Chery A15. Manual — part 279

(IV) Assembling the master pump

1. Apply both sides of the piston cup
with lithium-soap glycol grease.
2. Insert the piston into the master pump.
3. Fix the push rod assembly with the
spring snap ring.
(V) Fixing master pump
1. Fix the master pump.
Insert the quick coupler of the clutch
master pump into the clutch pedal and
screw tight the set nut. Torque: 7.8 N.m.
Fasten two nuts (M=11+1Nm) onto the
two welded bolts on the vacuum booster
bracket and fasten the clutch master
pump onto the vacuum booster bracket;
2. Connect the pipeline.
3. Bleed the air in the hydraulic system
and adjust the clutch pedal height.
II. Clutch sub-pump
(I) Unfixing sub-pump
1. Unfix the hydraulic pipeline of the
sub-pump
2. Release the two set bolts for the sub-
pump and the gearbox and then
dismantle the sub-pump.


(II) Disassembling sub-pump
1. Pull out the dust cover and push rod
2. Dismantle the piston with a caliper
and then blow the piston and the spring
out of the sub-pump with compressed air.


Note: use cotton cloth to hold the sub-
pump piston and spring during
blowing to avoid personal injury by
the flying piston.

(III) Checking sub-pump

Clean the disassembled parts with
compressed air.
1. Check if there is any scratch or rust on
the sub-pump and clean or replace the
sub-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.
(IV) Assembling sub-pump
1. Apply the piston with lithium-soap
glycol yellow oil.
2. Fix the piston and the spring into the
sub-pump;
3. Fix the dust cover and the push rod
onto the sub-pump
(V) Fixing sub-pump
1. Fasten two set bolts (M=11+1Nm) of
the sub-pump and gearbox.
2. Connect the hydraulic pipeline
between the master pump and the sub-
pump.
3. Add brake fluid and then bleed the air
in the clutch hydraulic pipeline.
4. Check if the hydraulic system suffers
any leakage.

Section Six: Disassembly and Repair of Clutch Parts


I. Disassembling the clutch
1. Mark accordingly on the flywheel and
clutch cover
2. Fasten the flywheel with a special tool
and release the set bolts of the clutch and
the flywheel in diagonal sequence one
round each time until the spring tension
is eliminated.

3. Screw off the set bolts of the clutch
pressure plate assembly and then take off
the clutch pressure plate assembly and
the wearing plate.

4. Dismantle the release bearing and
release fork from the transmission axle.

1. Clutch pressure plate assembly

2. Bolt

3. Special tool (flywheel bracket)

II. Checking the clutch
(I) Checking wearing plate
1. Check if the release bearing rotates
flexibly.
2. In the case of locked or inflexible
release bearing, please replace the
bearing.
3. Clutch wearing plate assembly:
measure the pitch between rivet head
and the wearing plate surface. Replace
the wearing plate assembly when the
pitch in any screw hole has reached the
limit.

Standard value

Maintenance

Rivet head set-in

pitch

1.5mm
0.06in

0.5mm
0.02in

(II) Clutch pressure plate assembly
1. Check if the diaphragm spring suffers
any abnormal abrasion or damage.

2. Check if the pressure plate suffers any
abrasion or overheated spot.
3. In the case of anything abnormal,
replace the pressure plate assembly. Do