Chery A series. Manual - part 24

Exhaust gas emission            CO%           HC (p.p.m.)   CO2 (%) 

Before catalytic converter        0.4 - 1           < 600         > 12 

After catalytic converter         < 0.35            < 90         > 13 

See the above table, using three-way catalyst converter can reduce three types of harmful 
gases in exhaust gas at the same time: HC, CO, NO

x

, while harmless CO

2

 increases. 

The following factors will rapidly damage the catalytic converter: 

——

Fuel contained lead, which will decrease converter efficiency even invalidate catalytic 

converter. 

——

Incomplete burned fuel in converter, for example, the catalytic converter will be melt and 
damaged only in 30 seconds by the fuel under 800°C (temperature in converter). 

Do not cut off the high voltage cable no matter the engine is running for any reason to insure 
ignition parts (static ignition coil, high voltage cable, spark) are effective. 

Oxygen sensor signal is displayed on diagnosis tester. 

This value shall continuously wave in a defined range (thin mixture<0.45V, thick 
mixture>0.45V). 

Oxygen sensor heater resistance is about 4～5Ω at environment temperature 20°C, and its 

battery voltage is 12V.

 

 

 

ASSEMBLY AND DISASSEMBLY OF EXHAUST SYSTEM 

1. Installation of exhaust system with 

three-way catalyst converter: 

 

  ①  Installation of back hose hook: 

——

Install back hose hook on the dash 
panel of the body. 

 

——

Screw down M8 lock nut, screw 
down torque is 12±1Nm. 

 

②

  Installation of front hoses assembly: 

 

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——

Install Oxygen sensor assembly on front hose assembly with a tightening torque of 
45±4.5Nm. 

——

Install 3 M10 double head studs on exhaust manifolds. 

——

Lay exhaust hose pad, install front hose assembly on exhaust manifolds. 

——

Mount 3 M10 copper nuts with a tightening torque of 60±3Nm.

 

 

③

  Installation of back hose assembly and three-way catalyst converter: 

——

Connect three-way catalyst converter assembly and back hose assembly flange with 2 
M8 bolts and 2 M8 flange plane nuts and lay sealing pad with a tightening torque of 
30±3Nm. The nuts shall near the three-way catalyst converter. 

——

Install back hose assembly on front hose assembly with a hose clamp. 

——

Connect back hose assembly to the back hose hook with a hang block. 

 

④

  Installation of three-way catalyst converter: 

——

Connect three-way catalyst converter assembly and front hose assembly flange with 2 
M8 bolts and 2 M8 flange plane nuts and lay sealing pad with a tightening torque of 
30±3Nm. 

——

Use one hang block connecting front hose of three-element catalytic converter to the 
hook of back hose. 

 

⑤

  Installation of back silencer: 

——

Install a buffer stopper on back silencer with a hose clamp around the opening position 
of back silencer. 

——

Set 2 hooks to welding bolts and tighten them using 2 M8 lock nuts with a torque of 
30±3Nm. 

——

Connect back silencer to the body with 4 flying rings (hang block). 

 

⑥

  Installation of front silencer: 

——

Install front silencer between three-way catalyst converter and back silencer. 

——

Install hose clamp assembly. 

——

Tighten all bolts in hose clamps and hose clamp assembly with a torque of 30±3Nm.        

 

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Note:  

·Eccentricity between front silencer and the intake/exhaust hose is 18mm. Adjust front 

silencer position in assembly to guarantee a gap between the front silencer and the 
channel heat insulator more than 10mm. 

·In assembly, hose clamp should not be aslant installed around the exhaust hose. 

·Distance between the expanding section on exhaust hose and the section of hose 

clamp should be 1～4mm in assembly. 

 

⑦

  Installation of exhaust hose bracket: 

——

Install exhaust hose bracket. 

——

Mount 4 M8 lock nuts and tighten them with a torque of 12±1Nm. 

 

2. Examine gas leakage in exhaust system connection and its adjustment method: 

Examine leakage in exhaust system interface after engine warm-up. Certain amount of gas 
leakage is permitted (but not permitted in interface between exhaust manifolds and front hose 
assembly). It can be taken as a principle of no leakage if no engine wobble and no sound 
like ’pu’, ’pu’ in interface heard. If the above phenomenon is found, loosen the hose clamp in 
interface and rotate it a few circles, then tighten it again after adjusting installation direction 
of hose clamp. 

Installation of heat insulator 

——

Install each heat insulators to its proper position, and then tighten the clip.

 

 

 

 

 

 

 

 

 

 

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FUEL SYSTEM

 

ASSEMBLY AND DISASSEMBLY OF FUEL SYSTEM 

 

Before repair procedure   

Warning：

 

·Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. 

Always keep sparks and flames away from fuel.   

·Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious 

injuries or death and damage. Fuel can also irritate skin and eyes. To prevent 
this, always complete the following  “Fuel Line Safety Procedure”. 

 

Fuel Line Safety Procedure 

Note 

·Fuel in the fuel system is under high pressure also when the engine is not 

running.  

1．Remove the fuel-filler cap and release the pressure in the fuel tank. 

2．Remove the fuel pump relay. 

3．Start the engine. 

4．After the engine stalls, crank the engine several times. 

5．Turn the ignition switch to LOCK position. 

6． 

Install the fuel pump relay.

 

 

After repair procedure   

Warning： 

·Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious 

injuries or death and damage. When installing the fuel hose, observe“Fuel 
Leakage Inspection” described below.  

 

Fuel Leakage Inspection     

Warning：

 

·Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious 

injuries or death and damage. Always carry out the following procedure with the 
engine stopped.   

 

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