2008 GEELY MK Brake system

Component ViewSection 4 Brake Master Cylinder AssemblyVacuum boosterBrake System -Brake Master Cylinder Assembly4-85Brake master cylinder
sub-assembly
Vacuum tube
Fluid level indicator lamp connector Manual Transmission
#1 clutch fluidr tank pipe No ABS
specified torqueN.
m :

Component ViewBrake System -Brake Master Cylinder Assembly4-86With ABS:
Cover
Brake fluid reservoir
Strainer
Automatic Transmission
O-ring
Retaining ring
Pin
Straight pinPiston guide
block
Cup
Washer
#1 piston & Spring
#2 piston
Spring Hole connectorHole
connector
Master cylinder
Without ABS
Cover
Strainer
PinManual Transmission
O-ring
Retaining ring
Hole connector
Piston guide block
Cup
#1 piston & Spring
#2 piston & Spring
Washer
Piston limit bolt Master cylinder Hole connectorSpecified torque
Non-reusable parts
Lithium soap base glycol lube

Repair1. Discharge the brake fluid.
Note: Never spray the brake fluid on the paint surface, otherwise
wash it immediately.
2. Remove the brake master cylinder.
(1) Pull out the connector of the level alarm light switch.
(2) Slide the clip, and pull out #1 clutch storage tank pipe (manual
transaxle).
(3) Remove the two brake pipes from the brake master cylinder
with special tool.(with ABS)
(4) Remove the three brake pipes from the brake master cylinder
accessory with special tool. (without ABS)
(5) Remove the two lock nuts, and pull out the brake master
pump.
3. Remove the storage tank.
(1) Put the brake master cylinder on the bench clamp.
(2) Remove the pin from the brake master cylinder body with
punch and hammer.
(3) Pull out the Brake fluid reservoir.
(4) Remove the cover and strainer from the storage tank.
(5) Remove the storage tank and the two hole connectors.
4. Remove the brake master cylinder.
(1) Put the brake master cylinder on the bench clamp.
(2) Remove the O-ring.
(3) Push the piston with hand, and remove the snap ring with
snap ring pliers.Brake System -Brake Master Cylinder Assembly4-87With ABS:
Without ABS

(4) Push the piston with hand, and turn the cylinder body to
remove the straight pin. (with ABS)
(5) Push the piston with hand, and remove the piston bolt and
washer. (without ABS)
(6) Pull out #1 piston, piston guide block, spring, cup and washer
straightly.
Note: If angle appears in the pulling process, it may cause
damage to the cylinder wall.
(7) Put two blocks and cloth on the workbench. Put the flange of
the master cylinder against the block edge and knock it till #2
piston and spring get out of the cylinder.
Tips:Brake System -Brake Master Cylinder Assembly4-88 Make sure the distance (A) between the working cloth and the block's top is at least 100mm.
Note:
If angle appears in the pulling process, it may cause damage to the cylinder wall.
5. Check the brake master cylinder.
(1) Check the cylinder wall whether there is any rust or nick.
(2) Check the cylinder wall whether there is any abrasion or damage.
Note:
If necessary, clean or replace the brake master cylinder.
Tips:
Clean the assembled parts with compressed air.
6. Install the brake master cylinder.
(1) Fix the brake master cylinder on the bench clamp.
(2) Apply the lithium soap-base glycol lube on the rubber parts with arrow.
(3) Install # 2 and # 1 pistons, spring, piston guide block, cup and washer.
Note:
If angle appears in the installation process, it may cause damage to the cylinder wall. Be careful not to
damage the edge of the cup on the piston.

Brake System -Brake Master Cylinder Assembly4-89 (4) Push the piston, and install the straight pin on the cylinder
body. (with ABS)
(5) Push the piston, and install the new washer and piston bolt.
Torque: 10N.m
(6) Push the piston, and install the snap ring with snap ring pliers.
(7) Install the O-ring on the brake master cylinder.
7. Install the Brake fluid reservoir.
(1) Apply the lithium soap-base glycol lube on the Brake fluid reservoir connector, and install it on the brake
master scylinder.
(2) Install the pin on the brake master cylinder with punch and hammer.
8. Check and adjust the vacuum booster push bar.
(1) Install a special tool on the brake master cylinder,and lower
the special tool mandril till it touches the piston.
(2) Mark the mandril top surface of the special tool with chalk.
(3) Overturn the special tool, and leave a clearance between the
special tool and the vacuum booster.
Tips:
If there is clearance between the special tool body and the booster hull, it means that the clearance is
standard value. If there is no chalk trace on the booster push bar, it means that the clearance exceeds the
standard value.

Brake System -Brake Master Cylinder Assembly4-90 (4) Adjust the length of the vacuum booster push bar with the
special tool till the push bar touches the mandril head.
9. Install the brake master cylinder.
(1) Install the brake master cylinder on the booster with two bolts.
Torque: 13N.m
(2) Connect the two brake oil pipes to the brake master cylinder
with a special tool. (with ABS)
Torque: 15N.m
(3) Connect the three brake oil pipes to the brake master cylinder
with a special tool. (without ABS)
Torque: 15N.m
(4) Connect # 1 clutch storage tank oil pipe with clip. (Manual
transaxle type)
(5) Insert the brake fluid level alarm switch connector.
10. Add the brake fluid to the Brake fluid reservoir.
11. Discharge the air in the brake master cylinder.
12. Discharge the air in the brake pipeline.
13. Check the level height in the Brake fluid reservoir.
14. Check the brake fluid whether there is any leakage.With ABS:
Without ABS

19151915131515
Fluid level indicator lamp connectorVacuum booster assembly
Gasket25Clip26 Clip Master cylinder
Manual Transmission
#1 clutch fluid tank oil pipe
HECU assemblyClipSection 5 Vacuum BoosterComponent ViewBrake System -Vacuum Booster4-91Battery
#2 relay box, engine chamber
Return spring
Pin
Push bar
U-connector Without ABSVacuum tube
Non-reusable parts
Lithium soap base glycol lubeSpecified torque

Check1. Check the brake booster.
(1) Air tightness check
a. Start the motor, and shut it down after one or two minutes,
then step on the pedal several times slowly.
Tips:
If the pedal goes down greatly at the first step, but it gradually
goes up after the second and third steps, it means the air
tightness is good.Brake System -Vacuum Booster4-92 b. When the motor is running, step down the brake pedal, and then shut down the motor.
Tips:
If the reserved distance does not change thirty seconds after
the pedal is stepped down, it means the air tightness is good.
(2) Operation check
a. When the ignition switch stays in OFF position, step on the
pedal several times, and then check that the reserved
distance should not change.
b. Step down the pedal, and start the motor.
Tips:
If the pedal goes down a little, it means the operation is ok.
2. Check the vacuum one-way valve.
(1) Check the vacuum one-way valve.
a. Slide the clip to unfix the vacuum tube.
b. Remove the vacuum one-way valve.
c. Check the booster is ventilated to the motor.
d. In case of any failure, replace the vacuum one-way valve.ONOFFPositiom 1Positiom 2Positiom 3 Good Poor