Chapter II Chassis System

Section I Suspension and Axle

I. Overview
1. Front axle and front suspension, Fig. 2-1.

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Fig. 2-1
1. Hexagon flange nut (36 N·m) 2. Front shock damper upper pressure plate
3. Left front shock damper assembly 4. Hexagon flange bolt (240 N·m)
5. Hexagon flange nut 4 (240 N·m) 6. Front stabilizer bar connecting rod assembly
7. Hexagon bolt with flat washer (horizontal: 180 N·m; vertical: 210 N·m)
8. Cotter pin 9. Hexagon flange slotted nut (100 N·m)
10. Left front lower arm assembly 11. Sub-frame rubber plug
12. Sub-frame assembly 13. Hexagon bolt with flat washer (210 N·m)
14. Hexagon flange nut (75 N·m) 15. Front stabilizer rod rubber mount
16. Front stabilizer rod hoop 17. Hexagon bolt with taper washer (23 N·m)
18. Front stabilizer rod assembly 19. Hexagon flange nut
20. Right front lower arm assembly 21. Right front shock damper assembly
22. Hexagon flange nut (75 N·m)

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They can receive larger traction under the same conditions. As the main indicator for automobile
performance, the dynamic power should be strengthened by all means thus to determine the drive
axle. Generally, autos are driven by rear axles because 2/3 weight of the entire vehicle is
burdened by the rear axle which thus can receive better traction. When the sedan, special for
passenger use, is fully loaded, the front axle together with the engine, transmission, driver and
co-driver will weight more than the passengers on the rear axle. The fat person always sits at the
co-driver seat and loads more on the front axle. Therefore, more traction will be achieved by the
front axle rather than the rear one.
When the vehicle is driven by the front axle, the increasing weight on the front axle will gain more
steering resistance, thus the steering response is stronger and operation becomes easier. The
engine is laterally placed, convenient for front axle drive and simplifying the main reducer,
reducing the cost and achieving an easy maintenance. Therefore, the front axle of LF620 sedan is
the steering drive axle, namely functioning as both a steering axle and a drive axle. It is composed
of steering knuckle, sub-frame assembly, left and right front lower arms assembly and their
suspensions. It is used to:
(1) Bear all force and torque, such as weight, payload, traction, brake force, inertia force,

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centrifugal force, lateral force and fatigue stress under alternating impact, etc.
(2) Reduce the impact from vibration, and advance the riding comfort and driving stability.
(3) Realize the steering.
(4) Transfer the engine torque to the left and right wheels after the torque is increased through
deceleration and then transform it to the forward traction.
The front suspension of LF620 sedan is a McPherson independent suspension. Refer to Fig. 2-1
for its structure.
It consists of coil spring, integrated asymmetric bidirectional canister-type shock damper, stabilizer
bar and triangle lower arm. The offset coil spring is connected with the canister shock damper,
thus to form the spring bracket of the suspension. The top of the bracket is flexibly connected with
the vehicle body. The limit stop is installed in the shock damper and the thrust ball bearing is fixed
on the boss ring over the shock damper. The front suspension kingpin center, center lines of the
shock damper and coil spring are not overlapped, and form a negative offset distance of kingpin
distance, namely the kingpin inclination angle is larger than that of the piston rod. Such a design
enjoys the following features:
(1) Avoiding the lateral misalignment of the steering wheel during the distortion of the strut type
independent suspension, and reducing the wear and tear of the steering wheel.
(2) While a flexible distortion happens to the suspension, the location parameters of the steering
wheels will complement each other although that of the kingpin change, and then improve the
stability of the vehicle.
(3) Compact structure. The shock damper, coil spring and steering kingpin are integrated, which
produces a small dimension and less space and is helpful for the location of the vehicle with a
front-built engine and front drive.
(4) There will be less change in the location of the front wheel during the usage period. Thus
please do not adjust the inclination and caster angle of the kingpin.
(5) The non-payload is lighter, which helps to decrease the impact load on the suspension and
improve the driving smoothness of the vehicle.
(6) The left and right wheels are independently hinged, which assists the wheels to contact the

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road surface better, reduces the vehicle vibration due to uneven road surface and enhances the
comfort and driving stability.
2. Rear suspension. Refer to Fig. 2-2.

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Fig. 2-2
1. Left rear shock damper assembly 2. Hexagon flange nut (75N·m)
3. Hexagon flange bolt (75N·m) 4. Hexagon flange bolt (85N·m)
5. Right rear shock damper assembly 6. Hexagon flange nut
7. Hexagon flange bolt (75N·m) 8. Hexagon flange bolt
9. Hexagon flange bolt 10. Big washer
11. Hexagon flange nut 12. Rear axle welding components (120N·m)
13. Rear stabilizer rod components
The rear axle of the suspension is a trailing axle, functioning as:
(1) Bearing all force and torque, such as weight, payload, traction, brake force, inertia force,
centrifugal force, lateral force and fatigue stress under alternating impact, etc.
(2) Reducing vibration and impact, and improving the vehicle comfort and driving stability.
The rear axle assembly of LF620 sedan is shown in Fig. 2-2.
The rear axle assembly is composed of rear axle welding component 13, left rear shock damper 1,
right rear shock damper 6, rear stabilizer bar component 14 and the left and right bushes of rear
axle.
The rear suspension is a trailing arm suspension with a torsion bar. The main axis of the body is
directly connected with the body and then with the suspension system; then the component is
installed on the body. And the spring and shock damper are installed near the vehicle axis. The
supporting arm moves around the axis of the center line of the vehicle body, namely parallel to the
vehicle axle which moves up and down, parallel to the vehicle body and no camber angle. The

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most prominent advantage lies in the large space between the left and right wheels together with
no camber angle of the body, and a sunken rear wheel of the swing arm suspension to balance
the vehicle body.
3. Specifications of wheel alignment parameters
If the wheels enjoy good geometric alignment, the fuel economic efficiency and tire service life will
be improved.
(1) Kingpin caster angle: It refers to the angle between the highest point of the wheel steering
center and the vertical direction in the view at the side of the vehicle, as shown in Fig. 2-3. The
caster angle is positive (+), while the front rake angle is negative. The retroversion of the kingpin
will influence the control on the direction of the steering mechanism, but not on the wear and tear
of the wheels. In case of a larger positive kingpin caster angle of a wheel than that of other wheels,
this wheel will drive towards the center line of the vehicle and the vehicle will move forwards
towards the side with a smaller positive kingpin caster angle.

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Fig. 2-3
(2) Wheel camber angle: Extroversion is viewed from the front of the vehicle. It refers to the angle
of the wheel off the vertical direction as shown in Fig. 2-4. If the top point of the angle is towards
outside, the camber angle is positive (+); while towards inside, it is negative (-). Extroversion will
not only influence the control on the direction, but also the wear and tear of the wheels. An
excessive extroversion will result in a worn wheel and cause the vehicle to move towards the
largest camber angle or to one side.

Fig. 2-4
(3) Toe-in of wheel: It refers to that the weel moves inward off the geometric center line/thrust line.

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The negative toe-in means that the wheel moves outward, as shown in Fig. 2-5.

Fig. 2-5

The toe-in is designed to ensure a parallel roll of the wheels. The toe-in can also complement the
little excursion of the wheel supporting system during driving forwards. Only with a proper toe-in
can the wheels run in parallel on the road surface.

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(4) Thrust angle: The front wheels direct or steer the vehicle while the rear wheels control the
same rut. The rut is related with the thrust angle which is the angle between the rut of the rear
wheels and the center line of the vehicle body (as shown in Fig. 2-6).

Fig. 2-6

(5) Wheel alignment parameters standard, Table 2-1.

Table 2-1

Name Idle load Full road

Front wheel camber angle 0°38′±30′ -0°55′±30′

Front wheel toe-in -2-2 -2-2

Kingpin inclination angle 11°15′±45′ 10°30′±30′

Kingpin caster angle 3°00′±30′ 4°00′±30′

Rear wheel camber angle 1°50′±30′ -1°55′±30′

Rear wheel toe-in -2-2 2-6

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II. Fault Elimination Table, Table 2-2.
Table 2-2
Fault Possible Cause Action

Check if the load is abnormal, if the ring

Incorrect vehicle height (high or low front or rear)
spring is sunken or is not standard spring.

Worn or broken steering gear or connecting rod. Check the steering system.
Leaning to one
Brake system. Check the brake.
side
Incorrect wheel alignment. Adjust the wheel alignment.

Check the front wheel bearing. See this

Worn front wheel bearing.
chapter.
Wheel and tire. Wheel transposition or replacement.

Check if the load is abnormal, if the ring

Incorrect vehicle height (high or low front or rear).
spring is sunken or is not standard spring.

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Unaligned Steering gear or connecting rod. Check the steering system.
steering wheel Carry out the test of ball joint in this
Suspension lower support arm ball joint.
chapter.
Incorrect wheel alignment. Adjust the wheel alignment.

Incorrect rear caster angle. Check the rear caster angle.

Incorrect track
Damaged rear suspension. Check the rear suspension.

Front or rear balance connecting rod, connector Check or install new suspension
or bush. components if necessary.
Check or install new suspension
Front suspension lower support arm bush.
Uncomfortable components if necessary.

riding Check or install new suspension

Rear suspension arm bush.
components if necessary.
Front bracket with spring. Check the front bracket with spring.

Rear shock damper. Check the rear shock damper.

Worn front wheel bearing. Check the wheel bearing.

Carry out the test of ball joint in this
Too large noise Suspension lower support arm ball joint.
chapter.
Damaged suspension. Check the suspension.

Improper worn Incorrect tire pressure. Adjust the tire pressure.

tire Incorrect wheel alignment. Adjust the wheel alignment.

Damaged or worn front wheel bearing Check the front wheel bearing.

Check the tire. Balance the tire or install a

Wheel and tire.
Vibration new one if necessary.

Incorrect wheel alignment. Adjust the wheel alignment.

Abnormal steering system operation. Check the steering system.

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III. Maintenance
i. Wheel alignment adjustment
1. Front wheel extroversion adjustment
The front wheel extroversion is adjusted as shown in Fig. 2-7. Raise the vehicle, and dismantle the
support from the vehicle. Fix the support on the bench clamp and gouge holes on the side panel.
The extroversion can be adjusted by the bolt hole between the file support and steering knuckle.

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Fig. 2-7
1. Camber angle 2. File upper bolt hole 3. File lower bolt hole

2. Front wheel toe-in adjustment, Fig. 2-8.

Fig. 2-8
1. Locking hexagon nut 2. Steering tie rod shaft 3. Seal clamp

Details as below:
(1) Dismantle the small boot clamp on the steering stabilizer bar.
(2) Adjust the steering wheel to the front center position.
(3) As shown in Fig. 2-8, release the hexagon bolt, and revolve the steering stabilizer bar for a
proper toe-in angle.
(4) Confirm that each steering stabilizer bar revolves for the same turns.
(5) Tighten the locking nut.
(6) Install the boot clamp.

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ii. Replacement of parts and components assembly
1. Replacement of front brake wheel hub assembly
(1) Disassembly of front brake wheel hub assembly
1) Raise and properly support the vehicle and dismantle the wheel assembly.
2) As per Fig. 2-9, disconnect the wheel speed sensor connector, and remove the sensor from the
bracket.

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Fig. 2-9

3) Remove the brake caliper bracket and brake caliper, and then secure the brake caliper on the
vehicle body to avoid bend or even damage of brake pipeline due to the weight of brake caliper,
and then dismantle the brake disk.
4) Remove the nuts of drive shaft.
5) As shown in Fig. 2-10, connect the removal tools of hub center shaft to the separating drive
shaft on the wheel bearing/wheel hub and the wheel bearing by 3 wheel nuts.

Fig. 2-10

6) According to Fig. 2-11, remove the wheel bearing.

Fig. 2-11

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(2) Installation of front brake wheel hub assembly
To install, reverse the removal procedure. When installing front wheel speed sensor, please
ensure that the connector clip is well matched.
2. Replacement of front stabilizer bar
(1) Disassembly of front stabilizer bar. Disconnect the related connections. Lower the whole front
sub-frame according to Fig. 2-12.

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Fig. 2-12

Remove the front stabilizer bar as shown in Fig. 2-13.

Fig. 2-13

(2) Installation: Install the front stabilizer, reverse the removal procedure.
3. Replacement of steering knuckle.

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The steering knuckle is replaced together with the brake gear assembly according to related
sections about brake gear.
4. Replacement of lower arm assembly
(1) Disassembly of the lower arm assembly
1) Revolve the steering wheel to move the relevant front wheel to the minimum side position.
2) According to Fig. 2-14, dismantle the cotter pin and slotted nut from the ball head bolt, and
knock the steering knuckle to remove the ball pin of the lower arm from the steering knuckle.

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Fig. 2-14

3) Dismantle the 2 bolts and nuts, and remove the front lower arm assembly according to Fig. 2-15.
Please do not rotate the locking nut because any rotation will cause damage to it.

Fig. 2-15

4) Check the lower arm assembly

① Before installing nuts, shake the ball pin bolt for over 5 times as described in Fig. 2-16.
② Use a torque wrench to rotate the nuts at a speed of a turn for each 2-4s, and record the

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tightening torque reading at the fifth turn. Tightening torque: 0.05～1.98Nm.

Fig. 2-16

(2) Installation
1) Temporarily screw down the front suspension lower arm assembly. Fasten the front suspension
lower arm assembly by 2 bolts and nuts. No need to use torque tools, as shown in Fig. 2-17.

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Fig. 2-17

2) Install the front suspension lower arm onto the steering knuckle by nuts. Tightening torque: 100
N·m. Follow Fig. 2-18.

Fig. 2-18

3) Install the cotter pin. Note: In case that the hole of cotter pin is not correctly aligned, please
further tighten the nut according to the hole of cotter pin.
4) Fully tighten the front suspension lower arm assembly. Secure the lower arm by 2 bolts as
shown in Fig. 2-17.

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5. Replacement of shock damper
(1) Disassembly of front shock damper assembly.
1) Dismantle the front wheel.
2) Disconnect the brake hose. Remove the bolt, brake hose and ABS vehicle speed sensor
harness clip from the shock damper bracket (of vehicle with ABS) according to Fig. 2-19.

Fig. 2-19
3) Dismantle the front shock damper with coil spring.

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① Remove the nuts connecting the connecting rod of front stabilizer bar and the front shock
damper. Then dismantle the shock damper from the steering knuckle after removing the 2 nuts
and bolts connecting the front shock damper assembly and the steering knuckle, as shown in Fig.
2-20.

Fig. 2-20

② Dismantle the front shock damper with coil sprint, and then the 3 nuts on the suspension
bracket according to Fig. 2-21.

Fig. 2-21
(2) Installation of front shock damper assembly.
To install, reverse the removal procedure

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(3) Disassembly of the rear shock damper assembly
1) Dismantle the rear wheel.
2) Dismantle the left and right rear shock damper assembly according to Fig. 2-22.

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Fig. 2-22

① Raise the rear axle frame by a jack.

② Dismantle the thickened flange nut connecting the rear shock damper from the rear sub-frame
assembly.
③ Dismantle a bolt and 2 nuts connecting the rear shock damper assembly and the vehicle body.
④ Dismantle the rear shock damper from the vehicle body.
(4) Installation of rear shock damper assembly
To install, reverse the removal procedure.
(5) Inspection of shock damper assembly. Check if there is abnormal resistance or noise when
pressing or pulling the push rod of shock damper. In case of any abnormal situation, please
replace the shock damper with a new one.

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 Section II Steering System

The steering system is a special mechanism to change or maintain the driving direction of a
vehicle. It is used to change the direction at a proper time according to the requirement of the
driver during driving, and cooperate with the driving system to keep the vehicle moving stably in
case that the vehicle moves off the driving direction due to the accidental impact from the road
surface. It is one of the important systems to keep safe driving. Therefore, check and maintenance
of the steering system in time is an effective measure to ensure safe driving and fewer accidents.
The steering wheel of LF620 sedan is composed of steering wheel 1, steering column 2, power
steering pump 5, oil tank 4, steering gear 3, etc. Follow Fig. 2-23.

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Fig. 2-23

1. Return line bracket 2. Hex bolt with flat washer

3. Return line clamp 4. Return line bracket B
5. Steering oil pump intake pipe 6. A-type worm-driven tube hoop
7. A-type worm-driven tube hoop 8. Power steering oil can assembly
9. Hex bolt with flat washer (75N·m) 10. Power steering oil can clip
11. Power steering oil can bracket 12. Power steering oil pump assembly
13. Steering return line assembly 14. Steering gear intake pipe assembly
15. Hexagon flange bolt (75N·m) 16. Oil pipeline bracket A component
17. Cotter pin 18. Hex slotted thin nut (75N·m)
19. Steering gear and tie-rod assembly 20. Hexagon flange bolt (75N·m)
21. Acoustic hood on the steering gear 22. Collar of acoustic hood on the steering gear
23. Steering column dustproof cap components 24. Steering column and adjustment mechanism assembly
25. Steering wheel assembly

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I. Fault Diagnosis of Steering System
1. Note for inspection
(1) Take extra care while replacing the components. Incorrect operation may affect the
performance of the steering system and lead to driving accident.
(2) Notes for SRS system. This vehicle is equipped with SRS, like driver air bag and front
passenger air bag. If failing to repair the air bag in correct order, the unexpected deployment of air
bag during the maintenance may lead to serious accident. Read the notes for supplement restraint
system before maintenance (including removal or installation, and check or replacement of
components).

II. Fault Elimination Table

With the help of Fault Elimination Table (as shown in Table 2-3), it is more convenient to discover
the fault. The Table indicates the frequent faults. Eliminate all faults according to measures
provided in this Table. Check each component in sequence. Repair or renew these components if
necessary.

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Table 2-3
Fault Possible Cause Actions

Incorrect tire size or pressure. Check the tire size and adjust the tire pressure.
Over loaded or uneven loaded. Adjust the load.
Replace the steering gear or tie-rod end with a
Loose or worn tie-rod or its end
When the new one if necessary.
steering wheel is
Loose or broken bolts of the steering gear Lock the bolt or install a new one.
fixed and in
Replace the suspension ball joint assembly with
straight forward Loose or worn suspension ball joint.
a new one.
direction, the
Loose bolts between the steering column Lock the bolts of pinion shaft.
vehicle moves
shaft universal joint and the pinion shaft. Lock the steering column shaft universal joint.
between two
Loose or broken steering column shaft Install a new steering column shaft universal
sides.
universal joint. joint.

Improperly adjusted toe. Adjust it if necessary.

Loose or broken rear suspension. Lock or install new rear suspension components.

Incorrect tire pressure. Adjust the tire pressure.

Incorrect tire size or different tire/tread

Install new tires if necessary.
types.
The vehicle leans
to one side when Over loaded or uneven loaded. Adjust the load.
running on
Improperly toe adjustment. Adjust it if necessary.
smooth road
Install new front suspension components if
surface. Broken front suspension components.
necessary.
Install new rear suspension components if
Broken rear suspension components.
necessary.

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 Table 2-3 (Continued 1)
Fault Possible Cause Actions
In case of a vehicle speed below 50 km/h
(30mph), turn the transmission to
NEUTRAL, and turn the ignition switch to
position I (engine OFF-sliding). In case that
the vehicle does not lean to one side when
stopping, install a new steering gear.
In case that the vehicle does not move
Unbalanced action of steering gear valve. when stopping, interchange the front wheel
assembly

The vehicle leans to In case that the vehicle does not lean to the

one side when other side, exchange the front and rear

running on smooth wheels at the same side.

road surface. In case the vehicle leans in the same

direction, check the front suspension

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components and adjust the toe.
Check if the front/rear brake is normal. Adjust it if necessary.

Check if the rear suspension components

Install new rear suspension components if
are bent and if the front/rear suspension
necessary.
ring spring is broken or sunken.

Install new rear suspension components if

Check if the rear suspension components
necessary.
or bolts are loose or worn.
Lock all bolts.

Steering gear input shaft connector. Install a new universal joint if necessary.

Feedback (whine or Loose/worn tie-rod. Install a new steering gear if necessary.

knock sound of the Loose or broken steering gear bolts. Lock or install new fixing bolts if necessary.
steering gear)-the Loose bolts and the steering column shaft
steering wheel feels Lock bolts.
and universal joint.
rough when driving
Lock or install new bolts or ball joints if
on the rough road. Loose suspension boot, bolts or ball joints.
necessary.
Bad steering column shaft. Install new steering column if necessary.
After steering, the Incorrect tire pressure. Adjust the tire pressure.
steering wheel will not Incorrect tire size or type. Install new tires if necessary.
go back to the central Unaligned steering column or the
Align the steering column.
position without the protecting hood rubs the steering wheel.
assistance of the Blocked steering column universal joint. Install a new universal joint.
driver. Besides, it may
feel obstructed or
unsmooth when the The sealed pad of the soleplatofsteering
Install a new sealed pad if necessary.
driver turns the column shaft may be torn
steering wheel to the
central position.

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 Table 2-3 (Continued 2)
Fault Possible Cause Actions

After steering, the steering Blocked or broken tie-rod. Install a new steering gear if necessary.
wheel will not go back to the Broken or worn front Install new front suspension components if
central position without the suspension components. necessary.
assistance of the driver. Incorrect toe adjustment. Adjust it if necessary.
Besides, it may feel obstructed
Blocked column bearing. Install a new steering column.
or unsmooth when the driver
turns the steering wheel to the
Contaminated steering oil. Wash the power steering system.
central position.
Insufficient power steering Refill the oil if necessary and check if there is
pump oil. oil breakage.
Incorrect tension of the
Check the tension of the accessory drive belt.
accessory drive belt.
Leakage in the hose or outer Repair or install a new hose or cooler if

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cooler. necessary.

Incorrect engine idle speed. Refer to the air discharge of power system.

Steering feels heavy when Loose or distorted power

Install a new power steering pump belt pulley.
steering and parking at the steering pump belt pulley.
road side Power steering pump flow or Check the pump flow and pressure. Refer to
pressure out of specification. the pump flow and pressure test in this chapter.
Obstructed hose or cooler Clean the hose or cooler or install a new one if
pipeline. necessary.
Check if there are foreign materials or
Contaminated steering shaft. contamination in the system. Wash the power
steering system.

Air in steering oil. Discharge the air in the system.

Excessively filled system. Correct the fluid level height.

Oil leakage Find out the suspicious component and repair
Leakage in components.
it if necessary.
The accessory drive belt utters
a long shriek (especially while Check if the tension of the
the steering wheel turns to the accessory drive belt is correct Install a new accessory drive belt if necessary.
end and parking the vehicle at or if the belt skids.
the original position)
Loose or broken accessory
Chatter from the steering pump Install a new accessory drive belt.
drive belt.
Insufficient oil and possible Refill the oil to the specified height.
leakage. Discharge the air in the system.
Noise from power steering
Check if there is a leakage. Repair it if
pump
Power steering pump. necessary.
Install a new power steering pump if necessary.

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 Table 2-3 (Continued 3)
Fault Possible Cause Actions

Oil at a temperature below 54°C

(130°F) flow into the bypass
Swish noise Normal.
valve of the housing of pump
valve.
With air in the oil and leakage in
Purify the air in the system.
the system.
Sob noise
Check O-ring oil seal of one-way Install a new power steering pump if
valve cap. necessary.

Too much oil. Correct the fluid level height if necessary.

Lost, loose or broken filler cap or Install a new filler cap or O-ring seal if
lost O-ring seal. necessary.

Loose or broken hose connector. Install a new hose connector if necessary.

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Leakage in shaft seal:
Broken oil seal.

Leakage in power steering Broken rotor shaft, e.g. groove or Install a new power steering pump.

pump or fuel tank bruise.

Worn bush or sleeve of shaft.

Inlet tube. Install a new power steering pump.

Perforated housing. Install a new power steering pump.

Loose nuts of outlet pipe

Lock it if necessary.
connector or plug valve.
Broken connector, nuts or plug of
Install a new power steering pump.
outlet pipe.
Refill the oil if necessary and check if the
Power steering oil (insufficient).
system has a leakage.

Universal joint (worn). Replace it if necessary.

Abnormal noise Power steering vane pump
Check and replace it if necessary.
(faulty).

Steering gear (faulty). Replace it if necessary.

Tire (improper inflation). Adjust the tire pressure.

Front wheel alignment

Align the wheels.
(incorrect).
Insufficient return
Steering column (bent). Align it and replace it if necessary.

Steering gear (malfunction). Replace it if necessary.

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 Table 2-3 (Continued 4)
Fault Possible Cause Actions

Steering knuckle (worn). Replace it if necessary.

Suspension arm ball joint (worn). Replace it if necessary.

Intermediate shaft, and slip

Over large clearance Replace it if necessary.
joint/yoke (worn).

Front wheel bearing (worn). Replace it if necessary.

Steering gear (malfunction). Replace it if necessary.

Tire (improper inflation). Adjust the tire pressure.

Refill the oil if necessary and check if there is

Power steering oil (little).
a leakage in the system.

Front wheel alignment (incorrect) Align the wheels.

Steering knuckle (worn). Replace it if necessary.

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Heavy steering Suspension arm ball joint (worn). Replace it if necessary.

Steering column (bent). Check and replace it if necessary.

Power steering vane pump

Replace it if necessary.
(malfunction).

Steering gear (malfunction). Replace it if necessary.

III. Maintenance
1. Check the free play of steering wheel
The methods for checking the free play of steering wheel are as follows:
(1) Make sure that the road wheels are in the straight ahead position.
(2) Gently turn the steering wheel, and check its free play. As shown in Fig. 2-24, the free play of
steering wheel ≤ 20°.

Fig. 2-24

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2. Steering wheel and column as shown in Fig. 2-25.

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Fig. 2-25

3. Removal and installation of steering wheel and column assembly

Note:
① Follow the notes for the maintenance of steering pump.
② Disconnect the negative terminal of the battery.
③ Make sure that the front wheels are in the straight ahead position.
(1) Removal
1) Remove the horn button assembly.
Note: Disconnect the connector of air bag in case that the ignition switch is at position “ON”.
2) Loosen the two bolts with socket wrench or screwdriver until the bolt head is locked into the bolt
housing, as shown in Fig. 2-26.

Fig. 2-26

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3) Push out the horn button assembly from the steering wheel, as shown in Fig. 2-27.

Fig. 2-27
4) Use a screwdriver to release the locked part of the air bag connector and then remove the air
bag connector.
Note: Do not drag the air bag harness when removing the horn button assembly; make the upper
surface upward when placing the assembly; do not disassemble the horn button assembly.
5) Disconnect the connector.
6) Remove the fixing nut of the steering wheel, as shown in Fig. 2-28.

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Fig. 2-28
7) Mark the matching place on the steering wheel assembly and the main shaft assembly.
8) Use a special tool to remove the steering wheel assembly.
9) Remove the lower cap of the steering column. Remove the three bolts, the upper & lower caps
of the steering column, as shown in Fig. 2-29.

Fig. 2-29

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10) Locate the ignition switch at position ACC, and dismantle the coil spring assembly. Note: The
combination switch is connected to the installation plate by a metal clip and 2 plastic clips. Firstly
prize the metal clip from the installation hole by a screwdriver and then remove the 2 plastic clips.
See structure drawing in Fig. 2-30.

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Fig2-30
11) Remove the left combination switch (headlamp dimmer switch assembly), as shown in Fig.
2-31.

Fig. 2-31
12) Remove the right combination switch (wiper switch assembly).
13) Remove the dustproof cap of the steering column.
14) Disconnect No. 2 steering intermediate shaft assembly, as shown in Fig. 2-32.

Fig. 2-32

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① Mark the matching place on the slip yoke and intermediate shaft.
② Loosen the bolt A and B, and then disconnect the intermediate shaft.
15) Remove the steering column assembly, as shown in Fig. 2-33.

Fig. 2-33

① Disconnect the connector and harness clip from the steering column assembly.
② Remove the 3 bolts and the steering column assembly.

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16) Remove No. 2 steering intermediate shaft assembly.
① Mark the matching place on the main shaft and intermediate shaft, as shown in Fig. 2-34.

Fig. 2-34

② Remove the bolt and intermediate shaft.

17) Dismantle the switch support from the steering column, as shown in Fig. 2-35.

Fig. 2-35

① Use a center punch to make center marks on the two conical bolts.
② Drill the two bolts by a 3-4mm drill.
③ Remove 2 bolts and switch support assembly on the steering column by a screwdriver.
18) Remove the steering column upper clip board.

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19) Remove the ignition switch lock core assembly as shown in Fig. 2-36.

Fig. 2-36
① Turn the ignition switch to position ACC.
② Press down the lock by a screwdriver and pull out the lock core.
20) Dismantle the unlocked warning switch assembly.
① Disconnect the unlocked warning switch from the ignition switch assembly.
② Dismantle the unlocked warning switch assembly.
21) Remove the ignition switch assembly. Remove the 2 bolts and also the ignition switch
assembly from the steering column bracket.
(2) Installation

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1) To install the ignition switch assembly and the unlocked warning switch assembly, reverse the
removal procedure.
2) Install the ignition switch lock core assembly.
① Make sure that the ignition switch is at position ACC.
② Install the ignition switch lock core assembly.
3) Check the action of steering lock.
① Check the steering locking mechanism with the key out.
② Check the steering locking mechanism for its activeness with the key in position ACC.
4) Install the switch support on the steering column.
(1) Adopt two new conical bolts for the temporary installation of the switch support assembly and
the clip on the steering column.
(2) Screw up the two conical bolts till their nut heads disconnect.
5) Install No. 2 steering intermediate shaft assembly.
① Align the matching mark on the intermediate shaft and main shaft.
② Install the intermediate shaft with bolt. Tightening torque: 36N·m.
6) Install the steering column assembly.
① Install the steering column assembly with three bolts. Tightening torque: 21N·m.
② Connect the connector to the harness clip.
7) Connect No. 2 steering intermediate shaft assembly.
① Align the matching mark on the intermediate shaft and slip yoke.
② Install the bolt B and screw down bolt A. Tightening torque: 28N·m.
8) Install the cover board of the steering column hole.
9) Install wiper switch. Install the wiper switch assembly and connector.
10) Install the headlamp dimmer switch assembly. Install the headlamp dimmer switch assembly
and connector.
11) Make the front wheel in the straight ahead position.
12) Install the clock spring when the key is at position ACC.
13) Check the inter-locking of the key.

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14) Install the upper cap of the steering column. Install the upper & lower caps of the steering
column with three bolts.
15) Align the clock spring.
① Make sure the ignition switch at position OFF.
② Make sure the negative terminal of the battery is disconnected. Note: Operate 90s later.
③ Rotate the cable disc counterclockwise with hand till it can not be rotated any more.
④ Rotate the cable disc clockwise about 2.5 circles, and align the mark.
Note: The cable disc can be turned around the center about 2.5 circles.
16) Install the steering wheel assembly.
① Align the matching mark on the steering wheel assembly and steering main shaft assembly.
② Install the steering wheel with fastening nut. Tightening torque: 50N·m.
③ Connect the connector.
17) Check the horn button assembly.
18) Install the horn button assembly.
Note:
① Do not use the air bag components removed from another vehicle. Renew as required.

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A. Make sure that the horn button assembly is installed with specified tightening torque.
B. When dropped or crack, depress or other defects detected on the housing or connector, replace
a new horn button assembly.
C. Make sure that the wire is not interfered and clipped by other components when install the horn
button assembly.
② Connect the air bag connector.
③ Install the horn button after clipping the bolt groove to the bolt cap.
④ Install two box bolts with torque socket wrench. Tightening torque: 8.8N·m.
19) Align the steering wheel.
4. Inspection for the power steering device
(1) Check the oil level for the power steering gear
① Park the vehicle in a flat place, and turn the steering wheel for several times without moving the
vehicle after starting the engine, in order to increase the oil temperature (to 50-60℃).
② Start the engine and turn the steering wheel from lock to lock several times.
③ No air bubble, flocculent deposits in the oil.
④ Stop the engine and check the fluid level for any change. Discharge air if the level change
exceeds 5mm.
5. Replacement of power steering fluid
Removal and inspection are required if fault occurs in the power steering device. At the same time,
replace the power steering fluid. Replace the fluid in time as well if it goes bad. The steps are as
below:
(1) Raise the front wheel with a jack or hoist the complete vehicle with a lifter.
(2) Disconnect the return hose from the steering fluid reservoir. Connect a plastic tube with the
return hose, and collect the fluid with proper container. Avoid splashing the fluid to the vehicle
body and components, or wipe up immediately.
(3) With idle operation of the engine, repeatedly turn the steering wheel from lock to lock, to
discharge the fluid; intermittently start the engine several times, to confirm that it has been totally
discharged.

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(4) Connect the return hose, and fix with clip.
(5) Fill the reservoir with the specified oil, neither higher than the maximum level, nor lower than
the minimum level.
Oil: ESSOATF.D. Filling amount for reference: 0.825L.
(6) With idle operation of the engine, repeatedly turn the steering wheel from lock to lock, to
discharge the air for the steering system.
(7) Check the oil level again. Fill the reservoir with the specified oil if necessary, in order to make
the oil reach the maximum level.
6. Air discharging of the power steering system
(1) Raise the front wheel by a jack.
(2) Intermittently start the engine for several times, and meanwhile turn the steering wheel from
lock to lock for 5 to 8 times to raise the oil temperature, and then make the steering wheel in the
straight ahead position and note the fluid level in the reservoir.
(3) Note the fluid level in the reservoir again in 3 to 5 minutes later after the engine misfires, and
compare the level with that in (2). If the gap is below 5mm and there is no bubble or emulsification
in the fluid, the air inside the system has been discharged completely. Otherwise, repeat step (4)

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and step (5) until the air is discharged completely.
(4) Check the fluid level. Fill the fluid reservoir with oil to the regulated level as necessary.
Note:
① During discharging air, the fluid should be higher than the minimum level of the reservoir.
Otherwise, fill more fluid.
② The air will be micronized and dissolved in the fluid if it is discharged with the engine on.
Therefore, discharge the air while starting the engine.
③ The fast increasing fluid level after the engine stops indicates an incomplete air discharging.
④ An incomplete air discharging in the system will cause a vibration noise from the pump and
abnormal sound from the flow control valve which may affect the service life of the pump and other
components.
7. Oil pressure checking (see Fig. 2-37)

Fig.2-37
(1) Disconnect the oil pump from the high pressure hose, and install the special tool.

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(2) Discharge the air and turn the steering wheel for several times to raise the fluid temperature to
50-60℃.
(3) Start the engine and keep it rotating at a speed of 1000±100r/min.
(4) Close the cut-off valve of the pressure gauge completely and check if the safety pressure of the
oil pump is within the standard value. Standard value: 8MPa.
(5) Replace the oil pump in case of a deflection from the standard value.
(6) Open the cut-off valve of the pressure gauge completely and check if the oil pressure is within
the standard value without load.
Standard value: 0.2-0.7MPa.
(7) Any deflection from the standard value can be considered to be caused by a poor fuel line or
steering gear. Repair it and measure the pressure again.
(8) Check if the oil pressure is within the standard value in a state of turning the steering wheel
from lock to lock. Standard value: 7.9MPa.
(9) In case of an oil pressure lower than the standard value, remove and install the steering gear;
in case of a higher one, replace the oil pump.
(10) Tighten the high pressure hose with specified tightening torque after removing the special tool.

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Tightening torque: 55±5N·m.
(11) Air discharging
8. Inspection of the power steering gear: see Fig. 2-38.

Fig. 2-38
1. Lower steering shaft 2. Bolt
3. Acoustic hood on the steering gear 4. Oil pipeline connector of steering gear
5. Bolt 6. Steering gear assembly
7. Sub-frame
(1) Removal

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① Discharge steering fluid.
② Dismantle the high pressure oil outlet pipe connected to the steering oil pump, screw off the
hollow bolt, and remove the hose bracket connected to the engine.
③ Disconnect the steering gear from the steering lower shaft.
④ Dismantle the connectors between steering gear and the return oil pipeline, and remove the
front sub-frame and steering assembly from the vehicle body.
⑤ Dismantle the steering gear assembly from the front sub-frame.
(2) Inspection of the power steering gear
Note: The internal components of the steering gear can not be disassembled, but replaced or
returned for repair by the producer.
1) Inspection of the shaking resistance of the steering tie-rod
① Shake the steering tie-rod forcibly for 10 times.
② Put one end of the steering tie-rod downwards, measure the shaking resistance by a spring
scale and compare it with the standard value.
Standard value: 1.5-4.9N·m.
③ In case of a value above the standard one, replace the steering tie-rod.

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④ In case of a value below the standard one, check if the ball joint is loose or creak can be heard.
If shaking smoothly, it is all right; if any looseness detected or abnormal sound heard, replace the
steering tie-rod.
2) Inspection of steering tie-rod ball joint end and dustproof cap
① Press the dustproof cap forcibly by finger and check if there is any crack or damage on the
dustproof cap.
② In case of any crack or damage detected on the dustproof cap, replace the steering tie-rod
outer joint; however, if caused by maintenance, only replace the dustproof cap.
3) Installation of power steering gear
To install, reverse the removal procedure.

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 Section III Brake System

The brake system is used to transform the force on the brake pedal from the driver to braking force
of all wheels. Then the hydraulic system will distribute the braking force to each wheel. The
vacuum brake booster is used to decrease the force from the pedal and increase the hydraulic
pressure. The parking brake operates by rear wheels and controls the operation manually.
LF620 sedan has two brake systems, namely driving brake system and parking brake system. The
driving brake system is an engine vacuum booster ABS hydraulic brake system. And the parking
brake is to control the rear brake by cable system which utilizes the self-adjusting ratchet and pawl
structure. The ABS is controlled by the hydraulic control unit (HCU) in the hydraulic system, and
only works when the vehicle speed sensor detects that the wheels are locked.

I. Fault Diagnosis
The fault elimination of brake system is shown in Table 2-4. The figures in the Table refer to the
sequence of possible faults. Check all components and parts in sequence. Replace related parts if

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necessary.

Table 2-4
Fault Possible Cause Actions

Alignment angle of wheels Check the alignment angle of wheels.

Brake pad Check and install a new component if necessary.

Brake runs off or drifts
Brake disc Check and install a new component if necessary.

Brake caliper Check and install a new component if necessary.

Brake fluid level sensor Refer to WDS.

Parking brake control device Release and adjust the parking brake.
Red brake warning lamp is
lighted continuously Excessively worn brake pad Check and install a new component if necessary.

Main piston rod of braking master

Install a new braking master pump.
pump

Brake pad Check and install a new component if necessary.

Vibration during brake action Brake caliper Check and install a new component if necessary.

Brake disc Check and install a new component if necessary.

With air in system Discharge the air in system.

Rapidly sunken Braking master pump Check the braking master pump.
pedal Brake disc Check and install a new component if necessary.

Brake pad Check and install a new component if necessary.

Brake caliper Check and install a new component if necessary.

Slowly sunken pedal
Brake master pump Check the brake master pump.

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 Table 2-4
Fault Possible Cause Actions

With air in system Discharge the air in system.

Low-position or soft pedal Brake pad Check and install a new component if necessary.

Brake booster Check the booster components.

Brake pad Check and install a new component if necessary.

Locked pedal when gently
Brake disc Check and install a new component if necessary.
stepping down the pedal
Brake booster Check the booster components.

Insufficiently lubricated sliding

Lubricate it if necessary.
part

Brake pad Check and install a new component if necessary.

Too long/unstable brake pedal
travel Brake disc Check and install a new component if necessary.

Wheel bearing Check the wheel bearing or install a new one.

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Brake pedal Check and repair the brake pedal.

Brake booster Check and repair booster components.

Brake caliper Check and install new components if necessary.

Brake daggles Electronic stability control system
Refer to WDS.
(if equipped)

Brake pedal Check and repair the brake pedal.

Electronic stability control system

Refer to WDS.
(if equipped)
Slow or incomplete return of Carry out test of brake master pump components in
Brake master pump
the pedal this chapter.

Brake pedal Check and repair the brake pedal.

II. Inspection of Brake system, Table 2-4.

i. Air discharging of brake fluid
Please purify the air if repairing the brake system or considering air in the brake pipeline.
Note: Do not splash the brake fluid on the paint, otherwise clean it immediately.

Fig. 2-39
1. Refill brake fluid into the reservoir (as shown in Fig. 2-39)

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Brake fluid: DOT4, filling amount: 0.72L.
2. Discharge the air in the brake master pump
Note: Discharge the air in the brake master pump if it has been dismantled or the reservoir is
empty.
1) Disconnect the oil pipeline connector from the brake master pump.
2) Slowly step down the pedal and maintain without movement, as shown in Fig. 2-40.

Fig. 2-40

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3) Block up the hole from outside by fingers, and release the brake pedal as Fig. 2-41.
4) Repeat step 2) and 3) for 3 or 4 times.

Fig. 2-41

3. Air discharging of brake oil pipe (Fig. 2-42)

Fig. 2-42
1) Connect the plastic pipe to the brake caliper and slave cylinder.

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2) Step down the pedal for times and then keep it stepped down, and then screw off the air
discharging bolt.
3) Screw down the air discharging bolt immediately when the brake fluid flows out, and release the
brake pedal.
4) Repeat step 2) and 3) until all air in brake fluid flow out.
5) Repeat the above steps to exhaust air from each brake slave cylinder. Tightening torque:
8.0N·m.
4. Check the oil level in the reservoir
Check the oil level. Refill brake fluid if necessary. Brake fluid: DOT4
ii. Inspection of brake pedal
1. Check the pedal height as shown in Fig. 2-43. Height above floor: 136mm-146mm.

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Fig. 2-43
2. Adjust the pedal height.
1) Remove the central console cover.
2) Dismantle the connector from the brake lamp switch.
3) Release the brake lamp switch locking nut and dismantle the brake lamp switch.
4) Release the locking nut of U connector.
5) Rotate the push rod of pedal, and adjust the pedal height.
6) Screw down the locking nut of the push rod. Tightening torque: 26N·m.
7) Install the brake lamp switch.
8) Insert the connector of brake lamp switch.
9) Push down the brake pedal for 5-15mm, and then turn the brake lamp switch until the lamp
goes out. Then lock the nut.
10) After installation, step down the brake pedal for 5-15 mm, and then check if the lamp is lighted
(it should be lighted).
3. Check the free play of the pedal

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1) Stop the engine, step down the pedal repeatedly until there is no vacuum in booster.
2) Step down the pedal until resistance is felt. Measure the distance shown in Fig. 2-44. Free play
of pedal: 1-6mm. In case of clearance out of specifications, check the clearance of the brake lamp
switch. In case of an incorrect clearance, diagnose the brake system. Brake lamp clearance:
0.5-2.4mm.

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Fig. 2-44
4. Check the braking distance. Fig. 2-45.
Loosen the push rod of the parking brake. When the engine runs, step down the pedal. Measure
the braking distance as shown in Fig. 2-45. Step down the pedal by a force of 140N. The braking
distance should be over 55mm above the floor. In case of a distance out of specifications,
diagnose the brake system.

Fig. 2-45

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 5. Removal and installation. See Fig. 2-46.

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Fig. 2-46
(1) Removal
1) Remove the components of instrument cluster.
2) Disconnect the U connector of the push rod of brake master pump. Dismantle the clip and push
rod pin, and disconnect the brake master pump from the brake pedal.
3) Remove the brake pedal support.
① Remove the bolts from the brake pedal support. See Fig. 2-47.

Fig. 2-47
② Disconnect the connector of the brake lamp.
③ Remove 4 nuts and the brake pedal support. See Fig. 2-48.

Fig. 2-48
4) Remove the brake pedal assembly.
① Remove the bolts and nuts from the brake pedal support.
② Remove the brake pedal and 2 bushes.

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5) Remove the brake lamp components.
① Release the brake lamp switch and locking nuts.
② Remove the brake lamp switch from the brake pedal support.
6）Remove the pad of brake pedal from the brake pedal.
(2) Installation
1) Install the brake pedal pad on the pedal.
2) Install the brake lamp components on the brake pedal.
3) Install the brake pedal.
① Smear lithium base glycol grease on the head face and side on the 2 new bushes.
② Install the brake pedal and 2 bushes onto the brake pedal support by bolts and nuts. Tightening
torque: 37N·m.
4) Install the brake pedal support.
① Install the brake pedal support by 4 nuts. Tightening torque: 13N·m.
② Connect the connector of brake lamp switch.
③ Encase the bolts into the brake pedal support. Tightening torque: 20N·m.
5) Connect the U connector of push rod of the brake master pump.

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① Smear lithium base glycol grease on the push rod pin.
② Connect the clip of push rod pin to the push rod of brake master pump.
6) Install the instrument cluster components.
7) Check and adjust the height of the brake pedal.
8) Check the free play of the brake pedal.
9) Check the braking distance of the brake pedal. After assembly, check and adjust the height,
free play and braking distance of the brake pedal.
iii. Inspection of brake master pump and vacuum booster
On-vehicle inspection
1. Inspect the vacuum booster
1) Check the air tightness. See Fig. 2-49.

Fig. 2-49
① Start the engine and then stop it after 1-2 min, and slowly step down the pedal for several times.
Note: It proves good air tightness in case that the pedal drops greatly at the first trample rises
gradually after the second or third trample.
② When the engine is running, step down the brake pedal and then stop the engine. Note: It
proves good air tightness if the braking distance has no change at 30s after the pedal is stepped
down.
2) Operation Inspection.
① When the ignition switch is at position OFF, step down the pedal for times, and then check if the

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braking distance is changed.
② Step down the pedal and start the engine. Note: The operation is normal if the pedal drops
slightly.
2. Check the vacuum one-way valve.
1) Glide the clip and disconnect the vacuum pipe.
2) Remove the vacuum one-way valve.
3) Check if the way from the booster to engine is ventilated.
4) Replace the vacuum one-way valve in case of a fault.
3. Check if there is brake fluid leakage outside the brake master pump.
4. After the engine stops, step down the pedal for times and keep brake force. Check if the pedal
falls and if there is pressure leakage inside the brake master pump. Replace the brake master
pump in case of a fault.
iv. Inspection of driving brake
1. Inspection of the front brake gear
(1) Removal
1) Remove the front wheel.

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2) Discharge the brake fluid. Note: Do not splash the brake fluid on the paint, otherwise clean it
immediately.
3) Remove the front disc brake caliper.
① Remove the connector bolts and washer from the front disc brake caliper, and then disconnect
the hose. See Fig. 2-50.

Fig. 2-50
② Remove the 2 bolts after securing the sliding pin of the slave cylinder of front disc brake. See
Fig. 2-51.

Fig. 2-51
4) Remove the front brake pad suite.
① Remove the 2 brake pads with silencer pads.
② Remove No.1 and No. 2 silencer pads from each brake pad.
5) Remove the front brake pad holding piece. Remove the 2 lining pads from the support of the

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brake master pump.
6) Remove the sliding pin of the slave cylinder of front disc brake. Remove the sliding pin from the
support of the disc brake master pump.
7) Remove the dustproof cover of the front disc sliding pin. Remove the 2 dustproof cover from the
support of the slave cylinder of front disc brake. See Fig. 2-52.

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Fig. 2-52
8) Remove the support of slave cylinder of left front disc brake. Take off the support after removing
the 2 bolts.
9) Remove the dustproof cover of the brake slave cylinder. Remove the fixing ring and dustproof
cover by a screwdriver. See Fig. 2-53.

Fig. 2-53
Note: Do not splash the brake fluid.
10) Remove the air discharging bolt of the front disc brake gear.
11) Remove the piston in the slave cylinder of front brake.
① Place a cloth or equivalent between the slave cylinder and piston.
② Blow out the piston from the slave cylinder by compressed air. See Fig. 2-54. Note: Do not put
your hand before the piston when blowing the compressed air.

Fig. 2-54

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12) Remove the oil seal of piston. Take out the oil seal from the brake slave cylinder by a
screwdriver. See Fig. 2-55.

Fig. 2-55
(2) Inspection
1) Inspect eh brake slave cylinder and piston. Check if the piston is rusty or scratched.
2) Check the lining thickness of the brake pad. Measure the thickness by a ruler. See Fig. 2-56.
Standard thickness: 11.0mm; min thickness: 1.0mm.

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Fig. 2-56
3) Check the sheet steel of the front brake wear indicator. Make sure that the sheet steel is
sufficiently flexible and free of rust, dirt and other foreign material, and has no crack or wear.
4) Check the thickness of the brake disc. Measure the thickness of the brake disc by a micrometer
caliper. Standard: 25.0mm; min: 23.0mm.
5) Take off the front brake disc.
① Mark on the brake disc and wheel hub.
② Take off the brake disc.
6) Install brake disc. Note: Install it through the part with min thickness.
7) Check the brake disc swaying.
① Temporarily tighten the brake disc. Tightening torque: 103N·m.
② Measure the swaying of brake disc at 10mm away from the outer edge of brake disc by a dial
indicator. See Fig. 2-57. Max: 0.05mm.

Fig. 2-57
③ In case that the swaying of brake disc reaches or exceeds the limit, check the axial clearance of
the bearing and the swaying of wheel hub. If both bearing and hub are normal, adjust the swaying
of brake disc.
(3) Installation
1) Temporarily screw down the air discharging bolt on the front brake slave cylinder.

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2) Install the oil seal of piston.
① Smear the lithium base glycol grease on the new oil seal of the piston.
② Insert the new oil seal into the brake slave cylinder.
3) Install brake piston.
① Smear the lithium base glycol grease on the brake piston.
② Install the piston into the front disc brake slave cylinder.
Note: Do not forcibly spin the piston into the brake slave cylinder.
4) Install the dustproof cover of brake slave cylinder.
① Smear the lithium base glycol grease on the dustproof cover of the new brake slave cylinder,
and install it into the brake pump. Note: Install the dustproof cover into the groove between the
slave cylinder and piston.
② Install the retaining ring by a screwdriver. Note: Do not damage the dustproof cover of the slave
cylinder.
5) Install the support of left front brake slave cylinder. Tighten the support by 2 bolts. Tightening
torque: 88N·m.
6) Install the dustproof cover of the front disc brake bush.

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① Smear the lithium base glycol grease on the surface of 2 new dustproof covers.
② Install the 2 dustproof covers into the support of front disc brake slave cylinder.
7) Install the sliding pin of the front disc brake slave cylinder.
① Smear the lithium base glycol grease on the sliding part of the 2 sliding pins and the surface of
oil seal.
② Install the 2 sliding pins into the support of the front disc brake slave cylinder.
8) Install the components of brake pad.
Note: The silencer pad must be replaced at the same time while the wear brake pad is replaced.
① Smear grease for disc brake on the two sides of each silencer pad. See Fig. 2-58.

Fig. 2-58
② Install silencer pad on each brake pad.
③ The wear indicator is upwards. Install the inside brake pad, and then the outside.
Note: The friction surface between the brake pad and the brake disc should be free of engine oil
or grease.
9) Install the front disc brake slave cylinder.
① Install the front disc brake slave cylinder by 2 bolts. See Fig. 2-59. Tightening torque: 34N·m.

Fig. 2-59

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② Install the new washer and hose by joint bolt. Tightening torque: 30N·m. Note: Secure the hose
tightly in the locking hole of the brake slave cylinder.
10) Discharge the air in the brake slave cylinder.
11) Discharge the air in the brake pipeline.
12) Check if there is brake fluid leakage.
13) Install the front wheel. Tightening torque: 103N·m.
2. Inspection of rear brake gear
Disassembly Diagram of rear brake gear components.
See Fig. 2-60.

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Fig. 2-60
(1) Disassembly
1) Remove the rear wheel.
2) Discharge the brake fluid.
Note: Do not splash the brake fluid on the paint, otherwise wash it immediately.
3) Dismantle the slave cylinder of the rear disc brake.
① Remove the joint bolt and washer from the slave cylinder of the rear disc brake, and then
disconnect the hose. See Fig. 2-61.

Fig. 2-61

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② Dismantle the 2 bolts after securing the sliding pin of the slave cylinder of the rear disc brake.
See Fig. 2-62.

Fig. 2-62
4) Dismantle the rear brake pad suite.
① Dismantle the brake pad with 2 silencer pads.
② Dismantle No. 1 and No. 2 silence pad from each brake pad.
5) Dismantle the rear brake pad holding piece. Remove the 2 friction pads from the support of the
brake master pump.
6) Remove the sliding pin of the slave cylinder of the rear disc brake. Remove the sliding pin from

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the support of the disc brake master pump.
7) Dismantle the dustproof cover of the rear brake sliding pin. Remove the 2 dustproof covers from
the support of the rear disc brake slave cylinder. See Fig. 2-63.

Fig. 2-63
8) Dismantle the left rear disc brake slave cylinder support. Remove the 2 bolts and then take off
the support.
9) Dismantle the dustproof cover of the brake slave cylinder. Remove the fixing ring and dustproof
cover by a screwdriver. See Fig. 2-64.

Fig. 2-64

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10) Dismantle the air discharging bolt of the rear disc brake gear.
11) Dismantle the piston of the rear brake slave cylinder.
① Place a cloth or equivalent between the slave cylinder and piston.
② Blow out the piston from the brake slave cylinder by compressed air. See Fig. 2-65.

Fig. 2-65
Note: Do not put your hand before the piston when blowing the compressed air. Do not splash the
brake fluid.
12) Remove the oil seal of piston. Take out the oil seal from the slave cylinder. See Fig. 2-66.

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Fig. 2-66
(2) Inspection
1) Check the slave cylinder and piston. Check if the piston is rusty or scratched.
2) Check the thickness of the lining of brake pad. Measure the thickness by a ruler. See Fig. 2-67.
Standard: 10.0mm; min: 1.0mm.

Fig. 2-67
3) Check the sheet steel of the front brake wear indicator. Make sure that the sheet steel is enough
flexible and free of rust, dirt and other foreign material, and has no crack or wear.
4) Check the thickness of the brake disc. Measure the thickness of the brake disc by a micrometer
screw. Standard: 9.0mm; min: 8.0mm.
5) Take off the rear brake disc.
① Mark on the brake disc and wheel hub.
② Take off the brake disc.
6) Install brake disc. Note: Install it through the part with min thickness.
7) Check the brake disc swaying.
① Temporarily tighten the brake disc. Tightening torque: 103N·m.
② Measure the swaying of brake disc at 10mm away from the outer edge of brake disc by a dial
indicator. See Fig. 2-68. Max: 0.05mm.

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 Fig.2-68
③ In case that the swaying of brake disc reaches or exceeds the limit, check the axial clearance of
the bearing and the swaying of wheel hub. If both bearing and hub are normal, adjust the swaying
of brake disc.
(3) Installation
1) Temporarily screw down the air discharging bolt on the rear brake slave cylinder.

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2) Install the oil seal of piston.
① Smear the lithium base glycol grease on the new oil seal of the piston.
② Insert the new oil seal into the brake slave cylinder.
3) Install brake piston.
① Smear the lithium base glycol grease on the brake piston.
② Install the piston into the front disc brake slave cylinder. Note: Do not forcibly spin the piston
into the brake slave cylinder.
4) Install the dustproof cover of brake slave cylinder.
① Smear the lithium base glycol grease on the dustproof cover of the new brake slave cylinder,
and install it into the brake pump. Note: Install the dustproof cover into the groove between the
slave cylinder and piston.
② Install the retaining ring by a screwdriver. Note: Do not damage the dustproof cover of the slave
cylinder.
5) Install the support of left rear brake slave cylinder. Tighten the support by 2 bolts. Tightening
torque: 88N·m.
6) Install the dustproof cover of the rear disc brake bush.
① Smear the lithium base glycol grease on the surface of 2 new dustproof covers.
② Install the 2 dustproof covers into the support of front disc brake slave cylinder.
7) Install the sliding pin of the rear disc brake slave cylinder.
① Smear the lithium base glycol grease on the sliding part of the 2 sliding pins and the surface of
oil seal.
② Install the 2 sliding pins into the support of the front disc brake slave cylinder.
8) Install the rear brake pad holding piece. Remove the 2 holding pieces from the rear disc brake
slave cylinder support.
9) Install the components of brake pad. Note: The silencer pad must be replaced at the same time
while the wear brake pad is replaced.

① Smear grease for disc brake on the two sides of each silencer pad. See Fig. 2-69.

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 Fig. 2-69
② Install silencer pad on each brake pad.
③ The wear indicator is upwards. Install the inside brake pad, and then the outside.
Note: The friction surface between the brake pad and the brake disc should be free of engine oil
or grease.
10) Install the rear disc brake slave cylinder.
① Install the rear disc brake slave cylinder by 2 bolts. See Fig. 2-70. Tightening torque: 34N·m.

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Fig. 2-70
② Install the new washer and hose by joint bolt. Tightening torque: 30N·m. Note: Secure the hose
tightly in the locking hole of the brake slave cylinder.
11) Fill brake fluid into the reservoir.
12) Discharge the air in the brake slave cylinder.
13) Discharge the air in the brake pipeline.
14) Check the brake fluid level in reservoir.
15) Check if there is brake fluid leakage.
16) Install the rear wheel. Tightening torque: 103N·m.
v. Inspection of parking brake system
Parking system as shown in Fig. 2-71

Fig. 2-71
1. Parking brake control lever assembly

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2. Front and rear cables support
3. Parking brake cable

1. Fault elimination
Table 2-5

Fault Possible Cause Action

1. Check the parking cable and

Inactive parking 1. Parking brake cable
adjustment
brake 2. Parking brake control
2. Check the parking brake control
Unreleased parking 1. Parking brake cable 2. Check the parking cable
brake 2. Parking brake control 2. Check the parking brake control
1) Parking brake rod play (maladjusted) Adjust it
2) Parking brake cable (blocked) Adjust it
3) Parking brake shoe clearance
Adjust it
(maladjusted)

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Blocked brake
4) Parking brake lining (cracked or
Replace it if necessary
distorted)
5) Pull-back or tensioned spring
Replace it
(broken)
Table 2-5 indicates the possible causes for faults. The figure indicates the sequence of the
possible faults. Inspect all components in order and replace them if necessary.
2. Adjustment
(1) Remove the rear wheel.
(2) Adjust the brake shoe clearance.
(3) Install the rear wheel. Tightening torque: 103N·m.
(4) Check the parking brake rod play. Hold the rod and count the number of clicks. Parking brake
rod play: 6-9 clicks under 200N force.
(5) Adjust the parking brake rod play. See Fig.2-72.

Fig. 2-72
1) Remove the glove box cover.
2) Rotate the No. 1 adjustment nut cable until the pulling rod play is normal.
3) Install the glove box cover.
3. Accessories of parking brake rod
Disassembly of parts and components as shown in Fig. 2-73

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Fig. 2-73
(1) Removal
1) Remove the trim strip of the instrument cluster and air conditioning control panel as shown in
Fig. 2-74.

Fig. 2-74
1. Trim strip of the instrument cluster
2. Air conditioning control panel
3. Bolt
4. Hand brake cover
5. Auxiliary fascia console sundries box

2) Remove the two bolts of the fixed fascia console and auxiliary fascia console beneath the
position of the air conditioning control panel.
3) Remove bolt 3 (both left and right).
4) Dismantle the floor brake cover.
5) Open the auxiliary fascia console sundries box cover, and dismantle the two bolts at the bottom.
6) Remove the lead of No. 1 adjustment nut.
7) Remove the accessories of the parking brake rod as shown in Fig. 2-75.

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 Fig. 2-75
① Dismantle the connector of the parking brake rod switch.
② Take off the parking brake rod after removing the 2 bolts.
8) Dismantle the parking brake switch components. Remove the bolts and parking brake switch
components.
(2) Installation
1) Install the parking brake switch components.
2) Install the parking brake switch components by bolts.

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① Install the parking brake cable onto the rod and install the lead of No. 1 adjustment nut.
② Tighten the parking brake rod by 2 bolts. Tightening torque: 13N·m.
③ Connect the connector of parking brake switch.
3) Open the auxiliary fascia console sundries box cover, and dismantle the two bolts at the bottom.
4) Dismantle the floor brake cover.
5) Remove and replace bolt 3 (both left and right).
6) Install the two bolts of the fixed fascia console and auxiliary fascia console beneath the air
conditioning control panel.
7) Install the trim strip of the instrument cluster and air conditioning control panel.
8) Check the parking brake rod play.
9) Adjust the parking brake rod play.

4. Accessories of parking brake rod

Disassembly of parts and components (as shown in Fig. 2-76)

Fig. 2-76
(1) Removal
Remove the No. 2 parking brake cable components by the same way with the right side.
1) Remove the trim strip of the instrument cluster and air conditioning control panel.
2) Remove the two bolts of the fixed fascia console and auxiliary fascia console beneath the
position of the air conditioning control panel.
3) Remove and replace the bolt 3 (both left and right)
4) Remove the floor brake cover.
5) Open the auxiliary fascia console sundries box cover, and dismantle the two bolts at the bottom.

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6) Remove the No. 1 adjustment nut lead.
7) Remove the accessories of the parking brake rod as shown in Fig. 2-76.
① Dismantle the connector of the parking brake rod switch.
② Take off the parking brake rod after removing the 2 bolts.
8) Dismantle the parking brake switch components. Remove the bolts and parking brake switch
components.
9) Dismantle the components of the front exhaust pipe.
10) Dismantle the No. 2 front floor heat-insulating pad. Remove the 2 bolts and take off the front
floor hear-insulating pad.
11) Disassemble the No. 3 parking brake cable components.
① Remove the No. 3 parking brake cable from the vehicle body after removing the 4 bolts.
② Remove the cable components after disconnecting the components of No. 3 parking brake
cable from the parking brake balancer.
12) Remove the rear wheel.
13) Remove the accessories of the brake disc.
14) Remove the front brake shoe.

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15) Remove the left rear self-adjusting rod.
16) Remove the rear brake shoe.
17) Remove the components of No. 3 parking brake cable. Disconnect the components of No. 3
parking brake cable from the soleplate after removing the bolts, as shown in Fig. 2-77.

Fig. 2-77

(2) Installation
1) Install components of No. 3 parking brake cable, as shown in Fig. 2-78.

Fig. 2-78

① Connect the components of No. 3 parking brake cable to the balancer.

② Tighten the No. 3 parking brake cable by 4 bolts. Tightening torque: 5.4N·m.
2) Install the components of No. 3 parking brake cable. Tighten the components of No. 3 parking

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brake cable to the soleplate by bolts. Tightening torque: 7.8N·m.
3) Smear the heat-resistant grease.
4) Install the brake shoe.
5) Install the pull-back spring of brake shoe.
6) Install the self-adjusting rod of LR brake.
7) Install the front brake shoe.
8) Inspect the installation of brake disc.
9) Install the accessories of brake disc.
10) Adjust the brake shoe clearance.
11) Install the rear wheel. Tightening torque: 103N·m.
12) Temporarily tighten the adjustment nut lead.
13) Install the No. 2 front floor heat-insulating pad. Tighten the No. 2 front floor heat-insulating pad
by 2 bolts. Tightening torque: 5.5N·m.
14) Install the components of the front exhaust pipe.
15) Install the front floor rod by 2 bolts.
16) Check the parking brake rod play.

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17) Adjust the parking brake rod play.
18) Check if there is air leakage.
19) Install the accessories of auxiliary fascia console sundries box.
20) Install floor shift lever components.
21) Install the auxiliary fascia console.
22) Install the accessories of the auxiliary fascia console.

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 Section IV Fuel System

I. Removal and Installation

1. Operation before removal
① Suck the fuel
② Avoid fuel flowing to the floor
③ Remove the secondary muffler
2. Operation after installation
① Fill fuel
② Confirm if there is fuel leakage
③ Install the secondary muffler
3 .Removal procedures as shown in Fig. 2-79

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Fig. 2-79
1. Components of hose connecting fuel tank and canister 2. Components of fuel tank return pipe
3. Components of fuel tank/filter hose 4. Steel band type flexible ring clamps
5. Fuel filter 6. Fuel pump assembly
7. Oil pump seal 8. Fuel tank assembly
9. Components of right fixing strap of fuel tank 10. Hex bolt with flat washer (40N·m)
11. B-type worm-driven hoop 12. Oil return hose
13. Components of left fixing strap of fuel tank 14. Air return tube mount B
15. Upper components of filler tube 16. Air return tube mount A
17. Snap spring under the oil filler shield 18. Oil filler shield
19. Snap spring above the oil filler shield 20. Components of oil filler cap
21. B-type worm-driven hoop 22. Lower section of filler tube
23. Filler tube lower shield
4. Notes for fuel tank removal
(1) Raise the vehicle by a lifter. Assistant support should be provided when supporting/raising the
fuel tank by a jack to avoid the fuel tank turning over.
(2) Do not attempt to repair a certain section of the rubber tube, but replace the entire tube
instead.

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(3) Cover the accessory and block the hole when the fuel system works to avoid dust and other
dirties entering the fuel system from open pipeline or entries.
(4) Take care to keep all components of fuel system clean.
Note:
(1) Reinstall the 4 M10 fixing bolts used for fuel tank, and tighten them by a tightening torque of
40N·m.
(2) Tighten all the clips and replace them if necessary.
(3) Check and conform all hoses are not circled or damaged during removal and installation.
(4) Open the ignition switch for 2s, and then close it for 10s. Then open it again and check if there
is oil leakage.

II. Electric Fuel Pump

1. Replacement of fuel filter
Removal of fuel filter
(1) Release the pressure of fuel system.
(2) Discharge the extra fuel into a suitable container.

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(3) Dismantle the oil pipelines at the two sides of the fuel filter. Fig. 2-80 shows a fuel filter after
removal.

2. Installation of fuel filter

(1) Remove the shield of the new fuel filter.
(2) Connect the fuel hoses at the two ends of the fuel filter.
(3) Screw down the cap of oil filling pipe of the fuel tank.
(4) Reconnect the battery negative pole cable.
(5) Open the ignition switch for 2s, and then close it for 10s. Then open it again and check if there
is fuel leakage.
Note:
After the high pressure pipe is connected, pull it in negative direction and check if it has been
connected and if there is an about 3mm clearance.

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 Section V Engine Cooling System

Warning:
Do not open the cover of radiator or loose the bolt for drainage when the engine runs or the
radiator is too hot, to avoid serious hurt caused by the boiling coolant and steam. Besides, the
engine and cooling system may also be damaged. Stop the engine and wait till it is cool.
Otherwise, extra care should be taken when you open the cover. Place a thick cloth on the cover,
and rotate it counterclockwise slowly and repeat this operation until the pressure is discharged.
When you ensure there is no pressure, press down the radiator cover by the cloth and then open
it.

I. Maintenance Standards Details

Maintenance standards value refers to the standard valve opening pressure of the radiator cover:
74-103kpa. Limit: 64kpa.

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II. Coolant
The coolant is antifreezer G11 with 8.5 L capacity.

III. On-vehicle Maintenance as Shown in Fig. 2-81.

Fig. 2-81
1. Radiator assembly 2. Hex bolt with flat washer 3. Upper installation support 4. Upper installation bush
5. Lower installation bush 6. Electric fan with a fan cowl 7. Hexagon flange nut
8. Steel band type flexible ring clamps 9. Fuel tank assembly with overflow pipe 10. Bolts with flat washer
11. B-type worm-driven hose hoop 12. Radiator water outlet pipe 13. Radiator water inlet pipe

1. Inspection of the valve opening pressure of the radiator cover

Standard: 74-103kPa
Limit: 64kPa
2. Inspection of coolant
(1) Check if the coolant level is between “F” and “L”;

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(2) Check if the coolant is mixed with engine oil.
3. Replacement of coolant
(1) Dismantle the bolt for drainage and radiator cover in order. Discharge the coolant in the
radiator, warm air blower and engine;
(2) Dismantle the drain valve of the cylinder body, and discharge the coolant in the water-cooled
jacket;
(3) Dismantle the coolant reservoir and discharge the coolant;
(4) After the coolant is discharged, fill water from the radiator cover and clean the coolant pipeline;
(5) Screw down the drain valve of the cylinder body by a specified tightening torque: 40±5N·m.
(6) Confirm that the drain bolt of radiator has been screwed down;
(7) Install coolant reservoir;
(8) Fill the coolant to the radiator opening, and fill coolant into the reservoir to level “F”;
Coolant: antifreezer G11. Total capacity: 8.5L
(9) Install the radiator cover;
(10) Start the engine and warm it up till the thermostat is opened;
(11) Stop the engine after it runs at a high speed for several times;

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(12) When the engine is cool, remove the radiator cover, and then fill the coolant to the water filler
of the radiator. The coolant in reservoir should also reach level “F”.

IV. Water Pump

1. Removal and installation
(1) Clean the foreign materials on the gasket by a scraper or a wire brush.
(2) Operation after installation and before removal:
① Discharge and filling of coolant. Smear sealant smoothly. It is not needed at some place.
② Removal and installation of timing belt cover.
(3) Install the water pump when the sealant is still damp.
Notes for installation:
2. Installation of water pump

V. Water Inlet and Outlet Hose

1. Operation after installation and before removal
(1) Discharge and filling of coolant (refer to related details in this chapter).
(2) Removal and installation of engine cover (refer to related details in this chapter).
(3) Removal and installation of lower housing plate.
(4) Removal and installation of battery and the bracket. To disassemble according to Fig. 2-81.
2. Notes for removal
(1) Disconnect the water inlet pipe and outlet pipe. Make alignment marks on the inlet and outlet
pipes of the radiator.
(2) Removal of water inlet pipe. Remove the installation bolt of the pressurizer tank resonator and
stagger the pressurizer tank resonator.
3. Notes for installation
(1) Firstly moisten the outer and inside installation surface of O ring, and then insert them.
(2) Installation of thermostat assembly (refer to details about engine)
1) Clean the foreign material on the gasket by a scraper or a wire brush.

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2) Smear the specified sealant evenly. Sealant and sealing is not need at some place.
3) Install the thermostat when the sealant is still damp (within 15 min).
(3) Connection of radiator water outlet and inlet pipes
1) Insert the water outlet and inlet pipes into the connectors or projected part of the drain pipe
connector.
2) Install according to the alignment mark on the water inlet pipe and clamp.

VI. Radiator
Removal and installation of radiator
(1) Operation before removal
Discharge the coolant
1) Remove the bolt for drainage and the cover of radiator in order, and then discharge the coolant
in the radiator, warm air blower and engine;
2) Dismantle the drain valve of the cylinder body, and discharge the coolant in the water-cooled
jacket;
3) Dismantle the coolant reservoir and discharge the coolant;

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4) After the coolant is discharged, fill water from the radiator cover and clean the coolant pipeline;
5) Remove the lower housing plate;
6) Remove the air cleaner;
7) Remove the battery and bracket.
(2) Operation after removal:
1) Smear the specified sealant on the screw thread of the drain valve on the cylinder body.
Sealant: Clear out the old sealant before using the new one LT5699. Tightening torque: 40±5N·m
2) Confirm that the bolt for drainage of the radiator cover has been screwed down;
3) Install the coolant reservoir;
4) Fill the coolant to the radiator opening, and fill coolant into the reservoir to level “F”;
Coolant: ShellFreeze Guardd. Total capacity: 7L
5) Install the radiator cover;
6) Start the engine and warm it up till the thermostat is opened;
7) Stop the engine after it runs at a high speed for several times;
8) When the engine is cool, remove the radiator cover, and then fill the coolant to the water filler of
the radiator. The coolant in reservoir should also reach level “F”.
9) ATF supplement and inspection;
10) Install the lower housing plate;
11) Install battery and bracket;
12) Install the air cleaner.
(3) Removal steps (Fig. 2-82)
Removal and installation of electronic fan assembly
Removal of water inlet and outlet pipes of radiator. Firstly make alignment marks on the inlet and
outlet pipes and clamps of radiator.
Notes for installation:
Installation of radiator outlet pipe. Insert the hose into the radiator and the projected part of the
engine according to the alignment mark on the pipe clamp of the radiator.

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 Section VI Intake and Exhaust System

I. Air Cleaner Assembly

Removal and installation (Fig. 2-82 shows the air cleaner assembly of sedan with TRITEC1.6L
engine).
Note: The filter core is made from waste paper and resin. Notes for operation:
① Do not inflict severe collision and load after assembly and removal.
② The core should be well cooperated with the housing below the air cleaner during assembly.

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Fig. 2-82
1. Steel band type flexible ring clamps 2. Crankshaft ventiduct
3. B-type worm-driven hoop 4. Engine intake hose assembly
5. Air cleaner upper cover 6. Air cleaner filter core components
7. Spring clip 8. Air cleaner lower cover
9. Air cleaner assembly 10. Hexagon bolt with flat washer
11. Liner tube 12. Anti-vibration pad
13. Snap button 14. Air cleaner intake pipe assembly
15. Spongy cushion of cavity resonator 16. Hexagon flange bolt
17. Cavity resonator assembly 18. Hexagon flange nut
19. Bearing weldment bolt

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II. Removal and Installation of Exhaust Pipe and Muffler
1. Removal and installation (Fig. 2-83 shows the exhaust system of the TRITEC1.6L engine)

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Fig. 2-83
1. Front floor lower heat-insulating pad of exhaust pipe
2. Dash panel lower heat-insulating pad of exhaust pipe
3. Lower heat-insulating pad 1 of exhaust pipe fuel tank
4. Right rear girder lower heat-insulating pad 1 of exhaust pipe
5. Hexagon bolt with flat washer 6. Hexagon nut with taper washer
7. Heat-insulating anti-vibration pad 8. Rear muffler assembly 1
9. Rear muffler rubber suspension block 2 10. Ball sealed pad 1
11. Compressed spring 2 12. Compressed spring bolt 2
13. Exhaust pipe anti-disconnection bracket 1 14. Exhaust pipe with pre-purifier assembly 1
15. Rubber suspension block 16. Ball sealed pad 1
17. Exhaust pipe assembly 1 18. Hexagon flange nut

1. Warning
Too hot engine and exhaust system may cause severe hurt. Stop the engine until the engine and
exhaust system are cool. And then remove the exhaust system.
1) Disconnect the battery negative pole harness.
2) See Fig. 2-83 for removal order.
3) To install, reverse the removal procedure.

2. Inspection
Start the engine and check if there is leakage in the components of the exhaust system
assemblies. In case of a leakage, repair or replace it as necessary.
Check all components or assemblies. In case of open weld or damage, replace it if necessary.

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