Chery QQ6 LHD 2006 2014 User Manual

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Service Manual For

CHERY QQ6

(Body Accessories and Dimensions)

After Sales Service Department of Chery

Automobile Sales Co., Ltd

TABLE OF CONTENTS

Chapter 1 Engine Hood and Luggage Compartment ........................................................................ 8

I. Removal of Engine Hood ......................................................................................................8

1. Preparation.................................................................................................................... 8

2. Precautions.................................................................................................................... 8

3. Disassembly/Reassembly of engine hood accessories ..................................................8

3.1. Removal Step ..................................................................................................... 8

3.2. Installation Step..................................................................................................8

Disassembly and adjustment of the engine hood assy....................................................... 9

Disassembly and assembly of air intake grille assy. .........................................................9

5.1. Removal Step ..................................................................................................... 9

5.2. Installation Step..................................................................................................9

Adjustment and assembly of the engine hood lock......................................................... 10

6.1. Removal Step ................................................................................................... 10

6.2. Installation of engine hood lock....................................................................... 10

7. Removal of hood lock control cable ...........................................................................10

7.1. Removal Step ................................................................................................... 10

7.2. Installation Step................................................................................................12

II. Disassembly/Reassembly of rear boot lid ..........................................................................12

1. Preparation.................................................................................................................. 12

2. Removal of Trunk Lid Ornament Plate....................................................................... 12

2.1. Removal Step ................................................................................................... 12

2.2. Installation Step................................................................................................12

3. Installation of luggage boot lock.................................................................................12

3.1. Removal Step ................................................................................................... 12

3.2. Installation Step................................................................................................13

4. Removal of license plate lamp ....................................................................................13

4.1. Removal Step ................................................................................................... 13

4.2. Installation Step................................................................................................14

Chapter 2 Disassembly/Reassembly of Interior Decorations.......................................................15

I. Disassembly/Reassembly of Seat Belt................................................................................. 15

1. Preparation.................................................................................................................. 15

2. Precautions.................................................................................................................. 15

3. Removal Step (Driver’s seat belt is taken as an example) ..........................................15

4. Installation Step...........................................................................................................17

II. Disassembly/Reassembly of Seat....................................................................................... 18

1. Front passenger seat removal step ..............................................................................18

2. Rear passenger seat removal step................................................................................18

3. Installation Step...........................................................................................................20

III. Disassembly/Reassembly of Console ...............................................................................20

1. Removal Step .............................................................................................................. 20

2. Installation Step...........................................................................................................21

IV. Disassembly/Reassembly of Carpet ..................................................................................22

1. Removal Step .............................................................................................................. 22

2. Installation Step...........................................................................................................22

V. Removal of Cushion Pad.................................................................................................... 23

1. Removal Step .............................................................................................................. 23

2. Installation Step...........................................................................................................24

Chapter 3 Removal and Maintenance of Door............................................................................. 25

I. Disassembly/Reassembly and Maitenance of Front Door...................................................25

1. System Composition Diagram ....................................................................................25

2. Preparation.................................................................................................................. 26

3. Precautions.................................................................................................................. 26

4. Disassembly/Reassembly Step....................................................................................26

5. Installation and Adjustment Step ................................................................................33

II. Disassembly/Reassembly and Maintenance of Rear Door.................................................34

1. Preparation.................................................................................................................. 34

2. Precautions.................................................................................................................. 34

3. Removal Step .............................................................................................................. 34

4. Installation and Adjustment Step ................................................................................40

Chapter 4 Disassembly/Reassembly and Maintenance of Front/Rear Bumper............................41

Disassembly/Reassembly and Maintenance of Front Bumper................................................41

1. System Composition Diagram ....................................................................................41

2. Preparation.................................................................................................................. 41

3. Precautions.................................................................................................................. 41

4. Removal Step .............................................................................................................. 42

5. Installation and Maintenance ......................................................................................44

Disassembly/Reassembly and Maintenance of Rear Bumper................................................. 45

1. System Composition Diagram ....................................................................................45

2. Preparation.................................................................................................................. 45

3. Precautions.................................................................................................................. 45

4. Removal Step .............................................................................................................. 46

5. Installation Step...........................................................................................................47

Chapter 5 Disassembly/Reassembly and Maintenance of Headlamp and Fog Lamp.................. 48

1. System Composition Diagram ....................................................................................48

2. Preparation.................................................................................................................. 49

3. Precautions.................................................................................................................. 49

4. Removal Step of Headlamp ........................................................................................ 49

5. Removal of Fog Lamp ................................................................................................52

6. Installation and Adjustment of Headlamp................................................................... 53

6.1. headlamp Installation Step............................................................................... 53

6.2. Introduction to headlamp function ................................................................... 53

6.2.1. Front view .............................................................................................53

6.2.2. Back view..............................................................................................53

6.3. Adjustment of headlamp light.......................................................................... 53

7. Tail Lamp Removal Step.............................................................................................55

Chapter 6 Disassembly/Reassembly of Ceiling ...........................................................................56

1. Preparation..........................................................................................................................56

2. Precautions.......................................................................................................................... 56

3. Disassembly/Reassembly of Sun Visor............................................................................... 56

3.1. Removal Step ........................................................................................................... 56

3.2. Installation Step........................................................................................................56

4. Disassembly/Reassembly of Roof Hand-Hold....................................................................57

4.1. Removal Step ........................................................................................................... 57

4.2. Installation Step........................................................................................................57

5. Disassembly/Reassembly of Front Ceiling Lamp............................................................... 57

5.1. Removal Step ........................................................................................................... 57

5.2. Installation Step........................................................................................................58

6. Disassembly/Reassembly of A Pillar Trim.......................................................................... 58

6.1. Removal Step ........................................................................................................... 58

6.2. Installation Step........................................................................................................58

7. Disassembly/Reassembly of B Pillar Trim .........................................................................58

7.1. Removal Step ........................................................................................................... 58

7.2. Installation Step........................................................................................................59

8. Disassembly/Reassembly of C Pillar Trim .........................................................................59

8.1. Removal Step ........................................................................................................... 59

8.2. Installation Step........................................................................................................59

9. Disassembly/Reassembly of Ceiling...................................................................................59

9.1. Removal Step ........................................................................................................... 59

9.2. Installation Step........................................................................................................60

Chapter 7 Disassembly/Reassembly of Instrument Panel............................................................ 61

I. Removal of Instrument Panel Accessories ..........................................................................61

1. Preparation.................................................................................................................. 61

2. Disassembly/Reassembly of Central Console Panel, Audio Unit, Emergency Switch,

A/C Control Switch, Ashtray ..........................................................................................61

2.1. Removal Step ................................................................................................... 61

2.2. Installation Step................................................................................................62

3. Disassembly/Reassembly of Front Ashtray ................................................................62

3.1. Removal Step ................................................................................................... 62

3.2. Installation Step................................................................................................63

4. Disassembly/Reassembly of Glove Case....................................................................63

4.1. Removal Step ................................................................................................... 63

4.2. Installation Step................................................................................................63

5. combination instrument Disassembly/Reassembly of..............................................63

5.1. Removal Step ................................................................................................... 63

5.2. Installation Step................................................................................................64

6. Disassembly/Reassembly of Combination Switch, Wiper Switch, Ignition Switch,

Heliax Cable ...................................................................................................................64

II. Removal of Instrument Panel.......................................................................................... 65

1. Disassembly/Reassembly of Instrument Panel ........................................................65

1.1. Removal Step ................................................................................................... 65

1.2. Installation Step................................................................................................67

2. Removal of Instrument Panel cross beam.............................................................68

2.1. Removal Step ................................................................................................... 68

2.2. Installation Step................................................................................................70

Chapter 8 Air Conditioning (A/C) System ..................................................................................71

I. System Composition............................................................................................................ 71

II. Removal of Evaporator Assy.............................................................................................. 71

1. Preparation.................................................................................................................. 71

2. Disassembly/Reassembly Step....................................................................................71

3. Installation of Evaporator Assy................................................................................... 73

4. Disassembly/Reassembly of Evaporator Interior ........................................................73

4.1. Removal Step ................................................................................................... 73

4.2. Installation Step................................................................................................78

III. Troubleshooting ................................................................................................................78

Chapter 9 Body Dimension..........................................................................................................80

I. Chassis Control Point .......................................................................................................... 80

II. Body Assembly Dimension ................................................................................................ 83

1. Front View ..................................................................................................................83

2. Rear View....................................................................................................................86

3. Left View ....................................................................................................................90

4. Top View ...................................................................................................................104

III. Dimension of Engine Compartment ............................................................................... 110

Windscreen Dimension......................................................................................................... 111

V. Dimension of Opening of Each Part................................................................................. 112

Chapter 10 Wire Harness ........................................................................................................... 113

Section 1 Battery Negative Electrode Harness .................................................................. 113

I. Schematic Diagram of Harness .................................................................................113

II. Main Connectors Description................................................................................... 113

III. Disassembly/Reassembly of Battery Harness......................................................... 113

(I). Preparation...................................................................................................... 113

(II). Precautions..................................................................................................... 113

(III). Removal Procedure ...................................................................................... 113

Section 2 Engine Compartment Harness .........................................................................115

I. Schematic Diagram of Harness .................................................................................115

II. Main Connectors Description................................................................................... 116

III. Disassembly/Reassembly of Engine Compartment Harness................................117

(I). Preparation...................................................................................................... 117

(II). Precautions: ................................................................................................... 117

(III). Removal Procedure ...................................................................................... 117

Section 3 Electronic Injector Harness................................................................................ 125

I. Schematic Diagram of Harness .................................................................................125

II. Main Connectors Description...................................................................................126

III. Disassembly/Reassembly of Engine Harness ......................................................... 127

(I). Preparation...................................................................................................... 127

(II). Precautions.....................................................................................................127

(III). Removal Procedure ......................................................................................127

Section 4 Interior Harness................................................................................................133

I. Schematic Diagram of Harness .................................................................................133

II. Main Connectors Description...................................................................................134

III. Disassembly/Reassembly of Interior Floor Harness ............................................... 135

(I). Preparation...................................................................................................... 135

(II). Precautions.....................................................................................................135

(III). Removal Procedure ......................................................................................135

Section 5 Instrument Harness Assy.................................................................................. 142

I. Schematic Diagram of Harness .................................................................................142

II. Definition of Main Connectors.................................................................................143

III. Disassembly/Reassembly of Instrument Harness ................................................150

(I). Preparation...................................................................................................... 150

(II). Precautions.....................................................................................................150

(III). Removal Procedure ......................................................................................150

Section 6 Evaporator Harness............................................................................................ 152

I. Schematic Diagram of Harness .................................................................................152

II. Definition of Main Connectors.................................................................................152

III. Disassembly/Reassembly of Evaporator Harness ...................................................153

(I). Preparation...................................................................................................... 153

(II). Precautions.....................................................................................................153

(III). Removal Procedure ......................................................................................153

Section 7 Front Left Door Harness.................................................................................... 155

I. Schematic Diagram of Harness .................................................................................155

II. Main Connectors Description...................................................................................156

III. Disassembly/Reassembly of Front Left Door Inner Harness.................................. 157

(I). Preparation...................................................................................................... 157

(二) , Precautions ..................................................................................................157

(III). Removal Procedure ......................................................................................157

Section 8 Front Right Door Harness.................................................................................. 159

I. Schematic Diagram of Harness .................................................................................159

II. Main Connectors Description...................................................................................160

III. Disassembly/Reassembly of Front Right Door Inner Harness................................160

1. Removal Step .................................................................................................... 160

2. Installation Step.................................................................................................160

Section 9 Rear Door Harness............................................................................................. 161

I. Schematic Diagram of Harness .................................................................................161

II. Main Connectors Description...................................................................................162

III. Disassembly/Reassembly of Rear Left Door Inner Harness ...................................163

(I). Preparation...................................................................................................... 163

(II). Precautions.....................................................................................................163

(III). Removal Procedure ......................................................................................163

IV. Disassembly/Reassembly of Rear Right Door Inner Harness.................................164

Section 10 Back Door Harness ..........................................................................................165

I. Schematic Diagram of Harness .................................................................................165

II. Main Connectors Description...................................................................................166

III. Disassembly/Reassembly of Back Door Inner Harness .......................................... 167

(I). Preparation...................................................................................................... 167

(II). Precautions.....................................................................................................167

(III). Removal Procedure ......................................................................................167

Section 11 Defroster Harness............................................................................................. 170

I. Schematic Diagram of Defroster Positive Harness.................................................... 170

II. Schematic Diagram of Defroster Negative Harness................................................. 170

III. Main Connectors Description .................................................................................170

IV. Disassembly/Reassembly of Rear Defroster Harness ............................................. 171

(I). Preparation...................................................................................................... 171

(II). Precautions.....................................................................................................171

(III). Removal Procedure ......................................................................................171

Chapter 1 Engine Hood and Luggage Compartment

I. Removal of Engine Hood

1. Preparation

Tool: flat head screwdriver, pliers, wrench

2. Precautions

2.1. During the removal, pay more attention to

the application of appropriate strength.

No rude operation.

2.2. During the removal/reassembly of trim,

especially pay more attention to the protection

of surface ornaments so that any ornament may

not be damaged.

3. Disassembly/Reassembly of engine hood accessories

3.1. Removal Step

3.1.1. Remove the clip from the heat insulation

washers (19 pcs in total) with a flat head

screwdriver, and detach the heat shield from the

engine compartment.

3.1.2. Pull off the washing liquid hose.

3.1.3. Detach two water spray nozzle clips from

the bottom of engine hood, push the nozzle

from the bottom of engine hood, and take out

the nozzle from the outside.

3.2. Installation Step

The installing steps are reverse to those for

removal.

4. Disassembly and adjustment of the engine hood assy.

Preparation of tool(s): 13# wrench

4.1. Take off four adjusting bolts from engine

hood. And remove the engine hood.

At the same time, unscrew four adjusting bolts

to adjust the front/rear position and right/left

position of the engine hood.

4.2. Installation of engine hood assy.:

The installing steps are reverse to those for

removal.

Installation torque is 30±1Nm

5. Disassembly and assembly of air intake grille assy.

Preparation of tool(s): cross screwdriver, socket

wrench

5.1. Removal Step

5.1.1. Open the engine hood by hand.

5.1.2. Use a cross screwdriver to remove the fix

screw from the intake grille.

5.1.3. Utilize a socket wrench to remove the

fixing bolts from the intake grille.

5.1.4. Detach the intake grille.

5.2. Installation Step

The installing steps are reverse to those for

removal.

Installation torque is 5±1Nm

6. Adjustment and assembly of the engine hood lock

Preparation of tool(s): 10# wrench

6.1. Removal Step

6.1.1. Unscrew three centering bolts from the

engine hood, and then remove the engine hood

lock.

Also unscrew these three bolts to adjust the

position of engine hood lock.

Torque: 9±1 Nm

6.1.2. Remove the lock cable of front engine

hood from engine hood lock assy.

6.2. Installation of engine hood lock

The installing steps are reverse to those for

removal.

Installation torque is 9±1Nm

7. Removal of hood lock control cable

Preparation of tool(s): 8# wrench, 10# wrench,

flat head screwdriver

7.1. Removal Step

7.1.1. Open the engine hood inside the driver’s

cab, and remove two fixing bolts from the

handle.

Installation torque is 9±1Nm

7.1.2. Remove the front hood cable from the

hood.

7.1.3. Remove the hood lock and detach the

engine hood lock control cable from the hood

lock assy..

7.1.4. Remove three clips used to fix the control

cable by hand or with a flat head screwdriver.

7.1.5. Draw out the control cable from the

engine compartment.

7.2. Installation Step

Preparation of tool(s): 10# wrench

The installing steps are reverse to those for

removal.

CAUTION: In case of installation, the groove

on control cable shall be inserted into the pull

groove; the control cable penerates into driver’s

cab through the engine compartment, and shall

passes through a small hole and then enters into

the cab, as shown in the figure.

II. Disassembly/Reassembly of

rear boot lid

1. Preparation

Tools: Flat head and cross screwdriver, socket

wrench, open-end wrench

Materials: clip

2. Removal of Trunk Lid Ornament Plate

Small hole

2.1. Removal Step

2.1.1. Remove the screws from the fixed

luggage boot internal guard plate with a cross

screwdriver.

2.1.2. Remove the disposable clips from the

fixed luggage boot internal guard plate with a

flat head screwdriver, and then remove the

luggage boot internal guard plate.

2.2. Installation Step

The installing steps are reverse to those for

removal.

3. Installation of luggage boot lock

3.1. Removal Step

3.1.1. Detach the connectors of the luggage

boot lock body motor.

3.1.2. Detach two locating bolts from the

luggage boot lock (the installation torque is 9±1

Nm)

3.1.3. Remove the luggage boot lock core.

3.1.4. Remove two fixing bolts from the trunk

(i.e. luggage boot) lock body with a socket

wrench.

3.1.5. Take off the trunk lock body.

3.2. Installation Step

The installing steps are reverse to those for

removal.

Precautions on installation of luggage boot

lock: check whether the lock column is

deformed, whether the riveted connections are

in its proper positions, and whether the lock

tongue can open or close flexibly, smoothly.

4. Removal of license plate lamp

Preparation of tool(s): cross screwdriver,

open-end wrench.

4.1. Removal Step

4.1.1. Remove the trunk internal ornament plate

(see Removal of trunk lid ornament plate)

4.1.2. Remove two fixing bolts from the license

plate lamp with an open-end wrench.

4.1.3. Disconnet the connecting plugs from the

right and left license plate lamps and then take

off the license plate lamp assy.

4.1.4. Remove two fix screws from the license

plate lamp with a cross screwdriver.

4.1.5. Take off the license plate lamp

4.1.6. Take off the bulb from the license plate

lamp.

4.2. Installation Step

The installing steps are reverse to those for

removal.

Chapter 2 Disassembly/Reassembly of Interior Decorations

I. Disassembly/Reassembly of

Seat Belt

1. Preparation

Tools: flat head screwdriver, wrench, sleeve.

Parts: disposable clips.

2. Precautions

Keep the seat belt clean, avoid the oil stain, and

check whether the seat belt is damaged.

3. Removal Step (Driver’s seat belt is taken as an example)

Prize the front threshold pressing plate

carefully with a flat head screwdriver.

3.2. Remove the weatherproof rubber strip of

the front door opening.

3.3. Remove the rear scuff plate.

3.4. Remove the weatherproof rubber strip of

the rear door opening.

3.5. Remove the seat belt lower ornament

cover.

3.6. Unscrew the fixing nuts with a 17# sleeve,

and detach the B pillar lower trim.

Installation torque is 50±5Nm

3.7. Unclench the ornament cover on the seat

belt regulator with a flat head screwdriver.

CAUTION: Pay attention to the breakage of

clip inside the regulator.

3.8. Loosen the fixing nuts with a 17# sleeve,

and then take off the seat belt.

Installation torque is 50±5Nm

fit clearance of lower trim shall be even and

3.9. Unclench the B pillar trim with a

right-angled screwdriver.

3.10. Take off the B pillar trim.

3.11. Remove the fix screws from the seat belt

with a cross screwdriver.

3.12. Loosen the fixing nuts with a 17# sleeve,

and then take off the seat belt.

4. Installation Step

The installing steps are reverse to those for

removal.

Note:

4.1. Keep the seat belt clean, avoid the oil stain,

and check whether the seat belt is damaged.

4.2. The pillar trim shall securely fit with the

body, without any loose symptoms; and the

trim shall fit well with the ceiling and rubber

strip.

4.3. The seat belt adjusting slide baffle on the B

pillar upper trim shall move freely, without any

influence on the adjustment of seat belt, and the

below 1mm;

4.4. The fit clearance between B pillar low trim

and front/rear scuff plate shall be even and less

than 1mm;

II. Disassembly/Reassembly of

Seat

Tool: 16# sleeve

1. Front passenger seat removal step

1.1. Pull the moveable handle under the left

seat to move the left seat backwards and reveal

the fixing bolts under the seat.

1.2. Remove two fixing bolts before the seat.

by sleeve

1.3. Turn the moveable handle and pull

forwards the seat, and expose two fixing bolts

on the rear of seat.

1.4 Disassemble two fixing bolts at the back

of seat with sleeve.

1.5 Pull off the inserter under seat and take

away the seat.

2. Rear passenger seat removal step

2.1 Lift up the rear passenger seat cushion by

hand, and then take out the cushion from the

clips of chassis and body.

2.2. Directly take out the seat cushion by both

hands.

2.3. Loosen the front fixing bolts at the right

side of rear right seat with an open-end wrench.

2.4. Loosen the front fixing bolts at the left

side of rear right seat with an open-end wrench.

2.5. Pull up the ring-pull of rear right seat,

and lay down the seat forwards.

2.6. Loosen the rear fixing bolts at the right side

of rear right seat with an open-end wrench.

2.7. Loosen the rear fixing bolts at the left side

of rear right seat with an open-end wrench, and

then remove the rear right seat.

2.8. Loosen the front fixing bolts of rear right

seat with a open-end wrench.

2.9. Pull up the ring-pull of rear left seat, and

lay down the seat forwards.

3.0. Loosen the rear fixing bolt of rear left seat

with a sleeve, and then remove the rear left

seat.

3. Installation Step

The installing steps are reverse to those for

removal.

Installation torque is 25±3Nm

III. Disassembly/Reassembly of

Console

Tool: cross head screwdriver

1. Removal Step

1.1. Remove each two bolts at left and right

sides with a cross screwdriver, these bolts of

which are used to joint the console and front

lower guard plate.

(The tightening torque is 2±0.5N.m)

1.2. Remove the bolts used to joint the console

and body lower guard plate with a cross

screwdriver.

(The tightening torque is 2±0.5N.m)

1.3. Detach the console hand brake ornament

plate by hand.

1.4. Pull out the cigarette lighter plug on the

console by hand.

1.5. Take off the console.

2. Installation Step

The installing steps are reverse to those for

removal.

IV. Disassembly/Reassembly of

Carpet

Tool: flat head screwdriver, cross head screwdriver; sleeve

1. Removal Step

1.1. Remove the seat. (See Disassembly of

Seat)

1.2. Remove the scuff plate, lower trims of B

and C pillars.

(See Disassembly of B and C Pillars)

1.3. Remove the A pillar lower trim.

1.4. Remove the armrest box and console. (See

Disassembly of Armrest Box and Console)

1.5. Prize the cover on the driver pedal with flat

head screwdriver.

1.6. Remove two fixing nuts from the driver’s

pedal with a socket wrench, and then take off

the pedal.

Installation torque: 7±1N.m

1.7 Take off the carpet after Pull off the carpet

connectors

2. Installation Step

2.1. Place the carpet into the vehicle, tightedly

press the carpet near the central passage, and

expose the corresponding hole from the carpet

hole, and lay the carpet reliably.

2.2. Lay the left central rear part of carpet

according to the shape of the vehicle bottom,

and reveal the installation holes of front left

seat and lay the carpet reliably.

2.3. Lay the right central rear part of carpet

according to the shape of the vehicle bottom,

and reveal the installation holes of front right

rear seat and lay the carpet reliably.

2.4. Lay well the rear part of carpet according

to the shape of vehicle bottom.

V. Removal of Cushion Pad

1. Removal Step

1.1. Disassemble the carpet (See disassembly of

carpet)

1.2. Take off all cushion pads.

2. Installation Step

2.1. The installing steps are reverse to those for

removal.

2.2. Precautions on reassembly of cushion pad:

2.2.1. Take out the connector harness from the

seat and rear oxygen sensors when the cushion

pad is laid.

2.2.2. Make the shock absorber lower surface

joint tightly with plate work.

Chapter 3 Removal and Maintenance of Door

I. Disassembly/Reassembly and Maitenance of Front Door

1. System Composition Diagram

2. Preparation

Tools: right-angled screwdriver, cross

screwdriver, 7#, 10# and 13# sleeves, plier.

3. Precautions

3.1 Please wear necessary labor protection

supplies to avoid accidents.

3.2 Power off accumulator to avoid damage the

electrical units.

3.3 Use the correct method to disassemble and

assemble the glass to avoid damage.

4. Disassembly/Reassembly Step

4.1. Unclench the protecting cover of glass

drive switch on the door inner guard plate with

a right-angled screwdriver.

4.2. Pull out the connector from the glass drive

switch by hand..

4.3. Unscrew the fix screws of front door inner

handle with a cross screwdriver.

4.4. Take off the inner handle frame by both

hands.

4.5. Separate the inner bar from the inner

handle with a right-angled screwdriver.

4.6. Remove the fix screws from the front door

inner guard plate with a cross screwdriver.

4.7. Lift up the door inner guard plate from the

lower to upper by both hands.

4.8. Directly take out the door inner guard plate

by both hands.

4.9. Tear down front door water-proof plastic

clothing.

4.10. Take off the interior set square of the

exterior rear-view mirror by hand.

4.11. Pull out the connector of the exterior

rear-view mirror by hand.

4.12. Remove three fix screws from the exterior

rear-view mirror with a sleeve.

4.13 Remove three fix screws from the exterior

rear-view mirror with a sleeve.

4.14 Take off the exterior rear-view mirror assy

by hand.

4.15. Unscrew four fixing screws from front

door sound box by cross head screwdriver.

Take out sound box assy.

4.16 Pull out the connector of the front door

sound box.

4.17 Reinsert the glass drive switch into the

harness, and descend the front door glass down

to its lowest position.

4.18. Loose two fixing screws on the glass by

cross head screwdriver.

And take out the glass assembly.

Torque: 4.5±0.5 N.m.

4.19 When the glass assy is being taken, erect

the glass assy so as to easily take off it.

4.20 Remove six fixing bolts from the window

glass regulator with a 10# sleeve.

Torque: 9±1 N·m.

4.21 Pull out the connector of window glass

regulator by hand.

4.22 Take off the window glass regulator assy.

4.23 Separate the upper fixing clips of front

door lock core rod from the lock by hand.

4.24 Separate the lower fixing clips of front

door lock core rod from the lock by hand.

4.25 Loosen the fix screws of front door

exterior handle with a sleeve.

4.26. Take out lock core and handle assy.

4.27 Remove three fix screws from the front

door lock core with a cross screwdriver.

Installation torque: 9±1 Nm

4.28 Pull out the fastener connector and then

take off the fastener.

4.29 Loosen two upper fixing bolts of front

door hinge from the door with a 13# wrench.

Torque: 36±4N.m.

4.30 Loosen two lower fixing bolts of front

door hinge from the door with a 13# wrench.

Torque: 36±4N.m.

4.31 Remove the fixing bolts of door limiter

from the door with a 10# sleeve.

Torque: 10±1 N.m

4.32 Remove the fixing bolts of door limiter

from the body with a 10# sleeve, and then take

off the door limiter.

Torque: 10±1 N.m

4.33 Pull out the door harness, and then take off

the door body.

5. Installation and Adjustment Step

5.1. The installing steps are reverse to those for

removal.

5.2. Adjustment of door

5.2.1. After the installation of door, check the

horizontial and vertical clearances and the

closing force of door. If the clearance is

incorrect and the closing force is big, timely

adjust the clearnace and force. See Body

Dimension for the adjustment of door

clearance.

5.2.2. The door clearance is adjusted by

regulating the fixing bolts of hinge at the body.

5.2.3. The closing force of door can be slightly

adjusted by regulating the position of front door

lock column.

Torque: 9±1Nm.

5.3. Adjustment of door glass regulator system.

5.3.1. Check the window regulator system after

this system is assembled. The duration of

window glass lifting from the lowest position to

the highest position shall be approximate 7 s.

If the time is too long, check the regulator in

time.

5.3.2 Check window regulator motor.

5.3.3. Check whether there is oil or dust in the

glass run channel which may result that the

resistance is overhigh when the window glass is

rising.

CAUTION: DO NOT apply any lubricating

grease on the glass run channel or glass so as to

avoid the adhesion of dust.

5.3.4. Check whether the installation of glass

guide is deviated from its proper position,

which may result that the glass is clamped due

to the nonuniform arc scale when the glass is

rising. The position of glass guide can be

adjusted by the guide fixing bolts.

II. Disassembly/Reassembly and

Maintenance of Rear Door

1. Preparation

Flat head screwdriver, cross head screwdriver,

No.7, 10, 13 sleeves and pliers.

2. Precautions

2.1 Please wear necessary labor protection

supplies to avoid accidents.

2.2 Power off accumulator to avoid damage the

electrical units.

2.3 Use the correct method to disassemble and

assemble the glass to avoid damage.

3. Removal Step

3.1. Prize two rear door glass slot protecting

boards with flat head screwdriver.

(See front door disassembly to disassemble

weather strip)

3.2. Unscew the fix screws of rear door inner

handle with a cross screwdriver.

3.3. Take off the inner handle frame by both

hands.

3.4. Separate the inner bar from the inner

handle with a right-angled screwdriver.

3.5. Unclench the protecting cover of glass

drive switch from the door inner guard plate

with a right-angled screwdriver.

3.6. Pull out the connector of glass drive switch

by hand.

3.7. Remove the fix screws from the front door

inner guard plate with a cross screwdriver.

3.8. Directly take off the door inner guard plate

by both hands.

3.9. Tear down front door water proof plastic

clothing.

3.10. Unscrew four fixing screws from front

door sound box with cross head screwdriver.

Take out sound box assembly.

3.11. Pull out the connector of front door sound

box.

3.12. Reinsert the glass drive switch into the

harness, and then descend the front door

window glass down to its lowest position.

3.13 Loosen two fixing screws on the glass

with cross head screwdriver.

And take out the glass assembly.

Torque: 4.5±0.5 N.m.

3.14. When the glass assy is being taken, erect

the glass assy so as to easily take off it.

3.15. Remove six fixing bolts from the window

glass regulator with a 10# sleeve.

Torque: 7±1 N·m.

3.16. Pull out the connector of window glass

regulator by hand.

3.17. Take off the window glass regulator assy.

3.18. Push aside the fixed mounting of lock

core rod from the door with a right-angled

screwdriver.

3.19. Separate the fixing clips of lock core rod

from the lock by hand.

3.20. Take off the lock core rod by hand.

3.21. Separate the upper fixing clips of front

door lock core rod from the lock by hand.

3.22. Separate the lower fixing clips of front

door lock core rod from the lock by hand.

3.23. Loosen the fix screws of front door

exterior handle with a cross screwdriver.

3.24. Take out lock core and handle assy.

3.25. Remove three fix screws from the front

door lock with a cross screwdriver.

3.26. Pull out the fastener connector, and then

take off the fastener.

3.27. Remove the fixing bolt from the door

limiter with a 10# sleeve.

Torque: 10±1 N.m

3.28. Remove the other fixing bolt from the

door limiter with a 10# sleeve, and then take off

the door limiter.

Torque: 10±1 N.m

3.29. Loosen two upper fixing bolts of front

door hinge from the door with a 13# wrench.

Torque: 36±4N.m.

3.30. Loosen two lower fixing bolts of front

door hinge from the door with a 13# wrench.

Torque: 36±4N.m.

3.31 Pull out the door harness, and then take off

the door body.

4. Installation and Adjustment Step

4.1. The installing steps are reverse to those for

removal.

4.2. Adjustment of door

4.1.1 Rear door clearance can not be adjusted

by hinge adjustment. If the door clearance is

improper, correct the body only to ensure the

clearance.

(See Body Dimension)

4.1.2 Please refer to Front Door Adjustment.

Chapter 4 Disassembly/Reassembly and Maintenance of

Front/Rear Bumper

I. Disassembly/Reassembly and Maintenance of Front Bumper

1. System Composition Diagram

Front/Rear Bumper

2. Preparation

No.7 and No10 sleeve, cross head screwdriver and flat head screwdriver.

3. Precautions

3.1. Please wear necessary labor protection supplies to avoid accidents.

3.2. To prevent scratch the bumper surface paint.

3.3. Carry out the disassembly and assembly at low temperature environment, do not use big force,

otherwise the bumper will be broken.

4. Removal Step

4.1 Open the front engine hood by hand.

4.2 Loosen the fixing bolts of front bumper

from the right and left sides of radiator cross

beam with a 10# sleeve. (The left side is taken

as an example)

Torque: 11N·m

4.3 Loosen the fixing bolts of front bumper

from the intermediate part of radiator cross

beam with a 10# sleeve.

Torque: 11N·m

4.4 Loosen two fixing bolts under the bumper

from the mud guard with a 7# sleeve.

Installation torque: 2±0.5 Nm

4.5. Unscrew mudguard fixing bolt beside the

bumper with No.7 sleeve.

Installation torque: 2±0.5N.m

4.6 Remove the fixing bolts of mud guard from

the side of bumper with a cross screwdriver.

4.7 Pull out the bumper from the fixed

mounting at the fender by hand.

4.8. Pull out fog lamp plug by hand, and take

out bumper assy.

4.9 Remove three screws applied to joint the

fog lamp and bumper with a cross screwdriver.

4.10 Remove the bumper body assy.

4.11 Loosen three fixing bolts and a fixing nut

used to secure the front bumper stiffening beam

with a 13# sleeve.

Torque: 25±3N.m

4.12 Loosen intake grille fixing screws from

both sides of bumper with a cross screwdriver.

5. Installation and Maintenance

5.1. The installing steps are reverse to those for

removal.

II. Disassembly/Reassembly and Maintenance of Rear Bumper

1. System Composition Diagram

Front/Rear Bumper

2. Preparation

Tools: cross screwdriver, 7# sleeve.

3. Precautions

3.1. Please wear necessary labor protection supplies to avoid accidents.

3.2. To prevent scratch the bumper surface paint.

3.3. When the rear bumper is disassembled/reassembled in the low temperature environment, the

force applied can’t be big so as to avoid the breakage of the bumper.

4. Removal Step

4.1. Open the luggage boot lid, and loosen two

fixing clips from the rear bumper with a cross

screwdriver. See right figure.

4.2. Loosen the fix screws and clips of rear

bumper and rear mud guard with a 7# sleeve.

Torque: 7N·m

4.3. Loosen the fix screws at the left side of

rear mud guard and rear bumper with a 7#

sleeve.

4.4. Loosen the fix screws at the right side of

rear mud guard and rear bumper with a 7#

sleeve.

4.5. Push out the fixing clips of rear bumper

from the rear mud guard by hand.

4.6 Pull out the bumper from the fixed

mounting at the fender by hand.

4.7. Take off rear bumper assy.

5. Installation Step

The installing steps are reverse to those for

removal.

Chapter 5 Disassembly/Reassembly and Maintenance of

Headlamp and Fog Lamp

1. System Composition Diagram

Lamp

2. Preparation

No.10 sleeve and No.7 open end wrench, cross

head screwdriver and flat head screwdriver.

3. Precautions

3.1 Please wear necessary labor protection

supplies to avoid accidents.

3.2 To prevent scratch the bumper surface

paint.

3.3. In case of disassembly/reassembly in the

low temperature environment, the force applied

can’t be big so as to avoid the breakage of the

bumper. Disconnect the control switch of

corresponding lamps, and remove the wire

connected to the battery.

3.4. When the headlamp is being removed, pay

more attention to its clips on the bumper. The

big force may damage the clips.

3.5 Pay attention to not scratch the headlamp

surface when disassemble and place.

4. Removal Step of Headlamp

4.1. Disassemble front bumper assy first. (See

disassembly/assembly of bumper)

4.2. Loosen headlamp two fixing bolts on

engine hood cross beam with No.10 sleeve.

Torque: 3.5±0.5N·m

4.3. Remove the fixing bolts under the

headlamp with a cross screwdriver.

Torque: 1.8±0.2N·m

4.4. Pull out the plug from the headlamp, and

then take off the headlamp assy.

4.5. Open the lamp holder clips by hand.

4.6. Pull out two harness connectors by hand.

4.7. Remove two fix screws with a cross

screwdriver.

4.8. Hold the bulb seat by hand, and take off the

bulb from the headlamp.

CAUTION: In case that the bulb is replaced,

DO NOT contact the bulb by hand, otherwise

the fingerprint remained on the bulb is heated

and volatilzes after the lamp lights, and then

deposits on the mirror surface, which may

result that the reflector darkens.

4.9. Screw off headlamp high beam seat cover.

4.10. Pull out two harness connectors by hand.

4.11. Remove two fix screws with a cross

screwdriver.

4.12. Hold the bulb seat by hand, and take off

the bulb from the headlamp.

CAUTION: In case that the bulb is replaced,

DO NOT contact the bulb by hand, otherwise

the fingerprint remained on the bulb is heated

and volatilzes after the lamp lights, and then

deposits on the mirror surface, which may

result that the reflector darkens.

5. Removal of Fog Lamp

5.1. Remove the bumper assy. Refer to

Disassembly of Bumper.

5.2. Pull out the plug of fog lamp.

5.3. Unscrew three fixing nuts from the fog

lamp with a cross screwdriver.

5.4 Take off the fog lamp assy.

6. Installation and Adjustment of Headlamp

6.1. headlamp Installation Step

The installing steps of headlamp are

reverse to those for removal.

6.2. Introduction to headlamp function

6.2.1. Front view

See right figure:

1 Low beam light

2 Position light

3 High beam

4 Turn light

6.2.2. Back view

See right figure:

1 Low beam light

holder

2 Headlamp’s plug

3 High beam light

holder

4 High beam up/down

adjusting nut

5 High beam left/right adjusting nut

6 Low beam up/down adjusting nut

7 Low beam left/right adjusting nut

6.3. Adjustment of headlamp light

Headlamp uses half closed light combination type. So it is easy to be maintained; it is halogen

light with less mechanism and high luminous intensity, which will prolong bulb life.

The correctness of headlamp adjustment will influence the driving safety. So it needs special

device to adjust the beam. Pay attention to law regulations and verify the following items before

adjustment:

a. Tire pressure should be conformity with standard;

b. Car is unload (except for spare tire and equipped tools, and include driver weigh for

sedan);

c. Park the car on horizontal road or workplace;

d. The lens surface of headlamp should be clean;

e. Check the power supplies if is working correctly, and the bulb installed correctly.

Adjust the governing mechanism equipped on

the lamps to implement the adjustment

rightward and leftward, upward and downward

of the lamp beam, according to the required

values in national standards. The coarse and

fine adjustment upward and downward is

integrated into one entity, which is located at

the upper edge of housing while the rightward

and leftward adjustment mechanism is located

at the central lower edge of the housing. It needs take off headlamp cover to adjust right

headlamp. The left headlamp and right

headlamp adjusting mechanisms are arranged

symmetrically, with the same adjustment

method is the same.

6.3.3. The beam of headlamp can be adjusted

with the light adjusting nut or electric adjusting

pushbutton (if equipped).

6.3.3.1. Insert a cross screwdriver into the

corresponding adjustment hole to adjust the

beam.

6.3.3.2. Height of CHERY S21’s standard

headlamp reference center:

Low beam: 717 mm; High beam: 755 mm.

6.3.3.3. The headlamp light beam shall be

adjusted according to the data specified in the

national stardards:

When checking the dip beam (i.e. low beam)

headlamp position, project the headlamp on a

screen 10 m away, the dark and bright changing

line angle or central height shall be 0.7H – 0.9

H (H is the height of the headlamp reference

center, the same below) for passenger cars, it

shall be 0.6H – 0.8 H for other motor vehicles

(excluding transportation tractor combinations).

The horizontal deviation to the left of the

dipped headlamp for motor vehicles (except the

vehicle with only one headlamp) shall not

exceed 10 mm and the right deviation shall not

exceed 350 mm.

(From national standard)

6.3.3.5. Please input the standard data obtained

into the headlamp beam regulator for the

convenience to use in the furture.

7. Tail Lamp Removal Step

7.1. Remove the fix screws from the tail lamp

with a cross screwdriver.

7.2. Open the trunk, and lift up the carpet of

trunk.

7.3. Remove the upper seat fixing nuts from tail

lamp with a fix wrench.

7.4. Remove the lower seat fixing nuts from tail

lamp with a fix wrench.

7.5. Pull out the tail lamp harness connector,

and the take off the tail lamp assy.

Chapter 6 Disassembly/Reassembly of Ceiling

1. Preparation

Tools: socket wrench, cross screwdriver, flat

head screwdriver

2. Precautions

2.1. During the disassembly/reassembly, pay

more attention to the application of appropriate

force, without crude operation.

2.2. During the disassembly/reassembly of

interior ornaments, especially pay more

attention to the protection of surface ornaments

so as to avoid the damage of the ornaments.

3. Disassembly/Reassembly of

Sun Visor

3.1. Removal Step

3.1.1. Loosen two fixing screws on left front

sun visor with a cross head screwdriver

Torque: 3±1Nm

3.1.2. Take off the front left sun visor.

3.2. Installation Step

The installing steps are reverse to those for

removal.

3.3. Refer to Disassembly/Reassembly of Front

Left Sun Visor for the disassembly/reassembly

of front right sun visor.

4. Disassembly/Reassembly of

Roof Hand-Hold

4.1. Removal Step

4.1.1. Remove the right/left fix screws with a

cross screwdriver.

Torque: 9±3Nm

4.1.2. Take off the hand-hold.

4.2. Installation Step

The installing steps are reverse to those for

removal.

4.3 Refer to Disassembly/Reassembly of Front

Right Hand-Hold for other hand-holds.

5. Disassembly/Reassembly of

Front Ceiling Lamp

5.1. Removal Step

5.1.1. Remove the front ceiling lamp cover with

a flat head screwdriver.

Note: do not scratch part surface.

5.1.2. Loosen the front ceiling lamp fixing bolt.

Torque: 1.5±0.5Nm

5.1.3. Pull out the harness connector, and then

take off the front ceiling lamp assy.

5.2. Installation Step

The installing steps are reverse to those for

removal.

6. Disassembly/Reassembly of A

Pillar Trim

6.1. Removal Step

6.1.1. Prize A pillar protective board with a flat

head screwdriver.

6.1.2. Take off the A pillar trim.

6.2. Installation Step

The installing steps are reverse to those for

removal.

7. Disassembly/Reassembly of B

Pillar Trim

7.1. Removal Step

7.1.1 Remove B pillar lower protective board

(refer to Disassembly/Assembly of Seat Belt)

7.1.2. Remove the B pillar upper trim with a

flat head screwdriver.

Note: protect the trim part surface from

scratching.

7.2. Installation Step

The installing steps are reverse to those for

removal.

8. Disassembly/Reassembly of C

Pillar Trim

8.1. Removal Step

8.1.1. Refer to Disassembly/Reassembly of

Rear Passenger Seat and Seat Belt.

8.1.2. Remove the C pillar upper trim with a

flat head screwdriver.

8.1.3. Remove the C pillar lower trim with a

flat head screwdriver.

8.2. Installation Step

The installing steps are reverse to those for

removal.

9. Disassembly/Reassembly of

Ceiling

9.1. Removal Step

9.1.1 Remove the left and right sun

visors.(Refer to Disassembly/Reassembly of

Sun Visor)

9.1.2. Remove the front ceiling lamp. (Refer to

Disassembly/Reassembly of Front Ceiling

Lamp)

9.1.3 Remove all the roof hand-hold.(Refer to

Disassembly/Reassembly of Roof Hand-Hold)

9.1.4. Remove the A/B/C pillar trim. (Refer to

Disassembly/Reassembly of A/B/C Pillart

Trim)

9.1.5. Remove the ceiling clips (5 pcs in total)

with a flat head screwdriver.

9.1.6. Remove the wheatherproof rubber strip

of four door opening by hand.

9.1.7. Open the trunk, and then remove the

ceiling. It is convenient to take off the ceiling

from the trunk and not easy to damage the

ceiling.

9.2. Installation Step

The installing steps are reverse to those for

removal.

Chapter 7 Disassembly/Reassembly of Instrument Panel

I. Removal of Instrument Panel Accessories

1. Preparation

Tool: socket spanner, cross head screwdriver, flat head screwdriver

Note: disconnect accumulator cathode before disassemble electrical parts

2. Disassembly/Reassembly of Central Console Panel, Audio Unit, Emergency Switch, A/C Control Switch, Ashtray

2.1. Removal Step

2.1.1. Remove the central console panel by

hand.

2.1.2. Remove four fix screws used to joint the

audio unit and instrument panel body with a

cross screwdriver.

Torque: 9±3 Nm

2.1.3. Remove two fix screws applied to joint

the emergency switch and instrument panel

body with a cross screwdriver.

Torque: 1.5±0.5Nm

2.1.4. take off the emergency switch and pull

out the wire harness.

2.1.5. take off the audio and pull out the wire

harness.

2.1.6. Remove four fix screws used to joint the

A/C control switch and instrument panel body

with a cross screwdriver.

Torque: 3.5±0.5 Nm

2.1.7. Remove the fix screws (at the bottom of

ashtray) from the console, take off the cigarette

lighter connecting wire, and remove the console

assy.

2.1.8. Remove the A/C control switch cable and

harness, and then take off the A/C control

switch.

Bolts under the astray

2.2. Installation Step

The installing steps are reverse to those for

removal.

3. Disassembly/Reassembly of Front Ashtray

3.1. Removal Step

3.1.1. Draw out the front ashtray.

3.1.2. Remove one fix screw from the bottom

of front ashtray guide run with a cross

screwdriver.

Torque: 10±1 Nm

3.1.3. Remove two fix screws from the front of

front ashtray guide run with a cross

screwdriver.

Torque: 3±1 Nm

3.1.4. Take off the front ashtray guide run.

3.2. Installation Step

Bolts under the astray

The installing steps are reverse to those for

removal.

4. Disassembly/Reassembly of Glove Case

4.1. Removal Step

4.1.1. Unclench the long clip core at the right

lower part of glove case with a screwdriver, and

take off the clips.

4.1.2. Swing and take off the glove case.

4.2. Installation Step

The installing steps are reverse to those for

removal.

5. combination instrument Disassembly/Reassembly of

5.1. Removal Step

5.1.1. Remove the central console panel, and

then remove the combination instrument

ornament frame.

5.1.2. Remove four fix screws from the

combination instrument with a cross

screwdriver.

Torque: 2±0.3Nm

5.1.3. Disconnec to the combination instrument

harness connector, and then take off the

combination instrument.

5.2. Installation Step

The installing steps are reverse to those for

removal.

6. Disassembly/Reassembly of Combination Switch, Wiper Switch, Ignition Switch, Heliax Cable

Please refer to Disassembly/Reassembly of

Steering Column in the Service Manual of

Chassis.

II. Removal of Instrument

Panel

1. Disassembly/Reassembly of Instrument Panel

1.1. Removal Step

1.1.1. Remove the steering wheel and

combination switch (see Remova of Steering

Wheel).

1.1.2 Remove glove box (Refer to Removal of

glove box)

1.1.3. Remove the console panel, audio unit,

emergency switch, A/C control switch, ashtray,

console (refer to Disassembly/Reassembly and

Removal of Console Panel, Audio Unit,

Emergency Switch, A/C Control Switch,

Ashtray).

1.1.4 Disassemble combined instrument (Refer

to Disassembly of Combined Instrument )

1.1.5. Remove the right/left A pillar upper and

lower trims.

1.1.6. Remove the weatherproof rubber strips

from the left front and right front door

openings.

1.1.7. Remove the left and right air outlet

covers and exterior rear-view mirror regulating

switch with a flat head screwdriver.

1.1.10. Take off the ornament cover, and

remove two fix screws from the right and left

front parts of upper instrument panel body and

seven fix screws from the lower instrument

panel body with a cross screwdriver, and then

take off the upper instrument panel assy

together with the right and left air outlets.

Torque: 3±0.5 Nm

1.1.11. Remove the right and left four cross

beams from the instrument panel and the fixing

bolts from the both sides of vehicle body with a

10# sleeve.

Torque: 23±2 Nm

1.1.12. Remove two cross beams from the

instrument panel and the fixing bolts from the

soleplate with a 10# sleeve.

Torque: 10±1 Nm

1.1.13. Obliquely place the instrument panel

and instrument panel cross beam, remove the

fixing bolts from the left, middle and right sides

of instrument panel with a 10# sleeve, and take

off the bond strap.

Torque: 4±0.5 Nm

1.1.12. Detach any related harness connector.

1.1.13. Lift out the instrument panel and

instrument panel cross beam by two operators.

1.2. Installation Step

The installing steps are reverse to those for

removal.

Note:

1.2.1. The instrument panel dual-vent and A/C

vent shall be fit well, without the improper

installation and air leakage. The instrument

panel air duct and instrument panel cross beam,

evaporator and other parts shall NOT interfere

and affect the installation of instrument panel,

which may result the improper installation of

instrument panel and its accessories.

1.2.2. The instrument panel and front

windscreen shall NOT interfere and affect the

installation of instrument panel and front

windscreen, and the clearance between front

windscreens shall be uniform.

1.2.3. The clearance between the instrument

panel and both sides of body shall be uniform

and can meet the assembly of weatherproof

rubber strip of door opening.

1.2.4. The glove case switch shall be flexible,

without the interference, clamped or locking

untightened symptom.

2. Removal of Instrument Panel cross beam

2.1. Removal Step

2.1.1. Disassemble instrument panel assembly

(Refer to Disassembly of Instrument Panel)

2.1.2. Remove seven fix screws from the air

duct as shown in the figure, and then take off

the air duct.

2.1.3. Remove the four fix screws from both

sides of instrument panel and cross beam with a

cross screwdriver.

Torque: 3±1 Nm

2.1.4. Take off the cross beam and air duct.

2.1.5. Remove two screws used to fasten the air

duct from the cross beam with a cross

screwdriver.

Torque: 3±1 Nm

2.1.6. Take off the air duct, and detach the

harness as required.

2.2. Installation Step

Refer to Removal Step and install it in reverse

order.

Chapter 8 Air Conditioning (A/C) System

Dry Fluid Reservoir Assy

I. System Composition

Air adjustment and distributing system: HVAC air mixing and distributor part, inside/outside

circulation air inlet, air outlet, outside circulation air filter.

Control system: control panel assy, wire drawing, micro-motor, fan, resistor, high/low voltage switch

Heating system: heater, hot water pipe, engine cooling water system.

Cooling system: compressor, condenser, reservoir dryer, expansion valve, evaporator, and pipe.

Condenser Assy

A/C Compressor Assy

4 Pipes Assy

II. Removal of Evaporator Assy

1. Preparation

Tool: cross head screwdriver, carp pliers, socket

spanner

Auxiliary material: refrigerant, antifreeze,

sponge rubber strip

HVAC Assy

Control Panel Assy

2. Disassembly/Reassembly Step

2.1 Recycling the refrigerant by refrigerant

recycling machine

Note:

(1) DO NOT dispose the coolant in a sealed

location or near fire.

(2) Do not splash the refrigerant into eyes and

skin.

2.2. Disassemble instrument panel assy and

front cross beam. Pull out the related electrical

connectors.

2.3. Loose fixing bolts on high/low pressure

pipe with spanner.

Torque: 5±1 Nm

2.4. Loosen two fixing bolts used to connect the

high/low pressure pipe to the expansion valve,

and pull outwards the high/low pressure pipe.

Torque: 8±1 Nm

2.5. Loosen three fixing bolts of evaporator and

front side.

Torque: 3.5±0.5 Nm

2.6. Remove the inlet/outlet pipe snap rings

from the evaporator radiator with a plier, and

pull out the water pipe.

CAUTION: The coolant may flow out from the

water pipe, and pay attention to the recovery of

coolant.

2.7. Loosen six fixing bolts of evaporator assy

fixed on the paintwork from the engine

compartment, and the fixed position is as

shown in the right figure.

Installation torque: 5±0.5 Nm

2.8. Take out evaporator and AC cable assy

from cab

3. Installation of Evaporator Assy

The installing steps are reverse to those for

removal.

4. Disassembly/Reassembly of Evaporator Interior

Preparation of tool(s): cross screwdriver, socket

wrench

4.1. Removal Step

4.1.1. Refer to the Removal of Evaporator Assy,

and take off the evaporator assy.

4.1.2. Remove the harness and connector from

the evaporator.

4.1.3. Remove three screws from the

intermediate part of the evaporator, and

partition the evaporator into two parts.

4.1.4. Remove the air direction regulating

mechanism from the distributor with a cross

screwdriver (as shown in the figure).

Torque: 1.5±0.5 Nm

4.1.5. Remove eight housing connection screws

from the distributor with a cross screwdriver (as

shown in the figure).

Torque: 1.5±0.5 Nm

4.1.6. Detach the distributor. In this case, take

off the air baffle from the interior.

4.1.7Remove four fix screws from the air inlet

with a cross screwdriver, and take off the air

inlet.

Torque: 1.5±0.5 Nm

4.1.8 Remove the fixing screws from the

inner-outer recirculating air control mechanism

with a cross screwdriver, and then take off the

inner-outer recirculating air control mechanism.

Torque: 1.5±0.5 Nm

4.1.9. Remove nine housing connection screws

from the other side of the evaporator with a

cross screwdriver (as shown in the figure).

Torque: 1.5±0.5 Nm

4.1.10. Remove four screws from two fixed

iron sheets of A/C heater pipe with a cross

screwdriver.

4.1.11. Remove two clips from the evaporator

with a flat head screwdriver.

4.1.12. Separate the upper part of the housing

from the lower part by both hands.

4.1.13. Take off the evaporator and expansion

valve from the lower housing.

4.1.14. Remove the fixing nuts from the fan

impeller with a 10# sleeve, and take off the fan

impeller.

Torque: 5±0.5 Nm

4.1.15. Remove the fix screws from two fan

motors with a cross screwdriver.

Torque: 5±0.5 Nm

4.1.16. Pull out the fan motor by hand.

4.2. Installation Step

The installing steps are reverse to those for

removal.

Carry out checks for system evacuating, keep

pressure, antifreeze leakage.

Check if the radiator is blocked. If the radiator

is blocked, utilize the compressed air to clean

it.

III. Troubleshooting

Types of pressure deviation Possible causes Method for troubleshooting

1. The pressure at the high pressure side

remains unchanged or just slightly rises

(compared with the value when the

engine stalls); the pressure at the low

pressure side is within or under the

range as shown; the air conditioner is

under refrigeration.

2. The pressure at the high pressure side is

normal; the pressure at the low pressure

side is within the range as shown; the

air conditioner is under refrigeration.

The pressure at the high pressure side is

higher than the specified value; the pressure

at the low pressure side falls rapidly to within

or under the range as shown; the air

conditioner is under refrigeration.

Initially, the pressures at the high and low

pressure sides are normal, but after a period

of time, the pressure at the high pressure side

is higher than the specified value and the

pressure at the low pressure side is within or

Lack of refrigerant or

the expansion valve

fails

The blockage or

throttling occur

somewhere in the

refrigerant pipelines

The expansion valve

fails

The expansion valve

fails

There exists vapor in

the refrigerant pipelines

Evacuate the refrigerant

● If the volume of the refrigerant is normal

1. Replace the expansion valve

2. Refill the refrigerant to the system

3. Test the pressure again

● If the volume of the refrigerant is short

1. Check if there is leaking, if there is

fix it

2. Refill the refrigerant to the system

3. Test the pressure again

Touch the pipelines to feel the temperature

change

● If there exists temperature differences on

several parts of a certain component

1. Utilize the compressed air and nitrogen

gas to dredge the pipeline and replace the

expansion valve

2. Replace the parts blocked

● If no trouble found

1. Dredge the pipelines with compressed

air and nitrogen

2. Test the pressure again

Check for dirt or rust in the expansion valve

and replace it when necessary

● Dredge the pipelines with compressed

air and nitrogen

under the range as shown; the air conditioner

is under refrigeration.

The pressure at the high pressure side is

higher than the specified value or is too high;

the pressure at the low pressure side is too

high; the air conditioner is under

refrigeration; the compressor makes

exceptional sounds (especially when just

starts the engine).

When turning off the engine, the pressure at

the high pressure side slightly rises while the

pressure at the low pressure side slightly

falls; the air conditioner is under

refrigeration.

High pressure side is correct, low pressure

side is too low, AC refrigerating correct,

sometimes the evaporator has ice(even the

refrigerant quantity is correct)

1. High/low pressure sides are correct, AC

refrigerating deficiency.

2. High/low pressure sides are correct, the

sound of compressor is abnormal (especially

when the engine is started), AC refrigerating

good

The reservoir can not be used

The refrigerant in the

refrigerant pipelines is

excessive

The expansion valve

fails or the compressor

is disabled

The compressor is

disabled

The expansion valve

fails or the compressor

is disabled

The transmission oil in

the air conditioner

pipelines is excessive

• Perforated

• The sealed position is

damaged

• Thread of fasten part

is damaged, outside air

entering to system

Evacuate the refrigerant

● If the volume of the refrigerant is normal

1. Replace the expansion valve

2. Refill the refrigerant to the system

3. Test the pressure again

● If the refrigerant is obviously excessive

1. Refill the coolant into the system

2．Test the pressure again

Note: If the system is still off normal after

retesting the pressure, install the expansion

valve replaced again and dredge the

pipelines with compressed air and nitrogen,

and then further replace the compressor and

the fluid reservoir and drying chamber.

Dredge the pipelines with compressed air

and nitrogen

Replace the compressor and the fluid

reservoir and drying chamber

Replace the expansion valve

Note: If the system is still off normal after

retesting the pressure, install the expansion

valve replaced again and dredge the

pipelines with compressed air and nitrogen,

and then further replace the compressor and

the fluid reservoir and drying chamber.

Evacuate the refrigerant

● Dredge the pipelines with compressed

air and nitrogen

Note: Adjust the volume of the lubricant

when replacing such component of the air

conditioner system as the compressor

Replace it

I. Chassis Control Point

Unit: mm

1. Front

Chapter 9 Body Dimension

2. Rear

3. Size of Control Point

Name

S/N

Name

Coordinate

Size of Hole

Coordinate

Size of Hole

S/N

Rear Left Trailing Arm Hole Rear Right Trailing Arm Hole Rear Bumper Installation Hole

Bumper Spring Hole

Bumper Hole

Engine Suspension Installation Hole

Rear Bumper Block Hole

Rear Crossbearer Installation Hole

Sub-frame Installation Hole

Bumper Spring Hole

Engine Suspension Installation Hole

Radiator Upper Crossbea m

Mid-bearer Installation Hole

Paintwork Process Hole

II. Body Assembly Dimension

1. Front View

1.1 Clearance between high beam lamp and engine hood at AA-AA: 5±1 mm

Engine Hood Outer Plate

Uniformity:1.0

High Beam Lamp

1.2 Clearance between high beam lamp and front bumper at AB-AB: 3±1mm

High Beam Lamp

Uniformity:1.0

Front Bumper

a) Clearance between low beam lamp and front fender at X-X: 2±1mm

Low Beam Lamp

Fender

Uniformity:1.0

1.4 Clearance between low beam lamp and front bumper at Y-Y: 8±1mm

Low Beam Lamp

Front Bumper

Uniformity:1.0

2. Rear View

a) Clearance between tail lamp and back door at AC-AC: 4±1mm

Back Door inner panel

Tail Lamp

Uniformity: 1.0

Back Door outer panel

2.2 Fit clearance between tail lamp and rear bumper at AD-AD: 3±1mm

Tail Lamp

Uniformity:0.5

Rear Bumper

2.3 Fit clearance between license plate lamp trim board and back door outer panel

Rear Bumper

at AE-AE: 6±1mm

Back Door Lock

License Plate Lamp Ornament Plate

Back Door outer panel

2.4 Fit dimension of back door and body at Q-Q:

Back Door inner panel

Back Door outer panel

Uniformity: 1.0

Uniformity:1.0

3. Left View

3.1 Clearance between side outer plate and fender at A-A: 2.5±0.5mm

Front Fender

Side Outer Plate

Uniformity: 0.5

3.2 Clearance between front fender and front door outer panel at B-B: 5.5±0.5mm

Front Part of Front Door inner panel

Front Door outer panel

Uniformity: 1.0

Uniformity: 0.5

Uniformity:

0.5

Front

Door outer panel

3.3 Clearance between the front door outer panel and rear door outer panel at C-C:

4.5±0.75mm

Rear Part of Front Door inner panel

Front Door outer panel

Uniformity:1.0

Front Part of Rear Door inner panel

Rear Door outer panel

3.4 Clearance between the A pillar and small quarter window glass at D-D: 3±1mm

Rear Part of Front Door inner panel

Uniformity: 0.5

Uniformity: 1.0

Side Outer Plate

3.5 Installation dimension of top cap and top cap trim at E-E: 0.75±0.75mm

Uniformity: 0.5

Installation dimension of side outer plate and top cap trim: 4.75±0.75mm Installation dimension of side outer plate and rear door window frame: 4.5±0.75mm

Top Cap Trim

Top Cap

Side Outer Plate

Uniformity: 1.0

Rear Window Frame

3.6 Clearances of rear windscreen and side outer plate at F-F are: 5.5±0.5 mm;

Back Door Outer

Panel

4±1mm, respectively.

Rear Windscreen

Rear Windscreen Fixing Glue

Uniformity: 1.0

Back Door Inner Panel

Side Outer Plate

3.7 Clearance between rear door outer panel and side outer plate at G-G:

4.5±0.75mm

Rear Part of Rear Door Inner Panel

Side Outer Plate

Rear Door Outer Panel

Uniformity: 0.5

Uniformity: 1.0

3.8 Installation clearances of back door outer panel and side outer plate at H-H are: 3.75±0.75 mm;

1.75±0.75 mm, respectively.

Back Door Outer Panel

Uniformity: 1.0

Back Door Inner Panel

Uniformity: 0.5

Side Outer Plate

3.9 The clearances of tail lamp and side outer plate at I-I are: 3±1mm;

0.25±0.25mm, respectively.

Tail Lamp

Side Outer Plate

Uniformity: 0.5

3.10 The installation clearances of side outer plate and rear bumper at J-J are:

1.25±0.75mm; 0.25±0.25mm, respectively.

Uniformity: 0.5

Side Outer Plate

Rear Bumper

3.11 Installation dimension of top cap and top cap trim at R-R: 0.75±0.75mm

Uniformity: 1.0

Side Outer Plate

Front Door Window Frame

Installation dimension of side outer plate and top cap trim: 4.75±0.75mm Installation dimension of side outer plate and front door window frame:

2.5±0.5mm; 4.5±0.75mm, respectively

Top Cap

Top Cap Trim

Uniformity: 1.0

3.12 Clearance between the upper part of front left door and the upper part of front right door at S-S: 4.5±0.75mm

Upper Part of Front Left Door

Uniformity: 1.0

Upper Part of Rear Left Door

Uniformity: 0.5

3.13 The fit clearances of rear door outer trim board and side outer plate at T1-T1 are:

Rear Door Outer Trim

Board

Side Outer Plate

4.75±0.25mm; 9.5±0.5mm, respectively.

Uniformity: 0.5

Uniformity: 1.0

3.14 The fit dimensions of front door outer quarter window and front door window frame at T2-T2 are: 5±1mm; 5±1mm, respectively.

Uniformity: 0.5

T2-T2 Scale: 1:1

3.15 The clearance between the fender and bumper at U-U: 0.5±0.5mm

Fender

Uniformity: 0.5

Front Bumper

3.16 The fit clearances of rear door outer panel and side skirt outer plate at V-V are: 6±0.5mm; 1.75±0.75mm, respectively.

Uniformity: 1.0

100

Chery QQ6 LHD 2006 2014 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual