2006 GREAT WALL SAFE oil change

BR-2Braking System
Notice and Troubleshooting
Notice:
1. Carefully change each part where necessary because any
mistake will affect the brake system properties, and will lead
accidents during driving. And the parts to be changed must
be the same in part number or equal in quality.
2. Keep the parts and each position clean when repairing the
braking system.
Troubleshooting
Trouble Causes Inspection items
Lower or soft pedal Abrasion of brake shoe
Abrasion of brake pad
Oil leakage of braking system
Master cylinder failure
Air in braking system
Wheel-brake cylinder failure
Failure in the automatic regulator of rear brake.Change the brake shoe; Change the brake
pad;
Repair the oil leakage;
Change the master cylinder;
Drain out the air from braking system;
Change the wheel-brake cylinder;
Repair or change the regulator
Brake stagnantPoor adjustment of parking brake;
The bracing wire of parking brake is seized;
Poor adjustment of vacuum booster pushrod)
Failure of the drag spring or the return spring
Pipe line blockage
Brake shoe breakage or deformation
Brake pad breakage or deformation
Seizing of the wheel-brake cylinder or the brake
caliper piston
Automatic regulator breakage
Master cylinder failureAdjust the parking brake;
Make repairing according to real situation;
Adjust the drag rod;
Change the drag spring or the return spring
Make repairing according to real situation;
Change the brake shoe
Change the brake pad
Make repairing according to real situation;
Change the regulator
Change the master cylinder
Over large braking
distanceUnsuitable tire inflation
There is oil stain or lubricant on the brake shoe or
brake pad;
Brake shoe deforms, the brake liner is worn or polished;
Brake pad deforms or is worn or polished;
Brake drum or brake disc deforms
Drag spring or return spring has trouble
The wheel-brake cylinder has trouble
The inner piston of wheel-brake cylinder is seized;
The brake pad is seized;Inflate the air to suitable pressure;
Change the brake shoe or the brake pad;
Change the brake shoe;
Change brake pad
Change the brake drum or the brake disc;
Change the spring;
Change the wheel-brake cylinder;
Change the wheel-brake cylinder
Change the brake pad
The brake pedal is hard
but doesn
t work;There is oil stain or lubricant on the brake shoe or
brake pad;
The brake shoe deforms, brake liner is worn or
polished, or the brake wheel is worn;
The brake pad deforms, or is worn or polished;
The piston of wheel brake pump is seized;
The vacuum booster has trouble
The vacuum degree is unsuitable
The brake pipe line is blockedChange the brake shoe brake pad;
Change the brake shoe
Change the brake pad;
Change the wheel-brake cylinder;
Change the vacuum booster;
Make repairing according to real situation;
Make repairing according to real situation;

BR-3
Troubleshooting (continued)
Braking System
Notice and Troubleshooting
Trouble Causes Inspection items
There is clatter noise when using
the brake(Drum-type brake)
The brake shoe is seized on the flange of rear baffle;
The flange of rear baffle is worn;
The pressure spring of brake shoe is loose or missing;
The fixed bolts of brake bottom plate is loose;
(disc type brake)
The brake pad support plate is loose or missing
The mounting bolts are loose;Add lubricant
Change the lubricating flange
Change
Tightening it
Change
Tightening it
There is hoarse noise or quack-
quack when using the brakeThe brake shoe or brake pad is worn;
The brake caliper, the wheel or the rotator interferes each
other.
There is friction between the dust cover and brake disc,
the brake bottom plate and the brake drum;
The other braking part has trouble
There is friction between the tire and bodyChange the part, and re-process
precisely the brake drum or
rotator if the abrasion is serious;
Make change according to real
situation;
repair or change
Make repairing according to
real situation;
Change
Check or maintain the part
There is such noise as
continuous screaming, quack-
quack, oscillating sound, etc.
Notice: the braking materials
may generate the natural noise
and heat during friction, and
thus emit the energy. Therefore,
it is normal to have the
screaming noise. These
phenomena will be more serious
under the condition of frigidity,
torridity, and over humidity,
snowing and mud. the
screaming noise occurring
occasionally will not lead the
fatal brake trouble nor reduce
the effective properties of the
brake.The brake drum, brake liner, liner or brake pad is worn
or scraped
The brake liner or brake pad is dirty or with oil stain or
polished.
The brake liner or brake pad is improperly used.
The brake pedal or vacuum booster drag rod is unsuitably
adjusted.
(disc type brake)
The brake pad silent pad is loss or damaged;
The brake pad is worn to the degree that the abrasion-
indicating lamp of brake pad has friction with the rotator.
There is burr or rust on the brake caliper.
(Drum type brake)
The pressure spring of brake shoe is soft in rigidity, or is
damaged or unsuitable.
The pressure spring pin or spring of brake shoe is loose
or damaged;
There is crack on the brake bottom plate flangeCheck, repair or change
Clean or change
Check or change
Check for adjustment
Change
Change
Clean or polish the burr
Check, repair or change
Check, repair or change
Check, repair or change

BR-6
Operation test of vacuum booster
Remark: check the operation of vacuum booster with the
vacuum booster tester if workable.
1.Operation inspection
(a) Before starting the engine, tread down the brake pedal
several times, and check the pedal reservation distance to
ensure there is no change occurs.
(b) Tread down the brake pedal and start the engine. If the
treaded pedals continue to move downward, which means
the operation is normal.
1. Inspection on Air-tight
(a) Start the engine for 1-2 min and then turn it off. Then
tread down the brake pedal slowly for several times, if the
pedal move downward continuously in the first, but
return gradually in the second or third time, which means
the vacuum booster has a good air-tight.
(b) Tread down the brake pedal when the engine is working,
then stop the engine, but tread the pedal down. If the
reservation distance doesnít change within the 30 seconds,
which shows the air tight of vacuum booster is good.
Air-bleeding of braking system
Remark: air-bleeding is required if any operation for braking
system is conducted or the pipe line is doubted to have air.
1. Fill the oil cup with the brake liquid
Check the liquid level of oil cup after the air in each wheel
brake pump is exhausted. If necessary, add the brake liquid.
2. Connect the vinyl resin pipe with the vent screws.
Insert the other end of pipe into the container with half brake
liquid.
Remark: the air-bleeding shall begin from the longest pipe line
when the wheel-brake cylinder is exhausting the air.
3. Air exhaust of the pipe line in braking system
(a) Tread down brake pedal slowly several times.
(b) Loosen the vent screws until the brake liquid flows out
while letting the assistant tread down the pedal. Then
screw up the vent screws.
(c) Repeat this approach until there is no air in the liquid.
4. Repeat the approach for the wheel-brake cylinder.
normal
abnormal
the third time
the second time
the first time
Braking System
Inspection and Adjustment

BR-14
Brake pad change
Remark: Check the thickness of the friction material of brake
pad through the observation hole on caliper body after the
vehicle covers thirty thousand; if the thickness fails to fall
within the specified range, change is required. (If the brake is
used often, the thickness of friction materials of brake
pad is required to check whether it is within the specified
range after the vehicle covers more than ten thousand,
if not, change it.
1. Tear down the front wheel;
2. Check the thickness of friction material of brake pad:
Check the thickness of friction material of brake pad through
the observation hole on caliper body, if it fails to be within the
specified range, change it.
Min thickness: 2.0mm
3. Raise the wheel-brake cylinder:
(a) Tear down the short bolts of sliding sleeve;
(b) Uplift the wheel brake pump and hang it with rope to
protect the brake oil pipe.
Remark: Do not loosen the brake oil pipe and the bleeding plug.
4. Tear down the following parts:
(a) Two braking pads;
(b) Two silent pad clusters;
(c) Four braking pad lock plates.
Braking System
Front Brake (Dr)

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-21
3. Disassemble the following parts:
(a) Guide pin snapping spring;
(b) Two guide pins;
(c) Brake pad snapping ring
(d) Two brake pads;
(e) Two silent pads; and
(f) Two separation pads
4. Measure the thickness of brake disc.
(See BR-24)
5. Measure the radial swinging of the brake disc.
(see page BR-24)
6. Mount on the new brake pad;
(a) Draw out a little brake liquid from the liquid container.
(b) Press in the piston with the hammer lever and similar tool.
Remark: Only one brake pad of the same wheel can be changed
in one time so as to prevent the piston on the other face ejecting
out.
(c) Mount two silent pads and two separation pads on the
new brake pad.
Remark: coat the brake oil for disc on the inner silent
pads.
(d) Mount the brake pad with the worn limit alarm pad on the
inner side, while the other brake pad on the outer side.
Note: Pollution of oil stain or coat is not allowed on the
work faces of brake pad or brake disc.
7. Mount the brake pad snapping spring;
Brake pad snapping spring shall be mounted at the lower
position;
Braking System
Front Brake(SF)

SR-2
Notice
The parts change should be conducted correctly because
any error will affect the properties of steering system, or lead
to accidental or damage when driving.
Troubleshooting
Trouble Causes Inspection items
Unsuitable tire inflation
Insufficient lubricant
Over-large inclination
Steering gear joint wear
Lower swing arm ball head wear
Steering column seize-up
Steering gear unsuitable adjustment or damage
Power steering conveyer looseness
Over-low liquid level in oil cup of steering pump
Failure in power steering mechanismInflate the tire to specified pressure
Lubricating the hanging devices
Check the Alignment of Front Wheel
Change the Steering gear joint
Change the lower swing arm ball
head;
Check the steering column
Adjust or repair the gear.
Adjust the conveyor.
Check the steering pump oil cup
Check the power steering devices
Poor returning
Unsuitable tire inflation
Insufficient lubricant
Incorrect wheel alignment
Steering column seize-up
Steering gear unsuitable adjustment or damageInflate the tire to specified pressure
Lubricating the hanging devices.
Check the Alignment of Front
Wheel
Check the steering column
Change the steering gear.
Over-large playFront wheel bearing wear
Steering drive shaft yoke wear
Lower swing arm ball head wear
Steering gear joint wear
Steering gear unsuitable adjustment or damageChange the front bearing
Change the steering drive shaft
Change the swing arm ball head
Change the steering gear joint
Change the steering joint
Abnormal noise
Steering drive lever looseness
Steering gear joint wear
Steering gear unsuitable adjustment or damage
Oil lack or poor sealing of steering machine.Tighten the steering drive lever
Change the steering gear joint
Change the steering gear
Add the oil or change the sealing
washer Steering system inspection
on vehicle.
Steering System
Notice and Troubleshooting
Difficulty in steering

SR-14Steering System
Power Steering (On-Vehicle Inspection)
Change of power steering liquid
1. Tear down the oil-returning hose from the oil cup to
drain the liquid into the container;
2. Run the engine in the idle status, and rotate the
steering wheel toward the max rotating angle for
several times in right or left direction while draining the
liquid, until the oil in steering liquid is drained up.
3. Turn off the engine.
4. Connect the oil-returning pipe and inject the new
power steering liquid in the liquid tank;
Hydraulic oil type: No.8 Liquid drive oil (Q/SH003.01.012-88)
5. Start the engine, and make it running in the idle status.
Rotate the steering wheel to the max rotating angle repeatedly
several times, meanwhile, supplement new power steering
liquid in the liquid tank until there is no foam or turbidities in
the liquid tank, and the oil indicating lamp reaches the marked
range when the engine is turned off.
6. Tighten the liquid tank cover
7. Exhaust the air in the power steering system;
Ai-r bleeding in power steering system
1. Check the liquid level height in the liquid tank
Check the liquid level and, if needed, supplement the liquid.
2. Start the engine in the idle status and rotate the
steering wheel repeatedly to the max rotating angle
several times.
3. Turn off the engine and connect the ethane pipe and
bleeding plug.
4. Start the engine and rotate the steering wheel
repeatedly to the max rotating angle several times.
5. Locate the steering wheel at the intermediate position.