torque GREAT WALL SAILOR 2006 Manual Online

SA-91
9. Mount on the differential bearing cover:
(a) Align the assembly marks on differential bearing cover
and the speed reducer housing, and press down the
differential bearing by hand.
(b) Mount on the double-eared stop washer and the hex nut.
10. Adjust the clearance between the driving bevel gear and
the axle driven bevel gear
(a) Screw up the hex nuts connecting the differential bearing
cover to the specified torque.
Tightening moment
(80-110)N
m
(b) Attach the measuring meter seat on the face of speed
reducer housing with the measuring head touching the
teeth face, run the axle driven bevel gear with hand to
measure the teeth engagement clearance, and then com-
pare it with the clearance value in step (d) to decide the
order of the adjusting ring tightening according to the
values.
(c) Adjust and screw up the adjusting rings with SST.
Tightening moment
(115-135)N
m
(d) Check the engagement clearance again until the clear-
ance value of the three spots evenly locates on the
circumference of axle driven bevel gear. Otherwise,
adjusting ring adjustment is suggested.
Engagement clearance
(0.13-0.25)mm
Suspension System and Automobile Axle (Rear)
(Dismantle of Rear Speed Reducer)

SA-93
12. Lock the double-eared stop washer to mount the stop
gasket and bolts:
(a) If the engagement trace satisfies the requirement, lock
tightly the double-eared stop washer with hand hammer
and pinch.
(b) Mount on the stop gasket, spring gasket and bolts, and
then screw up the bolts.
Tightening moment
(18-26)N
m
(c) Tap in he adjusting ring with the pinch and hammer.
13. Measure the total preload:
Preload: (1.8-2.4) N
m
If the preload is beyond the specified range, change the gas-
kets between the jacket and bearing 7607E, until they meet
the requirement.
(a) If the preload is larger than the specified value, change
the adjusting washer.
(b) If the preload is smaller than the specified value, screw up
the nuts again slowly but not exceed 160N.m.
Notice: if the screwing torque exceeds the max torque,
change the adjusting washer and repeat the preload
process. Do not screw back the main-tooth nut to reduce
the preload.
14. Check and adjust the flange bouncing
(a) Attach the dial indicating lamp seat on the speed reducer
housing with the measuring head contact the flange face,
run the flange to observe the swing out range of the dial
indicating lamp hand.
Radial full bouncing tolerance
0.10mm
Remark: the two bouncing values should be controlled within
0.10 mm, as for the parts of bounce exceeding the tolerance,
loosen the nut-driving bevel gear to assembly them in another
angle, measure the bounce value again. Observe carefully the
swing direction of the hands, which can be referred when
changing the locations of flange and the driving bevel gear. If
the requirement cannot be satisfied after several trials, change
the new flanges until the requirement is met. Suspension System and Automobile Axle (Rear)
Rear Speed Reducer (Disassembly of Speed Reducer)
30mm
15. Rivet the driving bevel gear nuts.s

SA-97Suspension System and Vehicle Axle
Rear Suspension (Leaf Spring Type)
Rear suspension(leaf spring)
Leaf spring and shock absorber
N
m
specified torque
90
10
110
10
liner
rront ear pinrear ear pin liner
u-shaped bolt
spring seat
90
10
Dismantle of leaf spring and vibration
damper
1. Raise the vehicle body with a jack and support it with a
bracket;
(a) Raise the vehicle body with a jack and support it with a
bracket;
(b) Lower the axle housing until the leaf spring is loosened
to the degree there is no tension existing. Keep the leaf
spring in such status.
2. Tear down the vibration damper.

SA-99
4. Mount the central bolt of leaf spring;
(a) Align the bolt with the spring hole after clamping the
steel spring with a table vice.
(b) Mount on and tighten the spring central bolt.
Tighten torque:
(50
5)N
m
5. Bend the spring clip to a correct angle.
Bend the spring clip to the correct position with a hammer.
Mount of leaf spring
1. Mount the steel spring;
(a) Encase the front end of leaf spring into the front bracket;
(b) Mount on the bolt of front ear pin.
(c) Screw on the nut of front ear pin with fingers;
(d) Encase the rear end of leaf spring into the rear bracket and
mount on the rear ear pin.
(e) Mount on the leaf and tighten the nuts with fingers.
2. Mount the U-shaped bolt;
(a) Mount the U-shaped bolt on the axle housing.
(b) Mount the spring seat and nut under the steel spring.
(c) Tighten the mounting nut of U-shaped bolt.
Tightening moment: (110
0)N
m
Suspension System and Vehicle Axle
Rear Suspension (Leaf Spring Type)

BR-4Braking System
Notice and Troubleshooting
Troubleshooting (continued)
Trouble Causes Inspection items
There are quack-
quack noises
without using the
brake.Alien materials such as stone is reeled inside the wheel shell
Nuts on hub is loose;
The brake pedal or vacuum booster pushrod is adjusted
improperly;
The wheel bearing is worn or damaged or lubricated
insufficiently;
(disc type brake)
The outer end edge of brake pad support plate or brake pad
is dog-eared;
The silent pad is poor in properties;
The sliding liner is worn;
The mounting bolt is loose
The piston returns incompletely
(drum type brake)
There is loose or redundant part.Clear away the alien materials
Tighten the nut to the specified torque; and
change it in case the bolt hole is enlarged;
Check and adjust
Check, lubricate or change
Check repair or change
Check and make change according to real
situation
Check and make change according to real
situation
Check and tighten according to the necessity.
Check, repair or change
Check, take out or repair.
There is continuous
screaming noise
without using brakeThe brake pedal or vacuum booster pushrod is adjusted
improperly
The vacuum booster, master cylinder or wheel-brake cylinder
returns incompletely.
(Disc type brake)
The piston is rusted or seized;
The brake pad in brake caliper locates improperly;
There is friction between the brake disc and brake caliper
shell;
The brake pad support plate is mounted improperly;
There is interference between the abrasion indicating lamp
of brake pad and the brake disc due to the brake pad
abrasion;
(Drum type brake)
The pressure spring of brake shoe is soft rigidity, damaged
or unsuitable;
There is crack on the brake bottom plate flange;
There is interference of brake bottom plate with the brake
drum after it is bending or warping.
The brake drum interferes with the brake bottom plate or
with brake shoe due to it is processed improperly;
Other brake parts

There is loose or redundant part in braking system;
The brake liner is polished due to it is adjusted over-tightly;
The wheel bearing is worn, damaged or lubricated
insufficiently.Check and adjust
Check, repair or change
Check and add the lubricant according to
the necessity;
Repair or change
Repair or change
Repair or change
Change
Change
Repair or change
Repair or change
Change the brake drum
Check, maintain and change according to
the necessity;
Check, maintain and change according to
the necessity;
Check, maintain and change according to
the necessity;

BR-9Braking System
Master Cylinder
Mount of Master Cylinder
1. Adjust the length of vacuum booster pushrod before
mounting the master cylinder;
2. Mount the master cylinder:
Mount the master and sealing washer on the vacuum booster
with four nuts.
3. Connect the two pipelines of braking system;
Mount the brake pipeline on the master cylinder with SST and
screw up the nuts.
Fastening torque

Dr SF
(18
2)N
m
SL SK SY SJ
(19
1)N
m
4. Connect the alarm switch joint for liquid level;
5. Fill the oil cup with brake liquid and exhaust the air in
the brake pipeline;
6. Check to see whether there is brake liquid leakage;
7. Check and adjust the brake pedal.
SST
SST

BR-15
5. Brake disc measurement
(See page BR-17)
6. Measure the radial run-out of the brake disc;
(See BR-18)
7. Mount the lock plate of brake pad.
8. Mount the new brake pad.
(a) Mount the silent pad cluster on brake pads of both the
inner and outer sides;
Remark: Pollution of oil stain or coat is not allowed on the
work faces of brake pad or brake disc.
(b) Draw out a little brake liquid from the liquid container to
prevent the brake liquid overflowing from the liquid
container;
(c) Press in the piston with the hammer lever or similar tool.
9. Mount the wheel-brake cylinder;
Mount and screw up the hex bolts (the hex bolts shall be coated
with the thread locking sealing agents.
Fastening torque
(38-50)N
m
Remark: only one brake pad can be changed in one time so as
to prevent the piston of other wheel being shot out.
Braking System
Front Brake (Dr)

BR-16
10. Mount the front wheel;
Screw up the fixing nut of wheel.
Fastening torque
(135
150)N
m
Disassembly of Wheel-brake Cylinder
1. Take apart the brake pipeline.
(a) Tear down the brake pipeline. And block the outlet with
a clean cork.
(b) Tear down the brake oil pipe bracket from the wheel-
brake cylinder.
2. Tear down the wheel-brake cylinder from the caliper
bracket.
Tear down the two hex bolts and the wheel-brake cylinder.
3. Tear down the brake pad:
(a) Two brake pad;
(b) Two silent pad cluster;
(c) Four brake pad lock plate.
Pump Disassembly of Wheel brake
1. Take apart the following parts:
(a) Two sliding sleeve;
(b) Four sliding sleeve dust cover;
(c) Two sliding liner.
Braking System
Front Brake (Dr)

BR-18
3. Measure the bouncing value of the brake disc face;
Remark: verify the bearing is aligned correctly before
measuring.
The bouncing value of max face: 0.11mm
4. Change the brake disc according to the requirements
(a) Tear down the calipers body from the steering knuckle.
(b) Tear down the hub and the brake disc (See Page SA-11).
(c) Mount the new brake disc and screw up the connecting
bolts according to the specified torque.
Fastening torque
(60
79)N.m
(d) Mount the hub and brake disc assembly (see page SA-12);
(e) Mount the caliper bracket on the steering knuckle and
screw up the bolts according to the specified torque.
Fastening torque
(85
105)N.m
Cylinder Assembly of Wheel-brake
1. Preparation
All parts shall be washed, dried and cleared away the alien
materials before the assembly. And coat moderate vacuum
silicon base grease on the work faces of sliding sleeve dust
cover, sliding sleeve and the sliding liner; and plaster the
moderate rubber lubricant on the work faces of piston, piston
dust cover and the rectangular sealing ring.
2. Encase the piston sealing ring and piston in the caliper body;
(a) Screw the vent screw in the vent hole of calipers.
Fastening torque
(8
13)N.m
(b) Coat moderate rubber lubricant on the work face rectan-
gular sealing ring and encase the caliper body in groove.
(c) Encase the piston in the caliper body.
3. Encase the piston dust cover and the dust cover
snapping ring in the wheel-brake cylinder.
Braking System
Front Brake (Dr)

BR-19
4. Mount the sliding liner, sliding sleeve dust cover and
sliding sleeve.
(a) Encase the sliding liner and sliding sleeve dust cover in
the wheel-brake cylinder.
(b) Ensure the sliding sleeve dust cover in the ring groove of
wheel-brake cylinder hard.
(c) Encase the sliding sleeve in the sliding sleeve dust cover.
(d) Ensure the sliding sleeve dust cover in the ring groove of
sliding sleeve.
Mount of Brake Calipers
1. Mount the brake pad;
2. Mount the wheel-brake cylinder:
(a) Mount the wheel-brake cylinder;
(b) Mount and tighten the two assembling bolts (the bolts
shall be coated with the thread locking sealing agent).
Fastening torque
(38
50)N.m
3. Connect the brake pipeline.
Connect the brake pipeline with the calipers.
Fastening torque
(21
2)N.m
4. Observe the height of brake liquid level and, if
necessary, add in the brake liquid and exhaust the air
in braking system.
Notice: prevent the brake liquid from spraying on the
brake disc when exhausting air.
5. Check to see whether there is leakage of brake liquid. Braking System
Front Brake (Dr)