Great Wall V200. Service Manual - part 12

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

Use the inner hexagon spanner to screw off the fastening blot and

remove the hub cap.

3. Remove the hub and brake disc

a.  Use the Philips screwdriver to screw off the lock screw and

     remove the lock washer.

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

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

special tools

special tools

diagram of special tools

grease

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 from the hub.

Check and repair of front hub

1. Check each bearing

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

       damage or wear.

2. Replace the bearing outer race

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

race.

b. 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.

Item

                                           

Typical data

Dropping point, C

                                

289

Leakage amount (104 C, 6h), g

               

 0.48

EP performance  OK value , N

                  

178

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.

4. Install the hub on the steering knuckle

a.

Install the hub on the steering knuckle.

 b.   Install the external bearing.

diagram of spe-

cial tools

special tools

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

diagram of spe-

cial tools

special tools

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 hub cap

a.   Coat the silicon rubber surface sealant on the matching surface of

hub and hub cap.

b. Coat the screw of the inner hexagon bolt with the screw lock sealant.

c. 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: 45

5N

m

9. Install the disc brake

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

specified torque.

     Tightening force: 140

10N

m

Steering knuckle
Disassembly of steering knuckle

1. Remove the disc brake and front hub

(Refer to section “Front Hub”)

2. Remove the brake cover

special tools

special tools

special tools

3. Disconnect the steering cross rod from the steering

    knuckle arm

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

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 steering knuckle from the

upper ball pin.

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

d. Use the special tools to disconnect the steering knuckle from

the upper ball pin.

 e.   Remove the steering knuckle.

Check and replacement of steering knuckle

Use the dye penetrant to check the steering knuckle for

crack.It should replace the steering knuckle if has crack.

Installation of steering knuckle

1. Install the steering knuckle

a. Install the lower ball pin on the steering knuckle and install the

slotted nut temporarily.

b. 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

c. 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.

Tightening force: 230

20N

m

e. 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.

     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

      loosed during the alignment.

     Tightening force: 23

3N

m

5. Install the front hub and disc brake

(see section of front hub)

Front suspension (2WD)

front stabilizer bar

rubber cover

clip

connecting rod of

stabilizer bar

flat shim

front shaft of

lower arm

split pin

adjusting bolt

lower adjusting block

fixed arm

upper adjusting block

lower arm

rear shaft of lower arm

torsion bar base

torsion bar

lower arm long bush

split pin

upper ball pin

upper arm shaft

upper arm bush

flat shim

lower arm

short bush

eccentric shim

disk shim

fill block

fill block

disk shim

shim

shock absorber

shim

shim

upper arm bush

upper arm shaft

lower ball arm

front wheel hub

and steering

knuckle assy

N  m:  specified torque

Used component which can not be used any more.

Pregummed component N 

m: specified torque

Ball pin

Inspection 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.Take down the steering knuckle and front wheel hub assy.

Installation of ball pin

1. Install the upper ball pin on the upper arm

Tightening force: 78

5N

m

2. Install the lower ball pin on the lower arm

Tightening force: 140

10N

m

3. Install the steering knuckle and front hub assembly

    (Refer to section Front Hub and Steering Knuckle)

Disassembly of ball pin

(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.

Torsion bar spring

Disassembly of torsion bar spring

Installation of torsion bar spring

Caution: There are the L and R indication marks, which must

not be exchanged on the read end of the torsion bar spring.

Mark L means the left andRforright

.

1. For reused torsion bar spring

a. Coat thin grease on the spline of torsion bar spring.

b. Align the assembly mark, install the torsion bar spring on the

torsion bar.

 c.   Align the assembly mark; install the adjusting arm onthtorsion

  bar spring.

d.  Tighten the adjusting bolt to make the extension length of the bolt

equal to the length before remove.

2. For new torsion bar spring

a. Remove the wheel.

b. Coat thin grease on the spline of the torsion bar spring.

c. Install the torsion bar spring on the torsion bar base.

d.  Lower the lower arm to the lower limitation position; install the

 adjusting arm in the torsion bar spring with the angle that the

 adjusting bolt just can be screwed on the upper adjusting block.

e. Tighten the adjusting bolt to the specified torque.

N u t   t i g h t e n i n g   l i m i t a t i o n :  A  i s   a b o u t   3 0 - 3 5 m m ;   i f  A >

 35mm, then it is adjusted through height of adjusting arm.

f. Install the wheel; remove the bracket; bounce the vehicle for

several times to make the suspension enters into the stable

status.

g. Rotate the adjusting bolt and adjust the ground clearance of

chassis (Refer to 4-Wheel Alignment).

2. Disconnect the vibration damper from the lower

    arm.

3. Disassembly of torsion bar spring

    (Refer to Section “Torsion Bar Spring”)

Lower suspension arm

Removal of lower suspension arm

1. Disconnect the connecting rod of stabilizer bar

    from the lower arm

     a.  Use the jack to support the lower arm.

  b. Remove the connecting nut; disconnect the connecting rod of

      sta bilizer bar form the lower  arm.

5. Remove the front shaft of lower arm

     a. Make the mark on the adjusting cam.

special tools

      b.Remove the nut and front shaft of lower arm.

6. Remove the rear shaft of lower arm

     Screw off the nut; remove the rear shaft of lower arm shaft; remove the

     lower suspension arm.

Replacement of lower suspension arm bush

1. Removal of short bush of lower suspension arm

Use the special tools to press the short bush from the lower arm.

2. Installation of short bush of lower suspension arm

Use the special tools to press the new short bush in the lower arm.

Remarks: Do not coat the bush with the grease.

special tools

special tools

3. Removal of long bush of lower suspension arm

Use the special tools to remove the long bush.

special tools

4. Installation of longbushoflowersuspensionarmUse

the special tools to install the new bush.

Remarks: Do not coat the bush with the grease.

Installation of lower suspension arm

1. Installation of lower suspension arm

a. Install the rear shaft of lower arm and tighten the nut to the

specified torque.

Tightening force: 290

25N

m

b. Install the front shaft of lower arm and screw on the nut

temporarily.

2. Installation of front hub and steering knuckle

    assem bly

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

3. Install the vibration damper on the lower suspension

    arm.

Install the vibration damper on the lowersuspensionarmbracket.

Tightening force: 90

10N

m

4. Connect the stabi lizerbar to the lower suspension

    arm

Tightening force: 63

5N

m

special tools

5. Install the torsion bar spring

(Refer to “Torsion Bar Spring”)

6. Tighten the nut of front shaft of lower arm to

    specified torque

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

several times to make the vibration damper enters into the

stable status.

b.   Align the assembly mark and tighten the nut to specified torque.

Tightening force: 240

20N

m

7. Check the wheel alignment parameter

(Refer to 4-Wheel Alignment)