Great Wall V200. Service Manual - part 14

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”)

Torsion bar spring

Disassembly of torsion bar spring

1. Make the assembly mark on the torsion bar spring,

    torsion base and adjusting arm

2. Measure the length A of extension section of bolt

    according to the length shown in figure.

Remarks: The measuring value is for reference when adjust the

ground clearance of chassis.

3. Loose the adjusting bolt until the torsion bar spring

    has not the tension.

4. Remove the fixed arm and torsion bar spring

Installation of torsion bar spring

Remarks: There are the L and R indication marks, which must not

be exchanged on the rear end of the torsion bar spring. Mark L

means the left while R for right

1. For reused torsion bar spring

a. Cost the spline of torsion bar spring with grease thin.

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

torsion bar.

 c.   Align the assembly mark and install the adjusting arm on the

  torsion bar spring.

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

bolt equal to the value before disassembly.

2. For new torsion bar spring

a.  Remove the wheel.

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

 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.

Remarks: It can repeat for several times until proper  when

adjust the angle.

e.  Tighten the adjusting bolt to the specified torque.

Nut tightening limitation: A is about 20-35mm; if 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).

Lower suspension arm

Disassembly of lower suspension arm

1.The disassembly of the front hub and steering knuckle

   assembly includes the removal of vibration damper,

   stabilizer bar and steering cross rod.

   (Refer to the section “Front Hub and SteeringKnuckle”)

2. Disassembly of torsion bar spring

   (Refer to section “Torsion Bar Spring”)

3. Remove the front shaft of lower arm

a. Make the assembly mark on the adjusting cam

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

4. Screw off the rear shaft of lower arm

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

remove the lower suspension arm.

Replacement of bush of lower suspension arm

1. Remove the short bush of lower suspension arm

Use the special tools to press out the short bush form

the lower arm.

2. Installation of short bush of lower suspension arm

Use the special tools to press the new short bush into

the lower arm

     Remarks: Do not coat the bush with the grease.

3. Removal of long bush of lower suspension arm Use

the special tools to remove the long bush.

special tools

special tools

4. Install of long bush of lower suspension arm Use

the special tools to install the new bush.

    

Remarks: Do not coat the bush with the grease.

special tools

special tools

Installation of lower suspension arm

1. Installation of lower suspension arm

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

the specified torque.

Tightening force: 290

25N

m

 b. Install the front shaft of lower arm and pretighten the nut.

2. Installation of front hub and steering knuckle

    assembly

    (Refer to section “Front Hub andSteeringKnuckle”)

3. Install the vibration damper on the lower suspen

    sion arm Install the vibration damper on the

    lower suspension arm bracket.

Tightening force: 90

10N

m

4. Connect the stabi lizer barto the lower susp

    ension arm.

Tightening force: 63

5N

m

5. Connect the steering cross rod to the steering

    knuckle arm

a. Connect the steering cross rod to the steering knuckle arm.

Tightening force: 120

10N

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.

6. Install the torsion bar spring

(Refer to the section “Torsion Bar Spring”)

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

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 the specified

torque.

Tightening force: 240

20N

m

8. Check the wheel alignment parameter

(Refer to 4-Wheel Alignment)

Upper suspension arm

Disassembly of upper suspension arm

1. Disconnect the upper ball pin form the steering

knuckleRemove 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

disconnect the brake hose from the upper arm oil pipe

bracket.

5. Remove the upper suspension armRemove two bolts

and remove the upper suspension from the armcarriage.

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.

special tools

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

procedure.

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 in

another 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

installation plane of ball pin is vertical to the installation

plane of upper arm shaft.

special

special

special

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 connectors of two two-way valves

to the specified torque if disassemble the right upper arm.

3. Connect the brake hose to the upper arm oil pipe

    bracket

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

 bracket.

 b.  Insert the sheet steel spring clip by the hammer 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.

5. Connect the brake hose to the brake caliper.

Install the copper gasket seal and tighten the hollow bolt to the

specified 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 disassembly the right upper arm.

7. Check the brake fluid for leakage

8. Tighten the upper arm front shaft nut to the

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 the specified

    torque.

Tightening force: 240±20N·m

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. Align the mark on the stabilizer bar to keep the

left and right gap of stabilizer bar are same. Then install the bolt

temporarily and pretighten it.

2. Connect the stabilizer bar to the connecting rod.

Install and 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

2N

m

Constant-speed drive shaft assembly

Installation and disassembly drawing of front drive shaft assembly on front drive axle

hanger plank 

R

universal-joint bearing

front reducer and electric clutch assembly

Power plug of electric clutch

circlip

hanger plank 

L

constant-speed drive shaft

circlip

lower segment of vent tube of front drive axle

circlip

circlip

Pregummed component

 

N 

m:    specified torque

universal-joint oil seal

universal-joint bearing

constant-speed drive shaft assembly

1. Place the car in the middle of repair platform or

   trench, support the front of the car steadily(support

on the carriage) then remove the left and right

front wheel.  (make the car in 2WD status before

the disassembly)

2. Remove the beam on the lower of front drive axle

    assembly.

3. Disconnect the connection of front drive axle

   flange and drive shaft and make the assembly

   mark

4. Drain the lubrication oil in reducer.

bolt

front hub cover

circlip

adjusting washer set

flange

disconnect three ports in this position

N 

m:   specified torque

9. Use the wrench to screw off the bolt which fixes

    the lower segment assembly of front drive axle

    vent tube on the vent tube bracket.

10. Support the front drive axle by the jack; screw

      off the lifting bolt of hanger plank and carriage.

11. Remove the complete drive axle.

12. Screw off the connecting bolt of hanger plank and

      front drive axle assembly.

13. Pull out the left and right front drive shaft

     assembly with the oil seal, hanger plank and

     bearing.

se the circlip pliers to remove the outside circlip

      of bearing.

15. Use the special tools pull out the bearing.

16. Use the circlip pliers to remove the circlip on

      another side of bearing.

Caution: During the disassembly, support the lower end of

drive shaft and prevent the drive shaft from sliding out from

the inner jacket, meanwhile, it could not damage the inner

and outer jacket.

wrench

circlip pliers

support the lower end

hold

special tools

shim

support the lower end

supporting position

Constant-speed drive shaft assembly

pliers

Disassembly of constant-speed drive shaft

assembly

1. Check the front drive shaft assembly

a.  Check the inner trumpet connector; it could slide in axial

direction smoothly.

b. Check the universal-joint position; it should be without the

clear clearance in radius direction.

c. Check the inner and outer jacket for damage.

Caution: It should use the pad when clamp the front drive

shaft to avoid the damage of it.

2. Remove the large clip of inner jacket

Caution: Do not damage the inner and outer jacket

inner trumpet connector

circlip

three-pin section assembly

large clip of inner jacket

inner jacket

small clip of inner jacket

small clip of outer jacket

outer jacket

large clip of outer jacket

outer trumpet connector

dustproof cover