Great Wall Sailor (2006 year). Service Manual — part 9
SA-23
3.
Mount the guide lever on the lower arm
Fastening torque
(96 0)Nm
4.
Link the transverse stabilizer rod with the lower arm.
Fastening torque
(23 3)Nm
5.
Mount the vibration damper.
6.
Mount the ending part of the drag rod:
(a)
Link the drag rod end to the steering knuckle arm, mount
and screw up the nuts according to the specified torque.
Fastening torque
(91 0)Nm
(b)
Lock the nut with the new split pin.
7.
Mount the torsion rod spring.
8.
Check the Alignment of Front Wheel.
(See the page SA-3)
Suspension System and Automobile Axle (Dr/2WD)
Front Suspension (Lower Arm and Vibration Damper)
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SA-24
Upper Arm
Dismantle of Upper Arm
1.
Take apart the ball stud from the upper arm:
(a)
Support the upper arm with a jack.
(b)
Take apart the four sets of bolt and nut.
2.
Take apart the upper arm
(a)
Tear down the bolts and adjusting gasket.
(b)
Take apart the upper arm.
Remark: Do not lose the adjusting gasket. Write down the
gasket thickness so that it can be mounted on the original place.
Change of the rubber liner of Upper arm
shaft
1.
Tear down the rubber liner of the upper arm.
(a)
Tear down the bolts and the pinch-off gasket of the upper
arm shaft bush.
(b)
Push out the rubber liner of upper arm with tools.
2.
Mount the upper arm rubber liner.
(a)
Push in the rubber liner of the upper arm with tools.
(b)
Mount on the pinch-off gasket of the upper arm shaft
bush and tighten the bolts manually.
Remark: it is not required to screw up the bolts according to the
specified torque.
Mount of Upper Arm
1.
Screw up the axle bolts of the upper arm according to
the specified torque,
Fastening torque
(100 0)Nm
Suspension System and Automobile Axle (Dr/2WD)
Front Suspension (Upper Arm)
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SA-25
2.
Mount the upper arm
(a)
Mount on the upper arm and the regulating gasket.
(b)
Screw up the bolts according to the specified torque.
Fastening torque
(96 0)Nm
Remark: Mount back the gaskets of the same thickness in the
same number on the original locations.
3.
Connect the upper ball stud and upper arm together.
Fastening torque
26Nm
4.
Check the Alignment of Front Wheel
(See page SA-3)
Suspension System and Automobile Axle (Dr/2WD)
Front Suspension (Upper Arm)
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SA-26
Suspension System and Automobile Axle (Dr/ 2WD)
Front Suspension (Guide Lever)
Guide Lever
Disassembly of Guide Lever
1.
Mark the assembly mark on the guide lever.
2.
Tear down the front fixing nuts from the guide lever.
3.
Tear down the guide lever from the lower arm.
Tear down the nuts that fix the guide lever on the lower
swimming arm, and then tear down the guide lever.
Mount of Guide Lever
1.
Mount on the front fixing nuts
Mount on the front fixing nuts and meanwhile align the
assembly marks on the guide lever.
4.
Screw up the fixing nuts according to the specified torque,
(a)
Dismantle the bracket so that make the vehicle bounce
sever times to put the suspension in balance.
(b)
Screw up the front fixing nut.
5.
Check the Alignment of Front Wheel
(See Page SA-3)
2.
Mount the guide lever on the bracket
(a)
Mount the washer and liner on the guide lever, and then
mount the guide lever on bracket.
(b)
Mount the sleeve ring, the liner and the washer on the
guide lever.
(c)
Screw up the fixing nuts with finger.
3.
Mount the guide lever on the lower swing arm.
Screw up the fixing nuts according to the specified torque.
Fastening torque
(96 )Nm
assembly mark
assembly mark
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SA-27
Suspension System and Automobile Axle (Dr/2WD)
Front Suspension (Transverse Stabilizer Rod)
Transverse stabilizer rod
Dismantle of Transverse Stabilizer Rod
1.
Tear down the torsion rod spring
2.
Tear down the transverse stabilizer rod from the lower
swing arm,
(a)
Tear down the nuts and cushion blocks that support the
two sides of the stabilizer rod from the lower swing arm
so as to disconnect the stabilizer rod.
(b)
Tear down the liner and bracket of the stabilizer rod and
then tear down the stabilizer rod.
Mount of Transverse Stabilizer Rod
1.
Put the transverse stabilizer rod on the frame,
Lay the stabilizer rod in place, and mount the stabilizer rod
liner on the bracket, then mount the bracket on frame, finally
screw up the bolts with fingers.
2.
Connect the transverse stabilizer rod to the lower swing arm.
Connect the two ends of stabilizer to two lower swing arm with
bolts, cushion blocks and new nuts.
As shown in the drawing, tighten the nuts according to the
specified torque.
Fastening torque
(29 )Nm
3.
Screw up the locating bolts according to the specified
torque,
Fastening torque
(29 )Nm
4.
Mount on the torsion rod spring.
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SA-28
Suspension System and Automobile Axle(SF/2WD)
Front Suspension
locking ring
cushion block
nut
locking ring
cushion block
upper arm
transverse stabilizer rod
bolt
transverse stabilizer rod gasket
rubber
snubber washer
restrictor tube
Brake
caliper
steering knuckle
brake oil pipe bracket
steering
knuckle arm
brake shell
dust cover
oil seal -front hub
front wheel
bearing(inner)
front wheel hub and
front brake disc
stop washer
lock plate
front hub bearing
(outer)
steering knuckle nut
liner
lower
ball stud
Parts that cannot be reused after being used
:specified torque
N
m
135-155
23
29
25
29
70-90
132-152
20-26
180
127-147
132
152
123
shock absorber
steering knuckle
outer flange cap
Front wheel hub and steering knuckle
Element figures
SF2WD
stabilizer rod gasket
stabilizer rod gasket
rubber snubber
washer
stabilizer rod gasket
stabilizer rod gasket
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SA-29
Front Wheel Hub
Disassembly of Front Wheel Hub
1.
Tear down the brake caliper.
(a)
Tear down the brake Bundy tube from the brake caliper,
and block the Bundy tube line with a cork.
(b)
Tear down the brake caliper from the steering knuckle.
2.
Tear down the steering knuckle outer flange cap.
3.
Tear down the front wheel hub and brake disc.
(a)
Open the lock plate with a screwdriver.
(b)
Tear down the steering knuckle nut with the SST tools to
take out the. lock plate
(c)
Tear down the other steering knuckle nut with SST tools
to take out the stop washer and the steering knuckle outer
bearing.
(d)
Tear down the front wheel hub and the brake disc
assembly.
4.
Tear down the front hub, oil seal, front hub bearing
(inner) inner race and roller assembly.
(a)
Pry out the oil seal.
Notice: the deformed oil seal should not be reused.
(b)
Take out the front hub bearing (inner) inner race and
roller assembly.
Suspension System and Automobile Axle (SF/2WD)
Front Wheel Hub and Steering Knuckle (Front Wheel Hub)
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SA-30
5.
Front hub bearing outer race inspection and change
(a)
Check each bearing
Wash the inner and outer races of each bearing, and check
them whether they are wearied or damaged.
(b)
Tear down the outer race of each bearing.
Tap out the bearing outer race with copper bar and
hammer.
Notice: bind the dismantled inner and outer races of
bearing together to prevent from mixing.
6.
Front brake disc inspection and change
(a)
Check the wear situation of front brake disc.
(b)
Tear down the bolts that connect the front wheel hub and
front brake disc.
(c)
Connect the front wheel hub and front brake disc and
screw up the bolts with moment spanner to the specified
torque diagonally
Fastening torque
(70-80)Nm
(d)
Conduct the dynamic balance test on the dynamic balancer,
the amplitude value displayed should not be above 13.5g
under the condition that the measuring rotating velocity
is 796 r/m and the locking rotating velocity 786 r/m,
otherwise, tap in the counter balanced clip, which is 4g
each, at the corresponding location, the number of the
clip should not be more than 4.
(e)
Tap in the new bearing outer race with the special service
tool.
Notice: the inner and outer races of bearing should be
changed in set.
Assembly of Front Wheel Hub
1.
Mount on the inner race and roller assembly of front hub
bearing (inner) as well as the front hub oil seal.
Coat the lithium base grease of 4 to 5 mm on the inside surface of
the bearing outer race and front wheel hub, and plaster the
lubricant in the front hub bearing (inner) and the roller assembly.
Coat a little lubricant on the lips of oil seal of front wheel hub, and
then tap the oil seal of front hub in place with special service tool.
Notice: do not coat the lubricant on the front brake disc face.
Suspension System and Automobile Axle (SF/2WD)
Front Wheel Hub and Steering Knuckle (Front Wheel Hub)
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SA-31
2.
Mount on the inner race and roller assembly of front hub
bearing (outer).
After coating 4 to 5 mm lithium base grease on the outer race
of bearing, put in the inner race and roller assembly of front hub
bearing (outer), and then plaster the lubricant.
3.
Mount the front wheel hub and front brake disc on the
steering knuckle.
Coat a little lubricant on the steering knuckle where the oil seal
locates, and mount the front wheel hub and front brake disc on
the steering knuckle, then mount on the stop washer.
4.
Adjust the preload
(a)
Mount on the steering knuckle nut and screw up them
according to the specified torque.
Tighten torque: (100-120)N
m
(b)
Run the front wheel hub about 1/4-1/3 round, and seat the
bearing.
(c)
Loosen the steering knuckle nut to ensure the front brake
disc can run freely. Screw up the steering knuckle nut
again according to the specified torque.
Fastening torque
25Nm
(d)
Mount on the lock plate and another steering knuckle nut.
Tighten torque
60Nm
(e)
Hold the front wheel hub bolts with a spring-tension
meter and drag the meter slowly in the direction of the
tangent line of this spot.
Suitable tension range: (29-54)N
The nuts should be retightened until falls within the suitable
range if the tension force is overlarge or over small.
(f)
Check the bearing and ensure that the clearance, which is
not larger than 0.05 mm, is not excessive.
(g)
Measure the bouncing value of the front brake disc face.
Bouncing value should not be above o.11mm.
Suspension System and Automobile Axle (SF/2WD)
Front Wheel Hub and Steering Knuckle (Front Wheel Hub)
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SA-32
(h)
Bend one tooth of the lock plate inside and other teeth
outside to lock the steering knuckle nut.
5.
Mount on the liner and the steering knuckle outer flange
cap.
Fastening torque
(23-29)Nm
6.
Mount the brake caliper
(a)
Mount the brake caliper on the steering knuckle and
screw up the bolts according to the specified torque.
Fastening torque
123Nm
(b)
Connect the Bundy tube.
Fastening torque
(20-22)Nm
7.
Check the height of the brake liquid level and add the
brake liquid as requirement, exhaust the gas in the
braking system.
Steering knuckle
Dismantle of Steering Knuckle
1.
Tear down the brake caliper, front wheel and the front
brake disc.
2.
Tear down the dust cover, and the brake shell.
3.
Tear down the steering knuckle arm from the steering
knuckle.
Suspension System and Automobile Axle (SF/2WD)
Front Wheel Hub and Steering Knuckle (Steering Knuckle)
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SA-33
4.
Tear down the vibration damper from the lower arm.
5.
Tear down the transverse stabilizer rod from the lower
arm.
6.
Tear down the steering knuckle;
(a)
Tear down the split pin and groove nut of upper ball stud.
(b)
Take apart the steering knuckle from the upper ball stud
with special service tool.
(c)
Tear down the split pin and groove of the lower ball stud.
(d)
Take apart the steering knuckle from the lower ball stud
with special service tool.
(e)
Press down the lower arm to tear down the steering
knuckle.
Suspension System and Automobile Vehicle (SF/2WD)
Front Wheel Hub and Steering Knuckle (Steering Knuckle)
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SA-34
7.
Tear down the lower ball stud assembly from the steering
knuckle.
Inspection on and Change of Steering
Knuckle
1.
Check the steering knuckle.
Check the steering knuckle with the dye penetration agent to
see whether there is crack or not.
If crack is found, the steering knuckle is required to be changed.
Mount of Steering Knuckle
1.
Mount the lower ball stud on the steering knuckle.
Connect the lower ball stud and steering knuckle with bolts,
which are tightened according to the specified torque.
Fastening torque
(70-90)Nm
2.
Mount on the steering knuckle
(a)
Press down the lower arm to mount on the steering
knuckle.
(b)
Mount on the lower ball stud, groove nut and screw up the
nuts according to the specified torque and then mount on
the split pin.
Fastening torque
(132-152)Nm
Suspension System and Automobile Axle (SF/2WD)
Front Wheel Hub and Steering Knuckle (Steering Knuckle)
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SA-35
(c)
Mount on the upper ball stud and the groove nut that are
screwed up according to the specified torque, and then
split pin.
Fastening torque
(132-152)Nm
3.
Mount the stabilizer rod on the lower arm.
Fastening torque
(20-26)Nm
4.
Mount the vibration damper on the lower arm.
Fastening torque
(127-147)Nm
5.
Mount the steering knuckle arm and the brake oil pipe
bracket on the steering knuckle.
Coat the sealing agent 1271 on the bolt thread.
Fastening torque
180Nm
6.
Mount the dust cover and brake shell, and align the
locating hole of the dust cover with the groove of the
steering knuckle to ensure that the dust cover is concen-
tric with the steering knuckle.
Fastening torque
(25-29)Nm
7.
Mount the front wheel hub and the front brake disc as well
as the brake caliper.
8.
Check the height of brake liquid level and add the brake
liquid as requirement, then exhaust the gas in the brak-
ing system.
Suspension System and Automobile Axle (SF/2WD)
Front Wheel Hub and Steering Knuckle (Steering Knuckle)
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SA-36
Front Suspension
Elemtents figures
Suspension System and Automobile Axle(SF/2WD)
Front Suspension
upper swing arm
shaft
upper arm
transverse
stabilizer rod
vibration
damper
lower arm shaft bush
pinch-off gasket(small)
lower arm
: specified torque
Parts that cannot be reused after being used
N
M
178
15
225
5
89
7
27
2
142
10
137
10
23
3
142
10
142
10
23
3
SF
upper arm shaft
bush(short)
upper arm shaft bush and tube(long)
torsion bar yoke
upper arm shaft bush
pinch-off gasket(large)
upper arm shaft bush pinch-off
gasket(small)
upper ball stud
eccentric
gasket
lower arm shaft bush
and tube
lower ball
stud
lower arm shaft bush
pinch-off gasket(large)
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SA-37
Ball Stud
Inspection on Ball Stud
1.
Check the lower ball stud to see whether it is excessively
loose:
(a)
Raise the vehicle with a jack and then support it with the
bracket.
(b)
Press down the brake pedal after verifying that the front
wheel is straightly forward.
(c)
Move the arm vertically to check whether the clearance
of lower ball stud is over large.
(Max vertical clearance): 0.5 mm
2.
Check whether the upper ball stud is loose excessively;
Move the wheel vertically to check whether the clearance of
the ball stud is over large.
(Max vertical clearance): 0.5 mm
3.
Check the rotating performance of the ball stud:
(a)
Tear down the ball stud;
(b)
Shake the ball stud column several times before mount-
ing on the nut, as shown in the drawing.
(c)
Rotate the nut continuously with the torsion meter at the
speed of one round each 2 to 4 seconds, read the meter
reading at the fifth round.
Fastening torque(running)
lower ball stud
(0.1-4)Nm
Upper ball stud: (0.1-4)N
m
Disassembly of Ball Stud
1.
Tear down the steering knuckle, steering knuckle arm
and the lower ball stud assembly.
2.
Tear down the ball stud from the steering knuckle;
3.
Tear down the ball stud from the upper ball stud.
Suspension System and Automobile Axle (SF/2WD)
Front Suspension (Ball Stud)
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SA-38
Mount of Ball Stud
1.
Mount the upper ball stud on the upper arm;
Fastening torque
(27 )Nm
2.
Mount the lower ball stud on the steering knuckle;
Fastening torque
(80 0)Nm
3.
Mount on the steering knuckle and hub brake disc
assembly
(See Page SA-34)
Suspension System and Automobile Axle (SF/2WD)
Front Suspension (Ball StudTorsion Rod Spring)
Torsion Rod Spring
(see Page SA-19)
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