Chery QQ6 (Chassis). Service Instruction — part 1

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Service Instruction For

CHERY QQ6

(Chassis)

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TABLE OF CONTENTS

CHAPTER 1 BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . ..4

I. System Maintenance Parameters. . . . . . . . . . . . . . . . . . . . . . . .4

1. Brake disc check: . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2. Thickness check . . . . . . . . . . . . . . . . . . . . . . . . . . . ..4

3. Brake lining thickness check . . . . . . . . . . . . . . . . . . . . . . ..4

4. Brake disc runout check. . . . . . . . . . . . . . . . . . . . . . . . ..4

Disassembly/Reassembly and Maintenance of Front Brake and Brake Caliper . . . . . . .5

1. Structural Diagram of System. . . . . . . . . . . . . . . . . . . . . . .5

2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..6

3. Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..6

4. Removal and Maintenance. . . . . . . . . . . . . . . . . . . . . . . ..6

III. Disassembly, Reassembly and Maintenance of Rear Brake . . . . . . . . . . . ... 11

1. Structural Diagram of System. . . . . . . . . . . . . . . . . . . . . ... 11

2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3. Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4. Removal Step. . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5. Installation Step . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

IV. Adjustment and Replacement of Hand Brake . . . . . . . . . . . . . . . . . .15

1. System Composition Diagram. . . . . . . . . . . . . . . . . . . . . ..15

2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3. Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4. Removal/Installation Step. . . . . . . . . . . . . . . . . . . . . . . .15

CHAPTER 2 ADJUSTMENT OF SUSPENSION SYSTEM AND FOUR-WHEEL

ALIGNMENT SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

I. Disassembly, Reassembly and Maintenance of Front Axle and Suspension System . . . 19

1. Structural Diagram of System. . . . . . . . . . . . . . . . . . . . . ...19

2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3. Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4. Removal/Installation Step. . . . . . . . . . . . . . . . . . . . . . . .21

4.1. Removal of shock absorber assy. . . . . . . . . . . . . . . . . . 21

4.2. Removal of control arm assy . . . . . . . . . . . . . . . . . . . .22

4.3. Removal of front axle . . . . . . . . . . . . . . . . . . . . . . 23

5. Installation Step . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

II. Disassembly, Reassembly and Maintenance of Rear Axle and Suspension System . . . 26

1. Structural Diagram of System. . . . . . . . . . . . . . . . . . . . . ...26

2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3. Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4. Removal/Installation Step. . . . . . . . . . . . . . . . . . . . . . . .27

4.1. Removal of shock absorber assy and absorber spring . . . . . . . . . ...27

4.2. Removal of lateral support bar assy. . . . . . . . . . . . . . . . ...28

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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. . . . . . . . . . . . . . . . . . . ...31

2. Adjustment of Front Wheel Camber Angle . . . . . . . . . . . . . . . . ..31

3. Adjustment of Kingpin caster and inclination angles . . . . . . . . . . . . ...32

4. Adjustment of rear wheel positional parameters. . . . . . . . . . . . . . ...32

IV. Installation of Tire and Regulation of Air Pressure. . . . . . . . . . . . . . . 32

1. Assembly of Tire Valve. . . . . . . . . . . . . . . . . . . . . . . ..32

2. Assembly of Tire. . . . . . . . . . . . . . . . . . . . . . . . . . ...32

3. Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

4. Installation of Wheel and Tire Assy. . . . . . . . . . . . . . . . . . . ..33

5. Method to Tighten the Wheel Nut . . . . . . . . . . . . . . . . . . . . 33

6. Installation of Trim Cover. . . . . . . . . . . . . . . . . . . . . . . .33

CHAPTER 3 DISASSEMBLY/REASSEMBLY AND MAINTENANCE OF STEERING

SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..34

I. Removal/Installation of Steering Wheel. . . . . . . . . . . . . . . . . . . . 34

1. System Composition Diagram. . . . . . . . . . . . . . . . . . . . . ..34

2. Decomposition Diagram of Steering Wheel . . . . . . . . . . . . . . . ..35

3. Schematic Diagram of Steering Universal Joint and Protective Sleeve. . . . . . 35

2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3. Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4. Removal/Installation Step. . . . . . . . . . . . . . . . . . . . . . . .36

5. Installation Step . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

II. Removal/Installation of Steering Column . . . . . . . . . . . . . . . . . . . 38

1. System Composition Diagram. . . . . . . . . . . . . . . . . . . . . ..38

2. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3. Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

4. Removal Step. . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

5. Installation Step . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

III. Adjustment of Clearance of Steering System . . . . . . . . . . . . . . . . . .43

IV. Adjustment of Power Steering System. . . . . . . . . . . . . . . . . . . . 43

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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. Brake lining thickness check

Standard thickness of front brake lining shall be 10 mm, service limit shall be 3 mm, and the

remaining thickness of limit of brake pad thickness shall be not less than 3mm.

Standard thickness of rear brake lining shall be 5 mm, service limit shall be 1 mm, and the

remaining thickness of limit of brake pad thickness shall be not less than 1 mm.

4. Brake disc runout check

Check the brake disc side face runout with a dial gauge. The service limit of front disc is 0.03mm,

and, if exceeding the limit, replace the disc.

Important notice:

After completion of replacing friction lining or brake disc, stop down brake for several times to

enable breaking-in between brake lining and brake disc. Make sure safety!

After replacing brake lining, check brake fluid level if is between MIN and MAX.

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Disassembly/Reassembly and Maintenance of Front Brake and Brake

Caliper

1. Structural Diagram of System

Structural Diagram of Front Brake Assy

(1) Brake Disc (2) Dust Cover

(3) Wheel Hub Bearing Unit (4) Caliper Assy

(5) Friction Lining (6) Steering Knuckle

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Front Left Brake

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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. DO NOT pour the fluid into the sewage system or

store the fluid together with the domestic wastes.

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 and Maintenance

4.1 Remove the tightening nuts from tire with a 19#

torque spanner or attached wrench, and the take off the tire.

Torque: 110±10N.m.

4.2 (Check the thickness of friction lining) Unscrew

the fixing bolt as shown in the picture with a 14# torque

spanner and a sleeve.

Torque: 22-23N.m.

Fixing Bolt

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4.3 Unscew the fixing bolt as shown in the picture with

a 14# torque spanner and a sleeve.

4.4 Unscrew the brake 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.

Fixing Bolt

Caliper Housing

Fixing Bolt

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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

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.

4.10 Remove the dustproof seal and check the damage

of dustproof seal. If necessary, replace it. Clean the

contact surface of brake piston and apply a thin layer of

muffler paste. Attention that the dustproof seal is NOT

allowable to contact the muffler paste because it may make

the seal swell.

Two

Bolt

9

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. It can be removed and reinstalled only by

profeesionals or under the dirctions of professionals.

4.12 Check the guide sleeve. Push the guide sleeve by hand,

and the sleeve shall move flexibly and freely. If clamped or

inflexible, replace it. Attention that lubricating grease shall

be applied on the guide sleeve when reassembling.

4.13 Carefully remove the seal ring with a plastic needle,

and clean the brake cylinder and parts with alcohol. And dry

them with the compressed air. Carefully check the brake

cylinder, piston and flange surface. It is unallowable to

machine the brake cylinder and piston.

4.14 (Installation of brake wheel cylinder) Apply a thin

layer of brake cyliner paste on the cylinder body, plunger and

seal collar. Install the seal ring into the ring groove at the rear

of brake cyliner. Install the dustproof seal into the front ring

groove, and press it completely into the groove.

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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.

CAUTION: IMMERSE THE DUSTPROOF SEAL AND

PISTON WITH THE BRAKE FLUID TO MAKE THE

SEAL MORE EASILY THROUGH.

4.17(Brake disc check) Check the thickness of brake disc.

If below the min. thickness, replace it. CAUTION: Replace

two brake discs on the same axle at the same time. Replace

the friction lining at the same time when replacing it with a

new brake disc.

4.18 Check the max brake disc face circular runout with a

dial gauge. If the runout exceeds 0.03 mm, please replace it.

(Also machine the disc to satisfy the max circular runout

under the premise of ensurance of brake disc thickness.)

4.19 Install the other parts according to Removal Step.

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III. Disassembly, Reassembly and Maintenance of Rear Brake

1. Structural Diagram of System

1. Brake Drum 2. Rear Brake Assy

3. Rear Wheel Hub Bearing Assy 4. Oil Seal

5. End Cover 6. Bolt

7. Rear Wheel Sensor 8. Rear Brake Pipe Retaining Clip

9. Double-Opening Pipeline Clip 10. Tower Bar

11. Rear Shoe Spring Leaf 12. Rear Shoe Spring

Structural Diagram of Rear Brake Assy

(1) Brake Drum (2) Rear Brake Assy

(3) Wheel Hub Bearing Unit (4) Brake Wheel Cylinder

(5) Dust Cover (6) Rear Brake Shoe

2. Preparation

Tools:

ratchet wheel, lug bar, 10#, 19#, 32# sleeve, 10# box wrench,

vice, torque spanner, right-angled screwdriver.

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. DO NOT pour the fluid into the sewage system or

store the fluid together with the domestic wastes.

4

5

6

Rear Left Brake

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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.

4.3 Swing the brake drum, and take off it.

4.4 Observe the structure of rear brake.

4.5 Remove the hand brake control cable with a caliper.

Bolts

Hand

Brake

Control Cable

13

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.

Remove
This Spring

14

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.

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.

Torque: 250±10 N.m

5. Installation Step

Refer to Removal Step.

Bolts

Lock Nuts

15

IV. Adjustment and Replacement of Hand Brake

1. System Composition Diagram

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.

3.2 When carrying out disassembly and assembly of elastic element, avoid the bounce that will

cause injury.

3.3 If the hand brake is removed or reinstalled near the exhaust pipe, wait for a period of time until

the temperature of exhaust pipe falls down to the normal value so as to avoid the injury.

4. Removal/Installation Step

4.1 Refer to the removal/installation step of rear brake, and

loosen the hand brake control cable.

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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.