in the illustration, and fix the inner spring retainer last.

----Adjust the split positions of the inner and

outer spring retainer so as to make their difference 180°. Then rotate the bearing inner

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race and observe whether it runs normally.

----Apply the lubricating grease on the hub spline and the bearing neck, and then press the hub into the bearing.

----Tighten three M6 bolts to fix the dust plate

with the tightening torque of 10N·m.

----Use the fuzz-free cloth to clean the working surface of the brake disc. If there is oil stain on the surface, clean it with ethanol. And then install the brake disc.

----Rotate the brake disc and observe whether there is lock or abnormal noise.

OVERHAUL OF THE LOWER CONTROL ARM

Check the status of damage, crack and bend of the control arm.

Replace the ball joint and the rubber cover of the lower control arm if they loose or wear.

Replace the front housing of the lower control arm

----Press out the front housing of the lower

control arm. (shown as the illustration)

----Apply the lubricating grease before installing the front housing of the lower control arm.

----Press in the front housing of the control arm.

(shown as the illustration)

M-20

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Replace the rear housing of the lower control arm

----When pressing out the rear housing of the lower control arm, if the elastic housing locks due to rust, please cut away the rubber on outer circle, saw off the steel cover, and then press out the elastic housing. (shown as illustration)

----The installing position of the elastic housing of control arm is shown as the illustration. The arrow B or C points at the upper pit on the lower control arm, and the kidney-shaped interspace on the housing (arrow A) points to the vehicle center.

----Use the special purpose tools to press in the rear housing of the control arm.

M-21

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REAR AXLE AND REAR SUSPENSION

Longitudinal bracket rear axle and rigid axle suspension are employed in Chery. The wheels on both sides are connected with the vehicle body by an integrated rear axle. The metal rubber holder for the rear axle is a type of holder which the trace is adjustable. It is almost the rigid connection in longitude and can only deform in lateral which ensures that the rear axle cannot turn in axial direction. Therefore, the rear axle processes the function of preferable control of the vehicle stability at high speed.

REMOVAL AND INSTALLATION OF THE REAR AXLE ASSY

1. Rear axle welding assy 2. Metal rubber holder 3.Rear brake hose

4. Hand brake cable clip 5. Left brake pipe assy of rear axle 6.Hand brake cable

7. Braker 8. Brake drum 9. Tire set bolt (110 N·m)

10. Rear axle bracket 11. Nut (60 N·m) 12. Bolt (70 N·m)

Illustration. Rear axle assy

M-22

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Installation of the rear axle assy:

----Installation of the metal rubber holder: press the metal rubber bush 2 into the axle body, and apply pressure till the edge of metal rubber bush reaches the solid axle.

----Use the bolt for hole 13 of the metal rubber holder to connect the two rear axle brackets. The standard tightening torque of the nut is 60 N·m; (shown as the picture)

----Install the braker, the brake drum and the axle shaft well;

----Connect the left and the right brake pipe assy of the rear axle with the left and the right braker assy respectively, and then use the pipeline clip to fix them on the rear axle. Meanwhile, maintain the connection between the reed and the rear brake hose by the rear axle bracket. The tightening torque is 13-19 N·m; (shown as the picture)

----Use the clip and the brake cable clip set on the rear axle to fix the hand brake cable. (shown as the picture)

M-23

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Caution: The removal of the rear axle is extremely dangerous. The drop of the rear axle could cause severe damage or even death. Please make sure that the jack has supported fully the rear axle before the removal.

M-24

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REMOVAL AND INSTALLATION OF THE REAR SHOCK ABSORBER ASSY

10 Rear bumper block 11 Dust cover 12 Valve cap 13 Rear shock absorber assy

14 Rear coil spring 15 Rear spring bottom tray 16 Bottom tray bearing pad

The structure of rear shock absorber assy is shown as the illustration:

Illustration. Rear shock absorber assy

1 Hexagon thin nut 15N·m 2 Rear strut upper cover 3 Belleville washer

4 Hexagon thin nut 15N·m 5 Rubber bearing block II 6 Bearing sleeve

7 Rear spring upper holder 8 Locating ring 9 Rear spring upper soft pad

17 Bowl washer 18 Rubber bearing block I 19 Support disc 20 Hexagon thin nut

25N·m 21 Bolt 22 Nut 70 N·m

M-25

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Assemblage of the rear shock absorber (refer to the illustration of the rear shock absorber assy)

----Cover the rear spring bottom tray 15 onto the rear shock absorber assy 13, fix it on the rear shock absorber with the pressure of 9.5~10kN, and then set the bottom tray bearing pad with the pressure of 2~3kN.

----Cover the rear coil spring 14 and the valve cap 12 onto the piston rod of the rear shock absorber in sequence, and then set into the rear bumper block 10 and the dust cover 11 which have been assembled together;

----Press the rear coil spring 14 to 280~300mm, and then fix the locating ring 8, the rear spring upper soft pad 9, the rear spring upper holder 7, the bearing sleeve 6, and the rubber bearing block II 5. Tighten the hexagon thin nut 4

to the specified torque (15N·m);

Installation position of the spring holder

Installation of the shock absorber spring

----As the illustration shows, aperture a must aim at the bush of the connecting sleeve 2 when install the rear spring bottom tray, otherwise the spring tray 1 would hit the tire under extreme steering condition.

----As the illustration shows, please pay attention to the installation position of the rear spring upper soft pad.

Installation of the rear shock absorber assy (refer to the illustration of the rear shock absorber assy)

M-26

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Installation position of the spring bottom

tray

----Install upward the rear shock absorber assy from the vehicle body bottom and extend the piston rod into the carriage through the rear shock absorber holder;

----Inside the carriage, cover bowl washer 17, rubber bearing block 18 and support disc 19 onto the piston rod in sequence, and then tighten the hexagon nut 20 with tightening torque of 20N·m. (shown as the assy picture above)

----Lift the vehicle, and then put the connecting sleeve of the rear shock absorber into the corresponding installation position on the rear axle assy and then tighten the bolt 21 and the nut 22 with the specified torque (70±7N·m)

----Fix the tire, ground the vehicle and tighten the hexagon thin nut 20 with the specified torque (25 N·m)

----Fix the belleville washer 3 and tighten the hexagon thin nut 1 with the specified torque (15 N·m)

----Fix the rear shock absorber upper cover 2, in order to keep away from the dust and dirt which could lead to abnormal wear on the piston rod. (shown as the picture)

M-27

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OVERHAUL OF THE FRONT AND REAR AXLE

Trouble Causes Solutions

1. Different tire pressure of both

sides

2. Half way releasing of front

braker

3. Invalidation of front spring or

Deflecting of

vehicle running

housing

4. Inaccurate alignment of front

wheel

5. Invalidation of shock absorber

6. Invalidation of metal rubber

bushes of suspension

7. Deformation of vehicle chassis,

frame or control arm

1. Inaccurate alignment of wheel

2. Serious wear or loose of metal

Abnormal wear

on tire

bushes of suspension system

3. Looseness of steering link ball

joint

4. Looseness of front wheel

bearing

1. Low or different tire pressure

2. Inaccurate alignment of front

wheel

Oscillation of

vehicle

3. Invalidation of stabilizer bar

4. Unbalance of wheels

5. Looseness of hub bearing

6. Improper adjustment of steering

gear or serious wear of components

1. Too small tightening torque of

chassis sub-frame bolt

Abnormal noise

of chassis

2. Looseness of rear axle bracket

3. Abnormal noise of front and

rear shock absorber

4. Looseness of rear axle rubber

hinge bolt looses

1. Adjust

2. Overhaul, adjust

3. Replace

4. Check, adjust

5. Replace

6. Check and replace the

damaged bushes

7. Replace or align

1. Check, adjust

2. Replace

3. Replace

4. Replace

1. Adjust tire pressure

2. Check, adjust

3. Replace

4. Balance

5. Adjust

6. Adjust

1. Tighten according to the

specified torque

2. Tighten

3. Check, replace

4. Check, tighten

M-28

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BODY ELECTRICAL SYSTEM

CHARGING AND STARTING SYSTEM … …… … …… …… … ………… ……… T-4

REMOVAL/INSTALLATION OF THE BATTERY …… … …… …… … ……T-4

INSPECTION OF THE BATTERY …… … …… …… … ………… …… ……T-4

CHARGING OF THE BATTERY …… … …… …… … ……… …… … …… ……T-5

REMOVAL/INSTALLATION OF THE GENERATOR …… …… …… … ………T-5

INSPECTION OF GENERATOR… …… … …… …… … ……… …………T-8

REMOVAL/INSTALLATION OF STARTER … ……… ……… ……… ……T-9

OVERHAUL OF STARTER … ……… ……… ……… ……… ………… ……T-9

LOAD INSPECTION OF STARTER … ……… ……… ……… ………… ……T-10

LIGHTING SYSTEM … ……… ……… ……… ……… ……… ………… ……T-11

REMOVAL/INSTALLATION OF LIGHTINGS FOR THE COMPLETE CAR…T-11

REMOVAL/INSTALLATION OF THE HEADLAMP … ………… ……… ……T-11

REMOVAL/INSTALLATION OF THE FRONT FOG LAMP … ………… ……T-11

REMOVAL/INSTALLATION OF THE SIDE TURN SIGNAL LAMP … ………T-12

FIXED REMOVAL/INSTALLATION OF TAIL LAMP … ……… ………… ……T-12

FLEXIBLE REMOVAL/INSTALLATION OF TAIL LAMP … ……… ………… T-12

REMOVAL/INSTALLATION OF LICENSE LAMP … ……… ………… ………T-12

REMOVAL/INSTALLATION OF INTERIOR CEILING LIGHT … ………… …T-13

REMOVAL/INSTALLATION OF TRUNK LAMP … ……… ………… ……… …T-13

REMOVAL/INSTALLATION OF HIGH MOUNTED STOP LAMP … ………… T-13

REMOVAL/INSTALLATION OF DOOR SWITCH … ……… ……… …………T-14

REMOVAL/INSTALLATION OF INSTRUMENT CONTROL SWITCH … ……T-14

REGULATION OF HEADLAMP … ……… ……… ……… ……… ………… …T-14

COMMON FAILURES OF LIGHTING SYSTEM … ……… ……… ………… …T-15

COMMON FAILURES TROUBLESHOOTING OF HEADLAMP … ………… …T-15

COMMON FAILURES AND TROUBLESHOOTING OF FOG LAMP … ………T-15

COMMON FAILURES AND TROUBLESHOOTING OF BACKUP LAMP … …T-16

COMMON FAILURES AND TROUBLESHOOTING OF STOP LAMP …… ……T-16

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T-1

COMMON FAILURES AND TROUBLESHOOTING OF TURN SIGNAL LAMP..T-17

IGNITION SYSTEM … ……… ……… ……… ……… ……… ……… ……… ……T-18

SUMMERY OF IGNITION SYSTEM … ……… ………… ……… ……… ……T-18

REMOVAL OF IGNITION COIL AND SPARK PLUP … ………… ……… ……T-19

OVERHAUL OF IGNITION SYSTEM … ………… ……………… ……… ……T-20

INSPECTION OF IGNITION TIMING … ………… ……… ……… ……… ……T-20

INSTRUMENT SYSTEM … ……… ……… ……… ……… ……… ……… ………T-22

INTRODUCTION OF INSTRUMENTS … ……… ……… ………………… ……T-22

SYSTEM COMPONENTS AND FUNCTION LIST … ……… ………… ……… T-23

WORKING SCHEMATIC DIAGRAM OF INSTRUMENT SYSTEM …… ………T-24

FUNCTION LIST OF INSTRUMENT SOCKETS … ……… ………… ……… …T-26

SPEEDOMETER … ……… ……… ……… ……… ……… ………… ……… …T-27

WATER TEMPERATURE METER … ……… ……… ……… ………… ……… T-27

WORKING PRINCIPLE OF WATER TEMERATURE SENSOR …… ……… …T-28

FUEL METER … ……… ……… ……… ……… ……… ……… ……… ………T-29

MALFUNCTION DIAGNOSIS AND TROUBLESHOOTING … ………… ……T-30

ELECTRIC WIPER AND WINDOW WASHER SYSTEM … ………… ……T-35

INTRODUCTION OF WIPER SYSTEM … ……… ……… ………… ……… …T-35

ELECTRIC SCHEMATIC DI AGRAM OF FRONT WINDOW WIPER AND

WAS HER…… … … …………………………………… … … ……………… T-37

FUNCTION TABLE OF WIPER AND WASHER COMPONENTS … ……………T-38

REMOVAL/INSTALLATION OF WIPER AND WASHER SYSTEM …… ………T-38

FAULT DIAGOSIS AND TROUBLESHOOTING … ……… ………… ……… …T-39

ELECTRIC WINDOW REGULATOR SYSTEM … ……… ………… ………T-44

INTRODUCTION OF ELECTRIC WINDOW REGULATOR SYSTEM …… ……T-44

FAULT DIAGNOSIS AND TROUBLESHOOTING … ……… ……… ………… T-45

CENTRAL DOOR LOCK SYSTEM … ……… ……… ……… ………… ……T-46

INTRODUCTION OF CENTRAL DOOR LOCK SYSTEM … ………… ………T-46

PRINCIPLE OF CENTRAL DOOR LOCK CONTROL … ……… ………… ……T-46

FAULT DIAGNOSIS AND TROUBLESHOOTING … ……… ………… ………T-46

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AIRBAG SYSTEM … ……… ……… ……… ……… ……… ……… ……… ………T-48

WORKING PRINCIPLE OF AIRBAG … ……… ……… ……… ………… ……T-48

OPERATION CONDITIONS … ……… ……… ……… ……… ………… ………T-49

OPERATION PROCESS ………………… ……… ……… ……… ………… ……T-49

ASSEMBLY PARTS AND WORKING PRINCIPLE OF AIRBAG … ………… …T-51

FAULT DIAGNOSIS AND OVERHAUL … ……… ……… ……… ………… …T-55

REMOVAL/INSTALLATION OF AIRBAG … ……… ……… ………… ………T-61

REMOVAL/INSTALLATION OF WIRINGS CONNECTORS … ……… ………T-64

REMOVAL/INSTALLATION OF SPIRAL CABLE … ……… ……… ………T-64

REMOVAL/INSTALLATION OF STEERING WHEEL AIRBAG … ………… …T-64

CONTROL MODULE … ……… ……… ……… ……… ……… ………… ……T-66

NOTES ON SAFETY OPERATION … ……… ……… ……… ……… ………T-67

SOUND SYSTEM … ……… ……… ……… ……… ……… ………… ……T-69

FUNCTIONS OF CONTROL INSTRUMENATION PANEL … ……… ……… …T-69

OPERATION INSTRUCTION … ……… ……… ……… ……… ………… ……T-70

OTHER FUNCTIONS … ……… ……… ……… ……… ……… ………… ……T-72

REMOVAL/INSTALLATION OF SOUND SYSTEM … ……… ………… ………T-73

MALFUNCTION DIAGNOSIS AND TROUBLESHOOTING … ………… ……T-75

CIRCUITRY DIAGRAM OF THE COMPLETE CAR（ATTACHMENT）

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CHARGING AND STARTING SYSTEM

REMOVAL/INSTALLATION OF BATTERY AND INSPECTION

Removal:

----Disconnect the negative and positive cables of battery.

----Loosen the bolt of front battery clamping steel plate, and remove the clamping steel plate.

----Move the battery forward, isolate the back clamping plate and take down the battery.

Note: After removing of the battery,

be sure not to simply dispose it around; it should be put horizontally in a designated place.

The installing steps are reverse to those for removal.

Bolt of battery clamping plate

Inspection procedure:

Battery inspection

Battery

Inspect the battery according to the following procedure

Procedure

Measure the open circuit voltage of battery

Quick charge for 30 minutes After that, re-inspect the voltage

Use load tester to apply load current (refer to the load test table) for battery, record the battery voltage after 15 seconds. Is the battery voltage exceeding the specified value?

Inspection description Results Measures

Above 12.4V Proceed to step 3

Below 12.4V

Above 12.4V

Below 12.4V Replace the battery

Yes Battery is normal

No Replace the battery

Proceed to next

step

Proceed to next

step 2

Battery anode voltage:

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Approximate temperature of battery Minimum voltage (V)

21°C（70°F） 9.6 16°C（61°F） 9.5 10°C（50°F） 9.4

4°C（39°F） 9.3

-1°C（30°F） 9.1

-7°C（19°F） 8.9

-12°C（10°F） 8.7

-18°C（0°F） 8.5

CHARGING OF BATTERY

Warning: Keep the battery away from any flammable materials. If not, the gas emitted

from the battery liquid that is easily flammable may cause severe injury or even death of people.

Note: In order to prevent the battery and other components from being damaged, all

attached devices and the generator should be shut down before maintaining or charging the battery.

REMOVAL/INSTALLATION OF THE GENERATOR

Warning: When connecting wires of the battery are in on-state, and at this time if you

contact the generator terminal with the car body, sparks will happen. It may cause body injury, fire and the sparks may damage electrical components. Therefore, before carrying the following operation, you must disconnect the negative grid of the battery first.

Note:

— The negative grid of battery should be

disconnected first during removal, and should be connected last during installation. It will avoid the damage to battery or any other electrical component.

— In order to prevent the battery or other

components from being damaged, all auxiliary devices and the generator should be shut down during maintaining or charging the battery.

— Place the battery in water basin so as to

prevent it from overheating; water level of the basin should be about half of the battery height. During charging, disconnect connectors of the battery and make sure to keep the upper

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part of the battery away from water.

—Connect the battery to the charger, and adjust

the charging current accordingly.

As heat discharged by the exhaust manifold could damage the generator, you must ensure that the heat discharging guard and insulation device are firmly installed on the generator.

Installation of generator bracket:

—Disconnect the negative grid of the battery.

— Mount the double-ended stud on top of

cylinder cover.

—Install the bracket of generator.

—Tighten flange nut of the double-ended stud

and bolt on the cylinder body, the tightening torque should be 40±4Nm.

The installing steps are reverse to those for removal.

Installation of generator:

—Disconnect the negative grid of the battery.

—Align one end of the generator with the

installation hole of bracket, and push it in by force until the installation hole and the shaft hole of the generator are aligned.

— Use a long bolt and an Allen screw

respectively to install the generator on its bracket, with a tightening torque of 25±2N.m.

—Connect the positive power source wire with

the generator and the cable lug of the battery warning lamp to the wiring terminal.

Note: The wiring harness must not be

grounding so as to avoid from catching fire.

The installing steps are reverse to those for removal.

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Installation of driving belt and tensioner assembly:

—Disconnect the negative grid of the battery.

— Use 3 M8 Allen screws to install the

tensioner assembly on the bracket of the generator, with a tightening torque of 25±2N.m.

—Install the multi-wedged belting; Pull out the

pin on the tensioner assembly so as to tension the driving belts in the tensioner pulley. Inspect the driving belts to see whether they are all inserted properly in the driving wedge of the pulley wheel.

The installing steps are reverse to those for removal.

Adjusting method of multi-wedge belting and tensioner assembly alignment:

—Disconnect the negative grid of the battery.

—Use spanner to rotate the engine crankshaft

belt pulley to drive the multi-wedged belting for at least one revolution.

—Observe the alignment status of the mult i

-wedge belting and tensioner assembly, if the multi-wedge belting center exceeds the tensioner assembly center, then remove the tensioner assembly and add spacers to adjust the centering.

The installing steps are reverse to those for removal.

Overhaul of generator:

—Inspect the accuracy of deflexion and

tension value of the driving belt, if it does not comply with the requirement, then the driving belts should be replaced.

—Shut down all the electro-devices, turn the

ignition switch to start the engine, inspect the rotation process of the engine to see whether the rotation of generator is smooth without any noise.

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—Use voltmeter to measure the voltage value

of the generator output terminal.

Standard value: Engine idling; Temperature: 20 ℃, Output voltage: 13-15V.

—Switch on the following devices and observe

the increase of readings of the voltmeter:

• Headlamp

• Air conditioning

• Back window defroster

INSPECTION OF GENERATOR

Warning lamp of generator

1. Confirm that the battery has been fully charged;

● If it necessary, the battery should be charged.

2. Confirm the accuracy of deflexion and tension values of the wedge type belts.

● If it does not comply with the requirement, then replace it with a new type of wedge type

belt.

3. Turn on the ignition switch, and inspect the generator warning lamp to see whether it is

indicating.

● If it does not comply with the specified requirement, then inspect the generator warning

lamp, or check whether the generator connectors are connected firmly.

4. Confirm whether the generator warning lamp is off after the engine is turned off.

● If it does not comply with the requirement, then inspect the instrument connector to see

whether they are connected properly; if the instrument is malfunction free, then you need to further inspect the generator itself to see whether there is any short circuit.

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REMOVAL/INSTALLATION OF STARTER

Warning:

When connecting wires of the battery are in on-state, and at this time if you contact the generator terminal to the car body, sparks will happen. This may cause body injury, fire and the sparks may damage the electrical components. Therefore before carrying the following operation, you must disconnect the negative grid of the battery first.

— Disconnect the negative grid of the

battery.

— Apply lubricating grease of about 5

grams evenly on the inserting shaft of the starter.

— Insert the starter into housing of the

clutch.

—Screw three bolts and tighten them，(one

of the bolts is M10×1×35), with the tightening torque of 40±4Nm.

— Connect the wiring harness to the

positive grid of the starter, and the starter wiring harness connector. Pay attention not to ground the wiring harness so as to prevent short circuit and catching fire.

The installing steps are reverse to those for removal.

OVERHAUL OF STARTER

No load test:

—Verify that the battery is fully charged.

—Close the circuit of the starter, battery, voltmeter and ammeter according to the following

diagram.

—Initiate the starter and check whether it operates smoothly.

—When the starter is rotating, measure its voltage and current values. If these values do not

meet the requirements, then replace the starter.

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Technical parameters

Voltage value（V）

Current value （A）

11 Less than 90

LOAD INSPECTION OF STARTER

1. Verify that the battery is fully charged.

2. Initiate the engine, and check whether any block or noise during the rotation of the starter

rotor.

● If there is no abnormality, then please check the followings:

—Remove the starter and check the solenoid switch and starter.

● Check the related winding coil and ignition switch.

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LIGHTING SYSTEM

REMOVAL/INSTALLATION OF LIGHTINGS FOR THE COMPLETE CAR

1. Headlamp

Removal （Disconnect the negative grid of the battery）

—Remove the radiator grille, and use sleeve to

remove the four fixing bolts of the headlamp.

—Unplug the wiring harness connector behind

the headlamp holder.

— Then place the headlamp on the

corresponding position.

Installation

— Install the headlamp properly on the

corresponding position, and ensure that the fixing hole position of the bolt is concentric with the welded nut on the crossbeam of the headlamp;

—Use 4 bolts, spacers and 1 nut to locate the

position of the front headlamp, put down the front hood, confirm and adjust position of the headlamp (whether it is extruding or intruding; the requirement is such that the headlamp should be slightly extruded beyond the front hood border. The arc shape of the headlamp can be felt by hand), after that tighten the fastener, with a tightening torque of 1.5±0.2 N.m；

—Install the radiator grille, and pay attention

not to scratch the paint on the protection bumper; ensure that the spacing between the left and right fenders is symmetrical.

—Connect the wiring harness plug to the lamp

holder socket.

2. Removal/Installation of the front fog lamp: (Disconnect the negative grid of the

battery)

—Connect the corresponding connector to the wiring harness of the fog lamp;

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—Place the fog lamp into the installation hole from the front, and ensure that the 3 screw

holes are concentric with the holes on the front bumper;

—Tighten the 3 self-tapping screws, with a tightening torque of 1.5±0.2N.m;

—Install the grilles on the bottom part (see instruction in car body)

3. Removal/installation of side turn signal lamp: (Disconnect the negative grid of the

battery)

—Connect the wiring harness from the lamp holder;

—First align the clipping end with car body in the correct direction, and then press it in by

force.

4. Removal/installation of fixed part of tail

lamps (including position lamp/brake lamp, and turn signal lamp):

—Align at the holes of car body, so as to install

the lamp on the body properly;

—Tighten the 3 fixing screws, pay attention to

adjust the facial gap with the car body, feel the difference in height with hand and make necessary adjustment while tightening;

— Plug the wiring harness onto the lamp

holder, and put back the carpet.

5. Removal/installation of moving part for

the tail lamp (including the backup lamp and tail fog lamp)

—Align at the holes of the car body, so as to

install the lamp on the body properly;

—Tighten the 4 fixing screws, pay attention to

adjust the facial gap and spacing (the trunk lid may be closed) with the car body and fixing parts, feel the difference in height with hand and make necessary adjustment while tightening;

— Plug the wiring harness onto the lamp

holder, and put down the trunk lid.

6. Removal/installation of license lamp

—Connect the connector of the wiring harness properly;

—Align the self-tapping screw with the hole center of expansion nut; tighten two self-tapping

screws with a tightening torque of 1.5±0.2N.m. Assemble the guard plate of license lamp;

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8. Removal/installation of trunk lamp

—Align lock core of the trunk with the hole, so as to match the guard plate with the car body

properly;

—Tighten 2 self-tapping screw, pay attention to adjust the facial gap, spacing and other

differences between the car body and the movable part, feel the difference in height with hand and make necessary adjustment while tightening;

—Open the trunk lid;

—Tighten 2 square nuts of the fixing bolt;

—Assemble the linkage rod, lid, etc. of the lock hole (see instruction of car body), and then

put down the trunk lid.

7. Removal/installation of interior ceiling

lamp

—Connect the connector of the wiring harness

properly；

—Place it right into the installation hole of the

ceiling towards the correct direction, firstly align one end with the ceiling and then press the ceiling light into the proper position with hand.

—Open the trunk lid;

—Connect the connector of the wiring harness properly;

—Use the clipping end side to latch with cover of the back loudspeaker, after that just press

the light into it with hand. Put down the trunk lid;

9. Removal/installation of high mounted stop lamp

—Press the two ends so as to separate the lamp holder and the lamp housing, and then pull out

the conducting wire connector;

—Plug both of the single-terminal sockets of the conducting wires into the inserting plates of

the windscreen;

—Install the lamp housing according to the combination structure of the clipping slot, pay

attention to the matching of the inverted slot with the fixing pin, so as to ensure that the lamp housing is firmly clipped to the position;

—Plug the conducting wire and lamp holder properly, and ensure that the lamp holder and

housing are assembled in the proper position.

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10.Removal/installation of door switch

—Disconnect the negative grid of the battery.

—Loosen the self-tapping screw of the door switch with a cross screw driver.

—Pull out the door switch, and separate the wiring harness connectors.

11.Removal/installation of control switch for dash lights

—Disconnect the negative grid of the battery.

—Reach the bottom part of the instrument panel with hand, and press down the clip of the

control switch for dash lights.

—Pull the control switch for dash lights forward and remove it.

The installing steps of above components are reverse to those for removal

12. Beam adjustment for headlamp

—The correctness of the beam adjustment for front headlamp is vital to the driving safety.

Therefore, only special instruments are allowed to be used to adjust the beam, and pay attention to the stipulated laws during adjustment.

13. The followings must be fulfilled before adjustment

—Air pressure of car tyres must comply with the standard;

—The vehicle should be non-load (other than the spare tyre and tool kit, the weight of the car

normally includes the weight of the driver);

—The car should be parked on a horizontal road or working site;

—The surface of the headlamp reflector must be clean without any contamination;

—Check whether power works normally and bulbs are installed properly.

—Two screws linking the front headlamp can be adjusted towards the horizontal or vertical

position.

—When adjusting the front right headlamp, the protection cover must be removed. The

adjustment screw for the front left headlamp is symmetrical with the front right one. The adjustment method is the same.

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COMMON MALFUNCTIONS OF LIGHTING SYSTEM / TROUBLESHOOTING

1.COMMON MALFUNCTIONS OF FRONT HEADLAMP / TROUBLESHOOTING

Malfunction Malfunction Diagnosis Troubleshooting

Neither high beam or low beam light is working

1.All of bulbs have been damaged.

2.The fuse has been burned down.

3.Headlamp switch is faulty.

4.The circuit is faulty.

1.Replace the bulb.

2.Replace the fuse.

3.Inspect and replace the headlamp switch.

4.Check the circuit.

Only one headlamp, that is either the high beam or low beam is working

Either side of the high beam or low beam is not working.

Both headlamps are not working.

1.The bulb has been damaged.

2.The fuse has been burned down.

3.The lamp holder or conducting wire is faulty.

1.The bulb has been damaged.

2.The fuse has been burned down.

3.The headlamp switch is faulty.

4.The conducting wire or the grounding is faulty.

1.The bulb has been damaged.

2.The fuse has been broken.

3.The headlamp switch is faulty.

4.The conducting wire or the grounding is faulty.

1.Replace the bulb.

2.Replace the fuse.

3.Check the lamp holder or conducting wire.

1.Replace the bulb.

2.Replace the fuse.

3.Check the headlamp

switch.

4.Inspect the circuit.

1.Replace the bulb.

2.Replace the fuse.

3.Check the headlamp

switch.

4.Check the circuit.

Warning:

● The bulb will generate heat of very high temperature during working. So if the

surface of the bulb becomes dirty, the excessive heat will be accumulated, which would result in shortening the life span of the bulb. When replacing the bulb, pay attention to hold the metal edge rather than the bulb itself.

2. COMMON MALFUNCITONS OF FOG LAMP AND TROUBLESHOOTING

Malfunction symptom Malfunction Diagnosis Troubleshooting Only one fog lamp is not working

Neither of fog lamps is not working

Fog lamp is always working

1. The bulb has been damaged.

2. The circuit or grounding is faulty.

1. The bulb has been damaged.

2. The fuse has been burned down.

3. The fog lamp relay has been damaged.

4. The fog lamp switch is faulty.

5. The circuit or grounding is faulty.

1. The switch of fog lamp is faulty.

2. The circuit is faulty.

1. Replace the bulb.

2. Check the circuit.

1. Replace the bulb.

2. Replace the fuse.

3. Check the relay.

4. Check the switch.

5. Check the circuit.

1. Check the switch.

2. Check the circuit.

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Warning:

● The bulb will generate heat of very high temperature during working. So if the

3. COMMON MALFUNCTIONS OF BACKUP LAMP AND TROUBLESHOOTING

Malfunction symptom Malfunction Diagnosis Troubleshooting One side of the backup lamp is not working

Neither sides of the backup lamps is not working

Backup lamp is continuously working

1. The bulb has been damaged.

2. The circuit or grounding is faulty.

1. The bulb has been damaged.

2. The fuse has been burned down.

3. The backup lamp switch is faulty.

4. The circuit or grounding is faulty. Incorrect adjustment or damage to the switch of backup lamp.

1. Replace the bulb.

2. Check the circuit.

1. Replace the bulb.

2. Replace the fuse.

3. Check the switch.

4. Check the circuit. Check the backup lamp switch.

4. COMMON MALFUNCTIONS OF STOP LAMP AND TROUBLESHOOTING

Malfunction symptom Malfunction Diagnosis Troubleshooting

One side of the brake lamps is not working

Neither of the brake lamps is not working

Brake lamp is continuously working.

1 The bulb has been damaged.

2. The conducting wire or grounding is faulty.

1. The bulb has been damaged.

2. The fuse has been burned down.

3. The brake lamp switch is faulty.

4. The conducting wire or grounding is faulty. Incorrect adjustment or damage to the switch of backup lamp.

1. Replace the bulb.

2. Check the circuit.

1. Replace the bulb.

2. Replace the fuse.

3. Check the brake lamp switch.

4. Check the circuit.

Check the brake lamp switch.

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5. COMMON MALFUNCTIONS OF TURN SIGNAL LAMP AND TROUBLESHOOTING

Malfunction

symptom

Left and right flashing frequencies are not the same or one side is not flashing.

Both sides are not flashing

The flashing frequency is too low

Malfunction Diagnosis Troubleshooting

1. The bulb of the “fast flashing frequency” side has been damaged.

2. The bulb power does not comply with the specification.

3. The relay of turn signal lamp is faulty.

4. The conducting wire or grounding is

faulty.

1. The bulb has been damaged.

2. The fuse has been burned down.

3. The relay of turn signal lamp is faulty.

4. The switch of turn signal lamp is

faulty.

5. The conducting wire or grounding is

faulty.

1. Battery voltage is too low.

2. The bulb power does not comply with specification.

3. The relay of turn signal lamp is faulty.

4. The circuit is faulty.

1. Replace the bulb.

2. Replace the standard bulb.

3. Check and replace the relay.

4. Check the circuit.

1. Replace the bulb.

2. Replace the fuse.

3. Check the relay.

4. Check the switch of turn signal lamp.

5. Check the circuit.

1. Check the battery and recharge battery.

2. Change into the standard

bulb.

3. Check/replace the relay.

4. Check the circuit.

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IGNITION SYSTEM

SUMMARY OF IGNITION SYSTEM

The ignition system is integrated with the fuel injection system. It is an electronic system equipped with built-in power supply module. It can provide various kinds of optimum ignition angular values. This task is being carried out through referencing of the input instantaneous physical parameter related with the engine working conditions. With the help of a circuit analyzing microprocessor, it is capable of writing in the various optimum ignition values into the program.

Circuit of ignition system

1. Knock sensor 2. Ignition coil 3. Rotary sensor 4. Ignition switch

5. Relay 6. Ignition / Fuel injection ECU 7. Fuse

When ECU is breaking off the current of the primary coil, the resulted induction effect of the secondary coil causes the voltage to rise (as high as 30,000V at idling speed), at this moment the breakdown voltage of the compression stroke stage in the cylinder is very high (>10,000V), and the breakdown voltage of the exhaust stroke stage in the cylinder is very low (approx. 500V). The spark plugs in the 1-4 cylinders and 2-3 cylinders are directly connected to the terminals of the secondary coils through high voltage cables.

Note: Take extreme care not to reverse the connection of high voltage cable during

reinstallation.

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REMOVAL /INSTALLATION OF IGNITION COIL AND SPARK PLUGS:

1. Disconnect the wiring harness terminal post

from the negative grid of the battery．

2. Pull out the 4 connectors of high voltage cable and ignition module plug.

3. Unscrew the three fastening screws for the ignition module, and remove the ignition module.

4. Pull out the high voltage cables, and uses a special spark plug socket spanner to remove the spark plugs. (Tightening torque: 10~14 Nm)

5. The installing steps are reverse to those for

removal.

Note:

Ensure that the spark plugs are restored to their

original positions during reinstallation. Any

incorrect installation will not only damage the

leading wires of the spark plugs and cause power

losses, but also cause adverse impact to the electronic components.

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OVERHAUL IGNITION SYSTEM

----Disconnect the negative grid of the battery.

----Remove the spark plugs with a special tool, and check whether the spark plugs have been

ablated and there is any crack at the skirt section.

----Check whether the gap of spark plugs complies with the requirement.

Standard value: 1.1±0.5mm

----Check the spark plugs.

Note:

l Do not check, adjust or clean the gap of spark plugs with a metal brush. Otherwise, it

will damage the platinum igniter.

When spark plugs are cleaned with compressed gas, the cleaning process should be completed within 20 seconds and the compressed gas value should not exceed 58.8kpa (6.6kgf/cm2, 8.5psi). After completion of cleaning, make sure that no foreign materials such as carbon or sand are left in spark plugs.

----Check whether there is any crack on the appearance of high voltage cables, and replace

the high voltage cable if the resistance is too high.

----Check whether the resistance of ignition coils complies with the specification.

Standard value: Primary coil resistance: 0.4Ω ±10%（at the temperature of 23±5°C）

Secondary coil resistance: 4900Ω±10%（at the temperature of 23±5°C）

If the resistance of ignition coils does not comply with the specification, please replace with the original spare parts designated by Chery Automobile so as to prevent the improper operation of the ignition system.

Inspection of ignition timing:

Note:

·The ignition timing must not be adjusted.

·Checking the ignition timing requires the usage of WDS or corresponding instrument.

1. Switch off all the electrical devices in the vehicle.

2. The procedures of preheating the engine are as follows:

(1) Start the engine

(2) Keep the rotation speed of the engine at about 3,000 R.P.M. until the cooling fan starts to rotate.

(3) Release the fuel-accelerating pedal.

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Chery A15 2006 2010, A15 2003, A15 2004, A15 2005 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual