Section 1 Introduction of Transmission Control. Geely MK
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Propeller Shaft/Driveshaft - Propeller Shaft, Driveshaft and Transaxle 4-17
Chapter 4 Propeller Shaft/Driveshaft
Section 1 Propeller Shaft, Driveshaft and Transaxle
I. Symptom Table
The table below can help find the causes of the problem. The numbers indicate the priority of the causes of the problem. Replace the parts if necessary.
Symptom
Deviation
Front wheel vibration
Noise (drive shaft)
Inspection Area
1. Wheel
2. Front wheel alignment
3. Rear wheel alignment
4. Front wheel hub bearing (worn)
5. Rear wheel hub bearing (worn)
6. Front shock absorber with coil spring
7. Steering linkage (loose or damaged)
8. Stabilizer bar
1. Wheel balance
2. Wheel hub bearing (worn)
3. Front shock absorber with coil spring
1. Outer joint (worn)
2. Inner joint (worn)
Reference
II. On-board Inspection
1. Check front wheel hub bearing
(1) Remove front wheel.
(2) Remove front brake caliper assembly.
(3) Remove front brake disc.
(4) Check the bearing backlash.
Set a dial indicator near the front wheel hub center to check
the backlash.
Maximum: 0.05mm
If the backlash exceeds the maximum value, replace the front
wheel hub bearing.
(5) Check the front wheel hub deviation
Using a dial indicator, check the deviation of the surface of the
wheel hub outside the hub bolt.
Maximum: 0.07mm
If the backlash exceeds the maximum value, replace the front
wheel hub subassembly.
4-18 Propeller Shaft/Driveshaft - Propeller Shaft, Driveshaft and Transaxle
(6) Install front brake disc.
(7) Install front brake caliper assembly
(8) Install font wheel.
Torque: 103N. m
2. Check back wheel hub bearing
(1) Remove rear wheel.
(2) Remove rear brake drum subassembly.
(3) Check bearing backlash.
Set a dial indicator near the rear wheel hub center to check the
backlash.
Maximum: 0.05mm
If the backlash exceeds the maximum value, replace the rear
wheel hub and bearing assembly.
(4) Check rear wheel hub deviation
Using a dial indicator, check the deviation of the surface of
the rear wheel hub inside the hub bolt.
Maximum: 0.07mm
If the backlash exceeds the maximum value, replace the rear
wheel hub and bearing assembly.
(5) Install rear brake subassembly
(6) Install rear wheel
Torque: 103N. m
Propeller Shaft/Driveshaft - Front Driveshaft
Section 2 Front Driveshaft
Component View
right constant velocity drive shaft assembly snap ring snap ring with ABS LF vehicle speed sensor
4-19 right constant velocity drive shaft assembly brake hose collar gasket front stabilizer bar
N . m : specified torque
Non-reusable parts gasket collar
Tie rod left end assembly cotter pin cotter pin set nut left lower swing arm
4-20
Component View
Propeller Shaft/Driveshaft - Front Driveshaft outboard rzeppa joint outboard joint big clamp outboard joint boot outboard joint small clamp
RH: drive shaft damper clamp right front drive shaft damper inboard joint small clamp inboard joint boot inboard joint big clamp tripod
Non-reusable parts retainer
tripod joint
Propeller Shaft/Driveshaft - Front Driveshaft
Overhaul
1. Drain manual transmission oil (M/T transmission)
Torque: 39N.m
2. Drain automatic transmission oil (A/T transmission)
Torque: 25N.m
3. Remove front wheel
4. Remove engine bottom left shield (M/T transaxle)
5. Remove engine bottom right shield (M/T transaxle)
6. Remove engine bottom shield assembly (A/T transaxle)
7. Remove front wheel hub left bolt
(1) Using a hammer and a drive shaft nut chisel, unstake the
staked part of the left wheel hub nut.
(2) While applying the brake pedal, remove the left wheel hub
nut.
Notice: the staked part of the nut should be fully unstaked,
otherwise it may damage the thread of the drive shaft.
8. Remove left front vehicle speed sensor (with ABS)
(1) Remove the bolt and clip, remove vehicle speed sensor and
brake hose from left front shock absorber assembly.
(2) Remove the bolt, separate the left front vehicle speed sensor
from steering knuckle.
9. Remove front stabilizer bar
(1) Use a 10mm wrench to hold the bolt, remove the nut
(2) Remove two collars, No.1 and No.2 gaskets, remove front
stabilizer bar
4-21
4-22 Propeller Shaft/Driveshaft - Front Driveshaft
10. Separate left lower swing arm assembly
(1) Remove cotter pin and nut
(2) On steering knuckle, remove the left lower swing arm
assembly with ball joint puller.
11. Separate steering gear with tie rod assembly
(1) Remove cotter pin and nut
(2) On steering knuckle, remove the steering gear with tie rod
assembly with ball joint puller.
12. Separate LF steering knuckle assembly
Using a plastic hamper, separate left front drive shaft assembly from left front steering knuckle assembly
Notice:
Do not damage the boot.
With ABS:
Be careful not to damage the vehicle speed sensor rotor.
13. Remove left constant velocity drive shaft assembly
Using a differential side gear shaft remover, remove the left constant velocity drive shaft assembly.
Notice:
Do not damage the boot and oil seal.
Be careful not to drop the drive shaft assembly.
14. Remove right constant velocity drive shaft assembly
Using a brass bar and a hammer, remove the right constant velocity drive shaft assembly.
Notice:
Do not damage the boot and oil seal.
Be careful not to drop the drive shaft assembly.
Propeller Shaft/Driveshaft - Front Driveshaft
15. Install LF steering knuckle assembly
Notice:
The hub bearing could be damaged if it is subjected to the vehicle
weight, such as when moving the vehicle with the drive shaft
bearing removed.
Therefore if it is absolutely necessary to place the vehicle weight
on the hub bearing, first support it with the special service tool for
front hub bearing.
16. Check left constant velocity drive shaft assembly
(1) Check the outboard joint for apparent looseness.
(2) Check that the inboard joint slide smoothly.
(3) Check the inboard joint for radial looseness.
(4) Check the boot for damage.
Notice:
Place the drive shaft assembly on level surface during the
inspection.
17. Remove inboard joint big clamp
Using a screw driver, loosen the inboard joint big clamp.
4-23
18. Remove inboard joint small clamp
Using a screw driver, loosen the inboard joint small clamp.
19. Separate inboard joint boot
Separate the outboard joint boot from the outboard Rzeppa joint assembly.
20. Remove left tripod joint assembly
(1) Wipe off the old grease from the tripod joint assembly.
(2) Place the matchmarks between the tripod joint assembly and
the outboard Rzeppa joint.
Notice:
Do not punch the matchmarks.
Mark
4-24 Propeller Shaft/Driveshaft - Front Driveshaft
(3) Remove the tripod joint assembly from the Rzeppa joint
assembly.
(4) Using a snap ring plier, remove the left drive shaft inner snap
ring.
(5) Place matchmarks on the tripod joint assembly and outboard
Rzeppa joint assembly.
Notice:
Do not punch the matchmarks.
(6) Using a brass bar and a hammer, remove the tripod joint from
the outboard Rzeppa joint assembly.
Notice:
Do not tap the roller.
(7) Remove the inboard joint boot clamp, boot, inner boot and left
boot small clamp.
Mark
21. Remove drive shaft damper clamp
Hint:
Perform the following operations only when disassembling the
right drive shaft.
Using a screwdriver, loosen the damper clamp.
22. Remove right drive shaft damper
Hint:
Perform the following operations only when disassembling the right drive shaft.
Remove the right driver shaft damper clamp.
23. Remove left constant velocity outboard joint boot big clamp
Using a screwdriver, loosen the left constant velocity drive shaft outboard joint boot big clamp.
brass bar
Propeller Shaft/Driveshaft - Front Driveshaft
24. Remove outboard joint boot small clamp
Using a screw driver, loosen the outboard joint boot small clamp.
25. Remove outboard joint boot
(1) Remove the outboard joint boot from the outboard Rzeppa joint assembly.
(2) Wipe off the old grease from the Rzeppa joint assembly.
26. Remove left front drive shaft tripod retainer
Using a screw driver, loosen the left front drive shaft tripod retainer.
27. Install left front tripod retainer
Install the new tripod retainer.
28. Install outboard joint boot
(1) Wrap vinyl tape around the spline of the Rzeppa joint to prevent damaging the boots.
(2) Install the new parts on the tripod joint in the following sequence.
a. Outboard joint boot big clamp
b. Outboard joint boot
c. Outboard joint boot small clamp
(3) Coat the left Rzeppa joint assembly with grease.
Grease amount: 69-79g
(4) Install the outboard joint boot on the Rzeppa joint assembly.
29. Install outboard joint boot small clamp
As shown in the illustration, use a screwdriver to install the outboard joint boot clamp.
4-25
4-26 Propeller Shaft/Driveshaft - Front Driveshaft
30. Install outboard joint boot big clamp
As shown in the illustration, use a screwdriver to install the outboard joint boot big clamp.
31. Install right front drive shaft damper
Hint:
Perform the following operations only when disassembling the
right drive shaft.
Set the following distance:
Distance (A) 470 ± 4.0mm
32. Install drive shaft damper clamp
Hint:
Perform the following operations only when disassembling the right drive shaft.
(1) Slide the damper clamp on the shaft.
Notice:
Make sure the clamp is correctly installed.
(2) As shown in the illustration, use a screwdriver to install the
damper clamp.
33. Install tripod joint assembly
Before installing the boot, wrap vinyl tape around the spline of the Rzeppa joint to prevent damaging the boots.
(1) Install the new parts on the tripod joint in the following sequence.
a. Inboard joint boot small clamp
b. Inboard joint boot
c. Inboard joint boot big clamp
(2) Align the matchmarks, install the tripod assembly on the
tripod joint outer shaft assembly.
(3) Using a brass bar and a hammer, install the tripod assembly.
Notice:
Do not tap the roller.
Make sure the tripod is correctly installed.
Mark
Propeller Shaft/Driveshaft - Front Driveshaft
(4) Using a snap ring plier, install the new retainer.
(5) Coat the tripod joint assembly with grease.
Grease amount: 99-109g
(6) Align the matchmarks, install the left intermediate shaft
assembly on the tripod joint assembly.
Mark
34. Install inboard joint boot
Install the inboard joint boot on the intermediate shaft and tripod joint outer shaft.
35. Install inboard joint boot small clamp
As shown in the illustration, use a screwdriver to install the inboard joint boot small clamp.
36. Install inboard joint big clamp
As shown in the illustration, use a screwdriver to install the inboard joint big clamp.
37. Check front drive shaft
(1) Check the outboard joint for apparent looseness.
(2) Check that the inboard joint slide smoothly.
(3) Check the inboard joint for radial looseness.
(4) Check the boot for damage.
Notice:
Place the drive shaft assembly on level surface during the
inspection.
4-27
4-28 Propeller Shaft/Driveshaft - Front Driveshaft
Hint:
Please refer to the following table for dimension (A).
M/T manual transmission
A/T automatic transmission
LH mm
528.3±5.0
527.0±5.0
RH mm
859.3±5.0
860.0±5.0
38. Install left constant velocity drive shaft assembly
(1) M/T
Coat the spline of the tripod joint assembly with gear oil.
(2) A/T
Coat the spline of the tripod joint assembly with ATF
(Automatic Transmission Fluid).
(3) Align the spline, use a brass bar and hammer to install the left
drive shaft assembly.
Notice:
Face the retainer open end downward.
Be careful not to damage the boot and oil seal.
Hint:
You can find out whether the tripod joint shaft contact the pinion shaft by rotating the shaft assembly, listening
to the sound and feeling.
39. Install right constant velocity drive shaft assembly
Hint:
The installation of the right side is the same as that of the left side.
Notice:
Install the retainer with its open end facing downward.
Be careful not to damage the boot and oil seal.
40. Install left steering knuckle assembly
Install the left constant velocity drive shaft assembly on the left steering knuckle assembly.
Notice:
Be careful not to damage the outboard joint boot.
With ABS:
Be careful not to damage the vehicle speed sensor rotor.
41. Install left steering gear with tie rod assembly
(1) Install the steering gear with tie rod assembly on the steering knuckle assembly with nuts.
Torque: 33N. m
(2) Install the new cotter pins.
Notice:
If the pin holes are not aligned, further tighten the nut by 60°.
42. Install left lower swing arm assembly
(1) Install the left lower swing arm assembly on the steering knuckle assembly with nuts.
Torque: 98N. m
Propeller Shaft/Driveshaft - Front Driveshaft
(2) Install the new cotter pins.
Notice:
If the pin holes are not aligned, further tighten the nut by 60°.
43. Install front stabilizer bar
(1) As shown in the illustration, install the stabilizer bar with two
No.1 collars and two gaskets and nuts.
Notice:
Make sure the gaskets and collars are correctly installed.
(2) Tighten the nut with a 10mm wrench.
Torque: 18N. m
44. Install left front vehicle speed sensor (with ABS)
(1) Install the left front vehicle speed sensor and brake hose on the
front shock absorber with bolts and clps.
Torque: 29N. m
(2) Install the vehicle speed sensor on the steering knuckle with
bolts.
Torque: 8.0N. m
Notice:
Be careful not to damage the wheel speed sensor.
Keep the vehicle speed sensor clean.
When installing the sensor,do not twist the sensor wire harness.
45. Install left steering knuckle wheel hub nut
(1) Install new left steering knuckle hub nuts
Torque: 216N. m
(2) Using a chisel and hammer, stake the hub locking nut.
46. Install engine bottom left shield
47. Install engine bottom right shield
48. Install engine bottom shield assembly
49. Install front wheel
Torque: 103 N. m
50. Add oil into manual transmission
51. Check and adjust the manual transmission fluid
52. Refill automatic transmission fluid
53. Check and adjust the automatic transmission fluid
54. Check and adjust front wheel alignment
55. Check ABS vehicle speed signal (with ABS)
4-29
4-30
Component View
With ABS
Propeller Shaft/Driveshaft Front Wheel Hub
Section 3 Front Wheel Hub
Left Constant Velocity
Drive Shaft Assembly
Left Front Vehicle
Speed Sensor
Brake Hose
No. 1 Cushion Collar
Left Tie Rod End Subassembly
Left Front Axle Assembly
Left Brake Caliper Assembly
Cushion
No. 1 Cushion Collar
Retainer
Dual Ball Bearing
Left Steering Knuckle
Left Front Brake Disc Dust Cover
Cotter Pin
Brake Disc
Front Stabilizer
Clip
Left No.1 Front Lower
Suspension Arm
Subassembly
Left Front Axle Hub Nut
Front Axle Hub Nut
Front Axle Hub
N . m : specified torque
Non-reusable parts
Propeller Shaft/Driveshaft - Front Wheel Hub
Replacement
1. Remove front wheel
2. Using a drive shaft nut chisel, remove the front axle hub left nut
3. Remove left front vehicle speed sensor (with abs)
4. Remove left front brake caliper assembly
Remove 2 bolts, remove the left front brake caliper assembly
from the steering knuckle.
5. Remove front brake disc
6. Remove front stabilizer
7. Remove left no.1 front lower suspension arm subassembly with a ball joint puller
8. Remove left tie rod end subassembly with a ball joint puller
9. Remove left front axle assembly
10. Remove left front shock absorber assembly
Remove 2 sets of bolts and nuts, remove the left front shock
absorber from the left front axle assembly.
4-31
11. Remove left front axle hub snap ring
Using a snap ring plier, remove front axle hub left snap ring.
12. Remove left front axle hub subassembly
(1) Remove the left front axle hub subassembly with rear axle
puller.
4-32 Propeller Shaft/Driveshaft - Front Wheel Hub
(2) Using sst, remove inner race of the left axle hub bearing from
the left axle hub sub assembly.
13. Remove front left brake disc boot
Remove 3 bolts and front left boot.
14. Remove left front axle hub bearing
(1) Place the left axle hub bearing inner race into the left axle hub
bearing outer race.
(2) Remove the left axle hub bearing from the steering knuckle
with press and sst
15. Install left front axle hub bearing
Install the new left axle hub bearing on the steering knuckle with press and sst
16. Install front left brake disc boot
Install the front left boot with 3 bolts.
Torque: 8.3N. m
17. Install left front axle hub subassembly
Install left axle hub assembly with press and sst.
18. Install left front axle hub snap ring
Install the new left snap ring with snap ring plier.
Propeller Shaft/Driveshaft - Front Wheel Hub
19. Install left front shock absorber assembly
Install the front left shock absorber assembly on the left front axle assembly with 2 sets of bolts and nuts
Torque: 132N. m
Notice:
Only coat the thread parts of the new bolts and nuts with engine
oil.
20. Install left front axle assembly
21. Install left tie rod end subassembly
22. Install left no.1 front lower suspension arm subassembly
23. Install front stabilizer
24. Install front brake disc
25. Install left front brake caliper assembly
Install the front brake caliper assembly on the steering knuckle with 2 bolts.
Torque: 88N. m
26. Install left front axle hub nut
Install new left axle hub nut.
Torque: 216N. m
27. Remove left front brake caliper assembly
28. Remove front brake disc
29. Check bearing backlash
30. Check axle hub deviation
31. Install front brake disc
32. Install left front brake caliper assembly
33. Install left front vehicle speed sensor (with ABS)
34. Install left front axle hub nut
Using a chisel and hammer, stake the left axle hub nut.
35. Install front wheel
Torque: 103N. m
36. Check and adjust front wheel alignment
37. Check abs vehicle speed sensor signal (with ABS)
4-33
4-34 Propeller Shaft/Driveshaft - Front Wheel Hub
Replacement
1. Remove front wheel
2. Remove left front brake caliper assembly
3. Remove front brake disc
4. Remove left front axle hub bolt
Using a ball joint puller and a screwdriver or similar, remove the left axle hub bolt.
5. Install left front axle hub bolt
(1) As shown in the illustration, install the gasket and nut on the
new left axle hub bolt.
(2) Using a screwdriver or similar,hold the left axle hub subassembly,
install the left axle hub bolt by tightening the nut.
Washer
Nut
6. Install front brake disc
7. Install left front brake caliper assembly
8. Install front wheel
Torque: 103N. m
The replacement of the right front axle hub subassembly is the same as that of the left one.
Propeller Shaft/Driveshaft - Rear Wheel Hub and Bearing Assembly
Section 4 Rear Wheel Hub and Bearing Assembly
4-35
Component View
Slip Control Sensor Wire Harness
With ABS
Left Rear Axle Hub Bolt
Brake Drum Assembly
Rear Axle Hub Unit
N . m : specified torque
Non-reusable parts
4-36 Propeller Shaft/Driveshaft - Rear Wheel Hub and Bearing Assembly
Replacement
1. Remove rear wheel
2. Remove rear wheel brake drum subassembly
3. Remove slip control sensor wire harness (with ABS)
4. Remove left rear axle hub and bearing assembly
Remove 4 bolts and left axle hub and bearing assembly.
5. Install left rear axle hub and bearing assembly
Install left axle hub and bearing assembly with 4 bolts
Torque: 63N. m
6. Connect slip control sensor wire harness (with ABS)
Notice:
Do not twist the sensor wire harness during connection.
7. Check bearing backlash
8. Check axle hub deviation
9. Install rear wheel brake drum subassembly
10. Install rear wheel
Torque: 103N. m
11. Check as vehicle speed sensor signal (with ABS)
Propeller Shaft/Driveshaft - Rear Wheel Hub and Bearing Assembly
Replacement
1. Remove rear wheel
2. Remove rear wheel brake drum subassembly
3. Remove left rear wheel axle hub bolt
Using a ball joint puller and a screwdriver or similar, remove the
left axle hub bolt.
4-37
4. Install left rear wheel axle hub bolt
(1) As shown in the illustration, install the gasket and nut on the
new left axle hub bolt.
(2) Using a screwdriver or similar, hold the left axle hub subassembly,
install the left axle hub bolt by tightening the nut.
Washer Nut
5. Install rear brake drum subassembly
6. Install rear wheel
Torque: 103N. m
The replacement of the right rear axle hub and bearing assembly is the same as that of the left one.
4-38 Front Suspension System - Front Suspension System
Chapter 5 Front Suspension System
Section 1 Front Suspension System
Description on front suspension structure
This model uses strut swing arm independent suspension with stabilizer bar.
The shock absorber upper end is flexibly connected to the body through the shock absorber mounting seat, the lower end is rigidly connected to the steering knuckle. The coil spring encloses the shock absorber (coil spring geometrical axial line does not coincide with that of the shock absorber piston rod), and is supported between the upper and lower spring seats.
Both ends of the stabilizer bar are connected to the shock absorber through the strut bar ball pin and the intermediate part is supported on the lower front body by the rubber bushing and support frame.
The front cushion sleeves the shock absorber piston rod head to restrict the wheel jump limit position and plays the role of buffer.
The thrust ball bearing, installed between the spring upper seat and the shock absorber mount, is used for the relative rotation upon steering of the shock absorber rigidly connected to the steering knuckle to the shock absorber mount flexibly connected to the body.
"L" type lower swing arm is secured to the lower engine compartment with the press plate through elastic rubber bushing and hinge, and its outer end is connected to the steering knuckle through the ball stud pin which is attached to the lower swing arm by 3 high intension bolts. The ball stud pin can be removed and replaced when it is worn.
The ball seat material is saturated polyester containing oil, featured in comparatively high intensity and wearability and good self-lubrication performance. Proper amount of grease has been added during the assembly and there is no need for additional filling during the normal operation.
See the table for the front suspension technical parameters
Item
Shock absorber operating cylinder diameter /mm
Shock absorber piston rod diameter /mm
Shock absorber stroke/mm
Wheel camber
Wheel toe-in/mm
King pin inclination
King pin caster
Remark: the wheel alignment parameter in the table is at free load.
Parameter
4 5
2 0
160
-0°30'±45'
1 ± 2
10°0'±45'
2°0'±45'
Front Suspension System - Front Suspension System 4-39
Symptom Table
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace parts.
Symptom
Off track
Body Descent
Sways
Front wheel shimmy
Abnormal tire wear
Suspected Area
1. Tires (Worn or improperly inflated)
2. Wheel alignment (Incorrect)
3. Steering system joint (Loose or worn)
4. Hub bearing (Worn)
5. Steering gear (Out of adjustment or worn)
6. Suspension parts (Worn or damaged)
1. Vehicle (Overloaded)
2. Spring (stiffness not comply with or damage)
3. Shock absorber (Worn)
1. Tire (Worn or improperly inflated)
2. Steering linkage (Loose or damaged)
3. Stabilizer bar (Bent or broken)
4. Shock absorber (Worn or damaged)
1. Tire (Worn or improperly inflated)
2. Tire (Dynamic balance is not as specified)
3. Shock absorber (Worn or damaged)
4. Wheel alignment (Incorrect)
5. Ball stud pin (Worn or damaged)
6. Hub bearing (Worn or damaged)
7. Steering linkage (Loose or worn)
8. Steering gear (Out of adjustment or worn)
1. Tire (Worn or improperly inflated)
2. Wheel alignment (Incorrect)
3. Shock absorber (Worn or damaged)
4. Suspension parts (Worn or damaged)
4-40
Component View
Front Suspension System - Front Suspension
Section 2 Front Suspension
suspension support front shock absorber with helical spring
With/ ABS: left front vehicle speed sensor brake hose left front helical spring left front spring bumper left front shock absorber assembly left front suspension bracket dust seal left front suspension bracket dust cover left front suspension bracket subassembly left upper front helical spring seat left upper helical spring pad
N . m : specified torque
Non-reusable parts
Component View
Front Suspension System - Front Suspension engine hood
4-41 front stabilizer bar rack and pinion power steering gear
Retainer pad
Retainer pad
Retainer
Front suspension Reinforcement
Rod front suspension cross beam subassy
Retainer pad
Retainer left lower front suspension arm subassy
Retainer pad clamp engine lower cover subassy
Right front suspension reinforcement beam
N . m : specified torque
Non-reusable parts
4-42
Component View
Front Suspension System - Front Suspension right front stabilizer bar bracket retainer pad pad bushing retainer
Front stabilizer bar bolt retainer pad retainer pad retainer pad retainer left lower front suspension arm subassy left front stabilizer bar bracket bushing front stabilizer bar pad retainer front stabilizer bar bolt retainer pad clamp retainer pad retainer
N . m : specified torque
Non-reusable parts
Front Suspension System - Front Wheel Alignment 4-43
Section 3 Front Wheel Alignment
Adjustment:
1. Check tire
2. Measure the vehicle height
Vehicle height:
Front
Tire size Front
1
(mm) Rear
2
(mm)
175 / 65R14 82H191 265
185 / 60R15 84H192 265
Rear
1. front measure point
Measure the distance between the ground and the front underside
suspension mounting bolt center
2. rear measure point
Measure the distance between the ground and the rear axle beam mounting bolt center
Notice:
Before the wheel alignment,adjust the body to the specified height.If the body height is out of spec,adjustment
shall be done by pressing or raising vehicle body.
3. Check the Toe-in
Toe-in:
If the toe-in is out of spec, adjust the ends of rack.
Front
4. Adjust the Toe-in
(1) Remove the clamp of the rack boot
(2) Loose the jam nut of tie rod
(3) Adjust the Toe-in by rotating the same turns of both ends of
rack.
Tips: Adjust the toe-in to the intermediate value of spec.
(4)Make sure the same length for both ends
The length difference of left and right: 1.5mm or smaller
(5)Tighten the jam nut of the tie rod
Torque: 47N. m
(6)Seat the boot and crimp the clamp
Tips: rack boot must not be twisted
4-44 Front Suspension System Front Wheel Alignment
5. Check the steering angle of wheel
Fully steer the wheel and measure the angle
The angle of wheel:
Inside wheel
Outside wheel
Manual steering Power steering
9-1 37.2°±2°
32°±2° 32°±2°
Front
Inside
Outside
If there is deviation with spec for right and left wheel angle, check the rack length of left and right ends.
6. Check the camber, caster and steering axle inclination angle
Camber angle
Left-right wheel deviation
Caster angle
Manual steering
Power steering
Left-right wheel deviation
Kingpin inclination
Manual steering
Power steering
Left-right wheel deviation
-0°30' ± 45' (-0.5° ± 0.75°)
45'(0.75°) or smaller
9-1
1°46' ± 45' (1.76° ± 0.75°)
45' (0.75°) or smaller
9°54' ± 45' (9.90° ± 0.75°)
45' (0.75°) or less locator meter
If the kingpin caster angle and the kingpin inclination be out of spec, check the damage and abrasion of suspension parts after the correct adjustment of camber angle.
7. Adjust the camber angle
Notice:
Check the toe-in after adjust the camber angle
(1)Remove the front wheel
(2)Remove the two nuts under the shock absorber
If you need to reuse the bolts and nuts, apply the engine oil on
the nut thread
(3)Clear the mounting surface of the knuckle and shock absorber.
Front Suspension System Front Wheel Alignment
(4) Mount 2 nuts temporarily.
(5) Adjust the camber angle by pushing or pulling the underside
of shock absorber in the direction of required adjustment.
(6) Tightening the nuts
Torque: 132N.m
(7) Mounting the front wheel
Torque: 103N.m
(8) Check the camber
Tips:
Adjust the camber to the median of spec.
Adjustment value of positioning the bolts: 6' ~ 30'.
(0.1° ~ 0.5°)
Adjusting bolt
4-45
Refer to the table below to fix the correct adjustment if the camber is out of spec, then select the bolts for camber adjustment.
Notice: Tighten the adjustment nuts with washer and new nuts.
bolt
Location bolt
A
11
Adjusting bolt
B
1 point
.11
C
2 point
.11.
Adjustment value
15'
30'
45'
1°00'
1 2 1 2 1
(9) Repeat the steps above, replace 1 or 2 bolts
Tips:
Only replace 1 bolt if 2 bolts are needed to be replaced.
2
4-46 Front Suspension System Front Strut Assembly
Section 4 Front Strut Assembly
Replacement
1. Remove screen wiper arm cover
2. Remove right screen wiper
3. Remove left screen wiper
4. Remove hood and seals of vehicle neck
5. Remove upper right ventilation shield of vehicle neck
6. Remove upper left ventilation shield of vehicle neck
7. Remove the wiper linkage assembly of windscreen
8. Remove the hood of vehicle neck
(1) Remove the bolt and 2 clips, disconnect the harness
(2) Remove the hose and harness (wiper)
(3) Remove the 8 bolts of ventilation shield of vehicle neck
9. Remove the front wheel
10. Remove the brake hose
(1) Remove the bolts, brake hose and the clamp of ABS sensor
harness from the shock absorber bracket (with ABS)
(2) Remove the bolts and brake hose from the shock absorber
(without ABS)
11. Remove the front shock absorber with helical spring
(1) Remove the shock absorber from knuckle after remove the two
nuts and bolts.
(2) Remove the front shock absorber with helical spring, remove
the three bolts mounting suspension bracket
12. Fix the front shock absorber with helical spring
(1) Mount the two bolts and one bolt onto the bracket of shock
absorber underside, and fix it onto the vise
(2) Hold down the helical spring
Notice: Don't use the impact wrench which can damage the
special tool
Front Suspension System Front Strut Assembly
13. Remove the duct cover of the bracket for left front suspension
Remove the end cap from the bracket of suspension
14. Remove the front bracket after removing the nuts of left front shock absorber
Hold it by the two nuts and a screwdriver or analogue, then remove centre nut
Notice: Don't damage the stud of suspension bracket.
15. Remove the bracket assembly of the left front suspension
16. Remove the seals of bracket dust hood for left front suspension
17. Remove the left upper front helical spring seat
18. Remove the left upper front helical spring insulator
19. Remove the left front helical spring
20. Remove the left front spring bumper
21. Remove the left front shock absorber assembly bumper
22. Check the left front shock absorber assembly
Check the abnormal resistance and noise in the operation by compressing and extending the pushrod, replace it if abnormal.
23. Mount the left front shock absorber assembly
24. Mount the left front spring shock absorber pad
25. Mount the left front helical spring
(1) Compress the helical spring with special tool
Notice: Don't use the impact wrench which may damage the
special tool
4-47
(2) Load the helical spring into the shock absorber
Attention: tighten the helical spring lower side to the gap of
spring lower seat.
26. Mount the left upper front helical spring insulator
Mount the upper insulator, mark " "toward vehicle outside.
27. Mount the upper seat of left front helical spring
Mount the upper seat, mark " " toward vehicle outside
4-48 Front Suspension System Front Strut Assembly
28. Mount the dust seals of left front suspension bracket
29. Mount the left front suspension bracket sub-assembly
30. Mount the front bracket onto the left front shock absorber nuts
(1) Hold the bracket by two bolts and a screwdriver or analogue.
Mount the new centre nut
Torque: 33N. m
Notice: DonÕt cause damage to the stud of suspension bracket.
(2) The special tool for remove
(3) Apply the multipurpose grease onto the suspension bracket
Multi-purpose grease
31. Mount the dust cap of left front suspension bracket
32. Mount the front stud assembly
(1) Mount the #2 suspension bracket
(2) Mount the front stud assembly by three nuts
Torque: 39N.m
(3) Mount the shock absorber onto the knuckle
(4) Film the engine oil onto the thread of two nuts
(5) Mount the two bolts and nuts
Torque: 132N. m
33. Mount the brake hose
Torque: 29N. m
34. Mount the front wheel
Torque: 103N. m
35. Mount the outside cover of vehicle neck
(1) Mount the outside cover of vehicle neck by 8 bolts
Torque: 5N. m
(2) Connect hose and harness (screen wiper)
(3) Mount the harness by bolts and two clips
36. Mount the linkage assembly of windshield wiper
37. Mount the ventilation hood of left vehicle neck
38. Mount the ventilation hood of right vehicle neck
39. Mount the engine hood and seals of vehicle neck
40. Mount the left front wiper arm
41. Mount the right front wiper arm
42. Check and adjust the front wheel alignment
Front Suspension System - Front Lower Swing Arm Assembly
Section 5 Front Lower Swing Arm Assembly
Disassemble
1. Remove the front wheel
2. Remove the subassembly of the engine #1 cover
3. Remove the engine hood
4. Sling the engine assembly
5. Remove the left front suspension cross beam
Remove the two bolts and left front suspension cross beam
6. Remove the right front suspension cross beam
Remove the two bolts and right front suspension cross beam
7. Disassemble the left lower subassembly of the front suspension
arm
(1) Remove the clips and nuts
(2) Remove the suspension arm from the knuckle by special tool
8. Disassemble the front stabilizer bar
(1) Remove the nuts, three retainers and two pads (left side) when
tightening the bolts of stabilizer rod
(2) Take the same steps on the other side as above.
4-49
(3) Remove the front stabilizer rod after removing four bolts
9. Disassemble the power rack & pinion gear assembly
Disassemble the power rack & pinion gear assembly by removing
two bolts
Tips: Pull up the power rack & pinion gear assembly.
4-50 Front Suspension System - Front Lower Swing Arm Assembly
10. Disassemble the subassembly of the front suspension beam
(1) Remove the bolt and two nuts.
(2) Lift the front suspension beam subassembly by lifting jack
(3) Disassemble the front suspension subassembly by removing
the four bolts.
11. Remove left lower front suspension subassembly
Remove left lower front suspension subassembly by removing
two bolts and nuts
Notice: Don't rotate the nuts
12. Check the left lower front suspension subassembly
(1) Swing the ball joint stud for 5 times before mounting the nuts,
as show in the figure.
(2) Continuously rotate the nuts with a speed of 2-4 seconds per
turn with the torque wrench,record the torque value at the 5th
turn.
Torque: 0.78~3.43 N.m
13. Temporarily tighten left lower front suspension subassembly
Temporarily tighten left lower front suspension subassembly
with two bolts and nuts.
Front Suspension System - Front Lower Swing Arm Assembly
14. Connect the front suspension beam subassembly
(1) Mount the front suspension beam subassembly by four bolts
Torque:
Bolt A: 70N. m
Bolt B: 116N. m
4-51
(2) Mount the bolt and two nuts
Torque: 52N. m
15. Mount the rack and pinion gear assembly
Mount the rack and pinion gear assembly with 2 bolts
Torque: 127N. m
16. Mount the front stabilizer bar
(1) Mount the front stabilizer rod with four bolts
Torque: 37N. m
(2) Mount the nuts, three retainers and two pads (left) when
tightening stabilizer rod bolts
Tip: Lift the lower controller arm by lifting jack
(3) Take the same steps on other side as above
4-52 Front Suspension System - Front Lower Swing Arm Assembly
17. Mount left lower front suspension subassembly
(1) Mount the lower suspension arm onto the knuckle by nuts
Torque: 98N. m
(2) Mount a new clip
Notice: Further tighten nuts for 60° if the holes are not in the
correct alignment
18. Mount the left front suspension cross beam
Mount the left front suspension cross beam with two bolts.
Torque: 47N. m
19. Mount the right front suspension cross beam
Mount the right front suspension cross beam with two bolts
Torque: 47N. m
20. Mount the front wheel
Torque: 103N. m
21. Stabilize the suspension
Stabilize the front suspension
22. Sufficiently tighten left front lower suspension arm subassembly
Tighten the lower suspension arm with two bolts
Bolt A: 88N. m
Bolt B: 132N. m
Attention: Don't rotate the nuts
23. Install engine hood.
24. Check and adjust front wheel alignment
Front Suspension System - Front Stabilizer Bar and Link Rod Assembly 4-53
Section 6 Front Stabilizer Bar and Link Rod Assembly
Disassemble
1. Remove the front wheel
2. Remove the front stabilizer bar bolts
(1) Remove two nuts, five retainers, four pads and stabilizer bolts when fixing bolts
(2) Take the same steps on other side as above.
3. Remove the front stabilizer bar
Remove four bolts and #1 front stabilizer bar bracket.
4. Mount the front stabilizer bar
Mount the stabilizer bar, two bushings, bracket and four bolts.
Torque: 37N. m
Notice:
Make the groove toward the vehicle rear
Tip:
Keep the bushing outside the paint line
Installation mark
5. Mount the front stabilizer bolts
(1) Mount the front stabilizer bolts, four pads and five retainers
Torque: 18N.m
(2) Take the same operations on other side as above process
6. Mount the front wheel
Torque: 103N.m
4-54 Rear Suspension System - Rear Suspension System
Chapter 6 Rear Suspension System
Section 1 Rear Suspension System
Component View
With ABS
Right rear helical spring
Left rear helical spring
Lower washer
Side slip control sensor wire
Rear shock absorber assembly
Upper washer
82
9 . 0
Washer
Brake hose
49
Clip
98
Load-sensing valve bracket
Rear supension crossmember
Left rear helical spring
Lower washer
Brake hose
N . m : specified torque
Non-reusable parts
Rear Suspension System - Rear Suspension System 4-55
I. Rear suspension structure description
This model uses strut independent rear suspension with stabilizer bar.
Rear suspension consists of the parallel front and rear double transverse arms, trailing rod, rear stabilizer bar and rear strut assembly. The shock absorber and cone coil spring are arranged eccentrically.
See the table below for the major technical parameters of the rear suspension
Item
Shock absorber operating cylinder diameter /mm
Shock absorber piston rod diameter/mm
Shock absorber stroke /mm
Camber
Toe in/mm
Remark: Wheel alignment parameter is at free load
Parameter
3 8
12.4
250
-0°56' ± 45'
3 ± 3
II. Symptom Table
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts.
Symptom
Off track
Body descent
Sways
Rear wheel shimmy
Abnormal tire wear
Suspected Area
1. Tires (Worn or improperly inflated)
2. Wheel alignment (Incorrect)
3. Hub bearing (Worn or damaged)
4. Suspension parts (Worn or damaged)
1. Vehicle (Overloaded)
2. Spring (Stiffness small)
3. Shock absorber (Worn)
1. Tire (Worn or improperly inflated)
2. Wheel (not within specification)
3. Shock absorber (Worn)
1. Tire (Worn or improperly inflated)
2. Wheel alignment (Incorrect)
3. Shock absorber (Worn)
4. Wheel (not within specification)
1. Tire (Worn or improperly inflated)
2. Wheel alignment (Incorrect)
3. Shock absorber (Worn)
4. Suspension parts (Worn or damaged)
4-56 Rear Suspension System - Rear Wheel Alignment
Section 2 Rear Wheel Alignment
Check
1. Check the tire
2. Measure the vehicle height
Notice:
Adjust the vehicle height to specified value before check the
wheel alignment
3. Check the rear toe-in
Toe in
( assembly )
A+B: 0°19' ± 19' (0.31 ± 0.31°)
C+D: 3.0 ± 3.0mm
Front
Check and replace the related suspension parts if the toe in out of spec.
4. Check the camber
(1) Mount the camber-caster-kingpin measuring device, place the vehicle on the wheel position device
(2) Check camber
Camber
Left-right deviation
-0°56' ± 45' (-0.93° ± 0.75°)
45' (0.75°) or smaller
Check the damage and performance decline of suspension parts and replace if necessary, if measurement out
of spec.
Rear Suspension System - LH/RH Rear Suspension Coil Spring
Section 3 LH/RH Rear Suspension Coil Spring
Replacement
1. Remove rear wheel
2. Remove the wire of the wheel speed sensor(with ABS)
(1) Remove the connector of wheel speed sensor.
(2) Remove bolts and wheel speed sensor from rear axle
frame.
Notes:
Remove the right sensor wire by using same process as left.
3. Remove the load-sensing valve bracket (without ABS)
Remove two nuts and load-sensing valve bracket from the axle
bracket
4-57
4. Remove the proportioning valve and rear right brake tube
(1) Remove the proportioning valve and rear right brake tube by
the special tool
(2) Remove the clips
Notes: Don't reuse the clips
5. Remove the proportioning valve and rear left brake tube
Notes: use the same operations of the proportioning valve and
rear right brake tube to remove #3 rear brake tube.
6. Remove right parking brake cable assembly
Remove nuts and right parking brake cable assembly
assembly from rear axle frame
7. Remove left parking brake cable assembly
8. Loose the rear axle assembly
Loose two 2 bolts
4-58 Rear Suspension System - LH/RH Rear Suspension Coil Spring
9. Remove the left rear shock absorber assembly
(1) Lift the rear axle at left sustainer by lifting jack
(2) Remove nuts, washers and left rear shock absorber assembly
10. Remove right rear shock absorber assembly
Notes: Remove right rear shock absorber assembly by using same
operations as left.
11. Remove left rear helical spring
Slowly lower lifting jack, remove helical spring and upper pads
and lower pads
12. Mount the left rear helical spring
(1) Mount the upper pad, let gap right on the helical spring.
(2) Mount lower pad, let and load the left helical sprig into the rear
axle.
13. Temporarily tighten the left rear shock absorber assembly
(1) Mount the left rear shock absorber onto rear axle frame when
lift jack.
(2) Temporarily tighten nut and washer.
14. Temporarily tighten the right rear shock absorber assembly.
Notes: Mount the right assembly by using same operations as left.
15. Mount right parking brake cable assembly
Mount right parking brake cable assembly by nuts
Torque: 5.4 N.m
16. Mount left parking brake cable assembly.
Tips: Mount the right assembly by using same operations as left.
17. Mount the proportioning valve and rear right brake tube
(1) Connect the brake hose with brake tube by special tool.
Torque: 1 5 N.m
(2) Mount clips
Rear Suspension System - LH/RH Rear Suspension Coil Spring
18. Mount rear right brake tube
Tips:
Mount the right assembly by using same operations as left.
19. Mount sideslip control sensor wire (with ABS)
(1) Tighten sideslip control sensor wire by bolts
Torque: 8.0 N.m
(2) Mount sideslip control sensor wire
Attention: Mount the right wire by using same operations as left.
20. Mount load-sensing valve bracket (without ABS)
Mount load-sensing valve bracket by two buts
4-59
21. Sufficiently tighten the rear axle frame assembly
(1) Stabilize the shock absorber assembly
Use the lifting jack and add 90Kg force on rear luggage
carrier if bolts can not be tightened at this point.
(2) Sufficiently tighten bolts
Torque: 82 N.m
22. Sufficiently tighten the left rear shock absorber assembly
Sufficiently tighten nuts
Torque: 49 N.m
23. Sufficiently tighten the right rear shock absorber assembly
Tips: Mount the right rear shock absorber by using same operations as left.
24. Release the air in the brake hose
25. Mount the rear wheel
Torque: 103 N.m
26. Check rear the wheel alignment
27. Check the wheel speed sensor signal of ABS( with ABS)
4-60 Rear Suspension System - Rear Absorber Installation Assembly
Section 4 Rear Absorber Installation Assembly
Component View
Washer
Upper suspension carrier
Rear vibration cushion
Shock absorber upper cover
Left rear shock absorber assembly
N . m : specified torque
Replacement
1. Remove the rear seat cushion assembly
2. Remove divided rear seat back assembly
3. Remove LH & RH rear seat back hinge (2 pieces)
4. Remove rear seat belt assembly
5. Remove left rear door molding washer
Rear Suspension System - Rear Absorber Installation Assembly
6. Remove rear left lower pillar interior panel
7. Remove the lower rear shelf interior panel
8. Remove rear left upper pillar interior pane
9. Remove rear right lower pillar interior pane
10. Remove the high brake lamp
11. Remove the rear shelf interior panel
12. Remove rear wheel
13. Remove the rear left shock absorber assembly
(1)Lift the rear axle frame by lifting jack (see right figure)
(2)Remove two nuts by clamping the piston push rod
(3)move the washer and upper suspension bracket
4-61
(4) Remove nut, washer and left rear shock absorber assembly
(5) Remove shock absorber upper cover
14. Check rear left shock absorber assembly
Check the abnormal resistance and noise in the operation by compressing and extending the push rod, replace it if any abnormal.
15.Mount rear left shock absorber assembly
(1) Mount shock absorber upper cover
(2) Mount shock absorber, upper suspension bracket and washer
onto vehicle body
(3) After clamp piston push rod, mount lower nut and let piston
push rod higher 15-18mm than nut (see right figure)
(4) Mount upper nut according lower nut
Torque: 25N. m
(5) Mount shock absorber onto rear axle frame by washer and nut
at lifting jack
Torque: 49N. m
16. Mount rear wheel
Torque: 103N. m
17. Check rear wheel alignment
4-62 Rear Suspension System - Rear Suspension Crossmember
Section 5 Rear Suspension Crossmember
Component View
with ABS
Right rear helical spring
Lower washer
Rear brake drum subassembly
Brake hose
Upper washer
Wheel speed sensor wire
Rear shock absorber subassembly
Right rear hub and bearing subassembly
Clamp
Upper washer
Left rear helical spring
Rear stabilizer bar bushing
Lower washer
Rear right support bushing
Brake hose
Rear suspension crossmentber
Bracket
Load-sensing valve bracket without
ABS
Rear left support bushing
Left rear hub&bearing subassembly
Rear brake assembly
Rear brake drum subassembly
Parking brake cable assembly
N . m : specified torque
Non-reusable parts
Rear Suspension System - Rear Suspension Crossmember
Disassemble:
1. Remove rear wheel
2. Remove sideslip control sensor wire (with ABS)
3. Remove load-sensing valve bracket (without ABS)
4. Remove proportioning valve and right rear brake tube
5. Remove proportioning valve and left rear brake tube
6. Remove right parking brake cable assembly
7. Remove left parking brake cable assembly
Tips: Remove right parts by using same operations as left
8. Remove rear brake drum subassembly
9. Remove left rear hub and bearing assembly
(1) Remove nuts and right parking brake cable assembly from
rear axle frame
4-63
(2) Remove four bolts and left rear hub and bearing assembly
(3) Remove rear brake assembly from rear axle frame
10. Remove rear right hub and bearing assembly
Tips: Remove right parts by using same operations as left
11. Loosen rear axle frame assembly
12. Disassemble rear left shock absorber assembly
13. Disassemble rear right shock absorber assembly
Tips: Remove right parts by using same operations as left
14. Remove rear left helical spring
15. Remove rear right helical spring
Tips: Remove right parts by using same operations as left
16. Remove rear axle assembly
(1) Lift rear axle assembly by lifting axel
(2) Remove two bolts and rear axle frame assembly
4-64 Rear Suspension System - Rear Suspension Crossmember
17. Remove rear stabilizer bar bushing
18. Remove left rear axle frame bushing
(1) Bend two bushing shoulders by chisel and hand hammer
Tips: Bend bushing shoulder till hooked by special tool
(2) Remove bushing from axle by special tool
Tips: Apply protective paint if axle frame scratched
Bending bushing shoulder
19. Remove rear right axle frame bushing
Tips: Remove right parts by using same operations as left
20. Mount rear left axle frame bushing
(1) As showed in graphic, Mount left rear axle carrier onto rear
axle frame
Front
(2) Mount bushing onto axle frame
Tips:
fix the jaw of special tool onto bushing
Don't chafe rubber of bushing
Don't deform the shoulder of bushing rubber part
21. Mount rear right axle carrier bushing
Tips: Mount right parts by using same operations as left
22. Mount rear stabilizer bar bushing
Rear Suspension System - Rear Suspension Crossmember
23. Temporarily fasten the rear axle frame assembly
(1) Lift rear axle frame by lifting jack
(2) Mount the rear axle frame by temporarily tightening two bolts
24. Mount rear left helical spring
25. Mount rear right helical spring
Tips:
Mount right parts by using same operations as left
26. Temporarily tighten rear left shock absorber assembly
27. Temporarily tighten rear right shock absorber assembly
Tips:
Mount right parts by using same operations as left
28. Mount rear left hub and bearing assembly
Mount rear brake assembly, rear left hub and bearing assembly by four bolts
4-65
29. Mount rear right hub and bearing assembly
Tips: Mount right parts by using same operations as left
30. Mount rear brake drum subassembly
31. Adjust the gap between brake drum and brake shoe
32. Mount #3 parking brake cable assembly
Tips: Mount right parts by using same operations as left
33. Mount #2 parking brake cable assembly
34. Mount #4 rear brake tube
35. Mount #3 rear brake tube
Tips: Mount right parts by using same operations as left
36. Connect sideslip control sensor wire(with ABS)
37. Connect load-sensing valve braket(without ABS)
38. Sufficiently tighten rear axle frame assembly
39. Sufficiently tighten rear left shock absorber assembly
40. Sufficiently tighten rear right shock absorber assembly
Tips: Mount right parts by using same operations as left
41. Release air from brake tube
42. Mount rear wheel
Torque: 103N.m
43. Check rear wheel alignment
44. Check the speed signal of ABS sensor( with ABS).
4-66 Wheel - Tire Inspection and Wheel Replacement
Charpter 7 Wheel
Section 1 Tire Inspection and Wheel Replacement
Check
1. Check tire
(1) Check appearance of tire and its pressure
Cool tire pressure:
Tire size
175/65 R14 82H
185/60 R15 84H
Front
(KPa)
230
(2) Check the runout of tire by dial indicator
Runout of tire: less than 3.0mm
Rear
(KPa)
210
2. Tire replacement
Notes: As showed in graphic, replacement position of every tire
including and not including the spare tire.
Front
3.Check tire dynamic balance
(1) Check and adjust wheel on the tire dynamic machine beside
vehicle
(2) Check and adjust wheel on the tire dynamic machine loaded
beside vehicle
Balance deviation after adjustment: less than 8.0g.
4. Check bearing gap
5. Check hub deviation.
Power Steering System - Power Steering System 4-67
Chapter 8 Power Steering System
Section 1 Power Steering System
1. Power Steering System Description
Power Steering System consists of the steering wheel, steering transmit device, power steering fixed device and steering pipelines. The steering gear is rack and pinion type.
2. Major parameters for steering system:
Item
Steering Wheel total revolutions
Maximum Front
Wheel Turn Angle
Inner
Outer
Minimum Turning Diameter
Parameter
3.58±0.1
37.2°±2°/ 32°±2°
37.2°±2°/ 32°±2°
10.4 m
3. Precaution:
(1) Precaution for steering system
Make sure of the correct replacement of parts, incorrect replacement might affect the performance of the
steering system and lead to driving accidents.
(2) Precaution for SRS System
This vehicle is equipped with SRS (Supplemental Restraint System), driver side air bag and front passenger
side air bag.
Failure to carry out service operations in the correct sequence could cause the unexpected deployment of
the air bag during servicing, possibly leading to a serious accident.
4. Symptom Table
The table below is helpful to find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. Repair or replace these parts or assemblies if necessary.
Symptom
Heavy steering
Poor return
Suspected Area
1. Tire (improperly inflated)
2. Power steering fluid (insufficient)
3. Front wheel alignment (incorrect)
4. Steering knuckle (worn)
5. Swing arm ball stud pin joint (worn)
6. Steering column (bent or binding)
7. Power steering pump assembly
8. Power steering gear assembly
1. Tire (improperly inflated)
2. Front wheel alignment (incorrect)
3. Steering column (bent or binding)
4. Power steering gear assembly
4-68 Power Steering System - Power Steering System
Symptom
Excessive clearance and play
Abnormal noise
Suspected Area
1. Steering knuckle (worn)
2. Swing arm ball stud pin joint (worn)
3. Intermediate shaft, sliding yoke (worn)
4. Front wheel bearing (worn)
5. Power steering gear assembly (worn)
1. Power steering pump fluid level (low)
2. Steering system ball joint (worn)
3. Power steering pump assembly (damaged)
4. Power steering gear assembly (damaged)
5. On-vehicle inspection
1 Check steering wheel free play
(1) Stop vehicle and keep the tires straight ahead.
(2) Rotate the steering wheel slightly, check the steering wheel
free stroke.
Maximum free play: 30mm
Max. free play
Power Steering System - Steering Drive and Control Mechanism
Section 2 Steering Drive and Control Mechanism
Component View
4-spoke steering wheel car
3-spoke steering wheel car
Steering wheel assembly (optional)
3 3 - 5 9
4-69
DriverÕs airbag module
Right combination switch
Steering column upeer cover
3 3 - 5 9
Quncunx cap screw
Steering wheel assembly
Quincunx cap screw
Clock spring
A/T:Parking lock cable
Left combination switch
Steering column assembly
Steering column lower cover
#2 counter shaft
2 2 - 2 9
Slidefork
2 2 - 2 9
1 6 - 2 6
Steering column spline dust shield
N . m : specified torque
4-70 Power Steering System - Steering Drive and Control Mechanism
Component View
Ignition switch cylinder
A/T lock cable
Conical head bolt snap ring
Upper and lower Steering column panel
Ignition switch bracket
Ignition switch assembly
Steering column
Main shaft snap ring
Non-reusable parts
Power Steering System - Steering Drive and Control Mechanism
Replacement
1. Precaution (refer to the steering system precaution)
2. Confirm that the wheel stays at a straight line running status.
3. Unfix the storage battery cathode terminal.
4. Remove the airbag assembly.
Remove the two screws on both sides, and pull out the cable connector.
Note: When removing the airbag assembly, never pull the airbag cables.
Caution: When put down the airbag assembly, make sure its top surface stays upward.
Never disassemble the airbag assembly.
Using
Socket
4-71
5. Remove the steering wheel assembly.
(1)Unfix the connector.
(2)Remove the set bolts of the steering wheel.
(3)Make a fit mark on the steering wheel assembly and main shaft assembly.
(4)Remove the steering wheel with special tool.
6. Remove the top shells and bottoms shell of the steering column shield.
(1)Remove the three screws.
(2)Remove the top part and bottom part of the steering column
shield.
7. Remove clock spring.
8. Remove the left combination switch assembly.
Separate the connector and remove the left combination switch
assembly.
9. Remove the right combination switch assembly.
Separate the connector and remove the right combination switch
assembly.
10. Remove the splined tube cover.
11. Detach No. 2 steering countershaft(see right figure)
(1) Make a mark on the fit between slide splined tube and countershaft.
(2) Loosen bolts A and B.
12. Remove the steering column pipe assembly.
(1) Remove the cable connector on the steering column pipe assembly.
(2) Remove the 3 bolts and steering column assembly.
Installation mark
4-72 Power Steering System - Steering Drive and Control Mechanism
13. Remove the No.2 steering countershaft assembly.
(1) Make a mark on the fit between main shaft and countershaft.
(2) Remove bolt and countershaft.
Installation mark
14. Remove the ignition switch bracket.
(1) Use the punch pin to make a mark on the 2 conical head bolt.
(2) Drill the 2 conical head bolts with the diameter of 3-4mm drill
bit.
(3) Remove the bolts and bracket for the ignition switch with the
thread die.
Thread die
15. Remove fixing panel on the steering column.
16.Remove the ignition switch lock core assembly.
(1) Turn the ignition switch to "ACC" position.
(2) press the stop pin and pull the lock core out.
17. After checking or replacing the steering column pipe assembly, install all parts in a reverse order.
Note:
(1) After installing the ignition switch lock core, check the operation of the steering locking function: when
pulling out the key, the steering device is locked; when the key is inserted and turned to ACC position, the
steering device is unlocked.
(2) Tighten the 3 bolts.
(3) Make sure all cables are connected reliably.
(4) After adjusting the combination switch as well as the top shell and bottom shell of the steering pipe shield,
fasten the three screws connecting the combination switch and the steering column assembly.
(5) Tighten the set bolt between the universal joint fork and the steering gear assembly with a torque of
22~39N. m.
(6) Install dust cover and its press plate.
(7) When installing the steering wheel assembly, align the steering wheel assembly and the fit mark of the
steering main shaft assembly. Tighten the special quincunx bolt with a torque of 33~59N. m.
(8) Check the airbag. It is not allowed to use a airbag part removed from another vehicle.
(9) Check the SRS warning lamp.
Power Steering System - Steering Pipeline Component
Component View
Section 3 Steering Pipeline Component
Drive belt
Power steering high pressure pipe
4-73
Return line (connecting fluld tank) Return line(connecting steering gear)
Power steering pump with bracket
N . m : specified torque
I. Onboard Check
1. Check the transmission strap.
Check the transmission strap whether it is worn out. If necessary, replace a new transmission strap.
Tips: Crack at the edge of the strap teeth is acceptable. If the strap teeth fall, replace a new strap.
2. Discharge the air in the power steering system.
(1)Check the liquid level.
(2)Lift the front part of the vehicle with a jack in a safety manner.
(3)Rotate the steering wheel.
After the motor is shut down, rotate the steering wheel to the left/right limit position lightly. Repeat such
operation several times.
(4)Loosen the jack, and put down the vehicle.
(5)Start the motor, and make it run idly for several minutes.
(6)Rotate the steering wheel to one side limit position for 2-3 seconds, and then rotate it to the other side limit
position for 2-3 seconds. Repeat such operations several times.
4-74 Power Steering System - Steering Pipeline Component
(7)Shut down the motor, and check whether there is any foam or
emulsification in the oil storage. If so, discharge the air
repeatedly.
(8)Check the level height, and check whether there is any
leakage.
2. Check the level height.
(1)Park the vehicle on the horizontal road.
(2)When the motor stops running, check the level height in the oil
tank. If necessary, add some more ATF DEXRONII steering
liquid.
Normal Abnormal
Tips: The level shall stay between the lowest level and the highest level.
(3) Check whether there is any foam or emulsification. If so, discharge the power steering liquid.
Replacement
1. Discharge the steering liquid in the power steering system.
2. Remove the power steering high & low pressure oil pipes.
3. Loosen the connector screws of the high & low pressure oil pipes on the steering gear assembly, and loosen the oil pipe clip.
4. Loosen the drive belt.
5. Remove the power steering pump strap support assembly from the motor. Remove the 3 coupling bolts between the power steering pump strap support assembly and the motor.
6. Install the power steering pump strap support assembly.
Fasten the steering pump strap support assembly on the motor, and tighten the M10 bolt with a torque of 45-
79N.m and M8 bolt with a torque of 16-26N. m.
7. Install the drive belt, and make sure the position is correct.
8. Install the high & lower pressure oil pipes of the power steering gear assembly.
(1) Connect the connector screw of the high and low pressure oil pipe to the steering gauge with a torque of
19-33N.m.
(2) Fasten the low pressure oil pipe on the body front baffle plate with clip.
(3) Connect the connector screw of the high pressure oil pipe to the power steering pump with a torque of
19-33N. m.
(4) Connect the connector screw of the low pressure oil pipe to the oil tank with a torque of 19-33N .m.
9. Discharge all air in the power steering pipe system, and check the pipe system whether there is any leakage.
10. Check the oil reservoir inner fluid level
Component View
Power Steering System - Power Steering Gear
Section 4 Power Steering Gear
4-75
2 7 - 3 9
Pin
Gear rack power steering device
125-152
2 5 - 3 2
*28-35
125-152
2 7 - 3 9
Pin
Front suspension crossmenber assembly
N . m : specified torque
* : Special tool
4-76
Component View
Power Steering System - Power Steering Gear
Left ball extension shaft
Lock nut
Steering rack # 1 dust shield
O-ring
Steering rack end sub-assembly
Steering hydraulic
oil pipe
O-ring
Clip
O-ring
Hoop
Steering rack end sub-assembly
Hoop
Clip
Steering rack # 2 dust shield
Specified torque
Non-reusable parts
Power steering oil
Special tool
Lock nut
Left ball extension shaft
Power Steering System - Power Steering Gear
Replacement
1. Drain the power steering system fluid
2. Loosen the high pressure pipes.
Loosen the high pressure pipes with special tool
3. Loosen the low pressure pipes
Loosen the low pressure pipes with special tool
4. Separate the tie rod from the steering knuckle
(1) Remove the cotter pin, loosen the groove type lock nut
(2) Separate the tie rod ball stud joint from the steering knuckle
taper hole
4-77
5. Loosen the thread screw of the high and low pressure pipe on the steering gear assembly
6. Remove the boot and press plate
7. Disconnect the power steering gear assembly from the steering column
Remove the steering gear pinion shaft spline lock bolt on the universal joint yoke
8. Remove power steering gear assembly
Remove 2 steering gear assembly set bolts. Remove the power steering gear assembly
9. Installation is in the reverse order of the removal
Notice:
(1) Insert the steering gear pinion shaft spline into the spline hole of the universal joint yoke, make sure that
the positions of the notch of the steering gear pinion shaft and the lock bolt of the universal joint yoke are
correct
(2) Secure the power steering gear with 2 bolts, torque: 125~152N.m
(3) Tighten the steering gear pinion shaft spline lock bolt on the universal joint yoke, torque: 22~34N. m
(4) Install the boot and press plate
(5) Install the threaded connector of the power steering high and low pressure pipe to the power steering gear,
torque: 25~32N.m
4-78 Power Steering System - Power Steering Gear
(6) Connect the tie rod ball stud pin with the steering knuckle, make sure that the mating surface of the tie rod
ball stud pin and the steering knuckle is clean, tighten the slot nut, torque: 27~39N. m. Install the cotter pin,
make sure of the correct installation
(7) Add appropriate amount of specified power steering fluid, bleed the power steering system
(8) Check the power steering pipeline system for leakage
(9) Check the front wheel alignment and front wheel left and right limit turn angle, adjust the toe in if
necessary and tighten the tie rod lock nut
(10) Check the position of the steering wheel. It is required that the steering wheel spokes are basically
symmetrical when the vehicle is driven straight ahead, reassemble the steering wheel if necessary
Brake System - Brake System 4-79
Chapter 9 Brake System
Section 1 Brake System
I. Precaution
1. It's very important to keep the parts and area clean when repairing the brake system.
2. Care must be taken to replace each part properly as it could affect the performance of the brake system and result in a driving hazard.
3. Do not let brake fluid remain on a painted surface when repairing any parts. Wash it off immediately.
4. If any work is done on the brake system or air in the brake pipelines is suspected, bleed the system of air.
5. Check the brake system for leakage after repairing the brake system.
6. Use specified brake fluid. Do not mix with other brand of brake fluid.
II. Symptom table
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts.
Symptom
Low brake pedal or recoil
Brake Stagnation
Suspected Area
1 Brake system (fluid leaks)
2 Brake system (air in)
3 Piston Cup in Sub-pump (worn or damaged)
4 Rear brake shoe clearance (out of adjustment)
5 Master cylinder (faulty)
6 Booster push rod (out of adjustment)
7 Brake shoe or lining (oily)
8 Disc/Drum scratched
1. Brake pedal free stroke is too small
2. Parking brake lever stroke (out of adjustment)
3. Parking brake cable (sticking)
4. Rear brake shoe clearance (out of adjustment)
5. Brake pad or lining (cracked or distorted)
6. Wheel cylinder piston (stuck or frozen)
7. Return spring (faulty)
8. Vacuum booster (faulty)
9. Brake master cylinder (faulty)
4-80
Symptom
Brake Deviation
Noise from brake
Brake System - Brake System
Suspected Area
1. Wheel cylinder piston (stuck)
2. Brake shoe lining (oily)
3. Disc (scratched)
4. Brake shoes or lining (cracked or distorted)
5. Wheel hub bearing (worn or damaged)
6. Tire pressure (not as specified)
1. Brake shoe lining (damaged)
2. Installation bolt (loose)
3. Disc (scratched)
4. Brake shoe (bad in quality)
5. Brake shoes lining (oily)
6. Sound isolating shim damaged
7. Hold spring of brake shoe (damage)
Brake System Brake Fluid
Section 2 Brake Fluid
Bleeding
1. Fill brake reservoir with brake fluid
Brake fluid: HZY4 complying with GB12981
4-81
2. Bleed brake pipeline system
(1) Connect the vinyl pipe to the wheel cylinder bleeder plug port
(2) Depress the brake pedal several times, and then loosen the bleeder plug with the pedal held down.
(3) At the point when fluid stops flowing out, tighten the bleeder plug, and then release the brake pedal.
(4) Repeat (2) and (3) until all the air in the fluid has been bled out.
(5) Repeat the above procedure to bleed the brake pipeline of the air for each wheel cylinder.
Notice: Fill brake fluid into the reservoir all the time when bleeding.
3. Check fluid level in reservoir
Check the fluid level and fill fluid if necessary.
Tips: Do not mix and use with other brand of brake fluid.
4-82
Component View
Brake master cylinder handspike U-connector
Brake System Brake Pedal
Section 3 Brake Pedal
Brake pedal bracket
Brake light switch
Brake light bushing
Specified torque
Non-reusable parts
Lithium soap-base glycol lube
25
Brake pedal axis
Lubrication bushing
Brake pedal return spring
Pad
Handspike pin
Clip
Brake pedal pad
Brake pedal
Brake System Brake Pedal
Adjustment
1. Check and adjust the height of brake pedal.
(1) Check the height of brake pedal.
Height from the floor: 124.3-134.3mm
(2) Adjust the height of brake pedal.
a. Remove the cover of the console.
b. Remove the coupler from the brake light switch.
c. Loosen the lock nut of the brake light switch, and remove
the brake light switch.
d.Loosen the lock nub of the U-connector.
e.Turn the pedal push bar to adjust the height of brake
pedal.
f. Tighten the lock nub of the push bar.
Torque: 26N.m
g. Install the brake light switch.
h. Insert the connector of the brake light switch.
i. Push the brake pedal (5-15ram), and turn the brake light
switch till it goes out. Lock the nut in this position.
j. After installation, step down the brake pedal (5-15mm),
and check the brake light is bright.
2. Check the pedal free stroke.
(1) Shut down the motor, and step on the brake pedal repeatedly
till the booster is not vacuum.
(2) Step down the pedal till resistance appears, and measure the
distance as shown in the figure.
Pedal free travel: 1-6mm
If the clearance does not meet the requirement, check the
clearance of the brake light switch. If the clearance is correct,
make diagnosis on the braking system.
Clearance: 0.5-2.4mm
3. Check the pedal reserved distance.
Loosen the parking brake extension rod.
When the motor is running, step down the pedal, and measure the pedal reserved distance as shown in the figure.
When stepping on the pedal 490N, the reserved distance from the asphalt floor is larger than 55mm
If the distance doesn't meet the requirement, make diagnosis on the braking system.
Braking lamp switch
Push par
Free travel for braking pedal
4-83
Braking pedel height
Reverse of braking pedal
4-84 Brake System Brake Pedal
Removal
After the installation, check and adjust the height, free stroke and reserved distance of the brake pedal.
1. Remove the combination instrument component (see figure 1).
2. Unfix the brake master cylinder push bar U-connector.
Remove the clip and pin, and unfix the master cylinder handspike from the brake pedal.
3. Remove the brake pedal bracket.
(1) Remove the bolt from the brake pedal bracket (see figure 1).
(2) Unfix the brake light coupler.
(3) Remove the four nuts and brake pedal bracket (see figure 2).
4. Remove the brake pedal sub-assembly.
(1) Remove the bolt and nut from the brake pedal bracket.
(2) Remove the brake pedal and the two bushings.
5. Remove the brake light switch component.
(1) Loosen the lock nut of the brake light switch.
(2) Remove the brake light switch from the brake pedal bracket.
6. Remove the brake pedal pad.
Remove the brake pedal pad from the brake pedal.
7. Install the brake pedal pad.
Install the brake pedal pad on the brake pedal.
8. Install the brake light switch component.
Install the brake light switch on the brake pedal bracket.
9. Install the brake pedal.
1
2
(1) Apply lithium soap-base glycol lube on the end surface and side surface of the two new bushings.
(2) Install the brake pedal and the two bushings on the brake pedal bracket with bolts and nuts.
Torque: 37N.m
10. Install the brake pedal bracket.
(1) Install the brake pedal bracket with four nuts.
Torque: 25N.m
(2) Connect the connector of the brake light switch.
(3) Install the bolt on the brake pedal bracket (see figure 3).
Torque: 20N.m
11. Connect and install the brake cylinder push bar U-connector.
(1) Apply the lithium soap-base glycol lube on the handspike pin.
(2) Connect the master cylinder handspike with pins and clips.
12. Install the combination instrument components.
13. Check and adjust the brake pedal height.
14. Check the brake pedal's free travel.
15. Check the brake pedal's reserved distance.
3
Brake System Brake Master Cylinder Assembly
Section 4 Brake Master Cylinder Assembly
Component View
Vacuum booster Brake master cylinder sub-assembly
Vacuum tube
4-85
No ABS
N . m : specified torque
Manual Transmission
#1 clutch fluidr tank pipe
Fluid level indicator lamp connector
4-86 Brake System Brake Master Cylinder Assembly
Component View
With ABS:
Cover
Strainer
Brake fluid reservoir
Automatic Transmission
Pin
O-ring
Retaining ring
Straight pin
Hole connector
Master cylinder
Without ABS
Cover
Hole connector
#2 piston
Cup
Washer
#1 piston & Spring
Spring
Strainer
Pin
Manual Transmission
Piston guide block
Retaining ring
O-ring
Hole connector
Hole connector
Master cylinder
Piston limit bolt
Specified torque
Non-reusable parts
Lithium soap base glycol lube
#1 piston & Spring
#2 piston & Spring
Washer
Cup
Piston guide block
Brake System Brake Master Cylinder Assembly
Repair
1. Discharge the brake fluid.
Note: Never spray the brake fluid on the paint surface, otherwise
wash it immediately.
2. Remove the brake master cylinder.
(1) Pull out the connector of the level alarm light switch.
(2) Slide the clip, and pull out #1 clutch storage tank pipe (manual
transaxle).
With ABS:
Without ABS
(3) Remove the two brake pipes from the brake master cylinder
with special tool.(with ABS)
(4) Remove the three brake pipes from the brake master cylinder
accessory with special tool. (without ABS)
(5) Remove the two lock nuts, and pull out the brake master
pump.
3. Remove the storage tank.
(1) Put the brake master cylinder on the bench clamp.
(2) Remove the pin from the brake master cylinder body with
punch and hammer.
(3) Pull out the Brake fluid reservoir.
(4) Remove the cover and strainer from the storage tank.
(5) Remove the storage tank and the two hole connectors.
4. Remove the brake master cylinder.
(1) Put the brake master cylinder on the bench clamp.
(2) Remove the O-ring.
(3) Push the piston with hand, and remove the snap ring with
snap ring pliers.
4-87
4-88 Brake System Brake Master Cylinder Assembly
(4) Push the piston with hand, and turn the cylinder body to
remove the straight pin. (with ABS)
(5) Push the piston with hand, and remove the piston bolt and
washer. (without ABS)
(6) Pull out #1 piston, piston guide block, spring, cup and washer
straightly.
Note: If angle appears in the pulling process, it may cause
damage to the cylinder wall.
(7) Put two blocks and cloth on the workbench. Put the flange of
the master cylinder against the block edge and knock it till #2
piston and spring get out of the cylinder.
Tips:
Make sure the distance (A) between the working cloth and the block's top is at least 100mm.
Note:
If angle appears in the pulling process, it may cause damage to the cylinder wall.
5. Check the brake master cylinder.
(1) Check the cylinder wall whether there is any rust or nick.
(2) Check the cylinder wall whether there is any abrasion or damage.
Note:
If necessary, clean or replace the brake master cylinder.
Tips:
Clean the assembled parts with compressed air.
6. Install the brake master cylinder.
(1) Fix the brake master cylinder on the bench clamp.
(2) Apply the lithium soap-base glycol lube on the rubber parts with arrow.
(3) Install # 2 and # 1 pistons, spring, piston guide block, cup and washer.
Note:
If angle appears in the installation process, it may cause damage to the cylinder wall. Be careful not to
damage the edge of the cup on the piston.
Brake System Brake Master Cylinder Assembly
(4) Push the piston, and install the straight pin on the cylinder
body. (with ABS)
(5) Push the piston, and install the new washer and piston bolt.
Torque: 10N.m
4-89
(6) Push the piston, and install the snap ring with snap ring pliers.
(7) Install the O-ring on the brake master cylinder.
7. Install the Brake fluid reservoir.
(1) Apply the lithium soap-base glycol lube on the Brake fluid reservoir connector, and install it on the brake
master scylinder.
(2) Install the pin on the brake master cylinder with punch and hammer.
8. Check and adjust the vacuum booster push bar.
(1) Install a special tool on the brake master cylinder,and lower
the special tool mandril till it touches the piston.
(2) Mark the mandril top surface of the special tool with chalk.
(3) Overturn the special tool, and leave a clearance between the
special tool and the vacuum booster.
Tips:
If there is clearance between the special tool body and the booster hull, it means that the clearance is
standard value. If there is no chalk trace on the booster push bar, it means that the clearance exceeds the
standard value.
4-90 Brake System Brake Master Cylinder Assembly
(4) Adjust the length of the vacuum booster push bar with the
special tool till the push bar touches the mandril head.
9. Install the brake master cylinder.
(1) Install the brake master cylinder on the booster with two bolts.
Torque: 13N.m
(2) Connect the two brake oil pipes to the brake master cylinder
with a special tool. (with ABS)
Torque: 15N.m
(3) Connect the three brake oil pipes to the brake master cylinder
with a special tool. (without ABS)
Torque: 15N.m
(4) Connect # 1 clutch storage tank oil pipe with clip. (Manual
transaxle type)
(5) Insert the brake fluid level alarm switch connector.
With ABS:
Without ABS
10. Add the brake fluid to the Brake fluid reservoir.
11. Discharge the air in the brake master cylinder.
12. Discharge the air in the brake pipeline.
13. Check the level height in the Brake fluid reservoir.
14. Check the brake fluid whether there is any leakage.
Component View
Brake System Vacuum Booster
Section 5 Vacuum Booster
Battery
#2 relay box, engine chamber
4-91
Pin
Return spring
15
Master cylinder
Vacuum tube
Clip 26
Without ABS
15
13
15
Manual Transmission
#1 clutch fluid tank oil pipe
15
Clip
25
Vacuum booster assembly
Gasket
Fluid level indicator lamp connector
Push bar
U-connector
19
Clip
19
HECU assembly
Specified torque
Non-reusable parts
Lithium soap base glycol lube
4-92 Brake System Vacuum Booster
Check
1. Check the brake booster.
(1) Air tightness check
a. Start the motor, and shut it down after one or two minutes, then step on the pedal several times slowly.
Tips:
If the pedal goes down greatly at the first step, but it gradually
goes up after the second and third steps, it means the air
tightness is good.
Good
Positiom 3
Positiom 2
Positiom 1
Poor
b. When the motor is running, step down the brake pedal, and then shut down the motor.
Tips:
If the reserved distance does not change thirty seconds after
the pedal is stepped down, it means the air tightness is good.
(2) Operation check
a. When the ignition switch stays in OFF position, step on the
pedal several times, and then check that the reserved
distance should not change.
b. Step down the pedal, and start the motor.
Tips:
If the pedal goes down a little, it means the operation is ok.
2. Check the vacuum one-way valve.
(1) Check the vacuum one-way valve.
a. Slide the clip to unfix the vacuum tube.
b. Remove the vacuum one-way valve.
c. Check the booster is ventilated to the motor.
d. In case of any failure, replace the vacuum one-way valve.
ON OFF
Brake System Vacuum Booster
Replacement
1. Discharge the brake fluid.
Note:
Never spray the brake fluid on the paint surface, otherwise wash it immediately.
2. Unfix the clutch fluid tank pipe (manual transaxle).
3. Remove the brake master cylinder.
4. Remove the HECU assembly (with ABS).
5. Remove the vacuum booster.
(1) Unfix the vacuum tube from the brake booster.
(2) Remove the return spring, clip and pin.
(3) Remove the four nuts and U-clip.
(4) Pull out the vacuum booster and washer.
6. Install the vacuum booster.
(1) Install the vacuum booster and new washer.
(2) Install and fasten the vacuum booster nut.
Torque: 25N.m
(3) Install the return spring, clip and pin.
7. Install the vacuum booster push bar.
8. Install the brake actuator. (with ABS)
9. Install the brake master cylinder.
10. Connect the clutch fluid pipe.
11. Add the brake fluid to the reservoir.
12. Discharge the air in the brake master cylinder.
13. Discharge the air in the brake pipeline.
14. Check and adjust the height of the brake pedal.
15. Check the free stroke of the pedal.
16. Check the reserved distance of the pedal.
17. Discharge the air in the clutch tank pipe (manual transmission).
18. Check and adjust the clutch pedal (manual transmission).
19. Check the level height in the brake reservoir.
20. Check the brake fluid whether there is any leakage.
21. Check the clutch fluid whether there is any leakage (manual transmission).
4-93
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