Chery A15 Maintenance Manual

Table of Content
Chapter One General Description 1
One Engine Assembly Drawing 1
Two Basic Data of Engine 1
Three Engine Nameplate 2
Four Transmission Belt 2
Chapter Two Engine 4
Section One Maintenance Data of the Engine 4
Section Two Commonly-used Special Tools 10
Section Three Unfixing the Engine 13
One Unfixing the crank shaft belt pulley 13
Two Bracket 13
Three Unfixing the engine 17
Four Fixing – Engine Assembly 19
Section Four Timing Chain 21
One Valve timing mark 21
Two Valve timing adjustment 21
Three Timing chain cover 22
Four Timing chain/guide board/sprocket wheel 24
Five Crank shaft sprocket wheel 26
Six Fixing the camshaft sprocket wheel 27
Seven Timing sprocket wheel and guide board 28
Section Five Cylinder Cover Components 31
One Cylinder cover 32
Two Valve chamber cover 38
Three Spark plug conduit seal 40
Four Spark Plug Conduit Oil Seal 41
Five Rocker arm shaft/rocker arm/adjustment 42
Six Camshaft 43
Seven Valve spring and valve oil seal 46
Eight Intake/exhaust valves and valve seat 49
Section Six Engine Cylinder Block Components 51
One General Description 51
Two Cylinder checking 52
Three Crank shaft bearing shell 52
Section Seven Piston and Connecting Rod Assembly 58
One Checking the connecting rod and bearing 58
Two Check the cylinder head and piston 58
Section Eight Engine Lubrication System 62
One Composition of Lubrication System 62
Two Engine oil pump 62
Three Engine oil filter 63
Four Engine oil filter 64
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Five Engine crankcase oil tray 65

Six Engine oil pump strainer 66
Section Nine Engine Cooling System 68
One Fixing/unfixing the heat radiator 68
Two Fixing/unfixing the heat radiator fan 68
Three Fixing/unfixing the water pump and power steering pump 69
assembly
Four Adding the cooling fluid 69
Five Draining the cooling system 69
Section Ten Air Intake and Exhaust Systems of the Engine 71
One Unfixing the air intake system attachments 71
Two Fiixng/unfixing the air intake manifold 71
Three Fixing the acceleration transmission mechanism 73
Four Fixing/unfixing the air exhaust manifold 74
Five Fixing the exhaust manifold 75
Section Eleven Generator and Starter 77
One Fixing/unfixing the storage battery 77
Two Structure of the AC generator 77
Three Precautions during maintenance 78
Four Installing the generator 79
Five Fixing/unfixing the starter 79
Section Twelve Fuel System 81
One Precautions for the maintenance of the fuel system 81
Two Relieve the pressure of the fuel system 81
Three Fixing/unfixing the fuel system 82
Section Thirteen Troubleshooting on Engine Mechanical Parts 84
One General description 84
Two Troubleshooting on the engine mechanical parts 84
Three Troubleshooting on the cylinder compression pressure 89
Four Cylinder compression pressure leakage test 90
Five Troubleshooting on impact noise 91
Six Troubleshooting on engine oil leakage 92
Seven Checking rear oil seal leakage 93
Eight Troubleshooting on damaged or worn-out parts 93
Nine Troubleshooting on engine cylinder gasket 94
Chapter Three Engine Control System 95
Section One System Introduction 95
One System features 95
Two Location of engine compartment component 96
Three Performance of the whole car and engine 96
Four Introduction of ECM system and its functions 98
Five Basic principles of ECU control system 101
Chapter Four System Working Parts 115
Section One Power Source and Computer 117
One System component power source and wire harness 117
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Two System component engine control module 118

Section Two Sensor Signal Collection System 122
One Description 122
Two Engine speed and crank shaft position sensor (CPS) 122
Three Manifold pressure/temperature sensor (MAP/MAT) 124
Four Cooling fluid temperature sensor 125
Five Throttle position sensor 126
Six Oxygen sensor 127
Seven Camshaft Position Sensor (CAM) 129
Eight Vehicle speed sensor (VSS) 130
Nine Knock sensor (KS) 131
Section Three Air Intake Control System 133
One General description 133
Two Throttle assembly 133
Three Idle speed control valve 134
Section Four Ignition System 136
One General description 136
Two Ignition coil 136
Three Spark plug 137
Four High voltage cable (spark plug wire lead) 138
Section Five Fuel Supply System 139
One General description 139
Two Fuel pump 139
Three Fuel rail assembly 141
Four Fuel pressure regulator 141
Five Spray nozzle 142
Six Fuel filter and fuel pipeline 143
Seven Basic checking of the system 144
Section Six Exhaust Emission Control Component 146
One Charcoal canister cleaning solenoid valve 146
Two Three-way catalyst 147
Chapter Five Engine Troubleshooting 149
Section One Reading and Elimination of Engine Troubleshooting Code 149
Section Two Interpretation of Troubleshooting Codes 156
Section Three Data Analysis and Test
Chapter Six Maintenance and Troubleshooting 193
Section One Precautions during Engine Maintenance 193
Section Two Diagnostic techniques 196
One Diagnostic method 196
Two Diagnosis classification 196
Three Diagnosis parameters 198
Section Three Basic Checking of the Engine 201
One Daily operation and maintenance 201
Two Basic checking 202
Three System initialization setup 202
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Section Four Troubleshooting on Electrical Control System 203

One Ordinary troubleshooting procedure 203
Two Troubleshooting procedure of apparent intermittent faults 203
Three Troubleshooting on failure of engine normal startup 205
Four Cleaning of throttle body 206
Five Maintenance tool 206
Six Troubleshooting on engine by diagnostic instrument data 207
flow
Seven Simple troubleshooting method 208
Eight Typical troubleshooting method 209