Service Manual For Chery v525 Car

Service Manual for CHERY V525 Car Body Accessories
Service Manual for Chery V525 Car
（Body Accessories）
After Sales Service Department of Chery Automobile Sales Co., Ltd
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Contents
Chapter One Engine hood and luggage compartment....................................................................8
I. Disassembly and assembly of engine hood ........................................................................8
1 Preparation ..................................................................................................................8
2 Note.............................................................................................................................8
3 Disassembly/assembly of engine hood accessories ....................................................8
3.1 Disassembly steps ............................................................................................8
3.2 Assembly steps.................................................................................................8
4 Disassembly and adjustment of the engine hood assembly ........................................9
5 Disassembly and assembly of air intake grille assembly ............................................9
6 Adjustment and assembly of the engine hood lock.....................................................9
6.2 Assembly of engine hood lock.......................................................................10
7 Disassembly of engine hood lock control cable........................................................10
7.1 Disassembly steps ..........................................................................................10
7.2 Assembly steps............................................................................................... 11
II. Disassembly and assembly of rear luggage compartment lid.......................................... 11
1 Preparation ................................................................................................................ 11
2 Disassembly of rear lid trim panel ............................................................................12
2.2 Installation of rear lid trim panel....................................................................12
The installing steps are reverse to those for removal. .....................................................12
3 Disassembly/assembly of luggage compartment lock ..............................................12
3.2 Assembly steps...............................................................................................13
4 Disassembly of luggage compartment lock core.......................................................13
4.2 Assembly steps...............................................................................................13
5 Disassembly of rear wiper water nozzle ...................................................................14
5.2 Assembly steps...............................................................................................14
6 Disassembly of rear wiper motor ..............................................................................14
6.2 Assembly steps...............................................................................................15
7 Disassembly of license plate light trim panel ...........................................................15
7.1 Disassembly/assembly steps ..........................................................................15
8 Disassembly of luggage compartment handle...........................................................16
8.2 Assembly steps...............................................................................................17
9 Disassembly of license plate light.............................................................................17

9.2 Assembly steps...............................................................................................17

The installing steps are reverse to those for removal. .....................................................................17
Chapter Two Disassembly and Assembly of Inner Trimming Parts............................................18
I. Disassembly and assembly of seat belt.............................................................................18
1 Preparation ................................................................................................................18
2 Note...........................................................................................................................18
3 Disassembly steps（e.g. front seat belt）.................................................................18
4 Assembly steps..........................................................................................................20
II. Disassembly/assembly of seat .........................................................................................20
1 Disassembly steps .....................................................................................................20
2 Assembly steps..........................................................................................................20
III. Disassembly and assembly of the Armrest Box and Sub Instrument Panel ...................21
Tool: cross head screwdriver...................................................................................................21
2 Assembly steps..........................................................................................................21
IV. Disassembly and assembly of carpet..............................................................................21
V. Disassembly of Shock Absorber......................................................................................24
1 Disassembly steps .............................................................................................................24
2 Assembly steps..........................................................................................................24
Chaper Three Disassembly/Assembly and Maintenance of Door................................................25
I. Disassembly/assembly and maintenance of front door.....................................................25
1. System diagram........................................................................................................25
2 Preparation ................................................................................................................26
3 Note...........................................................................................................................26
4 Disassembly/assembly steps .....................................................................................26
5 Assembly and adjustment steps ................................................................................33
5.1 Assemble door lock........................................................................................33
5.2 Door adjustment.............................................................................................36
II. Disassembly/Assembly and Maintenance of Rear Door .................................................37
1 Preparation ................................................................................................................37
2 Note...........................................................................................................................37
4 Assembly and adjustment steps ................................................................................40
4.1 Assembly of rear door glass...................................................................................40
Chapter Four Disassembly/Assemlby and Maintenance of the Front and Rear Bumper................41
I. Disassembly/assembly and maintenance of front bumper................................................41
1 System diagram.........................................................................................................41
2 Preparation ................................................................................................................41
3 Note...........................................................................................................................41
5 Assembly and maintenance.......................................................................................43
II. Disassembly/assembly and maintenance of rear bumper ................................................44
1 System diagram.........................................................................................................44
2 Preparation ................................................................................................................44

3 Note...........................................................................................................................44
5 Assembly steps..........................................................................................................46
Chapter Five Disassembly/Assembly and Maintenance of Front Headlamp and Fog Light .......47
1 System diagram............................................................................................................47
2 Preparation ...................................................................................................................47
3 Note...........................................................................................................................47
4 Disassembly steps for headlamp ...............................................................................48
5 Disassembly of fog lamp...........................................................................................49
6 Installation and adjustment of headlamp...................................................................50
6.1 Assembly steps of headlamp..........................................................................50
The installing steps of headlamp are reverse to those for removal. ........................50
6.2，Introduction of headlamp function.................................................................50
6.2.1，Front view ...........................................................................................50
6.2.2 Back view............................................................................................50
6.3 Adjustment for headlamp beam .....................................................................51
Chapter Six Disassembly/Assembly of Roof and Scuttle ............................................................52
I. Disassembly/Assembly of Roof .......................................................................................52
1 Preparation ................................................................................................................52
2 Note...........................................................................................................................52
3 Disassembly/assembly of sunvisor ...........................................................................52
3.2 Assembly steps...............................................................................................52
4 Disassembly/assembly of ceiling handle ..................................................................53
4.2 Assembly steps...............................................................................................53
5 Disassembly/assembly of front ceiling light .............................................................53
5.2 Assembly steps...............................................................................................54
6 Disassembly/assembly of rear ceiling light...............................................................54
7 Disassembly/assembly of A pillar protecting board..................................................55
7.2 Assembly steps...............................................................................................55
8 Disassembly/assembly of B pillar protecting board..................................................55
8.2 Assembly steps...............................................................................................56
9 Disassembly/assembly of C pillar and D pillar protecting board..............................56
9.2 Assembly steps...............................................................................................57
10 Disassembly/assembly of the roof ..........................................................................57
10.1 Disassembly steps ........................................................................................57
10.2 Assembly steps.............................................................................................58
II. Disassembly of Scuttle Assembly ...................................................................................59

1 Preparation ................................................................................................................59
3 Assembly steps..........................................................................................................59
III. Decomposing of Scuttle Assembly ................................................................................60
1 Preparation ................................................................................................................60
2 Disassembly/assembly of scuttle glass......................................................................60
2.2 Assembly steps...............................................................................................61
3 Disassembly and assembly of scuttle motor and scuttle control unit........................62
3.2 Assembly steps...............................................................................................63
4 Disassembly/assembly of scuttle sun visor ...............................................................64
4.2 Assembly steps...............................................................................................64
IV. Guide for scuttle maintenance........................................................................................64
1 Reset scuttle control unit...........................................................................................64
2 Typical fault diagnosis and trouble shooting.............................................................65
2.1 Scuttle looses it original position ...................................................................65
2.2 Water leaking of scuttle assembly..................................................................65
2.3 Strange noise of scuttle assembly ..................................................................65
3 Frequently appeared fault and their check and maintenance methods ......................66
4 Maintenance note and daily service ..........................................................................67
Chapter Eight Disassembly/Assembly of Instrument Panel ........................................................68
I. Disassembly of instrument panel accessories...................................................................68
1 Preparation ................................................................................................................68
2 Disassembly/assembly of central control panel and fog lamp switch.......................68
2.1 Disassembly steps： ......................................................................................68
2.2 Assembly steps：...........................................................................................69
3 Disassembly/assembly of AC control panel..............................................................69
3.2 Assembly steps...............................................................................................69
4 Disassembly/assembly of audio ................................................................................69
4.2 Assembly steps...............................................................................................69
5 Disassembly/assembly of front ashtray.....................................................................70
5.2 Assembly steps...............................................................................................70
6 Disassembly/assembly of glove box .........................................................................70
6.2 Assembly steps...............................................................................................71
7 Disassembly/assembly of combined instrument .......................................................71
7.2 Assembly steps...............................................................................................72
8 Disassembly of steering wheel..................................................................................72


8.2 Assembly steps...............................................................................................73
9 Disassembly/assembly of headlamp combined.........................................................73
switch, wiper switch, ignition switch, coil cable ............................................................73
(Please refer to disassembly/assembly of........................................................................73
steering column in Chassis Service Manual) ..................................................................73
II. Disassembly of Instrument Panel ....................................................................................74
1 Disassembly/assembly of instrument panel ..............................................................74
1.2 Assembly steps of instrument panel...............................................................76
2 Disassembly of instrument cross beam.....................................................................77
2.2 Assembly steps...............................................................................................80
Chapter Nine AC System.............................................................................................................81
I. System Composition.........................................................................................................81
II. Disassembly of evaporator assembly ..............................................................................81
1 Preparation ................................................................................................................81
3 Installation of evaporator assembly ..........................................................................83
4 Disassembly/assembly of interior evaporator ...........................................................83
4.1 Blower replacement .......................................................................................83
4.1.1 Disassembly steps ...............................................................................83
4.1.2 Assembly steps....................................................................................83
5 Disassembly/assembly of blower speeder module....................................................83
5.2 Assembly steps...............................................................................................84
6 Disassembly/assembly of heating water tank ...........................................................84
6.2 Assembly steps...............................................................................................86
7 Disassembly/assembly of mode ventilator................................................................86
motor and related mechanism .........................................................................................86
7.1 Disassembly/assembly steps ..........................................................................86
7.2 Assembly steps...............................................................................................87
8 Disassembly/assembly of mixing ventilator motor and related mechanism .............87
8.2 Assembly steps...............................................................................................88
9 Disassembly/assembly of inside/outside circulation ventilator motor and related
mechanism ......................................................................................................................88
9.2 Assembly steps...............................................................................................88
10 Disassembly/assembly of evaporator......................................................................88
10.2 Assemble evaporator assembly ....................................................................89
11 Disassemble other accessories from evaporator......................................................89


11.2 Assemble of other accessories for evaporator ..............................................90
III. Trouble shooting ............................................................................................................90
Chapter Ten Body Size ................................................................................................................93
I. Beam Dimension ..............................................................................................................94
II. Body assembly dimension...............................................................................................95
1 Front view .................................................................................................................95
2 Rear view ................................................................................................................100
3 Left side view－1.......................................................................................................105
4 Left side view-2 ......................................................................................................... 113
III．Engine Compartment Dimension.................................................................................. 117
IV. Windscreen Dimension ................................................................................................ 118
V. Dimension of All the Opening....................................................................................... 119

Chapter One Engine Hood And Luggage Compartment
I. Disassembly and assembly of engine hood
1 Preparation
Tool: flat head screwdriver, pliers, wrench
2 Note
2.1 Pay attention to use correct force during disassembly and assembly , and it is not allowed to
operate with too big force.
2.2 Pay attention to avoid scoring the surface during the inner trimming parts disassembly and
assembly.
3 Disassembly/assembly of engine hood accessories
3.1 Disassembly steps
3.1.1 Take off the snap clips(19 pieces) by screwdriver from

heat insulator, and take off the engine heat insulator.
3.1.2 Take off the hose of washing liquid.
3.1.3 Take off two water nozzle clips from engine hood, Push
the nozzles under the hood and get out of the nozzles front
outside.
3.2 Assembly steps
The installing steps are reverse to those for removal.

4 Disassembly and adjustment of the engine hood assembly
Tool: No. 13 spanner

4.1 Take off four adjusting bolts from engine hood.
And disassemble the engine hood.
At the same time, through unscrewing four adjusting bolts,
move and adjust the position of engine hood.
4.2 Assembly of front engine hood assembly:

Installation torque: 29±3Nm
5 Disassembly and assembly of air intake grille assembly
5.1.1 Take off four fixing bolts by spanner from air intake
grille assembly, see the chart.
5.1.2 Take off air intake grille.

Note: take off the air intake grille horizontally to avoid to
damage the clips on the grille.
5.2 Assembly of air intake grille

Installation torque: 5±0.5Nm
6 Adjustment and assembly of the engine hood lock
Tool: No.10 spanner
6.1.1 Disassemble the front engine hood lock by unscrewing

these three centering bolts from engine hood.
And also the lock position can be adjusted by these three
centering bolts.

6.1.2 Take off the lock cable from engine hood.
6.2 Assembly of engine hood lock

7 Disassembly of engine hood lock control cable
Tool: No. 8 spanner, No.10 spanner, flat head screwdriver
7.1.1 Disassemble two fixing bolts from engine hood opening handle inside of the cab.
7.1.2 Take off the front cover control cable from cover.
7.1.3 Take off engine hood lock, and disassemble the

cable from engine hood lock assembly.

7.1.4 Unscrew two clips from fixing cable by flat head

screwdriver.
7.1.5 Disassemble front bumper and driver’s side

fender (see fender disassembly)
7.1.6 Take out the plug where the cable go through

to cab.
7.1.7 Take out of the cable.
7.2 Assembly steps

Note: put the slot into pulling slot during cable installation.
II. Disassembly and assembly of rear
luggage compartment lid.
1 Preparation
Tool: flat head screwdriver, No. 13 socket spanner

Material: snap clip

2 Disassembly of rear lid trim panel

2.1.1 Take away the luggage compartment inside panel.
2.1.2 The snap clips on the inside panel are one time
using and should be carefully disassembly.
2.2 Installation of rear lid trim panel
3 Disassembly/assembly of luggage compartment lock

3.1.1 Separate the motor plug of upper lock
3.1.2 Take away three positioning bolts from luggage

compartment lock. (Installation torque is 9±1Nm）

3.1.3 Disassemble the pull rod
3.1.4 Take off control cable
3.1.5 Take off luggage compartment lock
3.2 Assembly steps

Note for installation：Observe the lock core for deformation,
the welding is correct or not, if the lock bushing is well, and
if the lock latch is flexible.
4 Disassembly of luggage compartment lock core
Tool: No. 10 socket spanner
4.1.1 Separate connect rod away from lock core
4.1.2 Loose the fixing bolt by socket spanner

(Torque is 9±1Nm），Take off the lock core.
Note: Do not throw away the washer of the lock core.
4.2 Assembly steps

Pay attention to assemble it to its correct position and joint
to door plate work.

5 Disassembly of rear wiper water nozzle
Tool: flat head screwdriver
5.1.1 Take out the rear water injection nozzle

(Prize it by flat head screwdriver but avoid to damage the
surface paint)
5.1.2 Enhance the nozzle and expose the water injection

hose
5.1.3 Take out the water injection hose
5.2 Assembly steps

Note：Water injection opening should be opposite to wiper
motor steering shaft.
6 Disassembly of rear wiper motor

6.1.1 Take away the rear wiper protecting cover by hand

6.1.2 Screw off the nut above the motor by No. 10

spanner and take out the rear wiper blades.
6.1.3 Disassemble these three fixing bolts from wiper

motor. Installation torque is 12±2Nm
6.1.4 Take off motor plug and take out of motor.
6.2 Assembly steps
7 Disassembly of license plate light trim panel
Tool: No. 10 socket
7.1 Disassembly/assembly steps
7.1.1 Disassemble the rear wiper motor first ( see rear

wiper motor disassembly)
7.1.2 Take out 7 nuts from the installation holes

below the luggage compartment.

7.1.3 Disassemble the trim panel
7.2 Assembly steps

8 Disassembly of luggage compartment handle
8.1.1 Disassemble rear wiper motor

（see disassembly of rear wiper motor）
8.1.2 Separate luggage compartment handle cable
8.1.3 Take off seven nuts from rear license plate light
trim cover
8.1.4 Disassemble the license plate light trim panel

(See disassembly and assembly of license plate light
trim panel)

8.1.5 Disassemble luggage compartment handle fixing

bolts by socket spanner and get off the luggage compart
ment handle.
8.2 Assembly steps
9 Disassembly of license plate light
Tool: flat head screwdriver
9.1.1 Take out the luggage compartment inside trim

panel (See disassembly of rear lid)
9.1.2 Disassemble the license plate light trim panel

(See disassembly of license plate light trim panel)
9.1.3 Break the connection plug of left and right

license plate light
9.1.4 Disassemble the fixing screw and license plate

light by cross head screwdriver.
Note: the right rear license plate light plug is located

inside of the rear cover and difficult to be pull out and
insert, disassemble the bulb of license plate light and
then pull out and insert.
9.1.5 Take off the license plate light
9.2 Assembly steps

Chapter Two Disassembly and Assembly of Inner Trimming
Parts
I. Disassembly and assembly of seat belt
1 Preparation
Tool: flat head screwdriver, spanner

Parts: one time using snap clip
2 Note
Keep the seat belt clean and far away from oil, check it
for damage.
3 Disassembly steps（e.g. front seat belt）
3.1 Prize the front threshold pressing plate carefully

with flat head screwdriver.
3.2 Disassemble the front door weather strip.
3.3 Disassemble the rear door threshold pressing panel

3.4 Disassemble rear door opening weather strip
3.5 Disassemble the seat belt lower trim cover
3.6 Loose the fixing nut, take out B pillar lower

protecting panel. Installation torque is 50±5Nm
3.7 Prize seat belt adjuster trim cover by flat head

screwdriver and make sure do not damage the inside clip
3.8 Loose the fixing nut by No. 17 spanner and take

off the seat belt.
Installation torque is 50±5Nm

4 Assembly steps

Note:
4.1 Keep the seat belt clean and far away from oil, check
it is damaged or not.
4.2 The pillar protecting board should be matched closely
with body and not allowed to appear loosing; and the match
with roof and weather strip should be good.
4.3 The seat belt adjusting slide back plate should can be
adjusted flexible on B pillar, and it will not influence the
seat belt adjustment. Clearance with lower protecting board
should be less than 1mm;
4.4 Clearance between B pillar lower protecting panel
and front/rear threshold pressing plate should be less than
1mm;
II. Disassembly/assembly of seat
Tool: No.16 sleeve
1 Disassembly steps
1.1 Push the seat back by pulling the moving

handle under the left seat and expose the lower fixing bolt.
1.2 Disassemble these two fixing bolts by sleeve

under the seat.
1.3 Move the handle by spanner and push forward the

seat, expose these two fixing bolts on the back side.
1.4 Disassemble these two fixing bolts at the back of seat by

sleeve.
1.5 Take off the connector under seat and take away the seat.
2 Assembly steps


III. Disassembly and assembly of the Armrest Box and Sub
Instrument Panel
Tool: cross head screwdriver
1 Disassembly steps
1.1 Disassemble these 4 connection screw from armrest box and sub instrument panel by cross
head screwdriver（fasten torque is 2±0.5N.m）and take away the armrest.
1.2 Take away two bolts which connected between sub instrument panel and front lower
protecting board by cross head screwdriver (fasten torque is 2±0.5N.m）,and take down the sub
instrument panel and 5 lower connecting plugs.
2 Assembly steps
IV. Disassembly and assembly of carpet
Tool: flat head screwdriver, cross head screwdriver; sleeve

1 Disassembly steps
1.1 Disassemble the seat (See disassembly of seat)
1.2 Disassemble threshold pressing plate, B pillar and C

pillar lower protecting board (See disassembly of B pillar
and C Pillar)
1.3 Disassemble A pillar lower trim panel
1.4 Disassemble armrest box and sub instrument panel (See

disassembly of armrest box and sub instrument panel)
1.5，Prize the cover on the driver pedal by flat head

screwdriver.

1.6 Take away two fixing screws on the driver pedal with
socket spanner and take off the pedal.
Installation torque is 7±1N.m
1.7 Take off the carpet by taking off the carpet connectors
2 Assembly of carpet
2.1 Put the carpet into car, take out the cable which
connected to seat and press the bypass way carpet solidly
2.2 Pave the left front carpet to brake pedal and expose
the hole from the carpet holes
2.3 Pave the carpet left, middle and rear side along the car
bottom shape solidly and expose the front and rear seat
installation holes.
2.4 Pave the carpet right front side to evaporator

underside

2.5 Take out the connecting cable of right front seat

from carpet holes and pave it solidly
2.6 Pave carpet right, rear and middle side along to the
shape of car bottom and expose right front seat installation
holes
2.7 Pave the carpet rear side along car bottom

V. Disassembly of Shock Absorber
1 Disassembly steps
1.1 Disassemble the carpet (See disassembly of carpet)
1.2 Take off all the shock absorbers
The positions of shock absorber are shown as below chart
Front right shock absorber（B14-5110013）
Central passage right shock absorber（B14-5110019）
Central right shock absorber（B14-5110023）
Left front shock absorber Central passage rear shock absorber（B14-5110037）

（B14-5110011）
Central passage left shock absorber Right rear shock absorber（B14-5110033）

（B14-5110017）
Central left shock absorber
（B14-5110021） Left rear shock absorber（B14-5110031）
2 Assembly steps
2.1 The installing steps are reverse to those for removal.

2.2 Note of installation：
2.2.1 Tidy up the seat and rear oxygen sensor connecting cable before installing the shock
absorber.
2.2.2 Make the shock absorber lower surface joint tightly with plate work.

Chaper Three Disassembly/Assembly and Maintenance of
Door
I. Disassembly/assembly and maintenance of front door
1. System diagram

2 Preparation
Tool: flat head screwdriver, cross head screwdriver, No. 7, 10 and 13 sleeve and pliers.
3 Note
3.1 To prevent accident please wear labor protection appliance.

3.2 Break down accumulator to avoid damage the electrical units.
3.3 Use the correct method to disassemble and assemble the glass
to avoid damage.
4 Disassembly/assembly steps
4.1 Disassemble door seal. The fixing clip is one type, press
upside of the seal during disassembly and push it to one direction
until one corner of the clip is exposed. And push the seal to opposite
direction until another corner is exposed. Do not drug the seal at its
perpendicular direct which will damage the seal.
4.2 Prize the plastic trim block which fix the outside rearview
mirror by flat screwdriver.
4.3 Unscrew these two fixing clips by cross head screwdriver

from front door panel.
4.4 Unscrew fixing screws from front door handle cover by cross
head screwdriver. Take off window regulator switch cable plug and
electrical rearview mirror adjuster switch plug.

4.6 Take out the cable clip of inside opening cable handle by
hand
4.7 Take off the courtesy light plug at the same time of getting
of front door panel assembly.
4.8 Disassemble two fixing screw from front door handle

cover by cross head screwdriver.
4.9 Tear down front door water proof plastic clothing.

（See disassembly of front door protecting panel assembly）
4.10 Pull out outside electrical control rearview mirror cable

plug (See disassembly of outside rearview mirror)

4.11 Unscrew three fixing bolts from outside rearview mirror by

No. 10 socket.
4.12 Prize front door inside and outside weather strip by

screwdriver.（See disassembly of window regulator system）
4.13 Connect window regulator switch to cable again and

decrease the glass to its lowest position.
4.14 Loose two fixing screws on the glass by cross head
screwdriver.
And take out the glass assembly. Torque is 2.5±0.5 N.m.
4.15 Take off up and lower fixing bolts from window regulator
by No. 10 socket. Torque is 7±1 N.m.
4.16 Disassembly three fixing bolts from window regulator

motor by No.10 socket. Torque is 7±1 N·m.

4.17 Unscrew these two fixing bolts from front glass guide
by No. 10 socket and take out front glass guide.
Torque is 9±1 N·m.
4.18 Disassemble two fixing bolts from rear glass guide by

No. 10 socket. Take out rear glass guide and glass slot
assembly. Torque is 9±1 N·m.
4.19 Unscrew four fixing screws from front door sound box
by cross head screwdriver. Take out sound box assembly.
Installation torque is 1.5±0.5 N.m.
4.20 Loose the fixing clip on door handle pull rod lock.
（See disassembly of front door lock）
4.21 Loose the fixing clip on the lock of front door lock core
pull rod by hand.

4.22 Loose safety lock pull rod fixing clip by hand.
4.23 Loose inside control cable fixing clip by hand.
4.24 Disassemble three front door lock fixing bolts by spline

wrench. Installation torque is 9±1N.m
(With thread locking rubber)
4.25 Rotate the lock cable direction to a certain degree and

take off the cable plug. Take out the lock assembly.
4.26 Disassemble the front door handle fixing screw by

spline wrench. Installation torque is 8±1 Nm

4.27 Prize the front door lock core fixing screw protecting
panel by flat head screwdriver.
4.28 Disassemble front door lock core fixing screws.

Note: The shim between lock core, door handle and car door
can not be ignored. Make sure assemble it during installation.
Otherwise it will influence the clearance between them.
Installation torque is 9±1 Nm
4.29 Take out lock core and handle assembly.
4.30 Loose two front door stopper fixing bolts by No.13

spanner. (See disassembly of front door hinge and stopper).
Torque is 36±4N.m.
4.31 Front door stopper is connected to body by a flexible

eye pin. This flexible eye pin is an elasticity pin made up of
steel, beat it by a hamper heavily during disassembly and get
it out.

4.32 Disassemble the fixing bolts of front fender on door

by No. 10 socket. (See disassembly of fender) and
torque is 10±1 N.m
4.33 Disassemble the fixing bolts of fender on windscreen by

No. 10 socket.
Note: You must disassemble wiper and
front cover assembly before disassemble this bolt.
Torque is 10±1 N.m
4.34 Disassemble two fixing bolts of fender on engine hood

by No.10 socket. Torque is 10±1 N.m
4.35 Disassemble fixing bolt between bumper and mudguard

by No. 7 sleeve.
Installation torque is 2±0.5 N.m
4.36 Prize the connection clip between front bumper and fender
by flat head screwdriver. Unscrew the plastic clip between
bumper
and fender by cross head screwdriver.

4.37 Unscrew two fixing bolts between fender and bumper

by No. 10 socket. Torque is 10±1 N.m
4.38 Unscrew two fixing bolts between fender and body

underside by No.10socket. Torque is 10±1 N.m
4.39 Disassemble two fixing bolts between door hinge and

body by No. 13socket and take away the front door assembly.
Torque is 36±4 N.m
5 Assembly and adjustment steps
5.1 Assemble door lock
5.1.1 Insert cable plug into lock.
5.1.2 Block the clip of inside opening cable onto lock.

5.1.3 Fix the safety lock pull rod onto lock.
5.1.4 Fix the lock onto door and fasten the fixing bolt, and it is
best to use thread locker.
Torque is 9±1Nm.
5.1.5 Assemble seal gasket to door handle and lock core.
5.1.6 Assemble door inside handle fixing holder and fasten the
screw. Installation torque is 8±1 Nm
5.1.7 Insert rear end of handle first and then the front end.

5.1.8 Insert handle pull rod connection pin into handle.
5.1.9 Insert lock core.
5.1.10 Fasten lock core fixing bolt.

5.1.11 Insert lock core pull rod into lock.
5.1.12 Insert handle pull rod into lock.

5.2 Door adjustment
5.2.1 After the door is assembled, check the horizontal and

vertical clearance and closing force. If the clearance is not correct
or the closing force is too big, adjust it immediately. The
adjustment of door clearance see (body size)
5.2.2 The clearance adjustment can be finished by move the
hinge fixing bolts on body.
5.2.3 The door closing force adjustment can be finished by

adjusting front door lock striker position.
Torque is 9±1Nm。
5.3 Adjustment of door glass regulator system.

5.3.1 Check the window regulator system after this system is
assembled. The time of the glass from the lowest position to the
highest position should be around 7s. If the time is too long,
check the regulator in time.
5.3.2 Check window regulator motor.
5.3.3 Check if there is oil or dust inside of glass slot which
cause big resistance force when the glass is rose.
Note: Do not lubricate the glass slot or glass to avoid dust
absorption.
5.3.4 Check if there is deviation of glass guide position, which
cause the rising radian is not consistent to block the glass. The
position of glass guide can be adjusted by the guide fixing bolts.

II. Disassembly/Assembly and Maintenance of Rear Door
1 Preparation
Flat head screwdriver, cross head screwdriver, No.7, 10, 13 sleeves

and pliers.
2 Note
2.1 To prevent accident please wear labor protection appliance.

2.2 Break down accumulator to avoid damage the electrical
units.
2.3 Use the correct method to disassemble and assemble the
glass to avoid damage.
3 Disassembly steps
3.1 Disassemble door weather strip. The fixing clip is one type,
press upside of the strip during disassembly and push it to one
direction until one corner of the clip is exposed. And push the seal
to opposite direction until another corner is exposed. Do not drug
the seal at its perpendicular direct which will damage the weather
strip.
3.2 Prize two rear door glass slot protecting boards by flat head
screwdriver.
(See front door disassembly to disassemble weather strip)
3.3 Unscrew armrest cover fixing screws by cross head

screwdriver.
3.4 The fixing clip of rear door trim panel is inside hiding clip,
prize the clip around trim panel by screwdriver equably.
3.5 Take out he inside opening cable fixing clips, and take off
door protecting panel assembly.

3.6 Unscrew two armrest bracket fixing screws by cross head

screwdriver.
3.7 Take off the water proof plastic clothing by hand.
3.8 Prize rear door outside weather strip fixing clips by flat
head screwdriver and take out the strip from one end. Take out
inside weather strip. Pay attention to that outside strip has metal
slot, and it will deform the metal slot if pull out the strip from
perpendicular direction.
3.9 Make the glass to its lowest position and loose two glass
fixing screws by cross head screwdriver.
Torque is 5±0.5 N·m
3.10 Loose front and rear glass guide fixing bolts by No. 10 sleeve
and take out of the glass guide. Take out glass assembly by hand. Pay
attention that stand outside of car door and take the narrow side first
and then the wide side.
Torque: Upside is 2±0.5 N·m
Lower side is 9±1 N·m

3.11 Loose the fixing bolts to fix the window regulator motor
and guide, and take out the window regulator assembly.
Torque is 7±1 N.m
3.12 Unscrew four sound box fixing screws by cross head

screwdriver, and take out sound box assembly.
Installation torque is 1.5±0.5N.m
3.13 Disassemble rear door lock assembly according to the

order to disassemble front door lock. (Disassembly of rear door
lock)
3.14 Unscrew rear door stopper fixing bolts by No. 13 sleeve and
spanner. (Disassembly of stopper and hinge)
3.15 Loose hinge fixing bolts by No. 13 spanner and

disassemble rear door assembly. Torque is 36±4 N.m

4 Assembly and adjustment steps
4.1 Assembly of rear door glass
4.1.1 Assemble window regulator slot.

4.1.2 Assemble window regulator assembly onto the door.
4.1.3 Put the narrow side of the glass into door from outside of the door and then put the wide
side into the door.
4.1.4 Fix the glass onto window regulator by screw.
4.1.5 Connect glass regulator switch plug and rise the glass。
to its highest position.
4.1.6 Assembly glass guide.
4.1.7 For other assembly steps, please refer to disassembly

steps.
4.1.8 Rear door clearance can not be adjusted by hinge
adjustment. If the door clearance is not correct, the only way to
correct it is to correct body
(See body size)
4.1.9 Please refer to front door assembly and disassembly for
other adjustment.

Chapter Four Disassembly/Assemlby and Maintenance of the
Front and Rear Bumper
I. Disassembly/assembly and maintenance of front bumper
1 System diagram
Front and rear bumper
2 Preparation
Tool: No. 7 and No10 sleeve, cross head screwdriver and flat head screwdriver.
3 Note
3.1 To prevent accident, please wear labor protection appliance.

3.2 To prevent scratch the bumper surface paint.
3.3 Carry out the disassembly and assembly at low temperature
environment, do not use big force, otherwise the bumper will be
broken.
4 Disassembly steps

4.1 Unscrew four fixing bolts for grille web cover water tank cross
beam by No. 10 sleeve.（See right figure）
4.2 Loose fixing bolts of bumper on water tank cross beam by

No. 10 sleeve.
Torque is 11N·m
4.3 Unscrew bumper two fixing screws at lower cross beam by

flat head screwdriver.
4.4 Unscrew mudguard two fixing bolts under bumper by No.7

sleeve.
Installation torque is 2±0.5 Nm
4.5 Unscrew mudguard fixing bolt beside the bumper by No. 7

sleeve.
Installation torque is 2±0.5N.m
4.6 Pull out bumper by hand from fender fixing base.

4.7 Pull out fog lamp plug by hand, and take out bumper
assembly.
4.8 Unscrew two bolts which fix shock absorber foam onto
bumper reinforcement member by No. 13 sleeve.
Torque is 3N·m
4.9 Unscrew three front bumper reinforcement member fixing

bolts and one fixing nut by No. 13 sleeve.
Torque is 25±3N.m
4.10 Unscrew bumper both sides air intake grille fixing screws
by cross head screwdriver.
4.11 Unscrew six bumper middle air intake grille fixing screws
by cross head screwdriver.
5 Assembly and maintenance
5.1 The installing steps are reverse to those for removal.

II. Disassembly/assembly and maintenance of rear bumper
1 System diagram
Front and rear bumper
2 Preparation
Tool: cross head screwdriver, flat head screwdriver, No. 7 sleeve.
3 Note

3.3 Carry out the disassembly and assembly at low temperature environment, do not use big
force, otherwise the bumper will be broken.
4 Disassembly steps
4.1 Open luggage compartment lid, unscrew two fixing clips on

rear bumper by cross head screwdriver ( e.g. left side)

4.2 Loose fixing screw and clip between rear bumper and rear
mudguard by No. 7 sleeve and cross head screwdriver.
Torque is 7N·m
4.3 Loose two lowest fixing screws between rear mudguard and
rear bumper by No. 7sleeve.
4.4 Loose fixing clip between rear bumper and body by cross head
screwdriver.
4.5 Prize rear bumper fixing clip on rear fender by hand.
4.6 Take off plugs of rear fog lamp and reverse radar probe
cable. And take off rear bumper assembly.

4.7 Prize reverse radar probe by flat head screwdriver from

bumper outside.
4.8 Loose two rear fog lamp fixing screws by cross head
screwdriver and take out of fog lamp assembly.
5 Assembly steps

Chapter Five Disassembly/Assembly and Maintenance of

Front Headlamp and Fog Light
1 System diagram
Lights
2 Preparation
Tool: No. 10 sleeve and No. 7 open end wrench, cross head
screwdriver and flat head screwdriver.
3 Note

3.3 Carry out the disassembly and assembly at low temperature
environment, do not use big force, otherwise the bumper will be broken
3.4 Pay attention to the clip on the bumper during headlamp is
disassembled, big force will damage the clip.
3.5 Pay attention to not scratch the headlamp surface when
disassemble and place it .

4 Disassembly steps for headlamp
4.1 Disassemble front bumper assembly first. (See

disassembly/assembly of bumper)
4.2 Loose headlamp two fixing bolts on engine hood cross beam
by No. 10 sleeve. Torque is 4.0±0.5N·m
4.3 Loose headlamp fixing bolt on AC condenser by No. 10

sleeve.
Torque is 4.0±0.5N·m
4.4 Loose clip seat fixing screw which is used to fix the bumper by
cross head screwdriver.
4.5 Loose headlamp fixing bolt by No. 10 sleeve.

4.6 Unplug headlamp cable plug and take out the headlamp
assembly.
4.7 Screw off headlamp high beam seat cover.

4.8 Press bulb fixing clip by hand and turn it upward, take the bulb
out.
4.9 Rotate the headlamp motor of 30 degrees clockwise, and take

out the motor and cable plug.
Note: The motor can not be maintained, if make sure there is
problem on the motor, open the motor cover to see if there is gear
falling down or block phenomenon. Replace with a new headlamp
assembly if the problem can not be solved by adjustment.
4.10 Screw off low beam bulb cover by hand.
4.11 Press the bulb fixing clip by hand and take out bulb assembly.
5 Disassembly of fog lamp
5.1 Disassemble bumper assembly. （ Refer to disassembly of

bumper）
5.2 Prize fog trim cover assembly by hand.

5.3 Loose two fog lamp fixing nuts by No. 7 sleeve.
5.4 Take out fog light assembly.

2
6 Installation and adjustment of
headlamp 1
6.1 Assembly steps of headlamp
The installing steps of headlamp are reverse

to those for removal.
4
6.2，Introduction of headlamp function
3
6.2.1，Front view
See right figure:

1 Low beam light
2 Position light
3 High beam
4 Turn light
7
6.2.2 Back view 2 3
9
1
See right figure:
1 Low beam light holder
2 Plug for low, high and position
light
3 Position light holder
4 High beam light holder
5 Turn light holder and plug
6 Low beam up/down adjusting nut
6
7 Low beam left/right adjusting nut 8 5
4
8 High beam up/down adjusting nut
9 High beam left/right adjusting nut

6.3 Adjustment for headlamp beam
6.3.1 Headlamp uses half closed light combination type. So it is easy to be maintained; it is
halogen light with less mechanism and high luminous intensity, which will prolong bulb life.
6.3.2 The correctness of headlamp adjustment will influence the driving safety. So it needs
special device to adjust the beam. Pay attention to law regulations and verify the following items
before adjustment:
a. Tire pressure should be correct;
b. Car is unload (except for spare tire and equipped tools, and include driver weigh for
sedan);
c. Park the car on horizontal road or place;
d. The lens surface of headlamp should be clean;
e. Check the power supplies if is working correctly, and the bulb installed correctly.
Move the adjustable mechanism on the light can adjust the beam up/down and left/right, operate it
with international standard. Adjuster for rough and fine up/down adjustment is one unit on casing
upside; adjuster for left/right on casing middle and lower side.
It needs take off headlamp cover to adjust right headlamp. Same to the symmetrical lay of left
headlamp adjustment mechanism and right headlamp.
6.3.3 Headlamp beam adjustment can be realized by moving beam adjusting nut or power
adjusting button (if it is equipped).
6.3.3.1 Insert cross head screwdriver to related
adjusting holes to adjust the beam.
6.3.3.2 Adjust the beam up and down by power adjusting

button on the instrument panel.
6.3.3.3 The norm central height for Chery V325 headlamp:

Low beam：717mm；High beam：755mm。
6.3.3.4 Adjust the headlamp beam according to international
standards:
During check headlamp low beam lighting position, irradiate the headlamp to the screen 10m far
away from headlamp, for low beam of passenger car, angle of cut-off line or height of midpoint
height should be 0.7H～0.9H （H is the midpoint height of headlamp, the same of below）, other
motor vehicles(except for tractor) should be 0.6H～0.8H. Deviation to left of horizontal direction
position headlamp low beam of motor vehicle (except for the vehicle with one front headlamp)is
not allowed to exceed 170mm，not exceed 350 mm to right.（From national standard）
6.3.3.5 Please input the standard data got from above into headlamp beam adjusting device for
future usage.

CHERY V325 Service Manual Body Accessories
Chapter Six Disassembly/Assembly of Roof and Scuttle
I. Disassembly/Assembly of Roof
1 Preparation
Tool: No. 7, No. 8, No. 13 and No. 17 socket spanner, cross

head screwdriver and flat head screwdriver.
2 Note
2.1 Use correct force during operation to prevent damage

the parts and it is not allowed to operate with too big force.
2.2 Protect the part surface from scratching during the

disassembly/assembly of inner trim.
3 Disassembly/assembly of sunvisor
3.1.1 Loose left front sunvisor two fixing screws by

cross head screwdriver and the torque is 3±1Nm
3.1.2 Pull out left front sunvisor cable plug.
3.1.3 Take away left front sunvisor.
3.2 Assembly steps
3.3 Disassembly/assembly of right front sun visor, please

refer to that of left front sunvisor.

4 Disassembly/assembly of ceiling handle
4.1.1 Prize handle fixing screw cover by flat head

screwdriver.
4.1.2 Disassemble fixing screw by cross head screwdriver.

Torque is 9±3Nm
4.1.3，Take off the handle.
4.2 Assembly steps
4.3 Disassemble/assemble other handles refer to right front

handle.
5 Disassembly/assembly of front ceiling light
5.1.1 Prize front ceiling light cover by flat head

screwdriver.
Note: do not scratch part surface.
5.1.2 Loose front ceiling light fixing bolt.

Torque is 1.5±0.5Nm

5.1.3 Open glasses box and disassemble fixing screw.

Torque is 1.5±0.5Nm
5.1.4 Take off cable inserting.
5.1.5 Take off front ceiling light assembly.
5.2 Assembly steps
6 Disassembly/assembly of rear ceiling light
6.1.1 Prize rear ceiling light trim cover by flat head

screwdriver. Note: do not scratch trim part.
6.1.2 Unscrew rear ceiling light fixing bolt.

Torque is1.5±0.5Nm
6.1.3 Take off rear ceiling light.
6.2 Assembly steps


7 Disassembly/assembly of A pillar protecting board
7.1.1 Disassemble A pillar protecting board lower trim

cover.
7.1.2 Prize A pillar protecting board by flat head

screwdriver.
7.1.3 Take out A pillar protecting board.
7.2 Assembly steps
8 Disassembly/assembly of B pillar protecting board
8.1.1 Disassemble B pillar lower protecting board (refer

to disassembly/assembly of seat belt)
8.1.2 Disassemble B pillar upper protecting board fixing

screw by cross head screwdriver.
8.1.3 Prize B pillar upper protecting board by flat head

screwdriver.
Note: protect the trim part surface from scratching.

8.2 Assembly steps
9 Disassembly/assembly of C pillar and D pillar protecting board
9.1.1 Unscrew luggage compartment glove box two

fixing bolts by No. 7 socket spanner. Take out glove box.
Torque is 1.5±0.5N.m
9.1.2 Unscrew glove box rear panel assembly fixing

bolt by No.8 socket spanner. Take out glove box panel.
Torque is 5±1 N.m
9.1.3，Unscrew rear seat lower fixing bolt by No. 17 socket

spanner. Take out rear seats.
Torque is 25±3 Nm
9.1.4 Loose C/D pillar lower protecting board fixing

screws (totally two) by No. 10 sleeve.
Torque is 9±3Nm
9.1.5 Prize C/D pillar lower protecting board fixing

clip by flat head screwdriver.

9.1.6 Take off rear door opening rubber seal by hand.
9.1.7 Prize C/D pillar lower protecting board by

screwdriver, take off C/D pillar protecting board.
9.1.8 Prize D pillar upper protecting board and take off D

pillar upper protecting board.
9.1.9 Prize C pillar upper protecting board and take off C

pillar upper protecting board.
9.2 Assembly steps
10 Disassembly/assembly of the roof
10.1.1 Disassemble left and right sunvisors.

(Refer to disassembly/assembly of sunvisors)

10.1.2 Disassemble front ceiling light (Refer to

disassembly/assembly of front ceiling light)
10.1.3 Disassemble rear ceiling light. (Refer to

disassembly/assembly of rear ceiling light)
10.1.4 Disassemble all the roof handles. (Refer to
disassembly/assembly of roof handle)
10.1.5 Disassemble A/B/C/D pillar protecting board.

(Refer to disassembly/assembly of A/B/C/D pillar
protecting board)
10.1.6 Take away scuttle trimming rubber strip by hand.
10.1.7 Disassemble roof clips (totally10 pieces) by

flat head screwdriver, and take off roof.
1 2 3 4
7 8
5
6
9 10
10.2 Assembly steps

II. Disassembly of Scuttle Assembly
1 Preparation
Tool: No.10, No.13 and No. 17 socket spanner, clamp pliers
2 Disassembly steps
2.1 Disassemble roof（see disassembly of roof）.

2.2 Take off scuttle cable inserting.
2.3 Disassemble scuttle water exhaust pipe by clamp

pliers(totally 4 pieces)
2.4 Loose scuttle fixing bolts. (totally 10 pieces)

2.5 Take off scuttle assembly.
3 Assembly steps

III. Decomposing of Scuttle Assembly
1 Preparation
Tool: Torx5，Torx10，Torx20，cross head screwdriver and flat head screwdriver.
2 Disassembly/assembly of scuttle glass
2.1.1 Operate the scuttle to completely open status.
2.1.2 Take away scuttle trimming strip by pushing

it backwards by hand.
2.1.3 Unscrew the scuttle fixing bolts by cross head

screwdriver (loose two middle screws first and then loose
the other four)
2.1.4 Take off the scuttle glass by hand from the car top.

2.2 Assembly steps
2.2.1 Operate the scuttle switch to move the sliding

mechanism without glass to complete opening position, put
glass into middle of sliding mechanism support bar.
(Note: the side with mark should be on the back)
2.2.2 Fasten scuttle glass six fixing bolts by cross head

screwdriver; first slightly fasten and then pull the glass
forward slightly and then fasten them one by one.
2.2.3 Operate the scuttle switch to move the scuttle to its

complete close status.
2.2.4 Begin to adjust and fasten these middle two fixing

nuts at the same time to drug the glass by hand. Fasten the
other four screws at the same time of move the glass to
correct height.
Torque:
2.2.5 Check the switch program of the scuttle if is correct.

Remarks: after the installation check the glass height/
starting noise and collision phenomenon.
2.2.6 Assemble trim strip after the first time adjustment.

2.2.6.1 Operate the scuttle to completely open status.
2.2.6.2 Block the scuttle trim strip to sliding mechanism

bracket bar by hand.

2.2.6.3 At last, check if the trim strip is blocked onto the

fixing bar
2.2.7 Regulate the scuttle switch program, starting program

and noise by power system to make sure that there is no
abnormal.
3 Disassembly and assembly of scuttle motor and scuttle control unit
3.1.1 Operate the scuttle to its completely close position

(named scuttle original position).
3.1.2 Disassembly of roof.（refer to disassembly of roof）
3.1.3 Brake power cable of accumulator, and disconnect the

cable of scuttle motor and scuttle control unit.
3.1.4 Disassemble three scuttle motor fixing bolts by

cross head screwdriver to take off scuttle motor.
3.1.5 Disassemble scuttle control unit fixing bolt by cross

head screwdriver and take off scuttle control unit.

3.2 Assembly steps
Note: Before assembling the scuttle motor, the scuttle must be at the position of completely
closed.
3.2.1 Put scuttle motor onto bracket.

Note: assemble motor gear onto the middle position of two
pull cable gears.
3.2.2 Fasten scuttle motor three fixing bolts by cross head

screwdriver.
3.2.3 Push scuttle control unit into along scuttle frame and
fix the cable onto scuttle control unit slot.
3.2.4 Fasten the fixing bolts of scuttle control unit, and fix
it again by band.

4 Disassembly/assembly of scuttle sun visor
4.1.1 Disassemble the roof. (See disassembly/assembly of roof)
4.1.2 Disassemble scuttle glass assembly (See disassembly/assembly of scuttle glass)
4.1.3 Loose scuttle central bracket fixing screw by TORX

tool and take out bracket.
4.1.4 Take away scuttle sunvisor stopper by hand.
4.1.5 Push scuttle sunvisor out from sunvisor slide guide,

take off scuttle sunvisor.
4.2 Assembly steps
IV. Guide for scuttle maintenance
1 Reset scuttle control unit
1.1 Scuttle control unit looses primary memory will cause faults.
1.1.1 Scuttle can not be completely closed and opened or stretched. Sometimes, there is shaking
phenomenon during the process from stretch to close.
1.1.2 Scuttle is opened or stretched or closed can not reach its original position.
1.1.3 Scuttle can not actuate the function of pushing the button and close/open the scuttle.
1.1.4 Scuttle mode can not control scuttle running.
1.2 Possible reason analysis

1.2.1 The battery is replaced when the scuttle is not at the original position;
1.2.2 Break the power of scuttle control unit suddenly during scuttle running;
1.2.3 When the scuttle control unit can not resume to right position;
1.2.4 Unplug the power supply during scuttle running;
1.3 Method to recall scuttle control unit

1.3.1 Run the scuttle glass to completely open status, press the opening button more than 15s
continuously, by this way, the scuttle control unit will be recovery to original memory position.
1.3.2 Confirm: Press opening function button, if the scuttle is started correctly, means the control
unit is recovery to its correct original position.
2 Typical fault diagnosis and trouble shooting
2.1 Scuttle looses it original position
2.1.1 Fault phenomenon:

The scuttle can not be opened and closed correctly or can not be closed to correct position; the
scuttle can not actuate correct running process.
2.1.2 Reason analysis:

See chapter 1.2
2.1.3 Solve method:

Reset the scuttle control unit (Refer to chapter1.3)
2.2 Water leaking of scuttle assembly

There is water leaking from outside to scuttle molding when the scuttle is closed completely.
2.2.2 Analysis and checking:

Check the clearance between scuttle glass and roof hole; check flow guiding pipe conditions;
check water guiding system conditions.
2.2.3 Solve method:

2.2.3.1 Reassemble the scuttle glass referring to the disassembly/assembly steps of scuttle
glasses, and make sure the clearance between glass and roof hole is within the correct tolerance.
2.2.3.2 Readjust the connection status of four water guiding pipe, and make sure there is no
water leaking.
2.2.3.3 Check the water guiding system and make sure there is no damage, if there is, replace the
damaged.
2.3 Strange noise of scuttle assembly

There is strange noise when the scuttle is running.
2.3.2 Analysis and check:

2.3.2.1 Check the position of scuttle; check clearance between scuttle and roof holes; check
scuttle motor. If there is strange noise, find the reason of that.
2.3.2.2 Check if there is damage of scuttle weather strip; check if there is friction of the scuttle
guide and find the reason of strange noise.
2.3.3 Solve method:
2.3.3.1 Reassemble the scuttle glass referring to glass assembly steps and make sure the
clearance between glass and roof holes should be at the correct tolerance.
2.3.3.2 Replace the motor with strange noise (Refer to disassembly/assembly of scuttle motor).
2.3.3.3 Replace with new scuttle inner trim strip (Refer to disassembly/assembly of scuttle glass)
3 Frequently appeared fault and their check and maintenance methods
Fault Reason Maintenance method
Water guide pipe is block or folded Check water guide pipe

Water
leaking Spread between scuttle glass and roof hole is too big
Adjust the glass relative position
or glass height not good
When spread between scuttle glass and roof hole is
Wind
big or glass height not good, or wind deflector does Adjust the glass relative position to correct
noise
not work.
Check connection cable, fuse and
Connection cable, fuse or grounding cable not good
grounding cable
Not Replace scuttle control unit and scuttle
Scuttle control unit, scuttle motor not good
correct motor after checking
start and Sunvisor fall down from sliding guide and weather Readjust sunvisor position. Assembly or
running strip is damaged replace weather strip.
There are something inside of sliding guide Check and get rid of something
There is guide friction when the sunvisor fall down Reassembly or readjust the sunvisor and
from guide or weather strip is damaged. weather strip (replace damaged parts)
Check if there is collision between body

Wrong
and wind deflector, and loose the
start (A.T.S)anti clamping function does not work
tensioning spring, check and get rid of
something from guide.
Scuttle motor does not work Replace motor
Noise
It is stopped caused by sun visor fall down from Reassembly or readjust the sun visor and
when start
guide or weather strip is damaged weather strip (replace damaged parts)
Stick sponge damping around water guide

There is collision between water guide pipe and body
pipe
Paint glass cement or plastic glue between

Collision between roof and scuttle frame
roof and scuttle frame
Spread between scuttle glass and roof hole is too big Readjust glass height and relative position

or glass height is not good
4 Maintenance note and daily service
4.1 Keep everything clean during maintenance, especially for sunvisor and weather strip.
4.2 Do not let scuttle screw fall down into sliding guide during scuttle disassembly, it will
influence the scuttle running correctly.
4.3 Be care to deal with the scuttle(especially for perpendicular direction), otherwise it will
damage the important parts inside of the sliding guide.
4.4 Operate the scuttle to completely close condition when it is need to break down the
power to scuttle during car maintenance.
4.5 The scuttle can not actuate sliding down and raise up at the same time: so at the
condition of sliding down, the scuttle can not be raised up; and at the condition of raise up,
the scuttle can not be slide down. It is necessary to shut down it and then start raise up or
sliding down.
4.6 You should not continue push the button when the scuttle is completely opened or closed,
otherwise it will cause scuttle motor and mode fault.
4.7 Clean the scuttle sliding guide at a fixed period by clean water to wash away the dust and
other particles inside of guide and rubber strip.
4.8 It may damage the scuttle glass and motor when you open the scuttle which is in a freezing
or snow covered conditions.

Chapter Eight Disassembly/Assembly of Instrument

Panel
I. Disassembly of instrument panel
accessories
1 Preparation
Tool: socket spanner, cross head screwdriver, flat head

screwdriver
Note: disconnect accumulator cathode before disassemble
electrical parts
2 Disassembly/assembly of central control panel

and fog lamp switch
2.1 Disassembly steps：
2.1.1 Disassemble central ventilator assemblies beside of

central control panel by hand.
2.1.2 Disassemble six screws to fix central control panel

and instrument panel.
Tool: cross head screwdriver
Installation torque: 1.5±0.5Nm
2.1.3 Unplug cigar lighter, switches for front and rear fog
lamps, double switch, rear windscreen defroster switch plugs.

2.1.4 Take off central control panel.
2.2 Assembly steps：
3 Disassembly/assembly of AC control panel
3.1.1 Disassemble central control panel

（Refer to disassembly steps of central control panel）
3.1.2 Unscrew 4 AC control panel fixing screws by

cross head screwdriver and take off rear plug, take off
AC control panel.
Installation torque: 1.5±0.5 Nm
3.2 Assembly steps
4 Disassembly/assembly of audio

(Refer to disassembly steps for central control panel)
4.1.2 Disassemble 4 audio fixing bolts by No.10 socket

spanner. Unplug rear plug and antenna, take off audio control
panel.
Installation torque: 9±3 Nm
4.2 Assembly steps

5 Disassembly/assembly of front ashtray

(Refer to disassembly steps for central control panel)
5.1.2 Unscrew 4 front ash tray fixing screws, take off ash
tray.
Installation torque: 1.5±0.5Nm
5.2 Assembly steps
6 Disassembly/assembly of glove box
6.1.1 Disassemble 2 engine hood opening handle fixing

bolts by No. 10 spanner.
6.1.2 Disassemble engine hood opening cable
6.1.3 Disassemble glove box and separate rear plugs (for

meters brightness and headlamp brightness); disassemble
AC interior temperature fixing screw and take off glove
box.

6.1.4 Disassemble 2 codriver side glove box fixing screws

and take off codriver side glove box.
Installation torque is 2±0.5Nm
6.2 Assembly steps
7 Disassembly/assembly of combined instrument
7.1.1 Prize combined instrument side trim plate by

screwdriver carefully.
7.1.2 Unscrew combined instrument 3 outside frame fixing

screws by cross head screwdriver.
7.1.3 Take off combined instrument outside frame

7.1.4 Disassemble 3 fixing screws which fix combined

instrument and instrument panel main body by cross head
screwdriver.
Installation torque is 1.5±0.5 Nm
7.1.4 Unplug 2 combined instrument rear plug and

take off the combined instrument.
7.2 Assembly steps
8 Disassembly of steering wheel
8.1.1 Prize two caps beside of steering wheel.
8.1.2 Use TORX T40 disassemble 2 air bag fixing bolts.

Installation torque is 1.6±2Nm
8.1.3 Take away air bag

8.1.4 Unplug horn plug
8.1.5 Disassemble steering wheel fixing nut by No.22

sleeve.
8.1.6 Pull the steering wheel out by extractor.
8.2 Assembly steps
9 Disassembly/assembly of headlamp combined
switch, wiper switch, ignition switch, coil cable
(Please refer to disassembly/assembly of
steering column in Chassis Service Manual)

II. Disassembly of Instrument Panel
1 Disassembly/assembly of instrument panel
1.1.1 Disassemble steering wheel and combined switch

(Refer to disassembly of steering wheel)
1.1.2 Disassemble glove box

(Refer to disassembly of glove box)
1.1.3，Disassemble audio, AC control panel

(Refer to disassembly of audio and AC control panel)
1.1.4 Disassemble front ash tray

(Refer to disassembly of front ash tray)
1.1.5 Disassemble combined instrument

(Refer to disassembly of combined instrument )
1.1.6 Disassemble armrest box and vice instrument panel

(Refer to disassembly of armrest box and vice instrument
panel)
1.1.7 Disassemble A pillar upper and lower trim plate.
1.1.8 Disassemble left front and right front door opening

weather strip
1.1.8 Prize sun light sensor out carefully by flat head

screwdriver.

1.1.9 Unplug the plug behind of sun light sensor.
1.1.10 Disassemble 7 fixing screws which fix upper instrument panel and lower instrument
panel body, take off up instrument panel assembly left and right ventilator. Installation torque is
1.5±0.5Nm
1.1.11 Unscrew 6 fixing screws and 2 fixing bolts of low ventilator assembly, take off instrument
panel AC ventilator assembly.
Tool: cross head screwdriver, No.8 socket spanner. Installation torque is 1.5±0.5 Nm
No. 8 bolt
screw
1.1.12 Unscrew two fixing bolts below lower instrument
panel at the driver side by No. 8 socket spanner.

1.1.13 Unscrew two fixing bolts above lower instrument panel

at the driver side by No. 8 socket spanner.
Installation torque is 7±1 Nm.
1.1.13 Unscrew 2 fixing screws on the middle of lower

instrument panel. Installation torque is 7±1 Nm
1.1.14 Unscrew two fixing bolts below lower instrument panel

at the codriver side by No. 8 socket spanner.
1.1.15 Unscrew 3 fixing bolts above lower instrument panel at

the driver side by No. 8 socket spanner.
1.1.16 Take off lower instrument panel body.
1.2 Assembly steps of instrument panel

Note:
1.2.1 The ventilator of instrument should be coincide with AC
air outlet, there should be no incorrect assembly, no air leaking,
no interference between instrument panel air passage and
instrument cross beam, and evaporator, which will influence the
instrument panel assembly.

1.2.2 There should be no interference between windscreen and

instrument panel, the clearance to windscreen should be even.
1.2.3 Clearance between instrument panel and body sides

should be even and can meet door weather strip assembly
requirements
1.2.4 Glove box should be flexible for opening and closing, no

interference, no block or lock loose.
1.2.5 Assemble the middle passage cover plate tightly, clearance

between sub instrument panel body, armrest box should be even
and less than 0.5mm.
1.2.6 Fasten torque of sub instrument panel front, middle end

and rear end of armrest box, middle passage cover plate middle
and rear end fixing bolt is 2±0.5N.
1.2.7 Fasten torque for vent of instrument panel and upper and
lower body fixing screw is 5±0.5N。
2 Disassembly of instrument cross beam
2.1.1 Disassemble instrument panel assembly (Refer to

disassembly of instrument panel)
2.1.2 Disassemble the plugs between instrument panel cross

beam cable and every elements, disassemble instrument cable
(Refer to disassembly/assembly of instrument cable)
2.1.3 Disassemble 2 instrument panel fuse box fixing screws

by cross head screwdriver, take off fuse box.

2.1.4 Disassemble connecting bolts between steering column

and cross beam by No. 10 socket spanner.
2.1.5 Disassemble 2 bolts below steering column by No. 10

socket spanner.
2.1.6 Disassemble 3 screws between cross beam bracket and

evaporator by cross head screwdriver.

2.1.7 Disassemble 4 fixing bolts between cross beam front

end and car body by No. 13 socket spanner.
2.1.8 Disassemble two fixing nuts marked in right figure by

No.13 sleeve.
2.1.9 Disassemble two fixing bolts between cross beam and left
side of car body.
2.1.10 Disassemble one fixing bolt between cross beam and

front side of car body by No. 10 socket spanner.
2.1.11 Disassemble two fixing bolts between cross beam and

lower side of car body.

2.1.12 Disassemble two bolts and two nuts

between cross beam and right side of car body by No. 13 sleeve.
2.1.13 Take off cross beam.
2.2 Assembly steps

Chapter Nine AC System
I. System Composition
Air adjustment and distributing system: HVAC air mixing and distributor part, inside/outside
circulation air inlet, air outlet, outside circulation air filter.
Control system: control panel assembly, micro motor, blower, speed regulating mode, high/low
voltage switch, AC temperature sensor.
Heating system: heating water tank, hot water pipe, and engine cooling water system.
Cooling system: compressor, condenser, reservoir dryer, expansion valve, evaporator and pipe.
Low pressure pipe assembly

High pressure pipe assembly
AC control panel
Dry Bottle AC compressor
Condenser
Evaporator assembly
II. Disassembly of evaporator assembly
1 Preparation
Tool: cross head screwdriver, carp pliers, socket spanner

Auxiliary material: refrigerant, antifreeze, sponge rubber strip
2 Disassembly steps
2.1 Recycling the refrigerant by refrigerant recycling machine

Note:
（1） Do not deal with the refrigerant at closed place or near flame.
（2） Do not splash the refrigerant into eyes and skin.
2.2 Disassemble instrument panel assembly and front cross beam.

Unplug related electrical connector (Refer to disassembly/assembly of instrument panel)
2.3 Loose fixing bolts on high/low pressure pipe by

spanner.
2.4 Loose the fixing bolt between high/low pressure pipe

and expansion valve, pull high/low pressure pipe outward.
2.5 Disassemble evaporator water tank inlet and outlet pipe

clip and take off water pipe.
Note: coolant will flow out from the water pipe, pay attention
to recycling the coolant.
2.6 Disassemble interior trim such as driver’s side pedal,

front seats, sub instrument panel, threshold pressing plate etc.
and take off the front end of carpet.
2.7 Disassemble AC cable grounding bolt.

2.8 Loose 5 fixing bolts of evaporator assembly on metal

sheet from front cab, positions see right figure.
2.9 Take out evaporator and AC cable assembly from cab
3 Installation of evaporator assembly
4 Disassembly/assembly of interior evaporator
Tool: cross head screwdriver, 4.0 hexagon wrench, socket spanner.
4.1 Blower replacement
4.1.1 Disassembly steps
4.1.1.1 Disassemble blower motor plug and motor speeder Plug of blower motor
module plug.
Plug of speeder module
4.1.1.2 Disassemble 3 blower motor screws and take out

blower.
4.1.2 Assembly steps
5 Disassembly/assembly of blower speeder

module
Blower motor plug
5.1.1 Unplug speeder module plug Speeder module plug

5.1.2 Disassemble 2 speeder module fixing bolts
5.1.3 Take off speeder module
5.2 Assembly steps
6 Disassembly/assembly of heating water tank
6.1.1 Disassemble evaporator assembly (see disassembly of

evaporator)
6.1.2 Disassemble AC cable (see disassembly of AC cable)
6.1.3 Disassemble evaporator water temperature sensor
6.1.4 Disassemble 2 socket head cap bolt from expansion

valve
Tool: 4.0 allen wrench

6.1.5 Take off expansion valve, tear down gasket around

expansion installation position.
6.1.6 Disassemble mode ventilator connection rod
6.1.7 Disassemble cooling/heating control ventilator

pull rod
6.1.8 Disassemble 14 bolts on evaporator housing,

decomposing evaporator housing.
Note: the sponge seal around housing is one time using
6.1.9 Disassemble 4 bolts on heating cover plate

assembly

6.1.10 Take off heating cover plate assembly
6.1.11 Tear down sponge seal around water inlet and

outlet pipe, take off heating water tank cover plate.
6.1.12 Take off heating water tank
6.2 Assembly steps

Carry out checks for system evacuating, keep pressure,
antifreeze leaking.
Check if the radiator is blocked. Clear the blocked radiator.
7 Disassembly/assembly of mode ventilator
motor and related mechanism
7.1 Disassembly/assembly steps
7.1.1 Take off motor plug

7.1.2 Disassemble mode ventilator connecting rod

7.1.3 Loose 3 fixing screws of mode ventilator motor,

and disassemble mode ventilator motor
7.1.4 Loose control disc fixing screw, take off control

disc
7.1.5 Disassemble 3 screws and shims which control

arm for defrost, blowing head and blowing feet behind
of control disc.
7.2 Assembly steps
8 Disassembly/assembly of mixing ventilator

motor and related mechanism

8.1.2 Disassemble mixing ventilator pull rod
8.1.3 Loose 3 screws of mixing ventilator control motor

, and disassemble the motor

8.1.4 Disassemble mixing ventilator control arm
8.2 Assembly steps
9 Disassembly/assembly of inside/outside
circulation ventilator motor and related
mechanism

9.1.2 Disassemble inside/outside circulation ventilator
pull rod
9.1.3 Loose 3 screws of inside/outside circulation

ventilator motor, and disassemble the motor
9.2 Assembly steps
10 Disassembly/assembly of evaporator
10.1.1 Disassemble evaporator assembly (Refer to

disassembly of evaporator)
10.1.2 Disassemble AC cable (Refer to disassembly of

AC cable)
10.1.3 Disassemble evaporator water temperature

sensor (Refer to disassembly of evaporator water
temperature sensor)

10.1.4 Disassemble mode ventilator connection rod

(Refer to disassembly of mode ventilator connection rod)
10.1.5 Disassemble cooling/heating control

ventilator pull rod
10.1.6 Disassemble 14 bolts from evaporator housing,

decomposing evaporator housing
Note: sponge seal around housing is one time using
10.1.7 Disassemble evaporator assembly
10.2 Assemble evaporator assembly

Carry out checks for system evacuating, keep pressure,
antifreeze leaking.
Check if the radiator is blocked. Clear the blocked radiator
11 Disassemble other accessories from

evaporator
11.1.1 Disassemble 4 bolts from lower ventilator by

cross head screwdriver
11.1.2 Take off ventilator
11.1.3 Disassemble inside/outside circulation ventilator

pull rod (Refer to disassembly of inside/outside circulation
motor)
11.1.4 Loose 4 bolts of inside/outside circulation

ventilator

11.1.5 Take off inside/outside circulation ventilator
11.1.6 Disassemble 4 inside/outside circulation ventilator

fixing bolts, and take off the ventilator
11.1.7 Disassemble interior temperature sensor holder
11.2 Assemble of other accessories for evaporator
III. Trouble shooting
Pressure deviated type Possible reasons Method for trouble shooting
1. Pressure on high pressure side Refrigerant is not enough or Take out refrigerant
is not changed or increased expansion valve failure. ● If the quantity of refrigerant is ok
slightly (compare to engine 1. Replace expansion valve
stopped); pressure on low 2. Refill refrigerant
pressure side is within the 3. Check the pressure again
schematic range or lower than ● If the quantity of refrigerant is not
that, means AC cooling ability enough
is not enough 1. Check if there is leaking, if there
2. pressure on high pressure side is is fix it
ok, pressure on low pressure 2. Refill refrigerant

side is within schematic range, 3. Check the pressure again

AC is cooling ability is not
enough
Pressure on high pressure side is There must be somewhere is Touch the pipe by hand feeling T changes
higher than stipulated value, and blocked or throttled in refrigerant ●If there is T difference between every
lower pressure side is decreased to pipe; positions of one part
schematic range or lower, the AC Expansion valve is invalid 1. Blow the pipe by compressed air and
cooling ability is not enough Nitrogen, replace expansion valve also
2. Replace blocked part
● If there is no fault
1, Blow the pipe by compressed air and
Nitrogen
2. Check the pressure again
At the beginning low pressure side is Expansion valve is invalid Check if it is dirty or rusty inside of the
ok, but after a while, high pressure There is vapor in refrigerant pipe expansion valve, replace it if necessary
side pressure is higher than specified ● Blow the pipe by compressed air and
value, and low pressure side is Nitrogen
within the schematic range or lower.
AC cooling ability is not enough
High pressure side is higher than The quantity of refrigerant is over Take out refrigerant
specified value or too high, low in the pipe ●If the quantity of refrigerant is ok
pressure side is too high, AC cooling Expansion valve is invalid or 1, Replace expansion valve
ability is not enough, there is strange compressor is damaged 2, Refill refrigerant
noise on compressor (especially at the 3, Check the pressure again
beginning when it is started) ● If the quantity of refrigerant is over
1. Refill refrigerant
2．Check pressure again
Note: after pressure recheck, if the
system can not work properly.
Reassemble the replaced expansion valve
and blow the pipe through by compressed
air and Nitrogen, replace compressor and
reservoir dryer.
High pressure side pressure is Compressor is damaged Blow the pipe through by compressed air
increased slightly, low pressure side is and Nitrogen
decreased slightly, AC cooling ability
Replace compressor and reservoir dryer
is not enough
High pressure side is ok, low pressure Expansion valve is invalid or Replace expansion valve
side is too low, AC cooling is compressor is damaged Refill refrigerant: recheck pressure, if the
correct, sometimes evaporator is system is not correct, reassemble the
freezing (the quantity of refrigerant replaced expansion valve and blow the
is correct) pipe through by compressed air and
Nitrogen, replace compressor and

reservoir dryer.
1, high and low pressure both are Quantity of lubricant inside of AC Take out refrigerant
correct, AC cooling ability is not pipe is over ●Blow the pipe through by compressed
enough air and Nitrogen
2. high and low pressure both are Note: pay attention to the lubricant
correct, compressor has strange noise quantity when replace compressor and
(especially at the beginning of engine other parts
started), AC cooling is correct
Reservoir can not be used • Perforation Replace
• Seal position is damaged

• Thread of fastener is damaged,
and outside air is entering into
the system at prolonged time.

Chapter Ten Body Size

I. Beam Dimension
Unit:mm

II. Body assembly dimension
1 Front view

1.1 Clearance between A-A headlamp and engine hood is 4±1 mm

Clearance between A-A headlamp and front bumper is 3±1mm
Engine hood
Headlamp
1.2 Clearance between B-B front fender and headlamp is 1＋0.5mm
Front fender
Right headlamp

1.3 Clearance between BB-BB front fog lamp and front bumper is 2±0.5mm
Front bumper grille
Front fog lamp cover
Front fog lamp
Around
Front bumper
1.4 Clearance between CC-CC engine hood and front grille is 8±1mm
Lock bracket Engine hood

liner
Engine hood cover
Engine hood weather strip

1.5 Assembly dimension between D-D section engine hood and front windscreen lower trim cover is 15±1mm
Upper instrument panel
Front windscreen
Front engine
outside cover
Trim cover body

Front engine cover
Trim cover
outside plate
Front panel

1.6 Clearance between E-E front windscreen and roof is 4.3±0.5mm
Top of car
Roof panel
Roof
Interior rearview
mirror

2 Rear view

2.1 Clearance between AA-AA roof and rear door is 7.5±1mm
Rear door
Roof outside plate
around High position

brake lamp
Rear door upper

weather strip
Rear windscreen

2.2 Clearance between B1B1-B1B1 rear door and rear windscreen is 2.5±0.5mm
Clearance between B1B1-B1B1 rear door to rear bumper is 7.5±1mm
Wiper
system
Rear windscreen
Rear door trim plate
Rear door lower trim

plate assembly
Rear
door
Rear door lock

reinforcement
Rear bumper

2.3 Clearance between CC-CC rear door and D pillar is 5±1mm

Rear door trim panel
Rear door
D pillar outside panel outside panel
Rear door
Trim panel
inside panel
D pillar reinforcement D pillar
2.4 Matching dimension between Z-Z rear door to body:
Roof
Reinforcement
Reinforcement
Rear door
Rear door reinforcement
Around
Roof
Rear door glass

2.5 Clearance between Z1-Z1 tail light and rear door is 5±1mm
Rear door inside panel
Rear tail lamp
Rear door

3 Left side view－1

3.1 Clearance between F-F engine hood and front fender is 4±1mm
Front engine cover outside panel
Front fender
Front engine cover inside panel
3.2 Clearance between G-G fender and front bumper is 1±0.5mm
Front fender
Front bumper

3.3 Clearance between H-H A pillar and fender is 3±0.5mm
A pillar reinforcement
A pillar inside panel
A pillar outside panel
Front fender
3.4 Clearance between K-K A pillar and quarter window glass is 3±1mm
Clearance between K-K A pillar and front windscreen is 4±0.5mm
A pillar outside panel

A pillar trim panel

3.4 Assembly dimension between KK-KK quarter window glass and instrument
panel is 4.5±0.5mm
3.5 Clearance between L-L quarter window and front door is 5.5±1mm
Front door opening weather strip

Front door
Pillar inside panel Front door trim panel
Pillar inside trim panel Front door inside reinforcement
Pillar reinforcement
Front door glass slot
前三角窗
Front quarter window Front door

3.6 Clearance between M-M A pillar and front door is 5.5±1mm
A pillar body
A pillar inside trim panel
前门
Front door
3.7 Clearance between N-N front door and front fender is 5.5±1mm
Front inside panel
Front inside reinforcement
Front fender Front door outside panel

3.8 Clearance between O-O body and front fender is 3.5±0.5mm
Body
Front fender
O—O
1 ：1
3.9 Clearance between P-P front door and side panel is 6±1mm
Front door panel

前门护板下部
lower part
Front前门
door
门槛护板
Threshold panel
门槛内板
Threshold inside panel
车身侧围
Body side panel

3.10 Clearance between Q-Q front door and roof is 5.5±1mm
车顶
Roof
车顶棚
Car roof
前车窗玻璃
Front window glass
3.11 Clearance between R-R front door and rear door is 5±1mm
B pillar trim panel
B pillar
B pillar reinforcement
B pillar
Front door inside panel
Rear door inside panel

Front door
Reinforcement Rear door outside panel

3.12 Matching dimension between S-S front door, rear door and B pillar:
B pillar lower trim panel

Front door panel
Middle reinforcement
Body
Front door inside panel Rear door inside panel
Front door Rear door
3.13 Matching dimension between SS-SS front door, rear door and B pillar:
Front door
Rear door

4 Left side view-2

4.1 Clearance between T-T rear door and roof is 5.5±1mm
body
Body reinforcement
Roof inside panel
Roof
Rear door glass
4.2 Clearance between U-U rear door and C pillar is 5.5±1mm
C pillar panel
C pillar inside panel
C pillar reinforcement
Rear glass
Glass slot
Body
Rear door

4.3 Clearance between V-V rear door and body is 5.5±1mm
Fuel tank
cap
Rear
Body bumper
Fuel port
seat
4.4 Clearance between X-X fuel tank cap and body is 3.5±1 mm
Rear door panel
Rear door lock
Reinforcement
Rear door
Body

4.5 Clearance between XX-XX rear bumper and body is 1±0.5mm
Body
Rear bumper
4.6 Clearance between Y-Y rear tail lamp and body is 2±1mm
D pillar trim panel
Reinforcement

Rear window glass
Rear door glass

Rea door
Body
Rear tail lamp

III．Engine Compartment Dimension
1513.2
1533.5
C A
1516
301.1
1163.9
I B
192.3 H
1477.4
J E
K
982.7 1273.2
O F
780
M
L
683.4 P
Q
N
1146
Code Name Ø（mm）

A/B Gullet assembly hole 7
C/D/E/F Fender assembly hole 7
G/ H Shock absorber assembly hole 87
I/J Engine right suspension bracket assembly hole 17
K/L Front headlamp assembly hole 7
M/N Headlamp assembly hole 7
O/P Bumper assembly hole 7
Q/R Front bumper cross beam assembly hole 13

IV. Windscreen Dimension
Rear windscreen lower corner

point (left is same as right)
Rear windscreen upper corner

point (left is same as right)
Roof and side panel joint

corner (left is same as right)
Front panel upper cover assembly

and A pillar inner panel joint
(left is same as right)

V. Dimension of All the Opening
Body size, left - right
Remarks: capital letter means left side, small letter means right side（look from rear side of car）
Code Name remark Code Name remark

A a Front door up hinge 11 H h Side panel rear door guide upper
assembly holder corner point
B b Front door lower hinge 11 I i Rear door support point
assembly holder
C c Side panel front door J j Rear side wind window left upper
guide upper corner point assembly point ( look from left side of
a car)
D d Rear door lower hinge 11 K k Rear side wind window left lower
assembly holder assembly point ( look from left side of
a car)
E e Rear door up hinge 11 L l Rear side wind window right upper
assembly holder corner point (look from left side of a
car)
F f Front door support point M m Rear side wind window right upper
corner point (look from left side of a
car)
G g Side panel rear door
guide upper corner point

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Service Manual for CHERY V525 Car Body Accessories

After Sales Service Department of Chery Automobile Sales Co., Ltd

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9.2 Assembly steps...............................................................................................17

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8.1 Disassembly steps ..........................................................................................72

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11.1 Disassembly steps ........................................................................................89

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Chapter One Engine Hood And Luggage Compartment

I. Disassembly and assembly of engine hood

Tool: flat head screwdriver, pliers, wrench

3 Disassembly/assembly of engine hood accessories

3.1 Disassembly steps

3.1.1 Take off the snap clips(19 pieces) by screwdriver from

3.1.2 Take off the hose of washing liquid.

3.2 Assembly steps

The installing steps are reverse to those for removal.

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4 Disassembly and adjustment of the engine hood assembly

Tool: No. 13 spanner

4.2 Assembly of front engine hood assembly:

5 Disassembly and assembly of air intake grille assembly

Tool: No. 10 spanner

5.1 Disassembly steps

5.1.2 Take off air intake grille.

5.2 Assembly of air intake grille

6 Adjustment and assembly of the engine hood lock

Tool: No.10 spanner

6.1 Disassembly steps

6.1.1 Disassemble the front engine hood lock by unscrewing

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6.1.2 Take off the lock cable from engine hood.

6.2 Assembly of engine hood lock

The installing steps are reverse to those for removal.

7 Disassembly of engine hood lock control cable

Tool: No. 8 spanner, No.10 spanner, flat head screwdriver

7.1 Disassembly steps

7.1.3 Take off engine hood lock, and disassemble the

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7.1.4 Unscrew two clips from fixing cable by flat head

7.1.5 Disassemble front bumper and driver’s side

7.1.6 Take out the plug where the cable go through

7.1.7 Take out of the cable.

7.2 Assembly steps

The installing steps are reverse to those for removal.

II. Disassembly and assembly of rear

luggage compartment lid.

Tool: flat head screwdriver, No. 13 socket spanner

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2 Disassembly of rear lid trim panel

2.1 Disassembly steps

Tool: No. 13 spanner

2.2 Installation of rear lid trim panel

The installing steps are reverse to those for removal.