check engine GREAT WALL FLORID 2008 Owner's Manual

Downloaded from www.Manualslib.com manuals search engine 105Brake System
3. Remove the check valve assembly.
Pull out the check valve and valve seat from the vacuum
booster's front case as shown on the left.
Disassembling the vacuum booster with
brake cylinder assembly
1. Brake master pump removal.
Take down the lock nuts between the fixed brake master
pump and front case with a M13 sleeve, and then forcibly
pull out the brake master pump.
Caution: Do not lose the rectangular sealing ring.
2. Remove the brake reservoir assembly.
Push out the elastic cylindrical pin from the hole of the oil
cup’s foot with a suitably sized screwdriver, and then pull
out the oil cup from the pump in the direction as shown on
the left. If necessary to take off the brake reservoir cover,
twist it off manually.
6. Screw off the coupling bolt between the vacuum booster
and the pedal bracket with a M13 sleeve.
7. Extract the vacuum booster with brake cylinder assem-
bly.
Removal of the vacuum booster with brake cylinder assembly
is now complete.
Check valveCheck valve seat
Lock nutRectangular sealing ring
Elastic cylindrical pin
Bolt

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4. Remove the dust cover.
If necessary to replace the dust cover, replace it using the
following steps.
(a) Twist off the rod clevis.
(b) Screw off the nut.
(c) Pull out the split ring.
(d) Pull out the dust cover.
R e m o v a l o f t h e v a c u u m b o o s t e r w i t h b r a k e c y l i n d e r
assembly is now complete.
Vacuum booster with brake cylinder assem-
bly installation
1. Install the brake cylinder assembly.
Tighten the cover of the brake reservoir, place the outlet
port of the brake reservoir against the master cylinder inlet,
push the brake reservoir assembly into the master cylinder
assembly, and then insert the cylindrical pin to complete the
installation.
Caution: Check and ensure the cleanliness of the
reservoir outlet port and master cylinder inlet. Do not
lose the sealing ring inside the master cylinder inlet.
2. Installation of the vacuum booster assembly.
Install each part of booster using the following steps.
(a) Install the check valve seat.
(b) Install the check valve.
(c) Install the dust cover.
(d) Install the split ring.
(e) Install the lock nut.
( f ) Install the rod clevis.
3. Installaion of the vacuum booster assembly and brake
cylinder assembly.
(a) Install the rectangular sealing ring, and then place the
brake pump assembly into the front case’s housing. Pay
attention when pushing the booster's push rod head into
the first piston hole.
(b) Put the two holes of the cylinder body’s flange surface
into the front case bolts of the vacuum booster, and
then tighten the nuts with a torque wrench.
Tightening torque: 20-26 N·m
4. The installation of the vacuum booster with brake
cylinder assembly is the reversed procedure of its
removal. Hence no more elaboration will be provided
here.
Tightening torque of the four lock bolts on the brake
pedal: 23±3 N·m
Tightening torque of master cylinder outlet port rigid
pipe: 15 N·m
Rod clevis
Nut
Split ring
Dust cover
Elastic cylindrical pin
Check valveCheck valve seat
Lock nut
Rod clevis
Split ring
Dust cover
Rectangular sealing ring
First piston

Downloaded from www.Manualslib.com manuals search engine 109Brake System
3. Installing the ABS rear wheel speed sensor with brack-
et assembly.
Use three hexagon head bolts, spring washers, and flat
washer subassembly connecting pieces to connect the sensor
to the rear hub unit, rear twist beam, and vehicle body.
ABS General Problem Maintenance and Areas of Importance
Common problems and solutions
1. When braking, the ABS hydraulic pressure unit noise is overly loud.
When the ABS is working, the motor inside the hydraulic pressure unit is ceaselessly rotating. At this time the
driver can feel the brake pedal bouncing back. However, this bounce back feeling will be entirely different
depending on the speed and road condition. Also, when performing an actuator movement test, the sound of the
running motor may also be sensed. When the vehicle is being driven and the brake is off, the sound of the motor
running can still occasionally be heard. This is the ABS undergoing component inspection, not a malfunction.
If the ABS hydraulic pressure unit noise is irregular, a movement test can be initiated. Compare the noise to that
of normal vehicles to determine if ABS hydraulic pressure unit noise is abnormal.
2. Inlet and outlet solenoid valve failure.
Once the ignition switch is ON, the ABS control unit automatically initiates a self-check. If an inlet and outlet solenoid
valve short circuit or open circuit is found, it will record the failure, light up the fault light, and abort the operation. If using a
scanner to adjust the problem code, make sure to use the movement test t\
o confirm that the solenoid valve has a problem and
then replace the hydraulic pressure unit directly.
X431 data flow: While the ABS is functioning, the inlet and outlet solenoid valves rapidly change operating
conditions.
EVFL - Front inlet valve LHOff / On
AVFL - Front outlet valve LHOff / On
EVFR - Front outlet valve RHOff / On
AVFR - Rront outlet valve RHOff / On
EVRR - Rear inlet valve LHOff / On
AVRR - Rear outlet valve LHOff / On
EVRR - Rear inlet valve RHOff / On
AVRR - Rear outlet valve RHOff / On
3. Wheel speed sensor malfunction.
With the engine running, use a oscilloscope to measure the voltage between the sensor's signal line and the
ground.
Output signal when wheel is stationary:
Output signal when the wheels are rotating: signal type is 0.44 V and 1.26 V square wave signal, duty cycle: 50: 50.
Rear hub unit assembly
Rear wheel speed sensor with bracket assembly
Hexagon head bolt, spring washer, and flat washer subassembly
Hexagon head bolt, spring washer, and flat washer subassembly
0
v
t
vv
0 0
tt
or

Downloaded from www.Manualslib.com manuals search engine 123Brake System
7. Install the caliper assembly.
(a) Install the caliper assembly.
(b) Install and tighten the hexagon bolt for flange face.
Tightening torque: 30±5 N·m
8. Connect the brake line.
Connect the brake pipeline to the caliper.
Tightening torque: 40±4 N·m
9. Fill the brake reservoir up with brake fluid and exhaust
the air from the brake system.
10. Check for leaking brake fluid.
Caution: Bleed the air after replacing.

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual126
6. Remove the return spring and ratchet adjuster assem-
bly.
(a) Remove the adjusting clearance shaft head.
(b) Remove the adjusting clearance wheel.
(c) Remove the return spring.
7. Remove the parking brake lever.
(a) Remove the split ring with pliers.
(b) Remove the brake lever rotating shaft.
(c) Remove the brake lever.
Caution: If it is the riveted structure, there is no need to
remove the parking brake lever, instead of replace the
brake trailing shoe assembly.
8. Remove the brake wheel cylinder.
(a) Remove the brake line with a M10 open-end wrench,
and use a clean plug to clog it.
(b) Use a M8 open-end wrench to remove the two bolts, thus
removing the wheel cylinder assembly.
9. Remove the following parts from the wheel cylinder as-
sembly.
(a) Two dust covers.
(b) Two pistons.
(c) One piston spring.
(d) Bleed screw.
(e) Bleed screw cap.
Brake components inspection
and maintenance
1. Inspect the components after disassembly.
After disassembling the components, check them for wear
and tear, rust, and damage.
2. Measure the rear brake drum's internal diameter.
Standard internal diameter: Ф200 mm
Maximum internal diameter: Ф201 mm

Downloaded from www.Manualslib.com manuals search engine 127Brake System
3. Measure friction plate thickness.
Standard thickness: 4.0 mm
Minimum thickness: 1.0 mm
If the friction plate thickness is smaller than the minimum
value or produces uneven wear and tear, the brake leading
and trailing shoe assemblies should be replaced.
Remark: If one of the brake shoe assembly needs to be
replaced, be sure to replace all the rear brake leading and
trailing shoe assemblies to ensure even braking ability.
4. Check to make sure the contacts of the friction plate
and rear brake drum are fine.
If the contacts of the friction plate and rear brake drum is not
good, the brake leading and trailing shoe assemblies should
be replaced.

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual130
7. Install the brake cable connector on the brake trailing
shoe with brake lever assembly.
(a) Install the brake cable connector on the brake trailing
shoe with brake lever assembly.
(b) Insert the brake trailing shoe with brake lever assembly
and the shoe end of the brake leading shoe assembly
into the wheel cylinder assembly.
Remark: Do not let oil or grease drip on the brake shoe's
lining.
8. Install the retainer spring.
9. Install the brake leading and trailing shoe assemblies
onto the brake back plate assembly.
(a) Insert the pressure spring bar into the brake back plate
assembly and brake leading and trailing shoe assemblies.
(b) Put the pressure spring on the pressure spring bar,
put in the pressure spring cap, and use SST (Special
Service Tools) to lock the pressure spring cap onto the
pressure spring bar.
10. Inspect the operating procedures of the automatic ad-
juster.
(a) Refer to the diagram for directions, step on and off the
brake pedal, and make sure the self-adjusting screws
can rotate. If they are unable to rotate, inspect the rear
brake to try to determine the source of the problem.
(b) Adjust the adjusting mechanisms length and make it as
short as possible.
(c) Install the rear brake drum.
(d) Press the brake pedal towards the floor until a clicking
noise cannot be heard.
11. Inspect the space between the brake's friction plate
and rear brake drum.
(a) Remove the rear brake drum.
(b) Measure the rear brake drum's internal diameter and
the brake shoe friction plate's external diameter, and
inspect if the difference between the two diameters is
within the regulated clearance range.
Single sided clearance: 0.25 mm
If not correct, inspect the braking system.
12. Install the rear wheel.
Tightening torque: 100 N·m
13. Fill the brake fluid reservoir up with brake fluid and
exhaust the air out of the brake system.
14. Check for leaking brake fluid
SST

Downloaded from www.Manualslib.com manuals search engine 131Brake System
Rear Support Axle
Components
Rear hub unit inspection and removal
1. Manually rotate the wheel according to the diagram,
and check the bearing of the rear hub unit for abnormal
noises and stiff rotation. If these flaws exist, please
replace the rear hub unit.
2. Remove the wheel.
3. Manually screw the two wheel nut's opposite angles on the
wheel bolt and fixed rear brake drum.
Remark: Alternately tighten the two nuts, and manually
screw it down as much as possible.
Rear brake drum
Rear brake assembly RH
R i g h t p a r k i n g b r a k e cable assembly
Rear hub unit
Trailing arm spindle sleeve with nylon bushing assembly
Rear twist beam assembly
Rear brake assembly LH
Rear brake drum
Rear hub unit
Left parking brake cable assembly
Disposable parts
Spring
Spring
9±1
: Specified torqueN·m
78-98
9±1
100
100

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual132
4. Measure the rear brake drum's outer end surface
runout.
S t i c k a d i a l i n d i c a t o r m a g n e t t o t h e r e a r w h e e l h u b ' s
mounting bracket. Point the dial indicator to the rear brake
drum's outer end surface diameter at about a Φ136 mm
circumference (refer to diagrams dotted line area). Rotate the
rear brake drum, measure its runout, and maximum runout
0.11 mm is approval.
Caution: When the runout exceeds the maximum limit
of 0.11 mm, the rear hub unit should be replaced.
5. Remove the rear brake drum (See rear brake removal
step 4).
6. Examine the rear hub unit's starting torque.
(a) M a n u a l l y r o t a t e t h e r e a r h u b u n i t a n d c h e c k f o r
abnormal sounds or looseness. If the above problems
exist, it should be replaced with a new rear hub unit.
(b) Use a spring dynamometer to inspect the load applica-
tion.
Load application (when start the engine): 1 N·m
Caution: If the load application is greater than 1 N·m,
the rear wheel hub unit must be replaced.
7. Use calipers to measure the rear brake drum's internal
diameter.
If the measured result exceeds 201 mm, the drum brake must
be replaced.
Trailing arm spindle sleeve assembly removal
1. Examine the trailing arm spindle sleeve.
(a) Inspect the trailing arm spindle sleeve for deformities,
shifting, partial or serious cracks, and the gaskets for
loosening.
(b) If it's not easy to see clearly any existing damage of
the trailing arm spindle sleeve, take the following
steps: Use clean water to wash the trailing arm spindle
sleeve's rubber areas. At the same time rub it clean with
cotton. Check and make sure the rubber surface has
none of the previously mentioned flaws. If the above
flaws exist, replace with a the new trailing arm spindle
sleeve assembly.Cotton

Downloaded from www.Manualslib.com manuals search engine 135Steering System
Troubleshooting
Fault
SymptomsMalfunction CausesTroubleshooting
Steering wheel
free play too
big / abnormal
noise
1. Too much clearance between the steering
gear and gear rack.
2. The inner and outer ball stud of the steering
tie rod ball is worn out.
3. Steering joint is worn out.
4. Steering propeller shaft and steering gear
connection is loose.
5. Steering wheel and steering column connec-
tor is loose.
6. Steering gear mounting bolt is loose.
7. The sliding spline of the lower propeller
shaft is worn and loose.
1. Have the clearance adjusted by professionals,
and if it cannot be adjusted, replace the steer-
ing gear.
2. After inspection, replace the ball stud if nec-
essary.
3. Replace the lower section of steering column.
4. Fasten the connection bolts in accordance
with the specified torque.
5. Fasten the lock nut of the steering wheel.
When the spline is damaged, make sure to re-
place the steering wheel or steering column.
6. Fasten the mounting bolts of the steering
gear.
7. Replace the lower section of steering column.
Hard steering
1. Tire pressure insufficient.
2. Front wheel alignment angle incorrect.
3. Clearance between the steering gear presses
too small.
4. Steering column's spider bearing broken.
5. Steering tie rod ball stud lacks oil or is dam-
aged.
6. Front shock absorber's support bearing bro-
ken.
7. Damaged lower swing arm ball end.
8. Damaged steering pump leads to insufficient
output volume and output pressure.
9. Power steering pump belt slides.
10.Power steering gear internal leakage too
much.
11. Power steering contains air bubbles and pro-
duces irregular noise.
12. Power steering insufficient.
1. Inflate according to the specified pressure.
2. Check and adjust the front wheel alignment
angle.
3. Replace the steering gear or have profession-
als adjust the clearance between the presses.
4. Replace the lower section of steering column.
5. Replace the lower section of the steering tie
rod ball.
6. Replace the connecting components of the
front shock absorber (refer to the front sus-
pension maintenance section).
7. Replace the lower swing arm (refer to the
front suspension maintenance section).
8. Replace the power steering pump.
9. Adjust the belt's tension.
10. Replace the power steering gear.
11.In place, repeatedly turn, exhaust the air
bubble, then after leaving it stationary for one
hour, replenish the power steering according
to the specific model number.
12.Fill the power steering (with specific model
number) until it reaches the PS fluid reser-
voir's specified scale mark.