Chery A series. Manual — part 23

ASEEMBLY AND DISASSEMBLY OF INTAKE SYSTEM

Remove accessories around the engine:

1.Loosen fastening clamp, demount air

cleaner and air intake hose.

2.Remove throttle cable and clutch cable.

3.Remove all intake pipes and vacuum

hoses around engine.

4.Put down water hose to discharge

anti-freeze liquid.

5.Disassemble the throttle position sensor/

canister solenoid/crankshaft position

sensor/Injection nozzle / knock sensor

and wire plugs on electric components

like fuel pressure switch.

CANISTER SOLENOID AND INTAKE/EXHAUST PIPE

Assembly:

——Fix the solenoid on the intake manifolds

with a semicircular clamp and tighten
two inner bolts.

——Install the solenoid intake pipe between

the activated canister and the solenoid,
then tighten the clamp around the intake
pipe with special tool.

——Install solenoid exhaust pipe between the

throttle body and the solenoid. then
tighten the clamp around the exhaust
pipe with special tool.

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OIL-VAPOR SEPARATOR

1.Oil-vapor separator 2. Air cleaner 3.Others---ventilating pipe in crankcase

Working principle:

Main function of the oil-vapor separator is leading gas in crankcase to intake manifolds
through oil-vapor separator, which keeps pressure in crankcase within a certain range and
prevent gas in crankcase from mixing and flowing out. Oil-vapor separator shall separate the
oil vapor mixture passed the crankcase to avoid the oil entering into engine where it will
generate carbon grains that causes engine wear.

Oil-vapor separator assembly, air cleaner and ventilating pipe assembly is showed in fig. A
connect to one interface on the engine valve cover; B connect to another interface on the
engine valve cover; C connect to the crankcase interface; D connect to the intake manifold
interface. Connect the ventilating pipe to the interfaces of oil-vapor separator, air cleaner
by-pass hose and engine valve with spring clamp.

Assembly and disassembly:

Fix three iron-ventilating pipes to the bolts in engine intake manifolds using 4 M8 nuts

with a tightening torque of 10±1Nm.

Maintenance of fuel-vapor separator:

Disassemble it per 5000km and wash it with lead-free gasoline, then blow it to dry.

1

A

B

2

C

D

E

F-8

EXHAUST SYSTEM

OUTLINE

Exhaust system inspection ：

·Start the engine and inspect each exhaust system component for exhaust gas leakage.

·If leakage is found, repair or replace as necessary.

Exhaust system removal/installation

Warning：

·When the engine and exhaust system are hot, they can badly burn. Turn off the engine

and wait until they are cool before removing the exhaust system.

Exhaust assembly and oxygen sensor position

1. Oxygen Sensor 2. Catalytic Converter 3. Silencer

OXYGEN SENSOR

To gain max. conversion efficiency from catalytic converter, the engine oxygen sensor always
keeps the concentration of fuel-gas mixture as chemical reaction equivalence ratio.

The sensor shall realize closed loop controlling to the mixture concentration through
measuring the proportion of oxygen in exhaust.

Oxygen sensor is installed in the first section of exhaust pipe near manifolds.

Oxygen sensor is a ZrO

2

porcelain (1) with a thin platinum layer on its surface and one end is

sealed with a protection pipe inserted in. (2), the outside bushed with a metal housing (3) to
protect the sensor and to enable it to install on the exhaust manifolds. The outside of porcelain
(b) is exposed in exhaust gas, the inside (a) communicate with outer surroundings. Working
principle: voltages generated by electrode will change with the variation of oxygen
concentration; oxygen sensor measure the components of the exhaust, thus ECU will obtain

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the mixture concentration value in time and change mixture thicker or thinner to make it
always be close to chemical reaction equivalence ratio. The voltage range of which is
0.980~1.020V.

To reach working temperature rapidly (~300°C), a resistor (4) installed in the sensor can
shorten the starting electric time of the porcelain. It means sensor can be installed in cold area
of exhaust hose. If mixed gas concentration is thinner than chemical reaction equivalence ratio
when working in full speed, ECU will give signal to the oxygen sensor to add mixture thicker
(half-closed loop).

Oxygen sensor doesn’t work under cut-off and full load condition, which is called open loop.

Recovery:

If fault occurs in sensor or resistor, all information will be ignored and the whole system will
work as an opened loop system.

Oxygen sensor test procedure:

If diagnosis tester displays signal as “lambda sensor error “, please check:

——

If there is air leakage in every manifold, pipes, brake booster, exhaust gas and fuel-vapor

re-cycle system.

——

Spark wear and efficiency of high voltage wire insulator.

——

If timing and positioning of TDC (top dead center)/rotate speed sensor is right or not.

——

Tappet clearance and engine compression ratio.

——

If supplied oil pressure is right or not.

F-10