Chery Fora (Elara A520). Manual — part 110

CHERY A520 SERVICE MANUAL CHASSIS

16

5)

Dismount fluid reservoir

Remark: Push the fluid reservoir upwards in
order to remove it from the master cylinder
and remove the O-shape seal ring from the
groove of fluid reservoir. Check whether the
fluid reservoir is cracked or deformed, and
replace it if necessary. Use clean denatured
alcohol to clean the fluid reservoir or use the
compressed air containing no lubricant to
clean the fluid reservoir.

6)

Use 13# sleeve and ratchet wrench to
dismount the fixing nut (each at both
left and right side) of brake master
cylinder, and take out the brake master
cylinder.

6.2 Assembly sequence:

Assembly

sequence

is

opposite

to

disassembly sequence.

SECTION VII REPLACEMENT OF
BRAKE

PEDAL

AND

VACUUM

BOOSTER

Needed tools: ratchet wrench, ratchet rod,
13# sleeve, vice clamp, 10#, 12# open end
wrenches and clamp pliers.

7.1 Disassembly sequence:

1)

Disassemble the brake master cylinder.
(The disassembly sequence is detailed
in the “disassembly of brake master
cylinder”).

2)

Use clamp pliers to dismount the clamp
nearby the hose connecting vacuum
booster and engine.

CHERY A520 SERVICE MANUAL CHASSIS

17

3)

Dismount the brake light switch plug
and remove the brake light switch.

4)

Use vice clamp to dismount the pin
connecting the vacuum booster pump to
the brake pedal, and remove the
connecting pin.

5)

Dismount the four fixed bolts of the
brake pedal bracket and the two bolts
connecting the brake pedal and car
body.

6)

Take out the brake pedal and vacuum
booster.

Note: The internal components of booster
cannot be repaired and the booster case
cannot be dismantled. The dismantling of
booster case shall result in permanent
deformation and improper capacity of thrust
augmentation.

CHERY A520 SERVICE MANUAL CHASSIS

18

7)

Loosen adjusting bolt to regulate the
brake pedal to standard height.

7.2 Assembly sequence:

The assembly sequence is opposite to
disassembly sequence.

CHERY A520 SERVICE MANUAL CHASSIS

19

SECTION VIII ABS SYSTEM MAINTENANCE

Needed tools: Chery-specific diagnostic tester, 10#, 13# open end wrenches, ratchet wrench
and 10# sleeve

8.1 Precautions prior to maintenance

1)

When the ignition switch is at the ignition position, you should not disassemble and
assemble the electric components and harness connectors of the system in order to
prevent the electronically controlled units (ECU) from being damaged. Before
disassembling and assembling, you should turn off the ignition switch.

2)

You are not allowed to supply extremely high voltage to ECUs, otherwise the ECUs
shall be easily damaged.

3)

Protect the ECUs from being impacted and knocked in order to avoid of damage.

4)

High temperature environment is prone to damage ECUs; therefore, you should remove
the ECUs from the car when baking paint for the car. In addition, when welding the
system components or wire harness, you should also pull out the harness connectors
from ECUs.

5)

Prevent oil stain from splashing onto ECUs, especially the terminal. Otherwise, it shall
lead to loose contact of terminal.

6)

When the battery voltage is too low, the system cannot be operated. Therefore, you
should check the battery voltage, especially at the circumstance that you launch the
initial startup after stopping driving the car for a long time.

7)

Prevent the wheel speed sensor and sensor gear ring from being polluted by oil stain or
other dirties. Otherwise, the wheel speed sensor shall generate inaccurate wheel speed
signal, which shall further impose influence on the accuracy of system control, and even
lead to system failure. Furthermore, you are prohibited to knock the rotation speed
sensor; otherwise, sensor-degaussing phenomenon may be prone to occur, which is
unfavorable for the normal operation of system.

8)

When repairing the hydraulic system, you should firstly discharge the high-pressure
brake fluid of the energy accumulator completely in order to protect persons from being
hurt by the splash of high-pressure brake fluid. In the case of discharging the
high-pressure brake fluid of energy accumulator, you should firstly turn off the ignition
switch, and repeatedly step on and loosen the brake pedal until it becomes very hard.
Additionally, before the brake hydraulic system is well installed, you are not allowed to
turn on the ignition switch with a bid to stop the electrically-driven pump from
operating.

9)

The brake system should use special pipeline, since brake system often has a very high
pressure. If general pipeline is utilized, it shall be easily damaged.

10) Because the wheel speed sensor, ECUs and brake pressure adjusting devices of the

antilock brake system (ABS) cannot be repaired, you should replace them completely if