air GREAT WALL DEER 2006 Owner's Guide

BR-11Brake System
Vacuum Booster
Inspection on Vacuum booster parts
Operation for one-way valve inspection
(Gasoline engine)
(a) Tear down the one-way valve;
(b) Check the air to see whether it flows from the vacuum
booster side toward the engine side.
(c) Check the air, change the one-way valve if the air flows
from the side of engine toward the vacuum booster.
(d) Mount the one-way valve in the right place.
(a) Tear down the one-way valve from the vacuum pipe.
(b) Check the air to see whether it flows from the side of
vacuum room to the hose.
(c) Check the air, and change the one-way valve if the air
flows to the hose to the vacuum room.
air
engine side booster side
air airless
air
hose side vacuum side
airairless
Mount of Vacuum Booster
1. Adjust the length of vacuum booster pushrod:
(a) Mount the sealing washer on the master cylinder;
(b) Put SST on the sealing washer and descend the pin rod
until it contact lightly the piston with its top;
(c) Put top of SST downward ,and mount it on the vacuum
booster.
(d) Check the clearance between the vacuum booster pushrod
and the head of pin on SST.
(e) Adjust the length of vacuum booster pushrod until the
pushrod touches the pinhead.
2. Mount the vacuum booster, sealing washer and Ushaped
clip head.
(a) Mount the vacuum booster and sealing washer.
(b) Mount the U-shaped clip head.
(c) Mount and tighten the assembling nuts of vacuum booster.
3. Connect the U-shaped clip head and the brake pedal:
Encase the U-shaped clamping pin in the hole of U-shaped clip
head and the brake pedal, and then mount the spring pin on the
U-shaped clamping pin.SST
washer
SST
(Diesel engine)

BR-12Brake System
Vacuum Booster
4. Mount the pedal return spring.
5. Mount the brake master cylinder
(see Page BR-8)
6. Connect the hose and the vacuum booster.
7. Fill the oil cup with brake liquid and exhaust the air in
braking system.
(see page BR-6)
8. Check the liquid leakage;
9. Check and adjust the brake pedal
(See page BR-5)
10. Check the operation
(See Page BR-6)

BR-17
2. Tear down the piston dust cover snapping ring and the
piston dust cover;
Tear down the piston dust cover snapping ring and the piston
dust cover with screwdriver.
3. Tear down the piston from the wheel-brake cylinder:
(a) Put a wooden plate between the piston and the caliper
body.
(b) Tear down the piston from wheel-brake cylinder with the
compressed air.
Warning: Do not put your finger in front of the piston when
using the compressed air.
4. Tear down the piston sealing ring from the caliper body.
Tear down the piston sealing ring with bent needle.
Notice: the tools used shall not be sharp so as not to
scrape the piston sealing ring.
Check the front brake parts
1. Measure the thickness of brake pad liner;
Standard thickness
10.0mm
Min thickness
2.0mm
If the thickness is less than the min thickness or is unevenly
worn; change the brake pad.
2. Measure thickness of brake disc
Standard thickness
25.0mm
Min thickness
23.0mm
If the brake disc is scraped, repair it, if the brake is serious
worn to the degree that its thickness is less than the min thickness,
brake disc requires to be changed 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)

BR-23
Wheel-brake cylinder disassembly:
1. Tear down the dust cover steel gripping hoop and the
dust cover.
Tear down the dust cover steel gripping hoops and piston dust
covers of the four wheel-brake cylinders with the screwdriver.
2. Tear down the piston from the wheel-brake cylinder:
(a) Prepare a wooden block with the dimensions as shown in
the drawing (which is used to support the piston)
(b) Put the wooden block between the pistons and insert one
brake pad on one side of the wooden block.
(c) Tear down the four pistons from the wheel-brake cylin-
der by using the compressed air.
Warning: do not put your fingers in front of the piston
when using the compressed air.
3. Tear down the piston sealing ring.
Tear down the four piston sealing ring from the wheel-brake
cylinder with the screwdriver.
Check the front brake parts
1. Measure the thickness of brake pad liner;
Standard thickness
9.0mm
Min thickness
2.0mm
In case the liner is less than the min thickness or the liner is
worn unevenly, change the brake pad. Braking System
Front Brake(SF)
mm
mm
mm

BR-24
2. Measure the thickness of brake disc;
Standard thickness
20.0mm
Min thickness
18.0mm
If the brake pad is scraped, repair it; where the abrasion is
serious and its thickness is smaller than the min thickness,
change the brake disc.
3. Measure the bounding value of the brake disc face;
Remark: the bearing is required to be verified in the suitable
adjustment before measuring.
Max face bouncing value: 0.11mm;
4. Change the brake disc according to the requirement:
(a) Tear down the hub and the brake disc. (see the paragraph
of front wheel hub)
(b) Mount the new brake disc and screw up the connecting
bolts as the specified torque.
(c) Mount the hub and brake disc assembly. (see the para-
graph of front wheel hub).
Fastening torque
(75
5)N
m
(d) Mount the caliper bracket on the steering knuckle and
screw up the bolts according to the specified torque.
Fastening torque
123N
m.
Assembly of Brake-wheel pump
1. Preparation
All parts shall be washed, dried and cleared away the alien
materials, and coat moderate rubber lubricant on the work
faces of piston, piston dust cover and rectangular sealing ring.
2. Encase the piston sealing ring in the caliper body Braking System
Front Brake(SF)

BR-25
3. Encase the piston in the caliper body.
4. Encase the piston dust cover, dust cover steel-
gripping hoop in the caliper body.
Mount of Brake Calipers
1. Mount the brake caliper and screw up the two
mounting bolts.
Fastening torque
123N
m
2. Mount the brake pads;
3. Connecting the brake pipeline;
Use the open spanner to connect the pipeline.
Fastening torque
(21
1)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: avoid the brake liquid of spraying on the brake disc
when exhausting the air.
5. Check to see whether there is leakage of brake liquid. Braking System
Front Brake(SF)

BR-29
Check and Repair the Rear Brake Parts
1. Check and test the disassembled parts;
Check the disassembled parts to see whether there is abrasion,
rust or damage.
2. Measure the inner diameter of brake drum;
Standard inner diameter)
254.0mm
Mix inner diameter: 256.0mm
3. Measure the thickness of brake shoe liner;
Standard thickness
5.0mm
Min thickness
1.0mm
In case the thickness of brake shoe liner is less than the min
thickness or there is uneven abrasion, change the liner.
Remark: if one of the brake shoes is needed to change, all of the
brake shoes are required to change so that the even braking
performance is maintained.
4. Measure the brake liner and the brake drum to see
whether they contact closely;
If there is poor contact between the brake liner and the brake
drum, repair the brake shoe with the grinding devices, or
change the brake shoe cluster. Braking System
Rear Brake (Dr)

BR-33
12. Check the clearance between the brake shoe and the
brake drum:
(a) Tear down the brake drum;
(b) Measure the inner diameter of the brake drum and the
outer diameter of brake shoe to check whether the differ-
ence of the two diameters falls within the standard
clearance range.
Shoe clearance: 0.6mm
If it is not correct, check the parking brake system.
13. Mount the brake drum and the rear wheel; screw up
the nuts of rear wheel hub.
Fastening torque
(145
10)N
m
14. Fill the liquid container with brake liquid and exhaust
the air in braking system.
15. Check to see whether there is leakage of brake liquid.
Braking System
Rear Brake (DR)

BR-37
Check and Repair the Brake Parts
1. Check the disassembled parts;
Check the disassembled parts to see whether there is abrasion,
rust or damage.
2. Measure the inner diameter of the brake drum;
Inner diameter
295.0mm
Max diameter
297.0mm
3. Measure the thickness of brake shoe liner;
Standard thickness
6.5mm
Min thickness
1.5mm
In case the thickness of brake shoe liner is less than the min
thickness or there is uneven abrasion, change the brake shoe.
Remark: if either brake shoe is required to change, all rear
brake shoes shall be changed to maintain the even braking
properties.
4. Check the brake shoe liner and the brake drum to see
whether there is close contact;
If there is poor contact between the brake shoe liner or brake
drum, repair or change the brake shoe cluster with the grinding
devices. Braking System
Rear Brake (SF)