Great Wall service chassis and body Manual - part 53

BR-8

Braking System

 Master Cylinder

Master Cylinder

Disassembly of Master Cylinder

1.

Tear down the alarm joint for liquid level;

2.

Exhaust the brake liquid with the injector:

Notice: brake liquid must not be left on the paint surface,

if any, clear it away.

3.

Tear down the pipeline of braking system;

Tear down the pipeline of braking system from the master

cylinder with SST.

4.

Take apart the master cylinder:

(a)

Tear down the four nuts and the three-way joint.

(b)

Tear down the master cylinder and sealing washer from

the vacuum booster

cup cap

filtering screen

oil cup

vacuum booster assembly

sealing liner

master cylinder body

front three-way valve

SST

SST

BR-9

Braking System

 Master Cylinder

Mount of Master Cylinder

1.

Adjust the length of vacuum booster pushrod before

mounting the master cylinder;

2.

Mount the master cylinder:

Mount the master and sealing washer on the vacuum booster

with four nuts.

3.

Connect the two pipelines of braking system;

Mount the brake pipeline on the master cylinder with SST and

screw up the nuts.

Fastening torque

Dr SF

(18 
 2)N
m

SL SK SY SJ

(19 
 1)N
m

4.

Connect the alarm switch joint for liquid level;

5.

Fill the oil cup with brake liquid and exhaust the air in

the brake pipeline;

6.

Check to see whether there is brake liquid leakage;

7.

Check and adjust the brake pedal.

SST

SST

BR-10

Brake System

 Vacuum Booster

Vacuum booster

Disassembly of Vacuum Booster

1.

Take apart the master cylinder

2.

Tear down the vacuum hose from the vacuum booster

3.

Tear down the return spring

4.

Tear down the clamping pin and U-shaped clamping pin

5.

Tear down the vacuum booster, sealing washer and U-

shaped clamping head

U-shaped clip head

shock pad

adjusting shim

shock pad

vacuum booster

front three-way valve

master cylinder body

bracket

one-way valve

sealing liner

Disassembly of Vacuum Booster

BR-11

Brake System

 Vacuum Booster

Inspection on Vacuum booster parts

Operation for one-way valve inspection

(Gasoline engine)

(a)

Tear down the one-way valve;

(b)

Check the air to see whether it flows from the vacuum

booster side toward the engine side.

(c)

Check the air, change the one-way valve if the air flows

from the side of engine toward the vacuum booster.

(d)

Mount the one-way valve in the right place.

(a)

Tear down the one-way valve from the vacuum pipe.

(b)

Check the air to see whether it flows from the side of

vacuum room to the hose.

(c)

Check the air, and change the one-way valve if the air

flows to the hose to the vacuum room.

air

engine side

booster side

air

airless

air

hose side

vacuum side

air

airless

Mount of Vacuum Booster

1.

Adjust the length of vacuum booster pushrod:

(a)

Mount the sealing washer on the master cylinder;

(b)

Put SST on the sealing washer and descend the pin rod

until it contact lightly the piston with its top;

(c)

Put top of SST  downward ,and mount it on the vacuum

booster.

(d)

Check the clearance between the vacuum booster pushrod

and the head of pin on SST.

(e)

Adjust the length of vacuum booster pushrod until the

pushrod touches the pinhead.

2.

Mount the vacuum booster, sealing washer and Ushaped

clip head.

(a)

Mount the vacuum booster and sealing washer.

(b)

Mount the U-shaped clip head.

(c)

Mount and tighten the assembling nuts of vacuum booster.

3.

Connect the U-shaped clip head and the brake pedal:

Encase the U-shaped clamping pin in the hole of U-shaped clip

head and the brake pedal, and then mount the spring pin on the

U-shaped clamping pin.

SST

washer

SST

(Diesel engine)