Chery Service Manual for A520

Body Dimension and Accessories DOOR

CHAPTER THREE I. 1. DISASSEMBLING FRONT DOOR THE LEFT

Remove the trim strip from the left front door;

Figure 44 2. Remove the outside weather strip from the left front door;

Figure 45 3. Remove the set screw. Pull out the harness and then remove the outside rear view mirror after detaches the door trim panel;

Assembly requirements: Make sure that the clearance between the rear view mirror rand and the door outside trim panel is uniform when fitting. The tightening torque for the screw is 5 0.5N!m. The rear view mirror could be freely, flexibly and reliably adjusted after installation. The plug in unit of the rear view mirror should be fixed inside of the door trim panel.

Figure 46

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4. Unscrew the set screw on inside door handle to detach the bezel for the inside door handle;

Figure 47 5. Remove the screws and take out the arm rest cover. Pry out the window regulator switch and pull out the harness;

Figure 48 6. Remove the fixing bolts on the left front door trim panel (in figure 49 and 50) to detach the door trim panel. Assembly requirements: Measures should be taken to prevent blurring the working area for cleaning when disassembling and installing. It is of great importance to keep clean during these jobs. The fit clearance between the door trim panel and the inner door panel should be uniform.

Window regulator switch

Figure 49

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Figure 50 7. Remove the protective film from the left front door;

Figure 51 8. Remove the set screw of inside door handle to loosen the inside control cable and the inner retention cable;

Figure 52

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9. Disassemble the set screws, pull out the harness, and then detach the speaker;

Figure 53 10. Unscrew the fixing bolts from the trim panel bracket and then dismount it;

Figure 54 11. Lower the glass to a proper position, remove the fixing bolts, move the glass to the bottom of door, and then take out the glass slantways. Assembly requirements: The glass should has a uniform upper and lower & left and right clearances to ensure an good fitting with the peripheral rubber strip. The sealing of the glass should be good without any leakage during the rain test.

Figure 55

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12. Unscrew the seven fixing nuts on the inner door panel;

Figure 56 13. Take out assembly; the window regulator

Assembly requirements: M, the torque of the fixing bolt or nut should be 7 1 N! m. Make sure that the glass could rise and fall smoothly and easily without any swinging, flapping and shocking after installation and adjustment. Electric requirement: Time of rise/fall not more than 5s.

Figure 57 14. Unscrew the fastening screws from the left front door rear glass guide rail;

Figure 58

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15. Take out the rear guide rail of the glass from inside the door;

Figure 59 16. Unscrew the fastening bolts from the lock with an internal spline wrench;

Figure 60 17. Loosen the latch rod and opening out push rod of latch of the left front door to take out the lock; Assembly requirements: Lock sealant should be applied at the middle of the fixing bolts of the side door lock. The tightening torque for the bolt is 9 1N! m. The tightening torque for the inside door handle assembly screw is 1.5 0.15N!m while the value for the bolts of the outside door handle assembly is 9 1N! m. The side door should fit tightly with its handle with reliable sealing. Be sure to position the fastener (the tightening torque of which is 23 2N! m) in the center of the latch mechanism and the lock could open and close easily.

Figure 61

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18. The latch mechanism is as shown in the figure:

D

A: Locking cable B: Opening out control cable C: Link the opening out push rod D: Link the latch pull rod
B A C

Figure 62 19. Unscrew the door handle bolt 1;

Figure 63 20. Unscrew the bolt 2;

Figure 64

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21. Take out the door handle; A: Latch pull rod B: Opening out push rod C: Latch (could be replaced directly on the vehicle)
C A B

Figure 65 22. Remove the door check; Assembly requirements: The tightening torque for the bolt is 7.2 0.7N!m and the value is 25 3 N! m while mounted on the door pillar and 9 1 N!m while mounted on the door. The door check should work easily, reliable without being hit and stuck. Grease should be applied into the room between the pull rod and the slider of the door check.

Figure 66 23. Remove the weather strip from the door opening; During installation, every corner should be fitted in place and no folds are allowed. The joint of weather strip should be placed in the lower middle of the door opening. The weather strip should have a proper rigidity and should not interfere with the opening and closing of the door after the lock and hinge have been adjusted to the operating mode. The hardness of the weather strip should be proper without great variation with the temperature changes. The surface of the assembled rubber strip should not have any defects such as hammering imprint, deformation and warp etc.

Figure 67

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24. Remove the glass run;

Figure 68 25. The inner harness of the door could be taken out from outside;

Figure 69 II. DISASSEMBLING THE REAR DOOR See left front door for considerations during disassembling the parts 1. Remove the trim strip from the left rear door;

Figure 70

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2. Unscrew the screws to detach the inner and outer trim panels of the triangle glass;

Figure 71 3. Unscrew the screw to detach the bezel for the inside door handle;

Figure 72 4. Unscrew the screw to detach the arm rest cover;

Figure 73

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5. Pry out the window regulator switch to pull out the harness;

Figure 74 6. The door trim panel could be removed;

Figure 75 7. Remove the protective film from the left rear door;

Figure 76

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8. Unscrew the fastening screw for the inside door handle to detach the handle;

Figure 77 9. Remove the fixing bolts from the trim panel bracket;

Figure 78 10. Lower the glass to a proper position, remove the set screws, move the glass to the bottom of the door, and then take out the glass slantways;

Figure 79

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11. Remove the fastening screws for the glass guide rail;

Figure 80 12. Remove the top screws to detach the glass rear guide rail and the triangle glass;

Figure 81 13. Remove the top fastening bolts from the window regulator;

Figure 82

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14. Remove the lower bolts from the window regulator;

Figure 83 15. Remove the lock fastening screws with an internal spline socket;

Figure 84 16. Loosen the opening out pull rod from the door handle, pull out the harness, and then detach the lock;

Figure 85

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17. Remove the door handle bolt 1;

Figure 86 18. Remove the door handle bolt 2 to take out the handle;

Figure 87 18. Remove the door check;

Figure 88

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19. Remove the weather strip from the door opening;

Figure 89 20. Pull out the inner harness of the door from outside;

Figure 90

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ADJUSTING THE DOOR I. ADJUSTING THE FRONT DOOR Adjust the front door in front, back and vertical directions: Unscrew the body hinge bolts to adjust the door with special tools for maintenance. Adjust the door in left, right and vertical directions: Unscrew the side hinge bolts for the door to adjust the door. REPLACING THE DOOR HINGE Remove the fender, support the door to unscrew the four fixing bolts from the upper and lower hinges, and then remove the hinges. II. ADJUSTING THE REAR DOOR Adjust the rear door in front, back and vertical directions: Unscrew the body hinge bolts to adjust the door with special tools for maintenance. Adjust the door in left, right and vertical directions: Unscrew the side hinge bolts for the door to adjust the door. REPLACING THE DOOR HINGE Unscrew the door check bolts, support the door to unscrew the four fixing bolts from the upper and lower hinges, and then remove the hinges. Figure 92

Figure 91

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