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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Service Manual for Chery V525 Car Chassis
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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Service Manual for Chery V525 Car Chassis
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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Service Manual for Chery V525 Car Chassis
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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Service Manual for Chery V525 Car Chassis
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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