Chery A15 / 480 LHD model. Manual — part 75

CLUTCH OVERHAUL

· Clutch friction disk: measure the dent depth of

rivet head, i.e. the distance between the rivet head
and the friction disk surface. In case it is found that
the depth reaches the using limit for any hole, the
friction disk shall be changed.

Standard value Maintenance

Rivet head

Dent depth

1.5mm

0.06in

0.5mm

0.02in

·Measure the clutch disc runout using a dial indicator.

If the runout is excessive, replace the clutch disc.

Runout 0.8mm max

Clutch pressure plate:

·Examine whether the diaphragm spring has

abnormal wear or damage.

·Examine whether the pressure plate has wear or hot

point.

·In case of any abnormality, the pressure plate shall

be changed. The pressure plate shall not be
disassembled into two parts: diaphragm spring and
pressure plate.

·Measure the clutch pressure plate runout using a dial

indicator. If the runout is excessive, replace the
clutch disc.

Runout 0.25mm max

Flywheel:

·Examine whether the connection surface of friction

disk exists abnormal wear or hot point; the change
or maintenance shall be conducted if necessary.

·Measure the flatness of the flywheel with a straight

edge and a feeler gauge. If not as specified, replace
the clutch cover.

Maximum clearance 0.05mm

Service limit 0.15mm

CLUTCH INSTALLATION

Before the assembly, flywheel surfaces and pressure
plate shall be clear and dry.
——Assemble the pressure plate on the crankshaft

and screw up bolts in accordance with
prescribed moment.

—— Assemble release disk and fit on snap ring.
—— Assemble clutch disk.

N•m

Kg-m

1b-ft

Pressure plate

assembly bolt

Torque

57-65

5.7-6.5

41.5-47.0

—— Assemble flywheel.
——Screw up flywheel bolt uniformly according to

the diagonal line.

——Coat a thin layer of grease on the input axle

and then assemble the transmission with
engine.

Remarks:
When put the input axle of transmission into the
clutch friction disk, the flywheel shall be revolved
until the input axle of transmission and spline
meshed.

N•m

Kg-m

1b-ft

Flywheel

bolt

Torque

18-28

1.8-2.8

13.5-20.0

TROUBLE DIAGNOSIS

Trouble

symptom

Cause

Treatment method

Slip of clutch

•Free travel (free play) of clutch pedal is wrong.
•Abrasion or oil stain for clutch friction disk.
•Distortion for friction disk 、 pressure plate or

flywheel surface.
•Diaphragm springs become weaker.

Adjust free travel

Change friction disk

Change

frication

disk,

pressure plate or flywheel

Change clutch pressure plate

Uncompleted

segregation of

clutch

•Free travel of clutch pedal is wrong.
•Diaphragm springs become weaker or abrasion for

stabber fingertip.

•Rust for input axle spline.
•Mutilation or abrasion for input axle spline of

transmission.
•Excessive nodding action for clutch friction disk

assembly.
•Abrasion or oil stain for clutch friction disk.

Adjust free travel

Change pressure plate

Lubricate

Change the input shaft

Change friction disk

Change friction disk

Vibration of

clutch

•Brighten of clutch friction disk (to become

glassiness).
•Oil stain for clutch friction disk.
•Bad skid of segregation bearing on the bearing

sleeve of transmission.
•Shimmy of clutch friction disk assembly or bad

connection of friction disk.
•Vibration reduction torsion springs of clutch

friction disk assembly become weaker.
•Loose of rivet of clutch friction disk.
•Distortion of pressure plate or flywheel surface.

•Loose of the binding bolt of flywheel or loose of

binding bolt of pressure plate assembly.

Repair or change friction

disk

Change friction disk

Lubricate

Change friction disk

Change friction disk

Change friction disk

Change pressure plate or

flywheel

Screw down

Clutch noise

•Abrasion or mutilation for segregation bearing.
•Abrasion for front bearing of input axle.
•Abnormal noise for clutch friction disk.
•Crack for clutch friction disk.
•Abnormal noise for pressure plate and diaphragm

spring.

Change segregation bearing

Change input shaft bearing

Change friction disk

Change friction disk

Change pressure plate

Non-separation of

clutch

•Clutch friction disk has fat liquor.
•Serious wear of clutch friction disk.
•Rivet head is displayed in surface of disk.
•Torsion springs become weaker

Change friction disk

Change friction disk

Change friction disk

Change friction disk

COOLING SYSTEM

DESCRIPTION OF COOLING SYSTEM

… … . . … . . … . …E-2

COMPONENTS OF 480 ENGINE COOLING SYSTEM … … . . . . E-2

WORKING PRINCIPLE OF COOLING SYSTEM … … . . … . . E-2

PARAMETERS OF COOLING SYSTEM … … . . … . . … . E-3

ENGINE COOLANT … … . . … . . … . . … . . … …E-3

COOLANT DISCHARGE … … . . … . . … . . . . …E-3

COOLING SYSTEM CLEANING … … . . … . . … . … …E-3

COOLANT FILLING … … . . … . . … . . … . . …E-4

COOLING SYSTEM CHECKUP . . . … . … . … . . …E-5

COOLING SYSTEM MAINTENANCE WARNING … … . . … . … …E-5

WARNING … … . . . . . . . . . . … . …E-5

WATER PUMP … … . . … . . … . … … … . . . . …E-6

STRUCTURE … … . . … . . … . . … . . … …E-6

DISASSEMBLY/ASSEMBLY … … . . … . . … . . … …E-6

THERMOSTAT

… … . . … . . … . . … . . … . …E-7

DISASSEMBLY/ASSEMBLY … … . . … . . … . . … …E-7

WATER TEMPERATURE SENSOR … … . . … . . … . . …E-9

DISASSEMBLY/ASSEMBLY … … . . … . . … . . … …E-9

CHECKING … … . . … . . … . . … . . … . E-9

COOLING FAN … … . . … . . … . . … . . … . E-9

DISASSEMBLY/ASSEMBLY … … . . … . . … . . … …E-9

GUIDELINE FOR DISASSEMBLY … … . . … . . … . … …E-10

EXPANSION RESERVOIR

… … . . … . . … . . … . …E-11

DISASSEMBLY/ASSEMBLY … … . . … . . … . . … …E-11

ASSEMBLY OF RADIATOR . . . … . … . … . . … . E-12

DISASSEMBLY/ASSEMBLY … … . . … . . … . . … …E-12