Introduction
Introduction
SERVICE INFORMATION
INTRODUCTION
WARNING This indicates that injuries to you or other people may happen.
This indicates that damage to repairing components may
CAUTION
happen.
ENVIRONMENTAL PROTECTION Dispose of waste materials according to local regulations.
Provide additional information to help you with service
HINT
operations.
2. Service procedure
Illustrations for service procedures are used to identify components, show the assembling relevance of
parts, and explain the visual check for parts. Removal and installation procedures are explained in words.
Service procedures include:
Detailed removal and installation instruction
Illustration
Torque specifications
Specifications
Sometimes, the illustrations of similar models are used. In this case, minor details may be different from
actual vehicle.
3. Diagnosis procedure
Diagnosis procedures are divided as below:
Diagnostic Trouble Code (DTC)
DTC is an important hint when troubleshooting is difficult to simulate. The malfunction can be
diagnosed quickly and accurately by performing specified DTC diagnosis and check.
Problem symptoms table
Malfunction locations can be determined quickly by troubleshooting in accordance with symptom type.
4. Specifications
This manual categorizes specifications as below:
Torque specifications
Clearance specifications
Capacity specifications
Preparation
1. Preparation for vehicle service
02
2
5
6 3
RM16020010
Lift Center
Front
RM16020020
02
Attachment
RM16020030
Service Operation
1. How to use fasteners
WARNING
Using incorrect fasteners may cause damage to components. Injury and death may occur without
observing the instructions below.
02
Reference values of fasteners and torque specifications in this service manual use metric unit.
Recycling all fasteners (nuts, bolts, etc.) during maintenance and service operation is important for
assembly.
If it is impossible to recycle fasteners, be sure to use other fasteners with the same specifications.
2. Remove parts
When repairing malfunction, try to determine the cause.
Before starting work, parts or sub-assemblies that have
to be removed and replaced should be confirmed first.
After removing parts, block all holes and ports to prevent
foreign objects from entering.
RM16020040
3. Disassemble components
If disassembly procedures are complicated and multiple parts need to be disassembled, make sure that
disassembly methods won't affect the performance or appearance of parts. Identify each part for assembly.
4. Check parts
After removal, check each part for deformation, damage or other problems.
5. Arrange parts
Carefully arrange all disassembled parts to make assembly easier.
Always separately arrange replaced parts and reusable parts, and make marks on them.
6. Clean parts
Make a thorough and careful cleaning for reusable parts.
WARNING
Blowing out dirt or other particles with compressed air may hurt your eyes. Be sure to wear goggles
during operation.
7. Assemble components
When assembling parts, always strictly use standard values (tightening torque and clearance value, etc.).
If following parts need to be replaced, replace them with
new ones.
Oil Seal Cotter Pin
- Oil seal
- Gasket
- O-ring Gasket Nylon Nut
- Lock washer 02
- Cotter pin
O-ring Lock Washer
- Nylon nut
RM16020050
RM16020060
Clamp Track
RM16020070
[Link]
When using a vise, install protective plates on jaws of
vise to prevent parts from being damaged.
02
RM16020080
[Link]
When testing vehicle on dynamometer, pay attention to the following:
Place a fan in front of vehicle. It is best to use a fan of which the power changes in proportion to vehicle
speed.
Connect an exhaust gas ventilator.
WARNING
Exhaust gas may cause injury and death. There is odorless, colorless Carbon Oxide (CO) in the exhaust
gas. People will faint and get poisoned after inhaling it.
VEHICLE INFORMATION
Vehicle Identification Information
1. Vehicle Identification Number (VIN)
VIN is located on the upper left part of instrument panel
on driver side, and can be seen from outside through * *
windshield. LVVDCXXXXXXXXXXXX
02
RM16020090
* *
LVVDCXXXXXXXXXXXX
RM16020100
1 2 3 4 5 6
RM16020110
No. Definition
1 World Manufacturer Identifier
2 Vehicle Features
3 Accuracy Check Digit
4 Model Year
02 5 Production Plant
6 Sequential Number
RM16020120
3. Engine number
Engine number is stamped on engine block.
* * *
SQRE4G16 XXXXXXXXX
02
RM16020130
4. Transmission number
Transmission number (for MT model) is stamped on
transmission case.
QR525MHE
XXXXXXXXX
RM16020140
RM16020150
Symbols
The symbols below are instrument cluster display symbols and some international standard symbols.
+ -
1 2 3 4 5 6
02 EPC
7 8 9 10 11 12
13 14 15 16 17 18
OFF
19 20 21 22 23 24
25 26 27 28 29 30
ཽ⪔⊳䖜
to another vehicle, inspect DLC on original vehicle.
If communication is still not possible when the tester is
connected to another vehicle, the tester itself is probably
defective.
RM16020160
Step Description
1 Obtain detailed information when electrical malfunction occurs.
Operate affected system, and perform a road test as necessary.
2 Confirm malfunction parameter.
If it is impossible to duplicate malfunction, refer to "Electrical Malfunction Simulation Test".
02 Collect proper diagnosis materials, which include:
Circuit Diagram
System Schematic Diagram
3 Relevant Chapter in Service Manual
Service Bulletin
Perform diagnosis according to system operation knowledge and customer feedback that we
possess.
Check if there is any bonding, loose connector or damaged wire harness in the system.
4 Determine related circuits and components, and diagnose according to circuit diagram and
wire harness layout diagram.
5 Repair circuit and replace component as necessary.
Operate system in all modes. Confirm that system can operate normally in all conditions.
6 Confirm that you have not inadvertently created new malfunctions during your diagnosis or
repair steps.
Slightly Vibrate
Slightly Wiggle
RM16020170
HINT:
When a connector is exposed to humid environment, a layer of corrosive film may be formed on its
terminals. With connector connected, this condition may not be found by visual check. If an intermittent
malfunction occurs, it may be caused by corrosion. It is recommended that terminals of relevant
connectors in system should be checked and cleaned after disconnecting the connectors.
b. Sensors and relays
Slightly vibrate sensors and relays in system being checked. The sensors or relays that are loose or
poorly installed may be found through this test.
c. Engine compartment
There are many reasons for electrical malfunction that occurred due to vehicle vibration, and it is
necessary to check following conditions:
- Connectors are not installed correctly.
- Wire harness is not long enough, so it is extended when engine is vibrating or shaking.
- Wire harness hangs over brackets or movable components.
- Ground wire is loose, dirty or corrosive.
- Wire harness is too close to high temperature components.
To inspect components under the engine hood, first confirm that ground connection is in perfect
condition (refer to the grounding inspection described below). First confirm that system is correctly
grounded. Then slightly vibrate the wire harness or components as previously instructed method to
check if connection is loose. Refer to the circuit diagram to check continuity of wire harness.
d. Backside of instrument panel
Improper wire clamping will cause wire harnesses to be entangled when installing accessories.
Vibration of vehicle will cause wire harnesses near the bracket or mounting screw to wind
excessively.
When vehicle vibrates, unclamped or loose wire harness will be stuck in seat components (such as
slide guide). When wire harness passes through the underside of mounting area, check if it is
damaged or stuck.
2. Thermosensitive test
In hot weather or after vehicle is parked for a short time, some users may worry about the vehicle
condition. At this time, it is necessary to perform thermosensitive test.
Perform test by heating components with a heat gun or equivalent.
CAUTION
3. Freezing test
If malfunction disappears after warming up vehicle in winter, it may be caused by freeze of some parts in
the wire harness/electrical system. Use following two methods to check this condition:
Method 1: Put vehicle outdoors overnight. Make sure that temperature is low enough to duplicate the
malfunction. Perform a quick and thorough diagnosis for component that may be affected in the morning.
Method 2: Put suspected part in refrigerating room and wait until it is frozen. Reinstall the part to vehicle
and check if malfunction reoccurs. If malfunction occurs, repair or replace the component.
4. Leakage test
Malfunction may occur only during high humidity or in
rainy or snowy weather. In this case, malfunction may
occur due to the water entering electrical parts. Leakage
can be checked by spraying water to vehicle (similar to
car wash).
AR
RIZ
07
CHERY
RM16020180
5. Load test
Malfunction occurs only when electrical equipment is
turned on. Turn on electrical equipment (A/C, rear
window defroster, radio and fog lights, etc.) one by one
and determine the relationship between electrical
equipment and malfunction. Determine the malfunction
by a load test.
RM16020190
If resistance of single wire harness measured by a digital multimeter is very low (0 Ω or close to 0 Ω), the
wire harness or circuit is normal.
Unnecessary resistance in circuit may be caused by poor, loose grounding, corrosive switch contact and
loose wire harness connector or adapter.
RM16020200
Disconnecting battery cable will delete the clock, audio and DTC records. Therefore, it is necessary to
confirm these records before disconnecting the cable.
Never connect electrodes of battery terminals reversely.
Only install components that meet the vehicle specifications.
1. Inspect input and output conditions of components and their functions before replacing control module.
When disconnecting components:
- Do not use excessive force when disconnecting connectors.
- If connector is installed with a tightening bolt, loosen bolt and then disconnect the connector by
hand.
When connecting components:
- Make sure that terminals are not bent or damaged, and then connect connectors correctly before
installation.
- Tighten bolt until painted area of connector is flush with the surface when installing connector with a
tightening bolt.
Never drop or hit control modules to prevent excessive impact.
Avoid that condensation is formed on control modules due to extreme change of temperature, and keep
them free from water drop or rain. If water is found on the control module, dry it thoroughly and then
install it to vehicle.
Be careful not to allow fluid to adhere to control module connectors.
Avoid cleaning the control module with volatile fluid.
When using digital multimeter, be careful not to get
testing probes to contact with each other to result in a
short circuit. Avoid damaging the battery due to short
circuit in power transistor inside a control module.
RM16020210
Use specified test adapter to check input and output signals of control modules.
2. Check fuse
Check that fuse wire is connected.
Good Blown
02
RM16020220
Terminal
Deformation
Slightly Pull
RM16020230
CIRCUIT INFORMATION
How to Read Circuit Diagram
1. Connector symbols
Most of connector symbols in circuit diagrams indicate
terminal side.
02 Terminal Side
Harness Side
RM16020240
2. Option splices
E-106 E-106
16 15 8 4
E-106 E-106
SENSOR SENSOR
E-106 E-106
RM16020260
Option splice is indicated by diamonds (solid line), and marked with terminal number inside.
[1] BATTERY
IGNITION SWITCH
ON OR START [14]
2 (86) 3 (30)
INSTRUMENT
[4] MAIN
RF14 PANEL FUSE [16]
RELAY BOX (A)
10A
1 (85) 5 (87) I-004
RF19
15A
VR
VR
A4 A3 A5 A1 A2 [13]
[21] *1 *2
VR
SENSOR
I-003
MT CVT [12]
VR
1 2
G
B
I-013
BW
RW
[8]
10 13 11 3 4
1 CONTROL
MODULE
I-001
MOTOR 7 8 9
[7] M E-011
GR
TO ILLUMINATION [18]
V
2 1 6
SWITCH
[9]
B
I-009
[11] [19] TO CAN
[10] SYSTEM
E-014 3 5
B
B
B
[20]
I-006
D1 D2 D3 D4 D5
1 2 3 4 5 6 7 8 9 10 11 12 13 A16 A15 A14 A9 A8 A7
14 15 16 17 18 19 20 21 22 23 24 25 26
A6 A5 A4
A13 A12 A11 A10
A3 A2 A1
[22] D6 D7 D8 D9 D10 D11 D12
E-049
I-001 I-004 [23] W
W W
1 2 3 4 5 6 7 8 4 5 6 1 2
1 2 1 2 3
9 10 11 12 13 14 15 16
I-009 I-003
I-013
E-011 W W
W
Gr EM16530000
ABBREVIATION TABLE
Abbreviation Table
Term Abbreviation
Anti-lock Brake System ABS
02 Acceleration Sensor AES
Accelerator Pedal Position Sensor APS
Automatic Temperature Control ATC
Automatic Transmission Fluid ATF
Body Control Module BCM
Brake Pressure Sensor BPS
Camshaft Position Sensor CMPS
Clutch Pedal Position Switch CPP Switch
Crankshaft Position Sensor CKP
Data Link Connector DLC
Diagnostic Trouble Code DTC
Engine Control Module ECM
Engine Coolant Temperature ECT
Engine Speed RPM
Evaporative Emission EVAP
Evaporative Emission Canister EVAP Canister
Evaporative Emission System EVAP System
Exhaust Gas Recirculation Valve EGR Valve
Front Left Wheel Speed Sensor FLS
Front Right Wheel Speed Sensor FRS
Rear Left Wheel Speed Sensor RLS
Rear Right Wheel Speed Sensor RRS
Ground GND
Heated Oxygen Sensor O2S
Idle Air Control IAC
Intake Temperature IAT
Ignition IGN
Ignition Control IC
Immobilizer Control Module ICM
Injector INJ
Input Shaft Speed Sensor ISS Sensor
Knock Sensor KS
Manifold Absolute Pressure MAP
Term Abbreviation
Mass Air Flow MAF
Malfunction Indicator Light MIL
Oil Pressure Switch OPS
Output Shaft Speed Sensor OSS Sensor
Positive Crankcase Ventilation Valve PCV Valve
02
Power Supply PWR
Supplemental Restraint System SRS
Throttle Position Sensor TPS
Transaxle Control Module TCM
Turbine Speed Sensor TSS
Vehicle Identification Number VIN
Vehicle Speed Sensor VSS