Great Wall Hover. Service Manual - part 13

special tools

Upper suspension arm

Disassembly of upper suspension arm

1. Disconnect the upper ball pin from the steering

    knuckle

     Remove the split pin and nut; use the special tools to disconnect

     the upper ball pin from the steering knuckle.

2. Remove the brake oil pipe on the upper arm shaft

a. Use the open-end wrench to screw off the oil pipe tight nut.

b. Pull out the brake oil pipe and plug it by the rubber plug.

Remarks: There are two two-way valves for rear brake oil pipe

beside the right upper arm shaft ; when remove the right

upper suspension arm, it must remove four oil pipe tight nuts

in the place and plug it by the rubber plug to prevent the brake

fluid from overflowing.

3. Disconnect the brake hose form the brake caliper

Remove the hollow bolt and disconnect the brake hose form the

brake caliper

Remarks: Must not lose the copper gasket seal.

4. Disconnect the brake hose from the upper arm oil

    pipe bracket.

Use the pliers to pull out the sheet steel spring clip and discon-

nect the brake hose from the upper arm oil pipe bracket.

5. Remove the upper suspension arm

Remove two bolts and remove the upper suspension from the

arm carriage.

Remarks: Keep the adjusting shim and don’t lose it. Record

the thickness of front and rear adjusting shim for convenience

of reinstalling them in the original position.

Replacement of upper arm bush

1. Remove the bush

a. Remove the bolt and washer

.

b. Use the special tools to push out the bush.

c. Remove the upper arm shaft; remove another bush in same proce-

dure

2. Install the bush

a. Use the special tools to press in the bush.

b. Install the upper arm shaft; use the special tools to press inanother

         bush.

3. Tighten the upper arm shaft to specified torque.

a. Coat the screw of both ends of upper arm shaft with the screw

lock sealant; install the washer and nut.

Remarks: Adjust the position of upper lower; make the installa-

tion plane of ball pin is vertical to the installation plane of upper

arm shaft.

special tools

special tools

special tools

b. Tighten the upper arm shaft nut to specified torque.

Tightening force: 210

10N

m

Installation of upper suspension arm

1. Install the upper suspension arm on the carriage

a. Install the upper suspension arm and camber adjusting shim.

b. Tighten all bolts to the specified torque.

Tightening force: 200

10N

m

Remarks: Install the shim with same quantity and thickness to

the original position.

2. Connect the brake oil pipe of upper arm shaft

Tighten the oil pipe compression nut to specified torque.

     Tightening force: 15-17N

m

Remarks: It should tighten four connector of two two-way

valves to the specified torque if disassemble the right upper

arm.

3. Connect thebrakehosetotheupperarmoilpipebracket

a. Thread the brake hose from the hole on upper arm oil pipe

bracket.

b. Use the hand hammer to knock in the sheet steel spring clip to

fix the brake hose.

4. Connect the upper ball pin to the steering knuckle

a. Tighten the slotted nut according to the specified torque.

Tightening force: 145

15N

m

b. Install the new split pin.

Remarks: It should align the notch of nut with the pinhole

when install the split pin; the nut can be tightened but not

loosed during the alignment.

Connect the copper gasket seal and tighten the hollowbolttospecified

     torque.

     Tightening force: 50

5N

m

6. Discharge the air in front brake system

(refer to relevant chapter)

Remarks: It must discharge the air in the rear brake system if

disassemble the right upper arm.

7. Check the brake fluid for leakage

8. Tighten the upper arm front shaft nut to the specified

     torque

       Install the wheel, remove the bracket and bounce the vehicle for

       several times to make the vibration damper enters into the stable

       status.

9. Check the wheel alignment parameter

(Refer to 4-Wheel Alignment)

Stabilizer bar

Disassembly of stabilizer bar

1. Disconnect the connecting bar which supports both

    ends of the stabilizer bar form the stabilizer bar.

     Use the inner hexagon spanner to fix the ball pin; remove the self-

      locking nut.

2. Remove the bush and clip of stabilizer bar; remove

    the stabilizer bar

Installation of stabilizer bar

1. Install the stabilizer bar on the carriage

Place the stabilizer bar in position; install the stabilizer bar bush

and clip on the carriage. Screw on and pretighten the bolt.

2. Connect the stabilizer bar to the connecting bar

        

Installand tighten the new nut to the specified torque

Tightening force: 63

5N

m

   

3. Tighten the clip position bolt to specified torque.

Tightening force: 23

3N

m

N 

m:     specified torque

Used component which can not be used any more.

precoated component

Front hub and steering knuckle (4WD)

stabilizer bar

flat shim

connecting rod

of stabilizer bar

hub and brake disc

flange

adjusting washer

circlip

hub cap

spring shim disc brake

split pin

lower suspen-

sion arm

split pin

upper suspension arm

drive shaft

oil seal

n e e d l e

bearing

lock washer

steering knuckle

lock nut

lock washer

screw

brake cover

spring shim

flat shim

disk shim

Shim

fill block

fill block

disk shim

oil seal

bearing

bearing

shock absorber

special tools

diagram of

special tools

Front hub

Disassembly of front hub

1. Remove the disc brake

Remove the brake caliper and hang it by steel cable.

Remarks: Do not remove the brake pipe and brake hose.

2. Remove the hub cap and flange

a. Use the inner hexagon spanner to screw off the fastening blot

and remove the hub cap.

b. Use the pliers to remove the circlip and remove the adjusting

washer.

c. Remove the flange.

3. Remove the hub and brake disc

a. Use the Philips screwdriver to screw off the tight screw;

remove the lock washer.

b. Use the special tools to remove the lock nut.

c.   Remove the hub and brake disc with the outer bearing.

4. Remove the oil seal and inner bearing

a. Use the screwdriver to pry out the oil seal

b. Remove the inner race of inner bearing form the hub.

Check and repair of front hub

1. Check all bearings

Wash the inner race and outer race of each bearing and check them for

wear and damage.

2. Replace the bearing outer race

a. Use the brass bar and hand hammer to knock out the bearing outer

race.

Use the special tools to knock in the new bearing outer race.

Assembly of front hub

1. Coat the inner surface of hub and bearing outer race

      with the grease.

The grease is the Jin HP-R grease or the grease met the requirement

in following table.

special

tools

diagram of

special tools

grease

Dropping point, C

Leakage amount (104 C, 6h), g

EP performance OK value , N

Item

Typical data

2. Place in the bearing inner race; use the fill the gap

between the inner and outer race of the bearing up

with the HP-R grease.

grease

grease

3. Install the inner bearing and oil seal

a. Place the inner bearing in the hub

b. Use the special tools to knock the new oil seal into the hub.

c. Coat the oil seal lip with HP-R grease.

diagram of

special tools

special tools

4. Install the hub on the steering knuckle

a. Install the hub on the steering knuckle

b. Install the outer bearing.

5. Adjust the pre-applied load

a. Use the special tools to screw on the locknut to specified

torque.

Tightening force: 80-100N

m

b. Rotate the hub to right and left 1/3

1/4 round respectively.

c. Screw off the nut until the nut can be loosed by hand.

d. Use the special tools to retighten the lock nut.

Tightening force: 28N

m

e. Use the spring tension meter to check the pre-applied load.

Pre-applied load (for starting): 28-56N

special

tools

diagram of

special tools

6. Install the lock washer

Install the lock washer with the surface with counterbore outwardly

and fix it on the lock nut by screw.

Remarks: If the screw installation hole on the lock washer can not

align with the screw hole on the lock nut, then it can remove the

lock washer and adjust he lock nut slightly (rotate in the direction

of Min. adjusting range ); then install the lock washer.

7. Recheck the pre-applied load

Use the spring tension meter to recheck the pre-applied load

Pre-applied load (for starting): 28-56N

If the pre-applied load does not meet the specified value, it must

remove the lock washer and adjust it by the adjusting nut.

8. Install the ring flange

a. Install the ring flange on the hub.

b. Install the adjusting washer.

c. Install the circlip.

9. Install the hub cap

a. Coat the screw of the inner hexagon bolt with the screw lock

sealant.

b. Use the inner hexagon bolt to fix the hub cap and ring flange on

the hub; tighten the bolt to the specified torque.

Tightening force: 78

5N

m

10. Install the disc brake

Install the disc brake on the steering knuckle; tighten the bolt to the

specified torque.

Tightening force: 140

10N

m

special

tools

special

tools

special

tools

Steering knuckle

Disassembly of steering knuckle

1. Remove the disc brake and front hub

(Refer to section “Front Hub”)

2. Remove the brake cover

3. Disconnect the steering cross rod from the steer-

ing knuckle arm

a. Remove the split pin and nut on the ball pin.

b. Use the special tools to disconnect the steering cross rod

from the steering knuckle arm.

4. Disconnect the connecting rod of stabilizer bar

from lower arm

Use the inner hexagon spanner to fix the ball pin; remove the

self-locking nut.

5. Remove the steering knuckle

a. Remove the split pin and nut on the upper ball pin

b. Use the special tools to disconnect the upper ball pin from

the steering knuckle.

c. Remove the split pin and nut on the lower ball pin.

d. Use the special tools to disconnect the upper ball pin from

the steering knuckle.

e. Use the jack to raise the lower arm; remove the steering knuckle.

Check and replacement of steering knuckle

1. Check of steering knuckle

Use the dye penetrant to check the steering knuckle for crack.

It should replace the steering knuckle if has crack.

2. Remove the steering knuckle oil seal

Use the screwdriver to pry out the oil seal from the steering knuckle.

3. Take out the thrust plate

4. Remove the needle bearing

Use the copper bar and hand hammer to knock out the needle

bearing.

5. Installation of needle bearing

Use the special tools and hand hammer to knock in the new

needle bearing slightly.

Remarks: The thicker end of needle bearing should be

upwardly when knock in. with thicker end.

chamfer

steering

knuckle

6. Installation of thrust plate

Coat the installation position of thrust plate of steering knuckle

with the HP-R grease; place the thrust plate with the surface

with chamfer facing the steering knuckle.

Remarks: It must measure the thickness of the thrust plate

before the installation; it should install the new thrust plate if

the thickness is less than 1.5mm. The nominal thickness of

the new thrust plate is 2mm.

7. Installation of steering knuckle oil seal

Use the special tools and hand hammer to knock in the new

steering knuckle oil seal slightly.

Installation of steering knuckle

1. Install the steering knuckle

a. Coat the drive shaft and inner of drive shaft dustproof cove

with the lithium base grease.

b. Insert the drive shaft into the steering knuckle, meanwhile

connect the lower ball pin to the steering knuckle and install the

slotted nut temporarily.

special

tools

special

tools

c. Press down the upper arm and connect the upper ball pin to the

steering knuckle. Install and tighten the nut to the specified

torque.

Tightening force: 145

15N

m

d. Install the new split pin.

Remarks: It should align the notch of nut with the pinhole when

install the split pin; the nut can be tightened but not

loosedduringthealignment.

e. Install and tighten the lower ball pin nut to specified torque.

Tightening force: 230

20N

m

f. Install the new split pin.

Remarks: It should align the notch of nut with the pinhole when

install the split pin; the nut can be tightened but not

loosedduringthealignment.

2. Connect the stabilizer bar to the lower arm

Support the lower arm by jack; use the inner hexagon spanner to fix

the ball pin and tighten the self-locking nut to specified torque.

Tightening force: 63

5N

m

3. Connect the steering cross rod to the steering

    knuckle arm

a. Tighten the slotted nut according to the specified torque.

Tightening force: 170

15N

m

b. Install the new split pin.

Remarks: It should align the notch of nut with the pinhole when

install the split pin; the nut can be tightened but not

loosedduringthealignment.

4. Install the brake cover

Tightening force: 23

3N

m

5. Install the front hub and disc brake

(Refer to section “Front Hub”)

clip

Front suspension (4WD)

N 

m:    specified torque

Used component which can not be used any more.

Pregummed component

rubber sleeve

front shaft of

lower arm

disk shim

fill block

shim

fill block

disk shim

shock Absorber

front hub and steering

knuckle assembly

split pin

lower ball pin

adjusting bolt

lower adjusting block

fixed arm

upper
adjusting
block

l ower arm

rear shaft of lower arm

Torsion base

torsion
bar

lower arm long bush

split pin

upper ball pin

upper arm

shim

upper arm bush

upper arm shaft

upper arm bush

shim

front stabilizer bar

flat shim

connecting rod of stabilizer bar

flat shim

lower arm short bush

eccentric shim

Ball pin

Check of ball pin

1. Check the lower ball pin for loose

a.   Raise the front of the car by jack and support it by the frame.

b. Ensure the front wheel is in straight advancing position and step

down the brake pedal.

c. Move the arm upwardly and downwardly; check

the clearance of lower ball pin.

 Max. vertical clearance: 0mm

2.  Check the upper ball pin for loose move the wheel

      upwardly and downwardly and check the gap of

      upper ball pin.

Max. vertical clearance: 0mm

3. Check the rotation of ball pin

a. Remove the ball pin.

b.   Shown as figure, shake the ball pin stud forwardly and backwardly

for several times before install the nut

c. Rotate the nut continuously by torsion meter and 2-4s for a

cycle; record the readout of torsion meter in the fifth cycle.

 Tightening torque (for rotary):

 Lower ball pin   0.1

4N

m

 Upper ball pin   0.1

4N

m

Disassembly of ball pin

1. Remove the steering knuckle and front hub assembly

(Refer to section “Front Hub and Steering Knuckle”)

2. Remove the lower ball pin form the lower arm

3. Remove the upper ball pin from the upper arm