Chery A1 2009 Manual de usuario

2009

CHERY

Service Manual

FOREWORD

This manual contains on-vehicle service

and diagnosis procedures for the Chery A1.

A thorough familiarization with this manual

is important for proper repair and

maintenance. It should always be kept in a

handy place for quick and easy reference.

The contents of this manual, including

drawings and specifications, are the latest

available at the time of printing. As

modifications affecting repair or

maintenance occur, relevant information

supplementary to this volume will be made

available at Chery dealers. This manual

should be kept up-to-date.

Chery Automobile Company, Ltd. reserves the

right to alter the specifications and

contents of this manual without obligation

or advance notice.

may be reproduced or used in any form or

by any means, electronic or mechanical—

including photocopying and recording and the

use of any kind of information storage and

retrieval system—without permission in

writing.

NOTE:

This A1 service manual only applies to the follow-

ing engines and transaxles:

•1.3L with M/T

•1.3L with AMT

Chery Automobile Company, Ltd.

Wuhu, Anhui Province, CHINA

CONTENTS

Title Section

GENERAL INFORMATION

ENGINE

ELECTRONIC ENGINE CONTROLS

FUEL DELIVERY

STARTING & CHARGING

COOLING

EXHAUST

TRANSAXLE

DRIVELINE & AXLE

SUSPENSION

STEERING

BRAKES

HEATING & AIR CONDITIONING

RESTRAINTS

BODY & ACCESSORIES

WIRING

ALPHABETICAL INDEX

2009 Chery Automobile Co., Ltd.

PRINTED NOVEMBER, 2009

GENERAL INFORMATION

CONTENTS page

Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1

Vehicle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9

Electrical Circuit Diagnosis Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-15

Electrical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-20

SERVICE INFORMATION

HOW TO USE THIS MANUAL 01-2

Topics 01-2

Service Procedures 01-2

Diagnostic Procedures 01-2

Specifications 01-2

VEHICLE SERVICE PREPARATION 01-3

Preparation For Vehicle Service 01-3

Tools and Testing Equipment 01-3

Special Tools 01-3

Disconnection of the Negative Battery

Cable 01-4

PROPER SERVICE PRACTICES 01-5

Removal of Parts 01-5

Component Disassembly 01-5

Inspection of Parts 01-5

Arrangement of Parts 01-6

Cleaning of Parts 01-6

Component Reassembly 01-6

Adjustments 01-7

Rubber Parts and Rubber Tubing 01-7

Hose Clamps 01-8

Vise 01-8

Dynamometer 01-8

01–1

Chery Automobile Co., Ltd.

HOW TO USE THIS MANUAL

Topics

This manual contains procedures for performing all required service operations.

The procedures are divided into three basic operations:

•Removal/Installation

•Disassembly/Assembly

•Inspection

Service Procedures

Most repair procedures begin with an illustration. It identifies the components, shows how the parts fit together and

describes visual part inspection. Removal & Installation procedures have written instructions.

Service procedures include the following elements:

•Detailed removal & installation instructions

•Integrated torque specifications

•Integrated illustrations

•Component specifications

Diagnostic Procedures

The diagnostic procedures are divided into the following two groups:

Diagnostic Trouble Codes (DTC)

•DTCs are important hints for repairing malfunctions that are difficult to simulate. Perform the specific DTC diag-

nostic inspection to quickly and accurately diagnose the malfunction.

Diagnostic Symptoms

•Symptom troubleshooting quickly determines the location of the malfunction according to symptom type.

Specifications

This manual contains specifications that are divided into the following groups:

•Torque specifications

•Clearance specifications

•Capacity specifications

01–2Chery Automobile Co., Ltd.

VEHICLE SERVICE PREPARATION

Preparation For Vehicle Service

•Always be sure to cover fenders, seats and floor

areas before starting work.

Tools and Testing Equipment

•Be sure that all necessary tools and measuring

equipment are available before starting any work.

•Inspect the vehicle and reference any needed ser-

vice information before starting any work.

Special Tools

•Use special tools when they are required.

BESM010004

BESM010005

BESM010006T

01–3

Chery Automobile Co., Ltd.

Disconnection of the Negative Battery Cable

•Before beginning any electrical work, turn the igni-

tion switch to LOCK, disconnect the negative bat-

tery cable and then wait two minutes to allow the

backup supply of the air bag diagnostic monitor unit

to deplete its stored power.

•Disconnecting the battery cable deletes the memo-

ries of the clock, audio and DTCs, etc. Therefore, it

is necessary to verify those memories before dis-

connecting the cable.

VEHICLE SERVICE PREPARATION

PZSM010001

01–4Chery Automobile Co., Ltd.

PROPER SERVICE PRACTICES

Removal of Parts

•While correcting a problem, also try to determine its

cause. Begin work only after first determining which

parts and subassemblies must be removed and dis-

assembled for replacement or repair. After removing

the part, plug all holes and ports to prevent foreign

material from entering.

Component Disassembly

•If the disassembly procedure is complex requiring

many parts to be disassembled, make sure that all

parts are disassembled in a way that will not affect

their performance or external appearance. Identify

parts so reassembly can be performed easily and

efficiently.

Inspection of Parts

•When removed, inspect each part for malfunction-

ing, deformation, damage and other problems.

BESM010007

BESM010008

BESM010009

01–5

Chery Automobile Co., Ltd.

Arrangement of Parts

•All disassembled parts should be carefully arranged

for reassembly.

•Be sure to separate and identify the parts to be

replaced from those that will be reused.

Cleaning of Parts

•Carefully and thoroughly clean all parts to be

reused.

WARNING!

Using compressed air can cause dirt and other particles to fly out causing injury to the eyes. Wear protective

eye wear whenever using compressed air.

Component Reassembly

•Standard values, such as torques and certain

adjustments, must be strictly observed in the reas-

sembly of all parts. If removed, replace these parts

with new ones:

Oil seals

Gaskets

O-rings

Lock washers

Cotter pins

Nylon nuts

PROPER SERVICE PRACTICES

BESM010010

BESM010011

BESM010012

01–6Chery Automobile Co., Ltd.

Depending on location:

•Apply sealant and gaskets, or both, to specified

locations. When sealant is applied, install parts

before sealant hardens to prevent leaks.

•Apply oil to the moving components of parts.

•Apply specified oil or grease at the prescribed loca-

tions (such as oil seals) before reassembly.

Adjustments

•Use suitable gauges and testers when making

adjustments.

Rubber Parts and Rubber Tubing

•Prevent gasoline or oil from getting on rubber parts

or tubing.

PROPER SERVICE PRACTICES

BESM010013

BESM010014

BESM010015

01–7

Chery Automobile Co., Ltd.

Hose Clamps

•When reinstalling, position the hose clamp in the

original location on the hose and squeeze the

clamp lightly with large pliers to ensure a good fit.

Vise

•When using a vise, put protective plates in the

jaws of the vise to prevent damage to parts.

Dynamometer

•When test-running a vehicle on a dynamometer:

Place a fan, preferably a vehicle-speed proportional type, in front of the vehicle.

Connect an exhaust gas ventilation unit.

WARNING!

Exhaust gases can injure or kill. They contain carbon monoxide (CO), which is colorless and odorless. Breathing

it can make you unconscious and can eventually poison you.

Cool the exhaust pipes with a fan.

Keep the area around the vehicle uncluttered.

Monitor the engine coolant temperature gauge.

PROPER SERVICE PRACTICES

BESM010016

BESM010017

01–8Chery Automobile Co., Ltd.

VEHICLE INFORMATION

VEHICLE IDENTIFICATION NUMBER

(VIN) 01-10

VIN Location 01-10

VIN Identification Codes 01-11

INTERNATIONAL SYMBOLS 01-13

International Symbols 01-13

FASTENER USAGE 01-14

Fastener Usage 01-14

01–9

Chery Automobile Co., Ltd.

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