Chery Fengyun 2 Service Manual

(Chassis)

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

 Contents

CHAPTER I TECHNICAL SPECIFICATIONS..................................................................................................... 4

I. MAIN PERFORMANCE PARAMETERS OF CHASSIS..................................................................................4

II. WHEEL ALIGNMENT PARAMETERS (NO-LOAD)..............................................................................................4

III. RIM AND TYRE MODELS.................................................................................................................................5
IV. TYRE PRESSURE...........................................................................................................................................5
V. STEERING SYSTEM.........................................................................................................................................5
VI. BRAKING SYSTEM TYPE................................................................................................................................5
VII. TORQUE LIST...............................................................................................................................................5

CHAPTER II BRAKING SYSTEM...................................................................................................................... 10

I. ASSEMBLY, DISASSEMBLY AND OVERHAUL OF THE FRONT BRAKE...................................................................10

1. System Structure Diagram......................................................................................................................10
2. Preparation..............................................................................................................................................11
3. Precautions.............................................................................................................................................11
4. Disassembly Procedure and Overhaul...................................................................................................11
5. Assembly Procedure...............................................................................................................................15
II. ASSEMBLY, DISASSEMBLY AND OVERHAUL OF THE REAR BRAKE....................................................................16
1. System Structure Diagram......................................................................................................................16
2. Preparation.............................................................................................................................................17
3. Precautions.............................................................................................................................................17
4. Disassembly Procedure and Overhaul...................................................................................................17
5. Assembly Procedure...............................................................................................................................19
III. ADJUSTMENT AND REPLACEMENT OF THE PARKING BRAKE...........................................................................20
1. System Structure Diagram......................................................................................................................20
2. Preparation.............................................................................................................................................20
3. Precautions.............................................................................................................................................20
4. Disassembly Procedure and Adjustment................................................................................................21
5. Assembly Procedure...............................................................................................................................22
IV. MAINTENANCE OF THE ABS SYSTEM............................................................................................................23
1. Preparation.............................................................................................................................................23
2. Precautions.............................................................................................................................................23
3. Disassembly Procedure..........................................................................................................................25
4. Assembly Procedure...............................................................................................................................25

2
CHAPTER III SUSPENSION SYSTEM AND ADJUSTMENT OF FOUR-WHEEL ALIGNMENT..................26

I. ASSEMBLY, DISASSEMBLY AND OVERHAUL OF THE FRONT AXLE AND SUSPENSION..........................................26

1. System Structure Diagram......................................................................................................................26
2. Preparation.............................................................................................................................................27
3. Precautions.............................................................................................................................................27
4. Disassembly Procedure..........................................................................................................................27
5. Assembly Procedure...............................................................................................................................31
II. ASSEMBLY, DISASSEMBLY AND OVERHAUL OF THE REAR AXLE AND SUSPENSION...........................................32
1. System Structure Diagram......................................................................................................................32
2. Preparation.............................................................................................................................................32
3. Precautions.............................................................................................................................................32
4. Disassembly Procedure..........................................................................................................................33
5. Assembly Procedure...............................................................................................................................35
III. ADJUSTMENT OF FOUR-WHEEL ALIGNMENT..................................................................................................36
1. Adjustment of Toe-in of Front Wheel......................................................................................................36
2. Adjustment of Camber Angle of Front Wheel.........................................................................................36
3. Adjustment of Positive Caster and Kingpin Inclination...........................................................................36
IV. ASSEMBLY OF THE TYRE AND ADJUSTMENT OF AIR PRESSURE......................................................................36
1. Assembly of the Tyre Valve....................................................................................................................36
2. Assembly of the Tyre..............................................................................................................................37
3. Inflation of Tyre.......................................................................................................................................37
4. Installation of the Wheel and Tyre Assembly..........................................................................................37
5. Method for Tightening the Wheel Nut.....................................................................................................37
6. Assembly of the Trim Cover....................................................................................................................38

CHAPTER IV ASSEMBLY, DISASSEMBLY AND OVERHAUL OF THE STEERING SYSTEM..................39

I. ASSEMBLY AND DISASSEMBLY OF THE STEERING GEAR..................................................................................39

1. System Structure Diagram......................................................................................................................39
2. Preparation.............................................................................................................................................40
3. Precautions.............................................................................................................................................40
4. Disassembly Procedure..........................................................................................................................41
5. Assembly Procedure...............................................................................................................................44
II. ASSEMBLY AND DISASSEMBLY OF THE STEERING COLUMN.............................................................................45
1. System Structure Diagram......................................................................................................................45
2. Preparation.............................................................................................................................................45
3. Precautions.............................................................................................................................................45
4. Disassembly Procedure..........................................................................................................................46
5. Assembly Procedure...............................................................................................................................49
III. ADJUSTMENT OF THE STEERING GEAR CLEARANCE......................................................................................50
IV. Adjustment of the Power Steering System................................................................................................50

3
 Chapter I Technical Specifications

I. Main Performance Parameters of Chassis

Item Parameter
SQR7150A13
Model
7
Minimum ground clearance (mm) 130
Minimum turning diameter (m) 11.0
Trafficability
Approach angle (°) 14
Departure angle (°) 15
Max. speed (km/h) 160
Min. stable speed at second top gear (km/h) 25
Acceleration time from the min. stable speed at second top gear to
Power 36
100km/h (s)
performance
Acceleration time from starting to 100km/h by continuous gearshift
16
(s)
Max. gradeability (%) 39
Coasting distance at initial speed of 50km/h (m) 550
Oil consumption at constant speed of 90km/h (L/100km) 6.0
Oil consumption at constant speed of 120km/h (L/100km) 8.8
Economic
Fuel consumption (city) (L/100km) 9.7
performance
Fuel consumption (suburb) (L/100km) 5.8
Fuel consumption (combined) (L/100km) 7.2
No-load (m) 13
Braking distance at initial speed of 50km/h (m)
Full load (m) 14
Braking Braking distance at initial speed of 80km/h (braking with engine
performance 40
disconnected) (m)
Braking distance at initial speed of 80% of the max. speed (braking
105
with engine connected) (m)
Noise Max. exterior vehicle noise during acceleration (dB (A)) 74

II. Wheel Alignment Parameters (No-load)

Item Parameter
Model SQR7150A137
Front wheel Camber angle of front wheel -30′±20′
Positive caster 3°18′±30′

4
 Kingpin inclination 11°42′±30′

Toe-in of front wheel 0°±10′

Camber angle of rear wheel -1°30′±10′
Rear wheel
Toe-in of rear wheel 5′±10′
Side-slip distance ≤3m/km

III. Rim and Tyre Models

Item Model
Rim 6J×15
Tyre 195/55R15 85V

IV. Tyre Pressure

In kPa
Item Front Tyre Rear Tyre Spare Tyre
No-load 220 200 250

V. Steering System

Model SQR7150A137
Steering gear Hydraulic power rack and pinion steering gear
Steering column Collapsible safety steering column

VI. Braking System Type

Model SQR7150A137

Braking system Dual-circuit braking system and X-type piping arrangement

ABS system ABS anti-lock braking system and front-disc/rear-drum brake

VII. Torque List

Torque List

Qty. for
No
Part Name Single Specification Torque (N·m) Application
.
Vehicle

Bolt - connecting the Connecting the rear axle

1 6 M10×28 70±5
bracket and the body bracket and the body

5
 Connecting the rear
M12×1.5×12
2 Bolt 2 87±5 longitudinal arm and the rear
2
axle bracket

Connecting the rear

3 Combination nut 2 M12×1.5 87±5 longitudinal arm and the rear
axle bracket

Connecting the subframe and

4 Short bolt 2 M12×1.5×65 130±10
the body

Hexagon flange face Connecting the water tank

5 2 M10×1.5×60 35~47
bolt cross beam and the body

Hexagon flange face Connecting the water tank

6 2 M10×1.5×20 35~47
bolt cross beam and the body

Connecting the front

7 Connecting bolt 4 M14×1.5×80 106~132 suspension cross beam
assembly and the body

Connecting the control arm

8 Long bolt 2 M12×1.5×76 130±10
and the subframe

Bolt - connecting the

Connecting the control arm
9 control arm and the 2 M12×1.5×82 130±10
and the subframe
subframe

Bolt - connecting the Connecting the gasket and

10 6 M8×26 35±3
gasket the front suspension

Hexagon flange face Fixing the gearshift

11 4 M8×1 25±2
bolt mechanism on the floor

Hexagon flange face Fixing the flexible shaft

12 2 M8×1 25±2
bolt bracket on the gearbox

Hexagon flange face

13 5 M8×1 25±3 Fixing the pedal
nut

Hexagon flange face

14 4 M8×1 25±3 Fixing the vacuum booster
nut

Hexagon flange face

15 2 M6×1 13±2 Fixing the fluid reservoir
nut

Fixing the electronic

Hexagon flange face
16 6 M6×1 13±2 accelerator pedal and the
nut
bracket

Bolt - clutch cover Connecting the clutch cover

17 6 M8×1.25 25±2
assembly and the flywheel

6
 Fixing the clutch master
18 I-type hexagon nut 2 M6×1 13±2
cylinder

Hexagon flange face

19 1 M6×1 13±2 Fixing the clutch bracket I
bolt

Hexagon flange face Fixing the clutch release

20 2 M8×1 25±2
bolt slave cylinder

Fixing the cable and the

21 Locking nut 2 M6×1 17±2
middle bracket

Fixing the cable and the

22 Nut 2 M8×1.25 25±3
trailing arm

Hexagon flange face Fixing the cable fixing bracket

23 3 M6×1 13±2
nut and the floor

Connecting the brake hard

24 Pipeline connector 20 M10×1 11~14
pipe and other connectors

Connecting the clamp and the

25 Bolt 3 M8×1.25 13±2
body

Connecting the engine

26 Nut 3 M6×1.0 13±2 compartment braking pipe
and the body

Connecting the dual two-way

27 Nut 3 M6×1.0 13±2
valve and the body

Hexagon flange face Connecting the ABS bracket

28 2 M6×1.0 13±2
bolt and the body

Connecting the ABS bracket

29 Nut 1 M6×1.0 13±2
and the body

Connecting the sensor and

30 Nut 4 M6×1.0 13±2
the body

Connecting the ABS module

31 Screw 2 M8×1.25 13±2
and the bracket

Connecting the sensor and

32 Bolt 4 M8×1.25 13±2
the brake

Connecting the sensor

33 Bolt 2 M8×1.25 13±2
bracket and the front strut

Connecting the sensor

34 Nut 4 M8×1.25 13±2
bracket and the body

Connecting the rear bearing

35 Bihexagon locking nut 2 M20×1.5 250±10
and the rear axle

7
 Connecting the rear wheel
36 Combination bolt 8 M10×1.25 70±10
hub bearing and the rear axle

Hexagon flange face

37 4 M8 30±3 Fixing the steering gear
bolt - slender rod

All-metal hexagon
38 4 M8 30±3 Fixing the steering gear
flange face locking nut

Non-metal insert Fixing the steering gear and

39 2 M12×1.5 35±3
locking nut the steering knuckle

Hexagon flange face Fixing the steering gear heat

40 3 M8×25 8±1
bolt shield

All-metal hexagon Fixing the steering gear heat

41 1 M6 8±1
flange face locking nut shield

All-metal hexagon Fixing the upper bracket of

42 2 M8 25±3
flange face locking nut steering column

All-metal hexagon
43 flange face locking 1 M6 15±2 Fixing the lower bracket
bolt

Hexagon bolt and

Connecting the steering
44 spring washer 1 M8×25 25±3
column and the steering gear
subassembly

Fixing the high-pressure oil

45 Hollow bolt 1 \ 45±3
pipe

Fixing the high-pressure oil

46 Hexagon flange nut 1 M6 8±1
pipe clamp

Fixing the oil suction pipe

47 Hexagon flange bolt 2 M6 11±1
clamp

All-metal hexagon Fixing the fluid reservoir

48 1 M6 8±1
flange face locking nut bracket

Hexagon flange face Fixing the fluid reservoir

49 1 M6 8±1
bolt bracket

Combination hexagon
Fixing the band wheel and the
50 socket head cap 3 \ 25±2
steering pump
screw

Fixing the steering pump, the

51 Hexagon flange bolt 8 M8×22 25±2 bracket assembly (6) and the
tension bracket (2)

Hexagon socket head Fixing the steering bracket

52 1 \ 55±5
bolt assembly

8
 Combination adjusting According to
53 1 \ Fixing the tension bracket
bolt the tightness

54 Tension nut 1 \ 25±2 Fixing the tension bracket

Fixing the steering pump

55 Hexagon flange bolt 1 M10×60 50±5
fixing bracket

Fixing the steering pump

56 Hexagon flange bolt 1 M10×55 48±3
fixing bracket

Hexagon Fixing the steering pump

57 1 M8×50 22±2
flange
更 bolt
改 校
编
日
签 fixing bracket

58 Nut 6 M6 9±3N.m Fixing the TPMS

All-metal hexagon Connecting the front strut and

59 6 M12x1.25 60±5N.m
flange face locking nut the body

Connecting the front strut and

60 Bolt 4 M12×1.5×58 100±10N.m
the steering knuckle

Connecting the front strut and

61 Nut 4 M12×1.5 100±10N.m
the steering knuckle

Connecting the rear strut and

62 Hexagon thin nut 2 M10×1.0 25±3N.m
the body

Locking the rear strut upper

63 Hexagon thin nut 2 M10×1.0 15±3N.m
gasket

Connecting the rear strut and

64 Bolt 2 M10×75 48±5N.m
the rear axle

Connecting the rear strut and

65 Nut 2 M10 48±5N.m
the rear axle

Fixing the left and right

66 Nut 2 M12×1.25 30±3N.m
connecting rods

Fixing the left and right rubber

67 Bolt 2 M8×18 25±2.5N.m
bearers

68 Wheel nut 12 M12×1.5 110±10N.m Fixing the wheel assembly

9
 Chapter II Braking System

I. Assembly, Disassembly and Overhaul of the Front Brake

1. System Structure Diagram

Front Steering Knuckle with Disc Brake Assembly

(1) Steering knuckle (2) Brake disc

(3) Brake caliper (4) Brake lining
(5) Steering knuckle with disc brake assembly (6) Front wheel bearing
(7) Front wheel hub (8) Bearing clip

10
2. Preparation
2.1 Tools
A set of double offset ring spanners, a set of sockets of common specifications, a torque spanner, a slotted
screwdriver, a cross screwdriver, a vernier caliper, a dial indicator, a pair of pincer pliers, a pair of long nose
pliers, a plastic hammer and an iron hammer.
2.2 Accessories
Brake fluid.
2.3 Protective Appliances
Gloves, outfit, helmet and safety shoes.
3. Precautions
3.1 Please wear the necessary protective appliances to prevent casualties.
3.2 In case of the poisonous brake fluid contacting with the skin or eyes, wash the skin or eyes with water and
see a doctor immediately if necessary.
3.3 The wasted brake fluid shall be stored in a container instead of being discharged into sewers or dumped
with domestic wastes.
3.4 Don’t step on the brake pedal or move the vehicle during assembling and disassembling.
3.5 The brake caliper piston can be removed only by specialized personnel or under the direction of
specialized personnel.
3.6 Keep the brake lining or brake disc away from oils during assembling. If there is any oil, wipe it out and
polish it with sand paper.
4. Disassembly Procedure and Overhaul
4.1 Disassembly (Take the left side as example)
4.1.1 Remove the four fastening bolts on the left front tyre with a
19# socket and a torque spanner, and then take out the tyre.
(The methods for disassembling and assembling tyres are the
same as those for other vehicle models. Thus, it is
unnecessary to give more details.)
Torque: 110±10N·m

4.1.2 Remove the left drive shaft fastening nuts with a 30#
socket and a torque spanner.
Torque: 270±20N·m

11
4.1.3 Remove the left drive shaft fastening nuts and the gaskets.

4.1.4 Remove the two bolts connecting the brake wheel cylinder
and the brake caliper with a 13# socket and a ratchet spanner,
and then lay them flatly on the dust shield and the steering
knuckle.
Torque: 22±1N·m

4.1.5 Take out the brake lining.

4.1.6 Remove the two bolts connecting the steering knuckle and
the brake caliper with a 17# socket and a ratchet spanner.
Torque: 85±5N·m

4.1.7 Remove the brake caliper.

12
4.1.8 Remove the nut connecting the brake oil pipe and the brake
wheel cylinder with a 14# double offset ring spanner, and then
use a clean container to recycle the brake fluid. After that,
remove the brake wheel cylinder. (If only the brake disc is to be
replaced during maintenance, it is not necessary to remove the
brake pipeline.)
Note:
Don’t let the poisonous brake fluid spatter on the clothes or skin
when removing the brake hose.
Torque: 17±1N·m

4.2 Overhaul
4.2.1 The standard thickness of the front brake lining is 11mm.
If the actual value is less than 9.5mm, replace it. The standard
thickness of the rear brake lining is 10.2mm. If the actual value is
less than 8.7mm, replace it. All brake linings shall be replaced in
pairs.

4.2.2 Remove the dustproof seal ring and check it for damage. If
necessary, replace it. Clean the contact surface of the brake
piston and apply a thin layer of muffling cream. Note: keep the
dustproof seal ring away from the muffling cream which will make
it expand.

4.2.3 Remove the piston. Put a board between the piston and the
wall of the brake caliper to block the piston. Gently press the piston
out with compressed air through the connecting hole.

13
Hint: Don’t hold the piston by fingers - in case of clamping!

4.2.4 Check the guide sleeve. Push the guide sleeve by hand, and

it shall move flexibly. If there is any seizure or inflexibility, replace it.

Note: apply some lubricating grease on the guide sleeve for

assembly.

4.2.5 Carefully remove the seal ring with a plastic needle, clean the
brake cylinder and its components with alcohol and dry them with
compressed air. Check the brake wheel cylinder, the piston and the
flange surface. Don’t conduct machining for the brake cylinder and
piston.

4.2.6 (Installation of brake wheel cylinder) Apply a thin layer of brake

cylinder cream on the cylinder block, plunger and gland cover. Install
a seal ring in the rear circular groove of the brake cylinder. Install a
dustproof seal ring in the front circular groove and press it in
completely.

4.2.7 Keep the area between the dustproof seal ring and the brake
caliper shell dry. Don’t let the seal ring be stained with any brake
cylinder cream or brake fluid so as to make sure the seal ring is
located at the correct position.

14
4.2.8 Use the extension stem bought from the market to fix the
brake piston and gently press it onto the dustproof seal ring. Blow
the dustproof ring with compressed air (max. 3.0bar) and fit the
piston ring onto the piston.
Note: Soak the dustproof seal ring and piston with brake fluid, so
that the seal ring may pass through easily.

4.2.9 (Check of brake disc) Check the thickness of the brake

disc. The standard thickness of the front brake disc is 25mm. If
the actual value is less than 23mm, replace it. The standard
thickness of the rear brake disc is 10mm. If the actual value is
less than 8mm, replace it. Note: The two brake discs on the
same axle shall be replaced together. Replace the brake lining as
well when replacing the brake disc.

4.2.10 Use a dial indicator to check the maximum circular run-out

of the brake disc. If it is more than 0.025mm, please replace the
brake disc. (It is allowable to conduct proper machining to
achieve the maximum circular run-out provided that the thickness
of brake disc is guaranteed.)
Important Hint:
As long as the brake lining or the brake disc is replaced, step on
the brake pedal for several times to run in the brake lining and
brake disc so as to ensure safety. Check whether the brake fluid level is between the marks of MIN and MAX
when the brake lining is replaced.

5. Assembly Procedure
The assembly procedure is in the reverse order with disassembly.

15
II. Assembly, Disassembly and Overhaul of the Rear Brake
1. System Structure Diagram

Rear Brake Assembly

1 Brake shoe upper return spring 2 Adjustment device spring 3 Rear-wheel cylinder assembly
4 Left self-adjusting shift plate 5 Brake shoe pressure spring 6 Brake shoe lower return spring
7 Brake drum 8 Rear brake assembly 9 Rear wheel hub bearing

16
2. Preparation
2.1 Tools
A set of double offset ring spanners, a set of sockets of common specifications, a torque spanner, a slotted
screwdriver, a cross screwdriver, a vernier caliper, a dial indicator, a pair of pincer pliers, a pair of long nose
pliers, a plastic hammer, an iron hammer and a puller.
2.2 Accessories
Brake fluid.
2.3 Protective Appliances
Gloves, outfit, helmet and safety shoes.
3. Precautions
3.1 Please wear the necessary protective appliances to prevent casualties.
3.2 In case of the poisonous brake fluid contacting with the skin or eyes, wash the skin or eyes with water and
see a doctor immediately if necessary.
3.3 The wasted brake fluid shall be stored in a container instead of being discharged into sewers or dumped
with domestic wastes.
3.4 Don’t step on the brake pedal or move the vehicle during assembling and disassembling.
3.5 The brake caliper piston can be removed only by specialized personnel or under the direction of
specialized personnel.
3.6 Keep the brake lining or brake disc away from oils during assembling. If there is any oil, wipe it out and
polish it with sand paper.
4. Disassembly Procedure and Overhaul
4.1 Disassembly (Take the left rear wheel as example.)
4.1.1 Remove the four connecting bolts on the left rear
wheel with a 19# socket and a torque spanner.
Torque: 110±10N·m

4.1.2 Remove the left rear wheel hub bearing nut with a 30#
socket and a torque spanner.
Torque: 230±10N·m

17
4.1.3 Remove the left rear wheel hub assembly.

4.1.4 Use a tripod puller to pull out the rear wheel hub
bearing unit.

4.1.5 Use a pair of pincer pliers to rotate the dowel pin on

the hand brake shoe and take out the limit spring seats (one
on the leading brake shoe and one on the trailing brake
shoe).

4.1.6 Pry out the connecting part between the hand brake
cable and the brake lever with a slotted screwdriver.

4.1.7 Remove the brake shoe.

18
4.1.8 Remove the four fastening bolts connecting the dust
shield and the rear axle with a 15# spanner.
Torque: 63±1N·m

4.2 Overhaul
The methods for overhaul are the same as those for the front
brake.

5. Assembly Procedure
The assembly procedure is in the reverse order with disassembly.

19
III. Adjustment and Replacement of the Parking Brake
1. System Structure Diagram

1
2 3

1. Handle 2. Cable 3. Right rear wheel cable 4. Left rear wheel cable
2. Preparation
2.1 Tools
A set of double offset ring spanners, a set of sockets of common specifications, a torque spanner, a slotted
screwdriver, a cross screwdriver, and a pair of long nose pliers.
2.2 Accessories
None.
2.3 Protective Appliances
Gloves, outfit, helmet and safety shoes.
3. Precautions
3.1 Please wear the necessary protective appliances to prevent casualties.
3.2 Avoid injury due to the ejected elastic elements when assembling and disassembling the elastic elements.
3.3 In case of assembling or disassembling around the exhaust pipe, the assembly or disassembly shall not
be conducted until the exhaust pipe is cooled down to the room temperature, so as to avoid scald.

20
4. Disassembly Procedure and Adjustment
4.1 Disassembly
4.1.1 Disassemble the auxiliary instrument panel (please
refer to the A13 Service Manual - Body and Accessories).
4.1.2 Use a 10# spanner to remove the hand brake cable
adjusting nut.

4.1.3 Remove the cable.

4.1.4 Use a 10# spanner or socket to remove the bolts

connecting the parking brake cable and the body (two at the
left side and one at the right side).
Torque: 10±1N·m

4.1.5 Remove the rear brake and use a slotted screwdriver

to pry out the connecting part between the hand brake cable
and the brake lever (one at the left and right sides
respectively).

Note: Remove the parking brake cable at the other side with the same method.
4.1.6 Remove the parking brake cable (one at the left and right sides respectively).

21
4.2 Adjustment
4.2.1 Adjust the hand brake operation:
(1) Adjust the parking brake and then adjust the hand brake.
(2) Set the hand brake handle at the lowest position.
(3) Adjust the nut to ensure the rear brake disc may rotate
freely.
(4) Pull up the hand brake handle for one gear to set the brake
disc at locking state.

5. Assembly Procedure
The assembly procedure is in the reverse order with disassembly.

22
IV. Maintenance of the ABS System
1. Preparation
1.1 Tools
A Chery’s special diagnostic tester, a set of open end spanners and a set of inner splines.
1.2 Protective Appliances
Gloves, outfit and safety shoes.
2. Precautions
2.1 When the ignition switch is at “ON” position, don’t assemble or disassemble the electric elements and
harness connectors in the system. Otherwise, it may damage the electronic control unit. Turn off the ignition
switch before assembling or disassembling the electric elements and harness connectors.
2.2 Don’t supply too high voltage to the ECU. Otherwise, it may damage it.
2.3 Prevent the electronic control unit from damage as a result of collision or impact.
2.4 The electronic control unit may be damaged under high temperature. Thus, it shall be removed from the
vehicle in the process of paint baking. Besides, the harness connectors shall also be removed from the
electronic control unit when welding the elements or lines in the system.
2.5 Keep the electronic control unit, especially the terminals, away from oil. Otherwise, the terminals may be
affected from poor contact.
2.6 The system will not work if the storage battery is of low voltage. Thus, do check the voltage of the storage
battery, especially when the vehicle is started for the first time after being parked for a long time.
2.7 Keep the wheel speed sensor away from oil or other dirt; otherwise, the signal of the wheel speed sensor
may be not accurate enough, and accordingly, the controlling precision of the system may be affected or the
system may even work abnormally. Besides, don’t knock the speed sensor; otherwise, the system will work
abnormally as a result of demagnetization of the sensor.
2.8 When conducting maintenance for the hydraulic system, first completely discharge the high pressure
brake fluid in the accumulator, so as to avoid injury due to the sprayed high pressure brake fluid. Before
discharging the high pressure brake fluid in the accumulator, turn off the ignition switch and then step on and
release the brake pedal for several times till the brake pedal becomes tight. Besides, before the hydraulic
system is completely installed, don’t turn on the ignition switch, otherwise the electric pump will be energized
and start working.
2.9 As the brake system is of high pressure, the brake system shall adopt special pipeline. Otherwise, it may
easily get damaged.
2.10 The wheel speed sensor, electronic control unit and brake pressure adjusting device in the ABS system
are not repairable. Thus, they shall be replaced in case of damage.
2.11 After conducting maintenance for the brake hydraulic system or when the brake pedal becomes loose
during operation, discharge the air in the brake system as per the required method and sequence.
2.12 Use the tyre recommended by the vehicle manufacturer. The tyre of other model can be used if its outer

23
diameter, adhesion performance and rotational inertia are similar to those of the original tyre. However, tyres
of different specifications shall not be mixed. Otherwise, the control effect of the ABS system may be affected.

24
3. Disassembly Procedure
3.1 Remove the ABS module connector, and push the black clip
as shown in the figure upwards, then the ABS module connector
will get out.

3.2 Remove the nut connecting the ABS assembly and the
pipeline with an 11# open end spanner.
Torque: 11~14N·m
Note: When disassembling the pipeline, keep the ABS
assembly away from foreign substances. It is better to plug the
oil port on the ABS with a piece of clean gauze when removing
the pipeline.

3.3 Remove the bolt connecting the ABS assembly and the
bracket with a TT25 inner spline, and then take out the ABS
assembly.
Torque: 13±2N·m

4. Assembly Procedure
The assembly procedure is in the reverse order with disassembly.
Note: After installation, switch on the power and use a diagnostic tester to read the trouble code in the system
and then clear it. After that, conduct a test.

25
 Chapter III Suspension System and Adjustment

of Four-wheel Alignment

The front axle of the Chery Fengyun 2 series car adopts the divided steering drive axle, MacPherson
suspension, cylindrical helical spring, single swing arm and double-acting telescopic shock absorber. The
upper part of the suspension is connected with the body while the lower part, as well as the steering
knuckle, is linked to ground by wheels. The rear axle is provided with the conventional torsion beam type
suspension, cylindrical helical spring and double-acting telescopic shock absorber.

I. Assembly, Disassembly and Overhaul of the Front Axle and

Suspension
1. System Structure Diagram
The front axle of the Chery A13 series car adopts the divided steering drive axle, MacPherson suspension,
cylindrical helical spring, single swing arm and double-acting telescopic shock absorber. The upper part of the
suspension is connected with the body while the lower part, as well as the steering knuckle, is linked to
ground by wheels.

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 Composition of Front Axle and Suspension System
2. Preparation
2.1 Tools
A set of double offset ring spanners, a set of sockets of common specifications, a torque spanner, a slotted
screwdriver, a cross screwdriver, a vernier caliper, a dial indicator, a pair of pincer pliers, a pair of long nose
pliers, a plastic hammer and an iron hammer.
2.2 Accessories
Power steering fluid.
2.3 Protective Appliances
Gloves, outfit, safety shoes and helmet.
3. Precautions
3.1 Please wear the necessary protective appliances to prevent casualties.
3.2 Please make sure the safety lock of the lifter is locked during the maintenance of chassis.
3.3 Avoid injury due to the ejected spring when assembling or disassembling the damping spring.
3.4 Don’t weld or straighten the load-bearing components of the wheel suspension or the guiding components
of the wheel.
3.5 To ensure safety, the self-locking nuts or rusted nuts shall be replaced when disassembling the
components of the chassis.
4. Disassembly Procedure
4.1 Disassemble the shock absorber assembly and damping spring:
4.1.1 Remove the fastening nut on the tyre with a 19# torque
spanner or on-vehicle spanner and then remove the tyre.
Torque: 110±10N·m

4.1.2 Pull out the wheel speed sensor harness and fix it at a
proper place where the disassembly of the shock absorber will
not be affected.

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4.1.3 Remove the two bolts connecting the shock absorber
assembly and the steering knuckle with an 18# socket.
Torque: 100±10N·m

4.1.4 Remove the three nuts connecting the shock absorber and
the body shell with a 16# socket. (One nut is under the lower trim
plate of the front windshield.)
Torque: 60±5N·m

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4.2 Disassemble the control arm assembly (take the left side
as example):
4.2.1 Remove the nut connecting the left control arm ball head
and the left steering knuckle assembly with a 17# socket
spanner.
Torque: 120±10N·m

4.2.2 Remove the bolt connecting the control arm and the
stabilizer bar with a 19# socket spanner.
Torque: 35±3N·m

4.2.3 Remove the bolt connecting the control arm and the subframe with a 19# socket spanner.
Torque: 130±10N·m

4.2.4 Remove the bolt connecting the control arm and the
subframe with a 19# socket spanner and then remove the
left control arm.
Torque: 130±10N·m

29
4.3 Disassemble the front axle assembly:
4.3.1 Use a 17# spanner to remove the nuts on the tie rod ball
head (one at the left and right sides respectively).
Torque: 35±3N·m

4.3.2 Remove the nut connecting the left control arm ball head
and the left steering knuckle assembly with a 17# socket
spanner.
Torque: 120±10N·m

4.3.3 Remove the two nuts on the bolts connecting the rear
engine suspension and the subframe with a 13# socket.
Torque: 75±5N·m

4.3.4 Remove the bolts connecting the subframe and the body
with a 13# socket and a torque spanner (one at the left and
right sides respectively).
Torque: 130±10N·m

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4.3.5 Remove the bolts connecting the body and the subframe
with a 19# spanner (one at the left and right sides
respectively), and then remove the front axle.
Torque: 130±10N·m

5. Assembly Procedure
The assembly procedure is in the reverse order with the disassembly of front axle and front suspension.

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II. Assembly, Disassembly and Overhaul of the Rear Axle and

Suspension
1. System Structure Diagram

Composition of Rear Axle and Suspension System

2. Preparation
2.1 Tools
A set of double offset ring spanners, a set of sockets of common specifications, a torque spanner, a
slotted screwdriver, a cross screwdriver, a pair of pincer pliers, a pair of long nose pliers, a plastic
hammer and an iron hammer.
2.2 Accessories
None.
2.3 Protective Appliances
Gloves, outfit, safety shoes and helmet.
3. Precautions
3.1 Please wear the necessary protective appliances to prevent casualties.
3.2 Please make sure the safety lock of the lifter is locked during the maintenance of chassis.
3.3 Avoid injury due to the ejected spring when assembling or disassembling the damping spring.
4. Disassembly Procedure
4.1 Disassemble the shock absorber assembly and damping
spring (take the right side as example):
4.1.1 Remove the fastening nut on the tyre with a 17# socket
and a torque spanner or on-vehicle spanner, and then take
out the tyre.
Torque: 110±10N·m

4.1.2 Remove the bolt connecting the shock absorber

assembly and the right rear lower control arm with 17#
and 19# sockets.
Torque: 75±2.5N·m

4.1.3 Remove the nut connecting the right rear shock

absorber and the body with a 17# socket and a racket
spanner, and then take out the right rear shock absorber.
Torque: 25±3N·m

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4.2 Disassemble the rear axle assembly (take the right side
example):
4.2.1 Use an open end spanner to remove the rear wheel
brake pipe and use a container to recover the brake fluid.

4.2.2 Pry out the parking brake cable on the rear axle with
a slotted screwdriver.

4.2.3 Pry out the fixing clip of the parking brake cable on
the rear axle with a slotted screwdriver.

4.2.4 Remove the rear parking brake (with the same

method for the rear brake as described in the previous
section) and then pull out the rear brake cable.

4.2.5 Take out the rear wheel speed sensor.

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4.2.6 Remove the bolt connecting the shock absorber
assembly and the right rear lower control arms with 17#
and 19# sockets.
Torque: 75±2.5N·m

4.2.7 Remove the fastening bolt connecting the rear axle

and the body as shown in the right figure with a 19#
socket and a racket spanner. After that, remove the rear
axle.
Torque: 80±8N·m

5. Assembly Procedure
The assembly procedure is in the reverse order with disassembly.

35
III. Adjustment of Four-wheel Alignment
Please check and adjust the parameters with the four-wheel alignment instrument recommended by
Chery Automobile Co., Ltd.
1. Adjustment of Toe-in of Front Wheel
The toe-in can be adjusted by an optical testing instrument or a mechanical toe-in adjusting instrument.
1.1 Properly conduct preparation for wheel alignment as required by the testing instrument.
1.2 Unscrew the locking nut and the elastic snap ring of the protective sleeve of the right steering tie
rod, and then adjust the length of the toe-in adjusting rod to the specified value by rotating it. Toe-in:
0°±10′
1.3 Tighten the locking nut and reinstall the elastic snap ring of the protective sleeve. Check if the
locking nut is tightened and the protective sleeve is in place.
Torque: 35±3N·m
1.4 When the toe-in of front wheel is adjusted properly, check if the steering wheel is leveled. If not,
unscrew its locking nut and level it up. After that, tighten its locking nut to the specified torque.
2. Adjustment of Camber Angle of Front Wheel
2.1 Normally, it is not required to adjust the camber angle after
assembling the independent suspension and the wheel
steering knuckle. However, if it is not within the tolerance due
to other reasons, conduct adjustment by adjusting the bolt
connecting the independent suspension and the steering
knuckle.
Camber angle of front wheel: -24′±20′

2.2 Before adjustment, visually check the components of the traveling system for damage. If any, replace
the damaged components.
2.3 If the camber angle of front wheel is not within the tolerance, unscrew the bolt connecting the front
shock absorber and the steering knuckle and rotate the wheel for adjustment.
3. Adjustment of Positive Caster and Kingpin Inclination
The positive caster and kingpin inclination are fixed in the design structure, so it is not required for
adjustment during operation. Positive caster: 3.95°±30′; kingpin inclination: 12.56°±30′. If the parameters
are not within the tolerance, replace the steering knuckle.

IV. Assembly of the Tyre and Adjustment of Air Pressure

1. Assembly of the Tyre Valve
Before assembling, check if the valve port on the tyre is smooth, without any burrs. After that, apply
some glycerine on the rubber part of the tyre valve, or alternatively, dip the tyre valve in the glycerine
for a while. Use a special tool to pull or press the positioning ring on the tyre valve through the hole on

36
the wheel by 200~400N, then the tyre valve is installed in place. (It is allowable to use soap water as a
substitute of glycerine.)
2. Assembly of the Tyre
Before assembling, apply some glycerine or soap water on the bead in the circumferential direction.
Beside, pay attention to the following points:
2.1 If the yellow dot is available on the rim, align it with the uniformity test mark.
2.2 If the yellow dot is not available on the rim, align the dynamic balance test mark with the tyre valve.
2.3 If the yellow dot is not available on the rim while the static balance test mark, instead of the dynamic
balance test mark, is available on the tyre, align the static balance test mark with the tyre valve.
2.4 The description about the uniformity test mark, dynamic balance test mark and static balance test
mark shall be provided by the Product Department of Chery Automobile Co., Ltd. or the supplier in
written form and marked on the technological card.
2.5 Conduct inflation for the tyre in strict accordance with the specified air pressure. During inflation, the
pressure shall not exceed 10% of the rated pressure. The rated inflation pressure for the subassembly
of the spare tyre assembly is 250kPa and the spare tyre shall be kept separated from the four wheels.
Before the four-wheel alignment, check the air pressures of the four tyres and adjust them to 220kPa
(front tyre) and 200kPa (rear tyre) respectively.
3. Inflation of Tyre
After inflation, screw down the tyre valve cap and conduct dynamic balance test. Install certain balance
blocks at the edge of the inside and outside of the rim as required. The degree of unbalance for the
assembly shall not exceed 100g·cm, that is, the weight of the balance blocks at the edges of the inside
and outside of the rim equals to 5g. Note: at most 1 balance block which weights no more than 70g can
be used at each side of each wheel. Don’t knock the balance block too heavily during assembling. If so,
replace the balance block in time and the replaced one can not be used any more.
4. Installation of the Wheel and Tyre Assembly
For the installation of the wheel and tyre assembly, first manually fit the wheel bolt onto the hub and
pre-tighten it. After that, use a special tool to tighten it diagonally with a tightening torque of
110±10N·m. It is forbidden to use impact wrench, or else, it may damage the wheel or make the bolt too
loose or tight. Don’t apply any lubricating grease on the wheel bolt. (The wheel bolt of the newly
installed wheel and tyre assembly shall be tightened once after traveling for 100km for the first time, so
as to ensure the tightening torque. The check for the tightening torque of the wheel bolt is one of the
tasks in daily maintenance.)
5. Method for Tightening the Wheel Nut
Tighten the fixing nut diagonally to the same extent. After tightening, the wheel shall rotate freely. When
tightening the nut for the last time, the wheel shall be placed on ground.

37
6. Assembly of the Trim Cover
Install the trim cover or put the trim cover in place as required. For the cartridge trim cover, knock it by
hand or with a rubber tool to set it in.

38
 Chapter IV Assembly, Disassembly and

Overhaul of the Steering System

I. Assembly and Disassembly of the Steering Gear

1. System Structure Diagram

1. Servo steering fluid reservoir 2. Fixing bolt of bracket

3. Fixing nut of bracket 4. Oil outlet pipeline
5. Fluid reservoir fixing bracket 6. Steering pump
7. Tensioner pulley 8. Self-locking nut
9. Adjusting nut 10. Adjusting pull rod
11. Pipe clamp 12. Steering gear
13. Oil outlet pipeline 14. Fixing bolt
15. Fixing bolt 16. Fixing nut
17. Oil return pipeline
The breakdown diagram of steering gear is as follows:

1-Locking nut N0111862 2-Tie rod 3-Input shaft 4-Left mounting bracket
5-Right mounting bracket

The steering universal joint and protective sleeve are as shown in the following figure:

Steering column protective sleeve

2. Preparation
2.1 Tools
A set of double offset ring spanners, a set of sockets of common specifications, a torque spanner, a
slotted screwdriver, a cross screwdriver, a pair of pincer pliers, a pair of long nose pliers, a plastic
hammer and an iron hammer.
2.2 Accessories
Power steering fluid.
2.3 Protective Appliances
Gloves, outfit, safety shoes and helmet.
3. Precautions
3.1 Please wear the necessary protective appliances to prevent casualties.
3.2 Keep the steering oil away from the skin or eyes when disassembling the steering system.

40
4. Disassembly Procedure
4.1 Disassembly (Take the left side as example)
4.1.1 Remove the nut connecting the left control arm ball
head and the left steering knuckle assembly with a 17#
socket spanner.
Torque: 120±10N·m

4.1.2 Remove the bolt connecting the control arm and

the stabilizer bar with a 19# socket spanner.
Torque: 35±3N·m

4.1.3 Remove the bolt connecting the control arm and

the subframe with a 19# socket spanner.
Torque: 130±10N·m

4.1.4 Remove the bolts connecting the subframe and

the body with a 13# socket and a torque spanner (one
at the left and right sides respectively).
Torque: 130±10N·m

41
4.1.5 Remove the bolts connecting the body and the
subframe with a 19# spanner (one at the left and right
sides respectively), and then remove the front axle.
Torque: 130±10N·m

4.1.6 Remove the nuts at the tie rod ball head with a 17#
spanner (one at the left and right sides respectively).
Torque: 35±3N·m

4.1.7 Remove the clamp of the power steering oil return

pipe with a pair of clamp pliers. Besides, prepare a
container for recovery during disassembling.

4.1.8 Remove the nut on the power steering oil inlet pipe
with a 17# open end spanner and recover the power
steering fluid with a container.
Torque: 25±2.5N·m

42
4.1.9 Remove the three nuts connecting the shock
absorber and the body shell with a 16# socket. (One nut is
under the lower trim plate of the front windshield.)
Torque: 60±5N·m

4.1.10 Remove the bolt connecting the steering column

universal joint and the steering gear with a 13# socket and
a racket spanner.
Torque: 25±2.5N·m

4.1.11 Lower down the front axle with a hydraulic lifting

conveyor and remove the front axle, suspension and
steering gear.

4.1.12 Remove the bolt connecting the subframe and the

left side of the steering gear with a 19# socket and a
racket spanner.
Torque: 100±10N·m

43
4.1.13 Remove the bolt connecting the subframe and the
right side of the steering gear with a 19# socket and a racket
spanner.
Torque: 100±10N·m

4.1.14 Remove the steering gear assembly.

5. Assembly Procedure
The assembly procedure is in the reverse order with disassembly.

44
II. Assembly and Disassembly of the Steering Column
1. System Structure Diagram

Steering wheel

Steering column assembly

Steering universal joint assembly

1. Steering wheel 2. Steering column assembly 3. Steering universal joint assembly

2. Preparation
2.1 Tools
A set of double offset ring spanners, a set of sockets of common specifications, a cross screwdriver, a
plastic hammer, an iron hammer, a puller and a pair of circlip pliers.
2.2 Accessories
Grease.
2.3 Protective Appliances
Gloves and outfit.
3. Precautions
3.1 Please wear the necessary protective appliances to prevent casualties.
3.2 Keep the steering oil away from the skin or eyes when disassembling the steering system.
3.3 Do disconnect the negative terminal of the battery before disassembling the steering wheel, so as to
prevent the airbag from explosion.

45
4. Disassembly Procedure
4.1 Turn the ignition switch to LOCK position to lock the
steering wheel.
4.2 Remove the trim covers at both sides of the steering
wheel with a pair of circlip pliers.

4.3 Remove the bolts at both sides of the steering wheel

with a hexagon spline wrench.

4.4 Remove the insertion pieces of the airbag and then

remove the trim cover for the airbag and steering wheel.

4.5 Remove the steering wheel nut with a 22# socket

and a racket spanner.
Torque: 35±5N·m

46
4.6 Remove the steering wheel with a special puller and
take down the steering wheel.

4.7 Use a cross screwdriver to remove the three screws

on the trim cover of the steering column. After that,
remove the upper and lower trim covers of the steering
column.

4.8 Remove the four screws on the combined switch with

a cross screwdriver and then remove the spiral cable.

4.9 Remove the insertion pieces on the combined switch

and the spiral cable.

47
4.10 Remove the combined switch.

4.11 Remove the white insertion pieces of the ignition

switch as shown in the figure.

4.12 Remove the bolt connecting the steering column and

the cross beam of the instrument panel with a 13# socket
and a racket spanner.
Torque: 25±3N·m

4.13 Remove the bolt connecting the steering column and

the cross beam of the instrument panel with a 13#
spanner. Torque: 25±3N·m

48
4.14 Remove the bolt connecting the steering column
universal joint and the steering gear with a 13# socket and
a racket spanner, and then remove the steering column.
Torque: 25±2.5N·m

5. Assembly Procedure
The assembly procedure is in the reverse order with disassembly.

49
III. Adjustment of the Steering Gear Clearance
1. Keep the wheels in a straight line.
2. Rotate the steering wheel leftwards and rightwards.
3. If there is any noise from the steering gear, adjust the screw at the position as shown in the figure till
no noise is heard when rotating the steering wheel.
4. Tighten the screw for another 1/8 circle (about 45°).
5. Conduct road test.
6. If the steering gear fails to return to the center, loosen the screw for 15°.
7. Conduct road test.

Adjusting
调整位置 position

Hint: The steering gear has already been adjusted before delivery. Thus, normally it is not required to
be adjusted.

IV. Adjustment of the Power Steering System

1. Correctly connect the power steering oil pipeline. The tightening torque for the connectors between
the oil return pipe, high-pressure oil pipe and steering gear shall be 35±3N·m and the tightening
torque for the hollow bolts connecting the high-pressure oil pipe and the power steering pump shall
be 45±3N·m. When filling the power steering oil, it is suggested to apply vacuum filling with a
special instrument. The requirements for the filling of hydraulic power steering oil and the exhaust
are as follows:
First, fill the hydraulic power steering oil into the steering oil tank assembly till it achieves the upper
limit, and then start the engine at a low speed (idle speed) to drive the steering pump, so that the
hydraulic oil will enter the steering system quickly. In the process of oil filling, the engine must only run
at idle speed to drive the blade pump. In addition, keep filling hydraulic oil to avoid air suction by the
blade as a result of low oil level.
2. When the hydraulic oil in the oil tank becomes emulsible or the noise from the pump is too loud
(normally, the noise shall not be louder than 80dB), it is required to discharge the air as per the
following procedure:
Jack up the front part of the vehicle to leave the two front wheels hung in the air. Then start the engine
and rotate the steering wheel leftwards and rightwards to the limit position alternately (try not to stay, or
not to stay for more than 2s after reaching the limit position). Repeat the above steps for several times
50
to gradually discharge the air in the system from the oil tank. In this process, keep filling hydraulic oil to
the specified level when the oil level in the oil tank becomes lower.
3. Regularly check and adjust the tightness of the power steering belt: apply a force of 100N vertically
to the middle of the belt. The maximum deflection of the belt shall be less than 5mm. If it is more
than 5mm, adjust the tightness of the belt to meet the above-mentioned requirements by adjusting
the tension bolt.
4. It is forbidden to rotate the steering wheel to the limit position during operation. If it is required to do
so, don’t keep the steering wheel at that position for more than 10s. Don’t run the power steering
pump when there isn’t oil. In case of difficulty in steering during operation, stop the vehicle
immediately for overhaul.

51