Chery A1 2009 User Manual

1080 pages

To Next Page

To Next Page

To Previous Page

To Previous Page

Page #497 background image

Loading...

Page #497 background image

Special Tools

Ball Joint Separator

CH-10002

GENERAL INFORMATION

10–4

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

Questions and Answers:

Need help?

Do you have a question about the Chery A1 2009 and is the answer not in the manual?

Chery A1 2009 Specifications

General

Brand	Chery
Model	A1 2009
Category	Automobile
Language	English

Related product manuals

Preview: Chery A5 2007

Preview: Chery Automobile

Chery Automobile

Preview: Chery TIGGO

Preview: Chery Tiggo 5 T21

Chery Tiggo 5 T21