Great Wall V200. Instruction - part 18

 

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Great Wall V200. Instruction - part 18

 

 

2. Install the rear bearing of drive bevel gear and ad

    justing washer

a. Select the proper adjusting washer according to “Meshing Condi

    tion of Drive Bevel Gear and Driven Bevel Gear”.

b. Install the rear bearing and selected adjusting washer by press

    machine.

3. Install the spacer.

a.Select the adjusting washer between the rear bearing and spacer

   based on the experience.

b.Install the spacer.

4. Install the front bearing inner race, oil baffle disc

    and oil seal of drive bevel gear

a. Place the front bearing inner race in the reducer housing; place the

    oil baffle disc.

b. Coat the position of reducer housing oil seal and lip of  oilseal

    with grease uniformly; place the oil seal in position. Start the

    press machine for installation.

5. Install the drive bevel gear, flange and dustproof

    cover assembly

a. Install the flange and dustproof cover assembly in the reducer

    housing, Press it to level by hand.

b. Insert the drive bevel gear installed with the spacer, rear bearing

    and adjusting washer into the flange through the spline; screw on

    the nut.

c. Use the nut to tighten the flange, plain washer and drive gear.

special tools

level

special tools

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6 Use the special tools to clamp the flange; use the

    torque wrench to tighten the nut.

Tightening force:   140

160N

m

7. Measure the rotation pretightening force of bearing

For new bearing  :   1.2

1.7N

m

For reused bearing  :   0.4

0.6N

m

If does not meet the requirement, replace the adjusting washer

under the spacer until meet the requirement.

Tightening torque :   0-3.5N

m

a. Reduce the thickness of adjusting washer if the measured value

    is less than standard value;

b. Increase the thickness of adjusting washer if the measured value

    is more than standard value.

8. Install the driven bevel gear on the differential

    housing.

a. Use the bolt and lock plate to connect the driven bevel gear to the

    differential housing.

b. Screw on for three rounds at least by hand; then use the pneu

         matic wrench to tighten it properly.

c. Use the torque wrench to tighten it.

Tightening force:   65-95N

m

Caution: Tighten the bolt in diagonal .

Use the hand hammer and flat head punch to lock the lock plate.

Special tools

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9. Install the differential side bearing by press.

Use the press machine and special tools to install the side bearing

on the differential housing by press.

10. Install the differential assembly

a.Remove the bearing gland. Do not mix the left up with right.

b.Install the differential assembly in the reducer housing.

11.Install the adjusting ring

Use the adjusting ring to press the bearing outer race in position;

tighten it properly. Adjust the clearance between the drive and

driven gear to the proper dimension.

12. Install the bearing gland

a. Align the assembly mark on the bearing cover with that on re

   ducer housing; Press down the press cover by hand.

b. Install the lock washer with double ears and nut; tighten the

    hexagon nut by pneumatic wrench properly.

13. Adjust the engagement clearance between the drive

     and driven gear.

a. Use the torque wrench to tighten four bolts on bearing cover by

    torque wrench.

Tightening force:   78-115N

m

special tools

special tools

assembly mark

-------------------------------------------------------------------------------------------------------------------------------------------------------------

b. Adhere the measuring meter base on the end surface of reducer

    housing; the measuring head contacts the tooth surface; rotate

    the driven gear by hand and measure the engagement clearance be

         tween the drive and driven gear.

c. If the engagement clearance does not meet the requirement, use

    the special tools to adjust the left and right adjusting ring until it

    meets the requirement.

d. Recheck the engagement clearance between the drive and driven

    gear.

Engagement clearance: 0.13-0.18mm

14. Check the meshing mark of drive and driven bevel

gear.

a. Paint 3-4 teeth with the red lead in three different positions of

    driven bevel gear.

b. Rotate the driven bevel gear in clockwise and anticlockwise by

    hand.Check the engagement of gear.

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sound contact

toe contact

dedendum contact

arge end contact

small end contact

select the shim which can make the small drive gear

close to the driven bevel gear

select the shim which can make the small drive gear away from the driven bevel gear

Select the proper washer from the table for correction if the intertooth

contacting status is bad. The thickness tolerance of washer is 

0.01mm.

15. Install the stop washer and stop plate

a. If the drive and driven gear engagement mark meets the requirement,

   then use the hand hammer and punch to lock the stop washer.

b. Install the stop plate, spring shim and bolt; tighten the bolt.

Tightening force:   18-25N

m

c. Use the punch and hand hammer to knock the lower end of stop

   plate in the adjusting ring hole.

Set NO.   Thickness

  Set NO.     Thickness

16. Measure the total pre-applied load

Pre-applied load :   1.8-2.4N

m

If the pre-applied load is beyond the specified; it should replace the

shim between the spacer and rear bearing until meet the requirement.

a. It should replace the adjusting washer if the pre-applied load is

    more than specified value.

b. If the pre-applied load is less than specified value, it can retighten

    the nut slowly and the torque should be no more than 160N

m.

Caution: When tighten the nut, if is beyond the Max. torque, re-

place the adjusting washer and repeat the pre-applied load process.

Do not reduce the pre-applied load by the method of screw off the

drive gear nut to loose.

washer

rear bearing

-------------------------------------------------------------------------------------------------------------------------------------------------------------

17. Check and adjust the run-out of flange.

a.Adhere the dial indicator base on the reducer housing; make the

  probe of dial indicator contact with the end surface of flange;

  rotate the flange and watch the rotation range of the dial.

Full run-out tolerance of end surface:   0.10mm

b.Adhere the dial indicator base on the reducer housing; make the

  probe of the dial indicator contact with the inner diameter of

  flange; rotate the flange by hand , and watch the rotation range of

  the dial.Radial full run-out tolerance:   0.10mm

18. Rivet the nut of drive bevel gear

Installation of reducer and differential assembly

1.Install the new  stiffening ring

2.Install the reducer and differential assembly

     Install the reducer and differential assembly in the rear axle housing;

    place the washer and nut. Tighten the nut to the specified torque.

Tightening force:   18-25N

m

3.Install the reducer and differential assembly flange

   on the drive shaft flange and align the assembly

   mark; use four bolts and nuts to connect them.

Tighten the bolt and nut to the specified torque.

Tightening force:   78

5N

m

4.Install the oil drain plug; fill the differential with the

   gear oil

oil number :   GL-5  hyperbolic gear oil

Viscosity:   SAE80W/90

Amount:   Filled with oil until the oil flow out from the oil filling

port.

Tighten the oil filling plug.

Tightening force:   140-150N

m

assembly mark

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Differential

Differential

1

Remove the reducer and differential assembly

(Refer to “Removal of reducer”)

2

Remove the differential from the reducer and dif

     ferential assembly.

(Refer to “Disassembly of reducer”)

Replacement of differential components

1.Disassembly of differential

Use the hammer and punch to knock out the pin. Remove the

planetary gear shaft, two half axle gears, two planetary gears and

two lock washers, two thrust plates.

2. Assembly of differential

a.Install the half axle gear and thrust plate of axle shaft gear

(Unit:   mm)

b.Install the planetary gear and planetary gear lock washer in the

         differential by rolling. (Unit:   mm)

differential housing

thrust plate

half axle

gear

straight pin

planetary gear

lock washer

half axle

gear

 thrust plate

planetary gear

lock washer 

planetary gear shaft

Set NO.        1             2

Thickness   1.2          1.5

Set NO.

Thickness

-------------------------------------------------------------------------------------------------------------------------------------------------------------

c.Use the feeler to measure the clearance between the thrust plate

  and differential housing; it can be replaced by the thrust plate with

  different thickness if the clearance is beyond the specified range.

Standard clearance:   0.45-0.75mm

     d.Install the straight pin

Use the hammer and punch to knock in the pin through the hole

on the differential housing and planetary gear shaft. Rivet the pin

with the differential housing.

Installation of differential

1 Install the differential assembly in the reducer hous

    ing

(Refer to “Assembly of Reducer”)

2 Install the differential

(Refer to “Installation of Reducer and Differential Assembly”)

f

eeler

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Rear suspension

m:       specified torque

bush clip

bush

rear stabilizer bar

rear connecting rod of stabilizer bar assembly

plain washer

short longitudinal
pull-rod fixed bolt

rubber pad

short longitudinal
pull-rod fixed bolt

long longitudinal
pull-rod assembly

long longitudinal
pull-rod fixed bolt

long longitudinal
pull-rodassembly

short longitudinal
pull-rod assembly

rear axle

assembly

coil spring

upper support pad

of coil spring

short longitudinal pull-rod assembly

long longitudinal

pull-rod assembly

rear vibration damper

cross pull-rod assembly

cross pull-rod

connecting bolt

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Removal of vibration damper

1. Use the lifter to raise the car firstly, then support

 the rear axle by bracket.

2. Remove the upper and lower fixing nut which is used

to fix the vibration damper; compress the vibration

damper by hand.

 

Remove the upper end firstly, then the

    lower end; take out the vibration damper .

Installation of vibration damper:

1. Lower tightening force of vibration damper:

1 7 0

5 N

m .

Upper tightening torque :  Compress the rubber block to 2/3 of

total height.

Caution: If the fixing nut of vibration damper is the lock nut, it

should be replaced by the new lock nut after replace the vibra-

tion damper.

Removal of coil spring:

1

. Remove the vibration damper (As previous )

2. Use the special tools to clamp the coil spring.

3. Place the car in the bounce status, take out the

    coilspring

4. Remove the special tools from the coil spring.

Installation of coil spring:

1. Firstly, use the special tools to clamp the coil spring

    to certain height (height when car is in bounce

    status).

2. Cautions for installation: Adjust the rubber gasket on

    the spring to ensure the spring in flat status.

3. Remove the special tools.

special tools

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Removal of connecting rod of stabilizer bar:

1.Shown as figure, firstly screw off the nut in the con

   necting place between the connecting rod of stabi

   lizer bar and carriage. (Need the inner hexagon

   spanner ).

2.Screw off the nut connected to stabilizer bar in same

   method; screw off the connecting rod.

Installation of connecting rod of stabilizer bar:

Tighten it to the specified torque during installation:

6 3

5 N

m

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Brake-1

  Chapter 8

  Brake

Cautions...................................................................................... 2

Troubleshooting............................................................................2

Check and adjustment..................................................................5

Brake pedal..................................................................................7

Parking brake...............................................................................8

Front brake...................................................................................9

Rear brake...................................................................................16

Rear parking brake......................................................................22

Sensor load proportional valve.....................................................29

Antilock Braking System (ABS)..................................................31

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Brake-2

Troubleshooting

Cautions

 

Failure cause 

Inspection 

content 

 

 

 

Pedal is low or soft 

brake pad is worn 

brake block is worn 

brake system is leaked 

master pump has failure 

Brake system has air 

Brake pump has failure 

Auto adjuster of rear brake has failure 

Replace the brake shoe   

Replace the brake block     

Repair the leakage 

Repair or replace the master pump 

Drain the air from brake system 

Replace the brake pump   

Repair or replace the adjuster 

 

 

 

 

Lag of brake 

Parking brake is adjusted badly. 

Pull wire of parking brake is locked 

Assist push rod    is adjust badly 

Extension spring or return spring has fault 

Pipeline is blocked 

brake pad is broken or deformed 

brake block is broken or deformed 

Auto adjuster is damaged 

Master pump has failure. 

Adjust the parking brake     

Repair if necessary   

Adjust the push rod 

Replace the extension spring 

Repair if necessary 

Replace the brake shoe   

Replace the brake block     

Replace the adjuster   

Replace the master pump 

 

 

 

 

 

Brake is stagnant 

Improper inflation of tyre 

There is grease spot or lubricant oil on the 

brake shoe or brake block. 

The brake shoe is deformed    ; the brake pad 

is worn or smoothed 

The brake block is deformed, worn or 

smoothed 

The brake drum or brake disc    is deformed 

Extension spring or return spring has failure 

Wheel pump has failure 

Pump has failure 

Brake block is blocked 

Charge the tyre to the proper pressure. 

Find out the cause. Replace the brake shoe or block. 

Replace the brake shoe   

Replace the brake block     

Replace the brake drum or brake disc     

Replace the spring   

Repair the wheel pump 

Replace 

Replace the brake block     

 

 

 

 

 

brake pedal is hard 

There is the grease spot or lubrication oil on 

the brake disc or brake block. 

The brake shoe is deformed; the brake pad is 

worn or smoothed 

The brake block is deformed, worn or 

smoothed  

Brake pump has failure. 

Brake assist has failure 

Improper vacuum degree   

The brake pipeline is blocked. 

Find out the cause . 

Replace the brake shoe or brake block     

Replace the brake block     

Replace 

Replace the assist   

Repair if necessary 

Repair if necessary 

 

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Brake-3

Troubleshooting (continued) 

 

failure cause 

Inspection 

content 

 

 

The brake generates the 

crack clatter during 

operation. 

 (drum brake)  

The brake shoe is blocked in the rear apron flange 

The rear apron flange is worn 

The brake shoe pull-out piece spring is loose or lost 

The fixed bolt of rear apron is loose (disc brake )   

Brake block support plate is loose or lost 

Installation bolt is loose 

 

Filled with lubricated oil 

Replace the lubricant flange 

Replace 

tighten 

replace 

tighten 

 

 

 

It has the rustle or rattler 

when use the brake 

The brake shoe gasket or brake block is worn 

The brake caliper and wheel or rotor are disturbed 

mutually 

The dustproof cover and rotor, rear apron and brake 

drum are disturbed mutually 

Failure of other brake system component 

Tyre generates the abrasion with the tyre and chassis 

Replace, if the scratch is heavy, 

then fine machine the brake drum or 

rotor again 

Replace it according to requirement 

Correct or replace 

Repair or replace it according to 

requirement 

Check or maintain 

It has the squeak, continuous 

scream, rattler or vibration 

noise when use the brake . 

Caution: The abrasion 

material in the brake will 

generate the inherent noise 

and heat during the 

abrasion, then emit the 

heat. So it is normal that 

generate the   squeak by 

accident. The condition 

will be serious in extreme 

environment, such as cold, 

hot, high humidity, 

snowing, saliferous and 

mud. The accident squeak 

will not cause the fatal 

failure of the brake, and 

will not reduce the effective 

performance of the brake. 

The brake drum and brake shoe gasket, rotor and 

brake block is worn or scratched. 

The brake pad or block is dirty, with oil or smoothed. 

The brake pedal or assistor push bar is adjusted 

incorrectly 

  (disc brake )   

The brake block silencing plate is lost or damaged. 

The abrasion of the brake block makes the brake 

block abrasion indication plate contacts the rotor 

The brake caliper has burr or is corrosive 

 (drum brake)  

The pull-out piece spring of brake shoe is soft, 

damaged or improper. The pull-out piece spring pin 

and spring of brake shoe is loose or damaged; and 

rear apron flange has crack 

Check, repair or replace 

clean or replace   

check, replace 

check and adjust 

replace 

replace 

clean or remove the flash 

check, repair or replace 

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Brake-4

failure cause  Inspection 

content 

 

 

 

 

 

 

 

 

 

 

 

It has the continuous 

scream and squeak 

when does not use the 

brake 

The brake pedal or assist push bar is adjusted 

incorrectly 

The return of brake assist or master pump or wheel 

pump is bad 

  (disc brake )   

The piston is corrosive or blocked 

The brake block in brake caliper is in improper 

position 

Shell abrasion of rotor and brake caliper     

The brake block support plate  in disc brake is 

installed improperly 

The brake block    abrasion indication plate  contacts 

the rotor for the abrasion of brake block 

 (drum brake)  

The press spring of brake shoe is soft, damaged or 

improper. 

The flange of rear back rear apron is cracked 

The rear apron interfere with the  brake drum 

mutually after bent or warp 

Improper machining of brake drum, cause the mutual 

interference of rear apron and    brake shoe   

components of other brake system:       

Brake system has loose or redundant components 

The brake pad is smoothed for the rear brake drum is 

adjusted too tight 

The wheel bearing is worn damaged or under 

lubricated  

Check and adjust 

 

Check, repair or replace 

 

 

Check and fill with lubrication oil if 

necessary. 

Repair or replacement   

Repair or replacement   

Repair or replacement   

 

Repair  

 

 

Repair  

 

Repair or replacement   

Repair or replacement   

 

Replace the brake drum   

 

 

Check, maintain and replace if 

necessary.  

It still has the rattler, 

click or cackle noise 

when does not use the 

brake. 

The stone or foreign enters into the inside of wheel 

protecting hood 

The hub nut is loose 

 

 

The brake pedal  or assistor push bar is adjusted 

improperly 

The wheel bearing is worn, damaged or lubricated 

insufficiently  

  (disc brake )   

The muffler spring is soft or lost; the brake block 

support plate or external end of brake block is coiled 

silencing plate  is unsound 

The slide bush is worn 

The installation bolt is loose 

Piston returns unsoundly 

 (drum brake)  

Have loose or redundant component 

Remove the foreign materials such as 

the stone 

Tighten it to the specified torque, it 

should be replaced if the bolt hole is 

enlarged 

Check and adjust 

 

Check, lubricate or replace 

 

 

Repair or replacement   

 

 

Check and replace if necessary 

Check and replace if necessary 

Check and tighten if necessary 

Check , repair or replace   

Check, take out or repair 

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Brake-5

Check and adjustment

Check and adjustment of brake pedal

1.  Check the correctness of height of pedal

Distance from pedal to lower front apron: 152mm, Operating stroke

of pedal push bar is 1mm.

a. Disconnect the brake lamp switch wire connector; loose the

tightened nut; rotate the brake switch to the position not contacted

to limit block of brake pedal

b.   Loose the lock nut of operating connecting rod; use the thinnose

      pliers to rotate the operating connecting rod to adjust the height

       of brake pedal to the standard value; lock the block nut tightenedly

      when reach the standard value.

c. Rotate the brake lamp switch to contact with the limit block of

brake pedal; then rotate 1/2

1 round continuously; tighten the

block nut;

d. Connect the wire connector of brake lamp switch;

e. The brake lamp should not be light when the brake pedal is

released.

3. Check the free stroke of pedal

Free stroke of pedal: 4

6mm

In the status of engine is stop, step on the brake pedal for 2

3 times

after eliminate effect of the brake assist, push down the brake pedal

by hand to just with the resistance, then measure its displacement

(free stroke). It should be in accordance with the standard value.

pedal push rod

parking lamp switch

free stroke of pedal

pedal push rod

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