2009 CHERY TIGGO brake

Downloaded from www.Manualslib.com manuals search engine Rear Disc Brake
The rear disc brake assembly consists of the following major components:
•Caliper
• Caliper adapter bracket
• Brake pads
• Rotor
• Parking brake shoes
CAUTION:
•Use DOT 4 brake fluid or equivalent from a tightly sealed container. Do not use petroleum-based
fluids, which will cause seal damage in the brake system.
• Brake fluid will damage painted surfaces. If brake fluid is spilled on any painted surfaces, wash
it off immediately with water.
• Never use gasoline, kerosene, alcohol, motor oil, transmission fluid, or any fluid containing min-
eral oil to clean system components. These fluids damage rubber cups and seals.
• During service procedures, grease or any other foreign material must be kept off the caliper
assembly, brake pads, brake rotor and external surfaces of the hub.
• When handling the brake rotor and caliper, be careful to avoid damaging the brake rotor and
caliper, and scratching or nicking the brake shoe lining.
Operation
Applying the brake pedal uses lever action to push a rod into the brake booster, which through the use of vacuum,
boosts the force of the rod and then transmits this force into the master cylinder. This produces hydraulic pressure in
the master cylinder. On vehicles not equipped with ABS, the hydraulic pressure is transmitted by brake fluid through
the brake tubes to the individual brake calipers or wheel cylinders. On vehicles equipped with ABS, the hydraulic
pressure is transmitted by brake fluid through the brake tubes to the ABS hydraulic control unit (HCU), which then
distributes that pressure to the individual brake calipers and wheel cylinders. The brake calipers use hydraulic pres-
sure to apply the brake pads. The application of the brake pads or shoes will cause the rotation of the wheels to slow
or stop depending on how much brake pressure is applied. The parking brakes carry out the same function except
that they are mechanically actuated by a cable that connects only to the rear brakes.
1 - Rear Hub Mounting Assembly
2 - Rear Brake Assembly
3 - Lock Nut
4 - Rear Wheel Hub Bearing Unit5 - Rear Brake Rotor
6 - Caliper Bolts
7 - Brake Caliper Assembly
7 - Disc Brake Caliper and Rotor Assembly
GENERAL INFORMATION
LTSM120002
12
12–3Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Specifications
Torque Specifications
DESCRIPTIONTORQUE (N·m)
Dust Shield Bolts 6.5 - 8.5
Locating Screws (Brake Rotor) 6 - 12
Brake Flex Hose Fitting - Front Caliper 19
Brake Flex Hose Banjo Bolt - Rear Caliper 20
Brake Pedal/Booster Mounting Nuts 25
Brake Tube Nuts 10
Disc Brake Caliper Adapter Bracket (To Knuckle) - Front 63
Disc Brake Caliper Adapter Bracket (To Support) - Rear 63
Disc Brake Caliper Guide Pin Bolts - Front 31 - 38
Disc Brake Caliper Guide Pin Bolts - Rear 23
Disc Brake Caliper Bleeder Screw 9 - 11
Fluid Reservoir Mounting Screw 11
Master Cylinder Mounting Nuts 23
Parking Brake Lever Mounting Nuts 6 - 12
Rear Brake Backing Plate Bolts 20
Wheel Mounting Nuts 110
Rotor Specifications
BRAKE ROTORROTOR
THICKNESS MINIMUM ROTOR
THICKNESS ROTOR DIAMETER ROTOR RUNOUT
Front Rotor 25 mm23 mm265 mm 0.1 mm
Rear Rotor 9 mm7 mm303 mm 0.1 mm
Brake Pad/Lining Specifications
Front Brake
APPLICATION SPECIFICATION (mm)
Brake Caliper Piston Diameter 57
Brake Rotor Diameter 265
Brake Rotor Thickness (New) 25
Min. Thickness Of Brake Rotor 23
Maximum Rotor Runout 0.1
Front Brake Pad Thickness (New) 17.8
Min. Thickness Of Front Brake Pad 7
GENERAL INFORMATION
12–4Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Rear Brake
APPLICATIONSPECIFICATION (mm)
Brake Rotor Diameter 303
Brake Rotor Thickness (New) 9
Min. Thickness Of Brake Rotor 7
Rear Brake Pad Thickness (New) 15
Min. Thickness Of Rear Brake Pad 7
Thickness Of Parking Brake Lining 2.5
Min. Thickness Of Parking Brake Lining 1.5
Special Tools
Dial Indicator
Digital Multimeter
Fluke 15B & 17B
GENERAL INFORMATION
12
12–5Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Electrical Schematics
Brake System (Page 1 of 1)
GENERAL INFORMATION
LTSMW120017T
12–6Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine DIAGNOSIS & TESTING
Diagnostic Help
Brake diagnosis involves determining if the concern is related to a mechanical, hydraulic, electrical or vacuum oper-
ated component.
NOTE :
The brake reservoir fluid level will decrease in proportion to normal lining wear.
NOTE :
Brake fluid tends to darken over time. This is normal and should not be mistaken for contamination.
Preliminary Brake Check:
•Check the condition of the tires and wheels. Damaged wheels and worn, damaged or under inflated tires can
cause a pull, shudder, vibration and a condition similar to brake grab.
• If a complaint was based on noise while braking, check the suspension components. Jounce the front and the
rear of vehicle and listen for anything that might be caused by a loose, worn or damaged suspension or steer-
ing component.
• Inspect the brake fluid level and condition.
1. If the fluid level is abnormally low, look for any evidence of leaks at the calipers, brake lines, master cyl-
inder and at the Antilock Brake System (ABS) Hydraulic Control Unit (HCU).
2. If the fluid appears to be contaminated, drain a sample to examine.
• The system will have to be flushed if the fluid is separated into layers, or contains a substance other than
brake fluid. The system seals, cups, hoses, master cylinder and HCU will also have to be replaced after flush-
ing. Use clean brake fluid to flush the system.
• Check the parking brake operation. Verify free movement and full release of the cables and the lever. Also note
if the vehicle was being operated with the parking brake partially applied.
• Check the brake pedal operation. Verify that the pedal does not bind and has adequate free play. If the pedal
lacks free play, check the pedal and the power booster for looseness or for a binding condition. DO NOT road
test the vehicle until the condition is located and corrected.
• Check the vacuum booster check valve and vacuum supply hose.
• If the preliminary checks appear to be OK, road test the vehicle.
Brake Noise
CONDITION POSSIBLE CAUSES CORRECTION
Disc Brake Chirp · Excessive brake rotor runout.
· Small particles· Diagnose and correct as
necessary.
Disc Brake Rattle Or Clunk · Broken or missing spring clips.
· Caliper guide pin bolts loose.
· Missing abutment shims.
· Small metal particles· Replace brake pads.
· Tighten guide pin bolts.
· Replace missing abutment shims.
Disc Brake Squeak At Low Speed
(While Applying Light Brake Pedal
Effort) · Brake shoe linings.
· Replace brake pads.
Scraping Or Whirring · ABS wheel speed sensor hitting
tone wheel.· Inspect, correct or replace faulty
component(s).
12
12–7Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Braking Concerns
CONDITIONPOSSIBLE CAUSES CORRECTION
Excessive Pedal Effort · Obstruction of brake pedal.
· Low power brake booster assist.
· Glazed brake pads.
· Brake pad lining transfer to brake
rotor.· Inspect, remove or move
obstruction.
· Refer to Power Brake Booster in
this section.
· Resurface or replace brake rotors
as necessary. Replace brake pads.
· Resurface or replace brake rotors
as necessary. Replace brake pads.
Excessive Pedal Effort (Hard Pedal
Unable To Lock-Up Wheels) · Power brake booster runout
(vacuum assist).· Check booster vacuum hose and
engine tune for adequate vacuum
supply.
Excessive Pedal Travel (Vehicle
Stops OK) · Air in brake lines.
· Bleed brakes.
Pedal Pulsates/Surges During
Braking · Disc brake rotor has excessive
thickness variation.· Isolate condition as rear or front.
Resurface or replace brake rotors as
necessary.
Pedal Is Spongy · Air in brake lines.· Bleed brakes.
Vehicle Pulls To Right Or Left On
Braking · Frozen brake caliper piston.
· Contaminated brake pad/shoe
lining (most likely front lining).
· Pinched brake lines.
· Leaking piston seal.
· Suspension problem.· Replace frozen piston or caliper.
Bleed brakes.
· Inspect and clean, or replace
pads/shoes. Repair source of
contamination.
· Replace pinched line.
· Replace piston seal or brake
caliper.
· See the Suspension section.
Parking Brake - Excessive Handle
Travel · Rear brakes out of adjustment.· Adjust rear parking brake shoes on
vehicles with rear disc brakes.
DIAGNOSIS & TESTING
12–8Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine ON-VEHICLE SERVICE
Brake Bleeding
Brake Bleeding Information
WARNING!
When bleeding the brake system, wear safety glasses. A clear bleed tube must be attached to the bleeder
screws and submerged in a clear container filled partially with clean brake fluid. Direct the flow of brake fluid
away from yourself and the painted surfaces of the vehicle. Brake fluid at high pressure may come out of the
bleeder screws when opened.
CAUTION:
Before removing the master cylinder cap, wipe it clean to prevent dirt and other foreign matter
from dropping into the master cylinder reservoir. Use brake fluid or an equivalent from a fresh,
tightly sealed container. Brake fluid must conform to DOT 4 specifications.
NOTE :
During the brake bleeding procedure, be sure the brake fluid level remains close to theMAXlevel in the master
cylinder fluid reservoir. Check the fluid level periodically during the bleeding procedure and add brake fluid as
required.
NOTE :
Do not pump the brake pedal at any time while having a bleeder screw open during the bleeding process. This will
only increase the amount of air in the system and make additional bleeding necessary. Do not allow the master
cylinder reservoir to run out of brake fluid while bleeding the system. An empty reservoir will allow additional air into
the brake system. Check the fluid level frequently and add fluid as needed. The following wheel circuit sequence for
bleeding the brake hydraulic system should be used to ensure adequate removal of all trapped air from the hydraulic
system.
Brake Bleeding Procedure
The following wheel circuit sequence for bleeding the brake hydraulic system should be used to ensure adequate
removal of all trapped air from the hydraulic system:
• Left rear wheel
• Right front wheel
• Right rear wheel
• Left front wheel
Manual Brake Bleeding
NOTE :
To bleed the brakes manually, the aid of a helper will be required.
Fill the brake master cylinder reservoir to the proper level with brake fluid.
12
12–9Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine NOTE :
Never allow the brake master cylinder to empty of brake fluid while bleeding the brake system.
Attach a clear plastic hose to the bleeder screw and
feed the hose into a clear jar containing enough fresh
brake fluid to submerge the end of the hose.
1. Turn the ignition switch off.
2. Have a helper pump the brake pedal three or four times and hold it in the down position.
3. With the pedal in the down position, open the bleeder screw at least one full turn.
4. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release thebrake pedal.
5. Repeat the above steps until all trapped air is removed from that wheel circuit (usually four or five times).
6. Bleed the remaining wheel circuits in the same manner until all air is removed from the brake system. Monitor the fluid level in the master cylinder reservoir to make sure it does not go dry.
7. Check and adjust brake fluid level to the MAXmark.
8. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in the system. Re-bleed the brakes as necessary.
9. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct.
Pressure Brake Bleeding
NOTE :
Follow pressure bleeder manufacturer’s instructions for use of pressure bleeding equipment.
Fill the brake master cylinder reservoir to the proper level with brake fluid.
Attach the pressure bleeding equipment to the master cylinder.
NOTE :
Never allow the brake master cylinder to empty of brake fluid while bleeding the brake system.
Attach a clear plastic hose to the bleeder screw and
feed the hose into a clear jar containing enough fresh
brake fluid to submerge the end of the hose.
1. Turn the ignition switch off.
2. Open the bleeder screw at least one full turn or more to obtain a steady stream of brake fluid.
3. After approximately 120-240 ml of fluid has been bled through the brake circuit and an air-free flow is main- tained in the clear plastic hose and jar, close the bleeder screw.
4. Repeat this procedure at all the remaining bleeder screws.
5. Check and adjust brake fluid level to the MAXmark on the reservoir.
ON-VEHICLE SERVICE
BESM120001
BESM120001
12–10Chery Automobile Co., Ltd.