Chery A15. Manual — part 212

(5). Brake disk shall be replaced when the wear limit 10mm is reached. Remove brake

caliper shell first before replacing brake disk. Dirt and preservative oil on friction

surface of new brake disk shall be evenly removed before installation.

(II). Replacing Friction Shoes of Front Wheel Disk Brake

(1). Lift the car and demount front wheel, then

remove lower fastening bolt of brake caliper shell.

(2). Lift up brake caliper from bottom to top and

demount brake shoe as shown in the figure.

(3). Press brake caliper piston back into the shell.

Check the brake fluid tank level before pressing

piston back, and suck some out if the level is too high so as to prevent fluid from

overflowing and damaging paint. Brake fluid is corrosive and toxic, therefore shall be

stored in special plastic bottle or other container.

(4). Fix the inside brake shoe on caliper bracket of steering knuckle, and then fix

outside brake shoe.

(5). When fixing brake caliper, make sure that the retracing spring on brake shoe is

properly positioned, otherwise brake noise will be caused.

(6). After assembly is finished, fully operate brake pedal for several times with the car

unmoved to set brake shoes in normal working position.

(III). Replacing Packing Ring in Brake Caliper Shell Wheel Cylinder

The packing ring in brake caliper shell wheel cylinder shall be replaced in case of

aging failure and brake fluid leakage.

(1). Loosen and remove brake caliper set bolts,

and take off the caliper to be hung on an iron wire.

(2). Press the piston out of caliper shell by compressed

air. Place a wood block in piston slot when pressing to

avoid piston damage, as shown in the figure.

(3). Pry out the packing ring carefully with a tool

as the figure shows.

(4). Fit the packing ring onto the piston with a dust

cover.

(5). Fix the inner packing ring into the seal

groove of brake caliper wheel cylinder with a tool,

as shown in the figure.

(6). Press the caliper piston into caliper shell with

the special piston fitting tool, as shown in the

figure. The outer sealing lip of dust cover shall be

fixed in piston slot, too.

(7). Assemble the brake caliper with replaced packing ring.

(IV). Checking Front Wheel Disk Brake

1. Maintenance of Brake Shoe

(1). Check brake shoe surface and sand off oil stains with sandcloth if any.

(2). Check brake shoe for crack or falling off, and replace it if any.

(3). Check brake shoe thickness, and replace it if worn out.

(4). Check brake shoe for worn condition, and replace it if it is smaller than service

limit or unevenly worn. Brake shoes on both sides shall be replaced at the same time,

and new shoes shall be made by the same one manufacturer. Wearing limit of brake

shoe is 7mm, lining board included.

2. Maintenance of Brake Disk

(1). Check brake disk and sand off oil stains with sandcloth if any.

(2). Check brake disk for crack, corrosion or severe stretch, and replace it if any.

(3). Check brake disk for scratch, and reprocess it in case of deep scratch.

(4). Check brake disk thickness, and replace it if exceeding limit. Standard thickness

of front wheel brake disk is 13mm, service limit is 10mm.

(5). Measure the ending beat of brake disk with a dial indicator. If the value exceeds

0.12mm, the disk shall be processed by turning or polishing, and if the overproof is

too large, the disk shall be replaced.

(6). Brake disks on both sides shall be replaced at the same time

3. Maintenance of Brake Caliper Assembly

(1). Check brake caliper for crack and deformation, and repair or replace it if any as

the case may be.

(2). Check piston dust cover for damage and crack, and replace it if any.

(3). Check piston packing ring for aging failure and crack, and replace it if any.

(4). Check piston for oil leakage, blocked movement and unsmooth retracting, and

repair if any. Check piston and cylinder wall for damage and corrosion, and replace

the brake caliper assembly if any.

II. Disassembly/Assembly and Inspection of Rear Wheel Drum Brake

(I). Disassembling/Assembling Brake Shoe

1. Set pin 2. Bolt 3. Brake wheel cylinder 4. Brake back plate 5. Rubber stopper
6. Shoe plate 7. Toothed regulating plate 8. Push rod 9. Toothed regulating plate spring
10. Brake shoe positioning spring 11. Lower retracting spring 12. Retracting spring

13. Parking brake arm drag 14. Brake shoe assembly 15. Limiting spring
16. Limiting spring seat 17. Brake drum assembly

1. Disassemble Steps:

(1). Demount rear wheel.

(2). Insert a screwdriver into the tire bolt hole in brake drum and press the shoe plate

clearance regulating wedge upwards to return the brake shoe.

(3). Disassemble brake drum.

(4). Remove brake shoe positioning spring and parking brake arm drag.

(5). Unfix shoe plate lower positioning spring seat and take down the spring.

(6). Take off wedge tension spring and retracting spring, as shown in the figures.

(7). Demount brake shoes and friction lining assembly.

(8). The whole assembly of brake shoes and friction lining shall be replaced at the

same time.

2. Assemble Steps

(1). Fix positioning spring as shown in the figure.

Fit brake shoe onto push rod and insert the wedge

with the bulge positioning side facing the brake

back plate.

(2). Assemble brake shoe and parking brake arm

drag onto push rod, and then fix retracing spring as

the figure shows.