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1100UE Service Manual

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3. 20 9 the PAT assembly 22 TO The Ghi DOE UE 23 carbomcanister 26 Zaibe engine control abit BC ono cineri tet rite p Eisen e atu 28 Dee CCRC T cR 30 A the 1 uu teneo ht fece Ub tem 32 way catal yti e e vede tad cust ege iha asa 33 16 the other ts connected with ECU Siotial oie uuu uu u NEM I Mu E 33 Chapter 3 Introduces the function of fault diagnosis system 34 control the fault lami iz iat esa alten anf cote acte c ut ptt ume aad atti 34 2 Connect ie Gia SNOSis ASTUNEN 34 TD 55 tum m 35 4 Erasedault Code uu u n 37 Chapter 4 Troubleshooting diagnostic process 38 1 Fault diagnosis according to the fault code description 38 2 System fault COde did NOSIS PIOCESS uu t Mee ce but ee ee e 38 2 1 Upstream oxygen sensor heater co
4. 53 2 28 Three cylinder injector circuit shorted to ground fault code P0267 53 2 29 Three cylinder injector circuit for the power supply circuit fault code P0268 54 2 30 Four cylinder injector circuit shorted to ground fault code P0270 55 2 31 Four cylinder injector circuit for the power supply circuit fault code P0271 55 2 32 Knock sensor Tault fault code P03295 iori GR E e eO bete eee 56 2 33 Crankshaft position sensor circuit fault fault code P0335 56 2 34 The camshaft position sensor fault fault code P0340 56 2 35 A cylinder ignition coil circuit fault fault code P0351 57 2 36 Two cylinder ignition coil circuit fault fault code P0352 57 2 37 Three cylinder ignition coil circuit fault fault code P0353 58 2 38 Four cylinder ignition coil circuit fault fault code P0354 58 2 39 Carbon irrigation control valve open circuit fault code P0444 59 2 40 Carbon irr
5. 7 10 Camshaft timing gear bolt Loctite 243 1 1 Oil collector stud Loctite 243 0 08 ml x2 The part screwed into the pump Screw of thermoregulator shell Loctite 243 0 08 ml x2 The part screwed into fixing bolt the cylinder head 6 56 7 FUEL INJECTOR SYSTEM Overhaul nios doti ERR E 7 2 Fuel Injector System Disassembly Installatlon 7 3 High Pressure Fuel Line Disassembly Installation 7 4 Throttle Body Disassembly Installation 7 4 Fuel rail with injector assy Disassembly Installation 7 5 Fuel injector Removal ASSembly u uuu 7 5 7 1 7 FUEL INJECTOR SYSTEM Overhaul Info CAUTION NOTE Gasoline is highly flammable therefore smoke and fire are strictly forbidden in the work place Special attention should also be paid to sparks Gasoline may also be explosive when it is vaporized so operation should be done in a well ventilated place Do not over twist or bend the cables The twisted cables may cause poor operation Loose the high pressure fuel line before disassembly discharge the fuel in the high pressure fuel line and put it in a container When the body of throttle valve is disassembled the air intake shall be covered by dishcloth or tape for avoiding the entry of other objects into the engine from the air intake
6. 1 20 HAS ENGES teas encodes eves 1 3 Tightening Torque 1 24 hound u k aa 1 5 Lubricating oil and brake liquid 1 25 Description and vehicle identification 1 18 VIN Number Engine Number 1 19 A Few Words About Safety Service Information The service and repair information contained in this manual is intended for use by qualified professional technicians Attempting service or repairs without the proper training tools and equipment could cause injury to you or others It could also damage the vehicle or create an unsafe condition This manual describes the proper methods and procedures for performing service maintenance and repairs Some procedures require the use of specially designed tools and dedicated equipment Any person who intends to use a replacement part service procedure or a tool that 1s not recommended by XinYang must determine the risks to their personal safety and the safe operation of the vehicle If you need to replace a part use genuine XinYang parts with the correct part number or an equivalent part We strongly recommend that you do not use replacement parts of inferior quality For Your Customer is Safety Proper service and maintenance are essential to the customer is safety and the reliability of the vehicle Any error or oversight while servicing a vehicle can result in faulty operation damage to the vehicle or injury
7. 1 SERVICE INFORMATION Compression Gauge A compression gauge Figure 33 measures combustion chamber cylinder pressure usually in PSI or kg cm2 The gauge adapter is either inserted or screwed into the spark plug hole to obtain the MS reading Disable the engine so it does not start hold the throttle in the wide open position when 34 performing a compression test An engine that does not have adequate compression cannot be properly tuned Refer to Chapter Three Multimeter A multimeter Figure 34 is an essential tool for electrical system diagnosis The voltage function indicates the voltage applied or available to various electrical components The ohmmeter function tests circuits for continuity or lack of continuity and measures the resistance of a circuit some manufacturer s specifications for electrical components are based on results using a specific test meter Results may vary if using a meter not recommended by the manufacturer Such requirements are noted when applicable Ohmmeter analog calibration Each time an analog ohmmeter is used or if the scale 1s changed the ohmmeter must be calibrated Digital ohmmeters do not require calibration 1 Make sure the meter battery is in good condition 2 Make sure the meter probes are in good condition 3 Touch the two probes together and observe the needle location on the ohms scale The needle must Align with the 0 mar
8. 1 SEAL RING 2 BOLT FLANGE M10x30 3 LOCKNUT FLANGE M10 4 EXHAUST PIPE 5 RUBBER WASHER A 6 TENSION SPRING EXHAUST PIPE 7 CATALYTIC CONVERTER 8 RUBBER WASHER B 9 MUFFLER 2 16 3 CHECKS amp ADJUSTMENT Ohi DEO ee Seen Aenea ey nen eee ee eee ewer aha ey EI ME ee NIE 3 1 3 2 Inspeccion 3 3 ohitt Linkage Inspection Adjustment oec u E ERRARE EE A EPOD EIE PR RE SE 3 6 wise IU EUIS MEN TETTE 3 8 b dea eer 3 10 SUSPENSION Syo DEN DEP Rab E UM M a Mae RPM RR MAE 3 12 Gear 5hifung Fuel tato do nauta e oA SNO dU OU pata 3 13 Hro oP eh ol een te ee ee ne eet tee eee rer nt estate er Tee 3 14 ODIT SU SITE 3 15 Overhaul Info Operation Cautions Note DO NOT keep the engine running for long time in a poorly ventilated or enclosed place because of the harmful components like CO etc the exhaust gas The muffler and engine are still very hot when the engine is just stopped Careless contact may cause serious burn Be sure to wear fatigue dress with long sleeves and gloves if the work has to be done after the engine 15 just stopped e Gasoline is highly flammable smoking 1 strictly forbidden the work place Keep alert on the electrical sparks Besides vaporized gasoline 1s highly ex
9. MIO2S 8 4050 RUBBER WASHER OF 5 ENGINESUPPORTA MIO25 4 4050 EE UU 21 CVT SECONDARY J 2 BALL M10x1 25 40 50 REAR LOWER UPPER 12 FRONT REARAXLENUT 4 18020 13 STEERING WHEEL M55 6 10 14 STEERING SHAFT 825 4 2030 1 FRONTAXLE 10 1 25 145 1 40 50 16 FRONTAXLE MI0412585 1 40 50 HOLDER FRONT AXLE FR RR aid E 18 MI2x125x115 2 4050 HOLDER REAR AXLE FR RR EE 20 FRONTDRIVESHAFT M amp 25 4 2030 w eom Cw Seamer wes a wm ee om um EN umaa a a 1 24 1 SERVICE INFORMATION NUT WHEEL v Tightening moment 1ON m UNS grade Specification and usage quantity for fuel Lubricating oil and brake liquid lead free gasoline E sang Gear box ae filter F s e j main driver SAE80W 90 GL 4 main driver Brake liquid GB1083 163 Engine coolant Distilled water Extremely cold area Glycol 1 1 Distilled water Glycol 2 3 1 25 2 Vehicle body Muffler Overhaul INO 2 1 Front COVEL vdd 2 11 TroubleshootiIng 2 1 Ca DODO 2 13 Steering wheel amp platfond 2 2
10. varying length allow the socket to be turned with varying an 1 1 force and at odd angles Extension bars allow the socket OF setup to reach difficult areas The ratchet is the most versatile It allows the user to Install or remove the nut 227 without removing the socket Sockets combined with any number of drivers make them undoubtedly the fastest Safest and most conventent tool for fastener removal and installation Impact Drivers An impact driver provides extra force for removing fasteners by converting the impact of a hammer into a turning motion This makes it possible to remove stubborn fasteners without damaging them Impact drivers and interchangeable bits Figure 10 are available from most tool suppliers When using a socket with an impact driver Make sure the socket Is designed for impact use Refer to Socket Wrenches Ratchets and handles in this section WARNING Do not use hand sockets with air or impact tools because they may shatter and cause injury Always wear eye protection when using impact or air tools Allen Wrenches Use Allen or setscrew wrenches Figure 11 on fasteners with hexagonal recesses in the fastener head These wrenches are available in L shaped bar Socket and T handle types A metric set is required when working on most motorcycles Allen bolts are sometimes called socket bolts Torque Wrenches Use a torque wrench with a socket
11. ve e tbe nr Although not as precise as a micrometer they allow reasonable precision typically to within 0 05 mm 0 001 1n Most calipers have a range up to 150 mm 6 1n Calipers are available 1n dial venire or digital versions Dial calipers have a dial readout that provides convenient reading Venire calipers have marked scales that must be compared to determine the measurement The digital caliper uses a liquid crystal display LCD to show the measurement Properly maintain the measuring surfaces of the caliper There must not be any dirt or burrs between the tool and the object being measured Never force the caliper to close around an object Close the caliper around the highest point so it can be removed with a slight drag Some calipers require calibration Always refer to the manufacturer s instructions when using a new or unfamiliar caliper To read a vernire Calipers refer to Figure 21 The fixed scale is marked in l mm increments Ten individual lines on the fixed scale equal 1 cm The yi poem dps movable scale is marked in 0 05 mm hundredth increments To obtain a reading establish the first m number by the location of the 0 line on the movable WI WWE scale in relation to the first line to the left on the fixed X scale In this example the number is 10 mm g determine the next number note which of the lines the movable scale align with a mark on th
12. Remove steering tie rod Pull up joint knuckle from the driveshaft remove front right suspension assy Disassembly Front Right Shock Absorber Disassembly ATTENTION You do not need to remove any other parts if you only replace the front suspension Park the vehicle on a level ground Remove front right shock absorber s bolt nut installed in arm Remove front right shock absorber Inspection Inspect the shock for oil leakage oil seal damage destroy replace if needed 8 FRONT WHEEL FRONT BRAKE SUSPENSION STEERING Constant Velocity Drive Shaft NOTE The removal inspection and installation of Left and Right Constant Velocity Drive Shafts of the Front Rear Axles are the same The following will give instruction only on the removal inspection and inspection of Left Constant Velocity Drive Shaft of Front Axle Refer to Left Constant Velocity Drive Shaft for removal inspection and installation of other drive shafts Left Constant Velocity Drive Shaft Front Axle Removal NOTE Maintenance of Left Constant Velocity Drive Shaft of Front Axle only does not require removal of Front Suspension Remove Front left wheel 8 3 Front left brake caliper 8 4 Front left wheel hub 8 3 Check dust boot Damaged dust boot Replace Shake constant velocity drive shaft check the agility of rzeppa universal joint free turning of bearing and any gap between rzeppa constant velocity joint
13. 2 BEARINGGO 1 4 jRETAINER q35 10 6 10 FRONT REAR AXLE 7 REAR AXLE HOUSING GROUP el wd 2 e tsps 23 OILSEALSSSS 1 24 01 J SRNO 25 BOLTM lO 1 15 Re TAINERGUIDEBAR 1 __6_ ft 6 jJBOTM l 7 STOPER 1 jRETANERSHETFORK 1 8 EXHAUSTVALVE 01 18 INNERCOVER 9 BEARNGGI2 1 O RING 160 2 65 10 7 10 10 FRONT REAR AXLE Inspection after front axle disassembly Check if there is damage or crack on the front differential gear case cover and bearing assembling hole 1s ok Replace case cover if necessary Check if front axle bearing clearance ok or turning stable and roll way steel ball needle and plate are ok Replace bearing 1f necessary Using special tools Check if oil seal lips and O ring shape ok Replace if necessary Check cylndrical surface of front axle and oil seal lips Replace broken parts if necessary Check drive pinion gear and differential gear inspect worn surface Replace broken if necessary Check driven gears surface gear center differential bracket differential wearing situation on the differential gear assembly Replace parts 1f necessary Check inside and outside spline washer wearing status 1n front axle Replace parts 1f necessary Check gear motor working status Replace with new parts 1f necessary Gear motor inspec
14. 4 Installation notes Oxygen sensor should be installed in the exhaust gas mixing place and when a vehicle moves air cooling metal shell and wire should be flow On the exhaust pipe can ensure the representative of the exhaust components and can meet the requirements of the temperature limit position Installation location should be as close as possible to the engine The exhaust pipe should be provided with screw screw in oxygen sensor used for nstall the attitude of oxygen sensor Oxygen sensor should be installed with the horizontal plane angle is greater than or equal to 45 degrees and the sensor tip down to avoid the cold start of condensed water accumulated between the sensor housing and sensing ceramic tube Oxygen sensor wire can not bend more than 60 degrees the bend arc radius is greater than or equal to 20 mm and the wire should not bear the tensile stress The following diagram A oo Z 11 19 11 EFI SYSTEM OF SQR 472ENGINE The exhaust pipe of the request to make the exhaust gas oxygen sensor in front region of the tube rapid heating If possible the exhaust pipe should be designed to tilt in order to avoid condensation water together in the front area of the sensor Do not use cleaning fluid oily liquids or volatile solids in the plug of the oxygen sensor Cannot use impact wrench fastening sensor Thread the oxygen sensor for M18 1 5 6e The six angle of the head size of oxy
15. Adjustable wrenches contact the fastener at only two points which makes them more subject to slipping off the fastener Because one Jaw 1 adjustable and may become loose this shortcoming 15 aggravated Make certain the solid jaw 15 the one transmitting the force Socket Wrenches Ratchets and Handles Sockets that attach to a ratchet handle Figure 7 are available with 6 point or 12 point openings Figure8 and different drive sizes The drive size Indicates the size of the square hole that accepts the Ratchet handle The number stamped on the socket is the size of the work area and must the fastener head As with wrenches a 6 point provides superior holding ability While a 12 point socket needs to be moved only half as for to reposition it on the fastener Sockets are designated for either hand or impact use 1 SERVICE INFORMATION Impact sockets are made of thicker material for more durability Compare the size and wall thickness of a 19 mmhand socket A Figure 9 and the 19 mm impact socket B Use impact sockets when using an impact driver or air tools Use hand sockets with hand driven attachments WARNING Do not use hand sockets with air or impact tools because they may shatter and cause injury Always wear eye protection when using impact or air tools 1 7 1 SERVICE INFORMATION Various handles are available for sockets Use the speed handle for fast operation Flexible ratchet heads in 11
16. Exhaust pipe Looseness or damage caused and muffler by improper installation Frame Looseness and or damage Others Lubrication amp grease of frame parts Abnormal parts Make sure if there is any which can be abnormal with relative parts determined when driving 3 5 3 CHECKS amp ADJUSTMENT Shift Linkage Inspection Adjustment Linkage rod adjustment is necessary when symptoms include No All Wheel Drive light Noise on deceleration Inability to engage a gear Excessive gear clash noise Shift selectors moving out of desired range NOTE Remove necessary components to gain access to shift linkage cable ends 1 Inspect shift linkage cable clevis pins and pivot bushings and replace 1f worn or damaged 2 Be sure idle speed is adjusted properly 3 Place gear selector in neutral Make sure the transmission bell crank 1s engaged in the neutral position detents 4 With two wrenches loosen the outside jam nut counterclockwise Turn the outside jam nut 1 1 2 turns Perform this procedure on the shift lever end also 5 After turning the outside jam nut 1 2 turns Hold the outside Jam nut with a wrench and tighten the inside jam nut clockwise until it is tight against the bracket 6 Repeat Step 4 and Step 5 until the proper adjustment 1s made for the transmission cable 7 Use this procedure to loosen or tighten the shift linkage cable as needed Fuel system and air intake Fuel L
17. The observed data stream pressure is about To step 5 101kPa numerical and Kia Next step Dial the joint air inlet pressure sensor on wire harness multimeter voltage check the joint 2 and 4 pins between whether the value is about 5V 4 Check the ECU X1 604 X1 464 484 pins were line between the sensor connector 2 us 4 pin is broken No Next Nextstep _ 5 Start the engine idle running Slow down on the accelerator to close to the fully open to observe the No Replace the sensor diagnostic instrument pressure value changes the display values should change little quick throttle to close to the fully open the display values should be can instantly reach above 90kPa 11 40 11 EFI SYSTEM OF SQR 472ENGINE 2 6 Manifold pressure sensor circuit for the power supply circuit fault code P0108 number results Connect the diagnostic instrument ignition switch 15 mw 1 in the ON 2 The observation data stream of pressure It 1 about 101kPa numerical and pressure Dial the joint air inlet pressure sensor on wire To step 5 harness multimeter voltage check the joint 2 and Nextstep ae 4 pins between whether the value is about 5V P 4 Check the ECU 602 462 1 48 Repair or EE the wire respectively in the line between the sensor harness connector for 1 2 4 pin is broken N Next step Start the engine idle running Slow down on
18. Lowest fuel consuming rate Lowest fuel consuming rate g Kw h h 275 lt 2gKKw h h Idling speed r min 85050 r min Engine Starting Performance The engine should be started smoothly in 30S without any special measure when the air temperature is 25 C Start test is allowed to start three times continuously as a row It can be restarted in 2 minutes later after the first failure The direction of camshaft rotary motion clockwise From the front end look at the crankshaft pulley Spark plug sss plug KORTG e Generators 14V75A whole alternator Lubricating oil category API SF SAE 10W 30 Engine oil pump type Rotor Style Oil filter type As a whole mounted rotating Fuel supply EFI 1 20 1 SERVICE INFORMATION Fuel type 93 unleaded gasoline high cleanliness Transmission V belt with teeth on auto stepless gear change plus gear change cam with change gear transmission Gear change type gear lever with hand Clutch type wet hoof centrifugal type Primary speed change ratio stepless speed 0 84 3 28 change Engine Speed change ratio Total speed reduce ratio Gearing H Gear 2 66 2 23 8 72 L Gear 5 527 4 64 18 13 Hydraulic Disc Bumper 5 Frame type Welded steel tube and plate Overhaul Datasheet Lubricating device Standard Oil pump Gap between inner 0 05 0 18mm 0 35mm Rotor and outer rotors Gap between rotor and 0 10 0 181mm 0 25mm body Engine
19. Replace valve clearance adjustment gasket Assembly of coolant pump LO Chery QQ Service Manual Mechanical Part of SQR 472Engine Chapter 2 Disassembly Assembly and Maintenance Disassemble or assemble the engine with roll over stand Disassemble or assemble the engine parts on the roll over stand 1 Timing Belt 1 Structure Diagram 1 Water pump pulley 2 Timing shroud 3 Timing belt 4 Torsional damper Timing belt back plate 6 Tension pulley 7 Camshaft timing pulley Components which may not be reused Unit N m kg cm 6 7 lt 2 Chery Service Manual Mechanical Part of SQR 472Engine ERI 2 Disassembly F il 2 1 Remove the water pump pulley as the view showing 5 x AW A It will be better of disassembling with special tool Torque 25 1 5 2 2 Disassembly of Timing Belt Cover Torque 6 1N m 2 3 Disassembly of torsional damper Use special tools to prevent the gear ring from rotating When disassembling the fixing bolts of the torsional damper make sure that the marks on the crankshaft timing pulley match with the timing marks on the engine oil pump 2 4 Remove the timing belt back plate d Y Chery QQ Service Manual Mechanical Part of SQR 472Engine EIE 2 5 Disassembly of tension pulley 2 5 Compress the top dead center at the first cylinder Timing Mark Clockwise piston After disassembly of timing c
20. 1 The fuel injectors for cylinders Main relay 3 The fuel injectors for cylinders 2 The fuel injectors for cylinders Injection signal ECU X1 62 Pin each injector has two pins SM1 and 02 Among them the foot with SM1 identifies the main relay The electrical output of 87 pin another in accordance with 1 2 3 4 cylinder are respectively connected with the ECU X1 24 X1 62 X1 61 B60 pin V1 4 said the first to the fourth fuel injectors 2 Installation position One end of the cylinder head intake valve close 3 Working principle Injection time of ECU through pulse width to control fuel injector Current flowing through the injector coil producing drag needle The electromagnetic force when the electromagnetic force increases to a certain extent the needle was beginning to rise fuel injection process begins when the current stops When the needle valve under the action of the spring heavy and closed end fuel injection process 4 Technical parameters 1 Limit data O S Storage temperature the original packaging 30 70 Permission temperature fuel injector ina not working 30 0 The working Continuous 30 L o H20 130 temperature of the After the hot start about 5 minutes 30 fuel injector time p The fuel injector waku fuel temperature short time about 3 minutes 30 sO _ reach e enn 540 0 reach 4 Allow fuel moisture 0 ring w
21. 12 6 Brake Light Switch 12 8 Overhaul Information Warning e Headlight bulb will be very hot when it is turned on Do not touch it after it 1s just turned off Operation should be done when the bulb is cooled down e Inspection of water temperature alarm may use fire source and liquid of high temperature Do not put flammable matters nearby and take care not to get burnt e The temperature of headlight is quite high when turned on Replacing with bare hand or stained glove will cause oil stains on the glass face which may form hot spot and cause deformation of glass face and damage to bulb e Pay attention to the following when replacing the bulb Do not replace the bulb when it is turned on Keep ignition switch in the OFF position and replace after the bulb is cooled down Replace the bulb with hands in clean gloves to avoid oil stains on the glass surface Clean the glass with a clean rag dipped in alcohol or isoamyl acetate In case of any oil stains on the glass surface If the Inspection has to be done with battery check if the battery is normal Inspection of switch continuity can be done without removing the switches from the vehicle After the inspecting and overhauling of each part cables and wires should be routed properly chapter 1 Refer to Chapter 2 for removal and installation of taillight and rear turning lights Overhaul Standard Mail switch fuse IDA 20A 30A Head lamp Headlight F
22. 4 2 5 Remove the spring seat of the oil pressure relief valve for the engine oil pump the coil spring oil pump and oil pressure relief valve etc 4 2 6 Remove the front crankshaft oil seal Notice The oil seal removed may not be reused 4 33 Routine Inspection 4 3 1 Inspect the engine oil pump for clearance 4 3 1 1 gear in the engine oil pump put the gears into the engine According to the marks for inner gear and outer oil pump that is in the cylinder block 4 3 1 2 Measure the clearance between the inner and outer gears with a feeler gauge Standard value positions Limit 0 35 mm 0 05 0 18mm average value of 9 6 34 Mechanical Part of SQR 472Engine Relief Valve Slide Block Relief Spring i Spring Seat n PHN LD fs ROM tal Oo CHERY ERI EIE Chery QQ Service Manual 4 3 1 3 Measure the clearance between the rotor and pump body Standard value 2 0 10 0 181mm Limit 0 25 mm 4 3 2 Inspect the oil pressure relief valve 4 3 2 1 pressure relief valve No abrasion or scrape shall be found on the oil 4 4 Installation 4 4 1 After the lip of the new oil seal for front crankshaft is spread with engine oil fix 1t with a special tool Notice Use new oil seal The oil seal should be left less than 0 5 mm at its outer edge after it is pressed down Pressed Direction 4 4 2 Assembly of the oil pressur
23. 5 9 main relay 212 pin check ECU yes Repair or replace the wire respectively In sensor connector 1 and oxygen harness sensor connector white 2 relative and oxygen No Diagnostic aid sensor connector pins between white relative whether the circuit breaker or the open 11 39 11 EFI SYSTEM OF SQR 472ENGINE 2 4 The lower oxygen sensor heater control circuit for the power supply circuit fault code P0038 number results 1 Connect the diagnostic instrument ignition switch is qm in the ON Dial the joint oxygen sensor wire harness check Next step with a multimeter the joint 1 and oxygen sensor No To step 4 connector white 2 relative and oxygen sensor connector relative to white is 12V about the value of voltage at pin Using a multimeter to check the oxygen sensor 1 white 2 white resistance between Pin value at No The replacement of Xu 20 1 in 5 4 6 6 ohm feelings 15 fuse check the main relay power lines of the Ye Replace the fuse the fuse _ Next step Check the ECU 9 the main relay 21 pins respectively and sensor connector 1 and harness oxygen sensor connector relative to white 27 No Diagnostic aid relative with the oxygen sensor cable whether to short circuit of power supply pin 29 ao sensor circuit shorted to ground fault code ts 5 results ai Connect the diagnostic instrument ignition switch 1s in the ON
24. 50N m ENGINE SUPPORT 10 1 25 40 50N m 5 1 5 REMOVAL OF ENGINE TRANSMISSION SYSTEM AND GEARSHIFT Disassembly Engine Remove cargo box Remove seat Remove plastic covers Remove air filter Remove exhaust pipe and muffler Remove hoop Remove water inlet hose of engine Remove bolt 1 Remove gear shift rod A Remove hoop Remove water outlet hose of engine Remove nut Remove the throttle cable Remove hoop Remove circulating water hose 5 2 LET MSP NNER E lt 21 a EI a gt LJ 2 aa Water outlet hose of engine 5 REMOVAL OF ENGINE TRANSMISSION SYSTEM AND GEARSHIFT s s Connector 4 Remove all the connector of engine Remove the connector of ECU Tension spring exhaust pipe Y E j P ZB pe S E y Falc Jal 274 Remove tension spring of exhaust pipe Remove catalytic converter Remove muffler 5 3 5 REMOVAL OF ENGINE TRANSMISSION SYSTEM AND GEARSHIFT Remove the connector of oxygen sensor Remove two nuts Remove exhaust pipe E 4 Remove hoop of air filter San 4 wa Remove two bolts Remove air filter Remove hoop of air inlet duct for CVT Remove bolt Remove air inlet duct of CVT 5 4 5 REMOVAL OF ENGINE TRANSMISSION SYSTEM AND GEARSHIFT Remove hoop of air
25. Fuel pressure 15 too large Diagnostic aid Valve clearance is too small 2 19 The oxygen sensor circuit fault fault code P0136 number results 1 Connect the diagnosis instrument the Next step ignition switch is in the ON Start the engine idle running to the Diagnostic procedures No coolant temperature reach normal values Next step iu Check the ECU 434 597 pins Repair or replace the wire harness observe diagnosis instrument monk oxygen sensor voltage items to pay changes the display values should lose uncle is in the range of 100Ma 900mA respectively In sensor connector 3 Next step the oxygen sensor grey connection line between pins line 1s faulty Exhaust system blocking Maintenance according Fuel injector is leaking diagnosis Fuel pressure 1s too large Diagnostic aid Valve clearance 1s too small Check the ECU 422 374 pins Yes Repair or replace the wire harness 11 48 11 EFI SYSTEM OF SQR 472ENGINE 2 20 Oxygen sensor circuit output voltage is too low fault code P0137 Serial Operation steps Test Next step results Connect the diagnosis instrument the Next step Start the engine idle running to the Diagnostic procedures coolant temperature reach normal values Next step observe diagnosis instrument monk oxygen sensor voltage items to pay changes the display values should lose uncle 1s in the range of 100Ma 900mA iu Check the ECU
26. ON Dial the joint oxygen sensor wire harness check Next step with a multimeter the joint connected with the Mud No To step 4 oxygen sensor white relative 1s about 12V value between I voltage at pin Using a multimeter to check the oxygen sensor white 2 white resistance between Pin value at 2 No Replace the sensor C 5 4 6 6 ohm Replace the fuse 2 3 4 15 fuse check the main relay power lines of the No Next step 5 Check the ECU X1 8 the main relay 21 No Repair or replace the wire pins respectively in sensor connector 1 and harness oxygen sensor connector relative to white 2 yes Diagnostic aid with the oxygen sensor is connected between pins relative color line to supply short circuit 2 3 The lower the oxygen sensor heater control circuit shorted to ground fault code P0037 number results Connect the diagnostic instrument ignition switch poe is in the ON Dial the joint oxygen sensor wire harness check Next step 2 with a multimeter the joint 1 with the oxygen No To step 4 sensor cable relative to white is 12V about the value of voltage at pin Using a multimeter to check the oxygen sensor 1 white 2 white resistance between Pin value at No Replace the sensor 20 C in 5 4 6 6 ohm 15A fuse check the main relay power lines of the Replace the fuse Next step fuse 15A fuse check the main relay power lines of the fuse 1
27. Start and warm up engine Stop the engine Check if the coolant level is between the upper and lower limit 3 15 3 CHECKS amp ADJUSTMENT When the coolant level is below the LOWER limit remove reservoir tank cap and add coolant till upper limit Add coolant or diluted original liquid Recommended coolant XYPOWER coolant Standard density 50 Freezing temperature of coolant varies according to the different mixture ratio Adjust the mixture ratio according to the lowest temperature in the place where the vehicle is used If the coolant reduces very fast check if there is any leakage The cooling system may be mixed with air when there 15 no coolant in the reservoir tank and the air should be discharged before ddi lant The coolant concentration Coolant Leakage radiator hose wRerpumpwaerppes fd wm see ne Mo ud In case of any leakage disassemble and do further check Refer to Chapter 4 60 Check the radiator hose for aging damages or cracks The rubber hose will naturally get aged after a period of service time The aged hose may get cracked when the cooling system is heated Nip the hose with fingers and check if there are any tiny cracks In case of any abnormal replace with a new hose Check the clamps of the coolant pipes and hose Tighten properly in case of any looseness Check radiator fins for mud and dust clog or damage Correct the bent fins
28. Working principle The two NTC thermistor 15 encapsulated in the temperature sensor the resistance value varies with the temperature of the cooling water cooling water temperature is low the resistance of the thermistor is large The cooling water temperature 1 high the resistance of the thermistor is smaller Conversion of resistance into the change of voltage input to the ECU ECU according to the temperature of cooling water the basic injection time carries on the revision to the idle speed and the air volume On the other hand it also output signals to the instrument the driving staff can directly by visually judge the operating state of engine As shown in Figure 6 structure temperature sensor 11 7 11 EFI SYSTEM OF SQR 472ENGINE 4 Technical parameters The water temperature sensor contains two thermistor a dedicated water temperature signal input pin ECU use A C a water temperature sensor and instrumentation for temperature signal input pin used for B and shell as earth Limit data Rated voltage Run with ECU 5V Nominal resistance at 25 C 1 825 to 2 155 Operating temperature range 30 130 7 Q Vibration acceleration license 2 Characteristic data number Temperature c A C end temperature tolerance of 0 1 C resistance Q of 0 1 C resistance Q 2 qun pwe S 9 2 pes s p 5 Installation notes The sensor should apply sea
29. fault code P0261 M results Connect the diagnosis instrument p ignition switch 1s in the ON 2 Dial the joint stiffness of injector on wire Yes To step 4 harness using a multimeter to check the Next step connector SM1 pin voltage and power for a few pieces of value 15 a 12V 3 Check in between cylinder injector Yes Repair or replace the wire harness connector and the main relay line is No Next step open circuit or short circuit to ground Using a multimeter to check a resistor Next step No between the fuel injectors for cylinders SM1 and SM2 pins at 20 C in 14 5 0 5 ohm Whether the 3 7 voltage with a multimeter Yes Diagnostic aid aid to check a cylinder injector connector 2 pin No M step and the negative pole of the power supply Between the 248 pin check cylinder Repair or Repair or replace the wire harness _ the wire harness injector connector 27 pin and the ECU line Tas Diagnostic is broken or the power supply or short circuit to ground Replace injector 11 51 11 EFI SYSTEM OF SQR 472ENGINE 2 25 A cylinder injector circuit for the power supply circuit fault code P0262 Serial Operation steps Test Next step number results Connect the diagnosis instrument ignition switch is in the ON Dial the joint stiffness of injector on wire harness using a multimeter to check the connector SM1 pin voltage and power for a
30. 1 Without flywheel 3 5 1 1 Hitch the part of crankshaft pulley with the belt of special tool 3 5 1 2 Hold on the handle of the special tool and prevent the toothed belt from rotating Tighten the bolts with the specified torque 98 0 10N m 10 1kgm Mechanical Part of SQR 472Engine Outside s Chery QQ Service Manual Mechanical Part of SQR 472Engine 2 22 With flywheel 3 5 2 1 Prevent the gear from rotating with special tool 3 5 2 2 Then screw down the bolt of torsional damper 3 6 Assembly of timing cover Mount the sealing strips at the positions as indicated in the right figure The sealing strips at the position 1 and 2 should be mounted before the assembly of the cylinder head assembly and the sealing strip at the position 3 should be mounted before tightening the water pump Install the timing cover screw in the bolts with hand and then tighten them Torque 6 1N m 3 7 Installation of water pump pulley Torque 6 1N m 6 13 Chery QQ Service Manual Mechanical Part of SQR 472Engine 2 Camshaft 1 Structure Diagram 1 2 3 4 5 6 7 8 9 a at ui A TREE 3 1 1 TIN eon vt p a Mm oe ES TAARI a pn Ww Kr L mir ME PE M z oa 1 r z M LIE Cylinder head chamber cover assembly Cylinder head cover gasket Camshaft timing belt Camshaft cove
31. 10 INNER HEX BOLT M10x25 LOCKNUT FLANGE M10x 1 25 RUBBER WASHER OF ENGING CLAMP 10 FUEL 10 5 400 GEAR BOX COBBRA ENGINE HOSE STOPPER ENGINE HOSE CIRCLIP 16 25 BOLT 12 1 25 45 LOCKNUT FLANGE M10X 1 25 BOLT FLANGE M12X 1 25 X 35 ENGINE SUPPORT B ENVELOP BOARD ENGINE OUTLET WATER GAP ENGINE BOLT M8x35 CVT SUPPORT COVER SPRING WASHER 12 BOLT FLANGE M12x 1 75 30 FLANGE PLATE CVT SUPPORT BOLT M10X20 NUT FLANGE M12X 1 25 BOLT M10X25 BOLT FLANGE 8 25 BOLT FLANGE M8x 30 STEEL BUSH STARTING MOTOR STARTING MOTOR 5 6 5 REMOVAL OF ENGINE TRANSMISSION SYSTEM AND GEARSHIFT Removal and Installation of Front and Rear Axle 5 Support the vehicle with jack make sure the vehicle will not fall Remove Plastic parts for frame Chapter 2 Front and rear wheels arms gt Chapter 8 Chapter 9 Air filter Chapter 5 gearbox Chapter 5 Engine Chapter 5 Front and rear brake caliper Chapter 8 Chapter 9 Remove front axle Remove bolt 1 R ive shaft front emove drive shaft front E Drive shaft front Front axle Remove bolt 2 Remove front axle Installation Installation as contradictorily process of remove Bolt torque of front axle M8 23 25N m Bolt torque of front 10 45 50N m Bolt torque of front drive shaft 8 23 25N m Remove rear axle Remove bolt 1 Rear axle
32. 10 Upper amp lower connecting rod bearing bushing Gnside 11 Crankshaft trust plate the side oF oil a T T L 2 oil seal and crankshaft front oil seal journal 00000 Rear oil seal and crankshaft rear oil seal journal Valve tappet and valve pipe hole Excircle and hole of valve tappet oo oo o s Excircle and hole of valve tappet 7 Camshaft journal and bearing base hole Camshaft driving gear 13 14 15 1 ON 2 Edge and excircle of oil seal 20 Oil seal journal and oil seal base hole 21 Surface oil filter sealing gasket 6 55 lt gt 2 Chery Service Manual Mechanical Part of SQR 472Engine zl ETHE Chapter 7 Positions on SQR472 Engine to be Spread with Sealant SQR472 Position to be spread with Form and amount of Type of sealant Remark sealant sealant reference a gd oingt surface of oil pan Loctite 5699 3 4 mm 2 Rear oil seal bracket Loctite 5699 o 3 4 mm 3 chamber cover Loctite 5699 o 3 4 mm EN oint surface if timing gear chamber Loctite 5699 o 3 4 mm mE cover sg oint surface of camshaft cover Loctite 5699 o 3 4 mm Sealing surface of the bowl shaped Loctite 11747 Spread uniformly plug of cylinder head 7 Flywheetbott 0125006 3 Intake pipe stud Loctite 262 0 125 ml x7 The part screwed into eer Exhaust pipe stud Loctite 262 0 125 ml x6 The part screwed into po mmm memo
33. 11 EFI SYSTEM OF SQR 472ENGINE 2 34 The camshaft position sensor fault fault code P0340 Serial Operation steps Test Next step number results round which is diagnostic instrument the Next step ignition switch is in the ON Dial the joint sensor wire harness using a To step 4 multimeter to check voltage between the 3 No Next step and 2 pins connector on sensor placement is around 12V Check phase sensor 3 pin and 87 pin of Repair or ere ene the wire harness the main relay whether the circuit breaker oa open ground between the 307 incisis step check phase sensor 2 pins with the ECU whether the circuit breaker 4 If the 9 9V about the value of voltage between the 72 pin and the negative pole of the power supply check phase sensor connector 1 pin and ECU 5 Between the 728 pin check phase sensor connector 1 pin and the ECU whether the circuit breaker Diagnostic aid round which is diagnostic instrument the Next step ignition switch is in the ON Dial the joint on wire harness for ignition To step 4 coil using a multimeter to check voltage No Next step between the 2 pin and the negative pole of the power supply 15 12 V Check the ignition coil between the 2 pin and the 87 pin of main relay circuit 1s open circuit or short circuit to ground Between the 4 pin check phase sensor and papillary 3 pins and ECU line is open circuit
34. 3 HOLDER 4 BOLT FLANGE M8x20 5 NUT M10 6 STABILIZER CUSHION RUBBER 7 WASHER 11x930x2 8 8 STABILIZER BOLT 9 BOLT FLANGE 10 1 25 50 10 LOCKNUT 10 1 25 11 REAR SHOCK ABSORBER 12 BUSH ARM 13 CENTER SPACER 14 BOLT FLANGE M10x1 25x90 15 REAR UPPER ARM ASSY 16 BOLT FLANGE M10x1 25x110 17 BUSH RR KNUCKLE S 18 BUSH RR KNUCKLE L 19 REAR LEFT ARM LOWER 20 REAR RIGHT ARM LOWER 21 REAR STEERING KNUCKLE 22 BEARING 23 CIRCLIP Q75 24 BOLT FLANGE M10x25 25 REAR BRAKE DISC 26 REAR WHEEL HUB 27 NUT 28 COTTER PIN 3x25 29 BOLT FLANGE M10x1 25x135 30 REAR CV JOINT L 31 REAR CV JOINT R Disassembly Stabilizer Bar Remove 9 REAR WHEEL REAR BRAKE SUSPENSION 1 RUBBER WASHER 2 HOLDER 3 3 BOLT FLANGE 8 20 4 NUT 5 CUSHION RUBBER 6 WASHER 11x 30x2 8 7 STABILIZER BOLT 8 Remove Stabilizer Bar Installation Reverse the removal procedure for installation Right rear absorber Removal Note Securely support the vehicle when removing rear left and right absorbers Maintenance of rear absorbers only does not require removal of rear suspension Remove the following parts for rear right shock absorber 11 Bolt 9 12 Nut 10 11 Bolt 9 12 Nut 10 Remove rear right shock absorber Installation Reverse the removal procedure for installation Rear Right Arm Refer to front right Arm in Chapter 8 for the removal inspec
35. A32 pin check phase sensor ae or replace the wire harness and papillary 3 pins and ECU line is open circuit or short circuit to ground Using a multimeter to check the ignition coll resistance 2 pin and 3 pin between stop should be 0 67 10 By using the universal resistance between Diagnostic aid the table to check the ignition coil 4 No Replace ignition coil cylinder column and ignition anode stop should be 9 2K 20 2 39 Carbon irrigation control valve open circuit fault code P0444 number results 1 round which is diagnostic instrument the ignition switch 1s in the ON Dial the joint on wire harness for ignition To step 4 coll using a multimeter to check voltage No Next step between the 2 pin and the negative pole of M the power supply 16 12V 3 Check that the carbon canister control valve power supply line is broken or open ground No Nextstep Nextstep 000 4 Using a multlmeter to check the canister control resistance between the 1 No Replace the control valve and 2 pins of the valve value at 20 is 26 C 5 Using a multimeter to check the carbon canister control valve street is about 3 7V voltage 2 pin and cathode will the house Between the X1 26 pin to check the carbon canister control valve connector 2 No Diagnostic aid pin and the ECU whether the circuit breaker 11 59 11 EFI SYSTEM OF SQR 472ENGINE 2 40 Carbon irrigation control valve short
36. Guide Inside Diameter Measurement Point RE s Chery QQ Service Manual Mechanical Part of SQR 472Engine 3 3 3 Replacement of valve guide 3 3 3 1 Heat the cylinder head with hot water to 80 100 67 3 3 3 2 out the valve guide from one side of combustion chamber with special tool as can be seen from the right picture Notice The removed valve guide may not be reused The intake valve guide and the exhaust valve guide may not be mis installed 3 3 33 Mount the new valve guide with special tool at the place as can be seen from the right picture Notice strike the conduit slowly to the position in the cylinder head do not strike too far and be careful for size The height of the part of valve guide struck into the cylinder head Type EF Item Height mm 13 71 0 25 3 3 3 4 Rub the inside diameter with reamer to reach the standard clearance value 3 3 4 Assorted surface of valve 3 3 4 1 Spread with red lead on the assorted surface of valve Do not rotate the valve but press lightly and check the assortment and width 6 26 lt 27 Chery QQ Service Manual Mechanical Part of SQR 472Engine EIE 3 3 4 2 Repair of valve seat insert Notice The repair of valve seat is always conducted in the course of the inspection of valve s fitting position The surface repaired should be free from any breakage Take it out slowly after the inspection 3 3 4 3 45wimble surfac
37. HALF DOOR L 20 INNER HALF DOOR R 21 WASHER 5 10 1 22 BOLT FLANGE M6 23 BOLT FLANGE 6 16 24 BOLT FLANGE 5 25 CABLE HALF DOOR 26 HANDLE HALF DOOR R 27 OUTER HALF DOOR L 28 OUTER HALF DOOR R 2 Vehicle body Muffler Triangular Cover Remove Remove bolt 1 Remove triangular cover Remove the triangular cover of the another side in the above way Installation Reverse the removal procedure for installation lt ERN C SER Rear Left Bo Rear Left Board Remove Remove bolt 2 Remove bolt 3 Remove rear left board Remove the rear right board in the above way Installation Reverse the removal procedure for Installation Bo t 2 2 5 2 Vehicle body Muffler Seat belt Remove Remove bolt 3 Remove bolt 4 Remove driver seat belt Remove the passenger seat belt in the above way Remove rear seat belt of passenger in same method Installation Reverse the removal procedure for Installation Install rear seat belt of passenger in same method Main Protect Pole ASSY Remove Remove bolt 1 Remove bolt 2 Remove the main protect pole assy of the another side in the above way Remove main protect pole assy Installation Reverse the removal procedure for Installation 2 6 2 Vehicle body Muffler XY1100UE 13 a 0 33 T OR P E ae ss CT T SAY 2 T i a 1 FRONT PR
38. J AS OI D 29 M R 20 oli li DIETE ET NEN EET E 30 o oi2i092502596225 269992 920980150259006 000 9 0 089508 9250039320006 O 30 SA P 30 4 Disassembly and Assembly of Engine Oil PUITID usi ER MEER ig Das 43 SM l ikili Zuna E A ET 42 NIG ASS MID 42 uuu E TTD EET 42 T E T E E E 44 SNB I OI Oo RETI PT 45 I CD Di i u E E E 45 SABDE E e KE EE EEEE EE AEE 46 SQ uu u TE EE mmm 46 34 ASSeImbl s OE OH e alk T E A E E A E T ETT 46 46 6 Crank COniectine Rod NIC CNA 46 T uu buses wedineanebdijansbedlauete 48 2 Disassembly of Crank Connecting Rod mechanitsm 48 Ne AIMED p MEERTEN REDE I UT MS 49 Oil u u ETT TE TEE 22 5 Assembly of Crank Connecting Rod la ahashaqiusashulsupushaqhuypstaqa
39. ON The observed data stream coolant temperature and whether the engine temperature quite Next step numerical and when the engine temperature Note if the display value often is constant that there may be circuit breaker failure Dial the wire harness connector on coolant kil Next step temperature sensor 11 44 11 EFI SYSTEM OF SQR 472ENGINE 2 12 The coolant temperature sensor circuit discontinuity fault code P0119 Serial Operation steps Test Next step number results Connect the diagnosis instrument the ignition Next step 11 switch is in the ON The observed data stream coolant temperature Yes To step 6 and whether the engine temperature quite specific No Next step figures and then the engine temperature related Note if the display value often is constant that there may be circuit breaker failure Dial the connector for coolant temperature sensor wire harness electrical multimeter check sensor a i mM Replace the sensor and c pins of value is commensurate with its temperature with specific reference to the relevant part of the repair manual 4 Dial the connector for coolant temperature sensor wire harness with a multimeter to check voltage Next step the joint a and c pins of about 5V Check the ECU 73 pin respectively in the line between the sensor connector a pin 1s harness open circuit cf No Nexstp start the engine idle running Observation
40. and spline Stagnated turning noise gap with spline Replace Warning An accident may occur if the rzeppa constant velocity joint cannot turn freely because of the loss of control of wheel steering Installation Press ball pin into arm with special tool Reverse the removal procedure for installation Note No shaking with the installed left and right arms Replace arms if any Tightening Torque 457 50N m 8 10 8 FRONT WHEEL FRONT BRAKE SUSPENSION STEERING Steering System Cover Steering Stem Removal Remove cover steering stem Chapter 2 Combination Switch Removal Remove combination switch 2 3 8 11 8 FRONT WHEEL FRONT BRAKE SUSPENSION STEERING Rear View Mirror Removal Remove left and right rear view mirrors Note Left rear view mirror is right threaded Turn counter clockwise for removal Note Right rear view mirror is left threaded Turn clockwise for removal 8 12 8 FRONT WHEEL FRONT BRAKE SUSPENSION STEERING Steering Stem Removal Remove Steering wheel gt 2 2 cover steering stem 2 2 Combination switch 2 3 Bolt Shaft assy steering joint Steering stem Shaft assy steering joint 8 13 8 FRONT WHEEL FRONT BRAKE SUSPENSION STEERING Installation of Combination Switch Install combination switch 2 11 Insert main cable with connector of combination switch 8 14 8 FRONT WHEEL FRON
41. axoao pL 1 6 4 NS 60 4 0 4 0 50 E S HE 1 5 ese was 2 165844 10 rae 5 B a G0 49 50440 60 8 9 e ad al a 5 Nun co 4 z 6804 S80 8 e s lt E 4 La eee d e vu ge AP m Se 50 0 o 5 Uv a lt 3 u m c is 1 amp l o p pa 7 Pu S0 V 09 E o 9o C80 AVA prodi So Ova ova gt 55 22 7 m n 680 VA 504 8 X A Ver ae z 5 61 cgo d is 2 p 9 g 8 m lt EH ze 5 5 405 044504 4020 E S80 03 soa gt P 5 Y x 50 E 96 er amp 580 61 S 59 lt 8 WN 1 eoe m om 2 5 uung ayy 4a fy e hs ml Two four wheel drive brake so 1 9 5 I a 60 1 9 p we Bg alo Spas lt 504 508 4 3 2 9465 un 140 105 ul UO Qy E meter ECU OE a k lt q E 401042038 0 SOA SUR lt uoj2aJpp OL C80 46 4 LEBHEBE 60 pi gt Q 8 8 a Pas SORIA E 2 2 turning light Hornn C S 84 9 E YOYOIIPU uonj2a4p ay ol 5 3 8 E om iu c 1 i on 9 gt wiper wW nc dump pump sw
42. bearing if necessary Special tools are required Check worn status of drive bevel gear and ring gear rear axle Replace if necessary Check oil seal lips o ring shape Replace parts if necessary Check cylndrical surface of rear axle and oil seal lips Replace if necessary Check inner and outsider spline Replace if necessary Check other parts Replace if necessary 10 12 11 EFI SYSTEM OF SQR 472ENGINE Foreword The 472 engine 1s a cylinder increase In R amp D base 372 engine to meet the more large capacity and power requirements On the structure and technical characteristics of the engine and it 1s the same as the 372 engine So everybody through this repair manual understanding should be able to quickly grasp the essentials of the 472 engine repair In order to help the technical service personnel to understand and familiar with Chery QQ SQR7110 models has the capability of rapid repair and maintenance specially written Chery QQ Technology Service Manual 472 engine mechanical part This manual details the disassembly inspection testing and diagnosis technology standard Chery QQ472 engine components or systems This manual is provided by Chery Engine Co Ltd The license without written authorization any part of the book can not be In any form or by any means to copy or use This manual interpretation of Chery Motor Sales Company Sales Service Department The editor August 2008 First editi
43. bolt nut absorber front 30 40 N m Fixing bolt nut absorber rear 30 40 N m Nut front rear rim 40 50 N m Nut rear wheel axle 180 200 N m 8 1 8 FRONT WHEEL FRONT BRAKE SUSPENSION STEERING Troubleshooting Heavy Steering Wheel Cannot Turn Freely Steering bearing is damaged or worn Faulty wheel bearing Inner amp outer bearing races are damaged Front wheel axle is bended worn or stepped Brake drag Steering stem 15 distored e Faulty steering structure Tire pressure 15 too low Front Suspension is Too Soft Worn tire Weakened front shock absorbers IM E e Tire pressure 15 too low teeri heel is not well tightened A ie NDA Front Suspension is Too Hard e Steering stem is loosened or not well installed e Mount seat steering wheel is not well tightened e Front shock absorber is bended e Bearing is damaged e Tire pressure is too high e Right and left shock absorbers are not matched Noise with Front Absorbers e Deflected tires e Donec e Faulty front shock absorbers e Worn tiers e Loosened tightening parts of front e Shaking of wheel bearing absorbers Vibration of Front Wheel Poor Brake Efficiency e qa Faulty brake adjustment e Stained brake disc Worn brake shoes e Faulty tire e Air in brake hose Improper balance of wheels Faulty wheel bearing Improper tightening of wheel axle 8 2 8 FRONT WHEEL FRONT BRAKE SUSPENSION STEERI
44. clean the mud with water and Compressed air When the damaged area of the radiator fin 15 over 20 replace with a new radiator Radiator Check Water Temperature Gauge When engine is not working the water temperature should be in the 0 position Start the engine to check if the indicator works If the indicator 1s not working do the maintenance in time 3 16 4 COOLING SYSTEM Overhauling Info 4 Adding Coolant 4 5 Trouble Shooting 4 2 Cooling System Chart 4 6 Check and Maintenance 4 3 Cooling System Assembly Disassembly Reservoir Tank oso odes 4 5 ass 4 7 Overhaul Information Note If the radiator cap is opened when the coolant temperature is above 100 C the pressure of coolant will drop and get boiled rapidly The steam jet may cause danger and injury Cover the cap with a piece of rag after the coolant temperature goes down and open the cap slowly Inspection of coolant should be done after the coolant is fully cooled Coolant is toxic Do not drink or splash it to skin eyes or cloth If coolant splashes in your eyes thoroughly wash your eyes with water and consult a doctor If coolant splashes on your clothes quickly wash it away with water and then with soap and water If coolant is swallowed induce vomit immediately and see a physician St
45. display 1 rotational speed coolant temperature solar term door opening ignition advance angle injection pulse width inlet pressure inlet temperature speed voltage injection correction the carbon canister erosion rate the idle air control oxygen sensor waveform 11 34 11 EFI SYSTEM OF SQR 472ENGINE 2 The target speed engine load ambient temperature relative ignition dwell time the evaporator temperature gas flow rate fuel consumption 3 Solar term door position sensor signal voltage coolant temperature sensor signal voltage the intake air temperature sensor signal voltage the intake pressure sensor signal voltage 2 EFI system status display Anti theft system state safety state program state cooling system condition stable condition dynamic condition emission control state the status of the oxygen sensor the idle state the malfunction indicator lamp status emergency condition air conditioning system automatic transmission torque request status 3 Actuator test function Fault lamp fuel pump air conditioning fan relay ignition fuel injection single cylinder oil 4 Odometer display The running mileage the running time 5 Version information display Frame number VIN ECU hardware number ECU number 6 Fault display The intake pressure sensor intake temperature sensor engine coolant temperature sensor solar term door position sensor oxygen sensor oxygen sensor heater circuit air
46. door body and idle bypass airway 7 The engine mechanical part The general procedure of diagnosis 4 Serial Operation steps Test Next step number results 1 Connect the fuel pressure gauge access Next step point for the fuel distribution pipe assembly No Maintenance of oil supply system inlet pipe end start the engine check the fuel pressure in the idling condition 1s about 3800kPa set aside seven minutes a cylinder cylinder Next step line connected to the spark plug spark d No Maintenance he ignition machine from the engine body aroun system 5mm start the engine check whether there is a blue and white high pressure fire Pulling off the coolant temperature sensor Yes Repair or replace the sensor line connector start the engine the engine Is successful up observation Or 2500 No Next step OHM Series in the coolant temperature sensor junction resistance to replace the coolant temperature sensor observation of the engine is successful Gently down on the accelerator observe Yes Cleaning solar term door and idle whether easy to start airway N Next Nextstep 000000 Remove the injector injector clogging to replace special cleaning analyzer check whether the No Next step injector is there is a leak or in Check the fuel situation observe whether Replace fuel Check the engine cylinder pressure of each engine cylinder pressure observe whether there 15 insufficien
47. fault and breakdown such as wire harness circuit transient Due to poor contact or connector control fault lamp When no fault ignition switch ON fault light fault detection speed signal lamp When there 15 a fault ignition switch ON fault light starting find the speed signal out if the fault lamp fault class is defined as a light mode then meet the corresponding Confirmation conditions after the fault light To connect 2 diagnostic instrument This system uses the K line of communication protocol and uses the ISO 9141 2 standard diagnostic connector see below The criteria for the diagnosis of joint is fixedly connected on the engine wire harness With the engine management system EMS is the standard diagnostic connector on the 4 7 and 16 pin Criteria for the diagnosis of joint 4 pin connected wire on the vehicle 7 pins connected to a ECU 77 pin namely engine data line 16 pin connected battery Connect the P as T BAG R diagnosis sl ECU ft DIAG _ K instrument Figure 1509141 2 Standard diagnostic connector connected to the engine control unit side Figure ISO9141 2 standard diagnostic connector connected to the engine control unit side The ECU communicates with external diagnostic device through the K line and can perform the following operations the function and diagnosis instrument operation refer to diagnostic instrument using the 1 the engine parameter
48. h Flow Qn 100 200 300 400 500 600 700 800 mbar Vacuum degree The carbon canister control valve flow chart 11 26 11 EFI SYSTEM OF SQR 472ENGINE 4 Technical parameters 1 Limit data measure value unit least typical maximum working voltage 1 minutes over voltage 22 5 Minimum starting voltage 0 80 4 The minimum voltage drop 1 0 V Permission temperature 30 120 G Working temperature term license License storage temperature the import and expo Ta Pase License vibration acceleration product 102 1300 ms Leakage of pressure difference at TOOmbar 2 Characteristic data measure value unit least typical maximum Rated voltage L BS 20CResstane 6 3 010 Stable voltage wires 1051 OA 11 Typical control pulsewidth I control Typical control pulsewidth width hamid 2 15 100 of traffic gt q m 100 of traffic 5 Installation notes The carbon canister control valve and the carbon canister intake manifold connected to see the installation diagram 1 1 From the tank 2 The carbon canister 3 The atmosphere 4 Carbon canister solenoid valve h Lm I 5 intake manifold a 7 AP S XEESIT h Ps 1 Pee 6 Throttle valve The carbon canister control valve installation diagram In order to transfer to avoid solid sound recommend the carbon ca
49. hub Inspection Brake disc thickness lt 3mm Replace Installation Install brake disc Tightening Torque Fixing bolt brake disc 40 50N m Brake Master Cylinder Disassembly Remove Blot 1 Cotter pin Pin shaft Do not remove brake master cylinder from vehicle Cotter pin unless when replacing master cylinder assembly ewm Note 1 p H Y Do not hang master cylinder on brake hose 8 4 Do not put the master cylinder upside down to avoid possible entrance of air into brake system gm U Keep the master cylinder in the installation E position Proper routing of brake hose Check brake efficiency after installation Brake pedal n 8 5 8 FRONT WHEEL FRONT BRAKE SUSPENSION STEERING Brake Pedal Removal Remove Cotter pin E clamp spring Brake Pedal Seperate Brake Pedal from vehicle Disassembly of front brake master cylinder 8 5 Installation E clamp spring Reverse the removal procedure for installation NOTE Do not put the master cylinder upside down to avoid possible entrance of air into brake system Keep the master cylinder in the installation position Refer to Chapter for proper routing of brake hose Check brake efficiency after installation 8 6 8 FRONT WHEEL FRONT BRAKE SUSPENSION STEERING Front Left Suspension NOTE DO NOT Remove both left and right suspension at the
50. of import license 2 Characteristic data measure maximum unit least typical maximum Rated pressure Rated pressure difference flowQ 801 flow Rated pressure difference flowQ 801 801 Changes in the flow in the 15 to 140 1 h range of the 5 pressure Fbwrae A slope characteristic curve as RN 3 The requirement of fuel Fuel pressure regulator can be used to meet the people s Republic of China national standard GB 17930 1999 unleaded gasoline for vehicle and the national environmental protection standards GWKB 1 1999 standard harmful substance control gasoline regulations fuel 4 Fault phenomenon and judgment method Fault phenomenon low fuel pressure or high difficult to start General failure due to long term use 1 Lack of maintenance filter plug 2 Impurity particles caused by large leakage 3 Man made mechanical damage etc Repair the matters needing attention 1 No impact of rail by high pressure gas to oil 2 A ban on the cleaned with strong corrosive liquid 3 No external force caused by deformation A simple method to measure Start the engine into the tubing connected to the fuel gauge enable the engine to run at idle speed check the fuel pressure is about 260kPa pulling off the fuel pressure regulator vacuum tube on the observation time the fuel pressure is about 300kPa 10 The fuel injector 1 Diagram and pin 11 23 11 EFI SYSTEM OF SQR 472ENGINE
51. or short circuit to ground Using a multimeter to check the ignition coll resistance 2 pin and 3 pin between stop should be 0 67 10 By using the universal resistance between Diagnostic aid the table to check the ignition coil 1 No Replace ignition coil cylinder column and ignition anode stop should be 9 2K Q 20 11 57 11 EFI SYSTEM OF SQR 472ENGINE 2 36 Two cylinder ignition coil circuit fault fault code P0352 M results round which is diagnostic instrument the ignition switch is in the ON Dial the joint on wire harness for ignition To step 4 coil using a multimeter to check voltage No Next step between the 2 pin and the negative pole of demum the power supply 15 12V Check the ignition coil between the 2 pin and the 87 pin of main relay circuit is open circuit or short circuit to ground 5 0 Tostep5 0 5 Between the A31 pin check phase sensor Repair or replace the wire harness and papillary 1 pins and ECU line is open Next step circuit or short circuit to ground Using a multimeter to check the ignition Yes Next step coil resistance 1 pin and 2 pin between No Replace ignition coil stop should be 0 67 10 By using the universal resistance between the table to check the ignition coil 2 No Replace ignition coil cylinder column and ignition anode stop should be 9 2K Q 20 2 37 Three cylinder ignition coil circuit fault fault code P0353 S
52. outlet duct for CVT Remove bolt Remove air outlet duct of CVT Remove the CVT disassembly installation 15 CVT SECONDARY SHEAVE 29 FLANGE PLATE CVT SUPPORT 37 CVT SECONDARY SHEAVE 38 ORIENTATION COVER SECONDARY SHEAVE 39 WASHER 6 12X 30X2 40 SPRING WASHER 10 41 BOLT M10x115 42 CVT DRIVER 43 CVT BELT 44 CVT IMPELLER 45 SPACER BUSH DRIVER 46 WASHER 12 5X 630X3 47 SPRING WASHER 12 48 BOLT 12 175 49 SEAL CVT COVER LONG 50 SEAL CVT COVER SHORT 51 BOLT M6x12 52 CRANKSHAFT SENSOR 53 CVT COVER LEFT 54 JOINT AIR INLET DUCT 55 BOLT M6x15 56 WASHER 66X 12X 1 6 57 CVT PIN 58 BOLT M6x25 59 CVT COVER RIGHT 60 CIRCLIP 80 100 61 RUBBER PIPE 85 92 60 62 CVT HOSE IMPORT WIND 63 EXPANSION SCREW M8x20 64 RUBBER PIPE 85 92 60 65 BOLT M6 X 20 66 CVT HOSE EXPORT WIND m m m Remove fixing nuts of engine Remove other fixing nuts of engine as shown below Fixing nuts of engine 5 5 5 REMOVAL OF ENGINE TRANSMISSION SYSTEM AND GEARSHIFT Engine and gearbox disassembly installation 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 ENGINE FAN BOLT FLANGE M6x16 FAN COVER BOLT FLANGE M8X 16 BOLT FLANGE M8x 160 SPACER BUSH ENGINE SUPPORT A SPRING WASHER
53. power supply voltage for 1 hours voltage for 1 hours 30 minutes of tolerance pressure Tolerance Storage Temperature 40000 oe 3 2 Characteristic data measure value unit typical Pressure test range 00000 test range i ge E sasa im t Operating supply fso 5 V ss ha Or the lad 59 m s 3 The limit data of temperature sensor Storage temperature 40 130 4 Characteristics of the data of temperature sensor Operating temperature 40 130 Rated voltage to lead resistance 1KO Operation under 5 V or to test the current running 1mA 20 rated resistance 2500 KO 4 Installation notes The sensor is designed for installation in the planes of an automobile engine intake manifold Pressure pipe and temperature sensor together out of the intake manifold to realize the sealing of the atmosphere with a O ring If you take the right way to install to the car extraction pressure from the intake manifold pressure over sloped down and so on can not ensure the formation of condensed water pressure sensitive element Drilling and fixed on the intake manifold must be carried out in accordance with the supply in order to ensure the long sealing and erosion resistance of medium Joint reliable electrical connection contact except mainly affected by components of joint but also with quality and size pre
54. side of the engine When the vehicle will be stored for more than one month the gasoline in the high pressure fuel line and cap of the fuel injector must be discharged Otherwise the gasoline will age and form colloidal elements which may block the nozzle of fuel injector therefore the engine cannot start or the rotate speed is unstable Overhaul Info Engine Starting Failure Hard Starting Stall After Starting Unsteady Too much fuel in the engine Idle Speed Ail filter clogged Idle air pipe clogged Idle air pipe clogged Fuel system clogged No fuel in the injector Ignition system not functioning properly Fuel filter clogged Fuel tank cap clogged High pressure fuel line clogged Fuel injector clogged 7 2 7 FUEL INJECTOR SYSTEM Fuel Injector System Disassembly Installation 1 FUEL TANK 2 FUEL PUMP 3 0 5 6 100 4 HOOP 6 120X2 5 JOINT FUEL HOSE 6 CLAMP 13 19 7 FUEL HOSE 300mm 8 BOLT FLANGE M8 X 16 9 FUEL FILTER ASSY 10 FUEL HOSE 400mm 11 PROTECTIVE SLEEVE FUEL TANK CAP 12 CAP FUEL TANK 13 SUPPORT FUEL TANK L 14 BOLT FLANGE M6X 12 15 SUPPORT FUEL TANK R 16 CLAMP 610 17 LOCKNUT FLANGE M6 18 INLET WINDPIPE FRONT 19 INLET WINDPIPE MIDDLE 20 RELAY CARBON CANISTER 21 INLET WINDPIPE RAER 22 CARBON CANISTER 23 DEAD PLATE CARBON CANISTER 24 RIVET 5x20 7 3 7 FUEL INJECTOR SYSTEM High Pressure Fuel Line Disassembly Loosen the sp
55. to others For Your Safety Because this manual is intended for the professional service technician we do not provide warnings about many basic shop safety practices e g Hot parts wear gloves If you have not received shop safety training or do not feel confident about your knowledge of safe servicing practice we recommended that you do not attempt to perform the procedures described in this manual Some of the most important general service safety precautions are given below However we cannot warn you of every conceivable hazard that can arise performing service and repair and procedures Only you can decide whether or not you should perform a given task can cause you to be seriously hurt or killed Important Safety Precautions Make sure you have a clear understanding of all basic shop safety practices and that you are 1 1 1 SERVICE INFORMATION wearing appropriate clothing and using safety equipment When performing any service task be especially careful of the following Read all of the instructions before you begin and make sure you have the tools the replacement or repair parts and the skills required to perform the tasks safely and completely Protect your eyes by using proper safety glasses goggles or face shields any time you hammer drill grind pry or work around pressurized air or liquids and springs or other stored energy components If there is any doubt put on eye protection Use other pro
56. traces inoue 2 16 Windshield assembly 2 3 Side dODRE 22 S iQ 2 4 Triangular cover amp rear board 2 5 Seat belt amp main protect pole assy 2 6 Front eie uay a vrbi e top 2 9 Front line cover amp front air guide cover assy 2 10 Overhaul Information Operation Cautions Warning Gasoline is highly flammable therefore smoke and fire are strictly forbidden in the work place Special attention should also be paid to sparks Gasoline may also be explosive when it is vaporized so operation should be done in a well ventilated place Remove and Install muffler after it 1s fully cold This chapter 15 on the disassembly and installation of rack visible parts exhaust pipe Muffler and fuel tank Hoses cables and wiring should be routed properly Replace the gasket with a new one after muffler is removed e After muffler is installed check if there is any exhaust leakage Tightening torque Muffler Exhaust Pipe Nut 40 50N m Troubleshooting Loud exhaust noise Broken muffler Exhaust leakage Insufficient power Distorted muffler Exhaust leakage Muffler clogged 2 1 Cover steering wheel Remove Exert upward to separate cover steering Wheel Installation Reverse the removal procedure for Installation Steering wheel Remove Remove six bolts 1 Remove steering wheel Installation Note Align the front w
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58. wrench refers to the distance CS C K of the fastener head i The box end wrench is an excellent tool because it grips the fastener on all sides This reduces the chance of the tool slipping The box end wrench 15 designed with either a or 12 point opening For stubborn or damaged fasteners the 6 point provides superior holding because it contacts the kL fastener across a wider area at all six edges For general use 88 B 2 OF 2E the 12 point works well It allows the wrench to be removed and reinstalled without moving the handle over such a wide are An open end wrench is fast and works best in areas with limited overhead access It contacts the fastener at only two points and is subject to slipping 1f under heavy force or if the tool or fastener Is worn A 1 6 box end wrench is preferred in most instances especially when braking loose and applying the final tightness to a fastener The combination wrench has a box end on one end and an open end on one end and an open end on the other This combination makes it a convenient tool Adjustable wrenches An adjustable wrench or Crescent wrench Figure 6 can fit nearly any nut or bolt head that has clear access around its entire perimeter An adjustable wrench 15 best used as a backup wrench to keep large nut or bolt from turning while the other end is being loosened or tightened with a box end or socket wrench
59. 0 FRONT RIGHT ARM UPPER Disassembly Front Left Shock Absorber Disassembly ATTENTION You do not need to remove any other parts if you only replace the front suspension Park the vehicle on a level ground Remove front left shock absorber s bolt nut installed in arm Remove front left shock absorber Inspection Inspect the shock for oil leakage oil seal damage destroy replace if needed 8 8 8 FRONT WHEEL FRONT BRAKE SUSPENSION STEERING Installation Reverse the removal procedure for installation Refer to front left shock absorber for removal installation and inspection of front right shock absorber Arm Assembly Attention There are 8 suspension arms in the vehicle they dismantle Inspection and assemble in the same way So here only introduce the way to dismantle inspection and assemble the front left upper arm and the front right lower arm Other arm assemble refers to the above Front Right Suspension NOTE DO NOT Remove both left and right suspension at the same time to avoid fall down of the vehicle Park the vehicle on a level ground and securely support front part of the vehicle Removal Remove Front wheel 8 3 Front wheel hub 8 3 Front brake caliper 8 4 Boltl Front Right Shock absorber Bolt Nut to Bolt for Front Right Arm Upper Bolt Nut to Bolt for Front Right Arm Lower Remove steering tie rod ball pin slot nut
60. 0 0 Arm EX ul can be seen from the picture and pull out the mountine auxiliary tool of valve oil seal Reference After being pressed down the size of the oil seal should comply with the value indicated in the right figure 3 4 3 2 Assembly of intake valve and exhaust valve 3 4 3 2 1 Assembly of valve spring Notice The painting is used for recognizing the different suppliers so the same engine should use the valve spring Painting with same painting 3 4 3 3 Assembly of valve keeper Warning Operate with goggle for protecting the eyes Be care for spring jumping out After assembly of valve spring and its seat press the valve spring with special tool and mount the valve keeper 3 4 3 4 Assembly of valve tappet and valve clearance adjustment gasket 3 4 3 5 Mount the cylinder head gasket and recognize the direction of front and back 3 4 4 Assembly of dust seal and cylinder head 6 28 lt Chery QQ Service Manual Mechanical Part of SQR 472Engine ERI EIE assembly Oil Spread 3 4 4 1 Spread a little oil on the flange side of bolt and Position threaded part 3 4 4 2 Tighten the cylinder bolts in the order indicated in the right figure for 3 times till the torque reaches the specified value The tightening torque for each time is set forth as follows First time 3022Nm second time 50 3Nm third time 70 3 5Nm Torque 70 3 5N m 3 4 4 3 Mount spark plug Torque 20 1Nm Not
61. 0 3 10 FRONT REAR AXLE 2 TWO FOUR DRIVE CONVERSION MECHANISM FOR GROUP 1 ommon 1 9 WASHER 3 3 ma 1 sona 3 o pommoso gt n mxwr gt bomma 3 o contacrcowee i _ 5 eonwracrcomronents o wsos gt _ s _ E Os mwa 1 omame 1 w 3 FRONT AXLE HOUSING GROUP DRIVEN BEVEL GEAR FRONT BEARING RETAINER M65x2 0HL ASLE LEVOROTARY Z 33 BEARING 6008 P6 MEE UNE ADJUST WASHER 54x mI WASHER 12x 30x4 Mere 66x0 2 DRIVE PINION GEAR DEXTRAL NUT FLANGE 12 1 25 9T BEARING TM6305 10 4 10 FRONT REAR AXLE 4 REAR AXLE HOUSING GROUP enu Li M 11 2 Ls 1 DRIVE GEAR ASSEMBLY DIFFERENTIAL ASSEMBLY BEARING NA2512 NIME DIFFERENTIAL GEAR CASE FRONT DIFFERENTIAL GEAR BOLT M8 40 CASE COVER DRAIN BOLT 10 20 10 5 10 FRONT REAR AXLE 5 REAR AXLE HOUSING GROUP aa 13113 ux 5 2 SUPPORT DIFFERENTIALGEAR R 1 10 ADJUSTWASHER 1 GEARSHAFTSELR 0 01 _ 4 ADJUSTWASHER 1 12 PLANETGEARSHAFTI 1 GEARSHAFTSELR 1 13 PLANETGEARSHAFT2 1 _ 6 RETANERGS 2 14 004 ee ae 8 SUPPORT DIFFERENTIALGEAR L 1 16 RETAINER WASHER 6 REAR AXLE HOUSING GROUP N m IS am 1
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63. 004 0 009mm Limit 0 015mm Mechanical Part of SQR 472Engine 6 44 Upper Stopper Position of Piston Lower Stopper Position of Piston ld imm Measurement Position of Piston Pin 24 Chery Service Manual ERI EIE 4 2 4 Measure the diameter of the piston 4 2 4 1 Measure at about 11 mm to the bottom of the piston along the direction vertical to the piston pin 0 013 Standard aug 9 7 2 0 4 2 5 Inspect the clearance between the piston ring and the ring gloove 4 2 5 1 Measure around the ring gloove with a piston ring and a feeler gauge Standard value Limit mm mm Finstring 003 006 ring 4 2 6 Inspect the end clearance of piston ring 4 2 6 1 the piston ring 45mm below the top surface of the cylinder hole Press down the piston ring with the piston head and then measure the opening with a feeler gauge 0 25 0 40 0 35 0 50 ring Oil ring 0 20 0 70 Mechanical Part of SQR 472Engine 6 45 Ead ere 4 2 7 Inspect the clearance between the piston and cylinder wall 4 2 7 1 Measure the inner diameter of the cylinder and the outer diameter of the piston at the positions as indicated in the right figure If the measurement results exceed the limit replace the piston or cylinder Standard value 0 018 0 030 Limit 0 10 Reference The clearance between the piston and cylinder bore is controlled by th
64. 123 Serial Operation steps Test Next step nuper results Connect the diagnosis instrument the ignition switch is in the ON The observation data stream of solar term door is opening value is between 4 10 numerical and models have different Slow down on the accelerator to the a open the observation data stream of d term door 1s opening think numerical with the throttle opening increases to about 85 95 specific numerical models different and 1n Repeat step 3 the observation data stream of solar term door 1s opening whether the existence of value changes in the process of change solar term door shifting joint position sensor wire harness between ECU org 458 X 382 32 a b dB and sensor connector pin c whether the circuit breaker short circuit or short circuit of power supply Using a multimeter to check voltage a and b pins of the joint between the value is about 5V 2 15 The oxygen sensor circuit fault fault code P0130 Next step Yes Replace the sensor Yes Repair or Repair or replace the wire harness _ the wire harness Replace the sensor No aid Serial Operation steps Test Next step number results 1 Connect the diagnosis instrument the ignition switch is in the ON start the engine idle running to the coolant temperature reach normal values instrument monk items to pay changes the display values should lose uncle is in
65. 2 8 4 Abnormal wearing of belt flank Abnormal Fall off with 2 8 5 Notice Replace the belt as any following situation occurs even though abrasion cannot be found directly The water pump leaks water out and requires continuing infusion If the belt is spotted with much oil stains and the rubber may be damaged due to expansion you should replace the belt Timing belt model and type Tension Pulley of Timing BeltRotate the bolt of tension pulley bracket and hear if it 1 noisy check the contacting surface look if it is damaged Model and type of tension pulley of timing belt 1 Check if the out 1S damaged Timing belt model and type CG ZL GS 2S Camshaft timing pulley diameter mm 0110 77 o2 Camshaft timing pulley diameter mm 54 651 0 13 s Chery QQ Service Manual Mechanical Part of SQR 472Engine Check the timing belt back plate for any deformation Standard size of crankshaft timing gear 3 Installation 3 1 Assembly of crankshaft timing pulley 3 2 Installation of timing at the top dead center of the first cylinder piston 3 2 1 Put the camshaft timing gear on the front end of the exhaust camshaft align the locating slot on the gear with the locating pin on the end of the camshaft and then fix the timing gear with bolts The tightening torque for the bolts is 1OO 5Nm Make sure that the clashing mark of crankshaft timing rs 2 suu x pulley aligns with the mark of oil pu
66. 22Pa 0 133322Kps 18N m 1 8kgf m kgf m 9 80665N m Volume 419ml ml 1 cm Ice 11 1000 I2N L2kgf Ikgf 9 80665N 1 2 1 SERVICE INFORMATION Cleaning Parts Cleaning parts 1s one of the more tedious and difficult service jobs performed in the home garage Many types of chemical cleaners and solvents are available for shop use Most are poisonous and extremely flammable To prevent chemical exposure vapor buildup fire and serious injury observe each product warning label and note the following 1 Read and observe the entire product label before using any chemical Always know what type of chemical is being used and whether it is poisonous and or flammable 2 Do not use more than one type of cleaning solvent at a time If mixing chemicals 1s required measure the proper amounts according to the manufacturer 3 Work in a well ventilated area 4 Wear chemical resistant gloves 5 Wear safety glasses 6 Wear a vapor respirator if the instructions call for it 7 Wash hands and arms thoroughly after cleaning parts 8 Keep chemical products away from children and pets 9 Thoroughly clean all oil grease and cleaner residue from any part that must be heated 10 Use a nylon brush when cleaning parts Metal brushes may cause a spark 11 When using a parts washer only use the solvent recommended by the manufacturer Make sure the parts washer is equipped with a metal lid that will lower case of fire Warning
67. 3 7 Q voltage with a multimeter to check a cylinder injector connector 2 pin No rere and the negative pole of the power supply P Between the 23 pin check cylinder _ Repair or replace the wire harness _ injector connector 2 pin and the ECU line is broken or the power supply or short circuit to ground 2 31 Four cylinder injector circuit for the power supply circuit fault code P0271 number results 1 Connect the diagnosis instrument ee ignition switch is in the ON Dial the joint stiffness of injector on wire harness using a multimeter to check the connector SM1 pin voltage and power for a ee few pieces of value 15 a 12V Check in between cylinder injector Yes Repair or Repair or replace the wire harness the wire harness connector SM pin and the main relay line is Ter S step open circuit or short circuit to ground Diagnostic aid between the fuel injectors for cylinders No Replace injector SM1 and SM2 pins at 20 C in 14 5 0 5 ohm Whether the 3 7 voltage with a multimeter Yes Diagnostic aid aid to check a cylinder injector connector 2 pin om and the negative pole of the power supply Between the 234 pin check cylinder Repair or replace the wire harness injector connector 2 pin and the ECU line 15 broken or the power supply or short circuit to ground 11 55 Using a multimeter to ch
68. 422 374 pins Repair replace the wire harness ignition switch is in the ON Exhaust system blocking Maintenance according respectively In sensor connector 3 Next step the oxygen sensor grey connection line between pins line 15 faulty diagnosis Diagnostic aid 2 21 Oxygen sensor circuit output voltage is too high fault code P0138 number results 1 Connect the diagnosis instrument the e ignition switch is in the ON start the engine idle running to the coolant temperature reach normal values Next step observe diagnosis instrument monk oxygen sensor voltage items to pay changes the display values should lose uncle is In the range of 100Ma 900mA Fuel injector is leaking Fuel pressure 1s too large NO Valve clearance 1s too small respectively In sensor connector 3 with x N ext step the oxygen sensor grey connection line between pins line 15 faulty Exhaust system blocking Maintenance according Fuel injector is leaking diagnosis Fuel pressure 15 too large Diagnostic aid Valve clearance is too small Check the ECU 422 37 pins Repair or replace the wire harness 11 49 11 EFI SYSTEM OF SQR 472ENGINE 2 22 The oxygen sensor is not active fault code P0140 results Connect the diagnosis instrument ignition switch 1s in the Start the engine idle running to the Yes Diagnostic procedures coolant
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70. BIG 12 LOCKNUT FLANGE M8 14 RIVET 5x20 16 DECORATING COVER CARGO BOX 18 BOLT FLANGE M8x12 20 BOARD CARGO BOX DOOR 22 HANDLE CARGO BOX DOOR 24 REAR HEIGHTEN WASHER R 26 LOCK GARGO BOX L 28 PIN 29 LOCK GARGO BOX R 33 TAILLIGHT SEAT 37 39 STARBOARD COVER CARGO BOX 43 45 47 49 CARGO BOX 53 55 3 3 4 5 NUT FLANGE M8 REAR REFLECTOR REAR CORNER COVER CARGO BOX L SCREW M6x30 BOLT FLANGE M8x20 PROTECT COTE TUBE SCREW M6x20 FRONT HEIGHTEN WASHER R 3 CIRCLIP 8 2 Vehicle body Muffler 30 CABLE CARGO BOX 32 DOOR BOARD CARGO BOX 34 TAILLIGHT 36 NUT FLANGE MS 38 REAR HEIGHTEN WASHER L 40 RUBBER WASHER 6 42 BUCKLE PLATE 44 CARGO BOX HANDLE RUBBER WASHER 46 FRONT HEIGHTEN WASHER L 48 NUT CLIP 6 50 CARGO BOX HANDLE RUBBER WASHER L 2 15 52 R 4 54 GAS SRPING CARGO BOX 56 LOCK GARGO BOX ASSY 2 Vehicle body Muffler Muffler Caution Perform disassembly only after the muffler is cooled down Remove Remove two flange bolts M1030 Remove tension spring of exhaust pipe Remove catalytic converter assy Remove exhaust pipe and muffler Note Replace seal ring when installing the muffler Installation Reverse the removal procedure for installation MUFFLER ASSY Warr M fr 7 y iL T
71. CE INFORMATION Self Locking Fasteners Several types of bolts Screws and nuts incorporate a system that creates interference between the two fasteners Interference is achieved in various ways The most common types are the nylon insert nut and a dry adhesive coating on the threads of a blot Self locking fasteners offer greater holding strength than standard fasteners which improves their resistance to vibration self locking fasteners cannot be reused The materials used to from the lock become distorted after the initial installation and removal Discard and replace self locking fasteners after removing them Do not replace self locking fasteners with standard fasteners Washers The two basic types of washers are flat washers and lock washers Flat washers are simple discs with a hole to fit a screw or bolt Lock washers are used to prevent a fastener from working loose Washers can be used as spacers and seals Or can help distribute fastener load and prevent the fastener from damaging the component As with fasteners When replacing washers make sure the replacement washers are of the same design and quality Cotter Pins A cotter pin is a split metal pin inserted into a hole or slot to prevent a fastener from loosening In certain applications such as the rear axle on UTV or motorcycle the fastener must be secured in this way For these applications A cotter pin and castellated slotted nut is used To use a cotter pin fi
72. Difficulty starting Che Cases iud ette doleas u ut iocus eds dips duas qa u 68 3 4 Difficult cold start 3 5 The normal speed any time starting difficulty 70 3 6 Start normal but any time idling Instabliltity 71 3 7 Normal starting warm process of unstable idle speed 72 3 8 Normal starting warm after the end of unstable idle speed 73 3 9 Normal starting part load such as air conditioning when idling instability or flameout 74 5 10 INormabstartime idle Speeds 100 BTE Bio ies eed aetas e et ome a ac eto ee ds 75 3 11 To accelerate the speed to go Up not to go OF stop TI 5 12 Neceleratlondespollse 1S SISWu uu kuu uuu A 78 3 13 Acceleration of weakness poor performance 11 EFI SYSTEM OF SQR 472ENGINE Chapter 1 Describes the SIMK 31 engine management system Overview The engine management system mainly consists of sensors microprocessors ECU executive device is composed of three parts the inhalation of air traffic control fuel injection and ignition advance angle of the engine work In the engine electronic control system senso
73. Each design has a specialized function Slip joint pliers are general purpose pliers used for gripping and bending Diagonal cutting pliers are needed to cut 17 wire and can be used to remove cotter pins Use needle nose pliers to hold or bend small objects Locking pliers Figure 16 sometimes called Vise _ Grips are used to hold objects very tightly They have many uses ranging from holding two parts together to gripping the end of a broken stud Use caution when g using locking pliers as the sharp jaws will damage the objects they hold Snap Ring Pliers Snap ring pliers are specialized pliers with tips that fit into the ends of snap rings to remove and install them Snap ring pliers Figure 17 are available with a fixed action either internal or external or convertible one tool works on both internal and external snap rings They may have fixed tips or interchangeable ones of various sizes and angles For general use select a convertible type pliers with interchangeable tips Figure 17 WARNING Snap rings can slip and fly off when removing and installing them Also the snap ring pliers tips may break Always wear eye protection when using snap ring pliers Hammers Various types of hammers are available to fit a number of applications Use a ball peen hammer to strike another tool such as a punch or chisel Use soft faced hammers when a metal object must be struck without damaging
74. LATION 1 RADIATOR 2 FAN ASSY 3 RADIATOR RESERVE 4 WATER HOSE 1 96x 10 450 5 CLAMP 10 6 BUFFERING COLLAR 7 BUMPERBLOCK RADIATOR 8 CLAMP 25 38 9 INLET PIPE ENGINE FRONT 10 TIE IN INTAKE PIPE 11 INLET PIPE ENGINE MIDDLE 12 INLET PIPE ENGINE REAR 13 T JOINT WATER PIPE 14 CLAMP 13 19 15 CYCLE PIPE REAR 16 OUTLET PIPE ENGINE FRONT 17 OUTLET PIPE ENGINE RAER 18 BOLT FLANGE M6 X 16 19 CYCLE PIPE FRONT 20 EXHAUST VALVE 21 CYCLE PIPE FRONT 22 BOLT M6 X 20 23 SPACER BUSH 24 WATER HOSE 2 10 200 4 7 5 REMOVAL OF ENGINE TRANSMISSION SYSTEM AND GEARSHIFT Inspection Information 5 1 Removal and Installation of Front and Rear Engine Removal and Installation 5 2 5 7 5 Removal and Installation of Gearshift 5 7 Inspection Information Note When removal Engine please use jack to support the bodywork Don t damnify the frame body of Engine bolt and cable etc Please blind up the frame when removal the engine Don t removal engine from the bodywork when operating as follows THROTTLE VALVE BODY AIR FILTER CVT SYSTEM CVT COVER FAN COVER ENGINE IGNITION COIL CAMSHAFT POSITION SENSOR CRANKCASE POSITION SENSOR Following operation require removal of engine from vehicle CRANKCASE Tightening torque RUBBER WASHER OF ENGINE 10 1 25 40 50N m ENGINE SUPPORT M10x25 40
75. LINE FR L 22 COVER RIGHT LINE FR R 23 SCALEBOARD METER PANEL 24 SEPTI BOARD STORE BOX 25 METER PANEL 26 AIRPROOF COVER GEARSHIFT 27 AIRPROOF COVER PARKING HANDLE 28 TEACUP COVER 29 COVER BOARD STORE BOX 30 PIN 31 SUPPORT PIN 2 12 Cargo box Remove Remove the connectors of taillights Remove R pin 4 Remove the pin of cargo box Use the same method to remove the R pin and cargo box pin on the other side of the cargo box Figure direction pulling tipping rocker of cargo box Remove R pin of gas spring Remove connection of gas spring and cargo Remove cargo box Installation Reverse the removal procedure for Installation Connectors of taillights 2 13 Pin cargo box 2 Vehicle body Muffler Cargo box Cargo box 3 7 Tipping rocker UM k vi L D T a A a 1 DECORATING COVER CARGO BOX 3 EXPANSION SCREW M8x20 5 FENDER CARGO BOX L 7 TIPPING ROCKER 9 POTHOOK SEAT 11 BOLT FLANGE M8x45 13 HEAT INSULATION BOARD 15 CARGO BOX FRAMRE 17 HALF DOOR FRAMRE 19 ROTATE PIN PIPE 21 REAR CORNER COVER CARGO BOX R 23 LOCKNUT FLANGE M6 25 TIE ROD HALF DOOR 27 BOLT FLANGE M8x20 2 14 2 Vehicle body Muffler 27 28 2 TAPPING SCREW STS5 2x20 4 LEFTWARD COVER CARGO BOX 6 FENDER CARGO BOX R 8 ROCKER COVER TIPPING 10 TORSION SPRING
76. Labels Most manufacturers attach information and warning labels to the UTV These labels contain instructions that are important to personal safety when operating servicing transporting and storing the UTV Refer to the owner s manual for the description and location of labels Order replacement labels from the manufacturer if they are missing or damaged FASTENERS Proper fastener selection and installation 1s important to ensure the motorcycle operates as designed and can be serviced efficiently The choice of original equipment fasteners 1s not arrived at by chance Make sure replacement fasteners meet all the same requirements as the originals Many screws Bolts and studs are combined with nuts to secure particular components to indicate the size of a nut Manufactures specify the internal diameter and the thread pitch The measurement across two flats on a nut or bolt indicates the wrench size Warning Do not install fasteners with a strength classification lower than what was originally installed by the manufacturer doing so may cause equipment failure and or damage Torque Specifications The material used in the manufacturing of the UTV may be subjected to uneven stresses if the fasteners of the various subassemblies are not installed and tightened correctly Fasteners that are improperly installed or work loose can cause extensive damage it 1s essential to use an accurate torque wrench as described in this chapter 1 3 1 SERVI
77. NG Front wheel Removal Securely support the front wheels Remove Wheel cap 4 bolts from wheel hub Front wheel Inspection Rim Damage warpage or serious scrapes Replace Replace with a new one if any Slowly turn the wheel measure the rim vibra tion with a dial gauge Service limit Axial 2 0mm Radial 2 0mm Assembly Press rim into wheel Install rim on the wheel hub Tightening Torque Bolt Wheel Hub 40 50 N m Front Wheel Hub Disassembly Remove Front wheel gt 8 3 Front brake caliper gt 8 4 Rim axle nut Brake disc and wheel hub 4 bolts from front brake disc Wheel hub Installation Reverse the removal procedure for installation Torque Rim axle nut 180 200N m 8 3 Brake disc Brake caliper 8 FRONT WHEEL FRONT BRAKE SUSPENSION STEERING Brake System Front brake caliper Front bra ke caliper Removal Remove Front wheel gt 8 3 2 bolts from arm Front caliper Inspection Check brake caliper for cracks and tightening parts for oil leakage Replace if any Installation Reverse the removal procedure for installation Tightening Torque Fixing Bolt Brake Caliper 45 50N m 8 4 8 FRONT WHEEL FRONT BRAKE SUSPENSION STEERING Bolt Brake Disc Brake disc Removal Remove Front wheel 8 3 Brake caliper gt 8 4 Front brake disc and wheel hub 4 bolts from brake disc Brake disc Wheel
78. Next step solar term door position sensor and No Repair or replace the sensor line think you are normal Remove the injector injector with Failure to replace special cleaning analyzer check whether the injector 1s there 1s a leak or blockage Check the fuel situation 1n order to ine just after refueling cause since just after refueling cause Check the ignition sequence engine specifications Check whether the smooth air exhaust pip No Maintenance of the corresponding line 11 77 Next step 11 EFI SYSTEM OF SQR 472ENGINE 3 12 Accelerating the slow response General fault location The fuel moisture content The intake pressure sensor and solar term door position sensor The spark plug Solar term door body and idle bypass airway The inlet Idle speed regulator The fuel injector The ignition timing N GO 1 ON BW NN The exhaust pipe The general procedure of diagnosis rember resus Check the air filter is clogged access point for the fuel No Maintenance of oil supply system distribution pipe assembly inlet pipe end start the engine check the fuel pressure the idle condition 1s about 380kPa observe its model and gap meets the specification Adjust or replace Remove the idle adjuster check the Cleaning of parts solar term door body idle speed No Next step regulator and idling bypass airway Check the intake pre
79. No oil tank 2 The fuel pump 3 Speed sensor 4 The ignition coil 5 The engine mechanical part 11 67 EFI SYSTEM OF SQR 472ENGINE The general procedure of diagnosis Serial Operation steps Test Next step number results Next step Maintenance supply coefficient Connect the fuel pressure gauge access point for the fuel distribution pipe assembly inlet pipe end start the engine check the fuel pressure In the idling condition is about 380kPa N instrument to observe the engine of data i SEE Repair speed sensor circuit items start the engine observe whether there 15 a speed signal output 1 S 2 S 3 Appropriated the sub cylinder line S cylinder which is connected to spark plug spark plug electrode distance engine body No Maintenance of the ignition around Smm start the engine check system whether there 15 a blue and white high pressure fire 4 Check the engine cylinder pressure of each Yes Exclusion of unloading failure engine cylinder pressure observe whether of engine Check the X1 1 X1 2 pin on the iron is normal N Maintenance of the corresponding line 3 3 Hot starting difficulty General fault location 1 The fuel moisture content 2 The fuel pump 3 The coolant temperature sensor 4 The fuel pressure regulator vacuum tube 5 The ignition coil 11 68 11 EFI SYSTEM OF SQR 472ENGINE The general procedure of diagnosis Serial Operat
80. OTECT POLE ASSY 2 HOOP 45 3 BOLT FLANGE 8 16 4 REAR THWARTWISE PIPE 5 FRONT BENT PIPE 6 CAP NUT M8 7 BACKREST PIPE 8 HEADREST 9 SCREW 5 20 10 BACKREST 11 RUBBER STORE BOX 12 CAP NUT M6 13 CENTER SPACER HOOP 14 PLATFOND 15 BOLT FLANGE M6x55 16 WASHER 6x 12x2 17 BOLT M10x30 18 LOCK CATCH SAFETY BELT 19 SAFETY BELT ASSY 20 FRONT PROTECT POLE ASSY R 2 7 XY1100UEL 1 FRONT PROTECT POLE ASSY L 2 HOOP 945 3 BOLT FLANGE 8 16 4 REAR THWARTWISE PIPE 5 FRONT BENT PIPE 6 CAP 8 7 BACKREST PIPE 8 HEADREST 9 SCREW M5x20 10 BACKREST 11 RUBBER STORE BOX 12 CAP NUT M6 13 CENTER SPACER HOOP 14 CEILING 15 BOLT FLANGE M6x55 16 WASHER 96x912x2 17 BOLT M10x30 18 LOCK CATCH SAFETY BELT 19 SAFETY BELT ASSY 20 FRONT PROTECT POLE ASSY R 21 REAR PROTECT POLE ASSY L 22 REAE PROTECT POLE ASSY R 23 BACKREST 2 Vehicle body Muffler Front Bumper Remove Remove bolt 1 Remove front cover cable Remove bolt 2 Remove front bumper Installation Reverse the removal procedure for Installation 2 Vehicle body Muffler Front Cover Cable ws i 1 COBBRA BUMPER 3 DECORATE COVER FRONT BUMPER 5 BOLT FLANGE M6 X 20 7 CABLE FRONT COVER 9 CABLE PULLEY 11 WINCH HOLDER 13 BOLT FLANGE M10 1 25 X70 2 FRONT BUMPER 4 SCREW M6 X20 6 BOLT FLANGE 8 16 8 LOCKNUT FLANGE MIO
81. Oil Volume when replacing 3500ml Capacity Full capacity 3600ml 1 21 1 SERVICE INFORMATION Recommended Oil see original Specially for 4 stroke motorcycle SAE 10W 40 20W 50 an BE EN UE 2 Substitutes must be used in zn wis I the following range m oT API S F e API type SE or SF grade 30 20 10 0 10 20 30 40 eSAE type Choose from as 14 32 59 98 B6 the left chart according to the environmental temperature Cooling Device Full Capacity 4500ml Coolant capacity Reservoir tank capacity 3300 ml Opening pressure of radiator cap 108kpa 1 1kgf cm Thermostat Temperature valve open Overall lift 3 5 4 5mm 95 Front Rear Wheel Standard Dom e NN Brake System Standard disc thickness 1 22 1 SERVICE INFORMATION Battery Charging System AC magneto Model Permanent magnet AC type Charging coil Resistance 20 C 0 2 0 3O Rectifier Three phase annular rectification Silicon controlled parallel connected regulated voltage Terminal point Fully charged 12 8V voltage Insufficient lt 11 8V charge Charging 0 9A 5 10H Ignition system ECU ignition C Spark plug gap 1 23 1 SERVICE INFORMATION Screwing moment of important bolts FRONT REAR SUSPENSION THREAD TORQUE REMARK FRONT REAR SHOCK M10x1 25x50 30 40 af 3 REARBRAKEDISK
82. R 472ENGINE 2 9 The coolant temperature sensor circuit output range character error error code P0116 M results Connect the diagnosis instrument the ignition jm 55 swltch 1s In the ON The observed data stream coolant temperature Next step and whether the engine temperature quite No To step 4 numerical and when the engine temperature Note if the display value often 1s constant that there may be circuit breaker failure Connector for coolant temperature sensor unplug the wire harness electrical multimeter check sensor a and c pins of value 1s commensurate with its No Repair or replace the wire temperature with specific reference to the relevant harness part of the repair manual Connector for coolant temperature sensor unplug the wire harness multimeter voltage check the joint No Next step a and c pins between whether the value is about 5 Check the ECU 1 31 X1 73 between pin are respectively connected with the sensor connector harness pin a c whether the circuit breaker No Replace the sensor Start the engine idle running To observe the diagnostic instrument coolant temperature value changes the display values should be increased along with the engine coolant temperature 11 43 11 EFI SYSTEM OF SQR 472ENGINE 2 10 The coolant temperature sensor circuit shorted to ground fault code P0117 Serial Operation steps Te
83. Remove drive shaft front Remove bolt 2 Remove front axle Installation Installation as contradictorily process of remove Bolt torque of rear axle M8 23 25N m Bolt torque of rear axle M10 45 50N m Bolt torque of rear drive shaft 8 23 25 m Drive shaft rea 5 7 5 REMOVAL OF ENGINE TRANSMISSION SYSTEM AND GEARSHIFT Front and rear axle assy disassembly installation 1 FRONT AXLE 2 FRONT DRIVE SHAFT 3 SPRING WASHER 98 4 BOLT M8x25 5 BOLT FLANGE MI0x1 25x145 6 BOLT FLANGE MI10x1 25x85 7 BOLT FLANGE M8x16 8 LOCKNUT FLANGE MIO 1 25 9 HOLDER FRONT AXLE FR 10 HOLDER FRONT AXLE RR 11 AIR HOSE 8 450 12 CLAMP 10 13 REAR AXLE A aes E oT oS 14 SUPPORT PARKING CALIPER 959 SWS 234 c 29 a Com WM Wik x 15 BOLT M8 45 L ZAS g lt a pe 16 32 AXE 6 17 BOLT FLANGE 12 1 25 115 gt 18 SUPPORT REAR AXLE R 19 HOLDER REAR AXLE RR 20 LOCKNUT FLANGE M12 X 1 25 21 COUPLING FLANGE 22 WASHER Q914x928x2 23 NUT M14x1 25 24 PARKING DISC 25 PARKING CALIPER 26 SPRING WASHER 8 27 BOLT M8x30 28 REAR DRIVE SHAFT 29 PARKING DISC PAD 5 8 s Chery QQ Service Manual Mechanical Part of SQR 472Engine CONTENTS Chapter 1 Reading E 2 1 Reading method of Maintenance rine Guevara pati tea Kota C
84. Service Manual 4x4 Vyper 4W D 1100cc Vyper 4W D 1100cc 4 seater GIO MOTORS FOREWORD This service manual is designed primarily for use by certified XINYANG Master Service Dealer technicians in a properly equipped shop and should be kept available for reference All references to left and right side of the vehicle are from the operator s perspective when seated in a normal riding position Some procedures outlined in this manual require a sound knowledge of mechanical theory tool use and shop procedures in order to perform the work safely and correctly Technicians should read the text and be familiar with service procedures before starting the work Certain procedures require the use of special tools Use only the proper tools as specified This manual contains an introductory description of procedures for inspection maintenance overhaul disassembly amp assembly removal and installation of components parts troubleshooting and service data together with illustrations of our vehicle Model XY1100UE and XY1100UEL The manufacturer reserves the right to make improvements or modifications to the products without prior notice Overhaul and maintenance should be done according to the actual state and condition of the vehicle CONTENTS Fuel injector system Circuit Diagram 00000000000 Circuit Diagram O ON O G N 1 SERVICE INFORMATION A few Words About Safety 1 1 Main Data Table
85. T BRAKE SUSPENSION STEERING Installation of Steering Wheel Install steering wheel 2 2 Steering System 1 STEERING ASSY 2 LOCKNUT FLANGE M3 3 BOLT FLANGE M8x16 4 BOLT FLANGE M8x90 5 STEERING SHAFT 6 BOLT FLANGE M8x25 7 SPRING WASHER 8 8 BRACKET STEERING STRENGTHENER 9 BOLT FLANGE M8x25 10 STEERING STRENGTHENER 11 FLANGE STEERING STRENGTHENER 12 BEARING 13 BOLT FLANGE M8x30 14 CIRCLIP 30 15 OIL SEAL STEERING STRENGTHENER 16 STEERING SHAFT TOP 17 14 26 3 18 SPACER BUSH NYLON 19 LOCKING NUT M8 20 SPACER BUSH NYLON 21 BOLT STEERING COLUMN 22 LOCKING NUT M6 23 GAS SRPINGSTEERING COLUMN 24 BOLT M6 25 STEERING COLUMN 26 SPRING WASHER 27 CORE SHAFT STEERING 28 STEERING WHEEL ASSY 29 DECORATING COVER 30 BOLT 5 15 8 15 9 REAR WHEEL REAR BRAKE SUSPENSION Overhaul EE YET 9 1 Rear 9 4 TroubleshootIng 9 2 Rear 9 5 scar Will enr 9 3 Overhaul info Note e Securely support the vehicle when overhauling the rim and suspension system e Use genuine parts of bolts and nuts for rear rim and suspension e Do not overexert on the wheels to avoid possible damage to the wheels e When removing tire from rim use special tire lever and rim protector to avoid damage to the rim Overhaul standard Standard Rim Longitud
86. T3 or DOT4 brake liquid till the maximum Maximum H limit line Do not mix with dust or water when adding brake fluid Minimum Use only the recommended of brake fluid to avoid chemical reaction Brake fluid may cause damages to the surface of the plastic and rubber parts Keep the fluid away from these parts Slightly turn the steering wheel left and right till the master cylinder is in horizontal then remove the fluid reservoir cap Brake Disc Brake Pad lt Wear of brake pad gt Check the brake pad wears from the mark as indicated Replace the brake pad if the wear has reached position of wear limit trough Note The brake pad must be replaced with a whole set Checking and replacing the brake disc REAR BRAKE DISC Front brake disc thickness lt 3 mm Replace Rear brake disc lt 3mm Replace Min limited thickness of the front brake disc 3mm PARKING BRAKE P Min limited thickness of the rear brake disc 3mm Change The Brake Fluid lt Changing Brake Fluid gt Change the brake fluid once every year 3 9 3 CHECKS amp ADJUSTMENT Wheels Lift front wheel on level place and make sure there is no loading on the wheels s Shake the front wheel left and right to check 55 whether the joint of front wheel is tightened N N check whether it sways lt Not tighten enough Tighten it sway Replace y d the rocker arm Front Toe in size Pa
87. X 1 25 10 LOCKNUT 8 12 WINCH 2 9 2 Vehicle body Muffler COVER LEFT LINE FR L Remove Remove bolt 1 Remove the front left line cover L Remove the front right line cover R in same method Installation Reverse the removal procedure for Installation FRONT AIR GUIDE COVER ASSY i Connector of headlight Remove Separate the connector of headlight Remove the eight bolts 2 Remove the front air guide cover assy Installation Reverse the removal procedure for Installation Front air guide cover as amd 2 10 2 Vehicle body Muffler FRONT COVER ASSY Remove Remove the front air guide cover assy 2 10 Remove the steering wheel assy 2 2 Remove the gear change handle Remove the two bolts 1 Remove the nine bolts 2 Loosen all electronic component and plugs Remove the front cover assy Installation Reverse the removal procedure for Installation 2 11 2 Vehicle body Muffler 1 HEADLIGHT L 2 TAPPING SCREW STS 2x20 3 WASHER 5 10 1 4 HEADLIGHT R 5 FRONT AIR GUIDE COVER ASSY 6 SCREW M6x20 7 NUT M6 8 BOARDING VENT GRILLE FRONT 9 FRONT MUDGUARDR R 10 EXPANSION SCREW 8 20 11 FRONT MUDGUARDR L 12 ENGINE COVER BOARD 13 TAPPING SCREW ST4 2x20 14 ENGINE COVER BOARD DECORATE COVER 15 SCREW M6x20 16 RUBBER WASHER 06 17 GEMEL 18 NUT CLIP M6 19 DECORATE COVER FRONT COVER 20 FRONT COVER 21 COVER LEFT
88. XC20 NCC B 878 ECU X135 STPB POS STB ECU X1 36 STPB_NEG 2 installation position Solar term door body 3 working principle Stepper motor is a miniature motor it is encircled by a ring composed of a plurality of steel stator and rotor see fig Each steel stator are around a coil the rotor is a permanent magnet permanent magnet center is a nut Stator coil all always electricity As long as the change of one coil current direction a point of the rotor 1s turned When the stator coil in the right order to change the current direction forming a rotating magnetic field of the permanent magnet the rotor rotates in a direction If the order is reversed the direction of current change over so the rotating direction of the rotor will be upside down Connect a wire rod drives the nut of the rotor center Because the spiral rod 1 designed into can not rotate so it can only move in the axial direction so it is also called linear axis End wire rod is a plug plug and therefore can be retracted or extended cross sectional area to increase or decrease the idle speed actuator bypass inlet passage until it blocked Whenever the current direction change of a coil rotor around a fixed point of view called step a number equal to 360 divided by the stator or coils The stepping motor rotor step is 15 Accordingly the screw rod every move distance 15 fixed ECU through the frequency control to replace the coil current di
89. ake manifold 3 Working principle Intake manifold absolute pressure sensor element consists of a silicon chip A pressure diaphragm etched on the silicon chip The pressure diaphragm has 4 piezoelectric resistance the 4 piezoelectric resistance as the strain components into a Wheatstone bridge The silicon chip in addition to the pressure diaphragm also has an integrated signal processing circuit The silicon chip with a metal shell to form a closed reference space gas reference space of the absolute pressure is close to zero Thus forming a microelectronic mechanical system Active surface silicon chip has a close to zero pressure its back through the manifold through a pipe into the test tube the absolute pressure The silicon chip thickness of only a few microns m so the intake manifold absolute pressure change makes silicon chip mechanical deformation 4 piezoelectric resistance followed by deformation the resistance value change By processing the signal processing circuit of silicon chips forming the linear relationship between the voltage signals and pressure Intake air temperature sensor element is a negative temperature coefficient NTC resistor the resistance changes with the intake air temperature sensor the transmission to the controller a voltage representing the intake air temperature change 11 20 EFI SYSTEM OF SQR 472ENGINE 3 Technical parameters 1 Limit data measure value unit Tolerance power Tolerance
90. allstud O O Brake Brake pedal Free play S O Pedal rear end 0mm System Brake Efficiency O O O 0 ______ rod oil pipe Slack and damage amp Hose brake and brake fluid level LOWER limit brake disc Brake disc Replace when the thickness of damage and wear front brake disc is less than 3mm rear brake less than 3mm Driving wheel Tire pressure Front tire 83kPa System 12 1PSI Rear tire 83kPa 12 IPSI Chap and damage No wear indication on the surface of tire the remained depth of groove should not be less than 3mm gemere abnormal wear Emu S nut and axle ee wheel bearing wheel bearing Buffer Suspension Sway of joint DI damage LM absorber damage Function PM ain lubrication lubrication emm 0 lubrication 3 3 3 CHECKS amp ADJUSTMENT Check liem Standard 1 2 year Drive Train Final shaft Looseness of Drive joint parts shaft Electrical Ignition System Device Ignition timing Battery Terminal Joint _ O T _ Wiring Looseness and damage of joints Engine Fueldeviee Fuelleakage O O ms Cooling Coolant level level system Coolant leakage 3 4 3 CHECKS amp ADJUSTMENT Check Item Standard 1 2 yen Lighting device Function O e e and turning indicators Alarm and lock Function device MT ml
91. alve Exhaust valve t gt Valve oil seal Components which may not be 92 Valve seat reused 4 Valve guide 2 Disassembly 2 1 Disassembly of spark plug 2 2 There are boltes on the cylinder head In the course 6 23 lt gt Chery Service Manual Mechanical Part of SQR 472Engine ERI EIE of the assembly of cylinder head slowly tighten these bolts in the order as indicated in the right figure for several times untill ther are tightened properly Notice Remove the cylinder head bolts with a torque socket wrench in the contrary order 2 33 Disassembly of cylinder head and cylinder head gasket Notice The cylinder head gasket is nonreusable 2 4 Disassembly of valve adjustment gasket and valve tappet 2 5 Disassemble the valve spring retainer lock spring retainer spring seat valve spring intake valve and exhaust Valve etc with special tools 2 6 Disassembly of valve oil seal and valve spring gasket 2 7 Cleanup 2 7 1 Clean the carbon dust on the valve pn C H 8 I0 803 LO Em 603 M e a Mh cda a Ras J cs I TR d mS es Es da REDE NE NE m T LI 2 7 2 Clean the bottom surface of cylinder head and the surface of intake and exhaust manifold with scraper knife Notice The surface of the cylinder head may not be scratched in the course of cleanup Do not pollute the intake po
92. ar of the camshaft 2 6 1 the right figure If using the special tools operate as indicated in Clamp the camshaft and plug the pins of special tool into the hole on gear rotate the gear to keep the meshing of driven gear and driving gear and then remove the fixing bolt of driven gear Notice The surface of the camshaft may not be damaged 2 6 2 If not using the special tools operate as indicated in the right figure 1 Screw 6 bolts onto the sub gear of the intake camshaft at the position as indicated in the right figure 2 Use the screwdriver to turn the gear as indicated in the figure and disassemble the fixing bolts of the sub gear Notice The surface of the camshaft may not be damaged 3 Disassemble the axial elastic retainer ring with tensioner and remove the saddle spring washer transmission ring and so on 2 7 Camshaft Chery QQ Service Manual Mechanical Part of SQR 472Engine VR M P EN 47S EA S d EN y T Fixing Bolt LI a LI PER 4 1 SANDIAS 2 Lh I w Ha x Je SST V For Fixing Bolt ene Chery QQ Service Manual Mechanical Part of SQR 472Engine ETH Ee 2 7 1 Measure the camshaft with micrometer caliper If it is below to the specified limit replace with a new one Camshaft journal Unit mm ZL RL GL GS ZS ps uibus Standard value EX 9230 0 IN 22 9 2 12 Inspe
93. ation position Camshaft end cover 3 Working principle The sensor makes use of the magnetic induction intensity changes by Holzer Holzer in the principle of voltage made into When a current of through the semiconductor chip a Holzer voltage Uh and the value of magnetic induction B in the right direction of current will and current vertical and current is proportional to Effect of magnetic induction intensity change by Holzer E voltage eee Peele ee Le ee ET eur Direction of Thy phase signal whee ki Output aignal mm Ir ms mms f mm ma f ecm ee w LL LLLI Schematic diagram of Holzer elements 1 Schematic diagram of Holzer elements 2 11 11 11 EFI SYSTEM OF SQR 472ENGINE 4 Technical parameters Limit data measure Value unit The sensor Storage temperature 00 DE withstand environment temperature during operation The whole 200hour 4 lifetime 1 l000hour Insulation resistance 2min test voltage SOOVDC 2 Characteristic data measure a a Ambient ss The target wheel speed DE 4000 5 Installation notes Installation method of sensor by indentation instead of hammering Recommended bolt fixed sensor M8 Tightening torque 10 14Nm The air gap between the camshaft position sensor and signal wheel allows the range 1s 0 3 to 2 0mm the Holzer elements working diagram two 6 fault phenomenon and judgment m
94. circuit fault code P0445 Serial Operation steps Test Next step number results 1 round which is diagnostic instrument the Next step ignition switch 1s in the ON Dial the joint on wire harness for ignition To step 4 coil using a multimeter to check voltage No Next step between the 2 pin and the negative pole of the power supply 16 12 V Check that the carbon canister control valve Yes Repair or replace the wire harness Using a multimeter to check the carbon power supply line is broken or open ground canister control resistance between the 1 No Replace the control valve and 2 pins of the valve value at 20 C is 26 1 Using multimeter to check the carbon canister control valve street 1s about 3 7V Next step voltage 2 pin and cathode will the house Between the X1_26 pin to check the carbon canister control valve connector 2 pin and No Diagnostic aid the ECU whether the circuit breaker 2 41 The speed sensor is not working properly fault code P0501 number results 1 round which is diagnostic instrument the ignition switch is in the OFF If the vehicle equipped with ABS system Check ABS system ABS System Pro check whether there is a m Next fault code N Maintenance instrument line Check whether the normal work of the Ye Nextstep Nextstep sensor The X1 39 pin signal line to check the speed sensor and ECU 3 Check the speed table pointer is working st
95. circuit for the power supply circuit fault code 0123 46 215s Oxygen sensor circuit fault fault code P0130 deae eeu tao tete a nee teat 46 2 16 Oxygen sensor circuit output voltage is too low fault code P0131 47 2 17 Oxygen sensor circuit output voltage is too high fault code P0132 47 2 18 The oxygen sensor is not active error code 0134 48 2 19 Oxygen Sensor circuit fault Tault code P0130 naa n b oae Pee DH Hie 48 2 20 Oxygen sensor circuit output voltage is too low fault code P0137 49 2 21 Oxygen sensor circuit output voltage is too high fault code P0138 49 2 22 The oxygen sensor is not active fault code P0140 50 2 23 P tnp primary line fault fault code P0230 doeet bin MM 50 2 24 cylinder injector circuit shorted to ground fault code P0261 5 2 25 A cylinder injector circuit for the power supply circuit fault code P0262 52 2 26 Two cylinder injector circuit shorted to ground fault code P0264 52 2 27 Two cylinder injector circuit for the power supply circuit fault code P0265
96. circuit of water temperature display Coolant leakage Faulty water seal O rings are aged damaged or improperly sealed Washers are aged damaged or improperly sealed Improper installation of pipes or hoses Pipes and or hoses are aged damaged or improperly sealed 4 2 4 COOLING SYSTEM Check and Maintenance Checking coolant density Note Open the radiator cap after coolant is fully cooled Open the front cover AS x The diagram in the direction of the arrow pulling cable ww _ of front cover Open the front cover Remove radiator cap counter clockwise Check with a densimeter if the coolant density adapts to the local temperature Check coolant for stains or impurities Inspection of radiator cap Note Open the radiator cap after the coolant is fully cooled Remove Remove bolt 1 and battery panel Remove radiator cap counter clockwise Note Apply coolant on the sealing surface of radiator cap before attaching the tester to the radiator cap Install the radiator cap tester to the radiator cap Apply the specified pressure radiator cap opening pressure for 6 seconds and make sure that there 1s drop in pressure TESTER Opening pressure of radiator cap RADI ATOR CAP 108 137kpa 1 1 1 4kgf cm Pressure testing of cooling system Install the radiator cap tester to the radiator cap Apply the specified pressure radiator cap opening pressure for 6 seconds and mak
97. cision materials joints matched the wire harness 6 bolt mounting torque is 8 10Nm 5 Fault phenomenon and judgment method Fault phenomenon poor idling flameout Common fault 1 using the process of abnormal high pressure or reverse current 2 the repair process of vacuum element Damage Repair note impact to the vacuum unit using high pressure gas no repair process find fault to replace the sensor The time to check whether the generator output voltage and current of the normal A simple method to measure Temperature sensor unloading joints digital multimeter to Ohm two probes are respectively connected sensor a b pin 20 C rated resistance is 2500KQ resistance value other corresponding can amount by the above characteristic curve Measurement can also be used when the simulation method in particular to send wind direction sensor with a hair dryer note not reliable too close observe the change of the sensor resistance the resistance should be reduced 11 21 EFI SYSTEM OF SQR 472ENGINE 6 106 120 Temperaturet 1 Intake air temperature sensor NTC resistance curve Pressure sensor Connect the connector The digital multimeter to DC voltage the black pen grounding the red pen is respectively connected with the c the d pin The idle state the reference voltage c pin should be 5V d pin voltage is about 1 3V about a specific numerical and models no load condition slowly open
98. clips 1 JOINT AIR CLEANER 2 CIRCLIP 3 PRIMARY COVER 4 FILTER ELEMENT 5 TAIL COVER 3 7 3 CHECKS amp ADJUSTMENT Steering Stem Park the vehicle on level place hold steering wheel and shake in the direction as illustrated on the right and see if there is any sway In case of any sway check if it is the problem of the steering stem or other parts and then do the maintenance accordingly J Y w t 7 AND I L ere a n b Aa 2 a nm f TTA n FA EIN e Ax ur In case of sway of the steering stem tighten the i i 6 Caw awa Lik ss ar LU cis eds X locknut or disassemble the steering stem for further check Park the vehicle on level place slowly turn the steering wheel left and right to see if it can turn freely In case there is any hindrance check if there 15 any interference If no check the steering tie rod end and check if the steering stem bearing 15 damaged Note Make sure the steering can be operated freely An accident may occur if the steering wheel is out of control 3 8 3 CHECKS amp ADJUSTMENT BRAKE SYSTEM Master Cylinder Fluid level Check the brake fluid level When the brake fluid level is near to the minimum Minimum 1 4H limit line check master cylinder brake hoses and joints for Display mirror Maximum leakage Remove fluid reservoir cap add DO
99. concentration is high the high potential difference oxygen ions from the medial to lateral the higher output voltage close to 8300mV 1000mV if the original lean mixture the ceramic tube and oxygen ion concentration 15 low the potential difference 15 low only a small amount of oxygen ions from the medial to lateral the output voltage is low close to 100mV 200mV Signal voltage in the theory of equivalent air fuel ratio A 1 occurred near mutation see below apt IT Ed s L an om EIS 600 C il 4 Technical parameters Limit data measure value unit Least typical maximum s m e case sichexagonmas 40 o e Cable metal buckles and connecting 40 210 cable The maximum allowable Ceramic tube short exhaust temperature of the heating element on the each factory 10 minutes a Cable metal buckles and total of up to 40 hours cable Rate of temperature change ceram ube endless o The rate of change ofthe six hexagon mut shet Wasmpemis s _ Connect te DE curenta s MA exhaust temperate is 350 C the maximum comectonACeuret ut Fuel additives permit Unleaded gasoline pay allows lead up to I3mg L The oil consumption and oil combustion Allowed values and data required by the customer through the deter
100. crankshaft 2 3 1 a dial gauge if it is beyond the limit it 1s necessary to Measure the axial clearance of the crankshaft with replace the axial thrust plate or the crankshaft Standard value 0 089 0 211mm Limit 0 30mm 0 03 Chery QQ Service Manual 6 41 Mechanical Part of SQR 472Engine Connecting Rod Connecting Cover ol __ a _ 7 F TIL ra r 2 Pa LY Hi E Ser eer E NES B EIE DU E EL o L bu dew Es EL E j i um im Ead mh aT de ax MN eC 2 m m 6 y m 9 ne oe eu E Xl al s ft lt Ys Chery QQ Service Manual Mechanical Part of SQR 472Engine ELE 2 4 Inspect the crankshaft for its radial clearance 2 41 Remove the crankshaft bearing cap by softly tapping with a resin hammer 2 4 2 Clean the inside and surface of the bearing bushing the inside and surface of the bearing cap the cylinder wall and journal Inspect them for abrasion and damage carefully 2 4 3 Adjust the radial clearance of the crankshaft with a clearance gauge and tighten the bearing bushing cover bolts with the specified torque Torque 70 3 5N m Notice After tightening the bolts the rotating torque of the crankshaft should be less than INm The torque of crankshaft without piston connecting rod 2 4 4 Remove the bearing and measur
101. ction of camshaft axial clearance 1 Replace the camshaft when the axial clearance value measured with dial gauge exceeds the standard value The axial clearance of intake camshaft is 0 1 0 170mm The axial clearance of exhaust camshaft is 0 1 0 173mm Limit 0 18mm 2 7 3 Inspect the clearance of the engaging tooth of camshaft 1 Install the camshaft into the cylinder head 2 Confirm the mark forwards on the bearing cap as well as the axle number and then tighten the bolts 3 Measure the clearance of engaging tooth of the intake camshaft with dia indicator Notice Measure at 4 points on the circle of the piston Turn the intake camshaft with special tools Make sure that the marks on the driven gear and the driving gear of the camshaft match with each other Inspect the clearance of the engaging tooth of camshaft Standard value Single tootj 0 04 0 13 3 Installation 3 1 Under the circumstance that special tools are used 3 1 1 Fix the 2 holes 06 of the camshaft gear assembly with special tool 3 1 2 Rotate the driven gear to the right with special tool and tally the mark hole of driven gear with that of camshaft driving gear or their marking way complies with each other fix the driven gear with bolts Thread M5 Thread pitch 0 8 For Fixing s Chery QQ Service Manual Mechanical Part of SQR 472Engine 3 2 Under the circumstance that special tools are not E HJ avallable IZel Screw the M6 bolts
102. d pump and once fell to the oil pump on the ground Oil fell to the ground to replace the pump tank Pressure is not allowed in the oil inlet plate Caulking can not have mechanical stress Pump clamp must be within the scope of the provisions see below r Pump clamping range Caulking department without mechanical Graph Pump clamping range If the pump has been used please rinse with test solution and dry in the air Do not allow the oil pump 11 31 11 EFI SYSTEM OF SQR 472ENGINE 5 Fault phenomenon and judgment method Fault phenomenon running noise poor acceleration can not start starting difficulty etc General failure due to the use of inferior fuel 1 glial accumulation formed on the insulating layer 2 Oil pump bushing and armature lock 3 oil level sensor assembly corrosion Repair note 1 according to the need of engine electric fuel pump can have different flow fuel pump has the same shape can hold up is not necessarily appropriate part No fuel pump repair by must be with the original agreement is not allowed to change the wrong 2 in order to prevent accidental damage to the fuel pump please don t run in the dry state 3 the need to replace the fuel pump please pay attention to the fuel tank and pipeline cleaning and replacing fuel filter A simple method to measure Remove connector Digital multimeter to Ohm two probes are respectively connected fuel pump two pins measuring internal resistance n
103. e ON Start the engine idle running to the Diagnostic procedures coolant temperature reach normal values A No Next step observe diagnosis instrument monk oxygen sensor voltage items to pay changes the display values should lose uncle is in the range of 100Ma 900mA coolant temperature reach normal values observe diagnosis instrument monk oxygen sensor voltage items to pay Exhaust system blocking Maintenance according Fuel injector is leaking diagnosis Fuel pressure 1s too large Diagnostic aid Valve clearance 1s too small respectively In sensor connector 3 ord bi Next step the oxygen sensor grey connection line between pins line 1s faulty No Check the ECU 432 597 pins Repair replace the wire harness 11 47 11 EFI SYSTEM OF SQR 472ENGINE 2 18 The oxygen sensor is not active error code P0134 Serial Operation steps Test Next step sa Connect the diagnosis instrument the ignition switch is in the ON start the engine idle running to the coolant temperature reach normal values No Next step observe diagnosis instrument monk oxygen sensor voltage items to pay changes the display values should lose uncle 1s in the range of 100Ma 900mA Exhaust system blocking Maintenance according respectively 1n sensor connector 3 with Next step the oxygen sensor grey connection line between pins line 1s faulty Fuel injector is leaking diagnosis
104. e distance engine body around 5mm start the engine check high pressure fire intensity 15 normal Check the cylinder spark plug Next step observe its model and gap whether No Adjust or replace payment specification Remove the idle adjuster check the Cleaning of parts solar term door body idle speed carbon deposition No Maintenance of the ignition system Check the intake pressure sensor Next step solar term door position sensor and Circuit aor Repair or replace the sensor line Remove the injector injector with Failure to replace special cleaning analyzer check Ng Next step whether the injector 15 there 15 a leak or blockage Check the fuel situation observe Replace fuel whether the failure phenomenon No Next step was caused due to gas Check the engine ignition is Xu and Yes Next step ignition timing specification compliance Maintenance of the ignition timing Check whether the smooth air Next step Repair or replace the exhaust pipe Check the X1 XI_2 pinonthe _ Diagnosticaid iron 1s normal Maintenance of the corresponding line 11 79 12 LIGHTING AND SWITCHES Overhaul Info 12 1 u ana 12 8 Troubleshooting 12 2 Replacing bulbs 12 3 FC AG Hoo e rS 12 5 Ignition Switch 12 5 Combined switch
105. e the fuel cooling and lubrication The battery to the electric fuel pump relay power supply relay Only when in starting and running of the engine makes the electric fuel pump circuit When the engine 1s stopped by accident When running automatic stop fuel pump 1 01 pump cover 2 Motor 3 0il passage 4 Vane pump 3 4 Graph electric fuel pump profile Electric fuel pump outlet pressure by the pressure relief valve between 450 and 650kPa But the pressure in the fuel system from the fuel pressure regulator 380kPa According to the need of engine electric fuel pump can have different flow For the convenience of production the same structure of the EKP13 series of electric fuel pump by adjusting step coils adjust the speed of the 11 30 11 EFI SYSTEM OF SQR 472ENGINE motor thereby adjusting flow So can not be electric fuel pump for vehicle use another type to 3 Technical parameters 1 Limit data 1 1 measure value unit typical maximum working voltage 8 14 system voltage O 30 kP Output voltage 40 650 kP C is m a a KPa 00 2 kPa The environment temperature suitable for 80 LUN The license ofthe fuel temperature 0 50 T 2 Characteristic data Electric fuel pump a fuel pressure flow with voltage proportional to The pump using the car plant of each are not identical Electric fuel pump capacity is 295 305g 4 Installation notes Electric fuel pump should be
106. e difference between the minimum inside diameter of piston hole and the maximum outer diameter of piston 4 2 7 2 After replacing the piston or the cylinder body confirm the clearance again Standard value 0 018 0 030 4 3 4 3 1 diameter 4 3 1 1 if the proper alignment is beyond the limit replace the crankshaft Limit 0 03 Notice The bending value should be equal to one second the run out value of crankshaft rotating one Crankshaft Inspect the proper alignment of the main axle Measure the proper alignment with a dial gauge circle 4 3 2 Inspect the crankshaft for the abrasion 4 3 2 1 Measure the connecting rod journal at the positions indicated in the left figure with a microcaliper and figure out the roundness and cylindricity Limit 0 005mm 4 3 2 2 Measure the connecting rod journal at the positions indicated in the right figure with a microcaliper and figure out the roundness and cylindricity Limit 0 004mm 5 Assembly of Crank Connecting Rod mechanism 5 1 Assembly of the piston connecting rod Chery QQ Service Manual Mechanical Part of SQR 472Engine Measurement position of piston Cuter Diameter Measurement position of piston Inner Diameter 6 46 Zo Chery QQ Service Manual CHERY ERI 5 1 1 Assemble the piston connecting rod and the piston pin with special tool following the instructions below 5 1 1 1 Spread engine oil over the pi
107. e difference caused by the maximum axial force 5 Installation notes Idle with stepping motor actuator is installed on the solar term door body castings constitute a bypass channel at both ends of the solar term door Bolt installation using two M5 0 8 14 Bolt tightening torque of 4 0 4Nm The installation and use of the spring washer and adhesive Idle with stepper motor actuator shaft should not be installed level or lower level so as to avoid cold Condensate water into Shall not be applied in any form of axial force to axial compression into or out of A Before the idle with stepper motor actuator into the solar term door body the shaft must be fully retracted position at 11 16 11 EFI SYSTEM OF SQR 472ENGINE point inaction 6 Fault phenomenon and judgment method Fault phenomenon idle speed 1s too high idling flameout idle vibration Repair the matters needing attention 1 shall not be applied in any form of axial force to axial compression into or out of a Before 2 idle speed with stepping motor controller into the solar term door body the shaft must be fully retracted position at 3 pay attention to the bypass air drain cleaning and maintenance 4 remove the battery or ECU pay attention to timely to the stepper motor reset A system reset method is open the ignition switch but not immediately start the engine wait 20 seconds and then start the engine If at this time that the engine idling bad
108. e fixed scale A number of lines will seem close but only one will align exactly In this case 0 50 mm ts the reading to add to the first number Adding 10 mm and 0 50 mm equals a measurement of 10 50 mm Micrometers A micrometer is an instrument designed for linear measurement using the decimal divisions of the inch or meter Figure 22 While there are many types and styles of micrometers most of the 1 SERVICE INFORMATION DECIMAL PLACE VALUES Indicates 1 10 one tenth of an inch or millimeter Indicates 1 100 one one hundredth of an inch or millimeter Indicates 1 1000 one one thousandth of an inch or millimeter This chart represents the values of figures placed to the right of the decimal point Use it when reading decimals from one tenth to one one thousandth of an inch or millimeter It is not a conversion chart for example 0 001 in 1s not equal to 0 001 mm procedures in this manual call for an outside micrometer Use the outside micrometer to measure the outside diameter of cylindrical forms and the thickness of materials A micrometer s size indicates the minimum and maximum size of a part that it can measure The usual sizes Figure 23 are 0 25mm 0 1 in 25 50 mm 1 2 in 50 75 mm 2 3 in and 75 100 mm 3 4 in Micrometers that cover a wider range of measurements are available These use a large frame with interchangeable anvils of various lengths This type of micrometer offers a co
109. e ignition timing the specifications No Maintenance Maintenance of the ignition timing the Maintenance of the ignition timing timing BOT a a an Iron is normal Maintenance of the corresponding line 11 76 EFI SYSTEM OF SQR 472ENGINE 3 11 Accelerate the speed to go up not to go or stop General fault location The fuel moisture content The intake pressure sensor and solar term door position sensor The spark plug Solar term door body and idle bypass airway The inlet Idle speed regulator The fuel injector The ignition timing The exhaust pipe N ANN O LO The general procedure of diagnosis Serial Operation steps Test Next step mamor Check the atr filter 1s clogged Yes Maintenance of air intake Maintenance of air intake system G iea M Nextstep 0 0 step Connect the fuel pressure gauge access point for the fuel distribution pipe assembly inlet pipe Maintenance of oil supply system end start the engine check the fuel pressure in the idling condition is about 390kPa Check the cylinder spark plug Yes Next step observe its model and gap meets the specifications No Adjust or replace or replace Remove the idle adjuster check the x MEE of Cleaning of parts 4 solar term door body idle speed LONE Next step regulator and idling bypass airway carbon deposition Check the intake pressure sensor
110. e is assorted standard value 3 3 4 4 Inspect the fitting position of the valve The best position is the center of the valve If no the valve should be adjusted 3 3 4 5 Cut wimble surface at the center of assorted position with inner 70and outer 30 3 3 4 6 Prepare for polishing of valve seal 3 4 Assembly of cylinder head 3 4 1 Cylinder head Pay attention to the following for installing the other auxiliary part of cylinder head 3 4 2 Protective tube of spark plug 1 Press the protective tube of spark plug into the protective tube hole on the cylinder head with the special Protective Tube of Spark Plug auxiliary tool Before pressing spread the protective tube with sealant The pressing depth is indicated in the right figure Notice Pay attention to the pressing depth and the uprightness to top of cylinder head when pressing During pressing the protective tube can not be deformed or leaking will be occurred at the cylinder head cover 6 27 lt 2 Chery QQ Service Manual Mechanical Part of SQR 472Engine Bet EIE 3 4 3 Installation 3 4 3 1 Assembly of valve spring washer and valve oil _ Auxilary Tool of Valve Spring Assembly 3 4 3 1 1 Clamp the special auxiliary tool on the top of Valve valve stem and spread oil around the auxiliary tool and the Valve Oil Seal Assembly Lower Surface of Valve Spring inner of new valve oil seal Then mount it at the position as I d
111. e meter panel gt 2 11 Disconnect 4P connector of ignition switch Combined switch Reverse the removal procedure for installation api Combined Switch Remove front cover gt 2 11 Remove meter panel 2 11 Disconnect connector of combined switch Check according to the following table if the connector terminals are in continuity 12 LIGHTING AND SWITCHES AWD 4WD 4WD Diff Lock Switch Horn button G W 0 5 _ 60 5 YNOS No continuity Change the switch S 5 Winch switch N 12 7 12 LIGHTING AND SWITCHES Brake Light Switch Disconnect brake light switch connector and check terminators for continuity Hold the brake pedal Brake lights are open Release the brake pedal Brake light 1s off When hold the brake pedal the brake light is off Replace brake pump assembly Horn Inspection Remove bolt Remove horn connector Connect with a fully charged 12V battery and check the horn sounds Faulty Horn Replace 12 8 XY1100UE XY1100UEL specified fuses Sandy 304 Standby 10 Sotlight Relay Ignition switch Relay injector Relay C80 D A
112. e micrometer has a ratchet stop use it to ensure that the proper amount of pressure 15 applied b If the adjustment is correct the 0 mark on the thimble will align exactly with the 0 mark on the sleeve line If the marks do not align the micrometer is out of adjustment c Follow the manufacturer s instructions to adjust the micrometer Care 4 Micrometers are precision instruments They must STANDARD METRIC MICROMETER be used and maintained with great care Note the following 1 Store micrometers In protective cases or separate padded drawers in a tool box r E mais 2 When in storage make sure the spindle anvil ii faces do not contact each other or another object If LONE 7 they do temperature changes and corrosion may damage the contact faces 3 Do not clean a micrometer with compressed air Dirt forced into the tool will cause wear 4 Lubricate micrometers with WD 40 to prevent corrosion Metric micrometer The standard metric micrometer Figure 24 15 accurate to one one hundredth of a millimeter 0 01 mm The sleeve line is graduated millimeter and half millimeter increments The marks on the upper half of the sleeve line equal 1 00 mm Each fifth mark above the sleeve line 1s identified with a number The number sequence depends on the size of the STANDARD INCH MICROMETER micrometer A 0 25 mm micrometer for example will eave Thimble have slee
113. e relief valve for engine oil pump and the cotter pin Notice The cotter pin 1s nonreusable 6 35 Mechanical Part of SQR 472Engine Special Tool Inner Side Oil Seal Below 0 5mm Cho Chery QQ Service Manual Mechanical Part of SQR 472Engine EIE 4 4 3 When the outer gear or inner gear is put into the engine oil pump its mark should be seen 4 4 4 The new weather strip should be fixed in the groove of oil pump cover 5 Disassembly of Oil Seal 5 1 Structure Diagram Components which may not be reused 6 36 d 2 Chery Service Manual Mechanical Part of SQR 472Engine ETE EIA 5 2 Disassembly 5 2 1 Remove the rear crankshaft oil seal with a screwdriver Notice The rear oil seal of the crankshaft is nonreusable 5 3 Inspection Inspect the oil seal for damage and the abrasion at its lip 5 4 Assembly of oil seal 5 4 1 Spread engine oil over the lip of the new oil seal 5 4 2 Mount the oil seal with special tool as indicated in the right figure Special Tool Special Tool 6 Assembly 6 1 Assembly of the oil seal seat Spread sealant over the oil seal seat as shown in the right figure Grease Loctite 5699 Notice Spread the liquid sealant on the position of the oil seal base which is to contact with the cylinder body and make sure the width of the sealant is 3 4mm Torque 25 1 5 6 2 Assembly of the new engine oil pump gaske
114. e sure it 1s applicable to the task As with all tools measuring tools provide the best results 1f cared for properly Improper use can damage the tool and cause inaccurate results If any measurement is questionable verify the measurement using another tool A standard gauge is usually provided with micrometers to check accuracy and calibrate the tool 1f necessary Precision measurements can vary according to the experience of the person performing the procedure Accurate results are only possible if the mechanic possesses a feel for using the tool Heavy handed use of measuring tools produces less accurate results Hold the tool gently by the fingertips to easily feel the point at which the tool contacts the object This feel for the equipment produces more accurate measurements and reduces the risk of damaging the tool or component Refer to the following sections for specific measuring tools Feeler Gauge Use feeler or thickness gauges Figure19 for measuring the distance between two surfaces A feeler gauge set consists of an assortment of steel strips of graduated thickness Each blade 1s marked with its thickness Blades can be of various lengths and angles for different procedures A common use for a feeler gauge 1s to measure valve clearance Use wire round type gauges to measure spark plug gap 1 SERVICE INFORMATION Calipers Calipers Figure 20 are excellent tools for obtaining inside outside and depth measurements
115. e sure that there 1s drop In pressure Note Do not apply pressure over the specified pressure 108 137kpa 1 1 1 4kgf cm or the cooling system may be damaged In case there is any pressure leakage check the pipe joint parts joints of water pump and drainage gt 4 5 Replacing Coolant Air Discharge Preparation of coolant Coolant is toxic DO NOT drink or splash it to skin eyes and clothes Ifcoolant splashes in your eyes thoroughly wash your eyes with water and consult a doctor If coolant splashes on your clothes quickly wash it away with water and then with soap and water If coolant is swallowed induce vomit immediately and see a physician Store the coolant properly and Keep it away from reach of children Note Mix the coolant undiluted with soft water according to the temperature 5 C lower than the actual lowest local temperature Coolant should be made from undiluted coolant with soft water Standard density of coolant 30 Recommended coolant XYPOWER coolant Direct application without having to be diluted Drainage of coolant Remove radiator cap cover Note Open the radiator cap after the coolant is fully cooled Remove Open the front cover gt 4 3 Remove Radiator cap 4 3 4 4 ETHYLENE 4 COOLING SYSTEM ANTIFREEZE SOLUTION V GLYCOLBASE LOW MINERAL SOLUTION OR DISTILLED WATER cooLANT 4 COOLING SYSTEM Reserv
116. e the maximum width with a clearance gauge If the measurement result exceeds the limit replace the bearing bushing Standard value 0 025 0 069mm Limit 0 10mm Width Compare of Clearance Gauge 2 4 5 Remove the main bearing bushing cap of the crankshaft crankshaft crankshaft bearing bushing and crankshaft axial thrust plate Notice Tighten the bolts for the crankshaft bearing cap in the order shown in the right figure Tighten the bolts for three times then the torque must be up to the specified value 6 42 cH Chery QQ Service Manual 2 5 Disassembly and assembly of the piston and connecting rod assembly 2 5 1 Remove the first ring second ring and the oil ring with a pair of piston ring moving pliers Notice Don t get the piston and piston ring of each cylinder confused 2 9 2 Remove the piston connecting rod the piston pin with special tool Disassemble the piston pin with special tool as indicated in the right figure 1 As indicated in the right figure disassemble the piston which is at the state mentioned above with special tools Remove the piston pin with special tool and then remove the piston and the connecting rod 3 Cleanup 3 1 Cylinder Body In the course of cleanup protect your eyes with eyeglass 3 1 1 Clean up the cylinder body cylinder head oil pan oil pump and the oil seal with a flat blade 3 2 Piston In the course of cleanup protect your eyes with ey
117. eage such as twenty thousand kilometers the large dust reduce it or solar term valve plate dust deposition 15 large the throttle valve of main channel and side channel cleaning cleaning agent is not conductive to the throttle body is cleaned dried check with a multimeter solar term door position sensor and idle speed step motor is correct can be loaded back 5 solar term door position sensor 1 Diagram and pin Series resistance C Output kipu PPEP A Power supply B Grounding B Solar term door Power supply ECUXI 45 TPS position s B Earth ECUXI 38 TCO_GND sipu 2 Installation position Solar term door body 3 Working principle The sensor has a linear output angle sensor comprising two arc shaped sliding contact resistance and the two sliding contact arm Slide arm shaft with the solar term door is connected on the same axis With 5V Vcc supply voltage between two ends of A terminal and the B terminal sliding contact resistance When the throttle valve is rotated the sliding contact arm rotates and move in the sliding contact resistance and the potential of the VP contacts as output voltage derived from 11 13 11 EFI SYSTEM OF SQR 472ENGINE the C terminal So it is in fact a angular potentiometer potentiometer output and solar term door position into a voltage signal proportional 4 Technical parameters The relationship between data for throttle valve openi
118. ecial cleaning analyzer to check whether the No Next step injector is there is a leak plugging or flow ui ultra difference phenomenon a Check the fuel situation observe whether Replace fuel sensor the failure phenomenon was caused due to Next step gas Check the engine cylinder pressure of each Remove engine mechanical fault engine cylinder pressure observe whether No Next step there are differences in the larger Compliance with the specification when Yes Next step ignition ignition sequence checking engine No Maintenance of the ignition timing Check the X1 14 1_1 pin on the iron is Y normal No Maintenance of the corresponding line 3 8 Start warm up after idling instability General fault location 1 The fuel moisture content 2 The coolant temperature sensor 11 73 11 EFI SYSTEM OF SQR 472ENGINE 3 The spark plug 4 Solar term door body and idle bypass airway 5 The inlet 6 Idle speed regulator 7 The engine mechanical part The general procedure of diagnosis Serial Operation steps 1 Check the air filter is clogged the intake NL 2 Check whether the idle speed regulator Clean or replace 3 Check the cylinder spark plug observe its Yes Next step model and gap meets the specifications Adjust or replace Check the solar term door body and idle speed organ exists the phenomenon of No Next step carbon deposition Remove the injector injecto
119. ecial fuel line clamp on fuel injector cap loosen the special fuel line clamp on fuel tank Disassemble High pressure fuel line NOTE Use container to keep the remaining fuel from high pressure fuel line when loosening the special fuel line clamp High Pressure Fuel Line Installation Reverse the disassembly procedure for installation Use clamp calliper to install the special fuel line clamp Th le B Di Body Disassembly Throttle cable Locknut ll Throttle body Remove the connector of throttle valve opening sensor o Air filter clamp Remove the connector of idling solenoid valve sensor E Loosen locknut remove adjust nut and remove the throttle cable from throttle rotory sleeve Loosen air filter clamp Remove intake tube of air filter Remove 2 clamps and remove circulating water hose Throttle valve opening sensor Remove 4 bolts and remove throttle body i Idli lenoid val NOTE Do not adjust the bolt on throttle body Ing SOlenold Valve Do not remove the cap on throttle body Throttle Body Installation Reverse the disassembly procedure for installation 7 FUEL INJECTOR SYSTEM Fuel rail with injector assy disassembly Disassemble the special high pressure fuel Remove the strap and fuel injector connector Disassemble 2 bolts and remove fuel rail with injector assy Fuel rail with injector assy installation Reverse the disassembly procedure for installatio
120. eck a resistor Next step 11 EFI SYSTEM OF SQR 472ENGINE 2 32 The knock sensor fault fault code P0325 Serial Operation steps Test Next step number results Connect the diagnosis instrument Nextstep 000002000 Next step Dial the joint of the knock sensor wire Repair or replace the wire harness harness using a multimeter to check the No Next step connection between 2 and ECUXI 10 54 is short circuited pin 3 Dial the joint of the knock sensor wire Repair or replace the wire harness harness using a multimeter to check the No Next step connection between 1 2 and ECUXI 1 a EE 21s short circuited pin 4 The replacement of the knock sensor check whether the fault has disappeared 2 33 The crankshaft position sensor circuit fault fault code P0335 serial Operation steps Test Next step number results 1 Ground which is diagnostic instrument the Next step ignition switch is in the OFF Dial the joint curve position sensor wire Ye harness electrical multimeter to check Iw Replace the sensor sensor 2 and 3 pins between the value at Check sensor connector 2 3 and ECU 298 27 between whether circuit breaker or the power supply or short Next step circuit to ground Check the 1 connector with the main relay output that 1s between the 27 pin ECU line is broken or the power supply or short circuit to ground Replace the signal disc 11 56
121. eglass 3 2 1 Use an old ring to remove the carbon in ring groove 322 Remove the carbon of parts with scavenger Notice Don t use hard articles such as metal brush Mechanical Part of SQR 472Engine Special Tool 6 43 Chery QQ Service Manual 4 Routine Inspection 4 Cylinder Body 4 1 1 Inspect the top surface of cylinder body for its flatness 1 Measure at the six points shown in the right figure with a ruler and a feeler gauge Limit 0 08mm 4 1 2 Use of bore gauge Measure the cylinder bore at the positions as indicated in the right figure with a bore gauge and figure out the difference between the maximum value and the miximum value If the difference exceeds the limit repair or replace the cylinder Limit 0 03mm Reference Roundness A B or a b Cylindric degree A a or Reference Standard diameter of cylinder 072 00 72 01mm 4 2 Piston 4 2 Inspect the piston pin hole for its clearance Measure the piston pin at several positions with a micrometer caliper shown in the figure make the maximum value as the diameter of pin 4 2 2 Measure the diameter of piston pin at several positions with an inner diameter dial gauge as shown in the figure make the minimum value as the diameter of the pin hole Work out the clearance with the difference between the pin diameter and pin hole diameter if the difference is beyond the standard value replace the piston pin or piston Standard value 0
122. ential injection Ignition control Idle speed control Provide power supply of sensor 5V 100mA Closed loop control adaptive Control the carbon canister control valve switch The engine fault indicator Fuel quantitative correction The output of the engine speed signal ESS signal The speed signal input Fault diagnosis Accept the engine load signal etc 11 28 11 EFI SYSTEM OF SQR 472ENGINE 3 Technical parameters Limit data measure value unit least typical maximum a The battery voltag operatio n mam mo function 18 0 tolerance limits and 2V engine can be i ss and fault code mam T 1 voltage tolerance AMNEM temperature Storage temperature 4 Note installation of electrostatic protection Pay attention to the protection of plug pin waterproof ring check the wiring harness side within the connector and yellow isolation plate 1s intact prevent corrosion caused by poor contact pin 5 Fault phenomenon and judgment method Fault phenomenon unstable idle speed acceleration not starting idle speed 1s too high exhaust exceed the standard starting difficulty empty Adjustable injector control failure failure flameout Common fault 1 due to the external device electrical overload caused by ECU may lead to the failure of internal parts burned 2 because ECU water and cause the circuit board corrosion etc Note 1 Repair repair process do not disa
123. ep properly 11 60 11 EFI SYSTEM OF SQR 472ENGINE 2 42 Idle speed step motor fault fault code P0505 M results Connect the diagnosis instrument ope ignition switch 1s in the ON Dial the idle adjuster connector electrical qNetsp idling regulator of A and D and the B and C ml the value at 20 C is 53 motor 5 3 were examined using a multimeter Between the check idle adjuster connector A pin and the D ECU 19 20 pin idle adjuster connector B between pin Diagnostic aid ECU 35 367 pin line is open circuit short circuit 2 43 The system voltage fault fault code P0560 number results ess pm ignition switch is in the OFF using a multimeter to check whether the Ye Next Nextstep batt It bout 12 attery voltage 1s about 12V MESE the Replace the battery The 87 pin check ECU X1 677 and x Repair or bine NN the wire harness main relay the line between whether there is open circuit or short circuit to ground No Next step the 1 22 pin and the ignition switch power supply line is broken or between the short circuit X1 44 63 and the positive pole of the power supply line is broken or on earth is short voltage in different speed range is No Changing engine between 9 16V Check the engine wiring harness ground 1s Diagnostic aid good Repair or replace the wire harness 11 61 11 EFI SYSTEM OF SQR 472ENGINE 2 44 I
124. er or section 2 The number in the figure refers to the disassembly sequence of each component The components which may not be reused and the tightening torque are indicated in the figure T 20 1 5 Nm m A Eh Seal Ring a Engine Oil Pump Cover Sheet Engine Oil Pump Outer Rotor Engine Oil Pump Inner Rotor Cotter Pin Oil Drain Valve Spring Seat Oil Drain Valve Spring Slide Block Crankshaft Front Oil Seal Engine Oil Pump Housing Components which may not be reused Unit N m kg cm G 1 3 Content Omitted this Manual The following operating procedures have been omitted in this Manual and they should be carried out in the actual operation 1 Operation relating to the lifter and the small sized elevator 2 Cleaning and wipping of common components 3 Relevant visual inspection s Chery QQ Service Manual Mechanical Part of SQR 472Engine 1 4 Definitions Standard value Refers to allowed value during inspection maintenance and adjustment Refers to the maximum or minimum value that should not be exceeded during Inspection maintenance and adjustment Set the standard value for simple measurement to prevent from its measuring difficulty and inconsistency to facts Difference Refers to the difference between maximum value and minimum value It carries the cases of damaging the vehicle and parts so you should pay attention to the operation description It records the o
125. erial Operation steps Test Next step results round which is diagnostic instrument the ignition switch is in the ON Dial the joint on wire harness for ignition coil using a multimeter to check voltage No Next step between the 2 pin and the negative pole of the power supply 16 12V Check the ignition coil between the 2 pin and the 872 pin of main relay circuit is open circuit or short circuit to ground No TostepS Toste5 0 02 5 Between the A31 check phase sensor and papillary 1 pins and ECU line is open circuit or short circuit to ground Using a multimeter to check the ignition coll resistance 1 pin and 2 pin between stop should be 0 67 10 u By using the universal resistance between Diagnostic aid the table to check the ignition coil 3 No Replace ignition coil cylinder column and ignition anode stop should be 9 2K 20 11 58 11 EFI SYSTEM OF SQR 472ENGINE 2 38 Four cylinder ignition coil circuit fault fault code P0354 number results 1 round which is diagnostic instrument the 1 1 ignition switch 1s in the ON Dial the joint on wire harness for ignition coll using a multimeter to check voltage No Next step between the 2 pin and the negative pole of dum the power supply 15 12V Check the ignition coil between the 2 pin and the 87 pin of main relay circuit is open circuit or short circuit to ground No TostepS Tostep5 0 5 Between the
126. ethod Fault phenomenon emissions exceed the standard increased fuel consumption General failure man made fault A simple method to measure thenthefragmentswereligatedwithan adapter open the ignition switch but do not start the engine the digital multimeter to DC voltage two probes are respectively connected sensor 3 2 pin to ensure that the reference voltage 12V Start the engine the 1 pin signal by the automotive oscilloscope check whether it is normal 11 12 11 EFI SYSTEM OF SQR 472ENGINE 4 The throttle body Throttle valve control intake air into the engine cylinder so as to control the engine speed and load The festival Flow valve is composed of two channels namely a main channel and side channel Solar term door pedal through the throttle cable control main channel opening gas flow throttling into a cylinder of the engine solar term door opening by the solar term door position sensor 1s transmitted to the engine control unit ECU Installation notes 1 the throttle body and the intake hose connection must be sealed to prevent dust entering the throttle body blocked the inlet channel 2 the throttle body and the intake manifold must seal pad and fastening and loosening leakage Every time after disassembling the throttle body need to replace the gasket new 3 coloring screw throttle body from the demolition to prevent the destruction of the initial setting 4 the vehicles running on certain mil
127. f the rigth side 1 is pressed down for 4 5mm 200 280N m 12 Compression pressure of cylinder 10 14bar Tension of generator belt When the part between the 3 generator and water pump is pressed down for 4 5mm 98N m 14 Refilling amount of engine oil including filter 3 5 Liter gt D c C e lt LU HU TELE 6 52 LN Chery QQ Service Manual Mechanical Part of SQR 472Engine Chapter 5 Table of Main Fitting Torque for SQR472 EngineSQR472 gt ss rm mas Dr peeeseem 9 _ Dima a os emen 9 Ds mens ow De emm s pom kesan He r hexagonal Exhaust camshaft Exhaust camshaft locking nut nut MAXISQ 1008s m n eei mim pewwaesm oe peeemueenm Ow a _ 0 9 a ome _ p me _ mamana 3 w _ Ls heeeemm e ome _ 22 Thermoregulator shell bolt M8 2 10 1 filter conncetor 3 4 16 H 23 40 2 5 24 20 1 5 dL Oil filter 3 4 16 6 53 Chery QQ Service Manual Mechanical Part of SQR 472Engine No Intake exhaust stud 101 Intake pipe nut 2541 5 Ignition coil bracket assembly b
128. fault now just gas caused by idle airway system 1 Nextstep 7 Gently down on the accelerator observe mE Failure to replace whether easy to start Next step Check the fuel situation observe whether Replace fuel the failure phenomenon was caused due to x p 7 Check the engine cylinder pressure of each Remove engine mechanical fault engine cylinder pressure observe whether z Next step there is insufficient Check the ignition sequence engine and Nextstep ss ition timi Maintenance of the ignition timing Check the 1 X1_2 pin ground is Diagnosticad Maintenance of the corresponding line 3 6 Start normal but any time idling instability General fault location 1 The fuel moisture content 2 The fuel injector 11 71 11 EFI SYSTEM OF SQR 472ENGINE 3 The spark plug 4 Solar term door body and idle bypass airway 5 The inlet 6 Idle speed regulator 7 The ignition timing 8 The spark plug 9 The engine mechanical part The general procedure of diagnosis Serial Operation steps Test Next step meme results Check the air filter is clogged the intake Check the intake system pipe is leaking Next step Check whether the card idle speed regulator Clean or replace Check the cylinder spark plug observe its Next step model and gap meets the specifications Adjust or replace Check the solar term door body and idle speed organ exists the p
129. few pieces of value is a 12V Check in between a cylinder connector SM pin and the main relay line is open circuit or short circuit to ground Using a multimeter to check a resistor between the fuel injectors for cylinders SM1 and SM2 pins at 20 C in 14 5 0 5 ohm Whether the 3 7 Q voltage with a multimeter to check a cylinder injector connector 2 pin and the negative pole of the power supply will be Between the 24 pin check cylinder injector connector 2 pin and the ECU line is broken or the power supply or short circuit to ground Next step Repair or replace the wire harness Next step Replace injector Diagnostic aid Repair or replace the wire harness Diagnostic aid 2 26 Two cylinder injector circuit shorted to ground fault code P0264 Serial Operation steps Test Next step number results 1 Connect the diagnosis instrument ignition switch is in the ON Dial the joint stiffness of injector on wire harness using a multimeter to check the connector SM1 pin voltage and power for a few pieces of value is a 12V Check in between a cylinder injector connector SM pin and the main relay line is open circuit or short circuit to ground Using a multimeter to check a resistor between the fuel injectors for cylinders SM1 and SM2 pins at 20 C in 14 5 0 5 ohm Whether the 3 7 voltage with a multimeter to check a cylinder injector connector 2 pin 4 and the negative pole of the power
130. for installation Tightening torque Rim Axle Nut 180 200N m 9 3 9 REAR WHEEL REAR BRAKE Rear Brake Rear Brake Caliper Remove e Rear right wheel 9 3 2 bolts from arm Brake caliper Inspection Brake Caliper Cracks Oil leakage Replace Installation Reverse the removal procedure for installation Note Refer to Chapter 1 for brake hose routing Rear Brake Disc Remove e Rear left wheel 9 3 e Remove mounting bolt rim e Remove wheel hub e Rear brake caliper gt 9 4 e Rear brake disc 8 3 Inspection Brake Disc Thickness 3mm Replace Installation Reverse the steps of removal for installation Note Refer to Chapter 1 for brake hose routing Parking caliper Remove rear wheel 9 3 Loosen the bolt 1 Remove the parking cable Remove bolt 2 Remove rear drive shaft Remove parking caliper Remove parking disc SUSPENSION A C y Wheel hub Brake disc Brake caliper Mounting bolt rim Parking cable x lt a ds TS Parking disc Parking caliper i EE val Rear driver shaft be 9 4 9 REAR WHEEL REAR BRAKE SUSPENSION Rear Suspension System Rear Right Suspension NOTE DO NOT remove both left and right suspension at the same time to avoid fall down of the vehicle 1 REAR STABILIZER BAR 2 RUBBER WASHER
131. ft the front wheel Make sure there 1s loading on the vehicle shake the wheel in axial direction for any sway In case of any sway disassemble the front wheel and check the bearing Suspension System Park the vehicle on lever place press the vehicle Several times up and down as illustrated on the right In case of any rocking or abnormal noise check whether there is any oil leakage from absorbers or any damage or looseness of tightening parts 3 12 3 CHECKS amp ADJUSTMENT Adjusting the Absorber Use special tools to adjust the length of absorber according to loading requirement Turn clockwise to adjust from high to low Gear Shifting Shift the gear to check for flexibility and gear engagement Adjust the gearshift rod if necessary ADJUSTLOCKNUT Release the lock nut to adjust the length of gearshift a 227 rod il GEARSHIFT ROD Fuel Device Status of the fuel system FUEL FILTER FEUL HOSE Remove the seat X Check the fuel hose for any aging or damage Aged or damaged fuel hose Replace Check if there is cracks or bending with the fuel hose Cracked or bended fuel hose Replace FUEL TANK FUEL HOSE AIR HOSE 3 13 3 CHECKS amp ADJUSTMENT Throttle Pedal Check Brake Pedal Throttle Pedal Check the free play of throttle pedal Free play 1 5 3mm If out of range then adjust Loosen locknut of throttle cable turn the regulator and adj
132. ften damaged by zs incorrectly fitting screwdrivers Quality Phillips i screwdrivers manufactured with their crosshead tip f fo machined to Phillips Screw Company specifications Poor quality or damaged Phillips screwdrivers can back M out cam out and round over the screw head In addition pM T L Weak or soft screw materials can make removal difficult horizontal The best type of screwdriver to use on Phillips SE screw 1s the ACR Phillips II screwdriver patented by the horizontal anti cam out ribs found on the driving faces or flutes of the screwdriver s tip figure 4 ACR Phillips II screwdrivers were designed as part of a manufacturing drive system to be used with ACR Phillips II screws but they work of tool companies offer ACR Phillips II EN Ea screwdrivers in different Tip size and interchangeable mU E bits to fit screwdriver bit holders C 4 ER 1 Jj NOTES C GRAFTSMAN ib Another way to prevent cam out and to increase MD uu the grip of a Phillips screwdriver is to apply valve grinding compound or permute screw amp socket Gripper onto the screwdriver tip After loosening 6 SON tightening the screw clean the screw recess to Lm Me prevent engine oil contamination Wrenches gt Open end box end and combination wrenches Aw figure 5 are available in a variety of types and sizes The number stamped on the
133. fuel ratio correction each cylinder injector fuel pump speed sensor phase sensor the carbon canister control valve cooling fan relay vehicle speed signal the idle speed idle speed adjustment device system voltage ECU air conditioning compressor evaporator temperature sensor relay fault lamp 3 The fault code list number failure code 0031 Oxygen sensor 1 heater control circuit shorted to ground 0032 Oxygen sensor 1 heater control circuit shorted for the power supply circuit P0037 Oxygen sensor 2 heater control circuit shorted to ground P0038 Oxygen sensor 2 heater control circuit shorted for the power supply circuit P0107 Manifold pressure sensor circuit shorted to ground 0108 Manifold pressure sensor circuit shorted for the power supply circuit 0112 Intake air temperature sensor circuit shorted to ground P0113 Intake air temperature sensor circuit shorted for the power supply circuit PO116 Coolant temperature sensor circuit scope nature of the error P0117 Coolant temperature sensor circuit shorted to ground 1 2 3 4 5 6 7 8 9 10 11 0118 Coolant temperature sensor circuit shorted for the power supply circuit EY N 0119 Coolant temperature sensor circuit intermittent EY gt 0122 Solar term door position sensor for short circuit to ground P0123 Solar term door position sensor for short circuit of power supply Un P0130 Oxygen sensor circu
134. g of fuel injector using special injector cleaning 11 25 11 EFI SYSTEM OF SQR 472ENGINE 11 Carbon canister solenoid valve 1 Diagram and pin 1 Current source ZECU Control output Garbon canister 7 Power supply V RLY solenoid valve 2 Pulse signal FCUX4126 CPPWM Pin the carbon canister control valve has two pins one by the main relay output pin another ECU 2 Installation position The vacuum line on the carbon canister and intake manifold 3 Working principle The carbon canister control valve consists of an electromagnetic coil armature and valve etc Inlet is provided with a filter screen Through the carbon canister control valve air flow of a connection with the ECU output to the carbon canister control valve electric pulse duty ratio on the other hand with the carbon canister control valve between the inlet pressure and the outlet pressure difference When no electric pulse the carbon canister control valve closed The carbon canister control valve section In the different pressure difference the carbon canister control valve in the 100 duty cycle i e all open under the conditions of the flow of each are not identical Here are two kinds of typical flow curve Can be seen from the graph the 700mbar pressure difference the carbon canister control valve fully open when the flow rate 1s 3 8m3 h In the 200mbar pressure difference the carbon canister control valve fully open when the flow rate 1s 3 0m3
135. gen sensor for 21 67 22 Tightening torque 34 44Nm oxygen sensor 5 Fault phenomenon and judgment method Fault phenomenon idling bad bad acceleration exhaust fuel consumption is too large exceed the standard Common fault 1 2 more than life engine oil burning causes the sensor surface area carbon 3 wet water vapor inside the transducer a temperature change probe fracture 2 oxygen sensor poisoning Pb S Br 51 Repair note prohibit the use of cleaning liquid oily liquids or volatile solids in the oxygen sensor repair A simple method to measure Remove connector digital multimeter to Ohm two probes are respectively connected sensor 1 white 2 white pin room temperature 23 5 C under the resistance of 5 4 6 6 Connect the connector under idling state the oxygen sensor at the working temperature of 350 C the digital multimeter to the DC voltage two probes are respectively connected sensor 3 grey 4 black pin the voltage should be in the rapid fluctuation between 0 1 0 9V 8 The intake air temperature and absolute pressure sensor 1 Structure diagram and pin MI iE 2 N i 3 Pressure Signa r9 1 intake air ECU XT 60 1 46 TMAP pressure sens ECU 1 56 Ground 2 Installation position The sensor consists of two sensors intake manifold absolute pressure sensor and the inlet temperature sensor assembly is installed in the The int
136. gram At e B 13 lant 185 400 EX e IL rra TEC ER E J IR 155 74 OR 407 05 Bie D2 5 UR OM DH ges Gye Byld xwmply ee ETRE odd Tay yir Vari opo E Dr E n E 2 Wu i1 pam DR LU a ZN DL FCU 2 25 23 52 68 67 65 62 58 18 20 25 25 74 77 m 70 ey Em 29 s3 10 5 5 E Rx FELE aas i x 23 a 1 BEES 82 je mm d 5 5 S sms 1 y X j nnn dg TE PI Mi 3888 ell 2421 6 2 T x d od 5 E a u Bm i at z JE i m 11 3 11 EFI SYSTEM OF SQR 472ENGINE 4 The ECU function module layout FS eS Fates x TAME AX ry Am AMAA al SR 11 EFI SYSTEM OF SQR 472ENGINE 5 Pin output defi
137. he opening of oil ring should be in the specified direction 5 4 2 The bolts of the connecting rod should be covered with nylon sleeves for fear of scraping the cylinder body and the axle 5 4 3 The surfaces of piston and connecting rod and other surfaces where relative motion exists should be spread with engine oil 5 4 4 Confirm the mark forwards of the piston and strike it into the cylinder body with the piston ring striking tool Notice The cylinder number of the piston and connecting rod assembly should be in accordance with the cylinder number 5 4 5 Assemble the connecting rod bearing cap and the connecting rod bushing pay attention to the following 5 4 5 1 Put the cover on the bolt as per the mark forwards spread a little engine oil over the joint surface between the nut and its seat 5 4 5 2 Tighten the right nut and the left nut alternatively for several times with specified torque Torque 40 2 Notice The connecting rod and the connecting rod bushing should be of the same subassembly Mechanical Part of SQR 472Engine 6 49 Forward Mark mens ee lt gt 2 Chery Service Manual Mechanical Part of SQR 472Engine ETE EIA Chapter 3 Table of Main Fit Clearance for SQR472 Engine SQR472 Clearance between Cylinder Hole and Piston Skirt Piston to Cylinder Clearance Name of Component Size and Tolerance Clearance or Value of Remark Interferenc m 0 005 Div
138. he connecting rod 2 1 1 Measure the axial clearance with a dial gauge feeler gauge Standard value 0 15 0 25mm Limit 1 2mm 2 2 Inspect the connecting rod bushing for its radial clearance 2 2 1 Remove the bushing cap Notice The components of each cylinder shall be placed in order 2 2 2 Clean the bearing bushing and the axle 2 2 3 Conduct radial adjustment for the axial diameter of connecting rod with clearance gauge Tighten the bushing cap with specified torque Torque 40 2N m Notice The crankshaft may not rotate 2 2 4 Remove the bushing cap measure the maximum thickness of the searcher Standard value 0 020 0 044 mm Limit 0 07 mm 6 40 2 2 3 bushing Notice Replacing the bearing bushing with the product of the same manufacturer s brand The thickness of the If it is beyond the limit replace the bearing connecting rod bushing which meets the requirements of clearance diameter of big end hold axial diameter of connecting rod standard value of bearing bushing clearance 2 2 6 Remove the connecting rod bearing cap and the connecting rod bearing bushing 221 of the connecting rod bolt so as to prevent the bolts Put vinyl resin protecting jacket on the threaded from scraping the cylinder hole and the crannkshaft connecting rod journal and then disassemble the piston connecting rod by using the hammer handle striking it out 2 3 Inspect the axial clearance of
139. he length of the posts Telescoping gauges are typically used to measure cylinder bores To use a small bore gauge select the correct size gauge for the bore Carefully insert the gauge into the bore Tighten the knurled end of the gauge to carefully expand the gauge fingers to the limit within the bore Do not over tighten the gauge because there is no built in release Excessive tightening can damage the bore surface and damage the tool Remove the gauge and measure the outside dimension Figure 30 Small bore gauges are typically used to measure valve guides Dial Indicator A dial indicator Figure 31 is a gauge with a dial face and needle used to measure variations In dimensions and movements Measuring brake rotor runout 1 a typical use for a dial indicator Dial indicators are available in various ranges and graduations and with three basic types of mounting bases magnetic B Figure 31 Clamp or screw in stud When purchasing a dial indicator select on with a continuous dial A Figure 31 Cylinder Bore Gauge A cylinder bore gauge is similar to a dial indicator The gauge set shown in Figure 32 consists of a dial indicator handle and different length adapters anvils to fit the gauge to various bore sizes The bore gauge 15 used to measure bore size taper and out of round When using a bore gauge follow the manufacturer s instructions 1 16 1 SERVICE INFORMATION 32 3
140. heel first and then adjust steering wheel Reverse the removal procedure for Installation Platfond Remove Remove four bolts 2 Remove platfond Installation Reverse the removal procedure for Installation 2 Vehicle body Muffler Cover Steering Wheel Platfond 2 2 2 Vehicle body Muffler Windshield Assembly Remove Separate the connector of wiper motor Remove four bolts 1 Remove windshield assembly Installation Reverse the removal procedure for Installation WIPER BLADE WIPER ARM BOLT M6x20 WINDSHIELD SCALEBOARD BOLT M6x16 FARDAGE WINDSHIELD CAP NUT M6 HOOP 45 WINDSHIELD IMMOBILITY PLANK TOP 10 WINDSHIELD IMMOBILITY PLANK BELOW 11 NUT FLANGE M6 12 WIPER 13 DUST COVER RUBBER 14 NUT M12 15 WASHER 012 16 RUBBER WASHER 17 WIPER ASSY O Q C A QU N 2 Vehicle body Muffler Side door LF Remove Remove bolt 1 Remove side door LF Remove the side door of the another side in the above way Installation Reverse the removal procedure for Installation 1100UEL Side door LR Side Door LR gP Remove b N Remove bolt 2 Remove side door LR Remove the side door of the another side In the above way Installation Reverse the removal procedure for Installation 15 TAPPING SCREW ST 4 2x20 16 SCREW 6 25 17 HANDLE HALF DOOR L 18 SCREW M5x20 19 INNER
141. henomenon of No Next step carbon deposition Remove the injector injector with special Failure to replace cleaning analyzer to check whether the No Next step injector is there is a leak plugging or flow ultra difference phenomenon Check the fuel situation observe whether Replace fuel the failure phenomenon was caused due to Check the engine cylinder pressure of each Remove engine mechanical fault engine cylinder pressure observe whether No Next step there are differences in the larger Compliance SAIS the specification when Yes the ignition timing Diagnostic aid Maintenance of the corresponding line 3 7 Start warm up process unstable idle speed General fault location 1 The fuel moisture content 2 The coolant temperature sensor 3 The spark plug 11 72 11 EFI SYSTEM OF SQR 472ENGINE 4 Solar term door body and idle bypass airway 5 The inlet 6 Idle speed regulator 7 The engine mechanical part 11 The general procedure of diagnosis Serial Operation steps 1 Check the air filter is clogged the intake ae 2 Check whether the card idle speed regulator Adjust or replace 3 Check the cylinder spark plug observe its Yes Cleaning of parts model and gap meets the specifications Check the solar term door body and idle Trim lines or replacement of the speed organ exists the phenomenon of carbon deposition Remove the injector injector with sp
142. ice Tools should be vertical to prevent the protective tube of spark plug from distorting or the oil will leak 6 29 Zo Chery QQ Service Manual Mechanical Part of SQR 472Engine 4 Water Pump 1 Structure Diagram Components which may not be reused D O ring nonreusable 2 Water pump body 3 Dust seal 2 Disassembly 2 1 6 Disassembly O ring Notice The O ring is nonreusable 2 2 Screw off bolts and disassemble water pump body 2 3 Disassembly of dust seal 3 Cleanup 3 1 Clean water pump joint surface 4 Routine Inspection 4 1 Check if itis deformed 4 2 Rotate it with hand and inspect whether the rotor rotates and is lubricated well 5 Assembly 5 1 Mount Dust seal 5 2 Mount Water Pump Body torque 25 1 5N m 5 3 Mount The New O ring 6 30 s Chery QQ Service Manual Mechanical Part of SQR 472Engine 5 Oil Pump 1 Structure Diagram K Components which may not be reused 1 Torque for oil pan bolt 8 2 N m 2 Oil collector 3 Oil collector spacer nonreusable 4 Oil pump 5 Oil pump spacer nonreusable 6 Rear oil seal bracket 2 Disassembly 2 1 Screw off the bolts and nuts and then remove the oil fu mua pan from the cylinder body with special tool The engine is placed on the disassemble shelf upside down Notice Don t make the oil pan flange deform 6 31 ene Chery QQ Service Manual Mechanical Part of SQR 472Engi
143. ided into two groups Group X F 72 Cylinder hole 972 Clearance for group 0 019mm 0 03mm csl 22 Clearance of group S 72 002 bbb 2 Clearance of Crankshaft Main Bearing Name of Component Size and Tolerance Clearance or Value of Remark Interferenc Crankshaft main journal 04216 o 016 Bearing bushing Clearance 0 025 0 069 40 041 Bore of cylinder main bearing 046 10 025 3 Clearance of Crankshaft Connecting Rod Bearing Crankshaft connecting 0 journal g37h 77919 Bore of connecting rodbig 40 041 end bearing qAUFs 10025 4 Clearance between Piston Pin and Piston Pin Hole Name of jiwa Size and Tolerance Clearance or Value of Remark Interferenc Divided into twogroups Notice When installed 40 007 Piston Pin Hole 18 40 002 Clearance for group A with hand the piston pin 0 004 mm 0 0085mm may pass through the Clearance for group B piston pin hole smoothly am 0 0045mm 0 009 mm without any obvious Piston pin p18 0 004 obstruction otherwise the piston pin should be replaced 5 Inteference between Piston and Small End of Connecting Rod Name of Component Size and Tolerance Clearance or Value of Remark Interferenc Connecting rod small end 0 026 Value of Interferenc hole 18 00 0 021 0 043 6 50 Lo Chery QQ Service Manual Mechanical Part of SQR 472Engine mm demo 6 Fit Clearance between Connecting Rod Body Hole and Bolt Bar Name of Component Size and T
144. if the display value often 1s constant that there may be circuit breaker failure Check the ECU 1272 X 2 pins respectively with the line between the sensor connector a b pin 1s open circuit short circuit fault start the engine open space part load operation Square diagnostic instrument the evaporator temperature value changes the display values should be with the engine running down until the 5 degrees celsius Test Next step results _ me Next step Repair or replace the wire harness Next step Diagnostic aid Replace the sensor 2 47 Short circuit on the air conditioning evaporator temperature sensor circuit fault code P1536 Serial Operation steps Test Next step number results 1 3 4 Connect the diagnosis instrument the ignition switch 1s in the ON The observation data stream in the evaporator temperature and whether the engine temperature quite numerical and then temperature Note if the display value often 1s constant that there may be circuit breaker failure Check the ECU 1272 X _ 2 pins respectively with the line between the sensor connector a b pin 1s open circuit short circuit fault Start the engine open space part load operation Square diagnostic instrument the evaporator temperature value changes the display values should be with the engine running down until the 5 degrees celsius 11 63 Repai
145. igation control valve short circuit fault code P0445 59 2 41 The speed sensor is not working properly fault code P0501 60 2 42 Idle stepper motor fault fault code P0505 61 243x The system voltage fault code 0500 uQ m aiba 61 2 44 Internal control module read only memory fault fault code P0605 62 62 2 45 Malfunction indicator lamp control circuit fault fault code P0650 2 46 Air conditioner evaporator temperature sensor for short circuit or open circuit power line fault l 63 2 47 Short circuit of the air conditioning evaporator temperature sensor circuit fault code PONS 63 2 48 Air pressure switch or air conditioning clutch relay line fault fault code P1545 64 2 49 Cooling tan relay line fault fault code P1624 u Rh RR eke 65 2 50 Fan relay or fan line fault fault code P1625 air conditioning 65 66 3 1 Start engine does not rotate or move slowly 3 2 When starting the engine can be dragged to but failed to start 67 Jos
146. inal om 2 0mm vibration Horizontal _ 0 Tire Remained Tire Tread T 1240 5PSI 82 543 5KPa pressure front T d 1240 5PSI 82 543 5KPa pressure rear Tightening torque Rear wheel axle nut 180 200N m Rim mounting bolt 40 50N m Front mounting bolt Shock absorber 30 40N m Rear mounting bolt Shock absorber 30 40N m 9 1 9 REAR WHEEL REAR BRAKE SUSPENSION Troubleshooting Rear wheel wobbles Rim warpage Faulty tire Tire pressure too low Improper wheel balance Improper tightening of wheel axle nut Loosened wheel nut Rear shock absorber is too soft Weak spring Oil leakage from rear shock absorber Rear shock absorber is too hard Bent rear shock absorber e Tire pressure is too high Poor brake efficiency Improper brake adjustment Stained brake pad or brake disk Worn or damaged brake pad 9 2 9 REAR WHEEL REAR BRAKE SUSPENSION Rear wheel removal Refer to front wheel remove 8 3 Inspection Rim Damage warpage serious scrapes etc Replace if necessary Slowly turn the wheel measure the rim vibration with a dial gauge Service limit Axial 2 0mm Radial 2 0mm Installation Refer to front wheel installation 8 3 Wheel hub removal Remove rear wheel 9 3 Remove brake caliper Remove mounting bolt rim Remove wheel hub Mounting bolt rim Installation Reverse the removal procedure
147. ines 1 Check fuel lines for signs of wear deterioration damage or leakage Replace 1f necessary 2 Be sure fuel lines are routed properly and secured with cable ties CAUTION Make sure lines are not kinked or pinched 3 Replace all fuel lines every two years 3 6 3 CHECKS amp ADJUSTMENT Air Filter Service It is recommended that the air filter be replaced annually Air Filter When riding in extremely dusty conditions replacement will be required more often The filter should be inspected periodically before each ride using the following procedure The air box is located rearward of the engine 1 Remove clips from air box cover and remove cover Inspect the gasket It should adhere tightly to the cover and seal all the way around 2 Remove air pre filter assembly Do not clean the main filter the filter should be replaced 3 Inspect main element and replace if necessary If the filter has been soaked with fuel or oil it must be replaced Installation 1 Reinstall the filter into the air box container Be sure the filter fits tightly in the air box NOTE Apply a small amount of general purpose grease to the sealing edges of the filter before installing 2 Check air box If oil or water deposits are found drain them into a suitable container NOTE Service more frequently if vehicle is operated in wet conditions or at high throttle openings for extended periods 3 Install air box cover and secure with
148. ing point and support tools Turn support tools counter clock and read the data Standard 0 10 0 25 Adjust washer 01 02 03 0 4 thickness 0 5 1 0 b Shift fork and drive clutch assembly should be against tightly to the arrow shape illustration 10 10 10 FRONT REAR AXLE ee 3 ELA 2 fee LN Y e Mrd SE T max 10 FRONT REAR AXLE c Use special equipment or vehicle control circuit into two stroke position M6 X 25 POSITIONING SCREW M6 x 25 v before gear motor assembly d Make sure b and c is assembled using illustrated positioning bolt before gear motor and front axle 10 11 10 FRONT REAR AXLE Needle bearing removal a Disassemble needle bearing 55BTM6820 as illustration if necessary b Disassemble needle bearing NA5903 as illustration after heating up to 150C I rea pA H Rear axle inspection after disassembly Check if there is crack or damage in rear gear case see mounting hole is ok Replace gear case or right cover if necessary Check if bearing clearance is normal and turning stability rollway stell ball neddle bearing as well Replace bearing if necessary Special tools are required Check rear axle if bearing clearance is normal turning status rollway stell ball neddle bearing as well Replace
149. injector with two card slots care should be taken not to card error can refer to the original installation position Fuel injector installation manual no knocking injector with a hammer and other tools Removing and reinstalling the injector must replace the O ring At this time no damage on the sealing surface of fuel injector Bearing washer O ring shall be pulled out from the injector When installation should avoid damage into the oil injector end O ring support ring the orifice plate and the electric plug If damaged should be banned Install injector fuel distribution pipe assembly tightness detection No leakage of Fang Wei qualified Failure to use manual disassembly Remove the injector clamp and then from the injector seat out of fuel injector After the demolition should guarantee the injector seat clean avoid pollution 6 Fault phenomenon and judgment method Fault phenomenon idling bad bad acceleration can not start starting difficulty or the high fuel consumption exhaust black smoke General failure due to lack of maintenance lead to the injector internal glial accumulation and failure or a cylinder injector does not work a cylinder injector often injection etc Note repair see installation notes A simple method to measure unloading joints digital multimeter to Ohm two probes are respectively connected injector two pin 20 C rated resistor of 12 Suggestion analytical instrument for regular cleanin
150. into the camshaft driven gear at the position indicated in the right figure Insert a Bolt screwdriver into the gap between the M6 bolt and the camshaft journal and trun the driven gear rightwards so that the fitting mark of the 2 gears match with each other or the tooth head of the 2 gears accord with each other and then fix the driven gear with bolts M5x0 8 Notice Don t damage the journal adjust the operation 3 3 Assembly of camshaft Notice Pay attention to the axial clearance of the camshaft 3 3 1 Spread grease on the gear of camshaft and the axial of cylinder head Timing Mark 3 3 2 Remove the fixing bolts for camshaft driven gear after mounting the camshaft 3 3 3 Mount the camshaft align the timing mark as be seen from the right picture Gear of Gear of Intake camshaft 3 3 4 Spread oil fully on the cam of camshaft assembly gears and axial of cylinder head 3 4 Tighten the camshaft bearing cap by the order of right picture Ea For Fixing i ka 3 5 Screw off the fixing bolts for driven gear of intake eM uud Pam l zh pro x camshaft assembly Ed d AX EXEC gt eil E LUN i gt lt 27 Chery QQ Service Manual Mechanical Part of SQR 472Engine ERI EIE 3 6 Assembly of camshaft cove Spread sealant on the position slot of camshaft cover as can be seen from the right picture 3 6 1 A
151. ion steps Test Next step number results 1 Connect the fuel pressure gauge access point for the fuel distribution pipe assembly inlet pipe end start the engine check the fuel pressure In the idling condition is about 380kPa Appropriated line a cylinder which is connected to spark plug sub cylinder spark plug electrode distance engine cao check whether there 1s a blue and white high around Smm start the engine pressure fire Pulling off the coolant temperature sensor connector start the engine when the engine is started successfully observed a 300 ohm resistor In series or m the coolant temperature sensor connector to replace coolant sensor observation of the engine 15 successful start Check the fuel pressure regulator vacuum tube whether there is loose or leakage 4 phenomenon Check the fuel situation observe whether 5 the failure phenomenon was caused due to gas Check the 1 2 pin on the iron is normal 3 4 Cold vehicle starting difficulty General fault location 1 The fuel moisture content 2 The fuel pump 3 The coolant temperature sensor 4 The fuel injector 11 69 No Maintenance supply coefficient Next step Maintenance of the ignition system Repair or replace the sensor line Repair or replace Replace fuel Diagnostic aid Maintenance of corresponding line 11 EFI SYSTEM OF SQR 472ENGINE 5 The ignition coil 6 Solar term
152. ir conditioning wiring harness end is a high level signal system Check system pressure air conditioning Next step compressor electromagnetic clutch and the No Maintenance of air conditioning air conditioning compressor pump is system normal Remove the injector injector with special Failure to replace cleaning analyzer check whether the NO Next step injector 1s there 1s a leak plugging or flow ultra difference phenomenon Diagnostic aid Check the 17 2 pin on the iron is LIBI L NN normal Maintenance corresponding line 3 10 Normal starting idle speed 1s too high General fault location 11 75 11 EFI SYSTEM OF SQR 472ENGINE 1 Solar term door body and idle bypass airway 2 The vacuum tube 3 Idle speed regulator 4 The coolant temperature sensor 5 The ignition timing The general procedure of diagnosis Serial Operation steps Test Next step results Check the throttle cable is stuck Check the intake system and Maintenance of air intake system vacuum pipe connection whether there is leakage No Next Nextstep Remove the idle adjuster solar term a of parts door body check idle speed regulator and idle speed was the No Next step existence of the phenomenon of carbon deposition in the airway Pulling off the coolant temperature sensor connector start the engine No Next step when the engine is idling too high the engin
153. irection indicator 12 V 1 6 W 15 LED Brake Light Tail Light Bulb Remove rear corner cover cargo box gt 2 13 Remove 3 nuts Remove taillight cover Replace brake light tail light bulb Bulb Specification Stop lamp 12 V 1 8 W 12 LED Rear position lamp 12 V 0 2 W 12 LED Reverse the removal procedure for installation Rear Turning Indicator Bulbs Remove taillight 12 4 Remove taillight cover Replace rear turning indicator bulbs Bulb Specification 12 V 2 W 15 LED Reverse the removal procedure for installation 12 4 12 LIGHTING AND SWITCHES Front turning indicator bulbs Headlight Remove Front air guide cover assy gt 2 10 4 fixing bolts of headlight Headlight Fixed bolt headlight headlight connector Headlight Reverse the removal procedure for installation Note Be careful not to damage main cable when assembling After replacing adjust the headlight beam Note Main cables and wires should be routed properly Ignition Switch Inspection Remove front cover gt 2 11 Disconnect 4P connector of ignition switch 12 LIGHTING AND SWITCHES Bolts Headlight N a Headlight connector Ignition Switch 12 LIGHTING AND SWITCHES Check according to the following table if the s Ignition Switch connector terminals are In continuity om 3A aed lt 7 Remove Remov
154. is in the ON 2 Dial the fan connectors relay on wire harness multimeter voltage check fan relay 55 Next st connector 85 86 pin and additional power Be between the value 1s about 12V 3 Check the fan relay between the 85 pin and Repair or replace the wire harness the 87 pin of main relay circuit 15 open circuit or short circuit to ground check the To step 5 fan relay between 86 positive power supply pin and whether the circuit breaker Check the fan power supply circuit fuse is Repair or replace the wire harness intact Check fan relay 87 increased with No Next step the fan power line 1s open circuit or short circuit to ground Check the fan relay connector 85 between Repair or replace the wire harness pin and ECU X 655 pin line is open circuit Diagnostic aid or short circuit to ground 2 50 Air conditioning compressor fan relay or fan line fault fault code P1625 Serial Operation steps Test Next step erm Fe Connect the diagnosis instrument the Next step ignition switch is in the ON pee ss Dial the fan connectors relay on wire harness multimeter voltage check fan relay i ie Next st connector 854 86 pin and additional power 9 between the value 15 about 12 3 Check the fan relay between the 85 pin and Repair or replace the wire harness the 87 pin of main relay circuit is open circuit or short circuit to ground check the No To step 5 fan relay between 86 p
155. ise it will affect the later Fault diagnosis and repair work 3 1 Starting when the engine does not turn or move slowly General fault location 1 The battery 2 Starting motor 3 Harness or ignition switch 4 The engine mechanical part The general procedure of diagnosis 11 66 EFI SYSTEM OF SQR 472ENGINE Serial Operation steps Test Next step number results Using a multimeter to check the battery Next step voltage between two terminals whether the No Replace the battery voltage of more than 8 12V when the engine Start The ignition switch is maintained at the start Next step position using a multimeter to check Repair replace the wire whether the terminal to start the motor h arness positive voltage above 8V Whether there is open circuit or due to No Next step insufficient lubrication card dead If the failure 1s occurred In the winter then The lubricating oil for the check for engine oil and gear selecting improper lead to start the motor power 15 too Next step appropriate label large Check the engine internal mechanical power Maintenance of internal engine is too large leading to start the motor does power not rotate or move slowly Repeat the above steps 3 Starting motor disassembly inspection Yes Repair or replace the starter starting motor Focus on examination of motor 3 2 Starting the engine can drag but failed to start General fault location 1
156. it Never use a metal faced hammer on engine and suspension components because damage occurs 1n most cases Always wear eye protection when using hammers Make sure the hammer face 1s in good condition and the handle is not cracked Select the correct hammer for the job and make sure to strike the object squarely Do not use the handle or the side of the hammer to strike an object 1 10 1 SERVICE INFORMATION Ignition Grounding Tool 18 p Some test procedures require turning the engine ROY over without starting it To prevent damage to the An pe 0 ignition system from excessive resistance or the S possibility of fuel vapor being ignited by an open spark lt remove the spark plug cap and ground it directly to a N good engine ground with the tool shown in Figure Y 2 1 8 78 _ 7 Make the tool shown from a No 6 screw and nut two washers length of tubing alligator clip electrical eyelet and a length of wire PRECISION MEASURING TOOLS The ability to accurately measure components 1s essential to perform many of the procedures described in this manual Equipment is manufactured to close tolerances and obtaining consistently accurate measurements is essential to determine which components require replacement or further service Each type of measuring instrument 1s designed to measure a dimension with a certain degree of accuracy and within a certain range When selecting the measuring tool mak
157. it fault ON P0131 Oxygen sensor 1 circuit output voltage is too low 1 P0132 Oxygen sensor 1 circuit output voltage is too high EY oO P0134 Oxygen sensor 1 is not activated mA P0136 Oxygen sensor 2 circuit fault 11 35 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 32 0137 0138 0140 0230 P0261 P0262 P0264 P0265 P0267 P0268 P0270 P0271 P0325 P0335 P0340 P0351 P0352 P0353 P0354 P0444 P0445 P0501 P0505 P0560 P0605 P0650 P1166 P1502 P1535 P1536 P1545 P1624 P1625 11 EFI SYSTEM OF SQR 472ENGINE Oxygen sensor 2 circuit output voltage is too low Oxygen sensor 2 circuit output voltage 1s too high Oxygen sensor 2 is not activated Circuit pump failure One cylinder injector circuit shorted to ground One cylinder injector circuit shorted for the power supply circuit Two cylinder injector circuit shorted to ground Two cylinder injector circuit shorted for the power supply circuit Three cylinder injector circuit shorted to ground Three cylinder injector circuit shorted for the power supply circuit Four cylinder injector circuit shorted to ground Four cylinder injector circuit short for the power supply circuit Knock sensor circuit failure Crankshaft position sensor circuit failure Camshaft position sensor fault One cylinder ignition coil circuit fault Two cylinder ign
158. itch 25 c E gt q amp 8 T is 5 5 3 2 Ed 2 S e lt S08 0 amp a 5 5 9465 uung a las J 2 5 C80 45 SS MP3 little light z m in gy i lt lli og Jed cu 1 gt 2 600 coo con lt 504 D 2 es 48 4 680 20 1 i ATS O OL 5 d 5 uang 30044 gt injector Ww amp Ads O ee z 5 5 a 5 2 S 8 eB 8 yaqins duo ayog 0 SAN EE nc OASO LL 460 99 c ignition coil za 2 as CIT X 08 5 2 5 lt Ns Soe 5 e u vog 2 8681 81 0 66 2 a E R amp us s vol gt lt ee Standby warm wind OX C08 coq a us as LI I AGO 9G 2 EM bg 1 P a 77246 vay L1 2 z D 2850 78 j 2 external power supply Spotlight 5 o3 a Q ie wh ol S08 04 eo u 5 z Xw xd duo a 0 d lt AT 0 9y a gt E a 2 Ii 50 4d amp i amp G0 4 NESO BY Boe lt 140 940396 Lighting S LO I S z Jd S08 co a 8950 8 1 146 24 240394 a MAS O VS gt 4461 uon sog te Fuel P n in 8 S a 60 d TE ue um 2 S jes co 4 D o 450 08 gt 5804 c8
159. ithin the region but shall not divulge 2 The allowable fuel The injector can be used only in accordance with the people s Republic of China national standard GB 17930 1999 unleaded gasoline for vehicle and the national environmental protection standards GWKB 1 1999 standard harmful substance control of gasoline fuel and provisions add detergent in gasoline In particular gasoline is stored for long time will go bad In particular LPG and gasoline dual fuel engine in a taxi long term to LPG as fuel gasoline is used for starting gasoline consumption rarely But the long term operation of fuel pump fuel tank temperature is high If gasoline is stored in the car s fuel tank it is very easy to be oxidized may cause injector blockage or damage The power supply voltage V 6 e Insulation voltage 10 MQ o 900 6 Vibration acceleration maximum permissible peak Can afford to not fuel pressure Capable of bending stress tolerance IEEE EE Can withstand the axial stress 60 Nm Characteristic data measure Value unit Least Typical maximum presure diference pressure difference aoe at 20 11 24 EFI SYSTEM OF SQR 472ENGINE In particular gasoline storage for a long time will go bad In particular LPG and gasoline dual fuel engine in a taxi long term with LPG as fuel gasoline 1s used for starting gasoline consumption rarely But the fuel pump in long term operation oil tem
160. ition coil circuit fault Three cylinder ignition coil circuit fault Four cylinder ignition coil circuit fault The carbon canister control valve circuit open The carbon canister control valve circuit shorted Speed sensor is not working properly Idle stepper motor fault The system voltage fault ECU read only memory fault Malfunction indicator lamp control circuit fault Oxygen sensor controller adaptive fault diagnosis Wheel speed sensor circuit open Air conditioning evaporator temperature sensor for short circuit or open circuit power supply Short circuit of the air conditioning evaporator temperature sensor circuit High voltage switch or air conditioning clutch relay Cooling fan relay line fault low speed Cooling fan relay line fault high speed 11 36 line fault 11 EFI SYSTEM OF SQR 472ENGINE 4 Clear fault codes The use of diagnostic instrument 1 Turn off the ignition switch 11 2 By reading the fault code the same method the diagnosis instrument to diagnose interface 3 Connected to the ignition switch 4 According to the diagnostic tester instructions clear fault code 5 To complete the fault code is cleared exit diagnosis procedure switch off the ignition and remove the diagnosis instrument from the diagnostic interface Do not use diagnosis instrument and computer 1 Turn off the ignition switch 2 Disconnect battery cathode line for more than 30 seconds then go on Note the fau
161. k to obtain accurate measurements 4 If necessary rotate the meter ohms adjust knob until the needle and 0 mark align 1 17 Description and vehicle identification 1 SERVICE INFORMATION 1 Meter adjust button 2 Driver model turn switch 3 Turning switch 4 Light switch 5 Low beams High beams turn 6 Horn switch 7 Gear Selector 8 Ignition Switch 9 Meter 10 Warning indicator light switch 12 Spot light optional 13 Cigarette lighter 15 Auxiliary DC jack 12V 120W 10A 11 Wiper switch optional 14 winch switch optional 1 SERVICE INFORMATION Identification number records Record the vehicle identification number and engine number in the spaces provided for assistance 1 when ordering spare parts from your dealer or for reference In case the vehicle 1s stolen ENGINE NUMBER Vehicle Identification Number 1100UE LCXRSAS3 Vehicle Identification Number 1100UEL LCXLSAS3 Engine Number SQRA72F NOTE The vehicle identification number is used to identify your machine 1 SERVICE INFORMATION Main Data Table 300Kg Tire Minimum turning radius 4500mm 5000mm Electric starter Type in line Vertical four cylinder water cooled DOHC Combustion Chamber Type Tent shaped 7266 5 mm 2 83 2 62 in Lubrication T pressure splash lubrication Cool Cool tye 000 Mandatory cycle of antifreeze coolant cycle of antifreeze coolant 15kw 90N M 3500 4000 rpm EEC ee ECT A
162. kawshaqususkaqhus 53 6 1 ene Chery QQ Service Manual Mechanical Part of SQR 472Engine Chapter 3 Table of Main Fit Clearance for SQR472 En glIne 55 Chapter 4 Table of Measurement Parameters of SQR472 EnglIne 59 Chapter 5 Table of Main Fitting Torque for SQR472 61 Chapter 6 Positions on SOR472 Engine to De Lubricated uu uu teresa abend Una Pe bea bene Fa da bnt 62 Chapter 7 Positions SQR472 Engine to be Spread with Sealant 65 s Chery QQ Service Manual Mechanical Part of SQR 472Engine Chapter 1 Reading Instruction 1 Reading Method of Maintenance Instruction 1 1 Auxiliary Materials If it 1s required in the operation instruction to prepare the auxiliary materials such as special tools tools measuring instruments and grease in advance you should list all auxiliary materials required in a table before carrying out each operation Since the ordinary tools lifter and spare parts are conventional materials used in the maintenance they are omitted here 1 2 Operating Sequence and Structure Diagram 1 The diagram of structure and components name of components and installation status are set forth at the beginning of each chapt
163. l the sharp edge facing away from the part producing the thrust E clips are used when it is not practical to use a snap ring Remove E clips with a flat blade Rounded edges screwdriver by prying between the shaft and E clip To Sharp edges install an E clip Center it over the shaft groove and push or tap it into place Observe the following when installing snap rings 1 Remove and install snap rings with snap rings w 77 Direction of thrust pliers Refer to Basic Tools in this chapter 2 In some applications it may be necessary to replace snap rings after removing them 3 Compress or expand snap rings only enough to install them If overly expanded Lose their retaining ability 4 After installing a snap ring Make sure it seats completely 5 Wear eye protection when removing and installing snap rings BASIC TOOLS Most of the procedures in this manual can be carried out with basic hand tools and test equipment familiar to the home mechanic Always use the correct tools for the job Keep tools organized and clean Store them in a tool chest with related tools organized together Quality tools are essential The best are constructed of high strength alloy steel These tools are light easy to use and resistant to wear Their working surface is devoid of sharp edges and carefully polished They have an easy to clean finish and are comfortable to use Quality tools are a good investment Some
164. lant in the installation process suggestions on the selection of conductive sealant Sealant should be applied in the graphic Figure 7 plane should ensure that adequate smear that sealant after tightening anhydrous leakage phenomenon pay attention to installation thread does not allow fluid sealant to ensure that the assembly and disassembly and good conductivity sensor Coating surface In the installation process of tightening tighten six angle plane using spanner copper sleeve May not be a plastic parts are tightened so as not to damage the product Maximum tightening torque 20N m 6 the malfunction phenomenon and the judgment method General failure 1 The starting difficulty A simple method for testing unloading joints digital multimeter to Ohm two probes are respectively connected sensor AZ C pin 25 C rated 1 825 2 155K resistors Measurement can also be used when the simulation method in particular to the sensor working area and dropped into the boiling water note the immersion time to fully observe the change of the sensor resistance the resistor should decline to 300 specific value as the temperature of boiling water 2 The water temperature indicating meter failure simple test method unloading joints digital multimeter to Ohm two probes are respectively connected sensor B pin and the copper shell using the simulation method in particular to the sensor working area and dropped into the boiling
165. le to clear 15 for the original ECU repeat the process again repair work 2 Fault code diagnosis flow 2 1 The upstream oxygen sensor heater control circuit shorted to ground fault code P0031 Serial Operation Vehicl Next step AN e speed detecti on TOTEM the diagnostic instrument ignition switch 1 Next step in the ON u Dial the joint oxygen sensor wire harness check with a Next DANE e a multimeter the joint 1 connected with the DEM sensor white relative 2 with the oxygen sensor To step w o cable relative to white 16 12V about the value of voltage at pin 3 Using a multimeter to check the oxygen sensor 17 white 27 Baise resistance between Pin value at no Replace the sensor 20 C in 5 4 6 6 ohm 4 15A fuse check the main relay power lines of the Replace the fuse fuse m 5 872 main relay 212 pin check yes Repair or replace the wire respectively 1 and oxygen sensor connector for harness connecting line is legendary white 2 with the no Diagnostic aid oxygen sensor white connection line between pins relative whether the circuit breaker or short circuit to ground 11 38 11 EFI SYSTEM OF SQR 472ENGINE 2 2 The upstream oxygen sensor heater control circuit for the power supply circuit fault code P0032 seria Operation steps Test Next step number results 1 Connect the diagnosis instrument the ignition Next step switch is in the
166. lt does not exclude fault codes will reappear 11 37 11 EFI SYSTEM OF SQR 472ENGINE Chapter 4 Troubleshooting diagnostic process 1 Fault diagnosis based on the fault code description 1 Has been recognized as a steady state current failure to the following maintenance otherwise it will lead to wrong diagnosis 2 The below mentioned multimeter occasion refers to the digital multimeter prohibit the use of pointer multimeter to check on line electronic fuel injection system 3 Maintenance of the vehicle anti theft system if the replacement ECU occasions appeared in the Next step bar pay attention to after the replacement of programming on ECU 4 If fault code for a circuit voltage is too low refers to the circuit may be shorted to ground if the fault code for a circuit voltage is too high refers to the circuit has the potential to supply short circuit if the fault code for a circuit fault refers to the circuit breaker may exist 1 or there are a variety of line fault Diagnostic aid 1 The fault code cannot clear failure is a fault if the breakdown of key check whether there 15 loose in the wire harness connector 2 According to the steps examination no abnormal situation 3 The maintenance process don t ignore automobile maintenance cylinder pressure mechanical ignition timing and the influence on the system 4 Replacing ECU test If fault code can remove the fault location fault code in the ECU if still unab
167. mbered 1 2 3 4 5 6 7 8 9 These numbers indicate 0 100 0 200 0 300 and so on The tapered end of the thimble has 25 lines marked around it Each mark equals 0 001 in One complete turn of the thimble will align its zero mark with the first mark on the sleeve or 0 025 in To read a standard inch micrometer perform the following steps and refer to Figure 27 1 Read the sleeve and find the largest number visible Each sleeve number equals 0 100 in 2 Count the number of lines between the numbered sleeve mark and the edge of the thimble Each sleeve mark equals 0 025 in 3 Read the thimble mark that aligns with the sleeve line Each thimble mark equals 0 01 in NOTE If a thimble mark does not align exactly with the sleeve line estimate the amount between the lines For accurate readings in ten thousandths of an inch 0 0001 in use a vernier inch micrometer 4 Add the readings from Steps 1 3 Telescoping and Small Bore Gauges Use telescoping gauges Figure 28 and small bore gauges Figure 29 to measure bores Neither gauge has a scale for direct readings Use an outside micrometer to determine the reading To use a telescoping gauge select the correct size gauge for the bore Compress the movable post and Care fully insert the gauge into the bore Carefully move the gauge in the bore to make sure it is centered Tighten the knurled end of the gauge to hold the movable post in position Remove the gauge and measure t
168. mination of appropriate scale test guideline values lt 0 25L 1000Km 11 18 EFI SYSTEM OF SQR 472ENGINE 2 Characteristic data measure new 250 hours after the bench test Exhaust temperature characteristics of data set 350 C 850 C 350 C 850 C Mixed gas concentration sensor voltage Mv 750 920 71070 840 80 LUN 1 1 3 Sensor data The new sensor with the At room temperature the heating element 500V DC gt insulation resistance Exhaust Exhaust temperature 350C 350 Exhaust temperature 350C 151 omen ang tae Exhaust temperature 850 C sensor joint The power supply Rated voltage m v voltage on the plug Working voltage 12 14 Working voltage up to 1 of the total life can be maintained the exhaust 15 temperature lt 350 To maintain the working voltage of up to 75 seconds exhaust temperature lt 350 C Teve II The working voltage is 13V the heating current at thermal equilibrium exhaust temperature is 35 C the exhaust velocity of about 0 7M s The working voltage is 15V the heating current thermal equilibrium 350 C the exhaust of greenhouse 5 gas flow velocity of about 0 7m s Fuse Fuse filament heating circuit Fuse filament heating circuit circuit 4 The use of life Oxygen sensor life associated with gasoline lead content see the following table Gasoline lead content g L Life km 30000 50000 lt 0 005 gasoline 160000
169. mp i Eg a n Timing Mark 3 3 Install the tension pulley After adjust the tension of timing belt install the tension pulley bolt and tighten it with the torque specified Adjust the tension of the timing belt acording to the following instruction and install the tension pulley 3 3 1 As indicated in the figure make the tensioner swing to the right with a screwdriver so that the distance between the edge of the tension pulley and the circular arc of the water pump body is 8mm and then tighten the tension pulley bolts with the torque of 2543Nm 6 11 ao Chery QQ Service Manual ETH EIE 3 3 2 Rotate the crankshaft along the rotating direction of the engine for 2 rounds so that the timing mark on the timing gear of camshaft and crankshaft is matched respectively and then tighten the crankshaft belt pulley bolts 3 33 The force required to press down the central position between the 2 pulleys at the 1n tension side of the timing belt for about 5mm is Reference 19 6 29 4N 2 0 3 0kg Notice when the deflection can not reach the standard it is necessary to adjust the fixing bolt of tension pulley mentioned above Tighten the fixing bolt of the tension pulley with the torque as specified The tightening torque is 254 3N m 3 4 Assembly of Timing Belt Back Plate Notice Install the timing belt back plate in the direction as indicated in the right figure 3 5 Install the torsional damper with special tools 3 5
170. must repeat the above steps A simple method to measure unloading joints digital multimeter to Ohm two probes are respectively connected regulator AD BC pin 20 C rated resistance was 53 5 3Q 7 Heated oxygen sensor 1 Structure diagram and pin s sume Ou SVS RA Heater pin A From the main relay power supply V RLY LSH DOWN PWM VL 5 0 OWN Lu 1 X 3 VL 5 0 OV N_ 1 4 Sensor signal 3 Sensor ground Black 1 Heater 2 Heater White White 2 Installation position Exhaust manifold tail before the three way catalytic converter 3 Working principle The sensing element of the oxygen sensor is a kind of porous ceramic tube tube wall is surrounded outside of engine exhaust the inside atmosphere Sensing the ceramic tube wall is a kind of solid electrolyte with electric heating elements see picture 11 17 11 EFI SYSTEM OF SQR 472ENGINE The oxygen sensor is the oxygen 1on concentration sensing ceramic tube inside and outside the difference into voltage signal output implementation When the sensing ceramic tube temperature reaches 350 which has the characteristics of solid electrolyte Because of its special material the oxygen ions can freely through the ceramic tube It is the characteristic the concentration difference into potential difference thus forming electrical signal output If the gas mixture of concentrated The ceramic tube and oxygen ion
171. n Fuel injector removal Use Slotted screwdriver to remove snap spring Remove fuel injector from fuel rail with injector assy Fuel injector assembly install Install fuel injector into the fuel rail with injector assembly Press the snap spring into groove of fuel E injector snap spring i 7 5 Fuel injector 45 222 joi Fuel rail with injector assy E 8 FRONT WHEEL FRONT BRAKE SUSPENSION STEERING Overhaul Info uu 8 1 Brake uuu Gu due dE 8 4 Troubleshooting 8 2 8 7 PRONE WCC ss ades 8 3 SECC ne 8 12 Overhaul Information Operating cautions Notes Securely support the vehicle when overhauling the front wheel and suspension system e Refer to chapter10 for overhaul and inspection of lighting instruments and switches Do not overexert on the wheel Avoid any damage to the wheel When removing tire use the special tire lever and rim protector Maintenance Standard Item Standard Service Limit Rim Longitudinal 0 8mm 2 0mm Vibration Lateral 0 8mm 2 0mm Remained groove 3 0mm 12 0 5 51 82 5 3 5 12 0 5PSI 82 5 3 5KPa Front brake Free play brake lever 0mm NEN Tire pressure Tightening Torque Nut Tie rod 20 30 Lock nut steering stem 20 30N m Nut front wheel axle 180 200 N m Fixing
172. n hole of the connecting rod assemble according to the group mark and direction mark of piston and connecting rod 5 1 1 2 Assemble the piston and the connecting rod with special tools shown in the right figure 5 1 1 3 Adjust and assemble the piston and connecting rod as indicated in the right figure Spread the piston pin with oil and then assemble the piston and connecting rod with a oressing machine Notice When pressing in the piston pin make sure the fitting direction is correct When the piston pin is pressed into the piston the small end of the connecting rod should be heated to 300 and the pin should be aligned properly 5 2 Install the first and second pistion ring and the oil ring according to the following instruction 5 2 1 Installation of piston ring Make the side with marks face upwards and then fix it with piston pin tools 2 2 2 Mount the steel tape combined oil ring bushing ring lower lower blade upper blade firstly and then mount the second gas ring and finally mount the first gas ring Opening angles of rings are shown in the figure Ring Front Bushing Ring 6 47 Upper Blade Mark Mechanical Part of SQR 472Engine 1 Ring 2nd Ring Oil Ring 2nd Ring Rear lt Chery QQ Service Manual Mechanical Part of SQR 472Engine ERI EIE 5 5 Resemble the crankshaft main bearing crankshaft crankshaft bearing bushing and
173. nd tighten the 8 bolts in the order as indicated in the right figure and with the specified torque Torque 6 1N m 4 Inspection of valve 4 1 Standard valve clearance Valve clearance 0 18 0 05 4 2 Make sure that the timing mark on the camshaft driving gear is aligned with that on the camshaft driven gear Gear of Exhaust of Intake 4 3 Inspect the valve clearance as specified in the figure below with the feeler gauge 4 4 Rotate the camshaft for a round to the position as indicated in the figure and then measure the valve Lo Chery QQ Service Manual Mechanical Part of SQR 472Engine clearance once again If the clearance exceeds the standard value adjust it by replacing the adjustment gasket Notice The position at which the measurement result exceeds the standard value as well as the measurement result should be recorded 4 4 1 Rotate the camshaft and make the cam head of the cylinder which exceeds the standard value faces upwards and the opening of the valve tappet face inwards 4 4 2 Rotate the crankshaft and press down the valve tappet with the crown head of the cylinder cam 4 4 3 As indicated in the right figure put special tools on and around the valve tappet from the inside of the cylinder head and then rotate the crankshaft so that the crown head of the cam face upwards Press the valve tappet with special tools and hold on 4 4 3 1 Pry out the adjustment gasket
174. ne ETH EIE 2 2 Remove the engine oil drainer engine oil collector gasket Notice The collector gasket is nonreusable 2 3 Remove the engine oil pump assembly and the engine oil pump gasket 2 4 Remove the rear oil seal bracket 3 Cleanup 3 1 Remove the old cushion from the pan pump and oil pan bracket with a scraper or shovel Notice Don t let the fragment of the cushion fall into the cylinder 6 32 s Chery QQ Service Manual Mechanical Part of SQR 472Engine 4 Disassembly and Assembly of Engine Oil Pump 4 1 Structure Diagram T 20 1 5 Seal Ring Engine Oil Pump Cover Sheet Engine Oil Pump Inner Rotor Engine Oil Pump Outer Rotor Cotter Pin Components which may Oil Drain Valve Spring base en Oil Drain Valve Spring Slide Block Crankshaft Front Oil Seal Engine Oil Pump Housing Unit N m kg cm G 4 2 Disassembly 4 2 1 CO O ring Notice The O ring is nonreusable 4 2 2 Remove the oil pump cover Notice If the screws are tightened use a screw driver to remove them as indicated in the figure 4 2 3 Remove the inner rotor outer rotor of the engine oil pump 6 33 3 Chery QQ Service Manual CHERY zi ETH EIA 2 4 Remove the cotter pin Notice The cotter pin is nonreusable Notice When removing the cotter pin be careful not to let the spring or the spring seat spring out or fall off abruptly
175. ng and voltage as shown m the following table Aperture 0 1 40 5 0 7 80 85 Fully open 0 20 30 Voltage V 0 33 0 78 Limit data measure value unit Mechanical angle between two extreme positions two extreme positions Slide arm current license 40 130 Characteristic data Slider protecting resistor slider at 710 1380 ano ff Operating temperature J40 1 ON gt wm voltage ratio we EN voltage ratto ee ee increase rate s e 5 The malfunction phenomenon and the judgment method 1 The fault phenomenon can not enter the idle state or step on the accelerator accelerate the powerless 2 The cause of failure of internal short circuit or open circuit sensor or throttle body to the engine control unit Connection or short circuit breakers 3 Note repair is not removable solar term door position sensor 4 A simple method to measure The power supply voltage measurement sensor A and B ends of the 5V Resistors A and B ends of the value is about Signal C solar term door idle position of voltage between 0 3 0 7V Signal C is fully open when the voltage to ground between 4 05 4 75V 11 14 11 EFI SYSTEM OF SQR 472ENGINE 6 Idle speed control motor 1 Diagram and pin m Lice d fi ES r iU T 99 2441413 F ERE S B DUUM 1 19 STPA POS D0 tcU
176. nister control valve installed in the pipe hanging on Must be installed with flow direction in accordance with the provisions the installation direction recommended vertical flip 1 e the plug downwards vertically Must through the appropriate measures such as filtration purification to prevent foreign bodies such as particulate matter from the carbon canister or hose into the carbon canister control valve Recommended to install a corresponding protective filter on the carbon canister outlet mesh size 50 m 6 Fault phenomenon and judgment method Fault phenomenon function failure 11 27 11 EFI SYSTEM OF SQR 472ENGINE General failure due to foreign body into the valve leading to corrosion or poor sealing etc Repair note 1 must be installed with flow direction in accordance with the provisions 2 when the body as black particles leads to a control valve failure need to replace the control valve please check the carbon canister status 3 repair process to avoid water oil and other liquid into the valve 4 in order to avoid solid transfer sound recommend the carbon canister control valve installed in the pipe hanging on A simple method to measure remove electric connector digital multimeter to Ohm two one two pin the carbon canister control valve respectively 20 C rated resistance was 26 3 12 The engine control unit ECU 1 installation position The cockpit 2 principle of work Multi point sequ
177. nition ECU Pin Connection point description Connection point description 1 The power of 1 Oxygen sensors downstream signal 8 Upstream oxygen sensor heater 9 The lower the oxygen sensor heater Input 12 The evaporator temperature signal 13 The evaporator temperature signal Earth 19 Stepper motor coil A Output 60 _Inletairpressure signal Input 20 Stepper motor coil A Output 21 The main relay power Output 22 After the ignition is switched power supply Input 23 The 3 cylinder output Output 26 The carbon canister control valve control Output 67 Main relay Output signal 27 Crankshaft signal Eath 68 The air conditioning compressor relay Output 29 Crankshaft signal input Output 31 The cooling water temperature signal Input 32 Solar term door position signal Earth 36 Stepper motor coil B Input output 37 The lower the oxygen sensor signal 38 Solar term door position signal 11 5 11 EFI SYSTEM OF SQR 472ENGINE 11 EFI SYSTEM OF SQR 472ENGINE Chapter 2 The working principle of engine management system components 1 Water temperature sensor 1 Diagram and pin Water temperature sensor EET al E ari ECUX173 TCO GND 2 Installation po Installed in the cooling water flow rate is high and can correctly reflect the engine cooling water temperature such as the water outlet of the engine or the engine cooling system circuit 3
178. njector circuit shorted to ground fault code P0267 results Connect the diagnosis instrument ignition switch is in the ON Dial the joint stiffness of injector on wire harness using a multimeter to check the connector SM1 pin voltage and power for a uli Next step few pieces of value is a 12V Check in between a cylinder injector connector SM pin and the main relay line is open circuit or short circuit to ground Using a multimeter to check a resistor Next step Diagnostic aid between the fuel injectors for cylinders No Replace injector SM1 and SM2 pins at 20 C in 14 5 0 5 ohm Whether the 3 7 voltage with a multimeter to check a cylinder injector connector 2 pin 4 and the negative pole of the power apply will be Between the 61 pin check cylinder ul Repair or Repair or replace the wire harness _ the wire harness Next step injector connector 2 pin and the ECU line is broken or the power supply or short circuit to Bn ground 11 53 11 EFI SYSTEM OF SQR 472ENGINE 2 29 Three cylinder injector circuit for the power supply circuit fault code P0268 Serial Operation steps Test Next step number results Connect the diagnosis instrument Next step ignition switch is in the ON Dial the joint stiffness of injector on wire harness using a multimeter to check the connector SM1 pin voltage and power for a fe
179. nternal control read only memory fault fault code P0605 M results Connect the diagnostic instrument wait Next step for 30 seconds or more to the ignition switch is in the ON Switch off ignition disconnect the M replacement of ECU battery positive power supply waiting for more than 30 seconds to the ignition No switch is in the ON Check whether there 15 a fault code 2 45 Fault display lamp control circuit fault fault code P0650 results 1 Connect the diagnosis instrument the MEL S UEM ignition switch is in the ON Pulling off the fault lamp connector pin Tostep 00025200 voltage check 1 and dia warm cathode Next step 7 fe will is about 12V i 3 Check the main relay power Repair or the wire harness circuit short circuit open circuit fault exists To step 5 Check the 2 pin and ECU pin X 70 Repair or replace the wire harness association exists between the open circuit re fault Check the fault lamp if there is a problem Diagnosticaid Replace faulty lamp 11 62 Serial number 11 EFI SYSTEM OF SQR 472ENGINE 2 46 Air conditioning evaporator temperature sensor for short circuit or open circuit power line fault code P1535 Operation steps Connect the diagnosis instrument the ignition switch is in the ON The observation data stream in the evaporator temperature and whether the engine temperature quite numerical and then temperature Note
180. ntrol circuit shorted to ground fault code P0031 38 2 2 Upstream oxygen sensor heater control circuit for the power supply circuit fault code P0032 39 2 3 The lower the oxygen sensor heater control circuit shorted to ground fault code P0037 39 2 4 Downstream oxygen sensor heater control circuit for the power supply circuit fault code 40 2 5 Manifold pressure sensor circuit shorted to ground fault code P0107 40 2 6 Manifold pressure sensor circuit for the power supply circuit fault code P0108 41 2 7 Intake air temperature sensor circuit shorted to ground fault code P0112 41 2 8 Intake air temperature sensor circuit for the power supply circuit fault code P0113 42 2 9 Coolant temperature sensor circuit output range character error error code P0116 43 11 EFI SYSTEM OF SQR 472ENGINE 2 10 Coolant temperature sensor circuit shorted to ground fault code P0117 44 2 11 Coolant temperature sensor circuit for the power supply circuit fault code 0118 44 2 12 Coolant temperature sensor circuit discontinuity fault code P0119 45 2 13 Solar term door position sensor circuit shorted to ground fault code P0122 45 2 14 Solar term door position sensor
181. oen vr ota eats uve obo ow eot 2 2 Meaning ol Marks and 3 2 De Cid MC ii KO P T ETA 4 Chapter 2 Disassembly Assembly and M3I UDBang0 uu u u 6 Mey lilii T PRI 0 6 Dili uuu m 6 NN atv 7 De TIS LA ATION u Lm 10 uuu ua RC 13 13 PAN BEC 14 Dg MANS eA CITUR 16 2 Ronnie PS tono VAN E S aaa i 19 22 jJ OU u TETTE 22 IDISASSEMIDLY PT 23 CN DIS acetic apaun nmay uu Wah ee E rich sina tact ns weet mata unstiu aan nb ea 23 PI sss sss sss sss 29 i BIER 29 LIBI Susp c 20 S EU T 9 M 20 T u u uuu uu us uu 29
182. of the road Party member on the coolant temperature Replace the sensor value changes the display values should be increased after the engine coolant temperature and elevated 2 13 Solar term door position sensor circuit shorted to ground fault code P0122 rumpor results Connect the diagnosis instrument the ignition switch is in the ON The observation data stream of solar term door is Next step opening value is between 4 10 numerical and No To step 5 models have different Slow down on the accelerator to the fully open the Yes Next step observation data stream of solar term door Is opening whether the data with the throttle opening To step 5 increases to about 85 95 specific data and models are different Repeat step 3 the observation data stream of solar term door is opening whether the existence Nextstep ee value changes in the process of change Dial the joints of I solar term valve position wire harness check the ECU 452 387 harness 1_32 pin connected circuit between a a c pin No Next step on the sensor circuit breaker or whether rg respectively on the power circuit Using a multimeter to check voltage a and b pins Replace the sensor of the joint between the value is about 5V Diagnostic aid 11 45 11 EFI SYSTEM OF SQR 472ENGINE 2 14 Solar term door position sensor circuit for the power supply circuit fault code P0
183. of the procedures in this manual specify special tools In many cases the tools 1s illustrated in use Those with a large tool kit may be able to replacement However in some cases the specialized equipment or expertise may make it impractical for the home mechanic to attempt the procedure When necessary such operations are recommended to have a dealership or specialist perform the task It may be less expensive to have a professional perform these jobs especially when considering the cost of equipment When purchasing tools to perform the procedures covered in this manual consider the tool s potential frequency of use If a tool kit Is just now being started Consider purchasing a basic tool set from a quality tool combinations and offer substantial savings when complicated specialized tools can be added Screwdrivers Screwdrivers of various lengths and types are mandatory for the simplest tool kit The two basic types are the slotted tip flat blade and the Phillips tip These are available in sets that often include an assortment of tip size and shaft lengths As with all tools use a screwdriver designed for the job Make sure the size of the fastener Use them only for driving screws Never use a screwdriver for prying or chiseling metal Repair or replace worn or 1 5 1 SERVICE INFORMATION damaged screwdrivers A worn tip may damage the fastener making it difficult to remove 4 NOR PHILLIPS 11 TIP Phillips head screws are o
184. oir Tank Remove Remove 2 bolts 3 Reservoir tank Remove front cover assembly 2 11 y Remove water hose of reservoir tank Remove reservoir tank discharge coolant Flush reservoir tank Install reservoir tank Adding Coolant Add coolant through filling port Start the engine and discharge air from cooling system Check from filling port that air 1s fully discharged from cooling system and install the radiator cap Remove reservoir tank cap and add coolant till the full limit Note Check coolant level when the vehicle is on an even ground Air Discharge Discharge the air from cooling system according to the following steps 1 Start the engine and run it several minutes at idle speed 2 Quickly increase throttle 3 4 times to discharge air from cooling system Add coolant till filling port Repeat step 2 amp 3 till no more coolant can be refilled Check coolant level in reservoir tank and refill till upper limit 6 Install reservoir tank cap Un dU 4 5 Reservoir tank Reservoir tank cap o 4 4 COOLING SYSTEM Cooling System Chart a 1 5 5 a gt m g gt A S m e E ac 54 m 52 Ti Nin JS gr gt E gt YUP JIOAJ9S81 J JBJA 4 6 4 COOLING SYSTEM COOLING SYSTEM ASSEMBLY DISASSEMBLY INSTAL
185. olerance Clearance or Value of Remark Interferenc The hole should be processed along Connecting rod body hole Value of Interferenc with the connecting rod body 0 008 0 032 0 032 Bolt Bar 08 08 6 40 023 7 Fit Clearance between Connecting Rod Cover Hole and Bolt Bar Name of Component Size and Tolerance Clearance or Value of Remark Interferenc l The hole should be processed along Connecting rod cover hole Clearance with the connecting rod body n 0 005 0 029 Bolt bar 08 08 fs 0 014 8 Radial Clearance of Camshaft Bearing Name of _ Size and Tolerance Clearance or Value of Remark Interferenc 0 021 1 bearing cap Cylinder Head 26H Clearance 0 020 0 054 1 bearing cap Camshaft Intak v Cylinder Head 2 3 4 amp 5 bearing caps inder Hea Clearance Camshaft 0 020 0 020 0 054 24 3 4 amp 5 bearing caps amsha 02316 0 033 0 021 1 bearing cap Cylinder Head p29H Clearance _ 0 020 0 020 0 054 bearing cap Camshaft 0295 0 033 Exhaust 0 021 27 3 4 amp 5 bearing caps Cylinder Head 23H Clearance 0 020 0 054 0 020 274 34 4 amp 5 bearing caps Camshaft 0234 0033 9 Fit Clearance between Hole Tappet Name of Component Size and Tolerance Clearance or Value of Remark Interferenc 021 Cylinder Head Hole T 0 000 0 020 0 054 28 0 033 6 51 s Chery QQ Service Manual Mechanical Par
186. olt EM 27 20 1 5 28 Front lifting lug bolt 20 1 5 29 Exhaust pipe nut 25 1 5 30 Exhaust pipe thermal shroud bolt 6x1 1005 Bolt on crankshaft pulley amp torsional damper M12X1 25 assembly un e ga p 32 6 1 ater pump pulley bolt ater temperature sensor 12 1 5 15 1 5 o 3 34 pressure switch 3042 Spark plug 14 1 25 35 20 1 36 Fixing Bolt of spark plug cover board 2 50 5 37 intake pipe front bracket 201 5 38 201 5 39 throttle cable 6 1 40 gas oil spearator bracket 6 1 41 throttle valve casing 6 1 Oxygen sensor 18 1 5 Bolt intake temperature amp pressure sensor 44 Fixing bolt of fuel guide rail 42 402 43 3 Bolt intake pipe rear bracket M4 M 16 2 2 3 1 4 1 1 4 1 4 2 2 A 1 1 2 7 3 8 8 8 8 8 6 6 6 8 8 6 6 6 6 6 UA 5 5x Ignition coil bolt 6 54 Lo Chery QQ Service Manual Mechanical Part of SQR 472Engine Chapter 6 Positions on SQR472 Engine to be Lubricated Type of lubricating oil Engine lubricating oil Designation of lubricating oil SAEIOW 30 50 SF Class No Position to be lubricated Inner wall of cylinder hole 7 Piston and piston ring Crankshaft main neck Se BED BE BE BE BE Connecting rod shaft neck 0000000 Upper amp lower main bearing bushing Gnsidey
187. on 11 EFI SYSTEM OF SQR 472ENGINE CONTENTS Chapter Description the SIMK 31 engine management system 1 aa TOTEM 1 A The basic components of electronic control system 1 The SIMK 31ECU module input and output electrical diagram 1 15 Themput and output SIMK 31 BCU modules tise o 1 2 Bngimemanapement System diac ram es 2 95 Wiring diaptam ol ECU uuu ER i Aet ee 3 4 ECU function module layOUL epe cR e A E A 4 os Pin output de Mimi on ECU r T RAGA 5 Chapter 2 The working principle of engine management system components Y the yy ale tempera SeIS0D2 u uuu u Ete butt hatt dtm Cb em 7 DAS Clam SMa lh OD SMS Ol MI EI 9 S the camshatt postton Senso cie ee id NL 11 A Tine trone Dody pcc 13 beri pos MONS sue od medien 15 6 1dIe Speed ues 15 TANG AVEC OXY SCHIS CMS OL se ME 17 8 the intake air temperature and absolute pressure sensor
188. ore the coolant properly and keep it away from reach of children Check radiator fins for mud block and or damage Correct the bent fins Clean off the mud With water and compressed air Replace with a new one if the damaged fin area reached 20 The overhauling of the water pump can be done without removing the engine Add coolant through reservoir tank Do not open the radiator cap except when disassembling the cooling system for adding or drainage of coolant Do not stain the plastic parts with coolant In case of any coolant stains flush with water immediately After disassembly of the cooling system check the joints for leakage with a radiator cap tester available 1n the market Refer to Chapter 10 for overhauling of temperature transducer Inspection standard Full capacity 4500ml Pian Reservoir tank capacity 3300ml owe Standard densit Opening pressure of radiator cap 108 Valve open temperature Thermostat Full open Temperature Fulopenlft Fulopenlft lift 4 1 4 COOLING SYSTEM Trouble Shooting 4 Sharp rise of water temperature Faulty radiator cap Air In cooling system Faulty water pump Faulty thermostat thermostat 1s not open Clogged radiator pipe or cooling pipes Damage or clogged radiator fin Coolant 15 not enough Faulty or malfunction of fan motor No rise or slow rise of water temperature Faulty thermostat thermostat is not closed Faulty
189. ositive power supply pin and whether the circuit breaker Check the fan power supply circuit fuse 15 Repair or replace the wire harness intact Check fan relay 87 increased with No Next step the fan power line is open circuit or short Check the fan relay connector 64 between pin ECU X 687 pin line is open circuit No Diagnostic aid or short circuit to ground 11 65 11 EFI SYSTEM OF SQR 472ENGINE 3 The fault diagnosis according to the fault phenomena In this note the fault appears after the preliminary examination Before starting the engine fault diagnosis according to the fault phenomena should be the first step a preliminary inspection 1 Confirm the engine fault indicator light work 2 Diagnosis instrument for inspection to confirm the absence of fault fault information record 3 Confirmed the existence of fault phenomena of complaints and confirm that the failure condition Then the visual inspection 1 Check whether the fuel pipeline leak 2 Check that the vacuum line whether there 1s fault kink the connection 15 correct 3 Check the intake pipeline is blocked leakage crushed or damaged 4 The high pressure line check ignition system 1s broken aging ignition sequence is correct 5 Check the wiring harness ground 15 clean firm 6 Check the sensor actuator connector 1s loose or poor contact Important if the above phenomenon exists then the fault phenomenon of repair work otherw
190. ot zero or infinity 1 e not short circuit open circuit state Connect the connector To start the engine into the tubing connected to the fuel gauge fuel pump observe whether work if it is not running check the pin if there 1s power supply voltage if the operation the idle condition check the fuel pressure is about 260kPa off the fuel pressure regulator vacuum tube whether fuel when the pressure is about 300kPa 14 The ignition coil Ignition coi L 1 92 ECU A31 IGC2 Supply ECUAR 1651 1 installation position Installed in the engine compartment 2 working principle Using double coil cylinder at the same ignition system 3 technical parameters Room temperature 23 typical working voltage of 14V the primary coil current 7A secondary output with 50pF load is 38K V 10 11 32 11 EFI SYSTEM OF SQR 472ENGINE 4 Installation notes Requirements for fixed bolt and nut firmly to prevent loosening caused by vibration ignition coil mechanical damage 5 Fault phenomenon and judgment method The high pressure line on the engine pulled out the spark plug on good will spark plug metal shell on the engine body by the spark plug spark ignition coil and the high voltage wire to judge whether good 15 Three way catalytic converter 1 Installation position Welding in the exhaust manifold pipe assembly 2 Working principle In the three way catalytic converter CO HC NOx respectively the reduction
191. over pull the bolt and clockwise rotate the timing gear with wrench And then align the timing mark of camshaft timing gear and the raised mark on camshaft cover i ni TE M I i x 2 E E fr i i l oft x F 1 i f KA C CONSUE WY DLE ay ae l i i i E P E i 2 5 2 Screw off the bolt of tension pulley and remove the tension pulley 2 6 Disassembly of timing belt Notice Do not use sharp tools like screwdriver during disassembly of belt sf AG Je i a otice Pay attention to following items during using Lk yt W A y gt the timing belt yU Aa li 1 L q ata 2 Do not bend the belt with small angle the rigging in belt will break Do not pollute grease and water because the using expectancy of belt 15 short Only clockwise rotate the engine after mounting the belt 2 7 Disassembly of crankshaft timing gear 6 9 Eus Chery QQ Service Manual Mechanical Part of SQR 472Engine ERI EIE 2 8 Inspect the timing belt carefully and replace new components under any of the following circumstances or when the mileage is up to the conditions of replacement 2 8 1 Chap of back side rubber 2 8 2 Chap of dedendum chap of separated cord fabric 2 8 3 Wearing gear missing and incomplete gear of cord fabric Chap Wearing
192. peration descriptions of cases about person accident Right Hand Right Hand Left Hand Left Hand SPECIAL Special Tool Special Tool TOOL Assembly Assembly Sub Assembly Sub Assembly Manual Transmission Manual Transmission Automatic Transmission Automatic Transmission Turbo Charger Turbo Charger RR LO Chery QQ Service Manual Mechanical Part of SQR 472Engine 3 Special Maintenance Tools C _ Name or symbol Engine disassembly and inspection auxiliary Mount on the engine service device stand Disassembly and assembly Engine service stand of engine Disassembly of camshaft Clamp hole wrench for camshaft timing gears timing gears Assembly of camshaft Oil Spring bushing puller seal Valve keeper remove tool Assembly and disassembly of valve spring retainer lock Auxiliary tools Assembly and disassembly wheel clam i of crankshaft gear Disassembly and assembly Valve guide punch pin l of Valve guide Axial Oil seal replacing device Oil seal base drive s Chery QQ Service Manual Mechanical Part of SQR 472Engine Piston pin puller E 5 9 CIC 2522 Embeded combination oll seal and helical gear puller Crankshaft pulley holding tool Wrench Water pump pulley locking wrench Disassembly and assembly of piston pin Installation of oil seal Disassembly and assembly of crankshaft pulley Disassembly and assembly of crankshaft driven gear
193. perature is high If gasoline is stored in the fuel tank it is very easy to be oxidized may cause the injector blockage or damage 5 Installation notes The fuel injector must must use certain plug not mix In order to facilitate the installation recommended the ring 15 connected with the fuel distribution pipes and clean the oil surface of the lower O ring is connected with the intake manifold mounting hole is coated with no silicon to clean oil coated with no silicon surface fuel injector and the intake manifold fuel distribution pipe mounting hole Be careful not to let the oil pollution inside the injector and nozzle The fuel injector to be perpendicular to the direction of the oil injector seat into the injector seat and then use the fuel injector 1s fixed on the spray clip Oil filter base Be careful The injector clamp by positioning for axial positioning clamp and axial and radial locating clamp should avoid misuse Fuel injector for the axial positioning of the installation slot should ensure bayonet clip intermediate completely card into the injector card slot clamps on both sides of the complete card into the outer edge flanging injector seat 3 And injector axial and radial positioning requirements should be used for the axial and radial locating clamp and the positioning of injector and fuel injector seat positioning pins are respectively located at the card groove clip the corresponding installation 4 If fuel
194. plosive so work should be done in a well ventilated place Be careful that your hands or clothes not get nipped by the turning or movable parts of the driving system Note The vehicle should be parked on hard and level ground Replace parts regularly Parts replacement time is subject to time or kilometers whichever occurs first 3 1 3 CHECKS amp ADJUSTMENT Regular Maintenance Table The table below lists the recommended intervals for all the required periodic maintenance work necessary to keep the vehicle at its best performance and economy Maintenance intervals are expressed In terms of kilometer miles and hours whichever occurs first Note More frequent maintenance may be required on vehicles that are used In severe conditions Initial Remarks 250km 500 km 1000 km Initial 20 Every 100 hours hours 0 18 0 05 EX 0 25 0 05 850 r min 50r min No carbon deposit Gap 0 9 1 lmm am nomin Fuel Hose carburetor M 1 B weas j 00 RR lcge RR Water Hose amp Pipes tt m Coolant R every 2 year I Check and adjust or replace if necessary R Replace C Clean 3 2 3 CHECKS amp ADJUSTMENT Inspection amp Maintenance O Interval Standard Part Item Daily 1 2 Year Annual Steering Steering Operation agility O O System wheel Steering O JO 202 System Installation condition of steering system Sway ofb
195. r Components which may Blanking cover i tb d Camshaft bearing cap not be reuse Unit N m kg Exhaust camshaft assembly nit N m kg cm Intake camshaft assembly Camshaft oil seal 10 Axial spring retainer ring 11 Saddle washer 12 Intake camshaft sub gear 13 Transmission ring Chery QQ Service Manual 2 Disassembly 2 1 OD Cylinder head chamber cover assembly 2 Disassembly sequence of cylinder head chamber cover 2 2 Remove the camshaft timing gear with special tool Notice The special tool should be made as indicated in the right figure Use the special tool to prevent the camshaft from rotating 2 3 Remove the camshaft bearing cap 2 31 The marks on the camshaft gear should match with each other as indicated in the right figure Gear of Exhaust Mechanical Part of SQR 472Engine Timing Mark Gear of Intake Camshaft Camshaft CHERY ERI EIE 2 3 2 Position the main sub gear on intake camshaft with bolts as can be seen from the right picture Notice In order to eliminate the radial force of the camshaft the camshaft should be kept at the horizontal position in the course of disassembly so as to prevent the damage caused by the excessively high radial force 2 4 Disassemble the bolts in the order as indicated in the right figure and then disassembly the camshaft bearing cap 2 5 Remove the spark plug 2 6 Disassemble the sub ge
196. r as input part for a variety of physical measurements temperature pressure and turn it into a corresponding electrical signal the role of ECU 1 to accept input signal sensor processing and calculation according to the program to generate a control signal output corresponding to the power drive circuit power driving circuit 1s driven by the actuator perform different actions make the engine run in accordance with the established control strategy at the same time fault diagnosis system of ECU for each component or control functions of the system for monitoring once detected faults and confirmation the memory fault code call Iimp home function when the detected fault 1s eliminate then normal recovery using The basic components of electronic control system The electronic controller ECU Injector Crank position sensor Oil rail Camshaft position sensor Carbon canister control valve Intake manifold Oxygen sensor Temperature sensor Three way catalytic converter Inlet pressure temperature sensor Ignition coil and the high voltage wire Idle speed regulator Oil pump assembly solar term door position sensor solar term door assembly Knock sensor Temperature sensor The SIMK 31ECU module input and output electrical diagram 1 Input and output module SIMK 31ECU The main sensor input signal in SIMK 31 system of ECU include Inlet air pressure signal Intake air temperature signals solar term door position signal Coolant
197. r or replace the wire harness Next step Diagnostic aid No Replace the sensor 11 EFI SYSTEM OF SQR 472ENGINE 2 48 Air conditioning high voltage switch or air conditioning clutch relay line fault fault code P1545 Serial number Operation steps Test Next step results Connect the diagnosis instrument Next step ignition switch is in the ON Dial the fan connectors relay on wire To step 4 harness multimeter voltage check fan relay Next step connector 85 867 pin and additional power between the value 1s about 12V Check the fan relay between the 857 pin and the 877 pin of main relay circuit is open circuit or short circuit to ground check the No Io step 5 fan relay between 86 positive power supply pin and whether the circuit breaker Check the fan power supply circuit fuse 1s intact Check fan relay 87 increased with No Next step the fan power line is open circuit or short Check the fan relay connector 852 between Repair or replace the wire harness pin and ECU X 687 pin line is open circuit No Next step or short circuit to ground High voltage switch circuit and the switch to Replace the switch check whether the damage to the air Diagnostic aid conditioning compressor 11 64 11 EFI SYSTEM OF SQR 472ENGINE 2 49 Cooling fan relay line fault fault code P1624 Serial Operation steps Test Next step number results 1 Connect the diagnosis instrument Next step ignition switch
198. r with special Failure to replace 5 cleaning analyzer to check whether the No Next step injector is there is a leak plugging or flow ultra difference phenomenon a Check the fuel situation observe whether Replace fuel the failure phenomenon was caused due to Next step gas Check the engine cylinder pressure of each engine cylinder pressure observe whether there are differences in the larger Compliance with the specification when ignition ignition sequence checking engine Maintenance of the ignition timing Check the 19 X 14 pin on the iron is Y normal No Maintenance of the corresponding line 3 9 Normal starting part load such as air conditioning when idling instability or flameout General fault location 1 Air conditioning system 11 74 11 EFI SYSTEM OF SQR 472ENGINE 2 Idle speed regulator 3 The fuel injector The general procedure of diagnosis Serial Operation steps Test Next step number results 1 Remove the idle adjuster check the solar term door body idle speed and idle bypass No Next step Observation on the output power of the EE the ai engine 1 increased when air Next step conditioning the phenomenon of EFI system diagnosis instrument of ignition advance angle injection pulse width and air conditioning wiring harness end is a high level signal 3 Disconnect the electrical control PIT Next Xl 687 pin connecting line check the ZI a
199. re value Replace the sensor changes the display values should be increased along with the engine air inlet temperature 11 41 11 EFI SYSTEM OF SQR 472ENGINE 2 8 The intake air temperature sensor circuit for the power supply circuit fault code P0113 number results 1 Connect the diagnostic instrument ignition switch pope is in the ON The observed data stream air temperature Whether in the 1 in intake pipe of equivalent No Next step temperature numerical and when the engine temperature Note if the display value of gastrointestinal constants that there may be line short circuit fault 3 Dial the joint air inlet pressure sensor on wire harness electrical multimeter check sensor 3 and 4 pins of value is commensurate with its No Replace the sensor temperature with specific reference to the evaluation of repair manual Dial the joint line beam The temperature sensor using a multimeter check resistance sensor a and No Nextstep 00 tst b pins between whether the value is about 5V pon Check the ECU 562 548 between closure and sensor connector pin 3 4 whether the harness circuit breaker No Mense Start the engine idle running To observe the diagnostic instrument air temperature value No Replace the sensor changes the display values should be increased along with the engine air inlet temperature 11 42 11 EFI SYSTEM OF SQ
200. reaction of oxidation of harmless CO2 2 and N2 containing precious metal platinum in the carrier Pe and Pd and rhodium Rh of noble metal catalysts Reaction formula of it as follows 2CO2NO 2CO2N2 4HCIONO 4CO22H205N2 There is a close relationship between the catalyst efficiency height and temperature the use of harmful components from the exhaust gas temperature to ideal operating condition transformation temperature more than 300 degrees Celsius and the catalytic converter for 400 700 degrees the maximum allowable temperature is 850 920 degrees Celsius or noble metal may produce thermal aging mainly due to activation surface temperature failure and alumina sintering Catalytic converter conversion efficiency and air fuel ratio in the ideal air fuel ratio 14 7 1 narrow area is 14 5 15 0 catalyst for CO HC and NOx conversion efficiency reached the highest at the same time When the air fuel ratio 1s too thick the pollutant conversion Efficiency were decreased CO and HC is more obvious while too thin when CO and HC conversion efficiency significantly NOx was significantly lower 3 Installation notes Transport and installation should be light light forbid throwing If you hear the three way catalytic converter assembly has abnormal noise possible catalyst carrier rupture exploratory confirmation To add high quality gasoline engine failure to prevent poisoning catalyst influence the emission 4 Fault phenomenon and judgmen
201. rection to control the stepper motor moves thereby regulating the bypass channel cross sectional area and flow of air traffic The air flow in a linear relationship with the step There is a spring plug the back screw rod end see below Can be used 1n the plug the elongation direction of the force is equal to the stepper motor force and spring force the retracting direction can use force on the plug is equal to the step force minus the spring force of stepping 11 15 11 EFI SYSTEM OF SQR 472ENGINE Shell Cup shaped parts Plate Spring washer Stater assembly Bobbin 0 ring s Magnet wire Compression spring Rotor sleeve Front bearing M Sor Dust cover LG 25 Sy amm 4 a BN Le d EET wx NAE 55555 IP aM Um Nf 1 Rear bearing NS SAS SRS Ball bearing Sleeve bearing Shaft pin Rotor assembly 0 ring b Linear axis Rotor core idle speed actuator stepper motor profile 4 Technical parameters 1 Limit data __ Working temperature 125 Stepper motor plug contact the maximum number of transposon Characteristic data Resistance Resistance of 20 C each coil 20 Resistance of 20 C each coil each coil 4770 7 Each resistance operating temperature range 35 CAC GST o Normal working oitige m poo The bypass passage is opened at both ends of the kPa pressure drop 7 Gas pressur
202. rk the vehicle on level place measure the front toe in Toe in B A 0 10mm Toe in out of the range Adjust the locknut of tie rod Note After the toe in has been adjusted slowly run the vehicle to check whether the direction of vehicle can be controlled by steering wheel STEERING ROD LOCKNUT 3 10 3 CHECKS amp ADJUSTMENT Tire pressure Check the pressure of the tires with a pressure gauge Note Check the tire pressure after tires are cooled Driving under improper tire pressure will reduce Y Tire Pressure Gauge the comfort of operation and riding and may 3 cause deflected wear of the tires Specified pressure tire Frontwheel Rearwheel Pressure 96 523 5 140 5PSI 96 523 5 1420 5PSI OPTIONAL Frontwheel Rearwheel 82 5 3 5 12 0 5PSI 82 5 3 5 12 0 5PSI Tire Tread Check the tire tread h ight i i d a Over 3mm Tread Height if lt 3mm then Replace with new tires Jt x Note oi fff When the tread height is less than 3mm the tire should be replaced immediately 3 11 3 CHECKS amp ADJUSTMENT Wheel Nut and Wheel Axle 2 AXLE NUT Check front and rear wheel axle nuts for looseness Loosened axle nuts Tighten Tightening Torque Front wheel axle nut 180 200N m 18 3kgf m 20 3kgf m Rear wheel axle nut 180 200N m 18 3kgf m 20 3kgf m Sway of Wheel Bearing Li
203. ront position lamp Light bulb Stop lamp Brake light Rear position lamp 12 1 TROUBLESHOOTING Head Light Cannot Turn On e Broken fuse Open circuit with main cable Burnt Bulb Faulty Switch 12 2 12 LIGHTING AND SWITCHES 12 LIGHTING AND SWITCHES Replacing Bulb Headlight Bulb Headlight bulb will be very hot when it is turned on Do not touch it after 1t 1s Just turned off Operation should be done when the bulb is cooled down Remove headlight 13 5 Disconnect headlight Remove dust proof cap headlight connector circlip and replace with a new bulb Warning e Wear clean gloves when replacing bulb e stains on the glass surface may cause break of bulb Clean the stained surface with alcohol or 1isoamyl acetate e Besure to hold the socket firmly when removing the bulb Never pull the lead otherwise it may be pulled out of the terminal in the coupler Head lamp 12 V 55 Wx 2 Front position lamp 12V 5W Reverse the removal procedure for installation After replacing the bulb adjust headlight beam Inspection of Headlight Turn the ignition switch to ON position turn light switch to the illuminating position and check if the headlight is on ON Normal Still off short circuit of main cable or broken main cable 12 3 Front Turning Indicator Bulbs Remove headlight 13 5 Remove cover of headlight Replace front turning Indicator bulbs Front d
204. rst make sure the diameter 1s correct for the hole in the fastener Aster correctly tightening the fastener and aligning the holes insert the cotter pin through the hole and bend the ends over the fastener Unless instructed to do so never loosen a tightened fastener to align the holes If the holes do not align Tighten the fastener enough to achieve alignment Cotter pins are available in various diameters and lengths Measure the length from the bottom of the head to the tip of the shortest pin Internal snap ring plain clip Snap Rings and E clips 1 Snap rings Figure 1 are circular shaped metal retaining clips They secure parts 1 place on parts such as shafts External type snap rings are used to retain items on shafts Internal type snap rings secure 7 N WS parts within housing bores In some applications in J 4 addition to securing the component s snap rings of varying thicknesses also determine endplay These HN ee are usually called selective snap rings The two basic types of snap rings are machined 7 and stamped snap rings Machined snap rings Figure 2 can be installed either direction Because both SS AV ee faces have sharp edges Stamped snap rings Figure T SSS MEC ee thrust ZS es 3 are manufactured with a sharp and a round edge SS 1 When installing a stamped snap ring in a thrust 1 4 1 SERVICE INFORMATION application instal
205. rt and water passage 3 Routine Inspection 3 1 Cylinder Head Measure the flatness at each point with ring gauge as indicated in the figure Cylinder head 0 10mm Surface of intake exhaust manifold 0 10 mm 3 2 Valve Spring 3 2 1 Measure the square degree of valve spring with square Replace if it exceeds the specified value Limit 1 2mm 6 24 Chery QQ Service Manual 3 2 2 Measure the free state of the spring Standard value 37mm 3 3 Inspection of valve 3 3 1 Check if it is deformed or abrades Inspection of valve Unit mm Limit Item Standard value 0 10 IN 0 85 1 41 LM Pex 107136 _ 3 3 2 Check the clearance of valve guide and valve stem 3 3 2 1 Measure the inside diameter of valve guide with dial gauge the outer diameter of valve stem with micrometer caliper 3 3 2 2 Figure out the difference of measured values and the clearance If the clearance is beyond the specified value replace valve or guide Notice As can be seen from the right picture at measuring point work out the clearance of last abrasion part Standard value Limit 0 10 Valve guide inside 5 0 diameter mm Valve guide outer 05 0 diameter mm 0 056 IN 0 07 0 020mm Clearance 0 066 0 08 0 030mm 6 25 Mechanical Part of SQR 472Engine Ss Thickness of Measurement Top Position of Outer Diameter Measurement Point Measurement of Valve
206. same time to avoid fall down of the vehicle Park the vehicle on a level ground and securely support front part of the vehicle Removal Remove Front wheel 8 3 Front wheel hub 8 3 Front brake caliper 8 4 Boltl Shock absorber Bolt2 Nut to Bolt2 for Front Left Arm Upper Bolt2 Nut to Bolt2 for Front Left Arm Lower Remove steering tie rod ball pin slot nut 3 Remove steering tie rod Pull up joint knuckle from the driveshaft remove front left suspension assy 8 7 Nut 1 Bolt 1 Front left LE r Shock absorber Nut 2 va Bolt 1 Front left arm Nut 2 ILS Steering pie rod 8 FRONT WHEEL FRONT BRAKE SUSPENSION STEERING 1 COTTER PIN 3x25 2 NUT Rear wheel axle 21 BOLT FLANGE 10 1 25 50 3 FRONT WHEEL 4 FRONT BRAKE DISC 22 LOCKNUT 10 1 25 5 BOLT M1025 6 CIRCLIP 072 23 FLANGE 10 1 25 90 7 BEARING 8 FRONT STEERING 24 BUSH ARM 25 CENTER SPACER KNUCKLE L 9 FRONT STEERING KNUCKLE R 26 FRONT SHOCK ABSORBER 10 BOLT FLANGE 8 55 27 FRONT CV JOINT L 11 LOCKNUT FLANGE M8 12 NUT M10x1 25 28 FRONT CV JOINT R 13 PIN SPLIT 2 5x20 14 32 29 SUSPENSION PROTECTOR L 15 JOINT ARM BALL 16 SCREW CAP DRIVE 30 SUSPENSION PROTECTOR R AXLETREEMI2 17 PIN SPLIT 3x30 31 SCREW TAP ST4 2x20 18 FRONT LOWER ARM 19 FRONT LEFT ARM UPPER 2
207. ssemble the ECU remove the above battery first 5 minutes remove 2 ECU 3 after removal of the ECU storage 4 banned in the ECU online connection with any line A simple method to measure 1 Connect the connector Using engine data K line read engine fault recording 2 Remove connector Checking ECU connection line is intact focus on examination of ECU power supply grounding line is normal 3 Check whether the normal work of the sensor the output signal is credible the line 1s intact 4 Check the actuator is working properly the circuit 1s intact 5 The replacement of the ECU test 11 29 11 EFI SYSTEM OF SQR 472ENGINE 13 Electric fuel pump e A FERT US e S V 1 Installation position Through the flange bracket 1s fixed in the tank Fuel pump relay Get an electric shock V BAT a BAT SWB Fusepump Coil ECU 1 69 Electric fuel pump with two pin connect the fuel pump relay Two stitches beside the pump shell engraved with and respectively connected with positive and negative 2 Working principle Electric fuel pump is composed of pump and the end of the DC electric motor a blade cover integrated check valve pressure relief valve and the electromagnetic interference element and other components see below Pump and motor are coaxially arranged and closed in the same chassis Around the pump and motor shell are filled Full of gasolin
208. ssembly of Camshaft Cover Tighten the bolts in the order as indicated in the right figure and with the specified torque 3 6 2 After spreading oil on the blanking aperture of cylinder head and the mounting surface of blanking cover press the blanking cover with special tool Notice The blanking cover should be installed in the direction as indicated in the right figure After being pressed the blanking cover should be Ix mm higher than the surface of thecylinder head 3 7 Spread the edge of the camshaft oil seal with oil and press it into the cylinder head with MIO bolt length 50 60mm and special tools Notice If the oil seal is reused spread it with oil before pressing it into the cylinder head After removing the bolt knock it with hand so as to inspect and confirm it 3 8 Assembly of camshaft timing gear After spreading sealant on the bolt prevent it from rotating with special tool and screw down the bolt of camshaft timing gear in specified torque Torque 100 5N m Notice Process the special tools as indicated in the right figure before using them LO Chery QQ Service Manual Mechanical Part of SQR 472Engine 3 9 Installation of cylinder head cover 3 9 1 The old cushion of the timing belt cover which contacts the cylinder head cover should be removed completely 3 9 2 Put the new cushion into the gloove of the timing belt cover accurately 3 9 3 Mount the cylinder head cover on the cylinder head a
209. ssure sensor solar term door position sensor and No Repair or replace the sensor line think you are normal Remove the injector injector with special cleaning analyzer check ru the inj oo 1S is a leak or blockage Check the fuel situation In order to ine just aftr refueling cause since just after refueling cause Check the ignition sequence engine specifications Check whether the smooth air exhaust pipe Maintenance of the corresponding line 11 78 11 EFI SYSTEM OF SQR 472ENGINE 3 13 Accelerating weakness poor performance General failure position 1 Fuel moisture content 2 The intake pressure sensor and solar term door position sensor 3 Spark plug 4 The ignition coil 5 Solar term door body and idle bypass airway 6 Inlet 7 Idle speed regulator 8 Injector 9 The ignition timing 10 The exhaust pipe 11 The general procedure of diagnosis Serial Operation steps Test Next step number results l Check the clutch slip the tire pressure is low the brake drag the No Next step tire size 1s incorrect four wheel positioning is not correct faults Connect the fuel pressure gauge access point for the fuel No Maintenance of oil supply system distribution pipe assembly inlet pipe end start the engine check the fuel pressure in the idling condition 1s about 38kPa Set aside money in a cylinder of the Next step cylinder connected to the spark plug the spark plug electrod
210. st Next step M results Connect the diagnosis instrument the ignition Next step switch is in the ON The observed data stream coolant temperature and To step 6 whether the engine temperature quite numerical and Next step when the engine temperature Note if the display value often is constant that there may be circuit breaker failure Dial the connector for coolant temperature sensor Next step wire harness electrical multimeter check sensor u part of the repair manual Dial the connector for coolant temperature sensor To step 6 wire harness using a multimeter to check the joint Next step line between the a c pin 15 broken Check the ECU 31 73 between pin Yes Repair or replace the wire respectively connected with the sensor connector harness pin a c whether the circuit breaker No Nexstp Nextstep start the engine idle running To observe a Diagnostic aid diagnostic instrument coolant temperature value Replace the sensor TM Replace the sensor and c pins of value is commensurate with its temperature with specific reference to the relevant changes the display values should be increased along with the engine coolant temperature 2 11 The coolant temperature sensor circuit for the power supply circuit fault code 0118 Serial Operation steps Connect the diagnosis instrument the ignition switch is in the
211. st savings but its overall size may make it less convenient When reading a micrometer numbers are taken from different scales and added together The following sections describe how to adjust care for and read the measurements of various types of outside micrometers For accurate results properly maintain the measuring surfaces of the micrometer There cannot be any dirt or burrs between the tool and the measured object Never force the micrometer to close around an object Close the micrometer around the highest point so it can be removed with a slight drag Adjustment Before using a micrometer check its adjustment as follows 1 Clean the anvil and spindle faces 2A To check a 0 1 in or 0 25 mm micrometer a Turn the thimble until the spindle contacts the anvil If the micrometer has a ratchet stop use it to ensure that the proper amount of pressure 1s applied b If the adjustment is correct the 0 mark on the thimble will align exactly with the 0 mark on the sleeve line If the marks do not align the micrometer is out of adjustment 1 13 1 SERVICE INFORMATION c Follow the manufacturer s instructions to adjust the micrometer 2B To check a micrometer larger than 1 in or 25 mm use the standard gauge supplied by the manufacturer A standard gauge Is a steel block disc or rod that is machined to an exact size a Place the standard gauge between the spindle and anvil and measure its outside diameter or length If th
212. stored in the original packaging box sealed inside Mounted on the car after the maximum allowable storage time was 6 months as accessories maximum storage time for 4 years Over this time by the manufacturers to test performance data pump In the storage place must be protected against atmospheric effects of oil pump During the storage period the original packaging shall not be damaged Electric fuel pump 15 applied only to the fuel tank Install the pump must be installed on the eye size of not more than 60 or agreed with the customer common inlet strainer Please pay attention not to make the beam injection holes spewing oil into the oil inlet filter pump bracket and the oil tank wall Be careful when handling pump First of all we must protect the oil inlet filter is not affected by the load and impact Oil pump should be installed to carefully remove from plastic packaging materials The protective cover only in the pump immediately to install to take Absolutely not allowed to take into the oil strainer Foreign body into the oil pump inlet or strainer can lead to pump damage Install the tubing should pay attention to clean Tubing must be clean Please use the new pipe clamp Please make sure the hose clamp The correct position and follow the method recommended by the manufacturer Not in the tubing or in the inlet filter holding pump at In order to prevent the pump is damaged please don t run the pump in the dry state Do not use damage
213. supply will be Between the 62 pin check cylinder injector connector 2 pin and the ECU line is broken or the power supply or short circuit to ground 11 52 Next step No Next step Repair or replace the wire harness w paw NN No Replace injector Diagnostic aid Next step Yes Repair or replace the wire harness 11 EFI SYSTEM OF SQR 472ENGINE 2 27 Two cylinder injector circuit for the power supply circuit fault code P0265 Serial Operation steps Test Next step Tumor results Connect the diagnosis instrument Next step ignition switch is in the ON Dial the joint stiffness of injector on wire harness using a multimeter to check the connector SM1 pin voltage and power for a few pieces of value is a 12V Check in between a cylinder injector Repair or replace the wire harness connector SM pin and the main relay line is a ie No Next step open circuit or short circuit to ground Using a multimeter to check a resistor Next step between the fuel injectors for cylinders Replace injector SM1 and SM2 pins at 20 C in 14 5 0 5 ohm Whether the 3 7 Q voltage with a multimeter to check a cylinder injector connector 2 pin No rere and the negative pole of the power supply P Between the 62 pin check cylinder _ Repair or replace the wire harness injector connector 2 pin and the ECU line is broken or the power supply or short circuit to ground 2 28 Three cylinder i
214. t Check the XI 2 pin on iron is Yes Diagnostic aid normal line 3 5 Speed normal any time starting difficulty General fault location 1 The fuel moisture content 2 The fuel pump 3 Coolant temperature sensor 4 Injector 5 Ignition coil 6 Solar term door body and idle bypass airway 7 Inlet 8 The ignition timing 9 Spark plug 10 The engine mechanical part 11 70 EFI SYSTEM OF SQR 472ENGINE The general procedure of diagnosis Serial Operation steps Test Next step results Check the air filter is clogged the intake Maintenance of air intake pipe 1s leaking system Connect the fuel pressure gauge access Next step point for the fuel distribution pipe Maintenance of oil supply inlet pipe end start the engine check the fuel pressure In the idling condition 15 about 38kPa Appropriated the sub cylinder line a cylinder which is connected to spark plug spark plug electrode distance of engine 15 Maintenance of the ignition about 5mm the starting engine check system whether there is a blue and white high pressure fire Check the cylinder spark plug the period of observation model gap four No Adjust or replace conformance to specification Pulling off the coolant temperature sensor Repair or replace the sensor line connector start the engine the engine Is starting to observe Check the fuel situation observe whether Cleaning solar term door and the
215. t and the engine oil pump assembly Torque 20 1 5N m 6 3 Assemble the new engine oil collector gasket and the 6 37 ene Chery QQ Service Manual Mechanical Part of SQR 472Engine ETH engine oil drainer Torque 6 1N m 6 4 Assembly of the oil pan 6 4 1 Clean up the joint surface between the oil pan with the cylinder 6 4 2 Spread sealant then assemble it Grease Loctite 5699 Notice The sealing line should be unbroken with its diameter being 3 4mm Assembly should take place fifteen minutes after glue spreading 64 3 Tighten the bolts in the middle first up to the specified torque then the bolts beside them as shown in the right figure Torque 6 1N m Front 6 38 Chery QQ Service Manual Mechanical Part of SQR 472Engine 6 Crank Connecting Rod Mechanism 1 Structure Diagram 1 x Components which may not be reused 1 Connecting rod cover 2 Connecting rod bushing 3 Piston connecting rod assembly 4 Main bearing cap Crankshaft 6 Crankshaft bearing bushing 7 Thrust plate Cylinder body First ring Second ring ID Steel tape combined oil ring 12 Piston Connecting rod Piston pin 6 39 LO Chery QQ Service Manual Mechanical Part of SQR 472Engine 2 Disassemble of Crank Connecting Rod Mechanism 2 1 Inspect the axial momentum of t
216. t angle to the No calculation needed drive head calibration is not required because the effective length has not changed To recalculate a torque reading when using a torque adapter use the following formula and refer to Figure 14 TW TAXL L A TW 1s the torque setting or dial reading on the wrench TA 15 the torque specification and the actual amount of torque that is applied to the fastener is the amount that the adapter increases or in some cases reduces the effective lever length as measured along the centerline of the torque wrench L is the lever length of the wrench as measured from the center of the drive to the center of the grip The effective length is the sum of L and A Example 15 TA 20 ft Ib 7 L 14in mo a TW 20x14 280 16 5 ft lb 7 1443 17 In this example the torque wrench would be set ps to the recalculated torque value TW 16 5 ft Ib EE c 1 9 1 SERVICE INFORMATION When using a beam type wrench tighten the fastener until the pointer aligns with 16 5 ft Ib In this example although the torque wrench is pre set to 16 5 ft Ib _ the actual torque is 20 ft Ib Pliers eee Pliers come in a wide range of types and sizes a Pliers are useful for holding cutting bending and EL AS Weng crimping Do not use them to turn fasteners Figure 15 and Figure 16 show several types of useful pliers
217. t method If the exhaust pipe assembly has abnormal noise or the exhaust back pressure is too high or driving performance variation accelerate the powerless visually exploration catalyst carrier is melting the blockage or rupture 16 The other is connected with ECU signal Malfunction 1 Powersupply indicator 2 Fault display signal ECU 107 O CAN High 17 Line for Tool CAN Low ECU XI 6 CANI L That engine speed signal of engine tachometer ECU X1_ 66 The speed signal Holzer ECU 12 Air conditioner evaporator Signal A ECU 12 temperature sensor Signal B ECU X1 13 11 33 11 EFI SYSTEM OF SQR 472ENGINE Chapter 3 Introduces the function of fault diagnosis system The electronic control unit continuously monitoring sensor actuator circuit fault indicating lamp and battery voltage and so on and the electronic control unit itself and the actuator driving signal and the internal signal of the sensor output signal such as closed loop control coolant temperature the idle speed control and battery voltage control for reliability detection Once found a link failure or a signal value is not trusted the electronic control unit immediately set up fault information recorded in the fault memory the RAM Fault recording information stored the fault code form has the display order according to the faults According to the fault frequency can be divided into
218. t of SQR 472Engine Remarks In the above tables the capital letter and suffix following the sizes For example H7 of 28H7 mean the process precision which are unconcerned with the maintenance and may be ignored in the course of maintenance Chapter 4 Table of Measurement Parameters of SQR472 EngineSQR472 O Measuring Items Axial clearance of crankshaft 0 089 0 21 1mm Assemble the crankshaft and tighten the main bearing cap bolt lt Nm Mount the piston connecting rod No 1 Torque of crankshaft assembly and tighten the connecting od bolt lt 5 5Nm uniform speed lt 2 Installing timing belt and spark plug 226 Nm Mount the valve spring and camshaft excluding timing bel when rotating at and spark plug on the cyllinder head tighten the camshaf bolt and then measure the torque of the camshaft rotating a uniform speed lt 32 Nm Distance between the outer edge of steel ball and the front end of camshaft 5 65 0 5mm Distance between the outer edge of steel ball and the rear end of camshaft 8 65 0 5mm 5 Axial clearance of intake camshaft 0 10 0 179 Axial clearance of exhaust camshaft 0 10 0 253 Jumping amount of installation surface of flywheel wearing Q 10mmmax Protrusion height of crankshaft woodruff key 2 2 20mm Intake valve clearance 0 18 0 05mm 10 Exhaust valve clearance 0 25x0 05mm Tension of timing belt When the middle part o
219. tective wear when necessary for example gloves or safety shoes Handing hot or sharp parts can cause severe burns or cuts Before you grab something that looks like it can hurt you stop and put on gloves Protect yourself and others whenever you have the vehicle up in the air Any time you lift the vehicle either with a hoist or a jack make sure that it 1s always securely supported Use jack stands Make sure the engine is off before you begin any servicing procedures unless the instruction tells you to do otherwise This will help eliminate several potential hazards e Carbon monoxide poisoning from engine exhaust Be sure there 15 adequate ventilation whenever you run the engine e Burns from hot parts or coolant Let the engine and exhaust system cool before working in those areas Injury from moving parts If the instruction tells you to run the engine be sure your hands fingers and clothing are out of the way Gasoline vapors and hydrogen gases from batteries are explosive To reduce the possibility of a fire or explosion be careful when working around gasoline or batteries Use only a nonflammable solvent not gasoline to clean parts Never drain or store gasoline In an open container Keep all cigarettes sparks and flames away from the battery and all fuel related parts Conversion Table Item Example Conversion Pressure 200Kpa 2 00kgt cm 98 0665kpa 33kpa 250mmHg 1000 ImmHg 133 3
220. temperature reach normal values No Next step observe diagnosis instrument monk oxygen sensor voltage items to pay changes the display values should lose uncle is In the range of 100Ma 900mA Check the ECU 422 374 pins Repair or replace the wire harness respectively In sensor connector 3 with x Next step the oxygen sensor grey connection line between pins line 15 faulty Exhaust system blocking Yes Maintenance according the Fuel injector 15 leaking diagnosis Fuel pressure 15 too large No Diagnostic aid Valve clearance is too small 2 23 Pump primary line fault fault code P0230 Serial Operation steps Test Next step results Connect the diagnosis instrument Next step ignition switch is in the OFF ignition switch to ON respectively No Nexisten check the pump relay power supply terminal 307 86 power supply voltage and pay some value is around 12V Check relay power supply line is broken Repair or replace the wire harness Check with a multimeter pump m Replace the fuel pump relay control terminal relay 85 pins and power No Next step to pay a few pieces of the resistance value is about 3 7V Check relay control end is between the Repair or replace the wire harness Xl 69 pin and the ECU pin relay 85 ers Diagnostic aid whether the circuit breaker or the power or the open 11 50 11 EFI SYSTEM OF SQR 472ENGINE 2 24 A cylinder injector circuit shorted to ground
221. temperature signal Crank angle signal The camshaft phase signal Oxygen sensor signal Air conditioning request signal Air pressure signal Air conditioner evaporator temperature 11 EFI SYSTEM OF SQR 472ENGINE Speed signal Knock signal The above information into the ECU after the treatment the actuator control signal needed these signals are driven by amplifying circuit at the output and transmitted to the corresponding actuator control signal which includes Idle speed regulator opening Fuel injection timing and injection duration Ignition coil closed angle and ignition advance angle The carbon canister control valve opening Oxygen sensor heater heating control Main relay Pump relay control The air conditioning compressor control relay Air conditioning cooling fan relay control Cooling fan relay Trouble light control 2 The engine management system management system diagram Ignition coil 22 n aR o Fuel filter E o lu OE lt r air Camshaft positio Carbon canister solenoid valve Air Oxygen sensor iy Idle speed 5 motor Three way catalytic Solar term door pdsition sensor converter sensor E Crankshaft position Water temperature sensor 1 signal whee ranksha 11 EFI SYSTEM OF SQR 472ENGINE 3 The ECU control principle dia
222. the Yes Diagnostic aid accelerator to close to the fully open observation instrument monk pressure numerical variation No Replace the sensor diagnosis the display value a little change quick throttle to close to the fully open the display values should be can instantly reach above 90kPa 2 7 The intake air temperature sensor circuit shorted to ground fault code P0112 Serial Operation steps Inspec Next step number tion results 1 Connect the diagnosis instrument the ignition switch 15 in the The observation data stream the temperature whether in the intake pipe of Next step equivalent temperature numerical and when the engine temperature Note if the display value often is constant that there may be line short circuit fault 3 Dial connection wire harness the intake air temperature sensor using a multimeter check Replace the sensor resistance sensor 3 and 4 pins of value 15 commensurate with its temperature with specific reference to the relevant part of the repair manual Dial the air intake temperature sensor connector on wire harness multimeter voltage check the joint a No Next step and b pins between whether the value 1s about 5V Check ECU 5672 48 between pin respectively connected with the sensor connector s lens pin 3 4 whether the circuit breaker Start the engine idle running To observe a diagnostic instrument air temperatu
223. the crankshaft axial thrust plate pay attention to the following 5 3 1 Assembling the bearing bushing its raised thrust block should fit into the locating groove in the cylinder body I Notice The bearing bushing is from the same Oil Tank manufacturer Spread Oil on the surface of p Beari earing Bushing 5 3 2 Spread the crankshaft bearing bushing upper piece with oil before assemble the crankshaft 5 3 3 Mount the thrust plate on the cylinder body bearing base and make sure that the side with oil gloove crankshaft shank face outwards Notice Spread the side of oil glove with oil 5 3 4 Fix the crankshaft bearing bushing lower piece in the bearing cap the bearing bushing should fit into the thrust groove 5 3 5 Spread engine oil over the friction surface of crankshaft bearing bushing lower piece assemble the bushing according to the mark forwards in the main bearing cap of the crankshaft 5 3 6 Spread oil over the bolts within three or two times tighten them with specified torque Torque 7043 5N m 5 3 7 Rotate the crankshaft after assembly it should rotates swiftly the rotating torque should be less than INm 6 48 Zo Chery QQ Service Manual CHERY ERI EIE 5 4 Assemble the piston and connecting rod assembly connecting rod bearing bushing and the connecting rod bearing cap pay attention to the following 5 4 1 The opening of compression ring t
224. the range of 100Ma 900mA Check the ECU 432 598 pins respectively 1n sensor connector 3 with observe diagnosis oxygen sensor voltage the oxygen sensor grey connection line between pins line 1s faulty Exhaust system blocking Fuel injector 1s leaking Fuel pressure 1s too large Valve clearance 15 too small 11 46 m Next step Diagnostic procedures Next step Yes Repair or replace the wire harness Next step ET Maintenance according diagnosis Diagnostic aid 11 EFI SYSTEM OF SQR 472ENGINE 2 16 Oxygen sensor circuit output voltage is too low fault code P0131 Serial Operation steps Test Next step M results Connect the diagnosis instrument Next step ignition switch 1s in the ON Start the engine idle running to the Diagnostic procedures No Next step changes the display values should lose uncle is in the range of 100Ma 900mA Check the ECU 432 597 pins m Repair or replace the wire harness respectively 1n sensor connector A with Next step the oxygen sensor grey connection line between pins line 1s faulty Exhaust system blocking Maintenance according Fuel injector is leaking diagnosis Fuel pressure 15 too large Diagnostic aid Valve clearance 1s too small 2 17 Oxygen sensor circuit output voltage is too high fault code P0132 serial Operation steps Test Next step number results 1 Connect the diagnosis instrument the Next step ignition switch is in th
225. the solar term door d pin voltage change little solar term door opened quickly voltage d pin can instantly reach 4V left and right specific numerical and vehicle and then drops to about 1 5V the specific numerical and vehicle y Voltage 47 ES a CF o MEM pU AE EP W 1 325 sj 0 25 9 06 Pressure cL Fs Pressure sensor characteristic curve 9 The fuel rail assembly The fuel rail assembly consists of the fuel distribution pipe rail composed of four injector and fixing clip 1 Installation notes Pay attention to dust dust shall not be allowed to enter the pipe or plug injector nozzle Fuel rail assembly shall not bump so as to avoid oil leakage accidents When installing the fuel injector sealing ring using clean no silicone oil lubrication Oil inlet fuel rail assembly and from the tank pipe connection should be fastened without leakage 2 Installation position The fuel rail assembly 11 22 11 EFI SYSTEM OF SQR 472ENGINE 3 Technical parameters 1 Limit data measure maximum maximum Continuous work Continuous work permit temperature temperature aot a The maximum allowable temperature of fuel N Maximum permissible pressure drift 30 C reversible 2 Maximum permissible pressure drift 85 C reversible 5 f42 fF qm e The maximum pressure fluctuation value
226. tion and installation of Rear Right Arm Rear Left Suspension Refer to Rear Right Suspension for the removal inspection and installation of Rear Left Suspension 9 6 10 FRONT REAR AXLE Front Rear Axle Overhaul Information 10 Standard Lubricating Period Item Capacit Initially SAEI5W 40 SF 1 0 28L R 0 25L or 350km 5000Km SAE85W 90 GL 5 1 0 48L R 0 45L I Initial R Replaced Tightening Torque Table Wmwem o Mee 3 S me wm wa e Menem 05 0 _ ewe Mensa _ rwr fas r ese 2 Mem _ Wasem s Mme j _ erate 1 Mee j _ b e awe jum 10 1 10 FRONT REAR AXLE Inspection amp Overhaul Inspection and overhaul if any of problems below happens to front and rear axle Unstable moving during accelerating Bearing broken decelerating or constant speed Gear clearance over under size Gear severely worn Gear blocked Drive shaft broken lack of lubricant Foreign matter in front or rear gear Abnormal sound in front rear axle Engine power transmission failure to front or C d rear wheels Note A B C problems are hard to distinguish Analysis is needed based on actual break down catagories Make sure engine works all right before disassembly of front or rear axle Observation and Judgement 1 Never ignore abnormal sound a Abnormal sounds d
227. tion must be carried out with special equipment or acted on the vehicle Check other parts Replace broken parts of necessary 10 8 Front axle assembly and adjustment Front axle case cover assembly Item3 1 tightening torque60Nm 24 tightening torque70Nm Note Use engine oil for oil seal bearing and drive clutch assembly 24 Use screw thread fastening glue Front differential gear case cover assembly Note Use engine oil for oil seal or bearing assembly Differential gear assembly M10x1 25x20 Tightening torque35Nm Note Use engine for bearing and dif ferential gear Use proper washer to make gear working freely Adjust washer 0 2 0 3 04 0 5 thickness 1 0 GEARINGRING 10 FRONT REAR AXLE 18 19 31 20 2221 ENS nos rs NM m Wi ils Id L 3 24 IDLE GEAR SAHFT SERERE qr m T IL Bearing le DIFFERE NTIAL mS BOLT M10x1 25 10 9 Front axle assembly and adjustment Illustration Tightening torque 1 25Nm Item 25 10Nm 3 0 13Nm Use fastening glue for item 30 assembly a Use proper washer 8 and 10 thick ness to adjust gear side clearance between drive pinion gear and differential gear Drive bevel gear clearance measurement Install sup port tools tightening bolts M10 x1 25 put up dial indicator make sure 21 mm is between measur
228. torque adapter or similar extension to tighten a fastener to a measured torque Torque wrenches come in several drive sizes 1 4 3 8 1 2 and 3 4 and have various methods of reading the torque value The drive size indicates the size of the square drive that accepts the socket adapter or extension Common methods of reading the torque value are the deflecting beam the dial indicator and the audible click Figure 12 When choosing a torque wrench consider the torque range drive size and accuracy The torque specifications In this manual provide an indication of the range required 1 8 1 SERVICE INFORMATION A torque wrench 15 a precision tool that must be properly cared for to remain accurate Store torque wrenches in cases or separate padded drawers within a toolbox Follow the manufacturer s instructions for their care and calibration Torque Adapters TORQUE WRENOH EFFECTIVE LENGTH Torque adapters or extensions extend or reduce the reach of a torque wrench The torque adapter shown in Figure 13 is used to tighten a fastener that cannot be reached because of the size of the torque wrench head drive and socket If a torque adapter changes the effective lever length Figure 14 the torque reading on the wrench will not equal the actual torque applied to the fastener It is necessary to recalibrate the torque setting on the wrench to compensate for the change of lever length When using a torque adapter at a righ
229. ue unit least maximum The phase accuracy The target wheel speed 8000 o Supply voltage 5 Installation notes The sensor is only allowed in the soon to be installed prior to the car or to the test device to remove from packaging materials Sensor installation direction specified as shown below signal wheel rotation direction Installation position of 1 and 2 Holzer device Installation method of sensor by indentation instead of hammering Recommended bolt fixed sensor M6 Tightening torque of 8 2Nm Holzer type crankshaft position sensor and signal disc tooth tip of the air gap between nominal value is 1 0mm allow the range is 0 3 to 1 7mm 6 The malfunction phenomenon and the judgment method Fault phenomenon not starting General failure man made fault Note repair installation method of repair process by pressing instead of hammering A simple method to measure thenthefragmentswereligatedwithan adapter open the ignition switch but do not start the engine the digital multimeter to DC voltage two probes are respectively connected sensor 1 3 pin to ensure that the reference voltage 12V Start the engine the 2 pin signal by the automotive oscilloscope check whether it 15 normal 11 10 11 EFI SYSTEM OF SQR 472ENGINE 3 The camshaft position sensor 1 Diagram and pin 2 GROUND Camshaft 17 ECUXI72 2 earth tCUXIX Power supply Ems 2 Install
230. uring accelerating decelerating have little to do with engine working but possibly with gear worn b Constant abnormal sounds during accelerating or decelerating might be cause by gear clearance wrongly adjusted during assembling Note Wrong assembly or adjustment of the front or rear axle will aggravate gear worn and block c Slight sounds will be noticed during low speed driving and should not be heard during high speed driving This is caused by gear block Note In case of above mentioned times stop the vehicle immediately for inspection until they are solved or will cause accident 2 Check lubrication 3 Check lubricant leakage a Rear axle surface oil stain inspection before through inspection b Oil stain on ground on the parking lot Lubricant splash inspection Check if there 15 gear case or oil seal leakage Replace broken parts if necessary 10 2 10 FRONT REAR AXLE Disassembly of front axle 1 FRONT AXLE HOUSING GROUP 1 FRONTAXLE LEFT CASE 1 H OIL SEAL 45x68x8 EN OIL SEAL 25x40x7 RE FRONT AXLE RIGHT CASE LIO Jenae um SPEED SENSOR ich ALUNINUM PAD 18x 10x1 5 Fi BOLT FLANGE M6x 16 ee BOLT FLANGE MI0x1 25x12 e e I 8 ALUNINUMPAD 18x 10x1 5 1 18 OIL SEAL Q 5x40x7 JOINT BREATHER PIPE BOLT FLANGE MS x 1 25x25 M10x1 25x10 10 NEEDLE BEARING NAS5903 m 4 1
231. ust free play of throttle pedal After adjusting tighten locknuts and install throttle cable sleeve Replace with a new throttle cable 1f the specified free play could not be acquired by adjusting the regulator or if there 15 still stickiness with the throttle 3 14 3 CHECKS amp ADJUSTMENT Cooling System Note Check coolant level from reservoir tank Do not check from radiator If the radiator cap is opened while the engine is hot over 100 C the pressure of the cooling system will drop down and the coolant will get boiled rapidly DO NOT open the radiator cap until the coolant temperature drops down Coolant is poisonous DO NOT drink or splash it to skin eyes and clothes 1 case the coolant gets to the skin and clothes wash with soap immediately In case the coolant gets into eyes rinse with plenty of water and go to consult the doctor In case of swallowing the coolant induce vomit and consult the doctor Keep the coolant a safe place and away from reach of children Coolant level Coolant might reduce due to natural evaporation Check the coolant level regularly Note Coolant can prevent rust and resist freeze Ordinary water may cause engine rust or cracks in winter due to freezing Park the vehicle on level ground for checking of the coolant Inclined vehicle body will cause incorrect judging of the coolant level Check the coolant after the engine is warmed up
232. ve marks numbered 0 through 25 in 5 mm increments This numbering sequence continues with larger micrometers On all metric micrometers each mark on the lower half of the sleeve equals 0 50mm The tapered end of the thimble has 50 lines marked around it Each mark equals 0 01 mm One completer turn of the thimble aligns its 0 mark with the first line lower half of the sleeve line or 0 50mm When reading a metric micrometer add the number of millimeters and half millimeters on the sleeve line to the number of one one hundredth millimeters on the thimble Perform the following 1 14 1 SERVICE INFORMATION steps while referring to Figure 25 1 Read the upper half of the sleeve line and count 21 the number of lines visible Each upper line equals Imm 2 See if the half millimeter line is visible on the lower sleeve line If so add 0 50mm to the reading in Step 1 3 Read the thimble mark that aligns with the sleeve NOTE If a thimble mark does not align exactly with the sleeve line Estimate the amount between the lines For accurate readings in two thousandths of a millimeter 0 002mm use a metric vernier micrometer 4 Add the readings from Steps 1 3 Standard inch micrometer The standard inch micrometer Figure 26 is accurate to one thousandth of an inch or 0 001 The sleeve is marked in 0 025 in increments Every fourth sleeve mark is nu
233. w pieces of value is a 12V Check in between a cylinder Repair or replace the wire harness connector SM pin and the main relay line is a ie Next step open circuit or short circuit to ground Using a multimeter to check a resistor Next step between the fuel injectors for cylinders SM1 and SM2 pins at 20 C in 14 5 0 5 ohm Whether the 3 7 voltage with a multimeter Yes Diagnostic aid to check a cylinder injector connector 2 pin No Nasi sis and the negative pole of the power supply P Between the X1 61 pin check cylinder x Repair or replace the wire hamness injector connector 2 pin and the ECU line is broken or the power supply or short circuit to EE ground 11 54 11 EFI SYSTEM OF SQR 472ENGINE 2 30 Four cylinder injector circuit shorted to ground fault code P0270 Serial Operation steps Test Next step number results Connect the diagnosis instrument Next step ignition switch is in the ON Dial the joint stiffness of injector on wire harness using a multimeter to check the connector SM1 pin voltage and power for a few pieces of value is a 12V Check in between a cylinder injector Repair or replace the wire harness connector SM pin and the main relay line is a ie No Next step open circuit or short circuit to ground Using a multimeter to check a resistor Next step between the fuel injectors for cylinders Replace injector SM1 and SM2 pins at 20 C in 14 5 0 5 ohm Whether the
234. water note the immersion time to fully observe the change of the sensor resistance the resistor should decline to 60 Q the specific value as the temperature of boiling water 11 8 11 EFI SYSTEM OF SQR 472ENGINE 2 The crankshaft position sensor 1 Diagram and pin 1 SUPPLY Crank 1 Power supply V RLY position 2 re sensor earth ECU 1 27 CRK_GND 2 Installation position The back of the engine flywheel plane 3 Working principle Holzer type crankshaft position sensor with the target wheel is matched provide check point information of engine speed and the cylinder piston Holzer type crankshaft position sensor integrated dynamic permanent magnet biased differential pair of Holzer IC When the target wheel in front of regional rotation sensor sensitive IC detection due to the lack of teeth and tooth alternation 1s produced by the variation of the magnetic field and the Schmidt trigger conversion by square wave signal 4 technical parameters 1 limit data tes Town Wememm _ temperatures Don t run when the environment 40 120 C Long term environmental temperature a The launch 750 ee Ops service life 3000 Special Ops Wire area as 150 C a whole lifetime Insulation resistance 2min test voltage Moh Pressure 60s 250V No breakdown 11 9 11 EFI SYSTEM OF 5 472ENGINE 2 Characteristic data measure val
235. with screw driver remove the gasket inside with magnet 4 4 3 2 Adjust the thickness of adjustment gasket with 6 21 d 2 Chery Service Manual Mechanical Part of SQR 472Engine ETE EIA micrometer caliper 4 4 3 3 Select the gasket on the basis of the standard value of valve tappet D Intake valve Select gasket thickness Unload thickness Measured valve clearance 0 25mm 2 Exhaust valve Select gasket thickness Unload thickness Measured valve clearance 0 25mm Reference 32 kinds of gasket with different thickness are listed in the following table 4 4 3 4 Adjust the valve clearance with selected adjustment gasket Notice Install the adjustment gasket with its identification mark facing downwards 4 4 3 5 Rotate the crankshaft so that the crown head of the cam faces downwards and presses down the the valve Pick up the special tool 4 4 3 6 Rotate the crankshaft for 2 3 rounds and confirm once again the valve clearance If it is still beyond the scope of standard value adjust and inspect the valve clearance according to the operation specified 4 1 4 4 3 Cylinder Head 1 Structure Diagram 6 22 s Chery QQ Service Manual Mechanical Part of SQR 472Engine Spark plug 20 1Nm Cylinder Head Weather Strip I Cylinder cushion Adjustment gasket Valve tappet Valve spring retainer Valve spring seat 1 ON C BPW NY Valve Spring Intake v

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