2008 GEELY MK Brake system

Rear Suspension System-Rear Suspension Crossmember4-63Disassemble:1. Remove rear wheel
2. Remove sideslip control sensor wire (with ABS)
3. Remove load-sensing valve bracket (without ABS)
4. Remove proportioning valve and right rear brake tube
5. Remove proportioning valve and left rear brake tube
6. Remove right parking brake cable assembly
7. Remove left parking brake cable assembly
Tips: Remove right parts by using same operations as left
8. Remove rear brake drum subassembly
9. Remove left rear hub and bearing assembly
(1) Remove nuts and right parking brake cable assembly from
rear axle frame
(2) Remove four bolts and left rear hub and bearing assembly
(3) Remove rear brake assembly from rear axle frame
10. Remove rear right hub and bearing assembly
Tips: Remove right parts by using same operations as left
11. Loosen rear axle frame assembly
12. Disassemble rear left shock absorber assembly
13. Disassemble rear right shock absorber assembly
Tips: Remove right parts by using same operations as left
14. Remove rear left helical spring
15. Remove rear right helical spring
Tips: Remove right parts by using same operations as left
16. Remove rear axle assembly
(1) Lift rear axle assembly by lifting axel
(2) Remove two bolts and rear axle frame assembly

4-6523. Temporarily fasten the rear axle frame assembly
(1) Lift rear axle frame by lifting jack
(2) Mount the rear axle frame by temporarily tightening two bolts
24. Mount rear left helical spring
25. Mount rear right helical spring
Tips:
Mount right parts by using same operations as left
26. Temporarily tighten rear left shock absorber assembly
27. Temporarily tighten rear right shock absorber assembly
Tips:
Mount right parts by using same operations as left
28. Mount rear left hub and bearing assembly
Mount rear brake assembly, rear left hub and bearing assembly by
four bolts
29. Mount rear right hub and bearing assembly
Tips: Mount right parts by using same operations as left
30. Mount rear brake drum subassembly
31. Adjust the gap between brake drum and brake shoe
32. Mount #3 parking brake cable assembly
Tips: Mount right parts by using same operations as left
33. Mount #2 parking brake cable assembly
34. Mount #4 rear brake tube
35. Mount #3 rear brake tube
Tips: Mount right parts by using same operations as left
36. Connect sideslip control sensor wire(with ABS)
37. Connect load-sensing valve braket(without ABS)
38. Sufficiently tighten rear axle frame assembly
39. Sufficiently tighten rear left shock absorber assembly
40. Sufficiently tighten rear right shock absorber assembly
Tips: Mount right parts by using same operations as left
41. Release air from brake tube
42. Mount rear wheel
Torque: 103N.m
43. Check rear wheel alignment
44. Check the speed signal of ABS sensor( with ABS).Rear Suspension System
-Rear Suspension Crossmember

Brake System -Brake System4-79Chapter 9 Brake SystemSection 1 Brake SystemI. Precaution 1. 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.II. Symptom table Use 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
Low brake pedal or recoil
Brake StagnationSuspected Area
1 Brake system (fluid leaks)
2 Brake system (air in)
3 Piston Cup in Sub-pump (worn or damaged)
4 Rear brake shoe clearance (out of adjustment)
5 Master cylinder (faulty)
6 Booster push rod (out of adjustment)
7 Brake shoe or lining (oily)
8 Disc/Drum scratched
1. Brake pedal free stroke is too small
2. Parking brake lever stroke (out of adjustment)
3. Parking brake cable (sticking)
4. Rear brake shoe clearance (out of adjustment)
5. Brake pad or lining (cracked or distorted)
6. Wheel cylinder piston (stuck or frozen)
7. Return spring (faulty)
8. Vacuum booster (faulty)
9. Brake master cylinder (faulty)

Brake System -Brake System4-80Symptom
Brake Deviation
Noise from brakeSuspected Area
1. Wheel cylinder piston (stuck)
2. Brake shoe lining (oily)
3. Disc (scratched)
4. Brake shoes or lining (cracked or distorted)
5. Wheel hub bearing (worn or damaged)
6. Tire pressure (not as specified)
1. Brake shoe lining (damaged)
2. Installation bolt (loose)
3. Disc (scratched)
4. Brake shoe (bad in quality)
5. Brake shoes lining (oily)
6. Sound isolating shim damaged
7. Hold spring of brake shoe (damage)

Bleeding1. Fill brake reservoir with brake fluid
Brake fluid: HZY4 complying with GB12981Section 2 Brake FluidBrake System -Brake Fluid4-812. 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.
Tips: Do not mix and use with other brand of brake fluid.

Component ViewSection 3 Brake PedalBrake pedal bracket
Lubrication bushing
Handspike pin
Pad
Clip
Brake pedal Brake light bushing25Brake System -Brake Pedal4-82Brake master cylinder
handspike U-connector
Brake light switch
Brake pedal axis
Brake pedal return spring
Brake pedal pad
Specified torque
Non-reusable parts
Lithium soap-base glycol lube

Adjustment1. Check and adjust the height of brake pedal.
(1) Check the height of brake pedal.
Height from the floor: 124.3-134.3mm
(2) Adjust the height of brake pedal.
a. Remove the cover of the console.
b. Remove the coupler from the brake light switch.
c. Loosen the lock nut of the brake light switch, and remove
the brake light switch.
d.Loosen the lock nub of the U-connector.
e.Turn the pedal push bar to adjust the height of brake
pedal.
f. Tighten the lock nub of the push bar.
Torque: 26N.m
g. Install the brake light switch.
h. Insert the connector of the brake light switch.
i. Push the brake pedal (5-15ram), and turn the brake light
switch till it goes out. Lock the nut in this position.
j. After installation, step down the brake pedal (5-15mm),
and check the brake light is bright.
2. Check the pedal free stroke.
(1) Shut down the motor, and step on the brake pedal repeatedly
till the booster is not vacuum.
(2) Step down the pedal till resistance appears, and measure the
distance as shown in the figure.
Pedal free travel: 1-6mm
If the clearance does not meet the requirement, check the
clearance of the brake light switch. If the clearance is correct,
make diagnosis on the braking system.
Clearance: 0.5-2.4mm
3. Check the pedal reserved distance.
Loosen the parking brake extension rod.
When the motor is running, step down the pedal, and measure the
pedal reserved distance as shown in the figure.
When stepping on the pedal 490N, the reserved distance from the
asphalt floor is larger than 55mm
If the distance doesn't meet the requirement, make diagnosis on
the braking system.Brake System -Brake Pedal4-83Braking lamp switch
Push parBraking pedel
heightFree travel for
braking pedalReverse of braking
pedal

1
2
3Brake System -Brake Pedal4-84Removal After the installation, check and adjust the height, free stroke and reserved distance of the brake pedal.
1. Remove the combination instrument component (see figure 1).
2. Unfix the brake master cylinder push bar U-connector.
Remove the clip and pin, and unfix the master cylinder handspike from the brake pedal.
3. Remove the brake pedal bracket.
(1) Remove the bolt from the brake pedal bracket (see figure 1).
(2) Unfix the brake light coupler.
(3) Remove the four nuts and brake pedal bracket (see figure 2).
4. Remove the brake pedal sub-assembly.
(1) Remove the bolt and nut from the brake pedal bracket.
(2) Remove the brake pedal and the two bushings.
5. Remove the brake light switch component.
(1) Loosen the lock nut of the brake light switch.
(2) Remove the brake light switch from the brake pedal bracket.
6. Remove the brake pedal pad.
Remove the brake pedal pad from the brake pedal.
7. Install the brake pedal pad.
Install the brake pedal pad on the brake pedal.
8. Install the brake light switch component.
Install the brake light switch on the brake pedal bracket.
9. Install the brake pedal.
(1) Apply lithium soap-base glycol lube on the end surface and side surface of the two new bushings.
(2) Install the brake pedal and the two bushings on the brake pedal bracket with bolts and nuts.
Torque: 37N.m
10. Install the brake pedal bracket.
(1) Install the brake pedal bracket with four nuts.
Torque: 25N.m
(2) Connect the connector of the brake light switch.
(3) Install the bolt on the brake pedal bracket (see figure 3).
Torque: 20N.m
11. Connect and install the brake cylinder push bar U-connector.
(1) Apply the lithium soap-base glycol lube on the handspike pin.
(2) Connect the master cylinder handspike with pins and clips.
12. Install the combination instrument components.
13. Check and adjust the brake pedal height.
14. Check the brake pedal's free travel.
15. Check the brake pedal's reserved distance.