Great Wall. Service manual for chassis and body (2006)

SA-15

Mount the steering knuckle

(a)

Support the lower arm of the steering knuckle with a jack.

(b)

Mount the steering knuckle on the lower ball stud and

screw on the nuts.

(c)

Press the upper arm to mount on the steering knuckle and

screw on the nuts.

(d)

Screw up the nuts of the upper ball stud according to the

specified torque.

Fastening torque

(100-120)N

(e)

Screw up the nuts of the lower ball stud according to the

specified torque.

Fastening torque

(98-118)N

(f)

Mount on the split pin between the upper and lower ball

studs.

Mount the steering knuckle arm and the front brake shell;

(a)

Screw up the two bolts of M8X16.

Fastening torque

(25-28)N

(b)

Screw up the two bolts and groove nuts (M12X67) to the

specified torque.

Fastening torque

(98-118)N

(c)

Mount on the two split pins.

In case the pin hole in the ball stud are not in alignment with

the groove nut, adjust the fastening torque and the rotating

angle under the condition that satisfying the minimum torque,

so as to ensure the torque falls within the specified range, if

cannot, mount the split pin with the minimum torque beyond

the range

Mount the front wheel hub and the front brake disc.

Check the Alignment of Front Wheel.

(See SA-3)

Suspension System and Automobile Axle (Dr/2WD)

Front Wheel Hub and Steering Knuckle (Front Wheel Hub)

SA-16

Front suspension

Element figure

Suspension System and Automobile Axle (Dr/2WD)

Front Suspension

torsion fork

transverse

stabilizer rod

lower ball stud

Parts that cannot be reused after being used

110

torsion bar

226

lower arm

142

150

pinch gasket of the upper arm shaft bush

rubber liner assembly for

the upper arm

guide lever

rocker arm

: specified torque

shock
absorber

SA-17

Ball stud

Inspection on Ball Stud

Check the lower ball stud to see whether it is excessively

loose or not.

(a)

Prop up the front of the vehicle with jack and then support

it with the bracket.

(b)

Tread down the brake pedal after verifying that the front

wheel are in straight line.

(c)

Move the arm vertically to check the lower ball stud to see

whether the clearance is overlarge.

Max vertical clearance : 0.5mm

Check the upper ball stud to see whether it is over-loose.

Move the wheel vertically to check whether the clearance of

the ball stud is over large.

Check the rotating performance of ball stud

(a)

Take apart the ball stud.

(b)

Shake the ball stud several times forward and backward

before mounting on the nut, as shown in the drawing.

(c)

Rotate the nut continuously with a torsion meter, which

rotates the nut round per 2 to 4 seconds, and read the

reading of the torsion meter after the fifth round.

Fastening torque (running)

Lower ball stud: (0.1-4)N

Upper ball stud: (0.1-4)N

Disassembly of Ball Stud

Tear down the steering knuckle.

(see the SA-14).

Take apart the lower ball stud from the lower arm; and

Take apart the upper ball stud from the upper arm.

Suspension System and Automobile Axle (Dr/2WD)

Front Suspension (Ball Stud)

SA-18

Mount of Ball Stud

Mount the upper ball stud on the upper arm;

Fastening torque

26N

Mount the lower ball stud on the lower arm;

Fastening torque

65N

Mount on the steering knuckle

(see page SA-15)

Suspension System and Automobile Axle (Dr/2WD)

Front Suspension (Ball Stud)

SA-19

Torsion Rod Spring

Dismantle of Torsion Rod Spring

Use the jack to raise up the frame and support it with the

bracket.

Take apart the locking nuts to measure the length of the

projecting end of the bolts, as shown in the drawing.

Remark: This measuring value can be referred when adjusting

the chassis ground clearance.

Take apart the dust cover.

Loosen the regulating nut until there is no tension on the

torsion rod spring.

Take apart the torsion arm, torsion rod spring and the

torsion regulating arm.

(a)

Tear down the mounting nuts of the torsion rod arm.

(b)

Take apart the torsion regulating arm from the adjusting

bolt, the torsion regulating arm should be taken apart with

the torsion rod spring and the torsion rod arm together.

Dr SL SK SY

Suspension System and Automobile Axle (Dr/2WD)

Front Suspension (Torsion Rod Spring)

SA-20

(f)

Screw up the adjustable nuts so that the protruding length

of the bolt is equal to that before tearing down.

(g)

Mount on the wheel and dismantle the bracket, bounce

the vehicle several times so as to make the suspension in

place.

(h)

Screw up the adjustable nut to regulate the ground

clearance.

Tighten the locking nuts according to the specified torque.

Tighten torque

(83

5)N

Mount on the dust cover.

Mount of Torsion rod Spring

Notice: the torsion rod spring marked with

(left) or

(right), do not mount the springs at the incorrect

location.

Mount the torsion rod spring, pedestal arm and torsion arm;

(a)

Coat the lithium base grease on the spline of torsion rod

spring.

(b)

Align the wide-teeth parts and then mount the pedestal

arm on the torsion rod spring.

(c)

Align the wide-teeth parts and then mount the torsion arm

on the torsion rod spring.

(d)

Mount the torsion rod spring on the side of torsion arm

and mount on the pedestal arm on the adjusting bolts.

(e)

Screw up the torsion arm nuts according to the specified

torque.

Fastening torque

(83

Suspension System and Automobile Axle (Dr/2WD)

Front Suspension (Torsion Rod Spring)

front

SA-21

Lower Arm and Vibration Damper

Disassembly of Lower Arm And Vibration

Damper

Take apart the torsion rod spring.

(see page SA-19)

Take apart the ending part of the torsion rod

(a)

Take apart the split pin and nuts.

(b)

Take apart the ending part of drag rod.

Take apart the vibration damper

Take apart the transverse stabilizer rod from the lower

arm.

Take apart the guide lever from the lower arm;

Take apart the lower ball stud.

Suspension System and Automobile Axle (Dr/2WD)

Front Suspension (Lower Arm and Vibration Damper)

SA-22

Take apart the lower arm

Tear down the nuts and lower arm.

Change of Lower Arm Shaft Bush

Take down the shaft bush.

(a)

Shear off the rubber on shaft bush, as shown in

drawing.

(b)

Take apart the shaft bush.

Mount the shaft bush.

Mount on the new shaft bush.

Mount of Lower Arm And Vibration

Damper

Mount on the lower arm.

Adjust the lower arm in the unloaded stage when screw up the

axial bolts of the lower arm.

Fastening torque

(226

5)N

Lower ball stud and lower arm connection

Assemble the lower ball stud and lower arm with three bolts.

Fastening torque

65N

Suspension System and Automobile Axle (Dr/2WD)

Front Suspension (Lower Arm and Vibration Damper)

SA-23

Mount the guide lever on the lower arm

Fastening torque

(96

0)N

Link the transverse stabilizer rod with the lower arm.

Fastening torque

(23

3)N

Mount the vibration damper.

Mount the ending part of the drag rod:

(a)

Link the drag rod end to the steering knuckle arm, mount

and screw up the nuts according to the specified torque.

Fastening torque

(91

0)N

(b)

Lock the nut with the new split pin.

Mount the torsion rod spring.

Check the Alignment of Front Wheel.

(See the page SA-3)

Suspension System and Automobile Axle (Dr/2WD)

Front Suspension (Lower Arm and Vibration Damper)

SA-24

Upper Arm

Dismantle of Upper Arm

Take apart the ball stud from the upper arm:

(a)

Support the upper arm with a jack.

(b)

Take apart the four sets of bolt and nut.

Take apart the upper arm

(a)

Tear down the bolts and adjusting gasket.

(b)

Take apart the upper arm.

Remark: Do not lose the adjusting gasket. Write down the

gasket thickness so that it can be mounted on the original place.

Change of the rubber liner of Upper arm

shaft

Tear down the rubber liner of the upper arm.

(a)

Tear down the bolts and the pinch-off gasket of the upper

arm shaft bush.

(b)

Push out the rubber liner of upper arm with tools.

Mount the upper arm rubber liner.

(a)

Push in the rubber liner of the upper arm with tools.

(b)

Mount on the pinch-off gasket of the upper arm shaft

bush and tighten the bolts manually.

Remark: it is not required to screw up the bolts according to the

specified torque.

Mount of Upper Arm

Screw up the axle bolts of the upper arm according to

the specified torque,

Fastening torque

(100

0)N

Suspension System and Automobile Axle (Dr/2WD)

Front Suspension (Upper Arm)

SA-25

Mount the upper arm

(a)

Mount on the upper arm and the regulating gasket.

(b)

Screw up the bolts according to the specified torque.

Fastening torque

(96

0)N

Remark: Mount back the gaskets of the same thickness in the

same number on the original locations.

Connect the upper ball stud and upper arm together.

Fastening torque

26N

Check the Alignment of Front Wheel

(See page SA-3)

Suspension System and Automobile Axle (Dr/2WD)

Front Suspension (Upper Arm)

SA-26

Suspension System and Automobile Axle (Dr/ 2WD)

Front Suspension (Guide Lever)

Guide Lever

Disassembly of Guide Lever

Mark the assembly mark on the guide lever.

Tear down the front fixing nuts from the guide lever.

Tear down the guide lever from the lower arm.

Tear down the nuts that fix the guide lever on the lower

swimming arm, and then tear down the guide lever.

Mount of Guide Lever

Mount on the front fixing nuts

Mount on the front fixing nuts and meanwhile align the

assembly marks on the guide lever.

Screw up the fixing nuts according to the specified torque,

(a)

Dismantle the bracket so that make the vehicle bounce

sever times to put the suspension in balance.

(b)

Screw up the front fixing nut.

Check the Alignment of Front Wheel

(See Page SA-3)

Mount the guide lever on the bracket

(a)

Mount the washer and liner on the guide lever, and then

mount the guide lever on bracket.

(b)

Mount the sleeve ring, the liner and the washer on the

guide lever.

(c)

Screw up the fixing nuts with finger.

Mount the guide lever on the lower swing arm.

Screw up the fixing nuts according to the specified torque.

Fastening torque

(96

assembly mark

SA-27

Suspension System and Automobile Axle (Dr/2WD)

Front Suspension (Transverse Stabilizer Rod)

Transverse stabilizer rod

Dismantle of Transverse Stabilizer Rod

Tear down the torsion rod spring

Tear down the transverse stabilizer rod from the lower

swing arm,

(a)

Tear down the nuts and cushion blocks that support the

two sides of the stabilizer rod from the lower swing arm

so as to disconnect the stabilizer rod.

(b)

Tear down the liner and bracket of the stabilizer rod and

then tear down the stabilizer rod.

Mount of Transverse Stabilizer Rod

Put the transverse stabilizer rod on the frame,

Lay the stabilizer rod in place, and mount the stabilizer rod

liner on the bracket, then mount the bracket on frame, finally

screw up the bolts with fingers.

Connect the transverse stabilizer rod to the lower swing arm.

Connect the two ends of stabilizer to two lower swing arm with

bolts, cushion blocks and new nuts.

As shown in the drawing, tighten the nuts according to the

specified torque.

Fastening torque

(29

Screw up the locating bolts according to the specified

torque,

Fastening torque

(29

Mount on the torsion rod spring.

SA-28

Suspension System and Automobile Axle(SF/2WD)

Front Suspension

locking ring

cushion block

nut

locking ring

cushion block

upper arm

transverse stabilizer rod

bolt

transverse stabilizer rod gasket

rubber
snubber washer

restrictor tube

Brake

caliper

steering knuckle

brake oil pipe bracket

steering

knuckle arm

brake shell

dust cover

oil seal -front hub

front wheel

bearing(inner)

front wheel hub and

front brake disc

stop washer

lock plate

front hub bearing

(outer)

steering knuckle nut

liner

lower

ball stud

Parts that cannot be reused after being used

:specified torque

135-155

70-90

132-152

20-26

180

127-147

132

152

123

shock absorber

steering knuckle

outer flange cap

Front wheel hub and steering knuckle

Element figures

SF2WD

stabilizer rod gasket

rubber snubber
washer

stabilizer rod gasket

SA-29

Front Wheel Hub

Disassembly of Front Wheel Hub

Tear down the brake caliper.

(a)

Tear down the brake Bundy tube from the brake caliper,

and block the Bundy tube line with a cork.

(b)

Tear down the brake caliper from the steering knuckle.

Tear down the steering knuckle outer flange cap.

Tear down the front wheel hub and brake disc.

(a)

Open the lock plate with a screwdriver.

(b)

Tear down the steering knuckle nut with the SST tools to

take out the. lock plate

(c)

Tear down the other steering knuckle nut with SST tools

to take out the stop washer and the steering knuckle outer

bearing.

(d)

Tear down the front wheel hub and the brake disc

assembly.

Tear down the front hub, oil seal, front hub bearing

(inner) inner race and roller assembly.

(a)

Pry out the oil seal.

Notice: the deformed oil seal should not be reused.

(b)

Take out the front hub bearing (inner) inner race and

roller assembly.

Suspension System and Automobile Axle (SF/2WD)

Front Wheel Hub and Steering Knuckle (Front Wheel Hub)

SA-30

Front hub bearing outer race inspection and change

(a)

Check each bearing

Wash the inner and outer races of each bearing, and check

them whether they are wearied or damaged.

(b)

Tear down the outer race of each bearing.

Tap out the bearing outer race with copper bar and

hammer.

Notice: bind the dismantled inner and outer races of

bearing together to prevent from mixing.

Front brake disc inspection and change

(a)

Check the wear situation of front brake disc.

(b)

Tear down the bolts that connect the front wheel hub and

front brake disc.

(c)

Connect the front wheel hub and front brake disc and

screw up the bolts with moment spanner to the specified

torque diagonally

Fastening torque

(70-80)N

(d)

Conduct the dynamic balance test on the dynamic balancer,

the amplitude value displayed should not be above 13.5g

under the condition that the measuring rotating velocity

is 796 r/m and the locking rotating velocity 786 r/m,

otherwise, tap in the counter balanced clip, which is 4g

each, at the corresponding location, the number of the

clip should not be more than 4.

(e)

Tap in the new bearing outer race with the special service

tool.

Notice: the inner and outer races of bearing should be

changed in set.

Assembly of Front Wheel Hub

Mount on the inner race and roller assembly of front hub

bearing (inner) as well as the front hub oil seal.

Coat the lithium base grease of 4 to 5 mm on the inside surface of

the bearing outer race and front wheel hub, and plaster the

lubricant in the front hub bearing (inner) and the roller assembly.

Coat a little lubricant on the lips of oil seal of front wheel hub, and

then tap the oil seal of front hub in place with special service tool.

Notice: do not coat the lubricant on the front brake disc face.

Suspension System and Automobile Axle (SF/2WD)

Front Wheel Hub and Steering Knuckle (Front Wheel Hub)

Great Wall. Service manual for chassis and body (2006) - page 12