2008 GREAT WALL FLORID brake

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual20
No.Important fastening piece locationsFastening piece name
and model numberQuantity
Tightening
torque
(N·m)
1.31Propeller shaft assemblyFront drive shaft nut (M22 × 1.5)2240±20
1.32Subframe & vehicle body (rear)Hexagon bolt for flange face and flat
washer subassembly2116±10
1.33Subframe & vehicle body (front)Hexagon bolt for flange face and flat
washer subassembly270±5
1.34Subframe strut bar & vehicle bodyHexagon head bolt and flat washer
subassembly447±5
1.35Swing arm & steering knuckleSwing arm ball end nut (M12 × 1.25)298±10
1.36Swing arm & subframeHexagon nut for flange face (M12 × 1.25)2\
1.37Swing arm & subframeHexagon head bolt and flat washer
subassembly2136±10
1.38Swing arm & subframeHexagon head bolt and flat washer
subassembly2107±10
1.39Front shock absorber & vehicle bodyHexagon nut for flange face (M8)639±4
1.40Front shock absorber & steering knuckleHexagon bolt for flange face (M14 × 1.5)4\
1.41Front shock absorber & steering knuckleHexagon nut for flange face4132±10
1.42Front stablizer bar bracket & frameHexagon head bolt and flat washer
subassembly423±3
1.43Hanger rod, swing arm & stablizer barType 2 non-metal insert lock nut223±3
1.44Trailing arm spindle sleeve assemblyHexagon head bolt and flat washer
subassembly282±5
1.45Rear shock absorber support shaftHexagon nut for flange face249±5
1.46Rear shock absorber componentsI type hexagon nut464±5
1.47Hub Wheel nut (M12 × 1.25)16103±10
1.48Steering wheel & steering column
mounting nutHexagon nut for flange face150±4
1.49Steering column & beam mounting boltHexagon bolt for flange face123±3
1.50Steering column & beam mounting boltHexagon head bolt and flat washer
subassembly223±3
1.51Steering pump adjustable bracket &
engine mounting boltHexagon bolt for flange face339±4
1.52Powr steering pump & bracket mounting
boltHexagon bolt for flange face164±5
1.53S t e e r i n g p u m p m o u n t i n g b r a c k e t
&engine mounting boltHexagon bolt for flange face235±3
1.54Steering gear & subframe mounting
bolt
Hexagon head bolt and flat washer
subassembly (M12 × 1.25 × 80)2107±7
1.55Steering gear & subframe mounting
bolt
Hexagon head bolt and flat washer
subassembly (M13 × 1.25 × 100)2107±7
1.56S t e e r i n g g e a r & s t e e r i n g k n u c k l e
mounting nutHexagon castle thin-nut250±10
1.57Steering protection plate & subframe
mounting boltHexagon bolt for flange face223±3
1.58ABS sensor & steering knackleHexagon head bolt and spring washer
subassembly29±2
1.59Rear brake & rear axleBolt: for installing brake850±5
1.60Brake pedal & boosterNut423±3

Downloaded from www.Manualslib.com manuals search engine 21Overall Parameters
No.Important fastening piece locationsFastening piece name
and model numberQuantity
Tightening
torque
(N·m)
1.61ABS sensor front wire harness & front
shock absorber
Hexagon head bolt and flat washer
subassembly223±3
1.62ABS & vehicle body Hexagon head bolt and flat washer
subassembly323±2
1.63Parking brake cable & vehicle bodyH e x a g o n h e a d b o l t a n d s p r i n g w a s h e r
subassembly69±2
1.64Parking brake cable & rear brakeH e x a g o n h e a d b o l t a n d s p r i n g w a s h e r
subassembly29±2
1.65ABS sensor rear wire harness, vehicle
body & rear brake
H e x a g o n h e a d b o l t a n d s p r i n g w a s h e r
subassembly69±2
1.66Parking brake fixed cable braket &
vehicle body
H e x a g o n h e a d b o l t a n d s p r i n g w a s h e r
subassembly19±2
1.67ABS sensor front wire harness & vehicle
body
Hexagon head bolt, spring washer and flat
washer subassembly29±2
1.68Parking brake control mechanismHexagon head bolt, spring washer and flat
washer subassembly223±3
1.69Rear brake pipe connector & vehicle
bodyHexagon bolt for flange face19±2
1.70Seven-hole tube clamp & vehicle bodyHexagon bolt for flange face19±2
1.71Brake pedal & vehicle bodyHexagon bolt for flange face123±3
1.72Brake cable & rear axleHexagon nut for flange face29±2
1.73All of the brake line connectors M1016±2
1.74All of the brake line connectors M1216±2
2Vehicle body
2.1Connected seat belt Front seat belt upper mounting bolt (7/16.)242±5
2.2Connected seat belt Seat belt lower mounting bolt (7/16.)438±5
2.3Connected seat belt retractorFront seat belt retractor lower bolt (7/16.)238±5
2.4Connected seat belt retractorHexagon bolt for flange face29±3
2.5Connected seat belt Rear seat belt upper mounting bolt (7/16.)238±5
2.6Connected seat belt retractorRear seat belt retractor bolt (7/16.)238±5
2.7Connected seat belt Mounting bolts on the middle seat belt
(7/16.)138±5
2.8Connected front seat belt mortise lockFront seat belt mortise lock bolt (7/16.)260±5
2.9Connected rear seat belt lockRear seat belt lock bolt (7/16.)238±5
3Air conditioner
3.1Compressor bracket & engineHexagon bolt for flange face Q1841030FD
(M10 × 1.25)464±5
3.2Comperssor bracket & compressorHexagon bolt for flange face-oversize
Q1860890FD423±3
3.3Condensor fan mounting boltHexagon head bolt and flat washer
subassembly Q1400630 (Q402) F3219±2
3.4Condensor mounting boltHexagon bolt for flange face223±3
3.5Compressor suction hose & HVAC
refrigeration line portHexagon bolt for flange face Q1460640F3219±2
3.6Air conditioner hose, compressor, and
condenser coupling boltHexagon bolt for flange face Q1840625F3249±2
3.7Expansion valve & HVAC refrigeration line portHexagon bolt for flange face Q1840630F3229±2

Downloaded from www.Manualslib.com manuals search engine 37Clutch Operational System
Areas of Importance
1. Clutch Rigid Pipe Installation
Before installing, check to make sure that the rigid pipe flare contact area is in good condition, the pipeline is
clean, and that there is no foreign materials.
2. Clutch Hose Installation
Check the surface of the clutch hose to make sure that there is no scuffing and that the pipeline is clean.
3. Coat grease on the U-joint of the pedal and the master cylinder.
4. Strictly adhere to the set torque guidelines when tightening the pipe fittings.
Rigid pipe and the master cylinder: M10 16±2 N·m
Clutch rigid pipe and hose: M10 16±2 N·m
5. While the clutch system is undergoing the exhausting process, make sure that all the air bubbles in
the pipeline are cleared out. Then check the brake fluid level in the reservoir, it should be between
MIN and MAX.
Troubleshooting
The numbers in the table represent the order of the possible malfunction causes, so be sure to check each part in
turn. If necessary, replace the part.
SymptomsPossible Causes
Clutch vibration1. Engine mounting bracket (loose)
2. Clutch plate (axial runout is too much)
3. Clutch plate (oil build-up)
4. Clutch plate (polished)
5. Clutch plate (hardened)
6. Diaphragm spring (damaged)
Clutch pedal is spongy1. Clutch pipeline (air entering)
2. Clutch master cylinder cup (damaged)
3. Clutch slave cylinder cup (damaged)
Clutch makes abnormal noise1. Clutch release bearing (wear and tear, dirty or damaged)
2. Driven plate torsion damper (damaged)
Clutch slips1. Clutch pedal (free play is out of alignment)
2. Clutch plate (oil build-up)
3. Clutch plate (polished)
4. Diaphragm spring (damaged)
5. Pressure plate (deformed)
6. Flywheel (deformed)
Clutch cannot be disengaged1. Clutch pedal (free play out of alignment)
2. Clutch pipeline (air entering)
3. Clutch master cylinder cup (damaged)
4. Clutch slave cylinder cup (damaged)
5. Clutch plate (axial runout is too much)
6. Clutch plate (wear out from friction)
7. Clutch plate (dirty or burnt)
8. Clutch plate (oil build-up)
9. Clutch plate (lack of grease on the spline)

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual38
Clutch Operational System
Components
Clutch Master Cylinder Removal
1. Use a combination plier to loosen the steel band elastic
hoop, and to remove the clutch feed connecting hose.
Caution: Release the brake fluid in the reservoir before
disconnecting the hose.
Steel band elastic hoop
Clutch feed connecting hose
Reservoir
Steel band elastic hoop
Clutch feed connecting hose
Clutch discharge pipe
Clutch master cylinder
Limit adjusting bolt
Return spring
Lock nut

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual40
Clutch Master Cylinder Installation
Installation of clutch system is reverse to its removal, but
since the whole clutch system uses hydraulic assistance,
make sure to air bleed it after the installation is completed.
Detailed steps as follows:
(a) Plug one end of the long transparent connection hose
(about 0.5 m long) into the bottom of bleed screw, and
the other end into a fixed container.
(b) Loosen the bleed screw via the open end of the M8,
meanwhile ask the assistant to step on the clutch pedal
repeatedly until no air bubbles can be seen in the hose.
R e m a r k : R e s i d u a l a i r i n t h e c l u t c h s y s t e m h a s b e e n
completely exhausted.
(c) Lastly, lock the bleed screw.
Caution: Refilling the brake fluid reservoir should be
performed while air bleeding the clutch.
Clutch Pedal Removal
1. Remove the battery's negative cable.
2. Remove the glove box at the left of the dashboard.
3. Remove the cotter pin at the U-joint of the clutch
master cylinder, and separate the center pin and the
pedal lever.
4. Remove the clutch pedal bracket from the cowl.
5. Remove the clutch pedal.
(a) Move the clutch pedal to the maximum stroke position.
(b) Take down the return spring.
(c) Remove the bolts and nuts.
(d) Take the pedal lever down from the pedal bracket.
Clutch Pedal Installation
1. Install the clutch pedal.
(a) Install the return spring.
(b) Install the clutch pedal lever.
(c) Install the bolts and nuts.
Tightening torque: 30 N·m
(d) Put the pedal lever at the maximum stroke position and
connect it with the spring, in order to set the pedal to its
initial position.
2. Install the clutch pedal onto the 2 studs of the clutch
master cylinder.
Use a M13 wrench to tighten the clutch pedal brackets with
two M8 nuts.
Tightening torque: 23±3 N·m
3. Install the clutch master cylinder push rod with the U-
joint.
(a) Coat the contact areas between the center pin and the
U-joint pedal connector with multi-functional grease.
(b) In succession, join the U-joint (pedal connector) and
the clutch pedal lever with a cotter pin.
Caution: Insert the center pin into the pedal lever from
the left side of vehicle.
(c) Install the cotter pin onto the center pin.
4. Check and adjust the clutch pedal.
5. Connect the negative cable of the battery.
Bleed screw

Downloaded from www.Manualslib.com manuals search engine 73Suspension System
Steering knuckle assembly removal
1. Preparation
First, remove the front wheel, the front shock absorber with
coil spring assembly, and the steering knuckle coupling
bolt in turn. For detailed steps, please refer to the removal
of the wheel and the front shock absorber with coil spring
assembly.
2. Remove propeller shaft nuts
(a) First, pry the flattened areas of the propeller shaft's nuts
into a circle with a chisel.
(b) Half-insert a long bolt or metal bar into the brake disc
holes to loosen the nuts (shown on the left).
Tightening torque: 225±20 N·m
Front Suspension
Components
(c) Pull out the mount point on the steering knuckle to
separate it from the mounting bracket under the front
shock absorber. Prop a wood stick or metal bar against
the propeller shaft's outer end, and then hammer the
stick or metal bar to get the propeller shaft out of the
hub (shown on the left).
Caution: When hammering, prop it up against the shaft
end's location holes (middle recess). Be sure not to
damage the thread.
Insert into this hole
Press plate on the front shock absorber column
Front shock absorber with coil spring assembly
Front stabilizer bar mounting bracket
Front stabilizer bar bushing
Front stabilizer bar
Lower swing arm assembly RH
Lower swing arm assembly LH
Subframe assembly
Front stabilizer bar hanger rod subassembly
Subframe strut bar

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual74
3. Remove the wheel speed sensor and the brake hose
Remove the wheel speed sensor's mounting bolts with a M10
sleeve to take off the wheel speed sensor. Remove the front
brake hose's mounting bolts with a M18 sleeve, and then
take off the brake hose.
Caution: When removing the brake hose, brake fluid
may flow out, catch the fluid with a container. Also,
b e c a u s e t h e b r a k e f l u i d i s c o r r o s i v e , p l e a s e p a y
attention to personal protection.
4. Remove the cotter pins and lock nuts of the steering tie
rod and the lower swing arm
Because the ball stud and steering knuckle act in conjunction
with the tapered bore, they can not yet be removed after re-
moving the nuts. Pound the steering knuckle arm (unfinished
surface) with a hammer. Positions are shown on the left.
Shake to loosen.
Caution:
1. To avoid separating the ball studs, do not pound the
tie rod and the lower swing arm with a hammer.
2. To avoid damaging the thread, do not hammer the
ball stud's head.
Front brake hose mounting bolt
Wheel speed sensor mounting bolts
Lightly hammer here

Downloaded from www.Manualslib.com manuals search engine 75Suspension System
Front shock absorber with coil spring assembly (Image)
Front shock absorber with coil spring assem-
bly removal and installation
1. Hoist up the vehicle so that the front suspension is in a
free suspension state.
2. Remove the wheel speed sensor and the brake hose.
Remove the wheels and take out the brake hose from the
shock absorber bracket. Then remove the wheel speed sensor
wire harness (shown on the left) from the steering knuckle.
3. Remove the coupling bolt between the front shock
absorber and steering knuckle and the brake hub
assembly.
Tightening torque: 132±10 N·m
4. Loosen the mounting nuts of the front shock absorber
and remove the front shock absorber with coil spring
assembly (shown on the left).
Tightening torque: 40±5 N·m
5. Installation of the front shock absorber with coil spring
assembly.
Installation follows the reverse order of removal, but
please pay attention to the areas of importance below:
(a) The Insertion direction of the bolts should be consistent
with direction shown in the image. Insertion order is
from up to down. After inserting, tighten them one by
one as required.
Front
Brake hose
Wheel speed sensor wire harness
E r e c t i o n s u p p o r t u n d e r the front shock absorber
Front shock absorber assembly
Erection support under the front coil spring
Front coil spring
Dust cover
Erection support on the front shock absorber column
Hexagon flange nut
Press plate on the front shock absorber column
Dust cover on the front shock absorber
Erection support on the front coil spring
Front bumper