Geely CK (2008). Manual part — 36
Geely CK (2008). Manual part - 36
141
Section 3 Brake Pedal
Components
1. Vacuum Booster Assembly
2. Liner
3. Spacer
4. Torsion Spring
5. Brake Pedal Arm
6. Cushion Gasket
7. Brake Pedal Mat
Replacement:
1. Separate the vacuum booster with brake master cylinder assembly
Remove the cotter pin, flat washer and pivot, separate the vacuum booster with brake master cylinder
assembly from the brake pedal
2. Remove the clutch and brake pedal assembly
(1) Remove 4 nuts connecting the vacuum booster with brake master cylinder assembly and brake
pedal support bracket.
(2) Remove 3 bolts connecting the clutch and brake pedal assembly and front cowl panel cross member.
Remove the clutch and brake pedal assembly.
3.Remove the brake pedal
Remove the bolt and nut, Torsion Spring, liner, brake pedal arm assembly , spacer
4. Remove the brake pedal arm assembly
Remove brake pedal mat and cushion gasket from the brake pedal arm.
5. The installation is in the reverse order of removal.
Notice:
(1) Apply No 3 molybdenum disulphide lithium base grease to the relatively moving faces.
(2) After assembling the brake pedal and the brake pedal support bracket, make sure the
brake pedal can turn freely.
Nut
Bolt
Brake Pedal Bracket
Brake Pedal
142
(3) The 3 bolts connecting the brake pedal support bracket and cowl panel cross member
Torque : 16-20N.m
(4) The 4 bolts connecting the brake pedal support bracket and the vacuum booster with
brake master cylinder assembly
Torque: 16-20N.m
Check the brake pedal
1. Check and adjust brake pedal height
(a) Brake pedal height from the ground: normal height is 176~181 mm.
(b) Adjust brake pedal height
(1) Loosen the brake lamp switch lock nut
(2) Adjust the brake lamp switch to the right position
(3) Check the brake lamp switch
Make sure the brake lamp is light by depressing the brake pedal for5~15mm
(4) Tighten the brake lamp switch lock nut
2. Check pedal freestroke
(1) Shut off the engine and depress the brake pedal several times until there is no more vacuum left in
the booster.
(2) Depress the pedal until the resistance begins to be felt
Pedal freestroke should be: 10~30mm
Worn Or Damaged
Worn Or Damaged
Worn Or
Damaged
Worn Or
Damaged
Worn Or Damaged
Worn Or Damaged
Distorted Or Damaged
Distorted Or Damaged
Bent Or Distorted
Freestroke
143
Section 4 Vacuum Booster with Brake Master Cylinder Assembly
Notice: The vacuum booster with brake master cylinder assembly must be repaired by
manufacturer. Replace it if it is faulty.
On-vehicle inspection
1. Check vacuum booster
(a) Air tightness check
(1) start the engine, run 1 or 2 minutes then shut off. Depress the brake pedal several times slightly.
Hint: if the pedal rises gradually after depressing the pedal, the booster is airtight.
(2) Depress the brake pedal while the engine is running, and stop the engine with the pedal depressed.
Hint: if there is no change in the pedal reserve stroke after holding the pedal for 30 seconds,
the booster is air--tight.
(b) Operating check
Depress the brake pedal and start the engine. If the pedal goes down slightly, operation is normal.
2. Check the vacuum check valve
(1) Remove the connecting pipe with the check valve
(2) Check the direction from the booster to the engine. Check valve for ventilation. It should not
ventilate in the reverse order.
(3) Replace it if it is faulty.
Notice: Pay attention to the matchmark on the connecting hose when connecting
the hose with vacuum check valve. Do not install it in reverse order.
Replacement
1. Remove the brake pipe on the brake master cylinder (master cylinder)
2. Refer to Brake Pedal Replacement for other operation
Notice:
(1) The torque of the union thread on the brake master cylinder (master cylinder )
and brake pipe: 12-16 N.m
(2) Bleed all the air in the brake system after installation
Good
Poor
Third
Second
First
144
Section 5 Front Brake Assembly
Components
Repairing
1. Remove the front wheel
2. Drain the brake fluid. Remove the brake hose
3. Remove the front brake caliper
(1) Remove the brake hose union thread from the front brake cylinder. Disconnect the hose
(2) Remove 2 installing bolts
4. Remove the front brake pad
5. Remove the front left disc caliper
6. Remove the sliding pin boot
Disk Brake Wheel
Cylinder Bracket
Sliding Pin Boot
Inner Floating Clip Plate
Screw Plug
Brake Caliper
Housing
Inner
Damper
Inner Pad
Backing
Plate
Inner Pad
Outer Pad
Outer Pad
Backing Plate
Outer
Damper
Outer Floating
Clip Plate
Alarm
Plate
Wheel
Cylinder
Piston
Wheel
Cylinder
Piston Seal
Wheel
Cylinder
Boot
Steel Wire
Snap Ring
Short Pin
Set Bolt
Short Bushing
Guide Boot (II)
Splash Shield
Front Ring Gear Retaining
Ring
Wheel Hub Bolt Front Wheel
Hub Bearing
Wheel Hub
Disc
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