Chery of Karry carbody components & dбн Maintenance Manual

Chery Karry Maintenance Manual

(Carbody Accessories & Dimension)

After-Sales Service Department of Chery Motor Sales Co., Ltd.

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TABLE OF CONTENTS

Chapter I Front Compartment Cover & Trunk..............................................................................8

I. Disassembly of the front compartment cover........................................................................8

1. Preparation..................................................................................................................8

2. Attention.......................................................................................................................8

3. Disassembly of the front compartment cover accessories........................................8

3.1. Disassembly steps..............................................................................................8

3.3. Assembly steps...................................................................................................8

4. Disassembly & adjustment of the front compartment cover assembly..................9

5. Disassembly & assembly of the air intake grille assembly ......................................9

5.1. Disassembly steps..............................................................................................9

5.2. Assembly steps...................................................................................................9

6. Adjustment & assembly of the front compartment cover lock................................9

6.1. Disassembly steps..............................................................................................9

6.2. Assembly steps.................................................................................................10

7. Disassembly of the compartment cover back guy.......................................................10

7.1. Disassembly steps............................................................................................10

7.2. Assembly steps.................................................................................................11

II. Disassembly of the rear door..............................................................................................11

1. Preparation................................................................................................................11

2. Disassembly of the rear cover trim panel................................................................12

2.1. Disassembly steps............................................................................................12

2.2. Assembly steps.................................................................................................12

3. Disassembly & assembly of the knob lock of the rear door...................................12

3.1. Disassembly steps............................................................................................12

3.2. Assembly steps.................................................................................................12

4. Disassembly of the lock core of the rear door.............................................................13

4.1. Disassembly steps............................................................................................13

4.2. Assembly steps.................................................................................................13

5. Disassembly of the trim of the license plate lamp...................................................14

5.1. Disassembly steps............................................................................................14

5.2. Assembly steps.................................................................................................14

6. Disassembly of the rear door handle .......................................................................14

6.1 Disassembly steps.............................................................................................14

6.2. Assembly steps.................................................................................................15

7. Disassembly of the license plate lamp........................................................................15

7.1. Disassembly steps............................................................................................15

7.2. Assembly steps.................................................................................................16

Chapter Ⅱ Disassembly & Assembly of the Internal Trim Parts..................................................17

I. Disassembly & assembly of the safety belt.........................................................................17

1. Preparation................................................................................................................17

2. Attention.....................................................................................................................17

3. Disassembly steps (e.g. driver’s safety belt).......................................................17

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4. Assembly steps....................................................................................................19

Assemble according to the inverted sequence of the disassembly.............................19

II. Disassembly & assembly of the seat..................................................................................20

2. Disassembly steps of middle row seats ....................................................................20

3. Disassembly steps of the back row seat...................................................................21

4. Assembly steps....................................................................................................22

III. Disassembly & assembly of the console...........................................................................22

1. Disassembly steps......................................................................................................22

2. Assembly steps...........................................................................................................23

IV. Disassembly & assembly of the carpet..............................................................................24

1. Disassembly steps......................................................................................................24

2. Assembly steps...........................................................................................................26

V. Disassembly of the shock pad.............................................................................................26

1. Disassembly steps......................................................................................................26

2. Assembly steps...........................................................................................................26

Chapter III Disassembly & Maintenance of the Car Door..............................................................27

I. Disassembly, assembly & maintenance of the front door....................................................27

1. Lamp system constitution diagram .........................................................................27

2. Preparation................................................................................................................28

3. Attentions...................................................................................................................28

4. Disassembly steps......................................................................................................28

5. Assembly & adjustment steps ..................................................................................32

II. Disassembly, Assembly & Maintenance of the Side Door.................................................33

1. Preparation................................................................................................................33

2. Attentions...................................................................................................................33

3. Disassembly & assembly steps.................................................................................33

4. Assembly steps...........................................................................................................36

Chapter IV Disassembly, Assembly & Maintenance of the Front & Rear Bumper........................37

I. Disassembly, assembly & maintenance of the front bumper...............................................37

1. Preparation................................................................................................................37

2. Attentions...................................................................................................................37

3. Disassembly steps......................................................................................................37

4. Assembly steps...........................................................................................................39

II. Disassembly, assembly & maintenance of the rear bumper...............................................39

1. Preparation................................................................................................................39

2. Attentions...................................................................................................................39

3. Disassembly steps......................................................................................................40

4. Assembly steps...........................................................................................................41

Chapter V Disassembly, Assembly & Maintenance of the Front Headlamp, Fog Lamp & Tail

Lamp...............................................................................................................................................42

1. Lamp system constitutional diagram......................................................................42

2. Preparation................................................................................................................42

3. Attentions...................................................................................................................42

4. Disassembly steps of the front headlamp................................................................42

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5. Disassembly of the front fog lamp ...........................................................................44

6. Disassembly of the rear fog lamp................................................................................46

7. Disassembly steps of the rear tail lamp...................................................................47

Chapter VI Disassembly& assembly of the Roof...........................................................................48

1. Preparation................................................................................................................48

2. Attentions............................................................................................................................48

3. Disassembly & assembly of the sunshade panel.................................................................48

3.1. Disassembly steps...................................................................................................48

3.2. Assembly steps........................................................................................................48

4. Disassembly & assembly of the roof handrail....................................................................48

4.1. Disassembly steps...................................................................................................48

4.2. Assembly steps........................................................................................................49

5. Disassembly & assembly of the front & rear ceiling lamp.................................................49

5.1. Disassembly & assembly of the front ceiling lamp..............................................49

5.1.1. Disassembly steps.........................................................................................49

5.1.2. Assembly steps..............................................................................................49

5.2. Disassembly & assembly of the rear ceiling lamp ...............................................50

5.2.1. Disassembly steps.........................................................................................50

5.2.2. Assembly steps..............................................................................................50

6. Disassembly & assembly of A pillar shield.........................................................................51

6.1. Disassembly steps...................................................................................................51

6.2. Assembly steps........................................................................................................51

7. Disassembly & assembly of side shield of the roof............................................................51

7.1. Disassembly steps...................................................................................................51

7.2. Assembly steps........................................................................................................51

8. Disassembly & assembly of B pillar shield........................................................................52

8.1. Disassembly steps...................................................................................................52

8.2. Assembly steps........................................................................................................52

9. Disassembly & assembly of the bottom board front storage box........................................52

9.1. Disassembly steps...................................................................................................52

9.2. Assembly steps........................................................................................................53

10. Disassembly & assembly of the roof................................................................................53

10.1. Disassembly steps.................................................................................................53

10.2. Assembly steps......................................................................................................53

Chapter VII Disassembly & Assembly of the Instrument Panel.....................................................54

Section I Instrument panel system constitutional diagram....................................................54

Section ⅡDisassembly & assembly of the instrument panel................................................55

I. Disassembly & assembly of the instrument panel accessories...............................55

1. Preparation................................................................................................................55

2. Attention..............................................................................................................55

3. Disassembly & assembly of the radio & tape player..........................................55

3.1. Disassembly steps...................................................................................55

3.2. Assembly steps........................................................................................56

4. Disassembly & assembly of the air conditioner controlled panel.......................56

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4.1. Disassembly steps...................................................................................56

4.2. Assembly steps........................................................................................56

5. Disassembly & assembly of the glove box.........................................................56

5.1. Disassembly steps...................................................................................56

5.2. Assembly steps........................................................................................57

6. Disassembly & assembly of the combined instruments......................................57

6.1. Disassembly steps...................................................................................57

6.2. Assembly steps........................................................................................59

7. Disassembly & assembly of the steering wheel..................................................59

8. Disassembly & assembly of combined switches, wiper switch and ignition

switch......................................................................................................................60

II. Disassembly & assembly of the main parts of the instrument panel ...................60

1. Preparation..........................................................................................................60

2. Attention..............................................................................................................60

3. Disassembly & assembly of the main parts of the instrument panel...................60

3.1. Disassembly steps...................................................................................60

3.2. Assembly steps........................................................................................62

Chapter VIII Air Conditioner System.............................................................................................63

I. System combination............................................................................................................63

II. Disassembly & assembly of the evaporator assembly........................................................63

1. Preparation................................................................................................................63

2. Disassembly steps......................................................................................................64

3. Assembly of the evaporator assembly......................................................................65

4. Disassembly & assembly of the interior evaporating tank....................................65

4.1. Disassembly steps............................................................................................65

4.2. Assembly steps.................................................................................................68

III. Standard sides pressure value of high pressure & low pressure of the air conditioner

system.....................................................................................................................................69

IV. Frequent Troubleshooting.................................................................................................69

Chapter IX Disassembly & Assembly of the Wiper System...........................................................72

I. Wiper system constitutional diagram...................................................................................72

II. Disassembly & assembly of the wiper mechanism............................................................72

1. Preparation................................................................................................................72

2. Attention.....................................................................................................................73

3. Disassembly steps......................................................................................................73

4. Assembly steps...........................................................................................................74

Chapter X Carbody Dimension....................................................................................................75

I.Main beam dimension..........................................................................................................75

II. Carbody assembly dimension.............................................................................................76

1. Right front view.........................................................................................................76

2. Right side view...........................................................................................................81

3. Rear view.................................................................................................................106

III. Engine room dimension..................................................................................................111

IV. Windscreen dimension....................................................................................................112

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V. Open size dimension of each part.....................................................................................114

Chapter Ⅺ Disassembly & Assembly of the Wiring Harness.....................................................115

Section I Wiring Harness of the Left Front Compartment....................................................115

I. Wiring harness sketch.............................................................................................115

II. Main plug-in units explanation.............................................................................116

III. Disassembly & assembly of the left front compartment ....................................119

(I).Preparation.......................................................................................................119

(II).Attentions........................................................................................................120

(III).Disassembly steps..........................................................................................120

(III).Assembly steps..............................................................................................124

Section ⅡWiring Harness of the Front Compartment.........................................................125

I. Wiring harness sketch.............................................................................................125

II. Main plug-in units explanation.............................................................................126

III. Disassembly & assembly of the right front compartment wiring harness.......127

(I).Preparation.......................................................................................................127

(II).Attentions........................................................................................................127

(III).Disassembly steps........................................................................................127

(IV).Assembly steps..............................................................................................129

Section III Electrical Spray Wiring Harness of the Engine...................................................130

I. Wiring harness sketch.............................................................................................130

II. Main plug-in units explanation.............................................................................131

(I).Preparation.......................................................................................................133

(II).Attention.........................................................................................................133

(III).Disassembly steps..........................................................................................133

(IV).Assembly steps..............................................................................................136

Section IV Wiring Harness of the Instrument.......................................................................137

I.Wiring harness sketch..............................................................................................137

II. Main plug-in units explanation.............................................................................138

III. Disassembly & assembly of the instrument wiring harness ..............................139

(I).Preparation.......................................................................................................139

(II) .Attentions.......................................................................................................139

(III).Disassembly steps..........................................................................................139

(IV).Assembly steps..............................................................................................140

Section V Wiring Harness of the left front door...................................................................141

I. Wiring harness sketch.............................................................................................141

II. Main plug-in units explanation.............................................................................142

III. Disassembly & assembly of the wiring harness of the left front door ..............142

(I).Preparation.......................................................................................................143

(II).Attentions........................................................................................................143

(III).Disassembly steps..........................................................................................143

(IV).Assembly steps..............................................................................................144

Section VI Wiring Harness of the Right Front Door.............................................................145

I. Wiring harness sketch.............................................................................................145

II. Main plug-in units explanation.............................................................................146

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III. Disassembly & assembly of the wiring harness of the right front door............146

(I).Preparation.......................................................................................................146

(II).Attentions........................................................................................................146

(III).Disassembly steps..........................................................................................147

(IV).Assembly steps..............................................................................................148

Section VII Roof Wiring Harness.........................................................................................149

I. Wiring harness sketch.............................................................................................149

II. Main plug-in units explanation.............................................................................150

III. Disassembly & assembly of the roof wiring harness..........................................150

(I).Preparation.......................................................................................................150

(II).Attentions........................................................................................................150

(III).Disassembly steps..........................................................................................150

(IV).Assembly steps..............................................................................................151

Section VIII Wiring Harness Inside Floor.............................................................................152

I. Wiring harness sketch.............................................................................................152

II. Main plug-in units explanation.............................................................................153

III. Disassembly & assembly of the inside floor wiring harness..............................157

(I).Preparation.......................................................................................................157

(II).Attentions........................................................................................................157

(III).Disassembly steps..........................................................................................157

(IV).Assembly steps..............................................................................................165

Section IX Wiring Harness of the Rear Trunk Door.............................................................166

I. Wiring harness sketch.............................................................................................166

II. Main plug-in units explanation.............................................................................167

III. Disassembly & assembly of the rear door wiring harness.................................167

(I).Attentions.........................................................................................................167

(II).Disassembly steps...........................................................................................167

(III)。Assembly steps...........................................................................................169

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Chapter I Front Compartment Cover & Trunk

I. Disassembly of the front compartment cover

1. Preparation

Tools: Socket wrench 10#, connecting rod, ratchet wrench, ring wrench 8#

2. Attention

In the process of the disassembly, pay particular attention to the suitable force using and the

careless operation is forbidden.

3. Disassembly of the front compartment cover accessories

3.1. Disassembly steps

3.1.1. Disassemble the earthed bolts with the tool, which is

shown as the figure

3.3.2. Take out the washing hose of the washing liquid

3.3.2. Press clips of 2 water nozzles below the front

compartment cover, drive water nozzles from the beneath

the front compartment cover and then take out water

nozzles from the outside

3.3. Assembly steps

Assemble according to the inverted sequence of the

disassembly

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4. Disassembly & adjustment of the front

compartment cover assembly

4.1.Unscrew 4 bolts of the front compartment cover, which can

take out the front compartment cover (At the same time, through

loosening 4 bolts, the front & rear positions and left & right

positions of the front compartment cover can be adjusted).

4.2. Assembly of the front compartment cover assembly

Assemble according to the inverted sequence of the disassembly

Assembly moment：（ 10±1）Nm

5. Disassembly & assembly of the air intake grille assembly

Tool: Ring wrench 8#

5.1. Disassembly steps

5.1.1. Unscrew 6 fixing bolts of the air intake grille

assembly shown as the figure with the wrench

5.1.2. Just take out the air intake grille assembly

5.2. Assembly steps

Assemble according to the inverted sequence of the disassembly

Assembly moment：（ 8 ± 0.5）Nm

6. Adjustment & assembly of the front compartment cover lock

Tools: A drill bit with 6mm diameter & electric drill

6.1. Disassembly steps

6.1.1. The lock device under the front compartment cover

is riveted with the cross bar of the water tank through the

rivet and normally not need to disassemble it, but should

take out the rivet when required disassembly

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6.1.2. Take out the back guy of the front compartment

cover lock from the lock assembly under the front

compartment cover

6.2. Assembly steps

Assemble according to the inverted sequence of the disassembly

7. Disassembly of the compartment cover back guy

Tools: Phillips screwdriver

7.1. Disassembly steps

7.1.1. Disassemble 2 fixing bolts of the handle which

can open the front compartment cover in the car cab

Assembly moment：5±0.5Nm

7.1.2 .Take out the back guy from its cover

7.1.3. Take out the back guy head from the lock device

under the front compartment cover

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7.1.4. Take out 2 buckles which can fix the back guy

with the Phillips screwdriver

7.1.5. Take out the back guy from the closure which is

from the front compartment through the car

7.1.6. Pull out the back guy

7.2. Assembly steps

Assemble according to the inverted sequence of the disassembly

Attention: When assembling, embed the slot of the back guy into the kerf

II. Disassembly of the rear door

1. Preparation

Tools: Phillips screwdriver, ring wrench 13#, socket wrench 10#, connecting

rod, ratchet wrench, flat-end screwdriver

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2. Disassembly of the rear cover trim panel

2.1. Disassembly steps

2.1.1. Just take out the buck one by one of the internal

trim panel of the rear door

2.2. Assembly steps

Assemble according to the inverted sequence of the

disassembly

3. Disassembly & assembly of the knob lock of the rear door

3.1. Disassembly steps

Tool: Flat-end screwdriver

3.1.1. Take 2 pull rods connecting with the lock of the

rear door

3.1.2. Unscrew 3 position-fixing bolts of the knob lock

with the Ring wrench 8#, and then may take out the

lock. (Assembly Moment is 9±1Nm）

3.2. Assembly steps

Assemble according to the inverted sequence of the

disassembly

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4. Disassembly of the lock core of the rear door

Preparation tool: Flat-end screwdriver

4.1. Disassembly steps

4.1.1. Separate the lock core with the connecting rod

4.1.2. Prize up the positioning clip with the flat-end

screwdriver, take it out and then just take out the lock core

Attention: Do not throw the washer of the lock core

4.2. Assembly steps

Assemble according to the inverted sequence of the

disassembly

Pay attention to right assembly which is completely jointed

with the plate work of the car door.

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5. Disassembly of the trim of the license plate lamp

Tool: Ring wrench 10#

5.1. Disassembly steps

5.1.1. Unscrew 2 bolts of the trim panel with ring wrench 10#

5.1.2. Take out the trim panel

5.2. Assembly steps

Assemble according to the inverted sequence of the

disassembly(Assembly moment: 10±1Nm）

6. Disassembly of the rear door handle

Tool: Ring wrench 10#

6.1 Disassembly steps

6.1.1. Disassemble the pull rod of the handle, and then

unscrew 2 positioning bolts of the handle with the tool.

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6.1.2. Take out the rear handle

6.2. Assembly steps

Assemble according to the inverted sequence of the

disassembly

7. Disassembly of the license plate lamp

Tool: Phillips screwdriver

7.1. Disassembly steps

7.1.1. Take out the connector of the left & right license plate

lamps

7.1.2. Align the bolts of the license plate with the Phillips

screwdriver, unscrew them and there are 4 bolts in all.

7.1.3. Take out license plate lamps

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7.2. Assembly steps

Assemble according to the inverted sequence of the disassembly

Assembly moment：5±0.5Nm

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Chapter Disassembly & Assembly of the Internal TrimⅡ Parts

I. Disassembly & assembly of the safety belt

1. Preparation

Tools: Slotted screwdriver, wrench and socket wrench

Parts: one-time buckle

2. Attention

Keep the safety belt clean, avoid being stained with the

oil and check whether the safety belt is spoiled or not

3. Disassembly steps (e.g. driver’s safety belt)

3.1. Prize up the protective cover of the bolts above the

safety belt with the slotted screwdriver

3.2. Unscrew fixing bolts above the safety belt with the

socket wrench 17#

Moment：50±10N·m

3.3. Carefully prize the protective cover of bolts below

the safety belt with the slotted screwdriver

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3.4. Unscrew fixing bolts below the safety belt with the

socket wrench 17#

Moment: 50±10N·m

3.5. Partially disassemble the rubber strip at the driver’s

side door

3.6. Prize up the upper shield of the B pillar with the

slotted screwdriver

3.7. Prize up the pressing panel of the threshold with the

slotted screwdriver

Attention: The inside is fixed by the clip.

3.8. Unscrew 3 fixing bolts of the down shield of the B

pillar with the slotted screwdriver

Moment: 3±0.5Nm

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3.9. Take out the down shield of the B pillar

3.10. Loosen fixing bolts with the socket wrench 17#

and take out the safety belt

Moment：50±10N·m

4. Assembly steps

Assemble according to the inverted sequence of the disassembly

Attention：

4.1. Keep the safety belt clean, avoid being stained with

the oil and check whether the safety belt is spoiled or not;

4.2. The pillar shield fits with the carbody firmly, flexible

phenomenon is not allowed to start; and it should fit with

the roof, sealing strip well;

4.3.The safety belt adjusting slide way baffle plate of the

upper shield of the B pillar should move smoothly, not

affect the adjustment of the safety belt and the fit clearance

with the down shield is even and less than 1mm;

4.4. The fit clearance between the down shield of the B

pillar & the threshold pressing panel of the front and rear

door should be less than 1mm;

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II. Disassembly & assembly of the seat

Preparation tools: Ring wrench 10#, socket wrench 17#

and slotted screwdriver

1. Disassembly of front row seats

1.1. Make the seat move forward through pulling the

moving handle below the seat and uncover the fixing

bolts under the seat

1.2. Unscrew 1 fixing bolt after seats with the socket

wrench 17#

Moment：25±3N·m

1.3. Unscrew the limiting bolts of the slide way under

seats with the ring wrench 10#

1.4. Move back seats through pulling the moving

handle under seats and take out seats

2. Disassembly steps of middle row seats

2.1. Pull up the cushion of the rear row seat by hands

and separate the cushion from the buckle of the

chassis of carbody.

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Chery of Karry carbody components & dбн Maintenance Manual

Chery of Karry carbody components & dбн Maintenance Manual

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