2006 GREAT WALL SAILOR steering

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-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)

SR-1
Notice .......................................................................... SR-2
Troubleshooting .......................................................... SR-2
Inspection on Vehicle .................................................. SR-3
Steering Column ......................................................... SR-4
Manual Steering Gear ................................................. SR-9
Power Steering ............................................................ SR-11
General Introduction ................................................ SR-11
Inspection on vehicle ............................................... SR-13
Power Steering Oil Pump ........................................ SR-16
Power Steering Gear ............................................... SR-18
Steering linkage .......................................................... SR-20
SR
Steering System
Page

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-3Steering System
On-vehicle Inspection
max play
On-vehicle Inspection
Steering wheel play
1.SR-18Check to see whether the steering wheel play is
correct;
Park the vehicle stably and align the tires in correct direction,
press the steering wheel with finger and swing it in left and
right direction. The play should not exceed the max play.
(Max play)
6
(Dr SF)
If the play is nor correct, adjust or repair the steering wheel as
requirement.
2. Adjust the steering wheel play:
(a) Align the wheel forward precisely;
(b) Loosen the locking nuts of steering gear;
(c) Rotate the adjusting screws of steering gear clockwise to
reduce the steering wheel play, while contrarotate the
adjusting screws to increase the steering wheel play.
Remark: screw the adjusting screws and enlarge the play a
little each time to check the adjusted play.
3. Check to see whether there is steering inconvenience
Rotate the steering wheel by half round in right and left
direction to check whether the play is correct, and whether the
wheel runs smoothly or any seize-up in its running.
4. Fix the adjusting screws and fasten the adjustable nut.
Oil level height
Check the oil level height in the steering gear housing.
Oil level height: flush with the filler opening.
If there oil is insufficient, add the gear oil and check to see
whether there is oil leakage.

SR-4Steering System
Steering Column
Steering Column
Element figure of non-adjustable steering column
Dr
SL SK SY
upper part of
steering column
steering drive shaft
30
2
N
m
specified torque
steering drive shaftupper part of steering column
50
5
universal cardan joint
dust cap
fixed support seat

SR-5
Steering Column
Element figure of adjustable steering column
Steering System
Steering Column
Dr SF
upper part of steering column
universal cardan joint
steering drive
shaft
upper part of steering column
steering drive shaftuniversal cardan joint
universal cardan jointsteering column
SL SK SY
SJ

SR-6Steering System
Steering Column
Dismantle of the steering wheel
1. Dismantle of the steering wheel;
(a) Take down the bugle cap;
(b) Pull down the bugle wire.
(c) Tear down the fixing nut of steering wheel.
2. Tear down the combined switch cover;
3. Tear down the cover at left bottom part.
4. Tear down the fixing bracket for the left-bottom cover.
5. Tear down the air passage;
6. Tear down the combined switch;
7. Tear down the fixed support seat bolts on front-wall panel;
8. Tear down the fixing bolts at upper part of steering
column, and
9. Tear down the connecting bolts of steering column
drive shaft.
10. Pull out the steering column.