Chery A1 2009 User Manual

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CHARGING SYSTEM

GENERAL INFORMATION

05-12

Description 05-12

Operation 05-12

Specifications 05-12

Special Tools 05-12

Electrical Schematics 05-13

DIAGNOSIS & TESTING

05-14

Generator Noise 05-14

ON-VEHICLE SERVICE

05-15

Generator 05-15

Removal & Installation 05-15

Generator Inspection 05-15

05

05–11

Chery Automobile Co., Ltd.

Table of Contents

Vehicle Information10
- Table of Contents10
- Vehicle Identification Number (Vin)11
- VIN Location11
- VIN Identification Codes12
- International Symbols14
- Fastener Usage15
Electrical Information21
- Connector Symbols22
- How to Read Electrical Schematics22
- Option Splices23
- Electrical Schematic - Example24
- Electrical Schematic Index26
- How to Locate Electrical Schematics in the Service Manual26
Engine 0230
- 1.3L Engine Mechanical30
- General Information33
- Description34
- Diagnosis & Testing42
- Engine Performance Diagnostics42
- Engine Mechanical Diagnostics43
- Cylinder Compression Pressure Test44
- Cylinder Head Gasket Test44
- Accessory Drive Belt45
- On-Vehicle Service45
- Removal & Installation45
- Air Cleaner Element47
- Air Cleaner Housing47
- Removal & Installation47
- Cylinder Head Cover48
- Removal & Installation48
- Camshaft51
- Removal & Installation51
- Cylinder Head55
- Removal & Installation55
- Front Crankshaft Oil Seal57
- Removal & Installation57
- Rear Crankshaft Oil Seal58
- Removal & Installation58
- Engine Mounts60
- Removal & Installation - Left Mount60
- Removal & Installation - Right Mount60
- Removal & Installation - Front Mount61
- Removal & Installation - Rear Mount61
- Engine Assembly62
- Removal & Installation62
- Engine Timing Belt69
- Removal & Installation69
- Exhaust Manifold73
- Removal & Installation73
- Intake Manifold75
- Removal & Installation75
- Oil Filter78
- Removal & Installation78
- Oil Pan79
- Removal & Installation79
- Oil Pump80
- Removal & Installation80
- Oil Strainer81
- Removal & Installation81
- Disassembly82
- Engine Block82
- Engine Unit Repair82
- Specifications82
- Assembly84
- Inspection84
- Pistons85
- Specifications85
- Disassembly86
- Inspection87
- Assembly89
- Connecting Rods90
- Disassembly90
- Specifications90
- Assembly91
- Inspection91
- Crankshaft92
- Disassembly92
- Specifications92
- Inspection93
- Assembly94
- Cylinder Head95
- Disassembly95
- Assembly97
- Inspection97
- Camshaft98
- Specifications98
- Disassembly99
- Inspection99
- Assembly101
- Disassembly102
- Specifications102
- Valve & Valve Guides102
- Inspection103
- Assembly104
- Specifications105
- Valve Springs105
- Disassembly106
- Assembly107
- Inspection107
Electronic Engine Controls 03108
- Special Tools113
- Electrical Schematics116
- Diagnosis & Testing128
- Diagnostic Help128
- Ground Inspection128
- Intermittent DTC Troubleshooting128
- Diagnostic Trouble Code (DTC) List129
- Power Supply and Ground Circuit133
- Power Supply and Ground Circuit Test133
- Diagnostic Trouble Code (DTC) Tests140
- Position Correlation Error140
- High Input160
- Performance220
- P0506 - Idle Control System RPM Lower than Expected247
- P0562 - System Voltage Low Voltage P0563 - System Voltage High Voltage249
- P0602 - Control Module ECM Programming Error254
- P0604 - Internal Controller Module256
- P0605 - Internal Controller Module256
- ROM Test Error, P0606 - ECM256
- P0645 - A/C Clutch Relay Circuit258
- P1545 - Throttle Position Control Performance262
- P2138 - Pedal Position Sensor Performance269
- Description276
- Engine Coolant Temperature Sensor276
- On-Vehicle Service276
- Operation276
- Removal & Installation276
- Description277
- Knock Sensor277
- Operation277
- Oxygen Sensor277
- Removal & Installation277
- Upstream Oxygen Sensor277
- Downstream Oxygen Sensor278
- Removal & Installation - Downstream Oxygen Sensor278
- Removal & Installation - Upstream Oxygen Sensor278
- Camshaft Position Sensor279
- Crankshaft Position Sensor279
- Description279
- Operation279
- Removal & Installation279
- Description280
- Operation280
- Removal & Installation280
- Vehicle Speed Sensor280
- Accelerator Sensor281
- Description281
- Manifold Absolute Pressure Sensor281
- Operation281
- Removal & Installation281
- Accelerator Pedal Position Sensor282
- Description282
- Electronic Throttle Control Actuator282
- Operation282
- Removal & Installation282
- Description283
- Engine Control Module (ECM)283
- Operation283
- Removal & Installation283
- Removal & Installation284
Engine Symptom Diagnosis285
- Diagnostic Help286
- General Troubleshooting Checks286
- Symptom Diagnostic Test List286
- Symptom Diagnostic Tests286
- Visual Inspection286
- Engine Cranks Normal but will Not Start287
- Engine will Not Crank289
- Hard Start / Long Crank / Erratic Start / Erratic Crank291
- Fast Idle294
- Lack / Loss of Power295
- Back Fires298
- Engine Poor Driveability300
- Low Idle / Stalls During Deceleration304
- Idle Speed Slow Return to Normal Idle306
Ignition Control307
- Description308
- General Information308
- Operation308
- Specifications308
- Special Tools309
- Electrical Schematics310
- Description311
- Ignition Coil311
- On-Vehicle Service311
- Operation311
- Removal & Installation311
- Removal & Installation312
- Spark Plug Wire312
- Removal & Installation313
- Spark Plug313
Evaporative Emissions314
- Description315
- General Information315
- Operation315
- Specifications315
- Special Tools316
- Electrical Schematics317
- Description318
- On-Vehicle Service318
- Operation318
- Removal & Installation318
- Vapor Canister Control Valve318
- Description319
- Operation319
- Vapor Canister319
Fuel Delivery 04320
- Fuel Delivery System324
- General Information324
- Diagnosis & Testing328
- Fuel Pressure Test328
- Description330
- Fuel Pressure Relief Procedure330
- Fuel Pump330
- On-Vehicle Service330
- Operation330
- Relieving Fuel System Pressure330
- Removal & Installation330
- Fuel Pump Inspection332
- Description333
- Fuel Filter333
- Operation333
- Removal & Installation333
- Description334
- Fuel Injector Rail334
- Operation334
- Removal & Installation334
- Description335
- Fuel Injector335
- Operation335
- Removal & Installation335
- Description337
- Fuel Injector Inspection337
- Fuel Tank337
- Operation337
- Removal & Installation337
Starting & Charging 05340
- Starting System343
Charging System350
- Description351
- General Information351
- Operation351
- Special Tools351
- Specifications351
- Electrical Schematics352
- Diagnosis & Testing353
- Generator Noise353
- Generator354
- Generator Inspection354
- On-Vehicle Service354
- Removal & Installation354
Cooling 06355
- Description356
- Operation356
- Cooling System357
- General Information357
- Cooling System Concentration Test360
- Cooling System Pressure Test360
- Diagnosis and Testing360
- Cooling System Troubleshooting Chart361
- Cooling System Draining and Filling362
- Cooling System Draining Procedure362
- On-Vehicle Service362
- Cooling System Filling Procedure363
- Description363
- Operation363
- Thermostat363
- Coolant Pump364
- Removal & Installation364
- Coolant Pump Inspection365
- Description365
- Operation365
- Radiator365
- Cooling Fan366
- Description366
- Operation366
- Cooling Fan Inspection368
Exhaust 07369
- Description370
- Exhaust System370
- General Information370
- Operation370
- Specifications371
- Diagnosis and Testing372
- Exhaust System Diagnostic Chart372
- Exhaust Pipe Assembly373
- On-Vehicle Service373
- Removal & Installation373
- Muffler374
- Removal & Installation374
- Catalytic Converter375
- Description375
- Operation375
- Removal & Installation375
Differential412
- Description413
- General Information413
- Operation414
- Special Tools414
- Specifications414
- Differential Carrier415
- Differential Unit Repair415
- Disassembly415
- Removal & Installation415
- Assembly416
- Inspection416
Clutch System418
- Description419
- General Information419
- Operation419
- Specifications419
- Special Tools420
- Clutch and Pressure Plate421
- Clutch Assembly Service421
- Removal & Installation421
- Clutch Cable423
- Clutch Release Mechanism423
- Removal & Installation423
Automated Manual Transaxle (Amt) Control System425
- Description426
- General Information426
- Operation426
- AMT Hydraulic Fluid Inspection427
- Specifications427
- Special Tools428
- Electrical Schematic429
- Automated Manual Transaxle (AMT) Control Module Connector Pin-Out Table435
- Diagnosis & Testing436
- Diagnostic Help436
- Diagnostic Tools436
- Ground Inspection436
- Intermittent DTC Troubleshooting436
- Procedure437
- AMT Re-Calibration and Self-Learning Procedure438
- Step 1: Stability Test438
- Step 2: Self-Learning Test438
- Step 3: Road Test438
- Automated Manual Transaxle DTC List439
- Diagnostic Trouble Code (DTC) List439
- Diagnostic Trouble Code (DTC) Tests441
- P0560 - Battery Voltage too Low441
- (Smp)447
- Main Micro Processor Error (MMP)447
- P0604 - Micro Processor Error, P060C447
- P0613 - Safety Micro Processor Error447
- P0715 - Clutch Speed449
- P0904 - Gear Position Sensor455
- P0914 - Shift Position Sensor461
- P0932 - Hydraulic Pressure Sensor467
- P2904 - Clutch Error472
- Automated Manual Transaxle (AMT) Electro-Mechanical Control Unit478
- On-Vehicle Service478
- Removal & Installation478
- Automated Manual Transaxle (AMT) Control Module481
- Automated Manual Transaxle (AMT) Gearshift Mechanism481
- Removal & Installation481
Driveline & Axle 09482
Rear Axle489
Suspension 10494
- Description495
- General Information495
- Operation496
- Specifications496
- Diagnosis & Testing498
- Removal & Installation499
Rear Suspension520
- Description521
- General Information521
- Operation522
- Specifications522
- Diagnosis & Testing523
- On-Vehicle Service524
- Description526
- Operation526
- Rear Shock Absorber526
- Rear Cross Stay527
Alignment531
- Description532
- Front Axle532
- General Information532
- Operation532
- Pre-Wheel Alignment Inspection532
- Rear Axle532
- Specifications533
- Wheel Alignment Setup533
- Alignment535
- Diagnosis & Testing535
- Tire Wear535
- Tire Wear Chart535
- Vehicle Inspection535
- Alignment Troubleshooting Chart536
- Front Axle Toe-In Adjustment537
- Front Camber Adjustment537
- Front Wheel Alignment537
- On-Vehicle Service537
- Rear Toe-In & Rear Camber Adjustment537
- Rear Wheel Alignment537
Wheels and Tires538
- General Information538
- Description539
- Operation539
- Specifications539
- Diagnosis & Testing540
- Tire and Wheel Vibration540
- Tire Wear Patterns540
- Wheel Out-Of-Round Inspection540
- Description541
- On-Vehicle Service541
- Repair Procedure541
- Replacement Procedure541
- Tire Replacement & Repair541
- Description542
- Description543
- Wheel Balance Procedure543
- Directional Tires544
- Non-Directional Tires544
- Operation547
Steering Column552
- Disassembly552
- Description553
- General Information553
- Operation553
- Specifications553
- Diagnosis & Testing555
- Loose Steering / Vehicle Leads / Drifts Troubleshooting Chart555
- On-Vehicle Service556
- Inspection - Steering System557
- Steering Column Shroud558
- Steering Column559
Steering Gear564
- General Information565
- Binding and Sticking Troubleshooting Chart566
- Diagnosis & Testing566
- Insufficient Assist / Poor Return to Center Troubleshooting Chart566
- On-Vehicle Service567
- Removal & Installation567
- Steering Gear - LHD567
- Removal & Installation573
- Steering Gear - RHD573
- Removal & Installation578
- Tie Rod578
- Inspection580
Power Steering Pump581
- Description582
- General Information582
- Operation582
- Specifications582
- Diagnosis & Testing583
- Insufficient Assist / Poor Return to Center Troubleshooting Chart583
- Steering System Noise Troubleshooting Chart583
- On-Vehicle Service584
- Power Steering Pump584
- Removal & Installation584
- Power Steering Fluid Reservoir586
- Removal & Installation586
- Power Steering Pressure Line588
- Removal & Installation588
- Power Steering Return Line589
- Removal & Installation589
Brakes 12591
- Description592
- General Information592
- Parking Brake592
- Special Tools594
- Electrical Schematics595
- Rear Wheel Cylinder603
- Removal & Installation603
- Front Brake Rotor604
- Inspection604
- Front Brake Pads606
- Rear Brake Shoes608
- Removal & Installation608
- Front Brake Caliper611
- Unit Repair611
- Inspection612
- Assembly613
Parking Brake670
- General Information671
- Operation671
- Special Tools671
- Specifications671
- Parking Brake Adjustment673
- Parking Brake Operation673
- Parking Brake Warning Light673
- Parking Brake Cable675
- Parking Brake Lever675
Air Distribution696
- Blower Motor Electrical Troubleshooting699
- Blower Motor Noise699
- Blower Motor Vibration699
- HVAC Housing700
- Blower Motor703
- Description703
- Operation703
System Plumbing705
- General Information706
- Operation706
- Specifications706
- Special Tools707
- A/C Compressor Noise Testing708
- Refrigerant System Leaks708
- Refrigerant System Empty709
- Refrigerant System Low709
- A/C System Evacuation and Recharge710
- Connecting Refrigerant Recovery/Recycling Station710
- A/C System Evacuation711
- A/C System Recharge711
- A/C Compressor712
- Operation712
- Evaporator714
- Operation714
- Condenser716
- Operation716
- Accumulator717
- Operation717
- Description718
- Liquid Line718
- Operation718
- Description719
- Operation719
- Suction Line719
- Description721
- Heater Core721
- Operation721
Table of Contents771
- Instrument Panel837
- Lower Console843
- Instrument Cluster846
- Diagnosis & Testing855
- Diagnostic Tools855
- Ground Inspection855
- Intermittent Troubleshooting855
- Instrument Cluster856
- On-Vehicle Service856
- Interior Lamps858
- Power Outlet865
- Power Windows868
- Power Window Motor872
- Power Window Motor Inspection882
- Rear Seat884
- Immobilizer Control Module887
- Diagnosis & Testing890
- Diagnostic Tools890
- Ground Inspection890
- Diagnostic Trouble Code (DTC) List891
- Immobilizer Control Module DTC List891
- B1000 - ECU Defect, Internal Errors892
- Diagnostic Trouble Code (DTC) Tests892
- Relay External Line Short Circuit to902
- B3055 - no Transponder Modulation or907
- B3060 - Unprogrammed Transponder912
- Disturbed or no Challenge/Response912
- On-Vehicle Service917
- No Response from Remote Keyless Entry (RKE) Transmitter919
- Remote Keyless Entry (RKE) Inoperative919
- Description1053
- General Information1053
- Operation1053
- Overview1054
- Body Fuse and Relay Box1055
- Description1055
- Operation1055
- Overview1056
Vehicle Wiring Harness Layout1057
- Description1058
- General Information1058
- How to Read Harness Layout Diagrams1058
- Operation1058
- Vehicle Harness Layout1059
- Vehicle Harness Routing Maps1059
- Engine Control Harness1060
- Engine Room Harness1062
- Main Harness1064
- Body Harness1066
- Front Door LH Harness1068
- Front Door RH Harness1069
- Rear Door RH Harness1070
- Rear Door LH Harness1071
- Back Door Harness1072
- Restraints Harness1073
- Body SUB Harness and Parking Sonar Harness1074

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Chery A1 2009 Specifications

General

Brand	Chery
Model	A1 2009
Category	Automobile
Language	English

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