Service Manual for Chery V525 Car Chassis Service Manual for Chery V525 Car (Chassis) Service & Technical Department of Chery Automobile Company PDF created with pdfFactory Pro trial version www.pdffactory.
Service Manual for Chery V525 Car Chassis Chapter One Brake System.................................................................................................................4 Ⅰ. System overhaul parameters .................................................................................................4 1. Brake disk surface check ................................................................................................4 2. Brake disk thickness check ............................................
Service Manual for Chery V525 Car Chassis 4 Disassembly and assembly procedures ..........................................................................24 4.1 Removal of shock absorber assembly.................................................................24 4.2 Removal of control arm assembly ......................................................................25 4.3 Removal of front axle assembly .........................................................................26 5. Assembly procedures ....
Service Manual for Chery V525 Car Chassis Chapter One Brake System Ⅰ. System overhaul parameters 1. Brake disk surface check The friction surface of brake disk shall be smooth, without conspicuous pits or groove. Otherwise, replace it. 2. Brake disk thickness check Use caliper to check the thickness of brake disk: Standard thickness of front disk（ventilation disk）shall be 22mm, application limit shall be 19mm, otherwise replace it.
Service Manual for Chery V525 Car Chassis Ⅱ. Disassembly, assembly and overhaul of front brake and brake caliper 1. System structural diagram Structural Diagram of Front Brake Assembly （1）Positioning bolt of brake disk （3）Hub bearing unit （5）Splash shield （7）Fixing bolt （9）Friction lining position sensor plug （11）Brake caliper assembly （2）Brake disk （4）ABS wheel speed sensor plug （6）Steering knuckle （8）Friction lining （10）Brake bracket （12）Fixing bolt PDF created with pdfFactory Pro trial version www.
Service Manual for Chery V525 Car 2. Preparation Tools：ratchet, ratchet rod, 8#, 13#, 15#, 19#, 20#, 32# sleeve, 11#, 13#, 14#, 17#, 30# box end wrench, vices, torque spanner. Accessories: brake fluid 3. Note 3.1 Wear necessary labor protection supplies to avoid accidents. 3.2 Brake fluid is a kind of toxic liquid; if contact with skin or eyes, please wash using large quantity of fresh water, and go to a doctor if necessary. 3.3 Waste brake fluid shall be put into vessels.
Service Manual for Chery V525 Car 4.4 Remove the brake caliper from steering knuckle, then separate brake caliper and brake hose. 4.5 Use punch to drift the lock trough, which drives nut shim from semi-axle head, until it is able to turn. 4.6Remove the driving nut using 32# sleeve and torque spanner. Torque: 180±10 N.m 4.7 Use cross screwdriver to unscrew the fastening screw of brake disk, and then remove the brake disk. Torque: 7-9 N.m 4.
Service Manual for Chery V525 Car 4.9 Check the max. circular runout of brake disk end face via dial indicator, if it is greater than 0.03mm, replace accordingly. (If the brake disk thickness can be guaranteed, appropriate mechanical processing also can be performed to satisfy maximum. circular runout) 4.10 Remove the connecting nut of knuckle and control arm using torque spanner and 18# sleeve. Torque: 110±5N.m 4.11 Remove three fixing bolts of hub bearing unit and knuckle using 17# sleeve.
Service Manual for Chery V525 Car 4.14.2 Lift the fixing bracket of brake caliper, and then takes out brake lining. 4.14.3 Measure the thickness of friction lining, if less than 10mm, please replace in pairs timely. 4.14.4 Remove the dust seal, check its damage condition, and replace if necessary. Clean the contact surface of brake piston and then coat with a thin noise silencing paste. Caution: due to noise silencing paste may cause expansion of dust seal, it is prohibited to contact with each other. 4.
Service Manual for Chery V525 Car 4.14.7 Carefully remove seal ring using plastic pin, then clean the brake cylinder and components via alcohol, blow via compressed air. Carefully check surface of brake cylinder, piston and flange, it is prohibited to carry out mechanical processing to the brake cylinder and piston. 5. Assembly procedures 5.1 Assembly of brake cylinder 5.1.1 Apply a think coat of brake cylinder paste onto cylinder body, plunger and seal sleeve.
Service Manual for Chery V525 Car Ⅲ. Disassembly, assembly and overhaul of rear brake 1. System constructional drawing （To be handled) 2. Preparation Tools: Ratchet wheel, ratchet rod, 8#, 13#, 15#, 20# sleeve, 13#, 14#, 17#, 30# box end wrench, vice, torque spanner and flat-tip screwdriver. Accessories: brake fluid 3. Precautions 3.1 Wear necessary labor protection supplies to avoid accidents. 3.
Service Manual for Chery V525 Car 3.4 When carrying out disassembly and assembly, never step on the brake pedal nor move the vehicle. 3.5 Keep oil or liquid away from friction lining or friction disk, it may affect brake performance. 4. Disassembly procedures 4.1 Remove the rear wheel (refer to the disassembly procedures for front wheel). 4.
Service Manual for Chery V525 Car 4.7 Remove brake caliper assembly. 4.8 Removal of brake caliper assembly: 4.8.1 Remove guide bolt using 17# box end wrench. Torque: 22-23N.m 4.8.2 Take out friction lining assembly. 4.8.3 Remove another guide bolt, separate brake cylinder. 4.8.4 Dismantle and overhaul brake cylinder (refer to the methods for front wheel brake cylinder) 5. Assembly procedures Refer to disassembly procedures. PDF created with pdfFactory Pro trial version www.pdffactory.
Service Manual for Chery V525 Car Chassis Ⅳ.Adjustment and replacement of handbrake control cable 1. System structural diagram To left rear brake assembly To right rear brake assembly Brake 1. Handle 2. Fixing bolt 3. Brake cable 4, 5. Right and left rear-wheel control cable 2. Preparation Tools: flat-tip screwdriver, cross screwdriver, pincers, 10#, 16#, 18# sleeve, knock stick. Accessories: none 3. Precautions 3.1 Wear necessary labor protection supplies to avoid accidents. 3.
Service Manual for Chery V525 Car 4.1.2 Remove the return spring of hand brake shoes via screwdriver. 4.1.3 Turn the guide pin of brake shoes to align the spring seat via pliers, and then take out the guide pin. 4.1.4 Compress the return spring of control cable until the control cable clip gets out of the guide pin of hand brake. 4.1.5 Remove the fixing bolt that fastens control cable and lower plate of hand brake assembly via 10# spanner. Torque: 7-14N.m 4.1.
Service Manual for Chery V525 Car 4.1.7 Prize out the lifting eye of exhaust pipe via screwdriver (it is unnecessary to remove the lifting eye behind silencer). 4.1.8 Disconnect the connecting nut of exhaust pipe and 3-way catalytic converter via 18# sleeve, and then remove the rear oxygen sensor (caution: along with the descend of exhaust pipe, it may result in rupture of rear oxygen sensor harness). Torque: 60±5 N.m 4.1.
Service Manual for Chery V525 Car Chassis 4.2.2 Unscrew total four screws of the plate guard of hand brake control mechanism via cross screwdriver. 4.2.3 Remove four fixing bolts of hand brake control mechanism via 10# sleeve, and then pull out the switch plug of hand brake. Torque: 25±3N.m 4.2.4 Remove the fixing nut of front hand brake control cable via 10# spanner. Torque: to be determined 4.3. Assembly procedures Refer to disassembly sequence. 4.
Service Manual for Chery V525 Car Chassis Ⅴ. Disassembly, assembly and overhaul of ABS system, brake master cylinder as well as vacuum booster 1. System structural diagram ABS Pipeline 1. Pipeline clip 3. Master cylinder brake line 5. ABS pump rack 7. ABS master cylinder fixing cushion 9. Right-rear wheel brake line 11. Left-front wheel brake line 13. Left-front wheel brake hose 15. Flange tri-slot fixing pipe clip 17. Brake copper tube 2. Master cylinder brake line 4. Right-front wheel brake line 6.
Service Manual for Chery V525 Car 3.2 When carry out maintenance to hydraulic system, first, completely discharge the high-pressure brake fluid in accumulator to avoid splashing injuries. When discharging high-pressure brake fluid in the accumulator, repeatedly apply and release the brake pedal, until the brake pedal become very hard. 3.3 Make sure electronic control unit is free from collision, knock, and avoid damage. 3.
Service Manual for Chery V525 Car 4.1.4 Remove the fixing bracket of brake reservoir via 8# sleeve, and then pull out the plug of brake fluid-level alarm. Torque: 11±1N.m 4.1.5 Dismount the connecting pipe between reservoir and brake master cylinder via clamp pliers. Then take out the small reservoir that is connected with brake master cylinder. 4.1.6 Loosen the connecting nuts of various pipelines of ABS assembly via 12# open-end wrench.
Service Manual for Chery V525 Car 4.2.2 Remove two stay bolts that secure vacuum booster via 13# sleeve. Note: there are two nuts behind the brake pedal in the driver's cabin connect with these stay bolts. Torque: 25±2.5Nm 4.2.3 Loosen the two nuts securing brake master cylinder and vacuum booster via 22# sleeve, and then take out brake master cylinder. 4.3 Disassembly of vacuum booster 4.3.1 Loosen the two fixing bolts of vacuum booster behind the brake pedal inside the driver's cabin via 13# sleeve.
Service Manual for Chery V525 Car 4.5.2 If replacing ABS control assembly, first, confirm whether the new assembly is of dry type (brake fluid is not full of the valve body) or wet type (brake fluid is full of the valve body). If it is of dry type, after assembly, carry out ventilation to the ABS assembly via Chery dedicated diagnostic instrument, if it is of wet type, it is unnecessary to carry out ventilation. 4.5.
Service Manual for Chery V525 Car Chassis Chapter Two Adjustment to Suspension System and Four-wheel Alignment Ⅰ. Disassembly, assembly and overhaul of front axle and suspension 1. System constructional drawing The front axle of Chery V325 car is a kind of disconnection turning and driving axle, it uses McPherson independent suspension, whose front suspension has driving and turning dual functions. The upper end of the suspension connects with vehicle body; lower end connects with steering knuckle.
Service Manual for Chery V525 Car 2. Preparation Tools: 8#, 13#, 15#, 18#, 19#, 21#, 22#, 24# sleeve, screwdriver 3. Precautions 2.1 Wear necessary labor protection supplies to avoid accidents. 2.2 When carry out maintenance and repair to chassis, please note that whether safety-lock of lifting machine is locked. 2.3 When carry out disassembly and assembly to shock absorber spring, prevent spring ejection from being injured. 2.
Service Manual for Chery V525 Car 4.1.4 Remove a fixing bolt at shock absorber assembly that is close to front guard-board assembly via 10# sleeve. Torque: 10±1 N.m 4.1.5 Prize up a corner of front guard-board using screwdriver, and then remove shock absorber bolt. 4.1.6 Remove three fixing bolts fastening shock absorber assembly and frame via 15# sleeve. Torque: 45±5N.m 4.1.7 Remove the shock absorber assembly. 4.1.
Service Manual for Chery V525 Car 4.2.2 Remove the fixing bolts fastening control arm and steering universal joint ball via 18# sleeve. Torque: 105±10N.m 4.2.3 Remove the connecting bolts fastening control arm and front axle via 18# sleeve. Torque: 180±15 N.m 4.2.4 Remove three rear fixing bolts fastening control arm and subframe via 13# sleeve, and then remove the control arm assembly. Torque: 90±8 N.m 4.2.5 Remove the self-locking nut that fastens control arm and connection board via 24# sleeve.
Service Manual for Chery V525 Car 4.3.2 Remove rear support-bracket bolt of transmission on the front side member via 15# sleeve. Torque: 80±6N.m 4.3.3Remove front support-bracket bolt fastening transmission and side member via 24# sleeve. Torque: 80±6N.m 4.3.4 Remove two front bolts of side member via 18# sleeve. Torque: 100-120 N.m 4.3.5 Remove two rear-fixing bolts of side member via 15# sleeve. Then remove side member assembly. Torque: 100-120 N.m 4.3.
Service Manual for Chery V525 Car 4.3.7 Remove the fixing bolt connecting head exhaust pipe and engine cylinder body via 13# sleeve. Torque: 45±5N.m 4.3.8 Remove the connecting bolts of head exhaust pipe and three-way catalytic converter via 18# sleeve. Torque: 55±5N.m 4.3.9 Remove the fixing bolt of power steering gear via 13# sleeve. Torque: 75±5 N.m 4.3.10 Remove the fixing bolt and nut at the left side of power steering gear via 13# and 15# sleeve. Bolt torque: 75±5 N.m Nut torque: 70±5 N.m 4.3.
Service Manual for Chery V525 Car 4.3.12 Remove another fixing bolts fastening subframe and vehicle body via 21# sleeve, and then removes the front axle assembly. Torque: 150±10 N.m 4.3.13 Remove the fixing bolt and nut of gum cover of stabilizer rod via 13# sleeve. Torque: 50±5N.m 5. Assembly procedures Refer to the disassembly procedures of front axle and front suspension. PDF created with pdfFactory Pro trial version www.pdffactory.
Service Manual for Chery V525 Car Chassis Ⅱ. Disassembly, assembly and overhaul of rear axle and suspension 1. System constructional drawing Structural diagram of Rear Axle and Suspension System 1. Fixing nut of shock absorber 2. Flat-tip shim 3. Shock absorber assembly 4. Fixing bolt of shock absorber 5. Fixing nut of shock absorber bearing 6. Fixing nut of shock absorber bearing 7. Rear axle connection hinge 8. Knuckle joint bolt 2.
Service Manual for Chery V525 Car 3. Precautions 3.1Please wear necessary labor protection supplies to avoid accidents. 3.2When carry out maintenance and repair to chassis, please note that whether the safety lock of lifting machine is locked. 3.3When carry out disassembly and assembly to shock absorber spring, prevent spring ejection from being injured. 4. Disassembly and assembly procedures 4.1. Removal of shock absorber assembly 4.1.
Service Manual for Chery V525 Car 4.1.5 Remove the fixing bolt of the back plate assembly of storage box via 8# sleeve. Torque: 7±1N.m 4.1.6 Remove the fixing bolt of seat via 17# sleeve. Torque: 25±3N.m 4.1.7 Prize up inner trim panel assembly via screwdriver. 4.1.8Remove the fixing nut of shock absorber bearing via 13# sleeve, and then remove shock absorber assembly. Torque: 90±8 N.m 4.1.9 Structural diagram of shock absorber assembly. PDF created with pdfFactory Pro trial version www.pdffactory.
Service Manual for Chery V525 Car 4.2 Removal of rear axle assembly 4.2.1Remove the four connecting bolts of rear axle and brake assembly via 13# sleeve. Torque: 70±5N.m 4.2.2 Remove the hinged bolts connecting rear axle and vehicle body via 17# sleeve. Then remove the rear axle. Torque: 110±10N.m 5. Assembly procedures The assembly procedure is reverse to that of disassembly. Ⅲ.
Service Manual for Chery V525 Car Torque: 55±5N.m 1.4 After adjusting toe-in of front wheel, check whether the steering wheel is horizontal. Otherwise, loosen the lock nut of steering wheel, adjust steering wheel to horizontal position, and tighten up the lock nut of steering wheel to the torque value as required. 2. Adjustment of front-wheel camber angle 2.
Service Manual for Chery V525 Car Chassis Ⅳ.Installation of tire and regulation of air pressure 1. Fit tire valve Prior to installing tire valve, firstly check the valve port to ensure whether it is smooth and free from burr, and then apply glycerol on the rubber body surface, will soak the tire valve into glycerol.
Service Manual for Chery V525 Car Chassis Chapter Three Disassembly, Assembly and Overhaul of Steering System Ⅰ. Disassembly and assembly of steering gear 1. System structural diagram 1. Power steering reservoir 3. Bracket fixing nut 5. Fixing bracket of reservoir 7. Tension pulley 9. Adjusting nut 11. Pipe clip 13. Oil outlet pipe 16. Fixing nut 2. Bracket fixing bolt 4.Oil outlet pipe 6. Steering pump 8. Self-locking nut 10. Regulating pull rod 12.Steering gear 14, 15. Fixing bolt 17.
Service Manual for Chery V525 Car 3. Precautions 3.1 Please wear necessary labor protection supplies to avoid accidents. 3.2 Avoid steering fluid to contact with skin or eyes when disassembling steering system. 4. Disassembly and assembly procedures 4.1 Remove the fixing nut of steering ball pin via 19# sleeve. Torque: 40±3 N.m 4.2 Remove the fixing bolt of power steering gear via 13# sleeve. Torque: 75±5 N.m 4.
Service Manual for Chery V525 Car 4.5 Remove the fixing bolt of steering universal joint via 13# spanner. Torque: 25±3N.m 5. Assembly procedures Refer to disassembly procedures. PDF created with pdfFactory Pro trial version www.pdffactory.
Service Manual for Chery V525 Car Ⅱ. Disassembly and assembly of steering post 1. System structural diagram 1. Steering post 2. Knuckle joint 3. Protective rubber cup PDF created with pdfFactory Pro trial version www.pdffactory.
Service Manual for Chery V525 Car 2.Preparation Tools: slotted screwdriver, cross screwdriver, 5.0 hexagon socket spanner, 8#, 10#, 13#, 22# sleeve, steering wheel puller. 3.Precautions 3.1Please wear necessary labor protection supplies to avoid accidents. 3.2Avoid steering fluid to contact with skin or eyes when disassembling steering system. 3.3Before disassembling steering wheel, disconnect negative of battery cell to avoid airbag ejection. 4. Disassembly procedures 4.
Service Manual for Chery V525 Car 4.5 Remove two clamp screws of steering wheel plate guard via cross screwdriver. Torque: 1.5±0.5N.m 4. 6Remove four fixing bolts of screw cable via cross screwdriver. Then remove screw cable. Torque: 1.5±0.5N.m 4.7 It should be noted that when fitting the screw cable, turn the inner disk to one direction until unable to be turned further, and then turn about 3.
Service Manual for Chery V525 Car 4.10 Remove two fixing bolts of air conditioning air outlet via screwdriver. Torque: 1.5±0.5N.m 4.11 Remove the connecting bolt of steering universal joint inside engine hood via 13# sleeve. Torque: 25±3N.m 4.12 Remove the lower fixing bolt of steering post via 10# sleeve. Torque: 25±3 N.m 4.13 Remove the two upper fixing nuts of steering post via 10# sleeve. Then remove the ignition-lock barrel assembly of steering post. Torque: 25±3 N.m 4.
Service Manual for Chery V525 Car Chassis Ⅲ. Adjustment to clearance of steering gear 1. Maintain wheel at straight line traveling position; 2. Turn steering wheel to both sides; 3. If heard noise of steering gear, adjust the bolt as shown in the diagram until no impinge noise is heard when turning steering wheel; 4. Tighten up the bolt for another 1 / 8 circle ( about 45°); 5. Road test; 6. If the steering mechanism can not return to the central position by itself, then loosen the bolt for 15°; 7.
