BRAKE

GENERAL INFORMATION 26-3 Inspection 26-19

Overview 26-3 Installation 26-19
Description 26-3 Brake Pedal Assembly 26-20
Specifications 26-4 Removal 26-20
Tools 26-5 Inspection 26-21
Installation 26-21
DIAGNOSIS & TESTING 26-7 Front Disc Brake Assembly 26-23
Diagnosis Content 26-7 Description 26-23
Problem Symptoms Table 26-7 On-vehicle Inspection 26-23
On-vehicle Inspection 26-8 Removal 26-24
Operation Step 26-8 Disassembly 26-25
ON-VEHICLE SERVICE 26-9 Inspection 26-26
Assembly 26-27
Brake Bleeding 26-9
Installation 26-29

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Operation Step 26-9
Front Brake Hose Assembly 26-30
Brake Fluid Replacement 26-12
Removal 26-30
Operation Step 26-12
Brake Fluid Reservoir Assembly
On-vehicle Inspection
26-13
26-13
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Installation
Rear Disc Brake Assembly
Description
26-31
26-32
26-32
Removal 26-13
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On-vehicle Inspection 26-33
Installation 26-14
Removal 26-33
Brake Master Cylinder Assembly 26-15
Disassembly 26-34
Removal 26-15
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Inspection 26-36
Installation 26-16
Assembly 26-37
Vacuum Booster with Brake
Installation 26-39
Master Cylinder Assembly 26-17
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Rear Brake Hose Assembly 26-40

On-vehicle Inspection 26-17
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Removal 26-40
Removal 26-18
Installation 26-40
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26-2 Chery Automobile Co., Ltd.

 26–BRAKE

GENERAL INFORMATION
BRAKE

Overview
Description
Front Ventilated Disc Brake Assembly

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3 6

4
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7
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BR0001001
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1 - Front Brake Caliper Assembly 2 - Front Brake Disc

3 - Front Hub 4 - Front Hub Bearing
5 - Bearing Retainer 6 - Front Dust Guard
7 - Front Steering Knuckle

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 26–BRAKE

Rear Solid Disc Brake Assembly

2
5

4
3

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BR0002001
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1 - Rear Steering Knuckle 2 - Rear Dust Guard
3 - Rear Hub Bearing Assembly 4 - Rear Brake Disc
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5 - Rear Brake Caliper Assembly

Brake system uses the following configuration: a ventilated disc brake is used for each front wheel, and
solid disc brake is used for each rear wheel (disc brake is used for service brake, and electric parking is
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used for parking brake).

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Using lever principle, brake pedal pushes the pushrod into vacuum booster, which boosts the force of
pushrod by using vacuum and then transmits the force to brake master cylinder assembly. Hydraulic
pressure, produced in the brake master cylinder assembly, is transmitted to ABS Hydraulic Control Unit
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(HCU) through the brake line, and then distributed to individual brake calipers. Brake calipers apply force
to brake linings using hydraulic pressure. Brake linings will cause wheel speed to decrease or stop
depending on the amount of brake pressure applied.

Specifications
Torque Specifications
Description Torque (N·m)
Wheel Mounting Bolt 110 ± 10
Master Cylinder Mounting Nut 13.7 ~ 21.6
Fixing Plug Between Brake Master Cylinder Assembly and Brake Pipe 18 ± 2
Fixing Nut Between Vacuum Booster Assembly and Brake Pedal
23 ± 2
Assembly
Fixing Nut Between Brake Pedal Assembly and Body 23 ± 2
Coupling Plug Between Front Brake Caliper Assembly and Front
20 ± 2
26 Brake Hose Assembly
Coupling Bolt Between Front Brake Caliper Assembly and Front
90 ~ 110
Steering Knuckle Assembly
Front Brake Disc Locating Screw 4.5 ± 0.5

26-4 Chery Automobile Co., Ltd.

 26–BRAKE

Description Torque (N·m)

Front Brake Caliper Bleeder Screw 9 ~ 11
Guide Bolt Between Front Brake Caliper Fixing Bracket and Front
22 ~ 32
Brake Cylinder Assembly
Coupling Plug Between Front Brake Hose Assembly and Front Brake
18 ± 2
Pipe
Coupling Bolt Between Rear Brake Caliper Assembly and Rear Brake
27 ± 2
Hose Assembly
Coupling Bolt Between Rear Brake Caliper Assembly and Brake
90 ~ 110
Caliper Mounting Board Assembly
Rear Brake Disc Locating Screw 4.5 ± 0.5
Rear Brake Caliper Bleeder Screw 9 ~ 11
Guide Bolt Between Rear Brake Caliper Fixing Bracket and Rear
22 ~ 32
Brake Cylinder Assembly
Coupling Plug Between Rear Brake Hose Assembly and Brake Pipe 18 ± 2
Parking Actuator Mechanism Fixing Screw 9 ~ 11

Front Disc Brake

Description Standard Thickness (mm) Minimum Thickness (mm) Brake Disc Runout (mm)

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Front Brake Disc 25 23 Less than 0.06
Front Brake Lining 11 2 -

Rear Disc Brake

Description Standard Thickness (mm)
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Minimum Thickness (mm) Brake Disc Runout (mm)
Rear Brake Disc 10 8 Less than 0.06
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Rear Brake Lining 10.2 2 -

Tools
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Special Tool
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G Type Pliers
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093

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Chery Automobile Co., Ltd. 26-5

 26–BRAKE

General Tools

Rear Brake Cylinder Release Tool

116

20
10

30
0

40
Dial Indicator and Magnetic Holder

90

50
80

60
70

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Vernier Caliper
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019
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Digital Multimeter
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002

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26-6 Chery Automobile Co., Ltd.

 26–BRAKE

DIAGNOSIS & TESTING

BRAKE

Diagnosis Content
Problem Symptoms Table
Hint:
Use symptoms table below to help determine cause of problem. Check each suspected area in sequence.
Repair or adjust faulty components, or replace as necessary.
Symptom Possible Cause Corresponding Measures
Brake disc thickness is out of limit thickness Check brake disc thickness difference
Real brake disc runout is out of limit amount Check real brake disc runout
Hub bearing is damaged or worn Check bearing damage
Brake assembly bolt becomes loose Check looseness of brake assembly bolt
Brake shakes
Steering/suspension part is loose or worn Check in accordance with Repair Manual
Tire dynamic balance Check in accordance with Repair Manual
Four-wheel alignment Check in accordance with Repair Manual
ABS operates Check in accordance with Repair Manual

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Spring plate is worn or deformed Check spring plate
Brake assembly bolt becomes loose Check looseness of brake assembly bolt
Abnormal noise occurs on bumpy
road brake caliper on bumpy road
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Abnormal noise is caused by slight axial movement of

Steering/suspension part becomes loose or shock

absorber is worn
Check guide pin and spring plate

Check in accordance with Repair Manual

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Loosen bleeder screw and discharge
Residual pressure in brake system
residual pressure
Bearing is damaged Check bearing
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Large sliding resistance of brake caliper Check sliding of brake caliper

Guide pin is deformed Check deformation of guide pin
Wheel dragging
Guide pin is not installed in place Check if guide pin is installed in place
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Guide pin dust boot is damaged Check if guide pin dust boot is damaged
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Linings are not installed correctly Check if tab of linings are installed in place
Drive shaft Check in accordance with Repair Manual
Chassis interference part Check in accordance with Repair Manual
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Metal scratching occurs during braking Check for interferences and alarms
Continuous "squeak" sound occurs for a longer time Check inside and outside linings for metal
during braking particles
Brake noise
A clear "click" sound occurs at the beginning of braking Check linings for looseness
Relevant bolts are loose Check in accordance with Repair Manual
Relevant parts are damaged Check in accordance with Repair Manual

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 26–BRAKE

On-vehicle Inspection
Operation Step
Warning/Caution/Hint
Caution:
• Use well-sealed brake fluid DOT4 or equivalent. DO NOT use oily solution, otherwise brake system
seal may be damaged.
• Brake fluid may damage paint surface. If brake fluid spills on paint surface, wash it off immediately with
water.
• DO NOT use gasoline, kerosene, alcohol, engine oil, transmission oil or any other fluid that contains
mineral oil to clean the system components. These kinds of fluid will damage the rubber cover and
seal.
• During servicing, be sure to clean the grease or other foreign matter on the outer surface of brake
caliper assembly, brake lining, brake disc and wheel hub.
• When operating brake disc and brake caliper, be careful not to damage brake disc and brake caliper
and scratch or cut brake shoe linings.
1. Check conditions of tires and wheels. Damaged or worn wheels and tires can cause a pull, shudder,
vibration and a condition similar to sudden braking.

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2. If noise occurs while braking, check suspension components. Bounce the vehicle up and down
several times and check suspension or steering components for any looseness, wear or damage.
3. Check brake fluid level and condition. co
(a) If brake fluid level is low, check ABS control unit assembly, brake caliper, brake line, brake
master cylinder assembly and brake fluid reservoir, etc. for leakage.
(b) If brake fluid is contaminated, drain a certain amount of fluid for inspection. Replace with new
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fluid as necessary.
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26-8 Chery Automobile Co., Ltd.

 26–BRAKE

ON-VEHICLE SERVICE
BRAKE

Brake Bleeding
Operation Step
Be sure to perform brake bleeding and clutch bleeding after replacing hydraulic parts related to brake and
clutch.
For details about clutch bleeding (See page 19-20)
There are 2 methods for brake bleeding, and specific operation procedures are as follows:
Method 1: Manual bleeding brake
Caution:
• When bleeding brake system, wear safety glasses.
• Be careful when bleeding air, as brake fluid at high pressure may spray out from bleeder screw.
Warning:
• Before removing brake fluid reservoir, wipe off any dust and other foreign matters on brake fluid
reservoir to prevent them from entering.
• Use fresh, clear and well-sealed brake fluid with specified type or equivalent.
• DO NOT allow the brake fluid to adhere to any paint surface, such as vehicle body. If brake fluid leaks

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onto any paint surface, immediately wash it off.
• During bleeding, do not depress brake pedal repeatedly at any time with bleeder screw opened.
Otherwise, air amount in the system will increase to make an extra bleeding.
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• DO NOT drain the brake fluid in brake fluid reservoir while bleeding brake system.
Hint:
• An assistant will be required to assist when bleeding brake system.
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1. Fill brake fluid reservoir with brake fluid to a proper level.
2. Loosen bleeder screw cap and connect a clear plastic hose to bleeder screw. Submerge the end of
hose into container.
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3. Have an assistant depress brake pedal 3 to 4 times

repeatedly; and depress and hold it at a lower position,
then loosen the bleeder screw.
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BR0003002

4. Tighten bleeder screw every time brake pedal goes

down quickly, then release the brake pedal.

BR0004002

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 26–BRAKE

5. Repeat above steps, and use the same procedures to

bleed brake line of each wheel in order of rear left wheel,
front left wheel, front right wheel and rear right wheel,
until no air exists in brake system.
Empty sign: A stream of fresh brake fluid flows into clear
container without bubbles.
Hint:
• During bleeding of brake system, make sure brake
fluid level in brake fluid reservoir is always near
"MAX" mark. Check brake fluid level at all times BR0005002

during bleeding. Add brake fluid as necessary.

6. Check and adjust the brake fluid level to "MAX" mark.
7. Check the brake pedal braking effect. If braking effect is poor or pedal is spongy, air may still exist in
system. Perform bleeding procedures for brake system again as necessary.
8. Test vehicle to confirm that brakes operate properly with good depressing feel.
Method 2: Bleeding brake using diagnostic tester
Warning:

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• Check that battery voltage should not be lower than 12 V.
• Bleeding order must be rear left/front left/front right/rear right.
• If it is necessary to repeat part or whole bleeding procedure, be sure to wait for 5 minutes to cool
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solenoid valve down, otherwise solenoid valve may be damaged due to overheat.
• Depress brake pedal repeatedly with a frequency of 0.5 times per second in the whole bleeding
process.
To reach sufficient pressure in hydraulic regulator, brake pedal needs to be depressed repeatedly during
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whole process.
9. Fill brake fluid reservoir with brake fluid to a proper level.
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10. Depress brake pedal more than 20 times with engine stopped.
11. Turn ENGINE START STOP switch to ON, and enter T18 "Anti-lock Brake System/Electronic Stability
Program" system using diagnostic tester.
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(a) Please select [ABS] on Diagnostic program screen.

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Diagnostic program
ENG System
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ABS
Help

ICM
File

BCM
PgUP

RADAR

pgDn
CLM

SRS Reset

RRM
Back

BR0005102

(b) Please select [Special function] on Diagnostic

program screen. Diagnostic program
Version information System

DTC
Help

Clear DTC
File

Data stream
PgUP

Freeze Frame Data

pgDn
Special function

Reset

26 Back

BR0005202

26-10 Chery Automobile Co., Ltd.

 26–BRAKE

(c) Please select [Repair Bleed] on Special function

screen. Special function
Yaw Sensor Calibration(ESP Only) System

Repair Bleed
Help

Write E&F Process Control Byte

File

PgUP

pgDn

Reset

Back

BR0005302

(d) Please select [Phase 1: Bleed the wheel rear left] on

Repair Bleed screen, then perform bleeding Repair Bleed

operation for rear left wheel. Phase 1:Bleed the wheel rear left System

Phase 2:Bleed the wheel front left

Help

Phase 3:Bleed the wheel front right

File

Phase 2:Bleed the wheel rear right

PgUP

pgDn

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Reset

Back

BR0005402

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12. Loosen bleeder screw cap of rear left wheel and connect
a clear plastic hose to bleeder screw. Submerge the end
of hose into container.
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BR0003002
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13. Use same bleeding procedures as rear left wheel to bleed air for brake lines of rear left wheel, front
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left wheel, front right wheel and rear right wheel, until no air exists in brake system.
Empty sign: A stream of fresh brake fluid flows into clear container without bubbles.
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Hint:
• During bleeding of brake system, make sure brake fluid
level in brake fluid reservoir is always near "MAX" mark.
Check brake fluid level at all times during bleeding. Add
brake fluid as necessary.

BR0005002

14. Check and adjust the brake fluid level to "MAX" mark.
15. Check the brake pedal effect. If braking effect is poor or pedal is spongy, air may still exist in system.
Perform bleeding procedures for brake system again as necessary.
16. Test vehicle to confirm that brakes operate properly with good depressing feel.
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 26–BRAKE

Brake Fluid Replacement

Operation Step
1. Drain the brake fluid.
(a) Start engine and run it at idle.
(b) Screw off filler cap of brake fluid reservoir assembly. Loosen bleeder screw cap and connect a
clear plastic hose to bleeder screw. Submerge the end of hose into container.
(c) Loosen bleeder screw, and depress brake pedal
continuously until no brake fluid comes out.

BR0003002

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2. Add brake fluid.
(a) Tighten bleeder screw after confirming that brake fluid has been drained. Fill brake fluid reservoir
with new brake fluid to a proper level.
3. Perform bleeding procedures.
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(a) After replacing with new brake fluid, be sure to bleed the brake system for normal operation.
For details of brake system bleeding (See page 26-9).
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26-12 Chery Automobile Co., Ltd.

 26–BRAKE

Brake Fluid Reservoir Assembly

On-vehicle Inspection
1. Check the brake fluid level warning switch.
(a) Remove the brake fluid reservoir filler cap.
(b) Disconnect the brake fluid level warning switch wire harness connector.
(c) Using ohm band of digital multimeter, check for
continuity between brake fluid level warning switch
+ -
terminals according to conditions shown in table
below.
1 2
Multimeter Connection Condition Specified Condition
Terminal 1 - Terminal 2 Float upward (switch ON) ’
Float downward
Terminal 1 - Terminal 2 ”1Ÿ
(switch OFF)

Hint: BR0006002
• There is a float in fluid reservoir. Position of float

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changes as brake fluid level rises or drops.
• If result is not as specified, replace brake fluid
reservoir assembly.
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(d) Unplug fluid level sensor connector when warning light comes on. If warning light remains on,
check wire harness and instrument cluster. If instrument cluster warning indicator goes off
immediately, the fluid level sensor is malfunctioning. (Precondition: Brake fluid is within scale
range)
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(e) Add brake fluid to MAX mark.
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Removal
1. Drain the brake fluid (See page 26-9).
Hint:
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• Drained brake fluid should be well kept in a container. Never discard it at will.
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Caution:
• Wash off brake fluid immediately if it comes in contact with any paint surface.
2. Remove the brake fluid reservoir assembly.
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(a) Disconnect the brake fluid level warning switch

connector (arrow).

BR0007002

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 26–BRAKE

(b) Disconnect clutch hose from brake fluid reservoir

assembly (for MT models).

Disposable part BR0008002

(c) Remove fixing screw (arrow) between brake fluid

reservoir assembly and brake master cylinder
assembly.
Tightening torque
5 ± 1 N·m

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BR0009002

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(d) Remove brake fluid reservoir assembly from brake master cylinder assembly.

Installation
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1. Installation is in the reverse order of removal.
Hint:
Perform bleeding procedures for brake system and add brake fluid to a proper level after completing
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installation.
Caution:
• Clutch hose only can be used once, and cannot be used repeatedly after removal and installation.
• After hose is bent, it is normal that some material between two corrugations is "whitish".
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26-14 Chery Automobile Co., Ltd.

 26–BRAKE

Brake Master Cylinder Assembly

Removal
Warning/Caution/Hint
Warning:
• To prevent brake master cylinder assembly damage and other dirt from being attracted by booster,
remove vacuum from vacuum booster before removing brake master cylinder assembly.
• Remove vacuum by depressing brake pedal repeatedly without engine running, until brake pedal is
depressed firmly.
• After removing brake line, sealing measure should be taken to prevent foreign matter form entering.
1. Drain the brake fluid (See page 26-9).
Hint:
• Drained brake fluid should be well kept in a container. Never discard it at will.
Caution:
• Wash off brake fluid immediately if it comes in contact with any paint surface.
2. Remove the air filter with intake hose.
3. Remove the brake fluid reservoir assembly (See page 10-8).

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4. Remove the brake master cylinder assembly (See page 26-9).
(a) Loosen 2 fixing plugs (arrow) between brake master
cylinder assembly and brake pipe.
Tightening torque
18 ± 2 N·m
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BR0009502

(b) Loosen 2 fixing nuts and washers (arrow) between

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brake master cylinder assembly and vacuum

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booster.
Tightening torque
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13.7 - 21.6 N·m

BR0010002

(c) Carefully slide brake master cylinder assembly vertically out of vacuum booster.
Caution:
• The design of brake master cylinder assembly and piston makes piston fall out easily. To
prevent the occurrence of this case, make sure the master cylinder is level or end surface
faces downward (piston surface facing upward) when operating brake master cylinder
assembly, to prevent master cylinder piston from dropping.
• Make sure that no foreign matter adheres to brake master cylinder assembly piston. If foreign
matter adheres, clean it off with a piece of clean cloth. Then, apply grease to entire outer
edge contact surface of the master cylinder piston.
• Master cylinder should be handled carefully. Avoid any impact to master cylinder, such as 26
dropping. It cannot be reused if dropped.
• DO NOT tap or pinch the master cylinder piston, and avoid damaging the master cylinder
piston in any other ways.

Chery Automobile Co., Ltd. 26-15

 26–BRAKE

Installation
1. Installation is in the reverse order of removal.
Caution:
• Be sure to tighten fixing bolt and nut to specified torque during installation.
• Perform bleeding procedures for brake system and add brake fluid to a proper level after
completing installation.
• Check if distance between brake master cylinder and brake pedal is within normal range after
installation.
Specified distance: 125 mm

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26-16 Chery Automobile Co., Ltd.

 26–BRAKE

Vacuum Booster with Brake Master Cylinder Assembly

On-vehicle Inspection
1. Check the vacuum booster assembly.
(a) Check air tightness:
• Start engine and stop it after 1 or 2 minutes, then disconnect negative battery cable. Slowly
depress the brake pedal several times.
• Make sure that booster is airtight. Check that every pedal depression amount becomes less
than the previous one. If pedal operation is not as specified, check the check valve. If check
valve is normal, replace the vacuum booster assembly.
• Start the engine. Depress and hold pedal, and then stop engine.
• Make sure that booster is airtight. Depress and hold pedal for 30 seconds, and check that
pedal reserve distance does not change.
(b) Check operation.
• Stop engine and disconnect negative battery cable.
• Depress the pedal several times and check that
pedal reserve distance does not change.

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BR0011002

• Depress and hold the pedal, and then start

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engine. Check that the pedal can only be

depressed slightly.
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BR0012002

• If pedal operation is not as specified, check the check valve. If check valve is normal, replace
the vacuum booster assembly.

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Chery Automobile Co., Ltd. 26-17

 26–BRAKE

Removal
1. Drain the brake fluid (See page 26-9).
Hint:
• Drained brake fluid should be well kept in a container. Never discard it at will.
Caution:
• Wash off brake fluid immediately if it comes in contact with any paint surface.
2. Disconnect the negative battery cable.
3. Remove the brake fluid reservoir assembly (See page 26-9).
4. Remove the vacuum booster with brake master cylinder assembly.
(a) Loosen 2 fixing plugs (arrow) between brake master
cylinder assembly and brake pipe.
Tightening torque
18 ± 2 N·m

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BR0009502

(b) Detach vacuum tube assembly with check valve

(arrow) from vacuum booster assembly.
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BR0013002
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(c) Remove locking pin (2) and push rod pin (1) from
vacuum booster push rod and disengage brake
pedal assembly.
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2
1

BR0014002

(d) Remove 4 fixing nuts (arrow) between vacuum

booster assembly and brake pedal assembly.
Tightening torque
23 ± 2 N·m

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BR0015002

(e) Move away the brake pedal.

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 26–BRAKE

(f) Remove vacuum booster with brake master cylinder assembly from engine compartment.

Inspection
1. Check the check valve.
(a) Remove check valve from vacuum tube assembly.
(b) Check that there is airflow (A) from vacuum booster
to engine, and no airflow (B) from engine to vacuum
booster. B
If result is not as specified, replace vacuum tube
assembly.
A

BR0016002

Installation

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1. Installation is in the reverse order of removal.
Caution:
• Be sure to tighten fixing bolt and nut to specified torque during installation.
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• Perform bleeding procedures for brake system and add brake fluid to a proper level after
completing installation.
• It is necessary to check or adjust brake switch assembly after removing vacuum booster with
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brake master cylinder assembly (Refer to installation of brake switch assembly).
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 26–BRAKE

Brake Pedal Assembly

Removal
1. Remove the brake light switch assembly.
(a) Disconnect brake light switch assembly wire
harness connector (1) and brake pedal fixing clip 1
(2).

BR0020002

(b) Press switch by hand and turn it counterclockwise,

align the switch body with lengthwise direction of
pedal installation hole, and pull out brake switch

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assembly along opening of pedal, then remove
brake switch assembly.

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BR0021002

2. Remove the brake pedal assembly.

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(a) Remove locking pin (2) and push rod pin (1) from
vacuum booster push rod and disengage brake
pedal assembly.
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BR0014002

(b) Remove 4 fixing nuts (arrow) between vacuum

booster assembly and brake pedal assembly.
Tightening torque
23 ± 2 N·m

BR0015002

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26-20 Chery Automobile Co., Ltd.

 26–BRAKE

(c) Remove fixing nut (arrow) between brake pedal

assembly and body.
Tightening torque
23 ± 2 N·m

BR0015102

(d) Remove brake pedal assembly from cabin.

Inspection
1. Check the brake light switch assembly.
(a) Using ohm band of digital multimeter, check for
continuity between brake light switch assembly
+ -
terminals according to table below.

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1 2
3 4
Multimeter Connection Switch Condition Specified Condition
Brake pedal depressed
Terminal 1 - Terminal 3 ”1Ÿ

Terminal 2 - Terminal 4
(switch pin released)
Brake pedal depressed
(switch pin released)
’
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Brake pedal released
Terminal 1 - Terminal 3 ’
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(switch pin pushed) BR0023002

Brake pedal released

Terminal 2 - Terminal 4 ”1Ÿ
(switch pin pushed)
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Hint:
• If result is not as specified, replace brake light
switch assembly.
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Installation
1. Install the brake pedal assembly. (Installation is in the reverse order of removal)
2. Install the brake switch assembly.
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(a) Before assembling brake switch to vehicle, the lever must be pulled out completely. If the switch
lever cannot be pulled out in the direction of axis, the lever has been pulled to the longest.
(b) Depress brake pedal fully, align brake switch body
with mounting hole of pedal and insert it into Buckle
mounting hole, press switch and turn it clockwise to
clamp switch clip into clip hole of pedal (before
assembly, brake pedal has been installed to brake
master cylinder).
Card hole

BR0064002

(c) Release brake pedal slowly to return brake pedal to initial position automatically under the action
of return spring, and automatically adjust brake switch lever to appropriate gear position
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 26–BRAKE

(d) Connect the back light switch assembly wire

harness connector (arrow).

BR0065002

(e) Installation is finished.

Caution:
• After completing installation, brake pedal should fully contact with brake switch lever (lever is
compressed).
• After brake pedal is fully depressed, the hand should not release pedal during auto return of
pedal and make pedal return to original position slowly. Avoid releasing pedal suddenly, large
impact may lead brake switch to jump.
• Be sure to tighten fixing nuts to specified torques during installation.

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• Check that brake light operates normally after installation.
• Check if brake pedal travel is within normal range after installing brake pedal.
Normal range: • 120 mm
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 26–BRAKE

Front Disc Brake Assembly

Description

1
2
3

14 5
6 8
7
13
9

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12

BR0024001
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1 - Brake Caliper Guide Bolt 2 - Brake Caliper Guide Bolt Guide Pin
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3 - Brake Caliper Guide Pin Rubber Dust Boot 4 - Front Disc Brake Cylinder
5 - Front Disc Brake Piston Seal Ring 6 - Front Disc Brake Piston
7 - Front Disc Brake Piston Dust Boot 8 - Front Disc Brake Caliper Fixing Bracket
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9 - Upper Support Shim 10 - Inner Brake Lining

11 - Outer Brake Lining 12 - Lower Support Shim
13 - Bleeder Screw 14 - Bleeder Screw Cap

On-vehicle Inspection
1. Check the brake disc runout.
(a) Remove the front wheel (See page 24-8).
(b) Fix dial indicator (1) to a proper position, then set its pointer to a position about 10 mm from out
edge of brake disc.

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 26–BRAKE

(c) Turn brake disc (2) slowly and check its runout,
mark the lowest and highest points and record these
measured value.
2

BR0025002

(d) Check the runout on the other side of brake disc in the same manner, mark the lowest and
highest points and record these measured value.
(e) Compare recorded runout value with limit value.
Front brake disc runout: Less than 0.06 mm
(f) If runout exceeds the maximum value, replace brake disc.

Removal
Warning/Caution/Hint

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Hint:
• Use same procedures for right and left sides.
• Procedures listed below are for left side.
1. Remove the front left wheel (See page 24-8).
2. Remove the front left brake caliper assembly.
co
(a) Remove 2 coupling bolts (1) between front left brake caliper assembly and front left steering
n.
knuckle.
Tightening torque
ag

90 ~ 110 N·m
(b) Remove coupling plug (arrow) between front left
brake caliper assembly and front left brake hose
assembly.
i
rd

Tightening torque
20 ± 2 N·m
1
Caution:
ca

• DO NOT allow brake fluid to be sprayed on your

clothes or skin when removing brake hose, as
brake fluid is corrosive.
BR0026002

(c) Remove the front left brake caliper assembly.

3. Remove the front left brake disc.
(a) Remove 2 locating screws (arrow) and front left
brake disc.
Tightening torque
4.5 ± 0.5 N·m

26
BR0028002

26-24 Chery Automobile Co., Ltd.

 26–BRAKE

Disassembly
Warning/Caution/Hint
Hint:
• Use same procedures for right and left sides.
• Procedures listed below are for left side.
1. Remove the bleeder screw (with bleeder screw cap).
(a) Remove bleeder screw (with bleeder screw cap)
(arrow) from brake caliper assembly.
Tightening torque
9 ~ 11 N·m

BR0029002

2. Remove the brake cylinder assembly.

m
(a) Remove 2 guide bolts (arrow) between brake
caliper fixing bracket and brake cylinder assembly.
Tightening torque
22 ~ 32 N·m
co
n.
ag

BR0030002

(b) Separate brake cylinder assembly from brake caliper fixing bracket.
3. Remove the front brake caliper guide bolt guide pin (with dust boot).
i

(a) Remove 2 brake caliper guide bolt guide pins (with

rd

dust boot) (arrow) from brake caliper fixing bracket.

ca

BR0031002

4. Remove the front brake lining.

(a) Remove inner brake lining and outer brake lining
(arrow) from brake caliper fixing bracket.

26
BR0032002

Chery Automobile Co., Ltd. 26-25

 26–BRAKE

5. Remove the brake lining support shim.

(a) Remove 2 brake lining support shims (arrow) from
brake caliper fixing bracket.

BR0033002

Inspection
1. Check brake caliper fixing bracket and brake caliper guide pin set.
(a) Clean the contact surfaces of brake caliper fixing bracket and brake lining support shims with
brake cleaner. Check for deformation, cracks, rust and foreign matter which is difficult to remove.
(b) Check brake caliper guide pin rubber dust boot for deformation, cracks, wear and foreign matter

m
which is difficult to remove.
(c) Install the brake caliper guide pin and its rubber dust boot to brake caliper fixing bracket. Brake
caliper guide pin set should move smoothly without sticking when pushing it with hand;
otherwise replace it. co
(d) After installing the brake lining, check if it is easy to drop (due to insufficient elasticity of support
shim). Replace as necessary.
n.
2. Check the brake lining.
(a) Visually check the brake lining for flatness, and also check for excessive wear. If the condition of
lining cannot be confirmed accurately only by visual inspection, perform physical inspection as
ag

necessary.
(b) Measure the minimum brake lining thickness. When
the minimum thickness of brake lining is 2 mm or
i

less, replace the brake linings.

rd
ca

BR0037002

(c) When replacing the excessively worn brake linings (inner and outer), it is also necessary to
replace the linings on opposite side of vehicle as well as unchecked linings to maintain proper
braking performance. If it is unnecessary to replace brake linings, be sure to reinstall brake
linings to original positions.
3. Check the brake disc.
(a) Minor scratch or wear on brake disc surface is acceptable. If severe scratch or deformation
exists, the brake disc must be replaced.
(b) Excessive wear of brake disc may cause poor contact between brake lining and surface of brake
disc. If protrusion on the disc is not removed before installing new brake lining, it will cause
abnormal wear of brake disc.
(c) It is normal that the surface of brake disc is worn when replacing brake lining. If cracks or burned
26 spots exist, the brake disc must be replaced.

26-26 Chery Automobile Co., Ltd.

 26–BRAKE

4. Check the brake disc thickness.

(a) Using a vernier caliper, measure brake disc
thickness at center of brake lining contact surface
as shown in illustration.
Standard thickness: 25 mm
Minimum thickness: 23 mm

BR0038002

(b) If it is less than the minimum thickness due to wear, replace brake disc.
Caution:
• DO NOT machine the brake disc, because it may make brake disc thickness less than the
minimum thickness.

Assembly

m
Warning/Caution/Hint
• Use same procedures for right and left sides.
• Procedures listed below are for left side.
Hint: co
• When assembling brake caliper assembly, always keep your hands clean.
• When assembling brake caliper assembly, always use new clean brake fluid.
• Never use old front disc brake piston seal ring.
n.
1. Install the brake lining support shim.
(a) Securely install upper and lower support shims
ag

(arrow) onto brake caliper fixing bracket.

i
rd
ca

BR0033002

2. Install the front brake lining.

(a) Securely install inner brake lining and outer brake
lining (arrow) onto brake caliper fixing bracket.
Make sure they are clamped in place.
Caution:
• Make sure contact surface of lining and brake
disc is free of oil and grease.

BR0032002

26

Chery Automobile Co., Ltd. 26-27

 26–BRAKE

3. Install the front brake caliper guide bolt guide pin (with dust boot).
(a) Apply a small amount of grease to the contact
surface between guide bolt guide pin and guide pin
rubber dust boot (arrow), and securely install them
to brake caliper fixing bracket.

BR0031002

4. Install the brake cylinder assembly.

(a) Using G type pliers, slightly retract brake cylinder
piston.

m
co BR0042002

(b) Align brake caliper guide bolts (arrow) with guide pin
n.
holes and securely install brake cylinder assembly.
Tightening torque
ag

22 ~ 32 N·m
i
rd

BR0030002

5. Install the bleeder screw (with bleeder screw cap).

ca

(a) Securely install bleeder screw (with bleeder screw

cap) (arrow) to front brake caliper assembly.
Tightening torque
9 ~ 11 N·m

BR0029002

26

26-28 Chery Automobile Co., Ltd.

 26–BRAKE

Installation
1. Installation is in the reverse order of removal.
Caution:
• Make sure contact surface of lining and brake disc is free of oil and grease.
• Before installing brake linings, completely retract brake caliper piston back into bore of brake
caliper.
• Depress brake pedal several times to secure brake linings to brake disc in order to ensure safety
after installing brake linings and before moving vehicle.
• Replace the brake linings in pairs. DO NOT replace one alone.
• DO NOT install inner brake lining and outer brake lining reversely.
• Be sure to check brake system for leakage after installation. Repair or replace malfunctioning
parts as necessary.
• Be sure to perform bleeding procedures for brake system after installation.
• Be sure to add brake fluid to a proper level after installation.

m
co
n.
i ag
rd
ca

26

Chery Automobile Co., Ltd. 26-29

 26–BRAKE

Front Brake Hose Assembly

Removal
Warning/Caution/Hint
Warning:
• Be sure to wear necessary safety equipment to prevent accidents when repairing.
• Try to prevent body paint surface from being scratched during removal and installation.
Hint:
• Use same procedures for right and left sides.
• Procedures listed below are for left side.
1. Remove the front left wheel (See page 24-8).
2. Drain the brake fluid (See page 26-9).
Hint:
• Drained brake fluid should be well kept in a container. Never discard it at will.
Caution:
• Wash off brake fluid immediately if it comes in contact with any paint surface.
3. Remove the front left brake hose assembly.

m
(a) Loosen coupling bolt (arrow) between front left
brake hose assembly and front left brake pipe, and 1
disengage fixing clip (1).
Tightening torque
18 ± 2 N·m
co
Caution:
n.
• DO NOT bend or damage brake tube.
• DO NOT allow any foreign matter such as dirt
and dust to enter brake pipe from joint parts.
ag

• After removing brake line, perform sealing BR0043002

treatment to prevent foreign matter from

entering.
i

(b) Disengage fixing part (arrow) of front left brake hose

rd

assembly from front left shock absorber assembly.

ca

BR0044002

(c) Remove coupling plug (arrow) between front left

brake caliper assembly and front left brake hose
assembly.
Tightening torque
20 ± 2 N·m
Caution:
• DO NOT allow brake fluid to be sprayed on your
clothes or skin when removing brake hose, as
26 brake fluid is corrosive.
BR0044502

(d) Remove the front left brake hose assembly.

26-30 Chery Automobile Co., Ltd.

 26–BRAKE

Installation
1. Installation is in the reverse order of removal.
• Be sure to tighten fixing plugs to specified torques during installation.
• Be sure to check brake system for leakage after installation. Repair or replace malfunctioning
parts as necessary.
• Be sure to perform bleeding procedures for brake system after installation.
• Be sure to add brake fluid to a proper level after installation.

m
co
n.
i ag
rd
ca

26

Chery Automobile Co., Ltd. 26-31

 26–BRAKE

Rear Disc Brake Assembly

Description

10

9
8

6
5

m
4
1

11
co
2
n.
3
12
ag

BR0045001
i

1 - Upper Support Shim 2 - Inner Brake Lining

rd

3 - Outer Brake Lining 4 - Rear Disc Brake Caliper Fixing Bracket

5 - Rear Disc Brake Piston Dust Boot 6 - Rear Disc Brake Piston
7 - Rear Disc Brake Cylinder 8 - Brake Caliper Guide Bolt Guide Pin
ca

9 - Brake Caliper Guide Bolt 10 - Parking Actuator

11 - Bleeder Screw 12 - Bleeder Screw Cap

26

26-32 Chery Automobile Co., Ltd.

 26–BRAKE

On-vehicle Inspection
1. Check the brake disc runout.
(a) Remove the rear wheel (See page 24-8).
(b) Fix dial indicator (1) to a proper position, then set its pointer to a position about 10 mm from out
edge of rear brake disc.
(c) Turn brake disc (2) slowly and check its runout,
mark the lowest and highest points and record these
measured value.
1

BR0046002

(d) Check the runout on the other side of brake disc in the same manner, mark the lowest and
highest points and record these measured value.

m
(e) Compare recorded runout value with limit value.
Rear brake disc runout: Less than 0.06 mm
(f) If runout exceeds the maximum value, replace brake disc.

Removal
co
Warning/Caution/Hint
n.
Hint:
• Use same procedures for right and left sides.
• Procedures listed below are for left side.
ag

1. Remove the rear left wheel (See page 24-8).

2. Remove the rear left brake caliper assembly.
Caution:
i

• Be sure to perform "Enter Parking Brake Maintenance Mode" using diagnostic equipment before
rd

removal.
(a) Unplug parking actuator connector (arrow) from
ca

EPB caliper.

BR0047102

26

Chery Automobile Co., Ltd. 26-33

 26–BRAKE

(b) Remove coupling bolt and washer (arrow) between

rear left brake caliper assembly and rear left brake
hose assembly.
Tightening torque
27 ± 2 N·m
Caution:
• DO NOT allow brake fluid to be sprayed on your
clothes or skin when removing brake hose, as
brake fluid is corrosive.
BR0047002

(c) Remove coupling bolts (arrow) between rear left

brake caliper assembly and left brake caliper
mounting board assembly.
Tightening torque
90 ~ 110 N·m

m
BR0048002

3.
(d) Remove the rear left brake caliper assembly.
Remove the rear left brake disc.
co
(a) Remove locating screws (arrow) from rear left brake
n.
disc, and remove rear left brake disc.
Tightening torque
4.5 ± 0.5 N·m
i ag
rd

BR0049002

Disassembly
ca

Warning/Caution/Hint
Hint:
• Use same procedures for right and left sides.
• Procedures listed below are for left side.
1. Remove the parking actuator.
(a) Remove 2 parking actuator fixing screws (arrow).
Tightening torque
9 ~ 11 N·m

26
BR0049102

26-34 Chery Automobile Co., Ltd.

 26–BRAKE

2. Remove the bleeder screw (with bleeder screw cap).

(a) Remove bleeder screw (with bleeder screw cap)
(arrow) from brake caliper assembly.
Tightening torque
9 ~ 11 N·m

BR0050002

3. Remove the brake cylinder assembly.

(a) Remove 2 guide bolts (arrow) between brake
caliper fixing bracket and brake cylinder assembly.
Tightening torque
22 ~ 32 N·m

m
co BR0051002

(b) Separate brake cylinder assembly from brake caliper fixing bracket.
n.
Warning:
• Slowly operate when performing this procedure using caliper with slanted spring, or brake
plate may be popped out by spring, be careful not to injuring your feet.
ag

4. Remove the rear brake caliper guide bolt guide pin (with dust boot).
(a) Remove 2 brake caliper guide bolt guide pins (with
dust boot) (arrow) from brake caliper fixing bracket.
i
rd
ca

BR0052002

5. Remove the rear brake lining.

(a) Remove inner brake lining and outer brake lining
(arrow) from brake caliper fixing bracket.

BR0053002
26

Chery Automobile Co., Ltd. 26-35

 26–BRAKE

6. Remove the brake lining support shim.

(a) Remove 2 brake lining support shims (arrow) from
brake caliper fixing bracket.

BR0054002

Inspection
1. Check brake caliper fixing bracket and brake caliper guide pin set.
(a) Clean the contact surfaces of brake caliper fixing bracket and brake lining support shims with
brake cleaner. Check for deformation, cracks, rust and foreign matter which is difficult to remove.
(b) Check brake caliper guide pin rubber dust boot for deformation, cracks, wear and foreign matter

m
which is difficult to remove.
(c) Install the brake caliper guide pin and its rubber dust boot to brake caliper fixing bracket. Brake
caliper guide pin set should move smoothly without sticking when pushing it with hand;
otherwise replace it. co
(d) After installing the brake lining, check if it is easy to drop (due to insufficient elasticity of support
shim). Replace as necessary.
n.
2. Check the brake lining.
(a) Visually check the brake lining for flatness, and also check for excessive wear. If the condition of
lining cannot be confirmed accurately only by visual inspection, perform physical inspection as
ag

necessary.
(b) Measure the minimum brake lining thickness. When
the minimum thickness of brake lining is 2 mm or
i

less, replace the brake linings.

rd
ca

BR0058002

(c) When replacing the excessively worn brake linings (inner and outer), it is also necessary to
replace the linings on opposite side of vehicle as well as unchecked linings to maintain proper
braking performance. If it is unnecessary to replace brake linings, be sure to reinstall brake
linings to original positions.
3. Check the brake disc.
(a) Minor scratch or wear on brake disc surface is acceptable. If severe scratch or deformation
exists, the brake disc must be replaced.
(b) Excessive wear of brake disc may cause poor contact between brake lining and surface of brake
disc. If protrusion on the disc is not removed before installing new brake lining, it will cause
abnormal wear of brake disc.
(c) It is normal that the surface of brake disc is worn when replacing brake lining. If cracks or burned
26 spots exist, the brake disc must be replaced.

26-36 Chery Automobile Co., Ltd.

 26–BRAKE

4. Check the brake disc thickness.

(a) Using a vernier caliper, measure brake disc
thickness at center of brake lining contact surface
as shown in illustration.
Standard thickness: 10 mm
Minimum thickness: 8 mm

BR0059002

(b) If it is less than the minimum thickness due to the wear of brake disc, replace brake disc.
Caution:
• DO NOT machine the brake disc, because it may make brake disc thickness less than the
minimum.

Assembly

m
Warning/Caution/Hint
Hint:
• Use same procedures for right and left sides.
• Procedures listed below are for left side.
Hint:
co
• When assembling brake caliper assembly, always keep your hands clean.
• When assembling brake caliper assembly, always use new clean brake fluid.
n.
• Never use old rear disc brake piston seal ring.
1. Install the brake lining support shim.
ag

(a) Securely install upper and lower support shims

(arrow) onto brake caliper fixing bracket.
i
rd
ca

BR0054002

2. Install the rear brake lining.

(a) Securely install inner brake lining and outer brake
lining (arrow) onto brake caliper fixing bracket.
Make sure they are clamped in place.
Caution:
• Make sure contact surface of lining and brake
disc is free of oil and grease.

BR0053002

26

Chery Automobile Co., Ltd. 26-37

 26–BRAKE

3. Install the rear brake caliper guide bolt guide pin (with dust boot).
(a) Apply a small amount of grease to the contact
surface between guide bolt guide pin and guide pin
rubber dust boot (arrow), and securely install them
to brake caliper fixing bracket.

BR0052002

4. Firmly press the brake piston.

(a) Using brake cylinder piston pressing tool, slightly
retract brake cylinder piston.

m
co BR0062002

5. Install the slanted spring.

n.
(a) Pinch the well installed brake plate with hand, so that it closes to brake disc.
(b) Install 2 legs of slanted spring into small holes on support lugs at the same side of inner and
outer brake plates separately, and install slanted spring on the other side while keeping brake
ag

plates clamped.
Warning:
• Slowly operate when performing this procedure using caliper with slanted spring, or brake
i

plate may be popped out by spring, be careful not to injuring your feet.
rd

6. Install the brake cylinder assembly.

(a) Align brake caliper guide bolts (arrow) with guide pin
holes and securely install brake cylinder assembly.
ca

Tightening torque
22 ~ 32 N·m

BR0051002

26

26-38 Chery Automobile Co., Ltd.

 26–BRAKE

7. Install the bleeder screw (with bleeder screw cap).

(a) Securely install bleeder screw (with bleeder screw
cap) (arrow) to rear brake caliper assembly.
Tightening torque
9 ~ 11 N·m

BR0050002

8. Install the parking actuator.

(a) Install 2 parking actuator fixing screws (arrow).
Tightening torque
9 ~ 11 N·m

m
co BR0049102

Installation
n.
1. Installation is in the reverse order of removal.
Caution:
ag

• Make sure to tighten fixing bolt and nut to specified torque during installation.
• Before installing brake linings, completely retract brake caliper piston back into bore of brake
caliper.
i

• Depress brake pedal several times to secure brake linings to brake disc in order to ensure safety
rd

after installing brake linings and before moving vehicle.

• Replace the brake linings in pairs. DO NOT replace one alone.
• DO NOT install inner brake lining and outer brake lining reversely.
ca

• Be sure to check brake system for leakage after installation. Repair or replace malfunctioning
parts as necessary.
• Be sure to perform bleeding procedures for brake system after installation.
• Be sure to add brake fluid to a proper level after installation.
• Be sure to perform "Exit Parking Brake Maintenance Mode" using diagnostic equipment after
installation.

26

Chery Automobile Co., Ltd. 26-39

 26–BRAKE

Rear Brake Hose Assembly

Removal
Warning/Caution/Hint
Caution:
• Be sure to wear necessary safety equipment to prevent accidents when repairing.
• Try to prevent body paint surface from being scratched during removal and installation.
Hint:
• Use same procedures for right and left sides.
• Procedures listed below are for left side.
1. Drain the brake fluid (See page 26-12).
Hint:
• Drained brake fluid should be well kept in a container. Never discard it at will.
Caution:
• Wash off brake fluid immediately if it comes in contact with any paint surface.
2. Remove the rear left brake hose assembly.
(a) Remove coupling bolt and washer (arrow) between

m
rear left brake caliper assembly and rear left brake
hose assembly.
Tightening torque co
27 ± 2 N·m
Caution:
• DO NOT allow brake fluid to be sprayed on your
n.
clothes or skin when removing brake hose, as
brake fluid is corrosive.
BR0047002
ag

(b) Loosen coupling plug (arrow) between rear left

brake hose assembly and rear brake pipe, and
1
move away clip (1).
i

Tightening torque
rd

18 ± 2 N·m
Caution:
• DO NOT bend or damage brake tube.
ca

• DO NOT allow any foreign matter such as dirt

and dust to enter brake pipe from joint parts.
• After removing brake line, perform sealing BR0063002

treatment to prevent foreign matter from

entering.
(c) Remove the rear left brake hose assembly.

Installation
1. Installation is in the reverse order of removal.
Caution:
• Be sure to tighten bolts and plugs in place during installation.
• Be sure to check brake system for leakage after installation. Repair or replace malfunctioning
parts as necessary.
• Be sure to perform bleeding procedures for brake system after installation.
26 • Be sure to add brake fluid to a proper level after installation.

26-40 Chery Automobile Co., Ltd.