Great Wall Hover. Instruction — part 13
special tools
Upper suspension arm
Disassembly of upper suspension arm
1. Disconnect the upper ball pin from the steering
knuckle
Remove the split pin and nut; use the special tools to disconnect
the upper ball pin from the steering knuckle.
2. Remove the brake oil pipe on the upper arm shaft
a. Use the open-end wrench to screw off the oil pipe tight nut.
b. Pull out the brake oil pipe and plug it by the rubber plug.
Remarks: There are two two-way valves for rear brake oil pipe
beside the right upper arm shaft ; when remove the right
upper suspension arm, it must remove four oil pipe tight nuts
in the place and plug it by the rubber plug to prevent the brake
fluid from overflowing.
3. Disconnect the brake hose form the brake caliper
Remove the hollow bolt and disconnect the brake hose form the
brake caliper
Remarks: Must not lose the copper gasket seal.
4. Disconnect the brake hose from the upper arm oil
pipe bracket.
Use the pliers to pull out the sheet steel spring clip and discon-
nect the brake hose from the upper arm oil pipe bracket.
5. Remove the upper suspension arm
Remove two bolts and remove the upper suspension from the
arm carriage.
Remarks: Keep the adjusting shim and don’t lose it. Record
the thickness of front and rear adjusting shim for convenience
of reinstalling them in the original position.
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Replacement of upper arm bush
1. Remove the bush
a. Remove the bolt and washer
.
b. Use the special tools to push out the bush.
c. Remove the upper arm shaft; remove another bush in same proce-
dure
2. Install the bush
a. Use the special tools to press in the bush.
b. Install the upper arm shaft; use the special tools to press inanother
bush.
3. Tighten the upper arm shaft to specified torque.
a. Coat the screw of both ends of upper arm shaft with the screw
lock sealant; install the washer and nut.
Remarks: Adjust the position of upper lower; make the installa-
tion plane of ball pin is vertical to the installation plane of upper
arm shaft.
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b. Tighten the upper arm shaft nut to specified torque.
Tightening force: 210
10N
m
Installation of upper suspension arm
1. Install the upper suspension arm on the carriage
a. Install the upper suspension arm and camber adjusting shim.
b. Tighten all bolts to the specified torque.
Tightening force: 200
10N
m
Remarks: Install the shim with same quantity and thickness to
the original position.
2. Connect the brake oil pipe of upper arm shaft
Tighten the oil pipe compression nut to specified torque.
Tightening force: 15-17N
m
Remarks: It should tighten four connector of two two-way
valves to the specified torque if disassemble the right upper
arm.
3. Connect thebrakehosetotheupperarmoilpipebracket
a. Thread the brake hose from the hole on upper arm oil pipe
bracket.
b. Use the hand hammer to knock in the sheet steel spring clip to
fix the brake hose.
4. Connect the upper ball pin to the steering knuckle
a. Tighten the slotted nut according to the specified torque.
Tightening force: 145
15N
m
b. Install the new split pin.
Remarks: It should align the notch of nut with the pinhole
when install the split pin; the nut can be tightened but not
loosed during the alignment.
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Connect the copper gasket seal and tighten the hollowbolttospecified
torque.
Tightening force: 50
5N
m
6. Discharge the air in front brake system
(refer to relevant chapter)
Remarks: It must discharge the air in the rear brake system if
disassemble the right upper arm.
7. Check the brake fluid for leakage
8. Tighten the upper arm front shaft nut to the specified
torque
Install the wheel, remove the bracket and bounce the vehicle for
several times to make the vibration damper enters into the stable
status.
9. Check the wheel alignment parameter
(Refer to 4-Wheel Alignment)
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Stabilizer bar
Disassembly of stabilizer bar
1. Disconnect the connecting bar which supports both
ends of the stabilizer bar form the stabilizer bar.
Use the inner hexagon spanner to fix the ball pin; remove the self-
locking nut.
2. Remove the bush and clip of stabilizer bar; remove
the stabilizer bar
Installation of stabilizer bar
1. Install the stabilizer bar on the carriage
Place the stabilizer bar in position; install the stabilizer bar bush
and clip on the carriage. Screw on and pretighten the bolt.
2. Connect the stabilizer bar to the connecting bar
Installand tighten the new nut to the specified torque
Tightening force: 63
5N
m
3. Tighten the clip position bolt to specified torque.
Tightening force: 23
3N
m
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N
m: specified torque
Used component which can not be used any more.
precoated component
Front hub and steering knuckle (4WD)
stabilizer bar
flat shim
connecting rod
of stabilizer bar
hub and brake disc
flange
adjusting washer
circlip
hub cap
spring shim disc brake
split pin
lower suspen-
sion arm
split pin
upper suspension arm
drive shaft
oil seal
n e e d l e
bearing
lock washer
steering knuckle
lock nut
lock washer
screw
brake cover
spring shim
flat shim
disk shim
Shim
fill block
fill block
disk shim
oil seal
bearing
bearing
shock absorber
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special tools
diagram of
special tools
Front hub
Disassembly of front hub
1. Remove the disc brake
Remove the brake caliper and hang it by steel cable.
Remarks: Do not remove the brake pipe and brake hose.
2. Remove the hub cap and flange
a. Use the inner hexagon spanner to screw off the fastening blot
and remove the hub cap.
b. Use the pliers to remove the circlip and remove the adjusting
washer.
c. Remove the flange.
3. Remove the hub and brake disc
a. Use the Philips screwdriver to screw off the tight screw;
remove the lock washer.
b. Use the special tools to remove the lock nut.
c. Remove the hub and brake disc with the outer bearing.
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4. Remove the oil seal and inner bearing
a. Use the screwdriver to pry out the oil seal
b. Remove the inner race of inner bearing form the hub.
Check and repair of front hub
1. Check all bearings
Wash the inner race and outer race of each bearing and check them for
wear and damage.
2. Replace the bearing outer race
a. Use the brass bar and hand hammer to knock out the bearing outer
race.
Use the special tools to knock in the new bearing outer race.
Assembly of front hub
1. Coat the inner surface of hub and bearing outer race
with the grease.
The grease is the Jin HP-R grease or the grease met the requirement
in following table.
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diagram of
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grease
Dropping point, C
Leakage amount (104 C, 6h), g
EP performance OK value , N
Item
Typical data
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2. Place in the bearing inner race; use the fill the gap
between the inner and outer race of the bearing up
with the HP-R grease.
grease
grease
3. Install the inner bearing and oil seal
a. Place the inner bearing in the hub
b. Use the special tools to knock the new oil seal into the hub.
c. Coat the oil seal lip with HP-R grease.
diagram of
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special tools
4. Install the hub on the steering knuckle
a. Install the hub on the steering knuckle
b. Install the outer bearing.
5. Adjust the pre-applied load
a. Use the special tools to screw on the locknut to specified
torque.
Tightening force: 80-100N
m
b. Rotate the hub to right and left 1/3
1/4 round respectively.
c. Screw off the nut until the nut can be loosed by hand.
d. Use the special tools to retighten the lock nut.
Tightening force: 28N
m
e. Use the spring tension meter to check the pre-applied load.
Pre-applied load (for starting): 28-56N
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diagram of
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6. Install the lock washer
Install the lock washer with the surface with counterbore outwardly
and fix it on the lock nut by screw.
Remarks: If the screw installation hole on the lock washer can not
align with the screw hole on the lock nut, then it can remove the
lock washer and adjust he lock nut slightly (rotate in the direction
of Min. adjusting range ); then install the lock washer.
7. Recheck the pre-applied load
Use the spring tension meter to recheck the pre-applied load
Pre-applied load (for starting): 28-56N
If the pre-applied load does not meet the specified value, it must
remove the lock washer and adjust it by the adjusting nut.
8. Install the ring flange
a. Install the ring flange on the hub.
b. Install the adjusting washer.
c. Install the circlip.
9. Install the hub cap
a. Coat the screw of the inner hexagon bolt with the screw lock
sealant.
b. Use the inner hexagon bolt to fix the hub cap and ring flange on
the hub; tighten the bolt to the specified torque.
Tightening force: 78
5N
m
10. Install the disc brake
Install the disc brake on the steering knuckle; tighten the bolt to the
specified torque.
Tightening force: 140
10N
m
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Steering knuckle
Disassembly of steering knuckle
1. Remove the disc brake and front hub
(Refer to section “Front Hub”)
2. Remove the brake cover
3. Disconnect the steering cross rod from the steer-
ing knuckle arm
a. Remove the split pin and nut on the ball pin.
b. Use the special tools to disconnect the steering cross rod
from the steering knuckle arm.
4. Disconnect the connecting rod of stabilizer bar
from lower arm
Use the inner hexagon spanner to fix the ball pin; remove the
self-locking nut.
5. Remove the steering knuckle
a. Remove the split pin and nut on the upper ball pin
b. Use the special tools to disconnect the upper ball pin from
the steering knuckle.
c. Remove the split pin and nut on the lower ball pin.
d. Use the special tools to disconnect the upper ball pin from
the steering knuckle.
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e. Use the jack to raise the lower arm; remove the steering knuckle.
Check and replacement of steering knuckle
1. Check of steering knuckle
Use the dye penetrant to check the steering knuckle for crack.
It should replace the steering knuckle if has crack.
2. Remove the steering knuckle oil seal
Use the screwdriver to pry out the oil seal from the steering knuckle.
3. Take out the thrust plate
4. Remove the needle bearing
Use the copper bar and hand hammer to knock out the needle
bearing.
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5. Installation of needle bearing
Use the special tools and hand hammer to knock in the new
needle bearing slightly.
Remarks: The thicker end of needle bearing should be
upwardly when knock in. with thicker end.
chamfer
steering
knuckle
6. Installation of thrust plate
Coat the installation position of thrust plate of steering knuckle
with the HP-R grease; place the thrust plate with the surface
with chamfer facing the steering knuckle.
Remarks: It must measure the thickness of the thrust plate
before the installation; it should install the new thrust plate if
the thickness is less than 1.5mm. The nominal thickness of
the new thrust plate is 2mm.
7. Installation of steering knuckle oil seal
Use the special tools and hand hammer to knock in the new
steering knuckle oil seal slightly.
Installation of steering knuckle
1. Install the steering knuckle
a. Coat the drive shaft and inner of drive shaft dustproof cove
with the lithium base grease.
b. Insert the drive shaft into the steering knuckle, meanwhile
connect the lower ball pin to the steering knuckle and install the
slotted nut temporarily.
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c. Press down the upper arm and connect the upper ball pin to the
steering knuckle. Install and tighten the nut to the specified
torque.
Tightening force: 145
15N
m
d. Install the new split pin.
Remarks: It should align the notch of nut with the pinhole when
install the split pin; the nut can be tightened but not
loosedduringthealignment.
e. Install and tighten the lower ball pin nut to specified torque.
Tightening force: 230
20N
m
f. Install the new split pin.
Remarks: It should align the notch of nut with the pinhole when
install the split pin; the nut can be tightened but not
loosedduringthealignment.
2. Connect the stabilizer bar to the lower arm
Support the lower arm by jack; use the inner hexagon spanner to fix
the ball pin and tighten the self-locking nut to specified torque.
Tightening force: 63
5N
m
3. Connect the steering cross rod to the steering
knuckle arm
a. Tighten the slotted nut according to the specified torque.
Tightening force: 170
15N
m
b. Install the new split pin.
Remarks: It should align the notch of nut with the pinhole when
install the split pin; the nut can be tightened but not
loosedduringthealignment.
4. Install the brake cover
Tightening force: 23
3N
m
5. Install the front hub and disc brake
(Refer to section “Front Hub”)
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clip
Front suspension (4WD)
N
m: specified torque
Used component which can not be used any more.
Pregummed component
rubber sleeve
front shaft of
lower arm
disk shim
fill block
shim
fill block
disk shim
shock Absorber
front hub and steering
knuckle assembly
split pin
lower ball pin
adjusting bolt
lower adjusting block
fixed arm
upper
adjusting
block
l ower arm
rear shaft of lower arm
Torsion base
torsion
bar
lower arm long bush
split pin
upper ball pin
upper arm
shim
upper arm bush
upper arm shaft
upper arm bush
shim
front stabilizer bar
flat shim
connecting rod of stabilizer bar
flat shim
lower arm short bush
eccentric shim
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Ball pin
Check of ball pin
1. Check the lower ball pin for loose
a. Raise the front of the car by jack and support it by the frame.
b. Ensure the front wheel is in straight advancing position and step
down the brake pedal.
c. Move the arm upwardly and downwardly; check
the clearance of lower ball pin.
Max. vertical clearance: 0mm
2. Check the upper ball pin for loose move the wheel
upwardly and downwardly and check the gap of
upper ball pin.
Max. vertical clearance: 0mm
3. Check the rotation of ball pin
a. Remove the ball pin.
b. Shown as figure, shake the ball pin stud forwardly and backwardly
for several times before install the nut
c. Rotate the nut continuously by torsion meter and 2-4s for a
cycle; record the readout of torsion meter in the fifth cycle.
Tightening torque (for rotary):
Lower ball pin 0.1
4N
m
Upper ball pin 0.1
4N
m
Disassembly of ball pin
1. Remove the steering knuckle and front hub assembly
(Refer to section “Front Hub and Steering Knuckle”)
2. Remove the lower ball pin form the lower arm
3. Remove the upper ball pin from the upper arm
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