Service Manual For CHERY QQ6 (Chassis) After Sales Service Department of Chery Automobile Sales Co.
TABLE OF CONTENTS CHAPTER 1 BRAKE SYSTEM ..................................................................................................4 I. System Maintenance Parameters.............................................................................................4 1. Brake disc check: ............................................................................................................4 2. Thickness check.............................................................................................
4.3. Removal of rear trailing arm assy......................................................................28 4.4. Removal of rear axle assy..................................................................................29 5. Installation Step ............................................................................................................30 III. Adjustment of Four-Wheel Alignment System...................................................................31 1. Adjustment of Front Wheel Toe-In...
Chapter 1 Brake System I. System Maintenance Parameters 1. Brake disc check: The friction surface of brake disc should be flat and has no apparent grooves; otherwise, replace it. 2. Thickness check The standard thickness of front disc (ventilation disc) is 17 mm with service limit of 15 mm; when exceeding the service limit, replace it. 3.
Disassembly/Reassembly and Maintenance of Front Brake and Brake Caliper 1.
2. Preparation Tools: ratchet wheel, lug bar, 13#, 14#, 16#, 18#, 19#, 32# sleeves, 10#, 13#, 14#, 16# box wrenches, vice, torque spanner, surveying rod. Accessories: brake fluid 3. Precautions 3.1 Please wear necessary labor protection supplies to avoid accidents. 3.2 The brake fluid is noxious. If it contacts your skin or eye(s) by careless, please use a lot of clean water to wash the skin or eye(s), and go to see a doctor in time, if necessary. 3.3 Waste brake fluid shall be put in vessels.
4.3 Unscew the fixing bolt as shown in the picture with a 14# torque spanner and a sleeve. Fixing Bolt Fixing Bolt 4.4 Unscrew the brake caliper housing. Caliper Housing 4.5 Take off two friction linings. 4.6 Measure the thickness of friction lining. If the thickness is below 3 mm, please replace it in time, and the lining shall be replaced in pairs.
4.7 (Maintenance of brake wheel cylinder) Unscrew two fixing bolts as shown in the picture below with a 18# torque spanner and a sleeve. Torque: 74-91 N.m Two 4.8 Unscrew the bolt as shown in the picture below with a 13# torque spanner, and then take off the caliper assy. CAUTION: The brake fluid is noxious. DO NOT splash the brake fluid to your cloth or skin when the brake hose was removed 4.9 Detach the caliper assy with a 14# spanner. 4.
4.11 Remove the piston. Prepare a wood plate applicable to block the piston, and place the plate into the position between the piston and caliper wall. Carefully press out the piston via the connecting hole with the compressed air. Place a protective plate (hard wood, etc) into the notch of brake caliper to protect the piston. CAUTION: DO NOT hole the piston with your fingers— Clamped Hazard! It is unallowable to remove the caliper piston as desired.
4.15 Keep the area between dustproof seal and caliper housing dry. DO NOT contact the brake cylinder paste or brake fluid in order to ensure the proper position of dustproof seal. 4.16 Secure the brake piston with the reinforcement parts which is sold in market, and slightly press it to the dustproof seal. Apply the compressed air (max. 3.0Bar) to blow the dustproof seal, and then cover the piston with a ring.
III. Disassembly, Reassembly and Maintenance of Rear Brake 1. Structural Diagram of System Rear Left Brake 1. Brake Drum 6 3. Rear Wheel Hub Bearing Assy 5. End Cover 7. Rear Wheel Sensor 9. Double-Opening Pipeline Clip 11. Rear Shoe Spring Leaf 2. Rear 4Brake Assy 5 4. Oil Seal 6. Bolt 8. Rear Brake Pipe Retaining Clip 10. Tower Bar 12.
3.4 DO NOT step on the brake pedal and move the vehicle during the disassembly/reassembly operation. 3.5 DO NOT make the friction lining or friction disc stained with the oil/fluid which may reduce the braking effeciency. 4. Removal Step 4.1 Remove the rear wheel (refer to the Removal Step for front wheel). 4.2 Remove two brake drum locating bolts with a cross screwdriver. Bolts 4.3 Swing the brake drum, and take off it. 4.4 Observe the structure of rear brake. 4.
4.6 Remove the upper return spring with a caliper. 4.7 Remove the lower return spring with a caliper. 4.8 Press down the brake shoe locating bar spring leaf by both hands (with glove) and turn it 90° in clockwise or anticlockwise direction, and then remove two brake shoe locating bars. 4.8 Take off two brake shoes. 4.9 Detach the spring and disassemble the brake shoes.
4.10 If the rear brake is found too tight during driving, adjust the length of push rod: Turn it in the cloclwise direction to eliminate the friction. 4.11 Remove three bolts as shown in the picture wit a 10# box wrench. Bolts 1.12 Take off the brake wheel cylinder, and detach and check whether it is in good condition. 4.13 If it is necessary to check the brake drum bearing, remove the lock nuts as shown in the picture with a 32# sleeve and a torque spanner, and take off the brake drum bearing.
IV. Adjustment and Replacement of Hand Brake 1. System Composition Diagram To Rear Right Brake Assy To Rear Left Brake Assy 1. Handle 2. Fixing Bolt 3. Control Cable 4. 5. Rear Right/Left Wheel Control Cable 2. Preparation Tools: ratchet wheel, lug bar, 10#, 13#, 14#, 16# sleeve, 10#, 13#, 14# box wrench, vice, torque spanner, right-angled screwdriver. 3. Precautions 3.1 Please wear necessary labor protection supplies to avoid accidents. 3.
4.2 Remove the bolt here from the hand brake control cable fixed support with a 13# box wrench. 4.3 Remove the other bolts from the hand brake control cable fixed support with a 10# box wrench or a 10# socket wrench.
4.4 Remove the hand brake control cable at the other side with the same method. 4.5 Remove two fixing bolts from the driver’s seat with a 16# socket wrench, and then take off the seat. 4. 6 Remove all fix screws from the auxiliary instrument panel assy with a cross screwdriver, and then take off the auxiliary instrument panel assy. 4.7 Remove two hand brake fixing bolts as shown in the picture with a 10# socket wrench. 4.
4.9 Remove the pin clip with a screwdriver 4.10 Take off the control cable take-up pulley. 4.11 Draw out the hand brake control cable from the bottom of vehicle body. 4.11 (Adjustement of hand brake) The design length of this vehicle’s hand brake control cable is fixed. Refer to the rear brake removal step for the adjustment of hand brake. Adjusting the length of jogger (loosening it in clockwire direction; tightening it in anticlockwise direction) can implement the adjustment of hand brake. 4.
Chapter 2 Adjustment of Suspension System and Four-Wheel Alignment System I. Disassembly, Reassembly and Maintenance of Front Axle and Suspension System 1. Structural Diagram of System The CHERY S21 car adopts the divided steering drive axle, with a McPherson independent suspension. The upper of the suspension connects to the body while the lower to the subframe. The McPherson independent suspension bears the drive and steering functions.
Details of Front Axle and Suspension System Composition Diagram 1 Nut 9 Nut 17 Nut 2 Gasket 10 Left Control Arm 18 Nut 3 Rubber joint I 10 Right Control Arm 19 Bolt 4 Rubber joint II 11 Nut 20 Bolt 5 Left Push Rod Welding Assy 12 Subframe 21 Clamp 5 Right Push Rod Welding Assy 13 Front Strut Assy. 22 Rubber Bush 6 Nut 14 Nut 23 Bolt 7 Bolt 15 Front Connecting Rod Assy.
2. Preparation Tools: 8#, 15#, 18#, 19# sleeves; 10#, 13#, 15# wrenches. 3. Precautions 3.1 Please wear necessary labor protection supplies to avoid accidents. 3.2 Please attention whether the safety lock of lifter is locked when maintaining the chassis. 3.3 When carry out disassembly and assembly to shock absorber spring, prevent spring ejection from being injured. 3.4 It is unallowable to weld and correct the load-carrying parts of wheel suspension and the guide parts of wheel. 3.
4.1.4 Remove three fixing bolts to the frame from the shock absorber assy with a 15# sleeve. Torque: 60±5N.m 4.1.5 Remove the shock absorber assy. 4.2. Removal of control arm assy 4.2.1 Remove the fixing bolts to the control arm from the front connecting rod assy with a 15# sleeve. Torque: 100±10 N.m 4.2.2 Remove the connecting bolts of front push bar and control arm with a 15# wrench. Torque: 75±5 N.m 4.2.3 Remove the ball bolts from the control arm and steering universal joint assy with a 18# sleeve.
4.3. Removal of front axle 4.3.1 Remove the fixing bolts from the mud guard of chassis with a 8# sleeve, and then take off the mud guard assy. Torque: 3±0.5 N.m 4.3.2 Remove the front bracket bolts to the subframe from the transmission with a 19# sleeve. Torque: 110±10N.m 4.3.3 Remove the rear bracket bolts to the subframe from the transmission with a 19# sleeve. Torque: 110±10N.m 4.3.4 Remove two connecting bolts from the exhaust manifold with a 15# sleeve. Torque: 50±5Nm. 4.3.
4.3.6 Remove the fixing bolts from the right side of power assist steering wheel with a 15# wrench. Torque: 75±5 N.m 4.3.7 Remove the fixing bolts from the left side of power assist steering wheel with a 15# wrench. Torque: 75±5 N.m 4.3.8 Remove the fixing bolts used to connect the push bar and subframe with a 19# sleeve. Torque: 105±10 N.m 4.3.9 Remove the fixed support from A/C pipeline on the subframe with a 10# wrench. Torque: 25±2.5 N.m 4.3.
4.3.11 Remove four nuts used to connect the subframe and body with a 18# sleeve, and then take off the front axle assy. Torque: 150±10 N.m 4.3.12 Remove the fixing bolts and nuts from gum cover of stabilizer rod with a 13# sleeve. Torque: 50±5Nm. 5. Installation Step Refer to Removal Step of Front Axle and Front Suspension System.
II. Disassembly, Reassembly and Maintenance of Rear Axle and Suspension System 1.
2. Preparation Tools: 11#, 13#, 15#, 18#, 19#, 30# sleeve; right-angled screwdriver; pincers. 3. Precautions. 3.1 Please wear necessary labor protection supplies to avoid accidents. 3.2 Please attention whether the safety lock of lifter is locked when maintaining the chassis. 3.3 When carry out disassembly and assembly to shock absorber spring, prevent spring ejection from being injured. 4. Removal/Installation Step 4.1. Removal of shock absorber assy and absorber spring 4.1.
4.1.4 Unclench the rear helical spring with a screwdriver. 4.1.5 Forcefully swing leftwards and rightwards the rear bumper block by hand and then take off the block. 4.2. Removal of lateral support bar assy 4.2.1 Remove the connecting bolts from the left side of body and lateral support bar with a 15# sleeve. Torque: 100±10N.m 4.2.2 Remove the connecting bolts from the right side of body and lateral support bar with a 15# sleeve, and then take off the lateral support bar assy. Torque: 100±10N.m 4.3.
4.3.2 Remove the connecting bolts from the intermediate of rear axle and trailing arm assy with a 13# sleeve. Torque: 100±10N.m 4.3.3 Remove the connecting bolts from the trailing arm and body with a 15# wrench, and then take off the rear trailing arm assy. Torque: 100±10N.m 4.4. Removal of rear axle assy 4.4.1 Remove the connecting bolts from the brake pipeline and rear axle with a 11# wrench. Attention to storage of brake fluid. Torque: 45±5 N.m 4.4.2 Remove the rear brake with drum assy by hand. 4.4.
4.4.4 Remove the lock nuts from the rear brake with drum assywith a 30# combination sleeve, and then take off the rear brake with drum assy. Torque: 180±10N.m 4.4.5 Remove the rear axle assy. 5. Installation Step The installation step is reverse to that of removal.
III. Adjustment of Four-Wheel Alignment System Please check and adjust the parameters with the help of the four-wheel alignment system recommended by the CHERY Automobile Co.. Ltd. S21 standard four-wheel alignment system parameters: Item Model Front Wheel Rear Wheel Parameter SQR7130S21 SQR7110S21 Front Wheel Camber Angle 0.87°±50′ 0.87°±50′ Kingpin Caster Angle 3.4°±30′ 3.4°±30′ Kingpin Inclination Angle 12.7° 12.
2.2 Before correction, check (visually) whether the parts of running system is damaged, and repalce the damaged parts; 2.3 If the front wheel camber angle is found out of the tolerance range, loosen the connecting bolts of front shock absorber and steering knuckle, and move the wheel to correct the angle. 3. Adjustment of Kingpin caster and inclination angles The Kingpin caster and inclination angles are guaranteed by the design structure, without adjustment in service. The Kingpin caster angle: 3.
for tires will be additionally provided in written forms by product division of Chery Company or suppliers, and indicated on process sheet. 2.5 Carry out tire inflation strictly in accordance with specified pressure. During inflating process, air pressure shall not exceed 10% of rated pressure. When performing separate packaging to spare wheel assembly, the rated inflation pressure shall be 3.0 bar, and the spare wheel assembly shall be stored separately from four wheels.
Chapter 3 Disassembly/Reassembly and Maintenance of Steering System I. Removal/Installation of Steering Wheel 1. System Composition Diagram 1. Power Assist Steering Fluid Reservoir 3. Support Fixing Nut 5. Fluid Reservoir Fixed Support 7. Tensioner Pulley 9. Adjusting Nut 11. Pipe Clamp 13. Oil Output Pipe 16. Fixing Nut 34 2. Support Fixing Bolt 4. Oil Output Pipeline 6. Steering Pump 8. Lock Nut 10. Adjusting Bar 12. Steering Wheel 14. 15. Fixing Bolt 17.
2. Decomposition Diagram of Steering Wheel 3 1 2 5 4 1-Lock Nut 2-Lateral Tie Bar 5--Right Installation Support 3-Input Shaft 2 4-Left Installation Support 3. Schematic Diagram of Steering Universal Joint and Protective Sleeve S21-3404060 Steering Universal Joint Protective Sleeve assy 2. Preparation Tools: 15#, 19# socket wrenches , 13#, 18# non-adjustable wrenches. Accessories: power steering fluid 3. Precautions 3.1 Please wear necessary labor protection supplies to avoid accidents. 3.
4. Removal/Installation Step 4.1 Remove the fixing bolts from the right and left sides of steering ball pin with a 19# sleeve. Torque: 40±5 N.m 4.2 Loosen the fixing bolts from the lower of power assist steering oil pipe with a 18# non-adjustable wrench. Torque: 25±5 N.m 4.3 Loosen the fixing bolts from the upper of power assist steering oil pipe with a 13# non-adjustable wrench. Torque: 25±5 N.m 4.
4.6 Remove the fixing bolts and nuts from the upper of left support of the power assist steering wheel with a 15# sleeve. Torque: 100±10 N.m 4.7 Remove the fixing bolts and nuts from the lower of left support of the power assist steering wheel with a 15# sleeve. Torque: 100±10 N.m 4.8 Remove the fixing bolts from the steering universal joint by hand. Then remove the steering wheel assy. 5. Installation Step Refer to Removal Step.
II. Removal/Installation of Steering Column 1. System Composition Diagram Steering Wheel Steering Column Assy Steering Universal Joint Assy 1- Steering Wheel 2- Steering Column Assy 3- Steering Universal Joint Assy 2. Preparation Tools: Flat head screwdriver, cross screwdriver, 5# allen wrench, 8#, 10#, 13#, 22# socket wrenches. 3. Precautions 3.1 Please wear necessary labor protection supplies to avoid accidents. 3.
4. Removal Step 4.1 Take off the horn hood of steering wheel by hand. 4.2 Pull out the connector of horn wire behind the horn hood by hand. 4.3 Pull out the connectors of horn wire and steering wheel mount by hand. 4.4 Remove the fixing nut from the steering wheel with 21# sleeve. Torque: 35±3 N.m 4.5 Take off the steering wheel by both hands.
4.6 Remove the five fixing bolts from the protective cover of combination switch with a cross screwdriver. Torque: 1.5±0.5Nm 4.7 Remove the four fixing bolts from the combination switch with a cross screwdriver. Torque: 1.5±0.5Nm 4.8 Pull out the connectors of ignition switch and combination switch. 4.9 Pull out the connector of combination switch. 4.10 Pull out the connector of combination switch.
4.11 Take off the combination switch by both hands. 4.12 Pull out the connector of ignition switch. 4.13 Remove the ignition lock body assy with an allen wrench. Torque: 25±3 Nm 4.14 Remove the two upper fixing nuts from steering column with 13# sleeve. Torque: 25±3 Nm 4.15 Remove the two lower fixing nuts from the steering column with a 13# sleeve.
4.16 Remove the connecting nuts of the steering column and steering universal joint with a 13# sleeve, and then remove the steering column assy. Torque: 25±3 Nm 4.17 Take off the connecting bolts from the steering universal joint and steering wheel. Take out the steering universal joint assy. 5. Installation Step Refer to Removal Step.
III. Adjustment of Clearance of Steering System 1. Maintain vehicle wheel at straight line traveling position; 2. Turn the steering wheel towards the both sides; 3. If heard steering gear noise, adjust the bolt position as shown in the figure until no impinging noise is heard while turning steering wheel; 4. Tighten up the bolt for another 1/8 circle (about 45º); 5. Road test; 6. If the steering mechanism can not return to the central position by itself, then loosen the bolt for 15º; 7. Road test.
