CHERY AUTOMOBILE

I. Overview

Development

Automotive air conditioning systems develop as vehicles develop. Its development, by

and large, falls into the following several phases:

Ø Only heating
Ø Only cooling
Ø Integration of heating & cooling
Ø Automatically controlled automotive air conditioning
Ø Microcomputer-controlled automotive air conditioning
 y
l
b
II. Functionality
m
e
s
s
a

r air conditioner
compressor
o
Ø Refrigerating system
t
Ø Heating system a evaporator
assembly

Ø Ventilation system r
air o
Ø Control system conditioner
harness
p
Ø Air purification system a
v
e
 III. Refrigeration Principle

Basic Knowledge of Thermodynamics

1. First Law of Thermodynamics 2. Second Law of Thermodynamics

ØAny matter in the nature has energy;
Energy cannot be created or destroyed;
However, it can be altered from one form
to another and during any transformation
the total amount of energy is constant.
ØHeat cannot spontaneously move from
low-temperature object to high-
temperature object without any sacrifice.

The law of Conservation of Energy is one of the basic laws in the nature.
 Evaporation of liquid R-134a Refrigerant

Cooled air
Temperature
sensitive tube Expansion
valve

Low-pressure and low-

temperature liquid

Evaporator
High-temperature and high-
pressure gas
Liquid
Air Blower Air refrigerant

High-temperature and high-pressure gas

Cooling fan
Compressor

Reservoir/dryer

Condenser
(liquefaction) Air High-temperature and high-pressure liquid

High-pressure end

Low-pressure end
 Refrigeration Cycle

1. Evaporation & heat absorption

Liquid refrigerant turns low-temperature and low-pressure wet steam through the expansion
valve, passes through the evaporator and thus is evaporated into gaseous refrigerant with low
temperature (0℃) and low pressure (0.15MPa). During the evaporation, it continuously absorbs
the heat from the air within the car. The gaseous refrigerant flowing from the evaporator is
sucked into the compressor and after being pressurized, is pumped into the condenser for
condensation for the next refrigeration cycle.

2. Compression process
The compressor compresses low-temperature (0℃) and low-pressure (0.15MPa) gaseous
refrigerant from the evaporator's low-pressure side into high-temperature (70~80℃) and high-
pressure (1.5MPa) gaseous refrigerant, and sends it into the condenser for condensation and
cooling.
3. Condensation & heat release
The high-temperature gaseous refrigerant sent into the condenser releases heat into the external
environment when its temperature is much higher than the external temperature. As a result, the
refrigerant is condensed into middle-temperature liquid refrigerant with the pressure of
1.0~1.2MPa.

In order to enhance the cooling effect, the condenser employs the air-cooled mode to forcibly
condense the refrigerant, so that the refrigerant can deliver the heat carried from the car as well
as the mechanical work done by the compressor in the form of heat to the external environment,
thus accomplishing the procedure of heat transfer from low-temperature object to high-
temperature environment.
4. Depressurization & cooling
After the liquid refrigerant passes through the expansion valve, its temperature and pressure
sharply drop due to the increased volume of the space it flows through and it becomes low-
temperature (-5℃) and low-pressure (01.5MPa) wet steam, which can be rapidly evaporated
through heat absorption after going into the evaporator. During the expansion process, flow
control is carried out to provide the needed refrigerant for the evaporator and thus realize
temperature control.

In a word, refrigeration cycle refers to the complete procedure including compressing,

condensing, expanding and evaporating the limited refrigerant in the closed refrigerating system.
Heat absorption and liquefaction of the refrigerant within the evaporator brings forth cooling of
the air within the car.
Iv. Refrigeration Principle

Ø Refrigerant
Ø Refrigeration oil
Refrigerant Selection
1. Formula: CH2F-CF3
R134a
2. Physical properties: boiling point: -26.5℃ freezing point: -101.6℃
3. Colorless, odorless, non-poisonous, non-inflammable and incombustible. When
under high temperature or contacting naked fire or glowing surface, however, it will
undergo decomposition and send out poisonous irritant gas.
4. Corrosive to some rubbers
5. Corrosive to nonferrous metals such as copper and lead
6. Having a certain ability to absorb moisture
7. Different from R12, it will destroy the ozone layer.
Refrigeration oil
Lubricating oil used in air conditioning system is often called refrigeration oil.
Purpose:
1. Lubricating:
Compressor is a machine that operates at high speed and its bearings, piston, piston ring,
connecting rod, crankshaft, etc. need to be lubricated so as to reduce resistance and wear,
extend their service life, reduce power consumption, and improve the refrigeration coefficient.
2. Sealing:
All compressors used in vehicles are semi-closed. Oil seal is required for sealing the input
shaft of the compressor so as to prevent the refrigerant from leaking. However, the oil seal
will work only on condition that lubricating oil is used. In addition, the lubricating oil on the
piston ring can reduce friction as well seal compressed steam.
Refrigeration oil
3. Cooling:
High-temperature friction surfaces in motion need to be cooled by using refrigeration oil. If
the refrigeration oil is insufficient, the compressor will have an excessively high temperature
and exhaust pressure, which will reduce the refrigeration coefficient or even damage it.
4. Reducing compressor noise
Matters needing attention when using refrigeration oil:
1. Different brands of refrigeration oil cannot be used together and otherwise, they will
deteriorate.
2. Refrigeration oil has an extremely high water absorption ability and therefore the
refrigeration oil bottle must be tightly capped immediately after use.
3. Do not use any deteriorated refrigeration oil. When different brands of refrigeration oil are
used together, there will be chemical reaction occurring because the antioxidants added into
these refrigeration oils are different, which leads to refrigeration oil deterioration and damage
to them.
4. In addition, refrigeration oil failing to work will reduce the heat exchange performance of
the heat exchanger. So, the amount of refrigeration oil added can only reach the specified
value and overuse is prohibited.

Note: the refrigeration oil for Chery air-conditioning systems is R134A and its
model is SP10 or PAG, i.e. Polyalokylene Glycol .
V. Functions & Common Faults of Main Parts of Air
Conditioning System

1. Compressor

2. Expansion valve

3. Reservoir
4. Condenser

5. Evaporator

6. Hose
1. Compressor

As the core part of the automotive air conditioning system, the compressor has two main
functions: one is to produce low pressure within the system; and the other is to compress the
gaseous refrigerant from low pressure to high pressure and increase its temperature. The
compressor is the conversion device within the refrigerating system between low pressure
and high pressure as well as between low temperature and high temperature. Its normal
working is prerequisite to accomplishment of heat exchange.
Main defect modes include:

1. Belt pulley is corroded due to overheat and sends out abnormal noise.
2. Contaminated system, jammed piston, abnormal noise, and no ability to carry out air
conditioning.
3. Valve plate is broken and the system cannot form pressure difference.
 Compressor: the heart of the whole refrigerating system with main
functions including air suction, compression and pumping.

Low-temperature and
low-pressure refrigerant Suck in low-temperature and low-pressure refrigerant
steam from the evaporator

Compress the refrigerant steam to increase its temperature

and pressure

Refrigerant 3.0.7 for Chery automotive compressor

High-temperature and Features of swing variable displacement compressor:

high-pressure refrigerant
•Features:
•Continuously variable displacement reduces engine
power consumption
• Torque change produced due to frequent clutch
working has been improved to enhance drive comfort.
• Reduced interior temperature fluctuation range
improves environmental comfort.
 Main shaft
Drive pin Central sleeve
Oil plug
Drive rod Clasp Return spring

Connecting rod Piston

Front thrust bearing
Valve plate

Main bearing

Suction cup Rear cover

Shaft seal

Rotor Planetary plate

Sliding pin guide plate Cylinder body
Front cover
belt pulley

Compressor section drawing

Symptom:
Abnormal noise from the compressor

Possible causes
Ø (1) Slipping or damaged electromagnetic clutch
Ø (2) Insufficient or excessive refrigerant
Ø (3) Loosened or seriously worn compressor bearing
Ø (4) Excessively low compressor refrigerant oil level
Ø (5) Worn or damaged internal part(s) of the compressor
2. Expansion Valve

Functions:
1. To reduce the refrigerant pressure and ensure that the
refrigerant is evaporated within the evaporator.
2. To adjust the flow rate of the refrigerant flowing into
the evaporator so as for it to adapt to the refrigeration
load change.
3. It is noticeable that expansion valve does not control
the temperature within the evaporator.
 p1
thermostatic charge

diaphragm
p2 low pressure gas
rod (pressure Pe,
temperature Te)
High pressure low pressure
liquid liquid - gas

p3
adjusting screw ball
 p1
thermostatic charge

diaphragm
p2 low pressure gas
rod (pressure Pe,
temperature Te)
High pressure low pressure
liquid liquid - gas

p3
adjusting screw ball
Common Faults with Expansion Valve

Ø Unsatisfactory refrigeration effect

Ø Frosted low-pressure tube or even liquid hammering occurring
Ø Jammed expansion valve: the low pressure side has a very low pressure or even is vacuum,
the system fails in refrigeration, the high-pressure side has a relatively low pressure, or/and
the condenser is not hot.
3. Reservoir

Functions:

Ø To store surplus refrigerant

Ø Filtering, moisture extraction & vapor-liquid separation

Ø Check whether the filling into the system is normal

 Figure 1-8-2 Reservoir/dryer
1 – from the condenser 2 - lay of filtering material 3
– desiccant 4 – outlet pipe 5 – to the thermal
expansion valve
Common Faults

Ø Jamming judgment method: there is a temperature difference between inlet and

outlet and the pressure meter indicates that the high pressure is relatively high and
the low pressure is relatively low.
Ø Desiccant failing to work: there is ice barrier and the pressure meter indicates that
both high pressure and low pressure are relatively low.
4. Condenser Function:
To enable high-temperature and high-pressure gaseous refrigerant from
Refrigerant inlet
the compressor to exchange heat with the external air, turn it into high-
temperature and high-pressure liquid refrigerant and release the heat
into the external environment.

Maintenance: flush it with

Refrigerant outlet water from inner to outer.
Main faults: leakage & jam
5. Evaporator
Function:
To boil and evaporate the throttled and depressurized liquid
refrigerant, which absorbs the heat on its surface and thus
reduces its temperature. And the motor-driven blower blows
the cold blast into the car, enabling heat exchange between
the refrigerant going into the evaporator and its external air.
Thus, the air outside the evaporator releases heat and is
cooled.

Possible problems:
Being easily dirty, leakage, excessive refrigerant
Evaporator Housing for Chery Vehicle & Blast Pipe

Fig. Independent housing system with air feeder

1.Air throttle; 2.Heater core; 3. Blower fan motor; 4. Fresh air; 5. Fresh/recirculated air
throttle; 6. Recirculated air; 7. Evaporator core; 8. combination air throttle; 9. To the panel;
10. A/C air throttle for defrosting; 11. To the defroster; 12. To the bottom outlet; 13. Air
throttle for heating and defrosting.
 6. Hose
The air-conditioning hose line connects various
refrigeration parts together to form an entire cycle
system, being mainly composed of the following four
hoses:
• Compress & condenser
• Condenser & dryer
• Dryer & evaporator
• Evaporator & compressor

Hose defect modes & determination

This hose's burst pressure is 80Kg/cm2

and the region neighboring the burst
point has burn marks produced due to
high temperature.
 VI. Refrigerant Filling

Ø Connect the refrigerant flow meter.

Ø Open the refrigerant tank.
Ø Bleed the air.
Ø Open the low-pressure hose for refrigerant flow meter.
Notice: strictly speaking, the refrigerant tank can only be
placed vertically and no tilting is allowed here.
Matters Needing Attention When Filling
Refrigerant

1. Keep refrigerant away from skin. Rubber gloves and safeguard glasses shall be worn
during the filling operation.
2. Be sure to operate in a place with good ventilation. This is because refrigerant is
colorless gas with its density more than the air density under the normal room
temperature and if ventilation is not insufficient, it will deposit on the maintenance
ground and further easily suffocate the operators.
3. Do not contact the refrigerant with any naked fire, and otherwise there will be poisonous
gas emitted.
4. Any O-ring can only be used once.
5. Chery A15RHD vehicle uses R134a refrigerant, which cannot be used together with R12.
Use of different compressor oils is prohibited. During the operating procedure, any tool
that has contacted some refrigerant is not allowed to contact any other refrigerant any
more.
 VII. Refrigeration Oil Filling

1. Carry out vacuum pumping

It is necessary to connect high-pressure as
well as low-pressure hoses.
2. Directly fill refrigeration oil
3. Fill refrigeration oil while filling refrigerant
 VIII. Air Conditioning Control System

1. Blower switch
2. Temperature control switch
3. Air flow distribution switch
4. A/C switch
5. Internal circulation switch

The compressor can work only on condition that the blower and A/C switch are simultaneously on.
1. Blower switch
2. Temperature control switch
3. Air flow distribution switch
4. A/C switch
5. Internal circulation switch
 Leakage Check

In the refrigerating system, leakage may occur at any joint of any two parts. The joints that
easily undergo leakage are as follows:
1. Joints of condenser parts just removed or troubleshot.
2. Joints of condenser inlet and outlet hoses.
3. Joints of expansion valve inlet and outlet hoses.
4. Joints of compress inlet and outlet hoses.
When visually examining the above parts, it can be regarded as leakage occurring at this joint
if oil stains are found on the surface. However, the visual examination method is not accurate
enough and therefore in this case it is necessary to employ some other method for
confirmation.
Now that no electronic leak detector is equipped in many service stations, the following mainly describes
two often used leak detection methods.
Soap bubble method
1. Cut a cake of soap into slices and dissolve them by immersing them into hot water to form thick
yellowish soapy water. (if 5~10% glycerol is added into it, the bubble presence time can be extended.)
2. Clean the joint to be examined by removing oil stains thereon and use a hairbrush to smear soapy water
onto it. Carefully examine it after several minutes.
3. If air bubbles continuously come into existence, it is indicated that the joint is just a leak point.
4. Make a mark on it and continue to examine the next joint of possible leakage. Change the relative faulty
parts after examining all joints of possible leakage.
Pressure method
This method applies to the scenarios that a certain pressure exists within the system. If the refrigerant within
the system has been completely leaked or if the system has not yet been filled with refrigerant after being
troubleshot and assembled, it is possible to fill some high-pressure gas into the system so as to search out
leak points. Keep its internal pressure being 1~2MPa and employ the soap bubble method for examination.
High-pressure gas used for filling into the system, often nitrogen gas, must be dry, non-corrosive and
noninflammable.
IX. A1-series Air
Conditioning Circuit
Diagram

A+ Positive pole of storage battery

E9 Blower switch
J5 Blower relay (in the electrical box)
F18 Temperature sensitive switch
J6 Rear window preheating relay (in the electrical box)
N23 Blower speed cascade regulation resistance
⑤ Grounding point, within the wire harness of the sheath I
V2 Blower
⑥ Grounding point, the ground support near the central electrical box.
V7 Fan motor
J32 Air conditioning relay
J69 High speed relay for cooling fan
J70 Low speed relay for cooling fan
 Air conditioning system

Air conditioning relay High speed

Blower relay
isolation relay

To the positive pole of the

storage battery

Evaporator temperature switch

Spare To ECU 36

A/C switch To ECU 104 To ECU 102

Air conditioning
working indicator
Internal circulation switch
light

Low speed relay

High speed relay

Blower switch

Internal circulation
Black electromagnetic valve

White To the main relay To the main relay

Red
Green
Blue
Violet Blower Fan motor Fan motor
Yellow
Pink Blower speed
Brown regulation module
Grey
Orange
Milk white
Livid
Fault symptom:
Hot blast is not hot

Possible causes:
Ø Water pipe disconnection
Ø Water valve for hot blast fails
Ø Jammed water way
Ø Low blower speed
Ø Combination air throttle cannot return
Ø Blower fails to work
CHERY AUTOMOBILE

Lecturer: Yao Zhikun

 Anti-theft System Overview (Cvt/A520)

Chery automotive electronic anti-theft system is a new automotive anti-theft system

reaching the international advanced level in late 1990s. This system employs a non-contact
wireless sensor technology for password transmission, calculation and authentication.
Compared with previous anti-theft & alarm systems, this electronic anti-theft system
mainly includes the following advantages:

Ø To directly cover the engine and integrate the key, electronic anti-theft device and
ECU through a complete anti-theft policy into an organic anti-theft system, thereby
considerably improving the car's entire security.
Ø To implement multi-layer password authentication between the key, anti-theft device
and ECU so as to improve the system security.
Ø To employ the induction mode with no moving part needed.
Ø To be free of noise, light contamination, misoperation, etc.
Ø No extra operation needed, easy to use and nearly imperceptible during its application.
Ø It is impossible to use a jumper wire to start the engine.
 Detachable Electronic Anti-theft Device

Anti-theft
computer

Coil
With a microprocessor To produce an induction
integrated therein, it field and transmit the
authenticates the communication signals
validity of the between controller and
transponder in service transponder.
through comparison
and controls the
operations of ECU.

Mechanical Transponder
key

Detachable electronic anti-theft device

 Schematic Diagram

Ignition lock
cylinder

Key head

Coil

Key housing

Transponder
Magnetic field
 Circuit Diagram

A1 30

A2 15
A4 GND
B1
Coil B2 Anti-theft A5
computer ECU
B3 A8

A7 Diagnosis tester
How to Recognize Whether A Key Contains A
Chip

AN

W
 Self-diagnostic Function

• The anti-theft device has the self-diagnostic function and can read fault codes corresponding
to specific faults through the special diagnostic tester.
Fault Code Fault Cause Troubleshooting
9000 Internal fault of anti-theft device Change it
1. Check the connecting wire harness for
the W-wire pin of anti-theft device.
B040 Communication error occurs on W wire
2. Change anti- theft device or electronic
injector.
Check the connecting wire harness between
B042 W wire grounded W wire of anti- theft device and the pin for
grounding wire.
Check connecting wire harnesses between
B043 W wire short-circuited to power source W wire, ignition end and the pin of storage
battery.
1) Check the connecting wire harness
LED circuit shorted to the ground or
B045 between LED and anti-theft device
unclosed, leading to abnormal working 2) Change the LED.
Fault Code Fault Cause Troubleshooting
1) Check the connecting wire harness
B048 LED circuit shorted to power source between LED and anti-theft device.
2) Change the LED.

1) Check the coil of anti-theft device.

B055 No key detected 2) Change the transponder chip within the
key.

No key information stored in anti- Use the diagnostic tester to write the key
B056
theft device information into the anti-theft device

Pin code not written into anti-theft Use the diagnostic tester to write the pin code
B057
device into the anti-theft device

No request signal received from Check the connecting wire harness for the
B059
electronic injector anti-theft device's R-wire pin.
Fault Code Fault Cause Troubleshooting
1) Match the key information again.
B060 Illegal key information received
2) Change the key chip.

Communication with the key 1) Check the coil of the anti-theft device
B061
interfered 2) Change the key chip

Read-only key information

B077 Change the key chip
detected
 Key Match

Switch the ignition switch

Connect the diagnostic tester to the position "ON" Input the car model
 Inquire About the Number of Keys

The diagnostic tester can be used to inquire

about the number of existing keys as well
as the maximum number of keys that can
be made.
 Brief Summary

q A15-series vehicle electrical system composition.

q Structure & operational principle of A1-series
vehicle electrical system.
Thanks！！！