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10. Check the axial clearance of bearing.Put the centimeter besides shaft hub center, and check the
axial clearance of bearing.
Maximal value: 0.05mm
If axial clearance exceeds the maximal value, change the bearing
assembly.11. Check the terminal face run-out of shaft hub.Use centimeter to check the terminal run-out of exterior sur-
face of shaft hub.
Maximal value: 0.07m
If terminal run-out exceeds the maximal value, change the shaft
hub.12. Assemble left rear brake assembly [64000137]
13. Assemble left rear brake branch pump assemblyTorque: 46 ± 5 N
⋅ ⋅⋅ ⋅
⋅m14. Assemble rear wheelsTorque: 103 ± 10 N
⋅ ⋅⋅ ⋅
⋅m15. Check the ABS speed sensor signal.
16. Inspection on road.Drive shaft--Left rear shaft hub and bearing assembly130
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Left rear shaft hub boltChange1. Disassemble rear wheels
2. Disassemble left rear brake caliper assembleDisassemble two bolts and take down brake caliper.3. Disassemble left rear brake assembly [64000137]
4. Disassemble left rear shaft hub bolt(a) Screw the shaft to the position in figure, then use special
tool to disassemble shaft hub bolt.
Note: shaft hub bolt should be screwed to the position
in figure, or you could not change shaft hub bolt.
(b) Use special tool and screw driver to disassemble shaft hub
bolt.5. Assemble left rear shaft hub bolt(a) Liking that shown in figure, assemble new gasket and screw
cap on new shaft hub bolt.
(b) Use screw driver to fix and lock screw cap to make the bolt
enter hole.6. Assemble left rear brake assembly [64000137]
7. Assemble left rear brake branch pump assemblyUse two bolts to assemble rear brake branch pump assembly.
Torque: 46 ± 5 N
⋅ ⋅⋅ ⋅
⋅m8. Assemble rear wheelsTorque: 103 ± 10 N
⋅ ⋅⋅ ⋅
⋅mDrive shaft--Left rear shaft hub bolt131
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Brake--Brake systemBrakeBrake systemNotes zIt is necessary to be very careful when changing any subassembly, for this will influence the perfor-
mance of brake system and incur the running becomes unsafe. It is necessary to use those parts with
same type or same grade when changing. zWhen repairing brake system, it is very important to keep the surface of every part clean.132
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Brake--Remove malfunctionRemove malfunctionMalfunction phenomenon tableUse following table to help you find the reason of malfunction, the number in table indicates the preferred
sequence of possible reasons of malfunction. Please check every part by sequence, if necessary, change
this part.Malfunction phenomenon Possible malfunction part Reference page
1. Brake system (leaking oil). -
The height of brake pedal is too 2. Brake system (entering air). 135
low or brake pedal is loose. 3. Piston oil seal (abraded or damaged). 141, 144
4. Brake main pump (invalid) 138
5. Vacuum booster lever (adjusted badly) 138
1. Brake pedal free travel (too small). 136
2. Parking brake handle travel (adjusted badly). 154
3. Parking brake pull cable (lag). 156, 158
4. Brake block (damaged or distorted). 141, 144
Brake lag 5. Piston (locked). 141, 144
6. Piston (freezed).141, 144
7. Tensility or return spring (invalid). 161
8. Vacuum booster lever (adjusted badly). 138
9. Vacuum boosting system (vacuum leakage). 138
10. Brake main pump (invalid). 138
1. Piston (locked). 141, 144
2. Brake block (oil dirt).141, 144
Brake offset 3. Piston (freezed).141, 144
4. Brake disk (scratched). 141, 144
5. Brake block (abraded or distorted).141, 144
1. Brake system (leaking oil).
2. Brake system (entering air). 135
3. Brake block (abraded). 141, 144
4. Brake block (damaged or distorted). 141, 144Brake pedal is too hard to make power lack.5. Brake block (oil dirt).141, 144
6. Brake block (sclerosesed). 141, 144
7. Brake disk (scratched). 141, 144
8. Vacuum booster lever (adjusted badly). 138
9. Vacuum boosting system (vacuum leakage). 138133
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Brake--Remove malfunction
1. Brake block (damaged or distorted). 141, 144
2. Assembled nut (loose). 141, 144
3. Brake disk (scratched). 141, 144
4. Support sheet of brake block (loose). 141, 144
Brake noise 5. Sliding pin (abraded). 141, 144
6. Brake block (oil dirt). 141, 144
7. Brake block(sclerosesed). 141, 144
8. Support pin or return spring (invalid). 161
9. Muffle gasket (damaged). 141, 144
10. Localizing spring (damaged). 161Malfunction phenomenon Possible malfunction part Reference page134
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Brake--Remove malfunction1. Add brake liquid in storage tank.Brake liquid: DOT-42. Discharge the air in brake main pump.Hint: if brake main pump or liquid storage tank is
disassembled, it is necessary to discharge the air in
brake main pump.
(a) Disassemble brake pipeline of brake main pump.
(b) Step down brake pedal slowly and keep this state.
(c) Plug oil hole with finger, then release brake pedal.
(d) Repeat (b) and (c) three times or four times.3. Discharge the air in brake pipeline.(a) Connect plastic pipe on exhaust bolt of brake branch pump.
(b) After stepping brake pedal several times, and step down
brake pedal, then release inflating bolt to discharge air.
(c) Lock exhaust bolt until brake liquid stops flowing out, then
release brake pedal.
(d) Repeat (b) and (c) until air is discharged completely.
(e) Repeat the procedure above, and release the air in brake
pipeline of every wheel.
Torque: 12.7-17.6 N
⋅ ⋅⋅ ⋅
⋅m4. Check the brake liquid storage tankCheck the liquid level in storage tank, if necessary, add brake
liquid.
Brake liquid: DOT-4.Brake liquidDischarge the air in brake systemHint: if any part of brake system has been damaged or
you disbelieve whether there is any air in brake pipeline,
it is necessary to discharge the air in brake system
completely.
Note: do not make brake liquid spill on paint surface, if
having, wash it cleanly.135
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Brake--Remove malfunction2. Check the free travel of pedal.(a) Extinguish the engine, and step brake pedal repeatedly until
there is no vacuum in vacuum booster.
(b) Press down pedal with hand until feeling the resistance,
then measure the distance of this section, liking that shown
in figure.
Free travel of pedal: 1-6mm.
If it is wrong, check the clearance of brake light switch.
Clearance of brake light switch: 0.5-2.4mm
If the clearance accords with the regulation, remove the
malfunction in brake system.3. Check the distance from pedal to floor.Release parking brake drag lever
When engine is running, step down brake pedal, then mea-
sure the distance from pedal to floor, liking that shown in figure,
Force 490 N on pedal, its distance from floor should be:
over 60mm.
If it is wrong, remove the malfunction in brake system.Brake pedal assemblyAdjustment1. Check and adjust the height of brake pedal.(a) Check the height of brake pedal.
Pedal distance from floor: 136.0-146.0mm
(b) Adjust the height of brake pedal.
(1) Disassemble lower trim board of panel.
(2) Disassemble switch joint of brake light.
(3) Loosen locking nut of brake switch, and disassemble
the switch of brake light.
(4) Loosen U-shaped clasp fixing nut of pedal lever.
(5) Turn pedal lever to adjust the height of pedal.
(6) Lock the fixing nut of lever.
Torque: 26
± ±± ±
±2 N⋅ ⋅⋅ ⋅
⋅m
(7) Assemble the switch of brake switch.
(8) Connect the switch joint of brake light.
(9) Press down the brake pedal for 5-15mm, and turn the switch of brake light to illuminate brake light,
then lock the nut.
(10) After assembling, press down the brake pedal for 5-15mm again, and confirm brake light has
illuminated.Pedal distance
from floorFree travel of
pedal Height of pedal Push rodBrake light switch136
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ChangeHint: after assembling, check and adjust the height, free travel of brake pedal and the height from
pedal to floor.Brake--Remove malfunctionBrake pedal bracket
Brake pedal bushing
Brake pedal shaft
Locking shaft
Brake main pump lever pin
Brake pedal Brake pedal
Rubber gasket137 N.
m: Regulated torqueDo not use the part repeatedlyLithium soap base glycol lubricating grease
