brake fluid GEELY CK 2008 Workshop Manual

Section 1 Propeller Shaft.................................................................................................. 97Chapter 5 Front Suspension System............................................................... 1 0 3Section 1 Front Suspension System................................................................................ 103
Section 2 Front Suspension............................................................................................105
Section 3 Front Wheel Alignment.......................................................................................106
Section 4 Front Strut Assembly....................................................................................... 107
Section 5 Lower Swing Arm Assembly............................................................................ 110
Section 6 Front Stabilizer Bar and Link Rod Assembly.....................................................113Chapter 6 Rear Suspension System................................................................116Section 1 Rear Suspension System
Section 2 Rear Suspension............................................................................................117
Section 3 Rear Wheel Alignment.................................................................................... 118
Section 4 Left & Right Rear Strut Assembly.....................................................................119
Section 5 Rear stabilizer bar assembly, strut rod components..........................................121
Section 6 Left & Right Trailing Rod Assembly.............................................................. 123
Section 7 No. 1 Transverse Arm Assembly..................................................................... 124
Section 8 No. 2 Transverse Arm Assembly..................................................................... 125Chapter 7 Wheel................................................................................................126Section 1 Tire Inspection................................................................................................. 126
Section 2 Wheel Replacement......................................................................................... 127Chapter 8 Power Steering System.................................................................. 1 2 8Section 1 Power Steering System.................................................................................... 128
Section 2 Steering Drive and Control Mechanism......................................................... 130
Section 3 Steering Pipeline Component.......................................................................... 133
Section 4 Power Steering Gear Retaining DeviceChapter 9 Brake System.................................................................................. 1 3 9Section 1 Brake System ................................................................................................... 139
Section 2 Brake Fluid....................................................................................................... 140
Section 3 Brake Pedal...................................................................................................... 141
Section 4 Vacuum Booster with Brake Master Cylinder Assembly....................................143
Section 5 Front Brake Assembly..................................................................................... 144
Section 6 Rear Brake
Section 7 Brake Line ....................................................................................................... 151..................................................................................116
.....................................................................................................147..........................................................136

95Replacement1. Remove the reservoir hose 1 and reservoir hose 2
Notice: Clutch hydraulic control system and hydraulic
brake system share the reservoir. Prevent the brake
fluid from overflowing when removing the reservoir
hose.
2. Disconnect the connection with the pedal
Remove the lock pin, flat washer, pin shaft to separate the clutch hydraulic control master cylinder from
the clutch pedal
3. Remove the connecting pipe
Loose the threaded connector connecting pipe and the clutch master cylinder. Remove the connecting
pipe.
4. Remove the clutch pedal assembly
Remove the nuts, bolts, 2 bushing, sleeve, clutch pedal assembly
5. Remove the hydraulic hose
Loosen the union thread connecting clutch hydraulic hose and pipe. Remove E-shaped clip plate fixing
the both ends of the clutch hydraulic hose

966. Remove clutch hydraulic control master cylinder
Remove the 2 fixing bolts between the clutch hydraulic control master cylinder and the pedal bracket
7. Install and replace the parts in the reverse order of the above procedure
Notice:
(1) Be careful not to leak brake fluid onto other objects or paint surface. Clean it immedi-
ately to avoid damage.
(2) Do not damage the seal rubber when installing and removing the pipe and make sure the
installation is correct
(3) Clutch pedal set thread torque : 20~25N.m
(4) Clutch hydraulic control master cylinder set bolt torque : 20~25N.m
(5) Torque of the union thread connecting the pipe and clutch master cylinder:
12~16N.m
(6) Torque of the threaded connector connecting the clutch hydraulic hose and pipe:
12~16N.m
(7) Bleed the air in the clutch hydraulic control system
(8) Check the clutch hydraulic control system for leakage
(9) Check the clutch hydraulic control system for reliable working
(10)Check the brake fluid level. Fill the brake fluid of the same brand if necessary.
(11) Check the clutch pedal installation height stroke and free stroke
a . The clutch pedal installation height: 180~186 mm
b . The clutch pedal stroke: 134~142mm
c . The clutch pedal free stroke: 10~20 mm

139Chapter 9 Brake SystemSection 1 Brake SystemPrecaution1. It's very important to keep the parts and area clean when repairing the brake system.
2. Care must be taken to replace each part properly as it could affect the performance of the brake
system and result in a driving hazard.
3. Do not let brake fluid remain on a painted surface when repairing any parts. Wash it off
immediately.
4. If any work is done on the brake system or air in the brake pipelines is suspected, bleed the
system of air.
5. Check the brake system for leakage after repairing the brake system.
6. Use specified brake fluid. Do not mix with other brand of brake fluid.Problem 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.Symptom Cause
1. Brake system (fluid leaks)
2. Brake system (air in)
3. P iston Cup in Sub-pump (worn or dama ge d)
4. Rear brake shoe clearance (out of adjustment)
5. Master cylinder (faulty)
6. Booste r push rod (out of a djustme nt)
7. Brake shoe or lining (oily)
8. Disc/Drum scratched
1. Brake pe dal free stroke is too small
2. P a rking brake le ver stroke (out of a djustme nt)
3. P a rking brake ca ble (stic king)
4. Rear brake shoe clearance (out of adjustment)
5. Brake pa d or lining (c rac ked or distorte d)
6. Wheel cylinder piston (stuck or frozen)
7. Return spring (faulty)
8. Va cuum booster (faulty)
9. Brake master cylinder (faulty) Low Brake P edal
Brake Stagnation

140Section 2 Brake FluidBleeding1. Fill brake reservoir with brake fluid
Brake fluid: JG4 GB10830
2. Bleed brake pipeline system
(1) Connect the vinyl pipe to the wheel cylinder bleeder plug port
(2) Depress the brake pedal several times, and then loosen the bleeder plug with the pedal held down.
(3) At the point when fluid stops flowing out, tighten the bleeder plug, and then release the brake pedal.
(4) Repeat (2) and (3) until all the air in the fluid has been bled out.
(5) Repeat the above procedure to bleed the brake pipeline of the air for each wheel cylinder.
Notice: Fill brake fluid into the reservoir all the time when bleeding.
3. Check fluid level in reservoir
Check the fluid level and fill fluid if necessary.Symptom Suspe ct a re a
1. Whee l cylinder piston (stuck)
2. Bra ke shoe lining (oily)
3. Disc (scratched)
4. Bra ke shoe s or lining (c ra cke d or distorte d)
5. Whee l hub be a ring (worn or da mage d)
Tire pressure (not as specified)
1. Bra ke shoe lining (da mage d)
2. Insta lla tion bolt (loose )
3. Disc (scratched)
4. Bra ke shoe (ba d in qua lity)
5. Bra ke shoe s lining (oily)
6. Sound isolating shim da mage d
7. Hold spring of bra ke shoe (da mage ) Brake Deviation
Noise from brake

144Section 5 Front Brake AssemblyComponents
Repairing1. 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 bootDisk Brake Wheel
Cylinder BracketSliding Pin BootInner Floating Clip PlateScrew PlugBrake Caliper
HousingInner
DamperInner Pad
Backing
PlateInner PadOuter PadOuter Pad
Backing PlateOuter
DamperOuter Floating
Clip PlateAlarm
PlateWheel
Cylinder
PistonWheel
Cylinder
Piston SealWheel
Cylinder
BootSteel Wire
Snap RingShort Pin
Set BoltShort BushingGuide Boot (II)Splash ShieldFront Ring GearRetaining
RingWheel Hub BoltFront Wheel
Hub Bearing
Wheel HubDisc

145Remove 2 boots from the brake cylinder support bracket.
7. Remove the brake cylinder guide boot
Remove the clip and boot with screwdriver.
8. Remove the bleeder screw
9. Remove the front brake piston
(1) Put a piece of soft cloth between the brake cylinder and piston.
(2) Blow the piston out from the brake cylinder with the compressed air
Notice: Be careful not to put your finger in front of the piston when blowing
the compressed air. Be careful of the splashed brake fluid
10. Remove the piston oil seal
Remove the oil seal from the brake cylinder with a screwdriver
11.Check the brake cylinder and piston
Check the cylinder wall and piston for rust and damage
12. Check the thickness of the brake pad
Measure the thickness with a ruler: Standard thickness: 10mm,
Minimum thickness: 1mm
13. Check the front brake alarm plate
Make sure the alarm plate has enough elasticity, and is not cracked
or worn. Clean all rust, dirt and foreign materials
14. Check disc thickness
Measure the disc thickness with micrometer:
Standard thickness: 11mm
Minimum thickness: 10mm

147Section 6 Rear BrakeComponents
Repairing1. Remove rear wheel
2. Drain the brake fluid
3. Remove the brake drum
(1) loose the parking brake handle
(2) Remove the cotter pin with a long nose pliers
(3) loose the spindle slot nut
Lower Return Spring
Oil Baffle Plate
Anchor Plate
Brake Bottom Plates
Left Cable Plate
Left Torsion Spring
Adjusting Pawl Shaft
Pin
Left Adjusting
Pawl
Left Adjusting
Plate
Brake Shoe I
Wheel Hub Bearing II
Rear Spindle Cap
Wheel Hub
Bearing I
Stop Washer
Wheel Hub
Bolt
Rear Ring Gear
Rear Brake Drum
Rear Spindle Cover
Brake Shoe I
Shoe Guide
Friction Shoe
Boot
Cup
Piston
Wheel Cylinder
Spring
Piston
BootCup
Parking Brake
Left Swing Arm
Rear Brake
Auto
Adjusting Lever
Adjusting Lever Spring
Return Spring

15019. Install rear brake clearance automatic adjustment lever
20. Adjust the installing position of the brake shoe£¬install the brake drum
21. Fill the brake fluid
22. Bleed the air in the brake system
23. Check the fluid level in the reservoir
24. Check the brake fluid for leakage
25. Install the rear tire, tire nut torque: 95~115 N.m
26. Check parking brake operating handle. Check the parking brake control handle stroke and adjust if
necessary. (See parking brake system)Adjust BoltBack Plate

152Replacement1. Drain the brake fluid in the brake pipeline
2. Separate rear left, right brake pipe compo.
(1) Loose union thread. Separate the rear left brake pipe compo. and rear left No. 1 brake pipe compo.
(2) Loose union thread. Separate the rear right brake pipe compo. and rear right No. 1 brake pipe
compo.
3. Remove the rear brake pipe No 3 & 4 compo.
(1) Loose the union thread connecting the hose. Remove E-shaped clip on the pipe bracket. Separate
the brake pipe.
(2) Remove pipe No. 3 & 4 compo.
Connect RF BrakeRear RH Brake Pipe Compo.Rear LH Brake Pipe Compo. Rear LH No. 1 Brake Pipe Compo.Rear RH No. 1 Brake Pipe Compo.
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