2008 GREAT WALL FLORID brake

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Wheel
General tire balancing procedures
Clean out the accumulated dirt and debris from the inside of the rim.
Warning:
The gravel on the tread must be eliminated to avoid flying out and injuring the operator when
undergoing rotational balancing. This is also a good way to acquire better balance. First thoroughly
inspect the tire's damaged condition, then according to the balancing device manufacture's
recommendations, carry out the balancing operation.
Off-vehicle balancing
Most off-vehicle balancers are more accurate and convenient than on-vehicle rotational balancers. They are
also able to perform dynamic (two sided) balancing. Although it does not correct drum brake and brake disc
imbalance like on-vehicle balancing, it achieves the same effect based on its accuracy.
On-vehicle balancing
On-vehicle balancing is different based on equipment and tool manufacturer. Therefore, when performing
balancing operations, be sure to comply to each manufacturer's operating\
instructions.
Warning: Control the wheel rotation speed to make sure the speedometer stays within 55 km/h.
This restriction is necessary because when a driven wheel slides while the other one stays still, the
speedometer will display only half of the actual wheel speed. When a wheel is sliding, be extremely
careful, because sliding wheels can reach very high speeds. This may lead to the tire rubber peeling
or differential damage, which may cause serious personal injury, or damage to the vehicle.
Tire installation and removal
• Install or remove tires with a tire changer. When operating machinery, make sure to comply to the machine
manufacturers operation manual. Please do not change tires merely with manual hand tools or tire installation
crowbars. This will damage the tire chafer or the vehicle wheel's rim.
• Use a wire brush or coarse steel wool to clean off grease and old rubber, as well as light rust or corrosion from
the rim tire bead's tire chafer seat. Before tire installation or removal, first use the indicated tire lubricant to
thoroughly lube the tire chafer portions one time.
• After installing the tire, inflate it to the specified pressure and make\
sure the tire bead is properly seated.
Warning: Do not over-inflate the tire. If the tire bead severally expands and exceeds the safety limit,
it may burst and cause serious personal injury. While inflating, do not exceed the specified pressure.
If the specified pressure does not allow the tire bead to sit properly, deflate the tire, re-lubricate, and
then re-inflate.
Spare tire usage
• Spare tire standard inflation pressure: 420 kPa.
• Spare tire pressure measurements should be taken under normal temperatur\
e conditions.
• After inflating the spare tire, soapy water should be used to check if the air nozzles core is leaking air, then
lock on the air nozzle cap.
• The spare tire should always be kept in a useable state. Check the air p\
ressure at least once a month.
• When the spare tire's working limit, indicated by the remaining pattern's depth, reaches 1.6 mm (and its pat-
tern groove bottom protrudes to the same level), for your safety, please stop using the spare tire.
Caution:
• The "" symbol on the tire bead of the spare tire in-
dicates the set position of the wear index (shown on
the left).
• The spare tire's maximum driven speed is 80 km/h,
and maximum distance 200 km per trip.
• Each vehicle is allowed to use only one spare tire.
• The spare tire is only used as a temporary backup.
Please go to a professional service station immediately
to get the initial tire repaired or replaced.

Downloaded from www.Manualslib.com manuals search engine 93Suspension System
Dynamic balance and static balance
There are two types of wheel balance: static and dynamic.
Picture 1 shows static balance. Picture 2 shows dynamic
balance.
Static balance means that the weight distribution around the
wheel is equal. If the wheel is static and unbalanced, violent
vibrations may be created, called jump vibration.This kind
of situation can ultimately lead to the uneven wear and tear
of the tires. Shown in diagram 1.
Dynamic balance means that the weight distribution on the
two sides of the medium plane of the wheel is equal, so
during the rotation process, the tire assembly cannot create a
tendency for the medium plane of the wheel to shift from one
side to the other. If the wheel is dynamic and unbalanced, it
can create a shimmying effect. Shown in diagram 2.
1. Wheel shimmy important points[C]: Counterweight not yet added
2. Locations to add counterweight[D]: Counterweight added
3. Axis
Wheel maintenance
Do not use welding, heating, or hammering to repair wheels. All damaged wheels must be replaced.
If the vehicle's wheel is twisted or deformed, sunken or depressed, having too much horizontal or radial hop,
leaking air from the welded parts, stretched out at the bolt holes , having flimsy nut bolt lock, or severely rusty,
the wheel must be replaced. When the wheel is hopping too much, it will lead to undesirable vibratio\
ns.
When replacing the tire, be sure that the load capacity, diameter, rim width, offset distance, and the installation
structure of it, are equal to the settings of original wheel. If the wheel dimensions are not appropriate, this will
influence the wheel and bearing's life, brake cooling effect, speedometer and odometer calibration, vehicle
ground clearance, as well as the clearance between the tire and the vehi\
cle body, and the tire and vehicle chassis.
Wheel (steel wheel) removal
1. Remove the wheelhouse and loosen the nuts, 1-2 turns is
enough.
2. Hoist the vehicle.
3. Screw off the nuts and remove the wheel.
Nut tightening torque: 110±10 N·m
Caution: Heating methods absolutely must not be used
to loosen tightened wheels, otherwise the heat will
reduce its use life and damage the hub bearing.
Wheel (steel wheel) installation
Installation according to the reversed instructions used for
removal, and pay attention to the following requirements:
Wheel nuts must be tightened in proper order and according to
the specified torque, as to avoid wheel or brake disc deformity.
When installing the wheel house, be sure to line up the wheel
housing notch locations with the inflation nozzle.
Tightening sequence: A – C – B – D
Caution: Before installing the wheel, first clean off the
corrosion on the wheel's mounting surface and drum
brake or brake disc's installation surface with a wire
brush, in order to make the wheel installing easier by
making the space between its metal firmly connect
to the mounting surface, otherwise it may lead to the
wheel nuts loosening to the extent that the vehicle's
wheel may come off while driving some day.
1
3
2[A][B]
1. Wheel hop important points[A]: Counterweight not yet added
2. Locations to add counterweight[B]: Counterweight added
3. Axis
Diagram 1
Diagram 2
[C][D]
1
3
2
AB
CD

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Brake System
Brake System Components Arrangement Schematics.......95
Brake System Maintenance................................................96
Brake Pedal ........................................................................\
98
Parking Brake Control Mechanism Assembly...................102
Vacuum Booster with Brake Cylinder Assembly ...............103
Anti-lock Brake System ....................................................107
ABS General Problem Maintenance and
Areas of Importance .........................................................109
Steering Knuckle and Hub Brake Assembly .....................112
Front Brake Caliper ..........................................................118
Rear Brake .......................................................................124
Rear Support Axle ............................................................131

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Brake System Components Arrangement Schematics
Brake pedal assembly
Vacuum booster with brake cylinder assembly
Left steering knuckle and hub brake assembly
Left parking brake cable assembly
Rear brake assembly RHRear brake drum
Rear wheel speed sensor assembly RH
Right parking brake cable assembly
ABS controller assembly
Right steering knuckle and hub brake assembly
Brake line assembly
Rear wheel speed
sensor assembly LH
Front wheel speed sensor assembly RHFront wheel speed sensor assembly LH
Rear brake assembly LH
Parking brake control mechanism assembly

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Brake System Maintenance
Brake fluid inspection and replacement
Brake fluid directly influences the brake performance and the operating conditions and use life of the brake
system components. Brake fluid has very strong hygroscopic properties, and thus absorbs water easily,
which will then deteriorate the metal and rubber pieces. Polluted and deteriorated brake fluid or its mixture
would cause the brake fluid to boil and gasify, hence reduces braking efficiency. Therefore, pay attention to
the items below when filling or changing the brake fluid:
1. Containers used to hold brake fluid must be tightly closed and sealed
2. Brake fluid is poisonous and damaging to the paint. Hence if it gets on the vehicle surface, rub it
off at once
3. If water or other contaminates found in the brake fluid, and the brake master cylinder's piston seal
has been broken, then the brake fluid and all the rubber pieces inside the brake system including
the brake hose must be replaced
4. The correct brake fluid level in the reservoir must be between MAX and MIN. After the vehicle has
been driven for over 1000 km, check the brake fluid level in the reservoir. If the brake fluid level is
not up to regulation, more brake fluid should be added to the reservoir \
until it reaches MAX.
Hydraulic component inspection and system flushing
1. If the oil-based solvent gets into the hydraulic system, flush the whole system and change all of
the rubber pieces
2. Clean your hands before installing new rubber pieces or other components
3. Do not use regular solvents (kerosene, gas, etc.) when inspecting or cleaning hydraulic
components, instead use absorbing alcohol or brake fluid
4. After inspecting the components, drain the brake fluid from the system. Use new brake fluid to
flush the system. Afterwards, add new brake fluid to perform hydraulic system exhaust
5. Flushing completion sign: When the brake fluid flowing out of the dump valve is clear from any
contaminate.
Hydraulic pressure system drainage
If the brake fluid inside the whole hydraulic pressure system needs to be emptied, open all the bleed screws
with each connected to a hose, as to allow the brake fluid to flow into a container. Step on the pedal slowly
until only air flows out. During the whole procedure, make sure all the \
valves are open.
Hydraulic pressure system air bleeding
The hydraulic brake system must work under a vacuum environment. The air will cause spongy brake or
overall brake failure when it flows into the hydraulic system. It is extremely necessary to bleed system air
when performing any operation on the brake system or if any air inside t\
he brake system is suspected.
1. Air bleeding sequence
If air inside the brake master cylinder is suspected, first perform air bleeding.
(a) If numerous valves are equipped, air bleed each valve
(b) Another sequence principle is: Air bleed from the wheel brake furthest away from the master cylinder.
The air bleeding sequence for the LHD modules is: rear right wheel - left rear wheel - front right wheel
- front left wheel, Right rudder vehicles: rear right wheel - left rear wheel - front left wheel - front right
wheel.
2. Air bleeding method
(1) Manual air bleeding
Use the brake pedal or pump as the air bleeding power source. When the air bleed screws are open, vent the
brake fluid containing the bubbles from the system. Usually this is simultaneously done by two people. One
steps on the brake pedal and the other operates the air bleed screws. Important points to take note of when
performing the operation:
(a) Place the ignition switch to the off position and step on the pedal repeatedly to remove the
vacuum pressure or hydraulic pressure.
(b) Before and after air bleeding, add clean brake fluid into the master cylinder until it reaches
the correct (stated) level.
(c) Check the fluid level frequently to make sure that more than half of the reservoir's capacity is
available.
(d) Bleed screws should only be opened when the pedal is pressed down, and closed before the
pedal is loosened. Meanwhile, check if the vented brake fluid has bubble\
s inside.

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(e) Make sure not to let the system valves block the air bleeding.
(f) When the brake fluid that flows out of the hose or connector has no bubbles, it means that the air
in the system has been exhausted. There is still air inside the system if the hose inserted into the
brake fluid is still bubbling when pressing down the pedal.
(g) Keep the free end of the hose immerged in the brake fluid to avoid air from flowing into the
system while opening the screw.
(h) While air bleeding, hammer the casting part of the vibrating brake device with a rubber hammer.
This is helpful for removing bubbles deep in the brake fluid.
(i) If air in the master cylinder is suspected, then perform air bleeding on the master cylinder first,
then the wheel cylinder or brake caliper.
(j) When releasing air from the tires, generally make sure to release air out of all the tires.
(k) To avoid the possibility of air reversely entering into the system, a bleeder hose that has a check
valve could be used.
(2) Pressure blow-off
Under the proper conditions, a pressure blow-off device can be used to release the air inside the brake system.
3. Air releasing sequence
(1) Master cylinder air bleeding
If the master cylinder does not have air bleed screws, perform the follo\
wing steps:
(a) Check the brake fluid level inside the master cylinder’s reservoir and add to it if necessary.
(b) Slowly take off the front brake pipe connector until the brake fluid flows out from the end.
(c) Reconnect the brake pipe, but do not tighten it.
(d) Slowly step down and press on the brake pedal, check if the brake fluid flowing out of the connector
contains bubbles.
(e) Tighten the pipe fitting.
(f) Have the assistant loosen the pedal, wait for 15 s.
(g) Repeat the above steps until all the air is released.
(h) Take off the rear brake pipe connector, repeat the above steps.
(2) Wheel brake air releasing
(a) Check the brake fluid level inside the master cylinder’s reservoir and add to it if necessary. During the
entire air releasing period, check repeatedly and add promptly.
(b) Connect one end of the bleeder hose with the bleed screw and the other end immerged in the brake fluid.
(c) Have the assistant step on the pedal several times, raise the pedal gradually until it cannot be stepped on
any more, then forcibly press on the pedal once more.
(d) Loosen the bleed screw, check if there are any bubbles in the brake fluid flowing out. Meanwhile, slowly
lower the pedal.
(e) When the brake pedal is close to the stroke end or the out flowing brake fluid does not have any bubbles,
tighten the bleed screw.
(f) Have the assistant release the pedal and wait for 15 s.
(g) Repeat the above steps until there are no bubbles in the flowing brake fluid when the screw is loosened.
(h) Release the air for all the wheels in turn using the same method.
(i) After releasing the air from the entire system, switch the ignition to the on position.
(j) Inspect the stroke of the brake pedal and its reaction.
(k) Inspect the lighting condition of the brake warning lamp, and repeatedly perform maintenance or air
bleeding if necessary.
( l ) Add brake fluid to the reservoir until the specified fluid level, air bleeding is complete.

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Brake Pedal
Components
Areas of Importance
1. During removal, all components should be gently handled to avoid knocking, especially the junction
surface. All components should be placed in order to avoid losing or taking the w\
rong parts.
2. Keep all parts clean and free of dust, scuffs, rust, corrosion, oil build-up, or any other contaminants.
3. All rubbing surfaces in a relative motion must be coated with lubricant\
.
4. During installation, strictly adhere to the standard torque for installi\
ng nuts.
5. While installing the return spring, be careful to avoid operator injury \
from it bouncing back.
Troubleshooting
SymptomsPossible causesEliminating methods
Brake pedal cannot return
to the original position
Return spring is brokenReplace the spring
Return spring's fixed end comes offCheck, secure in place
Feels slippery when
stepping on the pedal
Pedal pad is worn outReplace
Pedal pad comes offReinstall
Stepping on the pedal
produces abnormal noise
The plastic bushing is seriously worn outReplace
Spring brokenReplace
Spring's fixed end comes offCheck, re-fix
Pedal pad
Cotter pin
Return spring
Pedal shaft
Brake pedal bracket
welding assembly
Brake pedal lever welding assembly
Bushing
Nut
Limiting stopper
Center pin

Downloaded from www.Manualslib.com manuals search engine 99Brake System
Disassembly of the brake pedal assembly
1. Remove the lock nut with an outer hexagonal wrench.
2. Remove the pedal shaft.
Caution: Please do not place the pedal shaft directly
on the ground, as to guarantee its cleanness.
3. Remove the brake pedal assembly.
Caution: Set it down gently to avoid damaging its
surface finish.
4. Remove the pedal pad, bushing, and limiting stopper
from the pedal lever assembly.
Caution: Ensure cleanliness of the entire set's surface.
Installation of the brake pedal assembly
1. Apply lubricant on the inside of the axle tube-brake
pedal and the outside of the bushing, then install the
bushing into the axle tube-brake pedal.
Lock nut
Pedal shaft
Pedal lever assembly
Pedal pad
Axle tube
Bushing