Chery B14 2006 2016 User Manual

Service Manual for Chery V525 Car Chassis

Service Manual for Chery

V525 Car

(Chassis)

Service & Technical Department of Chery

Automobile Company

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Service Manual for Chery V525 Car Chassis

Chapter One Brake System.................................................................................................................4

. System overhaul parametersⅠ .................................................................................................4

1. Brake disk surface check ................................................................................................4

2. Brake disk thickness check.............................................................................................4

3. Brake disk runout check .................................................................................................4

4. Brake lining thickness check ..........................................................................................4

. Disassembly, assembly and overhaⅡ ul of front brake and brake caliper ................................5

1. System structural diagram ..............................................................................................5

2. Preparation......................................................................................................................6

3. Note ................................................................................................................................6

4. Disassembly procedure ...................................................................................................6

5. Assembly procedures ....................................................................................................10

. Disassembly, assembly and overhaul of rear brakeⅢ ............................................................11

1. System constructional drawing..................................................................................... 11

2. Preparation.................................................................................................................... 11

3. Precautions....................................................................................................................11

4. Disassembly procedures ...............................................................................................12

5. Assembly procedures ....................................................................................................13

.Adjustment and replacement of handbrake control cableⅣ ....................................................14

1. System structural diagram ............................................................................................14

2. Preparation....................................................................................................................14

3. Precautions....................................................................................................................14

4. Disassembly and assembly procedures.........................................................................14

4.1. Disassembly of rear hand brake control cable ...................................................14

4.2 Disassembly of hand brake control mechanism and hand brake front control

cable..........................................................................................................................16

4.3. Assembly procedures .........................................................................................17

4.4 Adjustment of handbrake control cable ..............................................................17

. Disassembly, assembly and overhaul of ABS system, brake master cⅤ ylinder as well as

vacuum booster.........................................................................................................................18

1. System structural diagram ............................................................................................18

2. Preparation....................................................................................................................18

3. Precautions....................................................................................................................18

4. Disassembly and assembly procedures.........................................................................19

4.1. Removal of ABS assembly ................................................................................19

4.2 Disassembly of brake master cylinder ................................................................20

4.3 Disassembly of vacuum booster .........................................................................21

4.4 Assembly procedures ..................................................................................................21

4.5 Ventilation of brake system.........................................................................................21

Chapter Two Adjustment to Suspension System and Four-wheel Alignment...................................23

. Disassembly, assembly and overhaul of front axle and suspensionⅠ ....................................23

1. System constructional drawing.....................................................................................23

2. Preparation....................................................................................................................24

3 Precautions.....................................................................................................................24

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4 Disassembly and assembly procedures..........................................................................24

4.1 Removal of shock absorber assembly.................................................................24

4.2 Removal of control arm assembly ......................................................................25

4.3 Removal of front axle assembly .........................................................................26

5. Assembly procedures ....................................................................................................29

. Disassembly, assembly and overhaul of rear aⅡ xle and suspension .....................................30

1. System constructional drawing.....................................................................................30

2. Preparation....................................................................................................................30

3. Precautions....................................................................................................................31

4. Disassembly and assembly procedures.........................................................................31

4.1. Removal of shock absorber assembly................................................................31

4.2 Removal of rear axle assembly ...........................................................................33

5. Assembly procedures ....................................................................................................33

. Adjustment Ⅲ of four-wheel alignment ..................................................................................33

1. Adjustment of front wheel toe-in..................................................................................33

2. Adjustment of front-wheel camber angle .....................................................................34

3. Adjustment of kingpin caster angle ..............................................................................34

4. Adjustment of rear wheel positional parameters...........................................................34

.Installation of tire and regulation of air pressureⅣ .................................................................35

1. Fit tire valve..................................................................................................................35

2. Fit the tire......................................................................................................................35

3. Tire inflation .................................................................................................................35

4. Installation of wheel and tire assembly.........................................................................35

5. Tightening method of wheel nut ...................................................................................35

6. Assembly of trim cover.................................................................................................35

Chapter Three Disassembly, Assembly and Overhaul of Steering System.......................................36

. Disassembly and assembly of steering gearⅠ ........................................................................36

1. System structural diagram ............................................................................................36

2. Preparation....................................................................................................................36

3. Precautions....................................................................................................................37

4. Disassembly and assembly procedures.........................................................................37

5. Assembly procedures ....................................................................................................38

. Disassembly and assembly of steering postⅡ ........................................................................39

1. System structural diagram ............................................................................................39

2.Preparation.....................................................................................................................40

3.Precautions.....................................................................................................................40

4. Disassembly procedures ...............................................................................................40

5. Assembly procedures ....................................................................................................42

. Adjustment to clearance of steering gearⅢ ............................................................................43

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Service Manual for Chery V525 Car Chassis

Chapter One Brake System

Ⅰ. System overhaul parameters

1. Brake disk surface check

The friction surface of brake disk shall be smooth, without conspicuous pits or groove. Otherwise,

replace it.

2. Brake disk thickness check

Use caliper to check the thickness of brake disk:

Standard thickness of front disk（ventilation disk）shall be 22mm, application limit shall be 19mm,

otherwise replace it.

Standard thickness of rear disk（solid disk）shall be 10mm, application limit shall be 8mm,

otherwise replace it.

3. Brake disk runout check

Use dial gauge to check the face runout of brake disk, the application limit of front disk shall be

0.03mm, the application limit of rear disk shall be 0.03mm, otherwise replace it.

4. Brake lining thickness check

Standard thickness of front brake lining shall be 19.3mm, application limit shall be 9mm, and the

remaining thickness of limit brake pad thickness shall be not less than 1mm.

Standard thickness of rear brake lining shall be 16mm, application limit shall be 8mm, and the

remaining thickness of limit brake pad thickness shall be not less than 1mm.

Important notice：

After completion of replacing friction lining or brake disk, apply the brake for several times to

enable breaking-in between brake lining and brake disk. Always ensure safety!

After replacing brake lining, check brake fluid level to ensure it is between MIN and MAX.

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. Disassembly, assembly and overhaul of front brake and brake Ⅱ

caliper

1. System structural diagram

Structural Diagram of Front Brake Assembly

（1）Positioning bolt of brake disk （2）Brake disk
（3）Hub bearing unit （4）ABS wheel speed sensor plug
（5）Splash shield （6）Steering knuckle
（7）Fixing bolt （8）Friction lining
（9）Friction lining position sensor plug （10）Brake bracket
（11）Brake caliper assembly （12）Fixing bolt

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2. Preparation

Tools：ratchet, ratchet rod, 8#, 13#, 15#, 19#, 20#, 32# sleeve,

11#, 13#, 14#, 17#, 30# box end wrench, vices, torque
spanner.

Accessories: brake fluid

3. Note

3.1 Wear necessary labor protection supplies to avoid
accidents.

3.2 Brake fluid is a kind of toxic liquid; if contact with skin or
eyes, please wash using large quantity of fresh water, and go
to a doctor if necessary.

3.3 Waste brake fluid shall be put into vessels. It is prohibited
to pour into sewerage or stack with domestic wastes.

3.4 When carrying out disassembly and assembly, never step
on the brake pedal nor move the vehicle.

3.5 Keep oil or liquid away from friction lining or friction
disk, it may affect brake performance.

4. Disassembly procedure

4.1 Unscrew tire clamp nut clockwise using 19#

torque spanner or driver's spanner and then remove the

tire.

Torque: 110N.m

4.2 Loosen the connecting bolt of brake caliper

assembly and steering knuckle using torque

spanner and 17# sleeve.

Torque: 85±5N.m

4.3 Use 11# and 19# box end wrench to unscrew

the connecting nut of brake hose and copper tube.

( if only replace friction disk, it is unnecessary to

loosen the brake line)

Caution: brake fluid is toxic,

when disassembling brake hose, always avoid brake

fluid to splash onto clothing or skin.

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4.4 Remove the brake caliper from steering knuckle,

then separate brake caliper and brake hose.

4.5 Use punch to drift the lock trough, which drives

nut shim from semi-axle head, until it is able to turn.

4.6Remove the driving nut using 32# sleeve and

torque spanner. Torque: 180±10 N.m

4.7 Use cross screwdriver to unscrew the fastening

screw of brake disk, and then remove the brake disk.

Torque: 7-9 N.m

4.8 Check the thickness of brake disk, if it is less than

minimum thickness, replace accordingly. Caution:

replace the two brake disks of the same vehicle axles

together, and when using new brake disks, the replace

friction lining at the same time.

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4.9 Check the max. circular runout of brake disk

end face via dial indicator, if it is greater than

0.03mm, replace accordingly. (If the brake disk

thickness can be guaranteed, appropriate mechanical

processing also can be performed to satisfy maximum.

circular runout)

4.10 Remove the connecting nut of knuckle and

control arm using torque spanner and 18# sleeve.

Torque: 110±5N.m

4.11 Remove three fixing bolts of hub bearing unit and

knuckle using 17# sleeve.

Torque: 120-128 N.m

4.12 Dismount the monitoring harness of friction lining

thickness from bracket.

4.13 Dismount brake caliper assembly.

4.14 Removal of brake caliper assembly:

4.14.1 Remove the fixing bolt of brake caliper bracket

respectively using a 13# and a 15# open-end wrench.

Torque: 22-23N.m

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4.14.2 Lift the fixing bracket of brake caliper,

and then takes out brake lining.

4.14.3 Measure the thickness of friction lining, if less

than 10mm, please replace in pairs timely.

4.14.4 Remove the dust seal, check its damage

condition, and replace if necessary. Clean the contact

surface of brake piston and then coat with a thin noise

silencing paste. Caution: due to noise silencing paste

may cause expansion of dust seal, it is prohibited to

contact with each other.

4.14.5 Remove the piston. Place a piece of board between

piston and brake caliper wall to block the piston. Carefully

squeeze out the piston via compressed air through

attachment hole. Place a plate guard (hardwood, etc.)

at the notch of brake caliper to protect the piston.

Caution: never hold the piston using fingers-watch

clamping!

It is prohibited to dismantle brake caliper piston other then

professionals or with the help of professionals.

4.14.6 Check the guide sleeve. The guide sleeve shall

be flexible and smooth when pushing by hand, if

stagnation or heaviness occurs, replace accordingly.

Caution: when assembly, grease shall be applied on the

guide sleeve.

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4.14.7 Carefully remove seal ring using plastic pin,

then clean the brake cylinder and components

via alcohol, blow via compressed air. Carefully

check surface of brake cylinder, piston and flange, it is

prohibited to carry out mechanical

processing to the brake cylinder and piston.

5. Assembly procedures

5.1 Assembly of brake cylinder

5.1.1 Apply a think coat of brake cylinder paste

onto cylinder body, plunger and seal sleeve.

Fix seal ring in the circular groove at rear

brake cylinder. Then mount dust seal in the

front circular groove, and the press it in position

completely.

5.1.2 Keep the space between dust seal and brake

caliper housing dry. It is prohibited to contact brake

cylinder paste or brake fluid to ensure dust seal

is in the right position.

5.1.3 Secure brake piston using common part available

in the market, slightly press it onto dust seal, blow the

dust seal via compressed air (Max. 3.0bar), then fit the

expansion ring over the piston. Note: soak the dust seal

and piston in the brake fluid to enable easier access of seal

ring.

5.2 Refer to disassembly procedures for the assembly of

other parts.

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Ⅲ. Disassembly, assembly and overhaul of rear brake

1. System constructional drawing

（To be handled)

2. Preparation

Tools:

Ratchet wheel, ratchet rod, 8#, 13#, 15#, 20#

sleeve, 13#, 14#, 17#, 30# box end wrench, vice,

torque spanner and flat-tip screwdriver.

Accessories: brake fluid

3. Precautions

3.1 Wear necessary labor protection supplies to

avoid accidents.

3.2 Brake fluid is toxic, if contact with skin or

eyes, please wash using large quantity of fresh

water, and go to a doctor if necessary.

3.3 Waste brake fluid shall be put in vessels. It is

prohibited to pour into sewerage or stack with

domestic wastes.

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3.4 When carrying out disassembly and assembly, never
step on the brake pedal nor move the vehicle.

3.5 Keep oil or liquid away from friction lining or friction
disk, it may affect brake performance.

4. Disassembly procedures

4.1 Remove the rear wheel (refer to the disassembly

procedures for front wheel).

4.2 Unscrew the connecting nut of brake oil pipe and

brake caliper via 13# box end wrench, then discharge the

brake fluid (if only friction disk is replaced, it is

unnecessary to remove the brake line).
Torque: 16～18Nm

4.3 Loosen the connecting screw rods (2 pieces) of

brake caliper and brake backing plate via 13# box

end wrench, and then remove the rear-brake caliper

assembly.

Torque: 70±5N.m

4.4 Remove the fixing bolts of brake disk, then dismount

brake disk.

Torque: 7-9 N.m

4.5 Pull out the plug of ABS sensor, remove four

connecting bolts of hub bearing and rear axle via 13#

sleeve and torque spanner.

Torque: 70±5 N.m

4.6 Remove hub-bearing assembly.

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4.7 Remove brake caliper assembly.

4.8 Removal of brake caliper assembly:

4.8.1 Remove guide bolt using 17# box end wrench.

Torque: 22-23N.m

4.8.2 Take out friction lining assembly.

4.8.3 Remove another guide bolt, separate brake cylinder.

4.8.4 Dismantle and overhaul brake cylinder (refer to the

methods for front wheel brake cylinder)

5. Assembly procedures

Refer to disassembly procedures.

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To left rear brake assembly

Ⅳ.Adjustment and replacement of handbrake control cable

1. System structural diagram

Brake

To right rear brake assembly

1. Handle 2. Fixing bolt 3. Brake cable 4, 5. Right and left rear-wheel control cable

2. Preparation

Tools: flat-tip screwdriver, cross screwdriver, pincers, 10#, 16#, 18# sleeve, knock stick.

Accessories: none

3. Precautions

3.1 Wear necessary labor protection supplies to avoid accidents.

3.2 When carrying out disassembly and assembly of elastic element, make every effort to avoid

being injured.

3.3 Before carry out disassembly and assembly to exhaust pipe, in case of scald, the pipe

temperature must be dropped to room temperature.

4. Disassembly and assembly procedures

4.1. Disassembly of rear hand brake control cable

4.1.1 In accordance with disassembly and assembly method

of rear-wheel brakes, remove such assemblies as tire, brake

caliper, brake disk, etc. of rear wheel. Then completely

expose the hand brake assembly (take right rear wheel for

example).

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4.1.2 Remove the return spring of hand brake shoes via

screwdriver.

4.1.3 Turn the guide pin of brake shoes to align the

spring seat via pliers, and then take out the guide pin.

4.1.4 Compress the return spring of control cable until

the control cable clip gets out of the guide pin of hand

brake.

4.1.5 Remove the fixing bolt that fastens control cable

and lower plate of hand brake assembly via 10# spanner.

Torque: 7-14N.m

4.1.6 Remove three fixing bolts that fasten hand brake

control cable and chassis via 10# sleeve.

Torque: 9-12N.m

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4.1.7 Prize out the lifting eye of exhaust pipe via

screwdriver (it is unnecessary to remove the lifting eye

behind silencer).

4.1.8 Disconnect the connecting nut of exhaust pipe and

3-way catalytic converter via 18# sleeve, and then

remove the rear oxygen sensor (caution: along with the

descend of exhaust pipe, it may result in rupture of rear

oxygen sensor harness).

Torque: 60±5 N.m

4.1.9 Loosen the heat insulation fixing shims (6 pieces

total) of exhaust pipe via flat tip screwdriver, then

remove the heat insulation shim of exhaust pipe.

4.1.10 Detach the hand brake control cable of right-rear

wheel from the control cable branch joint by hand, the

right-rear wheel hand brake control cable then can be

removed.

4.2 Disassembly of hand brake control mechanism
and hand brake front control cable

4.2.1 Remove front-seat assembly using 16# sleeve.

Torque: 25±3N.m

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Adjusting

4.2.2 Unscrew total four screws of the plate guard of

hand brake control mechanism via cross screwdriver.

4.2.3 Remove four fixing bolts of hand brake control

mechanism via 10# sleeve, and then pull out the switch

plug of hand brake.

Torque: 25±3N.m

4.2.4 Remove the fixing nut of front hand brake control

cable via 10# spanner.

Torque: to be determined

4.3. Assembly procedures

Refer to disassembly sequence.

4.4 Adjustment of handbrake control cable

After replacing hand brake shoes, control cable and control
mechanism, adjust hand brake clearance to prevent from poor
braking effect or blocking failures. The process of adjustment
is described as follows:

3.4.1 Release the parking brake handle.

3.4.2 Forcibly apply the brake pedal once.

3.4.3 Pull up parking brake handle until four teeth are
exposed.

3.4.4 Tighten up adjusting nut until the two wheels
cannot be turned by hand.

3..4.5 After adjusting the hand brake, never fail to
carry out road test on a down slope road. If not
applying the brake and without power output,
meanwhile, the vehicle is traveling at lower speed,
under this condition, if pulling up the hand brake can
stop the vehicle, and releasing the hand brake can
travel again, that means the hand brake is normal,
otherwise readjust accordingly.

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Ⅴ. Disassembly, assembly and overhaul of ABS system, brake master

cylinder as well as vacuum booster

1. System structural diagram

ABS Pipeline

1. Pipeline clip 2. Master cylinder brake line

3. Master cylinder brake line 4. Right-front wheel brake line

5. ABS pump rack 6. Fixing spring leaf

7. ABS master cylinder fixing cushion 8. Brake line fixed seat

9. Right-rear wheel brake line 10. Left-rear wheel brake line

11. Left-front wheel brake line 12. ABS assembly

13. Left-front wheel brake hose 14.Pipe clip

15. Flange tri-slot fixing pipe clip 16. Pipe connection

17. Brake copper tube 18. Brake hose

2. Preparation

Tools: cross screwdriver, clamp pliers, pliers, 8#, 10#, 12#,
13#, 22# box end wrench and adjustable spanner.
Accessories: brake fluid

3. Precautions

3.1 Switch off storage battery to protect ABS and other

electric system.

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3.2 When carry out maintenance to hydraulic system, first,

completely discharge the high-pressure brake fluid in

accumulator to avoid splashing injuries. When discharging

high-pressure brake fluid in the accumulator, repeatedly apply

and release the brake pedal, until the brake pedal become very

hard.

3.3 Make sure electronic control unit is free from collision,

knock, and avoid damage.

3.4 Never let oil stain contract ECU, especially connecting

terminals, otherwise it may result in poor contact of the

connecting terminals.

3.5 It is preferred to select tires recommended by automakers.

If intend to use other types of tires, the external diameter,

adhesiveness and moment of inertia shall be close to the

original ones. However, it shall not use tires with different

specifications at the same time, because this may affect ABS

performance.

4. Disassembly and assembly procedures

4.1. Removal of ABS assembly

4.1.1 Remove the two bolts connecting intake pipe nozzle

and engine hood cross beam via 10# sleeve.

Torque: 10±1N.m

4.1.2 Remove four fixing bolts of air filter box via 10#

sleeve.

Torque: 10±1N.m

4.1.3 Loosen the clip at intake manifold and intake hose

via cross screwdriver, and then pull out the connecting

pipeline between intake hose and valve housing cover.

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4.1.4 Remove the fixing bracket of brake reservoir via 8# sleeve,

and then pull out the plug of brake fluid-level alarm.

Torque: 11±1N.m

4.1.5 Dismount the connecting pipe between reservoir and brake

master cylinder via clamp pliers. Then take out the small

reservoir that is connected with brake master cylinder.

4.1.6 Loosen the connecting nuts of various pipelines of ABS

assembly via 12# open-end wrench. When loosening each

pipeline, pay attention to the position of pipelines on the ABS

assembly to avoid wrong assembly.

Torque: 17-20N.m

4.1.7 Remove the fixing bolt that fastens ABS assembly and

bracket via 10# spanner.

Torque: 11±2N.m

4.1.8 Manually press the black button on the plug of ABS

harness, turn counterclockwise to fix the clip, remove the plug

and then take out ABS assembly.

Caution: the ABS assembly of this vehicle model cannot be

repaired, if malfunction occurs, please completely replace it.

4.2 Disassembly of brake master cylinder

4.2.1 Loosen the fixing nut of brake line at brake master

cylinder via adjustable spanner. Note: this nut is of inch size,

when disassembly and assembly, please select appropriate to

avoid skidding. When take out two brake lines, pay attention to

make marks so as to avoid being mixed up.

Torque: 17-20N.m

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4.2.2 Remove two stay bolts that secure vacuum booster

via 13# sleeve.

Note: there are two nuts behind the brake pedal in the

driver's cabin connect with these stay bolts.

Torque: 25±2.5Nm

4.2.3 Loosen the two nuts securing brake master

cylinder and vacuum booster via 22# sleeve, and then

take out brake master cylinder.

4.3 Disassembly of vacuum booster

4.3.1 Loosen the two fixing bolts of vacuum booster

behind the brake pedal inside the driver's cabin via 13#

sleeve.

Torque: 25±2.5N.m

4.3.2 Remove the circlip of vacuum booster and brake

pedal joint pin via pincers, and then take out the pin.

Loosen the clamp clip, and then pull out the vacuum

tube of vacuum booster and intake pipe. Take out the

vacuum booster from front compartment. If the vacuum

booster assembly is out of service, please replace

accordingly.

4.4 Assembly procedures

Assembly sequence is reverse to that of disassembly.

4.5 Ventilation of brake system

4.5.1 After disassembly and assembly of brake system, it is

required to carry out system ventilation to ensure satisfactory

braking effect.

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4.5.2 If replacing ABS control assembly, first, confirm

whether the new assembly is of dry type (brake fluid is not

full of the valve body) or wet type (brake fluid is full of the

valve body). If it is of dry type, after assembly, carry out

ventilation to the ABS assembly via Chery dedicated

diagnostic instrument, if it is of wet type, it is unnecessary to

carry out ventilation.

4.5.3 No matter whether ABS control system is subject to

ventilation, brake line shall be ventilated.

4.5.4 Lift and adequately sustain the vehicle.

4.5.5 Continuously apply the brake pedal for five to six times

(each time must apply to the maximum limit), for the last time,

it must be applied to the limit.

4.5.6 Slowly open exhaust valve until brake fluid is able to

flow.

4.5.7 Close the exhaust valve until no bubble exists in the

brake fluid.

4.5.8 Perform ventilation to each wheel one by one in

accordance with sequence of rear left, right front, right back

and left front.

Caution: the above procedures are applicable for brake line

ventilation for each brake. After ventilation, when step on the

brake pedal, the driver ought to feel it is obviously hard as

prior to disassembly and assembly.

4.5.9 After ventilation, fill in brake fluid in accordance with

the liquid level mark on the brake reservoir. The brake fluid

(DOT3 or DOT4) shall conform to national standards.

Different types of brake fluids are not compatible, therefore,

before filling, pay close attention to the type of brake fluid.

4.5.10 Check whether there is leakage in the brake line to

ensure safe driving.

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Chapter Two Adjustment to Suspension System and

Four-wheel Alignment

Ⅰ. Disassembly, assembly and overhaul of front axle and suspension

1. System constructional drawing

The front axle of Chery V325 car is a kind of disconnection turning and driving axle, it uses

McPherson independent suspension, whose front suspension has driving and turning dual functions.

The upper end of the suspension connects with vehicle body; lower end connects with steering

knuckle. Subframe connects with vehicle body via elastic element, which improves diving stability

and ride comfort.

1 Nut

18 Nut

19 Bolt

20 Clamp

21Stablizer bar assy.

22 Cup shim

23 Nut

24Flat shim

25 Bolt

2 Front strut connecting lid

3 Front strut assy.
4 Nut
5 Elastic shim

6 Connecting plate assy.

7 Bolt

8 Bolt

9 Front

10 Bolt

11 Nut

12 Control arm assy.

13Nut

14Nut

15Front connecting rod assy.

16 Flat shim

17Bolt

Structural diagram of Front Axle and Suspension System

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2. Preparation

Tools: 8#, 13#, 15#, 18#, 19#, 21#, 22#, 24# sleeve,

screwdriver

3. Precautions

2.1 Wear necessary labor protection supplies to avoid

accidents.

2.2 When carry out maintenance and repair to chassis, please

note that whether safety-lock of lifting machine is locked.

2.3 When carry out disassembly and assembly to shock

absorber spring, prevent spring ejection from being injured.

2.4 Never carry out welding and rectification to the

supporting parts of wheel suspension and guiding parts of

wheel.

2.5 When demounting chassis assembly, always replace

self-locking nut and corrosive nut to ensure safety.

4. Disassembly and assembly procedures

4.1 Removal of shock absorber assembly

4.1.1 Unscrew tire clamp nut clockwise using 19# torque

spanner or driver's spanner, and then remove the tire

(take the left side tire for example).

Torque: 110N.m

4.1.2 Remove ABS harness fixing clip via screwdriver.

4.1.3 Remove the fixing bolts of steering knuckle and

shock absorber via 18# sleeve.

Torque: 135±12 N.m

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4.1.4 Remove a fixing bolt at shock absorber assembly

that is close to front guard-board assembly via 10#

sleeve.

Torque: 10±1 N.m

4.1.5 Prize up a corner of front guard-board using

screwdriver, and then remove shock absorber bolt.

4.1.6 Remove three fixing bolts fastening shock absorber

assembly and frame via 15# sleeve.

Torque: 45±5N.m

4.1.7 Remove the shock absorber assembly.

4.1.8 When assembling shock absorber, it should be

noted that the gap of shock absorber connection board

must align corresponding protrusion on the vehicle body;

otherwise, it cannot be assembled.

4.2 Removal of control arm assembly

4.2.1 Remove the fixing bolt that fastens balance bar and

control arm via 15# sleeve.

Torque: 90±8 N.m

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4.2.2 Remove the fixing bolts fastening control arm and

steering universal joint ball via 18# sleeve.

Torque: 105±10N.m

4.2.3 Remove the connecting bolts fastening control arm

and front axle via 18# sleeve.

Torque: 180±15 N.m

4.2.4 Remove three rear fixing bolts fastening control

arm and subframe via 13# sleeve, and then remove the

control arm assembly.

Torque: 90±8 N.m

4.2.5 Remove the self-locking nut that fastens control

arm and connection board via 24# sleeve.

Torque: 110±10 N.m

4.3 Removal of front axle assembly

4.3.1 Remove three rear fixing bolts fastening chassis

mudguard via 8# sleeve, and then remove the mudguard

assembly.

Torque: 3±0.5 N.m

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4.3.2 Remove rear support-bracket bolt of transmission

on the front side member via 15# sleeve.

Torque: 80±6N.m

4.3.3Remove front support-bracket bolt fastening

transmission and side member via 24# sleeve.

Torque: 80±6N.m

4.3.4 Remove two front bolts of side member via 18#

sleeve.

Torque: 100-120 N.m

4.3.5 Remove two rear-fixing bolts of side member via

15# sleeve.

Then remove side member assembly.

Torque: 100-120 N.m

4.3.6 Remove three connecting bolts of head exhaust

pipe via 15# sleeve.

Torque: 45±5N.m

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4.3.7 Remove the fixing bolt connecting head exhaust

pipe and engine cylinder body via 13# sleeve.

Torque: 45±5N.m

4.3.8 Remove the connecting bolts of head exhaust pipe

and three-way catalytic converter via 18# sleeve.

Torque: 55±5N.m

4.3.9 Remove the fixing bolt of power steering gear via

13# sleeve.

Torque: 75±5 N.m

4.3.10 Remove the fixing bolt and nut at the left side of

power steering gear via 13# and 15# sleeve.

Bolt torque: 75±5 N.m

Nut torque: 70±5 N.m

4.3.11 Remove the connecting bolts fastening front axle

and vehicle body via 22# sleeve.

Torque: 150±10 N.m

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4.3.12 Remove another fixing bolts fastening subframe

and vehicle body via 21# sleeve, and then removes the

front axle assembly.

Torque: 150±10 N.m

4.3.13 Remove the fixing bolt and nut of gum cover of

stabilizer rod via 13# sleeve.

Torque: 50±5N.m

5. Assembly procedures

Refer to the disassembly procedures of front axle and front suspension.

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Ⅱ. Disassembly, assembly and overhaul of rear axle and suspension

1. System constructional drawing

Structural diagram of Rear Axle and Suspension System

1. Fixing nut of shock absorber 2. Flat-tip shim

3. Shock absorber assembly 4. Fixing bolt of shock absorber

5. Fixing nut of shock absorber bearing 6. Fixing nut of shock absorber bearing

7. Rear axle connection hinge 8. Knuckle joint bolt

2. Preparation

Tools: 8#, 10#, 13#, 17#, 19# sleeve

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3. Precautions

3.1Please wear necessary labor protection supplies to avoid
accidents.

3.2When carry out maintenance and repair to chassis, please
note that whether the safety lock of lifting machine is locked.

3.3When carry out disassembly and assembly to shock
absorber spring, prevent spring ejection from being injured.

4. Disassembly and assembly procedures

4.1. Removal of shock absorber assembly

4.1.1 Unscrew tire clamp nut clockwise using 19#

torque spanner or driver's spanner, and then remove the

tire (take the left side tire for example).

Torque: 110N.m

4.1.2 Remove the fixing bolt fastening hand brake

control cable and rear axle via 10# sleeve.

Torque: 9-12N.m

4.1.3Remove the connecting bolts of shock absorber

assembly and rear axle via 19# sleeve.

Torque: 110±10N.m

4.1.4Remove the two fixing bolts of the luggage

compartment via 7# sleeve.

Torque: 7±1N.m

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4.1.5 Remove the fixing bolt of the back plate assembly

of storage box via 8# sleeve.

Torque: 7±1N.m

4.1.6 Remove the fixing bolt of seat via 17# sleeve.

Torque: 25±3N.m

4.1.7 Prize up inner trim panel assembly via screwdriver.

4.1.8Remove the fixing nut of shock absorber bearing

via 13# sleeve, and then remove shock absorber

assembly.

Torque: 90±8 N.m

4.1.9 Structural diagram of shock absorber assembly.

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4.2 Removal of rear axle assembly

4.2.1Remove the four connecting bolts of rear axle

and brake assembly via 13# sleeve.

Torque: 70±5N.m

4.2.2 Remove the hinged bolts connecting rear axle and

vehicle body via 17# sleeve. Then remove the rear axle.

Torque: 110±10N.m

5. Assembly procedures

The assembly procedure is reverse to that of disassembly.

Ⅲ. Adjustment of four-wheel alignment

Please use four-wheel alignment gauge as recommended by

Chery Company to carry out parameters detection and

adjustment.

1. Adjustment of front wheel toe-in

Optic test instrument or mechanical toe-in regulator can be

used for toe-in adjustment.

1.1 In accordance with requirements for test instrument, make

adjustment preparations for wheel alignment.

1.2 Loosen the lock nut fastening rightward connecting tie rod

and elastic ring, turn the toe-in regulation rod to adjust length

as required to get prescribed value.

Toe-in value: 10′±6′

1.3 Fasten the lock nut, remount circlip of the jacket, and

check whether the lock nut is tightened, and ensure the jacket

is in right position;

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Torque: 55±5N.m

1.4 After adjusting toe-in of front wheel, check whether the

steering wheel is horizontal. Otherwise, loosen the lock nut of

steering wheel, adjust steering wheel to horizontal position,

and tighten up the lock nut of steering wheel to the torque

value as required.

2. Adjustment of front-wheel camber angle

2.1 Under normal condition, it is unnecessary to adjust

camber angle after assembling independent suspension

and wheel steering knuckle, if found camber angle

exceeds tolerance range due to other reasons, the

connecting bolt of independent suspension and steering

knuckle can be used for adjustment. Front-wheel camber

angle: - 30′±60′.

2.2 Prior to adjustment, check (visual inspection) the

parts of running system, and replace worn parts accordingly.

2.3 If found front-wheel camber angle exceeding tolerance,

loosen the connecting bolt fastening shock absorber and

steering knuckle, and move the wheel for rectification.

3. Adjustment of kingpin caster angle

Kingpin caster angle guaranteed by designed structure, it is

unnecessary to adjust in service. Kingpin caster angle:

3.13°±1°, if parameters exceed prescribed limit, only replace

steering knuckle.

4. Adjustment of rear wheel positional parameters

All of the rear wheel positional parameters shall be

guaranteed through design process.

4.1 Rear wheel camber angle: 30′±30′.

4.2 Rear wheel toe-in: 15′±15′.

4.3 If rear wheel positional parameters are changed and

exceed prescribed limit due to rear axle deformation resulted

from tremendous impact force, it can only be remedied via

rectifying or replacing rear axle.

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Ⅳ.Installation of tire and regulation of air pressure

1. Fit tire valve

Prior to installing tire valve, firstly check the valve port to ensure whether it is smooth and free
from burr, and then apply glycerol on the rubber body surface, will soak the tire valve into glycerol.
Pull or press (200 - 400N) using special tools to make the locating ring of the valve can go through
the wheel holes, to this point, the assembly is completed (soap water is allowed to substitute
glycerol).

2. Fit the tire

Before fit the tire, apply glycerol or soap water along the cycle of tire bead, meanwhile, note that:

2.1 When there is colored dot on the wheel rim, align the uniformity testing mark of tire to the
colored dot mark of wheel rim.

2.2 When without colored dot on the wheel rim, align the dynamic balance testing mark of tire to
valve position.

2.3 When without colored dot on the wheel rim, additionally, there is no dynamic balance testing
mark, however, static balance testing mark is available, at this point, align the tire valve to the static
balance testing mark.

2.4 The description concerning the uniformity, dynamic balance and static balance testing marks
for tires will be additionally provided in writing by the product division of Chery Company or
suppliers. In addition, this kind of descriptions will clearly be indicated on process sheet.

2.5 Carry out tire inflation strictly in accordance with specified pressure. During inflating process,
air pressure shall not exceed 10% of rated pressure. When performing separate packaging to spare
wheel assembly, the rated inflation pressure shall be 3.5bar, and the spare wheel assembly shall be
stored separately from four wheels. Prior to carrying out four-wheel alignment, check four-wheel
tire pressure and adjust air pressure. Front wheel pressure shall be 2.0±0.2 bar; the rear wheel shall
be 2.2± 0.2bar.

3. Tire inflation

After completion of tire inflation, screw up the protective cap of valve, and then carry out dynamic
balancing test. Fit appropriate balance weight at the internal and external fringe of wheel rim as
required. It is required that the unbalancedness of the final assembly shall be less than 100g·cm,
which is approximately equivalent to a 5g balance weight at the internal and external fringe of
wheel rim.
Note: each wheel and each side can use only one balance weight. Additionally, its maximum mass
shall not be more than 70g. During assembling process, never hit the balance weight too heavy.
Otherwise, replace balance weight in time. In addition, never use the replaced balance weight
again.

4. Installation of wheel and tire assembly

When fixing wheel and tire assembly, first, manually screw up the wheel bolt onto the hub for
pretension, after that use special tools for tightening in accordance with diagonal process.
Tightening torque shall be 110±10N.m. It is prohibited to use impact wrench to prevent from wheel
damage, over loose or over tight. It is not allowed to apply grease on wheel bolt (For newly
assembled wheel and tire assembly, after initial 100km traveling, it is required to tighten the wheel
bolts once to guarantee appropriate tightening torque, and the inspection of wheel bolt tightening
torque is one of the routine maintenances).

5. Tightening method of wheel nut

Tighten the fixing nut in a decussate way, the tightening force shall be approximately equal, then
wheel shall be able to turn freely. When carry out final tightening, the wheel shall be on the ground.

6. Assembly of trim cover

Mount trim cover or place trim cover as required. When fitting clip- type trim cover, place knock
in position by hand or via rubber tools.

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Chapter Three Disassembly, Assembly and Overhaul of Steering

System

Ⅰ. Disassembly and assembly of steering gear

1. System structural diagram

1. Power steering reservoir 2. Bracket fixing bolt

3. Bracket fixing nut 4.Oil outlet pipe

5. Fixing bracket of reservoir 6. Steering pump

7. Tension pulley 8. Self-locking nut

9. Adjusting nut 10. Regulating pull rod

11. Pipe clip 12.Steering gear

13. Oil outlet pipe 14, 15. Fixing bolt

16. Fixing nut 17. Oil return pipe

System Structural diagram

2. Preparation

Tools: screwdriver, 8#, 10#, 13#, 18#, 19# sleeve, 5# hexagon

socket spanner.

Accessories: power steering fluid

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3. Precautions

3.1 Please wear necessary labor protection supplies to avoid

accidents.

3.2 Avoid steering fluid to contact with skin or eyes when

disassembling steering system.

4. Disassembly and assembly procedures

4.1 Remove the fixing nut of steering ball pin via 19#

sleeve.

Torque: 40±3 N.m

4.2 Remove the fixing bolt of power steering gear via

13# sleeve.

Torque: 75±5 N.m

4.3 Remove the fixing bolt and nut at the left side of

power steering gear via 13# and 15# sleeve.

Bolt torque: 75±5 N.m

Nut torque: 70±5 N.m

4.4 Remove the fixing nut of power steering oil pipe via

18# sleeve.

Torque: 30±3N.m

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4.5 Remove the fixing bolt of steering universal joint

via 13# spanner.

Torque: 25±3N.m

5. Assembly procedures

Refer to disassembly procedures.

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Ⅱ. Disassembly and assembly of steering post

1. System structural diagram

1. Steering post 2. Knuckle joint 3. Protective rubber cup

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2.Preparation

Tools: slotted screwdriver, cross screwdriver, 5.0 hexagon
socket spanner, 8#, 10#, 13#, 22# sleeve, steering wheel
puller.

3.Precautions

3.1Please wear necessary labor protection supplies to avoid
accidents.

3.2Avoid steering fluid to contact with skin or eyes when
disassembling steering system.

3.3Before disassembling steering wheel, disconnect negative
of battery cell to avoid airbag ejection.

4. Disassembly procedures

4.1 Prize up two cover board at the side of steering wheel

via screwdriver.

4.2 Remove two fixing bolt of airbag via 5＃ hexagon

socket spanner.

Torque: 16±2N.m

4.3 Remove the fixing nut of steering wheel via 22#

sleeve.

Torque: 30±3 N.m

4.4 Pull out steering wheel via steering wheel puller.

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4.5 Remove two clamp screws of steering wheel plate

guard via cross screwdriver.

Torque: 1.5±0.5N.m

4. 6Remove four fixing bolts of screw cable via cross

screwdriver. Then remove screw cable.

Torque: 1.5±0.5N.m

4.7 It should be noted that when fitting the screw cable,

turn the inner disk to one direction until unable to be

turned further, and then turn about 3.2 circles at a reverse

direction, after aligning the mark, and confirm the steering

wheel is in horizontal position, and then carry out

assembly.

4.8 Remove the clip of combination switch via flat-tip

screwdriver, then pull out ignition switch and the plug

of combination switch.

4.9 Remove the fixing handle of engine hood via 8#

sleeve.

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4.10 Remove two fixing bolts of air conditioning air

outlet via screwdriver.

Torque: 1.5±0.5N.m

4.11 Remove the connecting bolt of steering universal joint

inside engine hood via 13# sleeve.

Torque: 25±3N.m

4.12 Remove the lower fixing bolt of steering post via 10#

sleeve.

Torque: 25±3 N.m

4.13 Remove the two upper fixing nuts of steering post via

10# sleeve. Then remove the ignition-lock barrel assembly

of steering post.

Torque: 25±3 N.m

4.14 Remove the protective cover of steering gear.

4.15 Take out steering universal joint assembly.

5. Assembly procedures

Refer to disassembly procedures.

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Ⅲ. Adjustment to clearance of steering gear

1. Maintain wheel at straight line traveling position;

2. Turn steering wheel to both sides;

3. If heard noise of steering gear, adjust the bolt as shown in the diagram until no impinge noise is

heard when turning steering wheel;

4. Tighten up the bolt for another 1 / 8 circle ( about 45°);

5. Road test;

6. If the steering mechanism can not return to the central position by itself, then loosen the bolt for

15°;

7. Road test.

Ⅳ. Adjustment to power steering system

1. Correctly connect power steering oil pipe，where the tightening torque for the connector between
oil return pipe, high-pressure oil pipe and steering gear shall be 35±3N.m, the tightening torque of
hollow bolt connecting high-pressure oil pipe and power steering pump shall be 45±3N.m. When
filling power steering oil, it is recommended to use special purpose vacuum pumping oil. The
specifications for filling power steering hydraulic fluid and exhaustion are described as below:
Fill power steering hydraulic fluid into steering reservoir assembly to the maximum level, start
engine at low speed (idle speed) to drive the steering pump, the steering system will be quickly full
of hydraulic fluid. In the oil filling process, only let engine run at idle speed to drive vane pump.
Meanwhile, continuously add hydraulic fluid to prevent vane from sucking air due to oil level
drops.

2. When hydraulic fluid in the oil tank presents emulsification state, or the pump emits excessive
noise (under normal condition, max. noise shall be 80 db), it must carry out exhaustion process.
The exhaustion procedure is described as below:
Jack the front part of the vehicle till two front wheels are hung up, start the engine, turn the steering
wheel to right and left till reach limit position (caution: after come to the limit position, try not to
stop, even if stop, never maintain over 2 seconds). Repeat above action for several times, until the
air in the system is gradually exhausted from the oil reservoir. In this process, with the drop of oil
level, continuously supplement hydraulic fluid until the oil comes to specified level.

3. Regularly check and adjust the tension of power steering belt: vertically apply a 100N force at
the middle of the belt, the max. deflection of belt shall be less than 5 mm, otherwise adjust the belt
tension until meet the above requirement via adjusting tension bolt.

4. When in service, it is prohibited to turn the steering wheel to limit position, even if it has to do so,
never maintain at this position over 10 seconds. It is strictly prohibited to use power steering pump
without oil. If the driver suddenly feels the steering heavy in service, immediately stop the vehicle,
dismantle and repair accordingly.

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Service Manual for CHERY V525 Car Body Accessories

Service Manual for Chery V525 Car

（Body Accessories）

After Sales Service Department of Chery Automobile Sales Co., Ltd

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Service Manual for CHERY V525 Car Body Accessories

Contents

Chapter One Engine hood and luggage compartment....................................................................8

I. Disassembly and assembly of engine hood ........................................................................8

1 Preparation.................................................................................................................. 8

2 Note.............................................................................................................................8

3 Disassembly/assembly of engine hood accessories ....................................................8

3.1 Disassembly steps ............................................................................................8

3.2 Assembly steps.................................................................................................8

4 Disassembly and adjustment of the engine hood assembly ........................................9

5 Disassembly and assembly of air intake grille assembly ............................................ 9

5.1 Disassembly steps ............................................................................................9

6 Adjustment and assembly of the engine hood lock.....................................................9

6.1 Disassembly steps ............................................................................................9

6.2 Assembly of engine hood lock....................................................................... 10

7 Disassembly of engine hood lock control cable........................................................10

7.1 Disassembly steps ..........................................................................................10

7.2 Assembly steps...............................................................................................11

II. Disassembly and assembly of rear luggage compartment lid.......................................... 11

1 Preparation................................................................................................................ 11

2 Disassembly of rear lid trim panel ............................................................................12

2.1 Disassembly steps ..........................................................................................12

2.2 Installation of rear lid trim panel.................................................................... 12

The installing steps are reverse to those for removal. .....................................................12

3 Disassembly/assembly of luggage compartment lock ..............................................12

3.1 Disassembly steps ..........................................................................................12

3.2 Assembly steps...............................................................................................13

4 Disassembly of luggage compartment lock core.......................................................13

4.1 Disassembly steps ..........................................................................................13

4.2 Assembly steps...............................................................................................13

5 Disassembly of rear wiper water nozzle ...................................................................14

5.1 Disassembly steps ..........................................................................................14

5.2 Assembly steps...............................................................................................14

6 Disassembly of rear wiper motor .............................................................................. 14

6.1 Disassembly steps ..........................................................................................14

6.2 Assembly steps...............................................................................................15

7 Disassembly of license plate light trim panel ...........................................................15

7.1 Disassembly/assembly steps .......................................................................... 15

8 Disassembly of luggage compartment handle...........................................................16

8.1 Disassembly steps ..........................................................................................16

8.2 Assembly steps...............................................................................................17

9 Disassembly of license plate light............................................................................. 17

9.1 Disassembly steps ..........................................................................................17

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9.2 Assembly steps...............................................................................................17

The installing steps are reverse to those for removal. ..................................................................... 17

Chapter Two Disassembly and Assembly of Inner Trimming Parts............................................ 18

I. Disassembly and assembly of seat belt.............................................................................18

1 Preparation................................................................................................................ 18

2 Note...........................................................................................................................18

3 Disassembly steps（e.g. front seat belt）.................................................................18

4 Assembly steps..........................................................................................................20

II. Disassembly/assembly of seat......................................................................................... 20

1 Disassembly steps..................................................................................................... 20

2 Assembly steps..........................................................................................................20

III. Disassembly and assembly of the Armrest Box and Sub Instrument Panel...................21

Tool: cross head screwdriver...................................................................................................21

1 Disassembly steps..................................................................................................... 21

2 Assembly steps..........................................................................................................21

IV. Disassembly and assembly of carpet.............................................................................. 21

V. Disassembly of Shock Absorber......................................................................................24

1 Disassembly steps.............................................................................................................24

2 Assembly steps..........................................................................................................24

Chaper Three Disassembly/Assembly and Maintenance of Door................................................25

I. Disassembly/assembly and maintenance of front door..................................................... 25

1. System diagram........................................................................................................ 25

2 Preparation................................................................................................................ 26

3 Note...........................................................................................................................26

4 Disassembly/assembly steps ..................................................................................... 26

5 Assembly and adjustment steps ................................................................................33

5.1 Assemble door lock........................................................................................33

5.2 Door adjustment............................................................................................. 36

II. Disassembly/Assembly and Maintenance of Rear Door ................................................. 37

1 Preparation................................................................................................................ 37

2 Note...........................................................................................................................37

3 Disassembly steps..................................................................................................... 37

4 Assembly and adjustment steps ................................................................................40

4.1 Assembly of rear door glass................................................................................... 40

Chapter Four Disassembly/Assemlby and Maintenance of the Front and Rear Bumper................ 41

I. Disassembly/assembly and maintenance of front bumper................................................ 41

1 System diagram......................................................................................................... 41

2 Preparation................................................................................................................ 41

3 Note...........................................................................................................................41

4 Disassembly steps..................................................................................................... 41

5 Assembly and maintenance....................................................................................... 43

II. Disassembly/assembly and maintenance of rear bumper ................................................44

1 System diagram......................................................................................................... 44

2 Preparation................................................................................................................ 44

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3 Note...........................................................................................................................44

4 Disassembly steps..................................................................................................... 44

5 Assembly steps..........................................................................................................46

Chapter Five Disassembly/Assembly and Maintenance of Front Headlamp and Fog Light ....... 47

1 System diagram............................................................................................................47

2 Preparation................................................................................................................... 47

3 Note...........................................................................................................................47

4 Disassembly steps for headlamp ............................................................................... 48

5 Disassembly of fog lamp...........................................................................................49

6 Installation and adjustment of headlamp................................................................... 50

6.1 Assembly steps of headlamp.......................................................................... 50

The installing steps of headlamp are reverse to those for removal. ........................50

6.2，Introduction of headlamp function................................................................. 50

6.2.1，Front view ...........................................................................................50

6.2.2 Back view............................................................................................50

6.3 Adjustment for headlamp beam .....................................................................51

Chapter Six Disassembly/Assembly of Roof and Scuttle ............................................................52

I. Disassembly/Assembly of Roof .......................................................................................52

1 Preparation................................................................................................................ 52

2 Note...........................................................................................................................52

3 Disassembly/assembly of sunvisor ...........................................................................52

3.1 Disassembly steps ..........................................................................................52

3.2 Assembly steps...............................................................................................52

4 Disassembly/assembly of ceiling handle ..................................................................53

4.1 Disassembly steps ..........................................................................................53

4.2 Assembly steps...............................................................................................53

5 Disassembly/assembly of front ceiling light .............................................................53

5.1 Disassembly steps ..........................................................................................53

5.2 Assembly steps...............................................................................................54

6 Disassembly/assembly of rear ceiling light............................................................... 54

6.1 Disassembly steps ..........................................................................................54

7 Disassembly/assembly of A pillar protecting board..................................................55

7.1 Disassembly steps ..........................................................................................55

7.2 Assembly steps...............................................................................................55

8 Disassembly/assembly of B pillar protecting board..................................................55

8.1 Disassembly steps ..........................................................................................55

8.2 Assembly steps...............................................................................................56

9 Disassembly/assembly of C pillar and D pillar protecting board.............................. 56

9.1 Disassembly steps ..........................................................................................56

9.2 Assembly steps...............................................................................................57

10 Disassembly/assembly of the roof ..........................................................................57

10.1 Disassembly steps ........................................................................................57

10.2 Assembly steps............................................................................................. 58

II. Disassembly of Scuttle Assembly ...................................................................................59

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1 Preparation................................................................................................................ 59

2 Disassembly steps..................................................................................................... 59

3 Assembly steps..........................................................................................................59

III. Decomposing of Scuttle Assembly ................................................................................60

1 Preparation................................................................................................................ 60

2 Disassembly/assembly of scuttle glass......................................................................60

2.1 Disassembly steps ..........................................................................................60

2.2 Assembly steps...............................................................................................61

3 Disassembly and assembly of scuttle motor and scuttle control unit........................ 62

3.1 Disassembly steps ..........................................................................................62

3.2 Assembly steps...............................................................................................63

4 Disassembly/assembly of scuttle sun visor............................................................... 64

4.1 Disassembly steps ..........................................................................................64

4.2 Assembly steps...............................................................................................64

IV. Guide for scuttle maintenance........................................................................................64

1 Reset scuttle control unit........................................................................................... 64

2 Typical fault diagnosis and trouble shooting.............................................................65

2.1 Scuttle looses it original position ...................................................................65

2.2 Water leaking of scuttle assembly.................................................................. 65

2.3 Strange noise of scuttle assembly ..................................................................65

3 Frequently appeared fault and their check and maintenance methods...................... 66

4 Maintenance note and daily service .......................................................................... 67

Chapter Eight Disassembly/Assembly of Instrument Panel ........................................................68

I. Disassembly of instrument panel accessories...................................................................68

1 Preparation................................................................................................................ 68

2 Disassembly/assembly of central control panel and fog lamp switch....................... 68

2.1 Disassembly steps： ......................................................................................68

2.2 Assembly steps：...........................................................................................69

3 Disassembly/assembly of AC control panel..............................................................69

3.1 Disassembly steps ..........................................................................................69

3.2 Assembly steps...............................................................................................69

4 Disassembly/assembly of audio ................................................................................ 69

4.1 Disassembly steps ..........................................................................................69

4.2 Assembly steps...............................................................................................69

5 Disassembly/assembly of front ashtray.....................................................................70

5.1 Disassembly steps ..........................................................................................70

5.2 Assembly steps...............................................................................................70

6 Disassembly/assembly of glove box ......................................................................... 70

6.1 Disassembly steps ..........................................................................................70

6.2 Assembly steps...............................................................................................71

7 Disassembly/assembly of combined instrument ....................................................... 71

7.1 Disassembly steps ..........................................................................................71

7.2 Assembly steps...............................................................................................72

8 Disassembly of steering wheel..................................................................................72

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8.1 Disassembly steps ..........................................................................................72

8.2 Assembly steps...............................................................................................73

9 Disassembly/assembly of headlamp combined.........................................................73

switch, wiper switch, ignition switch, coil cable ............................................................73

(Please refer to disassembly/assembly of........................................................................73

steering column in Chassis Service Manual) ..................................................................73

II. Disassembly of Instrument Panel .................................................................................... 74

1 Disassembly/assembly of instrument panel ..............................................................74

1.1 Disassembly steps ..........................................................................................74

1.2 Assembly steps of instrument panel...............................................................76

2 Disassembly of instrument cross beam..................................................................... 77

2.1 Disassembly steps ..........................................................................................77

2.2 Assembly steps...............................................................................................80

Chapter Nine AC System............................................................................................................. 81

I. System Composition.........................................................................................................81

II. Disassembly of evaporator assembly .............................................................................. 81

1 Preparation................................................................................................................ 81

2 Disassembly steps..................................................................................................... 81

3 Installation of evaporator assembly .......................................................................... 83

4 Disassembly/assembly of interior evaporator ........................................................... 83

4.1 Blower replacement .......................................................................................83

4.1.1 Disassembly steps ...............................................................................83

4.1.2 Assembly steps.................................................................................... 83

5 Disassembly/assembly of blower speeder module....................................................83

5.1 Disassembly steps ..........................................................................................83

5.2 Assembly steps...............................................................................................84

6 Disassembly/assembly of heating water tank ...........................................................84

6.1 Disassembly steps ..........................................................................................84

6.2 Assembly steps...............................................................................................86

7 Disassembly/assembly of mode ventilator................................................................ 86

motor and related mechanism .........................................................................................86

7.1 Disassembly/assembly steps .......................................................................... 86

7.2 Assembly steps...............................................................................................87

8 Disassembly/assembly of mixing ventilator motor and related mechanism ............. 87

8.1 Disassembly steps ..........................................................................................87

8.2 Assembly steps...............................................................................................88

9 Disassembly/assembly of inside/outside circulation ventilator motor and related

mechanism ......................................................................................................................88

9.1 Disassembly steps ..........................................................................................88

9.2 Assembly steps...............................................................................................88

10 Disassembly/assembly of evaporator...................................................................... 88

10.1 Disassembly steps ........................................................................................88

10.2 Assemble evaporator assembly.................................................................... 89

11 Disassemble other accessories from evaporator......................................................89

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11.1 Disassembly steps ........................................................................................89

11.2 Assemble of other accessories for evaporator .............................................. 90

III. Trouble shooting ............................................................................................................90

Chapter Ten Body Size ................................................................................................................93

I. Beam Dimension ..............................................................................................................94

II. Body assembly dimension...............................................................................................95

1 Front view .................................................................................................................95

2 Rear view ................................................................................................................ 100

3 Left side view－1....................................................................................................... 105

4 Left side view-2 ......................................................................................................... 113

III．Engine Compartment Dimension.................................................................................. 117

IV. Windscreen Dimension ................................................................................................ 118

V. Dimension of All the Opening....................................................................................... 119

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Chapter One Engine Hood And Luggage Compartment

I. Disassembly and assembly of engine hood

1 Preparation

Tool: flat head screwdriver, pliers, wrench

2 Note

2.1 Pay attention to use correct force during disassembly and assembly , and it is not allowed to

operate with too big force.

2.2 Pay attention to avoid scoring the surface during the inner trimming parts disassembly and

assembly.

3 Disassembly/assembly of engine hood accessories

3.1 Disassembly steps

3.1.1 Take off the snap clips(19 pieces) by screwdriver from

heat insulator, and take off the engine heat insulator.

3.1.2 Take off the hose of washing liquid.

3.1.3 Take off two water nozzle clips from engine hood, Push

the nozzles under the hood and get out of the nozzles front

outside.

3.2 Assembly steps

The installing steps are reverse to those for removal.

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4 Disassembly and adjustment of the engine hood assembly

Tool: No. 13 spanner

4.1 Take off four adjusting bolts from engine hood.

And disassemble the engine hood.

At the same time, through unscrewing four adjusting bolts,

move and adjust the position of engine hood.

4.2 Assembly of front engine hood assembly:

The installing steps are reverse to those for removal.

Installation torque: 29±3Nm

5 Disassembly and assembly of air intake grille assembly

Tool: No. 10 spanner

5.1 Disassembly steps

5.1.1 Take off four fixing bolts by spanner from air intake

grille assembly, see the chart.

5.1.2 Take off air intake grille.

Note: take off the air intake grille horizontally to avoid to

damage the clips on the grille.

5.2 Assembly of air intake grille

The installing steps are reverse to those for removal.

Installation torque: 5±0.5Nm

6 Adjustment and assembly of the engine hood lock

Tool: No.10 spanner

6.1 Disassembly steps

6.1.1 Disassemble the front engine hood lock by unscrewing

these three centering bolts from engine hood.

And also the lock position can be adjusted by these three

centering bolts.

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6.1.2 Take off the lock cable from engine hood.

6.2 Assembly of engine hood lock

The installing steps are reverse to those for removal.

Installation torque: 9±1Nm

7 Disassembly of engine hood lock control cable

Tool: No. 8 spanner, No.10 spanner, flat head screwdriver

7.1 Disassembly steps

7.1.1 Disassemble two fixing bolts from engine hood opening handle inside of the cab.

Installation torque: 9±1Nm

7.1.2 Take off the front cover control cable from cover.

7.1.3 Take off engine hood lock, and disassemble the

cable from engine hood lock assembly.

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7.1.4 Unscrew two clips from fixing cable by flat head

screwdriver.

7.1.5 Disassemble front bumper and driver’s side

fender (see fender disassembly)

7.1.6 Take out the plug where the cable go through

to cab.

7.1.7 Take out of the cable.

7.2 Assembly steps

The installing steps are reverse to those for removal.

Note: put the slot into pulling slot during cable installation.

II. Disassembly and assembly of rear

luggage compartment lid.

1 Preparation

Tool: flat head screwdriver, No. 13 socket spanner

Material: snap clip

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2 Disassembly of rear lid trim panel

2.1 Disassembly steps

Tool: No. 13 spanner

2.1.1 Take away the luggage compartment inside panel.

2.1.2 The snap clips on the inside panel are one time

using and should be carefully disassembly.

2.2 Installation of rear lid trim panel

The installing steps are reverse to those for removal.

3 Disassembly/assembly of luggage compartment lock

3.1 Disassembly steps

Tool: No. 10 spanner

3.1.1 Separate the motor plug of upper lock

3.1.2 Take away three positioning bolts from luggage
compartment lock. (Installation torque is 9±1Nm）

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3.1.3 Disassemble the pull rod

3.1.4 Take off control cable

3.1.5 Take off luggage compartment lock

3.2 Assembly steps

The installing steps are reverse to those for removal.
Note for installation：Observe the lock core for deformation,

the welding is correct or not, if the lock bushing is well, and
if the lock latch is flexible.

4 Disassembly of luggage compartment lock core

Tool: No. 10 socket spanner

4.1 Disassembly steps

4.1.1 Separate connect rod away from lock core

4.1.2 Loose the fixing bolt by socket spanner
(Torque is 9±1Nm）， Take off the lock core.

Note: Do not throw away the washer of the lock core.

4.2 Assembly steps

The installing steps are reverse to those for removal.

Pay attention to assemble it to its correct position and joint

to door plate work.

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5 Disassembly of rear wiper water nozzle

Tool: flat head screwdriver

5.1 Disassembly steps

5.1.1 Take out the rear water injection nozzle

(Prize it by flat head screwdriver but avoid to damage the

surface paint)

5.1.2 Enhance the nozzle and expose the water injection

hose

5.1.3 Take out the water injection hose

5.2 Assembly steps

The installing steps are reverse to those for removal.
Note：Water injection opening should be opposite to wiper

motor steering shaft.

6 Disassembly of rear wiper motor

6.1 Disassembly steps

Tool: No. 10 socket spanner

6.1.1 Take away the rear wiper protecting cover by hand

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6.1.2 Screw off the nut above the motor by No. 10

spanner and take out the rear wiper blades.

6.1.3 Disassemble these three fixing bolts from wiper

motor. Installation torque is 12±2Nm

6.1.4 Take off motor plug and take out of motor.

6.2 Assembly steps

The installing steps are reverse to those for removal.

7 Disassembly of license plate light trim panel

Tool: No. 10 socket

7.1 Disassembly/assembly steps

7.1.1 Disassemble the rear wiper motor first ( see rear

wiper motor disassembly)

7.1.2 Take out 7 nuts from the installation holes

below the luggage compartment.

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7.1.3 Disassemble the trim panel

7.2 Assembly steps

The installing steps are reverse to those for removal.

8 Disassembly of luggage compartment handle

Tool: No. 10 socket spanner

8.1 Disassembly steps

8.1.1 Disassemble rear wiper motor
（see disassembly of rear wiper motor）

8.1.2 Separate luggage compartment handle cable

8.1.3 Take off seven nuts from rear license plate light

trim cover

8.1.4 Disassemble the license plate light trim panel

(See disassembly and assembly of license plate light

trim panel)

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8.1.5 Disassemble luggage compartment handle fixing

bolts by socket spanner and get off the luggage compart

ment handle.

8.2 Assembly steps

The installing steps are reverse to those for removal.

9 Disassembly of license plate light

Tool: flat head screwdriver

9.1 Disassembly steps

9.1.1 Take out the luggage compartment inside trim

panel (See disassembly of rear lid)

9.1.2 Disassemble the license plate light trim panel

(See disassembly of license plate light trim panel)

9.1.3 Break the connection plug of left and right

license plate light

9.1.4 Disassemble the fixing screw and license plate

light by cross head screwdriver.

Note: the right rear license plate light plug is located

inside of the rear cover and difficult to be pull out and

insert, disassemble the bulb of license plate light and

then pull out and insert.

9.1.5 Take off the license plate light

9.2 Assembly steps

The installing steps are reverse to those for removal.

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Chapter Two Disassembly and Assembly of Inner Trimming

Parts

I. Disassembly and assembly of seat belt

1 Preparation

Tool: flat head screwdriver, spanner

Parts: one time using snap clip

2 Note

Keep the seat belt clean and far away from oil, check it

for damage.

3 Disassembly steps（e.g. front seat belt）

3.1 Prize the front threshold pressing plate carefully

with flat head screwdriver.

3.2 Disassemble the front door weather strip.

3.3 Disassemble the rear door threshold pressing panel

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3.4 Disassemble rear door opening weather strip

3.5 Disassemble the seat belt lower trim cover

3.6 Loose the fixing nut, take out B pillar lower

protecting panel. Installation torque is 50±5Nm

3.7 Prize seat belt adjuster trim cover by flat head

screwdriver and make sure do not damage the inside clip

3.8 Loose the fixing nut by No. 17 spanner and take

off the seat belt.

Installation torque is 50±5Nm

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4 Assembly steps

The installing steps are reverse to those for removal.

Note:

4.1 Keep the seat belt clean and far away from oil, check

it is damaged or not.

4.2 The pillar protecting board should be matched closely

with body and not allowed to appear loosing; and the match

with roof and weather strip should be good.

4.3 The seat belt adjusting slide back plate should can be

adjusted flexible on B pillar, and it will not influence the

seat belt adjustment. Clearance with lower protecting board

should be less than 1mm;

4.4 Clearance between B pillar lower protecting panel

and front/rear threshold pressing plate should be less than

1mm;

II. Disassembly/assembly of seat

Tool: No.16 sleeve

1 Disassembly steps

1.1 Push the seat back by pulling the moving

handle under the left seat and expose the lower fixing bolt.

1.2 Disassemble these two fixing bolts by sleeve

under the seat.

1.3 Move the handle by spanner and push forward the

seat, expose these two fixing bolts on the back side.

1.4 Disassemble these two fixing bolts at the back of seat by

sleeve.

1.5 Take off the connector under seat and take away the seat.

2 Assembly steps

The installing steps are reverse to those for removal.
Installation torque is 25±3Nm

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III. Disassembly and assembly of the Armrest Box and Sub

Instrument Panel

Tool: cross head screwdriver

1 Disassembly steps

1.1 Disassemble these 4 connection screw from armrest box and sub instrument panel by cross
head screwdriver（fasten torque is 2±0.5N.m）and take away the armrest.

1.2 Take away two bolts which connected between sub instrument panel and front lower
protecting board by cross head screwdriver (fasten torque is 2±0.5N.m）,and take down the sub

instrument panel and 5 lower connecting plugs.

2 Assembly steps

The installing steps are reverse to those for removal.

IV. Disassembly and assembly of carpet

Tool: flat head screwdriver, cross head screwdriver; sleeve

1 Disassembly steps

1.1 Disassemble the seat (See disassembly of seat)

1.2 Disassemble threshold pressing plate, B pillar and C

pillar lower protecting board (See disassembly of B pillar

and C Pillar)

1.3 Disassemble A pillar lower trim panel

1.4 Disassemble armrest box and sub instrument panel (See

disassembly of armrest box and sub instrument panel)

1.5，Prize the cover on the driver pedal by flat head

screwdriver.

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1.6 Take away two fixing screws on the driver pedal with

socket spanner and take off the pedal.

Installation torque is 7±1N.m

1.7 Take off the carpet by taking off the carpet connectors

2 Assembly of carpet

2.1 Put the carpet into car, take out the cable which

connected to seat and press the bypass way carpet solidly

2.2 Pave the left front carpet to brake pedal and expose

the hole from the carpet holes

2.3 Pave the carpet left, middle and rear side along the car

bottom shape solidly and expose the front and rear seat

installation holes.

2.4 Pave the carpet right front side to evaporator

underside

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2.5 Take out the connecting cable of right front seat

from carpet holes and pave it solidly

2.6 Pave carpet right, rear and middle side along to the

shape of car bottom and expose right front seat installation

holes

2.7 Pave the carpet rear side along car bottom

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Front right shock absorber

（

B14-5110013

）

）

C

entral right shock absorber

（

B14-5110023

）

V. Disassembly of Shock Absorber

1 Disassembly steps

1.1 Disassemble the carpet (See disassembly of carpet)

1.2 Take off all the shock absorbers

The positions of shock absorber are shown as below chart

Left front shock absorber

（B14-5110011）

（B14-5110017）

Central passage left shock absorber

Central left shock absorber

（B14-5110021）

Central passage right shock absorber（B14-5110019）

Central passage rear shock absorber（B14-5110037

Right rear shock absorber（B14-5110033）

Left rear shock absorber（B14-5110031）

2 Assembly steps

2.1 The installing steps are reverse to those for removal.

2.2 Note of installation：

2.2.1 Tidy up the seat and rear oxygen sensor connecting cable before installing the shock

absorber.

2.2.2 Make the shock absorber lower surface joint tightly with plate work.

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Chaper Three Disassembly/Assembly and Maintenance of

Door

I. Disassembly/assembly and maintenance of front door

1. System diagram

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2 Preparation

Tool: flat head screwdriver, cross head screwdriver, No. 7, 10 and 13 sleeve and pliers.

3 Note

3.1 To prevent accident please wear labor protection appliance.

3.2 Break down accumulator to avoid damage the electrical units.

3.3 Use the correct method to disassemble and assemble the glass

to avoid damage.

4 Disassembly/assembly steps

4.1 Disassemble door seal. The fixing clip is one type, press

upside of the seal during disassembly and push it to one direction

until one corner of the clip is exposed. And push the seal to opposite

direction until another corner is exposed. Do not drug the seal at its

perpendicular direct which will damage the seal.

4.2 Prize the plastic trim block which fix the outside rearview

mirror by flat screwdriver.

4.3 Unscrew these two fixing clips by cross head screwdriver

from front door panel.

4.4 Unscrew fixing screws from front door handle cover by cross

head screwdriver. Take off window regulator switch cable plug and

electrical rearview mirror adjuster switch plug.

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4.6 Take out the cable clip of inside opening cable handle by

hand

4.7 Take off the courtesy light plug at the same time of getting

of front door panel assembly.

4.8 Disassemble two fixing screw from front door handle

cover by cross head screwdriver.

4.9 Tear down front door water proof plastic clothing.
（See disassembly of front door protecting panel assembly）

4.10 Pull out outside electrical control rearview mirror cable

plug (See disassembly of outside rearview mirror)

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4.11 Unscrew three fixing bolts from outside rearview mirror by

No. 10 socket.

4.12 Prize front door inside and outside weather strip by
screwdriver.（See disassembly of window regulator system）

4.13 Connect window regulator switch to cable again and

decrease the glass to its lowest position.

4.14 Loose two fixing screws on the glass by cross head

screwdriver.

And take out the glass assembly. Torque is 2.5±0.5 N.m.

4.15 Take off up and lower fixing bolts from window regulator

by No. 10 socket. Torque is 7±1 N.m.

4.16 Disassembly three fixing bolts from window regulator

motor by No.10 socket. Torque is 7±1 N·m.

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4.17 Unscrew these two fixing bolts from front glass guide

by No. 10 socket and take out front glass guide.

Torque is 9±1 N·m.

4.18 Disassemble two fixing bolts from rear glass guide by

No. 10 socket. Take out rear glass guide and glass slot

assembly. Torque is 9±1 N·m.

4.19 Unscrew four fixing screws from front door sound box

by cross head screwdriver. Take out sound box assembly.

Installation torque is 1.5±0.5 N.m.

4.20 Loose the fixing clip on door handle pull rod lock.
（See disassembly of front door lock）

4.21 Loose the fixing clip on the lock of front door lock core

pull rod by hand.

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4.22 Loose safety lock pull rod fixing clip by hand.

4.23 Loose inside control cable fixing clip by hand.

4.24 Disassemble three front door lock fixing bolts by spline

wrench. Installation torque is 9±1N.m

(With thread locking rubber)

4.25 Rotate the lock cable direction to a certain degree and

take off the cable plug. Take out the lock assembly.

4.26 Disassemble the front door handle fixing screw by

spline wrench. Installation torque is 8±1 Nm

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4.27 Prize the front door lock core fixing screw protecting

panel by flat head screwdriver.

4.28 Disassemble front door lock core fixing screws.

Note: The shim between lock core, door handle and car door

can not be ignored. Make sure assemble it during installation.

Otherwise it will influence the clearance between them.

Installation torque is 9±1 Nm

4.29 Take out lock core and handle assembly.

4.30 Loose two front door stopper fixing bolts by No.13

spanner. (See disassembly of front door hinge and stopper).

Torque is 36±4N.m.

4.31 Front door stopper is connected to body by a flexible

eye pin. This flexible eye pin is an elasticity pin made up of

steel, beat it by a hamper heavily during disassembly and get

it out.

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4.32 Disassemble the fixing bolts of front fender on door

by No. 10 socket. (See disassembly of fender) and

torque is 10±1 N.m

4.33 Disassemble the fixing bolts of fender on windscreen by

No. 10 socket.

Note: You must disassemble wiper and

front cover assembly before disassemble this bolt.

Torque is 10±1 N.m

4.34 Disassemble two fixing bolts of fender on engine hood

by No.10 socket. Torque is 10±1 N.m

4.35 Disassemble fixing bolt between bumper and mudguard

by No. 7 sleeve.

Installation torque is 2±0.5 N.m

4.36 Prize the connection clip between front bumper and fender

by flat head screwdriver. Unscrew the plastic clip between

bumper

and fender by cross head screwdriver.

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4.37 Unscrew two fixing bolts between fender and bumper

by No. 10 socket. Torque is 10±1 N.m

4.38 Unscrew two fixing bolts between fender and body

underside by No.10socket. Torque is 10±1 N.m

4.39 Disassemble two fixing bolts between door hinge and

body by No. 13socket and take away the front door assembly.

Torque is 36±4 N.m

5 Assembly and adjustment steps

5.1 Assemble door lock

5.1.1 Insert cable plug into lock.

5.1.2 Block the clip of inside opening cable onto lock.

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5.1.3 Fix the safety lock pull rod onto lock.

5.1.4 Fix the lock onto door and fasten the fixing bolt, and it is

best to use thread locker.

Torque is 9±1Nm.

5.1.5 Assemble seal gasket to door handle and lock core.

5.1.6 Assemble door inside handle fixing holder and fasten the

screw. Installation torque is 8±1 Nm

5.1.7 Insert rear end of handle first and then the front end.

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5.1.8 Insert handle pull rod connection pin into handle.

5.1.9 Insert lock core.

5.1.10 Fasten lock core fixing bolt.

Installation torque is 9±1 Nm

5.1.11 Insert lock core pull rod into lock.

5.1.12 Insert handle pull rod into lock.

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5.2 Door adjustment

5.2.1 After the door is assembled, check the horizontal and

vertical clearance and closing force. If the clearance is not correct

or the closing force is too big, adjust it immediately. The

adjustment of door clearance see (body size)

5.2.2 The clearance adjustment can be finished by move the

hinge fixing bolts on body.

5.2.3 The door closing force adjustment can be finished by

adjusting front door lock striker position.
Torque is 9±1Nm。

5.3 Adjustment of door glass regulator system.

5.3.1 Check the window regulator system after this system is

assembled. The time of the glass from the lowest position to the

highest position should be around 7s. If the time is too long,

check the regulator in time.

5.3.2 Check window regulator motor.

5.3.3 Check if there is oil or dust inside of glass slot which

cause big resistance force when the glass is rose.

Note: Do not lubricate the glass slot or glass to avoid dust

absorption.

5.3.4 Check if there is deviation of glass guide position, which

cause the rising radian is not consistent to block the glass. The

position of glass guide can be adjusted by the guide fixing bolts.

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II. Disassembly/Assembly and Maintenance of Rear Door

1 Preparation

Flat head screwdriver, cross head screwdriver, No.7, 10, 13 sleeves

and pliers.

2 Note

2.1 To prevent accident please wear labor protection appliance.

2.2 Break down accumulator to avoid damage the electrical

units.

2.3 Use the correct method to disassemble and assemble the

glass to avoid damage.

3 Disassembly steps

3.1 Disassemble door weather strip. The fixing clip is one type,

press upside of the strip during disassembly and push it to one

direction until one corner of the clip is exposed. And push the seal

to opposite direction until another corner is exposed. Do not drug

the seal at its perpendicular direct which will damage the weather

strip.

3.2 Prize two rear door glass slot protecting boards by flat head

screwdriver.

(See front door disassembly to disassemble weather strip)

3.3 Unscrew armrest cover fixing screws by cross head

screwdriver.

3.4 The fixing clip of rear door trim panel is inside hiding clip,

prize the clip around trim panel by screwdriver equably.

3.5 Take out he inside opening cable fixing clips, and take off

door protecting panel assembly.

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3.6 Unscrew two armrest bracket fixing screws by cross head

screwdriver.

3.7 Take off the water proof plastic clothing by hand.

3.8 Prize rear door outside weather strip fixing clips by flat

head screwdriver and take out the strip from one end. Take out

inside weather strip. Pay attention to that outside strip has metal

slot, and it will deform the metal slot if pull out the strip from

perpendicular direction.

3.9 Make the glass to its lowest position and loose two glass

fixing screws by cross head screwdriver.

Torque is 5±0.5 N·m

3.10 Loose front and rear glass guide fixing bolts by No. 10 sleeve

and take out of the glass guide. Take out glass assembly by hand. Pay

attention that stand outside of car door and take the narrow side first

and then the wide side.

Torque: Upside is 2±0.5 N·m

Lower side is 9±1 N·m

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3.11 Loose the fixing bolts to fix the window regulator motor

and guide, and take out the window regulator assembly.

Torque is 7±1 N.m

3.12 Unscrew four sound box fixing screws by cross head

screwdriver, and take out sound box assembly.

Installation torque is 1.5±0.5N.m

3.13 Disassemble rear door lock assembly according to the

order to disassemble front door lock. (Disassembly of rear door

lock)

3.14 Unscrew rear door stopper fixing bolts by No. 13 sleeve and

spanner. (Disassembly of stopper and hinge)

3.15 Loose hinge fixing bolts by No. 13 spanner and

disassemble rear door assembly. Torque is 36±4 N.m

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4 Assembly and adjustment steps

4.1 Assembly of rear door glass

4.1.1 Assemble window regulator slot.

4.1.2 Assemble window regulator assembly onto the door.

4.1.3 Put the narrow side of the glass into door from outside of the door and then put the wide

side into the door.

4.1.4 Fix the glass onto window regulator by screw.

4.1.5 Connect glass regulator switch plug and rise the glass。

to its highest position.

4.1.6 Assembly glass guide.

4.1.7 For other assembly steps, please refer to disassembly

steps.

4.1.8 Rear door clearance can not be adjusted by hinge

adjustment. If the door clearance is not correct, the only way to

correct it is to correct body

(See body size)

4.1.9 Please refer to front door assembly and disassembly for

other adjustment.

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Chapter Four Disassembly/Assemlby and Maintenance of the

Front and Rear Bumper

I. Disassembly/assembly and maintenance of front bumper

1 System diagram

Front and rear bumper

2 Preparation

Tool: No. 7 and No10 sleeve, cross head screwdriver and flat head screwdriver.

3 Note

3.1 To prevent accident, please wear labor protection appliance.

3.2 To prevent scratch the bumper surface paint.

3.3 Carry out the disassembly and assembly at low temperature

environment, do not use big force, otherwise the bumper will be

broken.

4 Disassembly steps

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Service Manual for CHERY V525 Car Body Accessories

4.1 Unscrew four fixing bolts for grille web cover water tank cross
beam by No. 10 sleeve.（See right figure）

4.2 Loose fixing bolts of bumper on water tank cross beam by

No. 10 sleeve.

Torque is 11N·m

4.3 Unscrew bumper two fixing screws at lower cross beam by

flat head screwdriver.

4.4 Unscrew mudguard two fixing bolts under bumper by No.7

sleeve.

Installation torque is 2±0.5 Nm

4.5 Unscrew mudguard fixing bolt beside the bumper by No. 7

sleeve.

Installation torque is 2±0.5N.m

4.6 Pull out bumper by hand from fender fixing base.

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Service Manual for CHERY V525 Car Body Accessories

4.7 Pull out fog lamp plug by hand, and take out bumper

assembly.

4.8 Unscrew two bolts which fix shock absorber foam onto

bumper reinforcement member by No. 13 sleeve.

Torque is 3N·m

4.9 Unscrew three front bumper reinforcement member fixing

bolts and one fixing nut by No. 13 sleeve.

Torque is 25±3N.m

4.10 Unscrew bumper both sides air intake grille fixing screws

by cross head screwdriver.

4.11 Unscrew six bumper middle air intake grille fixing screws

by cross head screwdriver.

5 Assembly and maintenance

5.1 The installing steps are reverse to those for removal.

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Service Manual for CHERY V525 Car Body Accessories

II. Disassembly/assembly and maintenance of rear bumper

1 System diagram

Front and rear bumper

2 Preparation

Tool: cross head screwdriver, flat head screwdriver, No. 7 sleeve.

3 Note

3.1 To prevent accident, please wear labor protection appliance.

3.2 To prevent scratch the bumper surface paint.

3.3 Carry out the disassembly and assembly at low temperature environment, do not use big

force, otherwise the bumper will be broken.

4 Disassembly steps

4.1 Open luggage compartment lid, unscrew two fixing clips on

rear bumper by cross head screwdriver ( e.g. left side)

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Service Manual for CHERY V525 Car Body Accessories

4.2 Loose fixing screw and clip between rear bumper and rear

mudguard by No. 7 sleeve and cross head screwdriver.

Torque is 7N·m

4.3 Loose two lowest fixing screws between rear mudguard and

rear bumper by No. 7sleeve.

4.4 Loose fixing clip between rear bumper and body by cross head

screwdriver.

4.5 Prize rear bumper fixing clip on rear fender by hand.

4.6 Take off plugs of rear fog lamp and reverse radar probe

cable. And take off rear bumper assembly.

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Service Manual for CHERY V525 Car Body Accessories

4.7 Prize reverse radar probe by flat head screwdriver from

bumper outside.

4.8 Loose two rear fog lamp fixing screws by cross head

screwdriver and take out of fog lamp assembly.

5 Assembly steps

The installing steps are reverse to those for removal.

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Service Manual for CHERY V525 Car Body Accessories

Chapter Five Disassembly/Assembly and Maintenance of

Front Headlamp and Fog Light

1 System diagram

Lights

2 Preparation

Tool: No. 10 sleeve and No. 7 open end wrench, cross head

screwdriver and flat head screwdriver.

3 Note

3.1 To prevent accident, please wear labor protection appliance.

3.2 To prevent scratch the bumper surface paint.

3.3 Carry out the disassembly and assembly at low temperature

environment, do not use big force, otherwise the bumper will be broken

3.4 Pay attention to the clip on the bumper during headlamp is

disassembled, big force will damage the clip.

3.5 Pay attention to not scratch the headlamp surface when

disassemble and place it .

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Service Manual for CHERY V525 Car Body Accessories

4 Disassembly steps for headlamp

4.1 Disassemble front bumper assembly first. (See

disassembly/assembly of bumper)

4.2 Loose headlamp two fixing bolts on engine hood cross beam

by No. 10 sleeve. Torque is 4.0±0.5N·m

4.3 Loose headlamp fixing bolt on AC condenser by No. 10

sleeve.

Torque is 4.0±0.5N·m

4.4 Loose clip seat fixing screw which is used to fix the bumper by

cross head screwdriver.

4.5 Loose headlamp fixing bolt by No. 10 sleeve.

Installation torque is 5±1 Nm

4.6 Unplug headlamp cable plug and take out the headlamp

assembly.

4.7 Screw off headlamp high beam seat cover.

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Service Manual for CHERY V525 Car Body Accessories

4.8 Press bulb fixing clip by hand and turn it upward, take the bulb

out.

4.9 Rotate the headlamp motor of 30 degrees clockwise, and take

out the motor and cable plug.

Note: The motor can not be maintained, if make sure there is

problem on the motor, open the motor cover to see if there is gear

falling down or block phenomenon. Replace with a new headlamp

assembly if the problem can not be solved by adjustment.

4.10 Screw off low beam bulb cover by hand.

4.11 Press the bulb fixing clip by hand and take out bulb assembly.

5 Disassembly of fog lamp

5.1 Disassemble bumper assembly. （ Refer to disassembly of
bumper）

5.2 Prize fog trim cover assembly by hand.

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Service Manual for CHERY V525 Car Body Accessories

5.3 Loose two fog lamp fixing nuts by No. 7 sleeve.

5.4 Take out fog light assembly.

6 Installation and adjustment of
headlamp

6.1 Assembly steps of headlamp

The installing steps of headlamp are reverse

to those for removal.

6.2，Introduction of headlamp function

6.2.1，Front view

See right figure:

1 Low beam light

2 Position light

3 High beam

4 Turn light

2

1

4

3

6.2.2 Back view

7

2 3

1

See right figure:

1 Low beam light holder

2 Plug for low, high and position

light

3 Position light holder

4 High beam light holder

5 Turn light holder and plug

6 Low beam up/down adjusting nut

7 Low beam left/right adjusting nut

8 High beam up/down adjusting nut

9 High beam left/right adjusting nut

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6

8

4

9

5

Service Manual for CHERY V525 Car Body Accessories

6.3 Adjustment for headlamp beam

6.3.1 Headlamp uses half closed light combination type. So it is easy to be maintained; it is

halogen light with less mechanism and high luminous intensity, which will prolong bulb life.

6.3.2 The correctness of headlamp adjustment will influence the driving safety. So it needs

special device to adjust the beam. Pay attention to law regulations and verify the following items

before adjustment:

a. Tire pressure should be correct;

b. Car is unload (except for spare tire and equipped tools, and include driver weigh for

sedan);

c. Park the car on horizontal road or place;

d. The lens surface of headlamp should be clean;

e. Check the power supplies if is working correctly, and the bulb installed correctly.

Move the adjustable mechanism on the light can adjust the beam up/down and left/right, operate it

with international standard. Adjuster for rough and fine up/down adjustment is one unit on casing

upside; adjuster for left/right on casing middle and lower side.
It needs take off headlamp cover to adjust right headlamp. Same to the symmetrical lay of left

headlamp adjustment mechanism and right headlamp.

6.3.3 Headlamp beam adjustment can be realized by moving beam adjusting nut or power

adjusting button (if it is equipped).

6.3.3.1 Insert cross head screwdriver to related

adjusting holes to adjust the beam.

6.3.3.2 Adjust the beam up and down by power adjusting

button on the instrument panel.

6.3.3.3 The norm central height for Chery V325 headlamp:
Low beam：717mm；High beam：755mm。

6.3.3.4 Adjust the headlamp beam according to international

standards:

During check headlamp low beam lighting position, irradiate the headlamp to the screen 10m far

away from headlamp, for low beam of passenger car, angle of cut-off line or height of midpoint
height should be 0.7H～0.9H （H is the midpoint height of headlamp, the same of below）, other
motor vehicles(except for tractor) should be 0.6H～0.8H. Deviation to left of horizontal direction

position headlamp low beam of motor vehicle (except for the vehicle with one front headlamp)is
not allowed to exceed 170mm，not exceed 350 mm to right.（From national standard）

6.3.3.5 Please input the standard data got from above into headlamp beam adjusting device for

future usage.

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CHERY V325 Service Manual Body Accessories

Chapter Six Disassembly/Assembly of Roof and Scuttle

I. Disassembly/Assembly of Roof

1 Preparation

Tool: No. 7, No. 8, No. 13 and No. 17 socket spanner, cross

head screwdriver and flat head screwdriver.

2 Note

2.1 Use correct force during operation to prevent damage

the parts and it is not allowed to operate with too big force.

2.2 Protect the part surface from scratching during the

disassembly/assembly of inner trim.

3 Disassembly/assembly of sunvisor

3.1 Disassembly steps

3.1.1 Loose left front sunvisor two fixing screws by

cross head screwdriver and the torque is 3±1Nm

3.1.2 Pull out left front sunvisor cable plug.

3.1.3 Take away left front sunvisor.

3.2 Assembly steps

The installing steps are reverse to those for removal.

3.3 Disassembly/assembly of right front sun visor, please

refer to that of left front sunvisor.

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CHERY V325 Service Manual Body Accessories

4 Disassembly/assembly of ceiling handle

4.1 Disassembly steps

4.1.1 Prize handle fixing screw cover by flat head

screwdriver.

4.1.2 Disassemble fixing screw by cross head screwdriver.

Torque is 9±3Nm

4.1.3，Take off the handle.

4.2 Assembly steps

The installing steps are reverse to those for removal.

4.3 Disassemble/assemble other handles refer to right front

handle.

5 Disassembly/assembly of front ceiling light

5.1 Disassembly steps

5.1.1 Prize front ceiling light cover by flat head

screwdriver.

Note: do not scratch part surface.

5.1.2 Loose front ceiling light fixing bolt.

Torque is 1.5±0.5Nm

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CHERY V325 Service Manual Body Accessories

5.1.3 Open glasses box and disassemble fixing screw.

Torque is 1.5±0.5Nm

5.1.4 Take off cable inserting.

5.1.5 Take off front ceiling light assembly.

5.2 Assembly steps

The installing steps are reverse to those for removal.

6 Disassembly/assembly of rear ceiling light

6.1 Disassembly steps

6.1.1 Prize rear ceiling light trim cover by flat head

screwdriver. Note: do not scratch trim part.

6.1.2 Unscrew rear ceiling light fixing bolt.

Torque is1.5±0.5Nm

6.1.3 Take off rear ceiling light.

6.2 Assembly steps

The installing steps are reverse to those for removal.

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CHERY V325 Service Manual Body Accessories

7 Disassembly/assembly of A pillar protecting board

7.1 Disassembly steps

7.1.1 Disassemble A pillar protecting board lower trim

cover.

7.1.2 Prize A pillar protecting board by flat head

screwdriver.

7.1.3 Take out A pillar protecting board.

7.2 Assembly steps

The installing steps are reverse to those for removal.

8 Disassembly/assembly of B pillar protecting board

8.1 Disassembly steps

8.1.1 Disassemble B pillar lower protecting board (refer

to disassembly/assembly of seat belt)

8.1.2 Disassemble B pillar upper protecting board fixing

screw by cross head screwdriver.

8.1.3 Prize B pillar upper protecting board by flat head

screwdriver.

Note: protect the trim part surface from scratching.

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CHERY V325 Service Manual Body Accessories

8.2 Assembly steps

The installing steps are reverse to those for removal.

9 Disassembly/assembly of C pillar and D pillar protecting board

9.1 Disassembly steps

9.1.1 Unscrew luggage compartment glove box two

fixing bolts by No. 7 socket spanner. Take out glove box.

Torque is 1.5±0.5N.m

9.1.2 Unscrew glove box rear panel assembly fixing

bolt by No.8 socket spanner. Take out glove box panel.

Torque is 5±1 N.m

9.1.3，Unscrew rear seat lower fixing bolt by No. 17 socket

spanner. Take out rear seats.

Torque is 25±3 Nm

9.1.4 Loose C/D pillar lower protecting board fixing

screws (totally two) by No. 10 sleeve.

Torque is 9±3Nm

9.1.5 Prize C/D pillar lower protecting board fixing

clip by flat head screwdriver.

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CHERY V325 Service Manual Body Accessories

9.1.6 Take off rear door opening rubber seal by hand.

9.1.7 Prize C/D pillar lower protecting board by

screwdriver, take off C/D pillar protecting board.

9.1.8 Prize D pillar upper protecting board and take off D

pillar upper protecting board.

9.1.9 Prize C pillar upper protecting board and take off C

pillar upper protecting board.

9.2 Assembly steps

The installing steps are reverse to those for removal.

10 Disassembly/assembly of the roof

10.1 Disassembly steps

10.1.1 Disassemble left and right sunvisors.

(Refer to disassembly/assembly of sunvisors)

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