Chery A series. Manual — part 78

REPLACEMENT OF FRICTION SHOES OF FRONT WHEEL DISC BRAKE

--

Lift up the vehicle and remove the front wheel,

and then detach the lower fixing bolt of the caliper
housing.

-- Lift up the brake caliper from the bottom to top,

and remove the brake lining (as shown in the
figure).

-- Press the caliper piston back into the caliper

housing. Use a suction hose to pump some fluids
out from the brake fluid reservoir if its fluid level
is too high before the piston is pressured back, the
purpose of which is to prevent the brake fluid
from overflowing and damaging the paintwork.
Since the brake fluid is corrosive and toxic, it
shall be stored in a special plastic bottle or other
containers.

-- Install the inside brake lining on the brake caliper

bracket of the steering knuckle, and then refit the
outside brake lining.

-- Ensure that the return spring shall be in its proper

position when installing the brake caliper;
otherwise it may cause the brake noise.

-- Tighten the lower fixing bolt of the caliper

housing.

-- Keep the vehicle in its original position after the

completion of installation, and forcefully step on
the brake pedal several times so as to make the
brake lining in its normal working position.

REPLACEMENT OF INTERNAL SEALING RING OF THE WHEEL CYLINDER IN
CALIPER HOUSING
-- The sealing ring inside the wheel cylinder in

caliper housing shall be replaced in case of aging
failure to make the sealability bad and brake fluid
leakage.

-- Loosen and remove the securing bolts from the

brake caliper, and remove the brake caliper. The
brake caliper removed shall be hung using an iron
wire.

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-- Use the compressed air to press the piston out of

the brake caliper housing. Place a wooden block
in the piston indent when pressing so as to avoid
the piston damage, as shown in the figure.

-- Apply a tool to carefully pry out the sealing ring,

as shown in the figure.

-- Install the sealing ring into the piston with a dust

boot.

-- Use a tool to install the internal seal ring into the

seal groove inside the wheel cylinder of brake
caliper, as shown in the figure.

-- Apply the special piston assembly tool to press the

piston of brake caliper into the caliper housing, as
shown in the figure. The external sealing lip of
dust boot shall be installed into the groove of
piston.

-- Install the brake caliper body whose sealing ring is

already replaced.

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INSPECTION OF FRONT WHEEL DISC BRAKE

Maintenance of brake lining

* Check whether there are some oil stains on the surface of brake lining, and use an

abrasive cloth to grind off it, if any.

* Check the crack, dropout and other defectives on the brake lining, and replace the brake

lining, if any.

* Check the thickness of brake lining, and replace it if worn out.

* Check the wear condition of brake lining, and replace it if the thickness of brake lining is

less than the service limit or the lining is worn unevenly. The brake linings on both sides
shall be replaced at the same time when replacing them with new linings, and the new
ones shall be supplied by the same one manufacturer. The wear limit of brake lining shall
be 7 mm, including the backing plate.

Maintenance of brake disc

* Check whether there are some oil stains on the surface of brake disc, and use an abrasive

cloth to grind off it, if any.

* Check the crack, corrosion, severe score and other defectives on the brake disc, and

replace it if any.

* Check the scratch of brake disc, and machine it again if the scratch is too deep.

* Check the thickness of brake disc, and replace it if the thickness is greater than the limit

value. The standard thickness of front wheel brake disc is 13 mm with the service limit of
10 mm.

* Use a dial gauge to measure the face run-out of brake disc, and apply the turning,

polishing and other methods to treat its end surface if the run-out exceeds 0.12 mm, and
replace the brake disc if the derivation is too large.

* The brake discs on the both sides shall be placed at the same time when replacing.

Maintenance of brake caliper assy.

* Check the crack and deformation of the brake caliper, and correct or replace it as

appropriate.

* Check the breakage and crack of the dust boot of piston, and replace the boot, if any.

* Check the aging, crack and other defectives of the sealing ring of piston, and replace the

ring, if any.

* Check the oil leakage, motion blocked, unsmooth return of the piston, and repair it, if

any. Check the damage, corrosion and other defectives of the piston and cylinder wall, and
replace the brake caliper assy., if any.

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Maintenance of brake caliper assy.

* Check the crack and deformation of the brake caliper, and correct or replace it as

appropriate.

* Check the breakage and crack of the dust boot of piston, and replace the boot, if any.

* Check the aging, crack and other defectives of the sealing ring of piston, and replace the

ring, if any.

* Check the oil leakage, motion blocked, unsmooth return of the piston, and repair it, if

any. Check the damage, corrosion and other defectives of the piston and cylinder wall, and
replace the brake caliper assy., if any.

EXPLOSION CHART AND STRUCTURAL CHARACTERISTICS OF FRONT
WHEEL DISC BRAKE

The front wheel disc brake adopts the single-cylinder floating caliper structure in where the
brake caliper body may slide in the axial direction relatively to the brake disc, the structure
of which is shown in the figure below.

Front Wheel Disc Brake

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