Chery A15. Manual — part 278

1. Clutch sub-pump; 2. Clutch main cylinder; 3. Vacuum booster bracket
4. Clutch pedal assembly; 5. Outlet pipeline assembly






Section Two: Troubleshooting



Symptom Cause

Solution

Skidding
clutch

Wrong clutch pedal free stroke (clearance)
Worn-out or polluted clutch wearing plates
Deformed wearing plates, pressure plate or
flywheel

Weakened diaphragm spring

Adjust free stroke
Replace wearing plate
Replace wearing plate,
pressure plate or
flywheel
Replace clutch pressure
plate assembly

Clutch not
fully

Wrong clutch pedal free stroke
Weakened diaphragm spring or worn-out

Adjust free stroke
Replace pressure plate

disengaged tapered head.

Rusted input shaft spline
Damaged or worn-out gearbox input shaft spline
Clutch wearing plate assembly vibrates too
much
Damaged or polluted clutch wearing plate

Air in the hydraulic system
Leakage in the hydraulic system

assembly
Lubricate
Replace input shaft
Replace wearing plate
assembly
Replace wearing plate
assembly
Bleed the air
Check and repair the
leakage

Vibrating
clutch

Worn-out of clutch wearing plate (like glass)

Polluted clutch wearing plate
Release bearing has difficulty sliding on the
gearbox bearing sleeve
Vibrating clutch wearing plate assembly or bad
contact of wearing plate
Weakened damping spring of clutch wearing
plate assembly
Clutch wearing plate rivet loosened

Deformed pressure plate or flywheel

Damaged engine fixing pad or loosened set bolt
or nut.

Repair or replace
wearing plate
Replace wearing plate
Lubricate

Replace wearing plate
assembly
Replace wearing plate
assembly
Replace wearing plate
assembly
Replace pressure plate
assembly or flywheel
Screw tight or replace
fixing pad

Noisy
clutch

Worn-out or damaged release bearing
Worn-out input shaft front bearing

Abnormal noise of clutch wearing plate

Cracked clutch wearing plate

Abnormal noise of pressure plate and diaphragm
spring

Replace release bearing
Replace input shaft
bearing
Replace wearing plate
assembly
Replace wearing plate
assembly
Replace pressure plate
assembly

Clutch
can’t be
disengaged

Polluted clutch wearing plate

Severe abrasion of clutch wearing plate

Exposed rivet

Weakened torsion spring

Leakage in the hydraulic system

Air in the hydraulic system

Replace wearing plate
assembly
Replace wearing plate
assembly
Replace wearing plate
assembly
Replace wearing plate
assembly
Check and repair leakage
Bleed the air
Bleed the air

Section Three: Bleeding Clutch System

When the clutch is being repaired or it is
suspected that there is air in the clutch
pipeline, it becomes necessary to bleed
the air in the clutch assembly.
Note: wash away any brake fluid on
painted surfaces.
1. Add brake fluid into the fluid tank of
clutch. Frequently check the brake fluid
level in the fluid tank and add if
necessary.
2. Connect one plastic tube to one
bleeding bolt (as the figure shows) and
insert the other end of the tube into the
brake fluid container that is half

topped

.

3. Bleed the air in the clutch pipeline.
(a) Slowly step down the clutch pedal;
(b) Do not release while stepping down
the clutch pedal, release the bleeding
bolt of the clutch sub-pump until the

fluid starts to outflow and then fasten the
bleeding bolt.
(c) Repeat the above procedure until
there is no air bubble in the fluid.

Section Four: Clutch Pedal

I. Checking and adjusting clutch pedal
1. Check the height of pedal.
Height of pedal from carpet: 160-180mm (6.33-7.10inch). Adjust the pedal height
adjusting nut and rotate the set bolt until the proper height is achieved and then fasten the
nut.
2. Check the pedal free stroke and push rod clearance.
Pedal free stroke
Push the pedal outward until the resistance is felt from the clutch. Free stroke: 5-15mm
(0.197-0.591inch).
Push rod clearance
Push the pedal slightly with one finger until the resistance increases a little. Push rod
clearance on top of pedal: 1-5mm (0.039-0.197inch).
3. Adjust pedal free stroke and push rod clearance if necessary.
(a) Release the set nut and turn the push rod until the free stroke and clearance are proper.
(b) Fasten the set nut.
(c) Adjust the pedal free stroke and check pedal height.
4. Check clutch disengagement location.
(a) Pull the parking brake handle and place the wheel wedge.
(b) Start the engine for idle running.
(c) Do not step down the clutch pedal and slowly push the gear lever to reverse position
until gear engagement.

(d) Slowly step down the clutch pedal and measure the stroke from the disappearance of
gear noise (disengagement location) to the stroke terminal.
Standard stroke: 25mm (0.98inch) or above (from pedal stroke terminal to the
disengagement location).
If the stroke does not comply with requirements, please check the following:

• Check the pedal height

• Check the push rod clearance and pedal free stroke
• Bleed the air in the clutch pipeline

• Check the clutch over and disc.

Section Five: Hydraulic Control System


I. Clutch master pump
(I) Unfixing the master pump
1. Suck out the brake fluid with a sucker.
2. Detach the clutch pipeline.
3. Detach the clutch master pump push
rod from the clutch pedal.







4. Screw off the set nut, detach the
clutch pedal from the master pump and
pull out the master pump.

(II) Disassembling master pump
1. Dismantle the pipeline
2. Dismantle the push rod, pull back the
protective hood and unfix the spring
snap ring with a spring caliper.
3. Dismantle the piston.
(III) Checking master pump
Clean the disassembled parts with
compressed air.
1. Check if there is any scratch or rust on
the master pump and clean or replace the
master pump if any.
2. Check if the piston and piston cup
suffers any abrasion, scratch, crack or
burr.
3. Check if the push rod suffers any
abrasion or damage.