ABS GEELY CK 2008 User Guide

108Replacement1. Remove the front wheel.
2. Remove the ABS sensor from the steering knuckle. Separate the sensor and signal wire from the wire
harness bracket on the front shock absorber.
3. Separate the front brake hose
Remove 2 clips and separate the front brake hose from the front shock absorber bracket.
4. Remove the stabilizer bar link rod assembly
Remove the nut connecting the stabilizer bar link rod assembly and the shock absorber.
5. Remove the front shock absorber with the coil spring
(1) Remove the nuts and bolts connecting the shock absorber and brake.
(2) Remove the 4 nuts connecting the front shock absorber and vehicle body.
Notice: reliable object shall be used to support the brake assembly!

1096. Disassemble the front strut assembly
(1) Remove the nut on the shock absorber.
Notice: the elasticity of the spring is recovered!
(2) Remove the washer, collar, shock absorber mount seat and big washer.
(3) Remove spring upper seat, front coil spring , front shock absorber boot, front dumper, front coil spring
lower insulator.
7. Assemble the front strut assembly
The assembly of the front strut assembly is in the reverse order of disassembly.
Notice:
(1) Use special fixture when installing the nut on the shock absorber piston rod, be
careful not to let the spring rebound. Torque: 80~90 N.Sm.(2) Install the 4 bolts attaching the front strut assembly to the body. Torque: 25~30N.m.(3) Install the 2 bolts and nuts of the front strut assembly and the brake.
Torque: 90~100N.m.
(4) Install the attaching nuts on the stabilizer bar link rod assembly and shock absorber.
Torque: 50~60N.m.
(5) Install the ABS sensor and secure the signal wire.

114ReplacementHint
1. Remove the stabilizer bar left link rod
(1) Remove the nuts connecting the stabilizer bar left link rod and front shock absorber.
(2) Remove the nut connecting the stabilizer bar left link rod and the left side of stabilizer bar.
2. Remove the front stabilizer bar
Remove the 4 bolts, front stabilizer bar rubber bushing, front stabilizer bar clamp.
3. Remove the front stabilizer bar left support frame welding assembly
Remove the nuts connecting the stabilizer bar left support frame welding assembly and vehicle body.
4. Install the front stabilizer bar support frame welding assembly
Set the front stabilizer bar support frame welding assembly to the vehicle body with bolts.
Torque: 50~60N.m

1155. Install the front stabilizer bar
Install stabilizer bar, 2 rubber bushings, the front stabilizer bar clamp and 4 bolts.
Torque: 50~60N.m
Notice:
(1) Align the inner rubber bushing with the mark on the stabilizer bar.
(2) The 4 bolts connecting the stabilizer bar clamp and front stabilizer bar support
frame welding assembly differ in length. The two short ones are close
6. Install stabilizer bar link rod assembly
(1) Attach the stabilizer bar link rod to the stabilizer bar with nuts.
Torque: 40~50 N.m
(2) Attach the stabilizer bar link rod to the front shock absorber bracket with nuts.
Torque: 40~50 N.mto engine.

116Chapter 6 Rear Suspension SystemSection 1 Rear Suspension SystemRear suspension structure descriptionThis 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 suspensionProblem Symptoms TableUse 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.Items Parameter Items Parameter
Shoc k a bsorbe r operating
cylinder diameter /mm￠
56 Cambe r -20´±30´
Shoc k a bsorbe r piston rod
diameter/mm￠
18 Wheel toe-in/mm 1～
5
Shoc k absorbe r stroke/mm 230mm
Remark: Wheel alignment parameter is at free loadSympto m Sus pe cte d Are a
1. Tires (Worn or imprope rly infla te d)
2. Wheel alignment (Incorrect)
3. Hub be a ring (Worn or da ma ge d)
4. Suspe nsion pa rts (Worn or da ma ge d)
1. Ve hic le (Ove rloa de d)
2. Spring (Stiffness small)
3. Shoc k a bsorbe r (Worn)
1. Tire (Worn or imprope rly inflate d)
2. W he e l ( not w it hin s pe c if ic a t ion)
3. Shoc k a bsorbe r (Worn)
1. Tire (Worn or imprope rly inflate d)
2. Wheel alignment (Incorrect)
3. Shoc k a bsorbe r (Worn)
4. W he e l ( not w it hin s pe c if ic a t ion)
1. Tire (Worn or imprope rly inflate d)
2. Wheel alignment (Incorrect)
3. Shoc k a bsorbe r (Worn)
4. Sus pe nsion pa rts (Worn) Abnormal tire wearDeviation
Body Desc ent
SwaysRear wheel shimmy

117Section 2 Rear SuspensionComponents
LR Strut Assembly
LR ABS Sensor Wire Harness
LR Brake
LR Brake Pipe
Clip
Clip
RR Strut Assembly
Clip
RR ABS Sensor Wire Harness
RR Brake Hosex2
No. 2 Transverse Arm
Left Trailing Rod Assembly
Body
Body
Body Body
No. 1 Transverse Arm
No. 1 Rocker Arm
Clip
RR Brake Pipe
RR Brake Hose
RR Brake
Right Trailing Rod Assembly
Rear Stabilizer Bar Assembly
No. 2 Transverse Arm
Rear Stabilizer Bar Retainer
Rod Components

119Section 4 Left & Right Rear Strut AssemblyComponentsReplacement
1. Remove the rear wheel
2. Remove ABS sensor
(1) Remove ABS rear wheel sensor retaining bolt. Remove the sensor.
(2) Remove the retaining bolt of ABS rear wheel sensor on rear shock absorber bracket
3. Separate brake pipe and rear strut assembly
Remove the elastic clip on the pipeline bracket attaching the brake pipelineCushion (Dumper)Dust Prevent
SleeveRear Suspension
Spring Lower
InsulatorRear Left
Shock Absorber Upper Mount
CushionUpper MountRear Suspension
Spring Insulator
Rear Suspension Conical Spring

1204. Remove the left and right rear strut assembly
(1) Remove the threaded connect of the rear strut assembly and rear brake assembly
(2) Remove the 3 nuts attaching the rear suspension upper mount to the body
Caution: reliable object shall be used to support the rear brake assembly! Make sure that the
brake pipeline is not affected or damaged!
5. Disassembly the left, right rear strut assembly
(1) Set the rear strut assembly with special tool. Remove the nut on the top of the
rear shock absorber piston
Caution: The spring may rebound!
(2) Remove the rear suspension upper mount, rear suspension upper mount cushion,
rear suspension spring upper insulator, rear suspension spring, rear shock absorber
cushion, rear shock absorber dust preventing sleeve, rear suspension spring lower insulator in order
6. The assembly is in the reverse order of the disassembly.
Caution:
(1) when installing the nut on the shock absorber piston rod upper end, use special fixture
and be careful that the spring may rebound!
Torque : 32~38N.m
(2) Rear strut assembly to body thread torque : 32~38 N.m
(3) Strut assembly to rear brake assembly thread torque : 81~96 N.m
(4) Install the ABS rear wheel sensor and the secure the signal wire
(5) When securing the brake line, make sure that the brake line does not interfere with
other parts
(6) Wheel nut torque : 95~115N.m
(7) Check the brake system for leakage, bleed air in the brake system as necessary
(8) Check whether the ABS signal is normal
(9) Check rear wheel alignment, adjust it as necessary

1549. Remove rear left, right brake pipe No 1 compo.
Loose the union thread that connects the brake pipe compo to HECU controller (ABS module)
10. Separate HECU controller assembly wire harness
11. Remove HECU controller bracket
Remove the 3 hex bolts connecting the bracket and the body
12. Remove HECU controller assembly from the bracket
Using special wrench, remove 3 inner torx bolts and insulator
13. Installation is in the reverse order of the procedure aboveNotice:
(1) The HECU controller bracket to body bolt torque: 20~25N.m
(2) Hose and pipe union thread torque: 12~16N.m
(3) All the hose, pipe should be fixed. The distorted clamp and E-shaped clip should
be replaced. Never interfere the hoses and pipes with other parts.
(4) Bleed the brake system
(5) Check the pipeline and the pipe union for leakage
(6) Inspect HECU control system with ABS diagnosis tester

158III. CUSTOMER FAULT ANALYSISNOTES:
1. When the troubleshooting analysis is underway, make sure to confirm the fault symptom correctly. Re-
move kinds of suppositions in order to make an exact judgment. In order to find out what on earth the fault is,
it is extremely important to ask customers about the fault symptoms and the conditions when faults occurred.
2. The 5 items below are the key points to analyze. Those faults that were considered irrelevant and the
repair history, etc are sometimes helpful. Therefore, try your best to collect relevant information, and find out
the relationship between the information you collected and the present information, in order to make refer-
ence in troubleshooting.
Key points of the Customer fault analysis:
1Vehicle model, system name
2Date, time, frequency fault occurs
3 Pavement conditions
4Running performance, driving and weather conditions
5Fault symptomIV. FAULT SYMPTOM AND DTCSNOTES:
1. The diagnosis system of the Free Cruiser possesses many features. The first important feature is the DTC
Checking. Input a fault from the ECU signal circuit in the form of code, and store it into the ECU memory.
The other feature is Input Signal Inspection. Inspect if the signals from different switches are correctly
inputted into the ECU. These features can quickly narrow the range of troubleshooting, to make an efficient
troubleshooting analysis. In the model of Free Cruiser, the systems below all possess the diagnosis feature.
1EFI system
2 ABS system
3Supplemental Restraint System (SRS)
2. When a DTC is checked, the very important point is: make sure if the fault shown by a DTC still exists, but
is normal now. In addition, when checking the fault symptom, you must check if there is direct relationship
between the fault shown by the DTC and the fault symptom. Therefore, the DTC should be checked before
and after confirming the fault symptom in order to confirm the present conditions. If you do not do so, it is
possible to make some unnecessary troubleshooting analysis on normal systems in some certain circumstances,
thus making it more difficult to locate the fault or repair according to the fault. So, a DTC check should be
done by a normal procedure.
3. The procedure below shows how to make a troubleshooting analysis by checking a DTC and how to make
efficient use of DTC check. Then carefully check the result, make a troubleshooting analysis of the DTC and
a troubleshooting analysis of the symptom.
1Inspect DTC
2Record and clear all DTCs
3Confirm fault symptom