Great Wall. Service manual for chassis and body (2006) — page 22

BE-17

Body Electric System

Starting System

Starting system

The starter, powered by the accumulator, is driven by the direct current motor and is in normal operation through

the drive device and control mechanism.

fuse

ignition switch

ACC ON ST

4

5

3

2

5

3

1

4

starter

SL SK SY SJ

Dr SF

4

3

2

1

8

7

6

5

5

4

3

2

1

10

9

7

6

8

Vehicle models in the parenthesis belong to the Dr SF model.

battery

BE-18

Parts inspection

Body Electric System

Starting System

Ignition switch

Check the conductance situation of the switch

Remark: in case the conductance fails to satisfy the specified requirement, change the switch.

LOCK

ACC

ON

START

4

3

2

1

8

7

6

5

R

Q

P

O

N

U

T

V

NM

aê=pc

pi=ph=pv=pg

5/10

R

4

3

2

9

G

W

R/W

Y

R

G

W

R/W

terminal

switch position

LOCK

ACC

ON

START

4

1

5

3

B

Bl

B/Y W/Bl

SLdiesel SYdiesel

OFF

LOCK

ACC

ON

START

terminal

switch position

4

1

5

3

LOCK

ACC

ON

START

ACC

terminal

switch position

LOCK

ON

START

4

3

2

1

8

7

6

5

BE-19

Body Electric System

Lighting System

Lighting system

The lighting system includes the front combination lamp, rear combination lamp, fog lamp, inside lamp, instrument

lighting lamp, air-conditioner panel lighting lamp and various signal indicating lamps. The small lamps shown in the

small lamp system drawing include the instrument lighting lamp, air-conditioner panel lighting lamp, fog lamp, license

lamp and ashtray lighting lamp.

Upper/lower beam lighting system

Dr SF

fuse

3

3

10

17

1

1

light

surpass vehicle

low beam

high beam

small light

headlamp

combined switch

1

2

3

4

5

6

7

14

13

12

11

10

9

8

21

20

19

18

17

16

15

The vehicle model in the parenthesis belongs to Dr model.

battery

fuse

passing-light headlamp

upper beam indicating

lamp

main-beam headlamp

large lamp relay

large lamp switch

BE-20

Body Electric System

Lighting System

Upper/lower beam lighting system (continued)

SL SK SY SJ

frse

connecting to combination instrument

lower beam

upper beam

10

8

7

T

small lamp

head lamp

N

combined switch

8

7

6

5

NS

15

14

13

12

11

10

9

4

3

2

1

battery

upper beam indicating lamp

large lamp relay

head lamp switch

out-drive

frse

BE-21

Body Electric System - Lighting System

Small lamp, steering and alarming system

Small lamp system

Dr

fuse

small lamp switch

10

ON

OFF

8

front small lamp

ear small lampv

license lamp

receiver lighting lamp

air-conditioner panel lamp

alarming switch lamp

fog lamp switch

ON

OFF

1

3

fog lamp indicating

lamp

left rear fog lam

right rear fog lamp

combined switch

fog-lamp switch lamp

1

2

3

1

2

3

4

8

9

10

11

18

17

16

15

5

6

7

14

13

12

21

20

19

battery

small lamp relay

fog lamp relay

fuse

instrument lighting system

B0-26

Wheel-trims wrapping angle and exterior trim panel (

)

Element mounting position

Vehicle Body

Wheel-Trims Wrapping Angle and Exterior Trim Panel

adhesive strip of wheel-trims

front wheel-trims

rear wheel-trims

front wrapping angle

rear wrapping angle

SY

B0-27

Wheel-trims wrapping angle and exterior trim panel (

)

Element mounting position

Vehicle Body

Wheel-Trims Wrapping Angle and Exterior Trim Panel

trim panel at front door

front wheel-trims

rear wheel-trims

front wrapping angle

rear wrapping angle

Top-grade SY

trim panel at rear door

luminous channel

B0-28

Wheel-trims wrapping angle and exterior trim panel (

)

Element mounting position

Vehicle Body

Wheel-Trims Wrapping Angle and Exterior Trim Panel

front wheel-trims

rear wheel-trims

front wrapping angle

rear wrapping angle

SJ

rim panel at rear door

trim panel at front door

B0-29

SJ

SJ

SJ

Vehicle Body

Wheel-Trims Wrapping Angle and Exterior Trim Panel

Change of trim panel at front door

1.

Tear down the trim panel at front door;

Prize up the clip of trim panel at front door and take down the

trim panel at front door. (SJ)

Uncover the luminous strip to tear down the five screws, then

open the front door and take down the trim panel at front door

after tearing down the five screws. (top-grade SY)

Change of front wrapping angle

1.

Tear down the front wrapping angle;

Tear down the three screws and take down the front wrapping

angle and adhesive strip of wrapping angle lightly (there is two

screws in top-grade SY vehicle)

2. Mount the front wrapping angle

(a)

Mount on the three screws (mount two screws for top-

grade SY vehicle)

(b)

Contact the front wrapping angle with the front bar

closely, and the seam between the front wrapping angle

and the front Wheel-trims should be even with a smooth

transmission (by the way, the adhesive strip of wrapping

angle should be pressed tightly and evenly)

Change of front Wheel-trims

1.

Tear down the front Wheel-trims

Tear down the four screws and the pressing plate of mudguard,

and take down the front Wheel-trims and adhesive strip of

Wheel-trims tightly (SY)

Tear down the five screws and the pressing plate of mudguard,

and take down the front Wheel-trims and adhesive strip of

Wheel-trims tightly (SJ)

Tear down the four screws and uncover the lighting channel of

the front Wheel-trims, take down the front Wheel-trims after

tearing down one screw (top-grade SY).

2.

Mount the front Wheel-trims

(a)

Flush the front end of front Wheel-trims with the lower

edge of wing panel; the adhesive strip of wheel-trims

should be pressed tightly and evenly. (SY)

Flush the front end of front Wheel-trims with the lower

edge of wing panel, the rear end of front Wheel-trims

with rear edge of wing panel. (top-grade SY SJ)

(b)

Mount the four screws (five screws for SJ model) and the

pressing plate of mud guard and stick the lighting strip.

(top-grade SY)

B0-30

Top-grade

SY

SJ

SJ

Top-grade

SY

Vehicle Body

Wheel-Trims Wrapping Angle and Exterior Trim Panel

2.

Mount the trim panel at front door;

(a)

Flush the arc lines of the front and rear ends of trim panel

at front door in consistent with the door waist line, and the

rear end should flush with the rear end of front door, but

the front end should not interfere with the wing panel.

(b)

Tap the positions of six clipes of trim panel at front door

manually to mount it on.(SJ)

Mount the five screws at upper part after aligning the

holes, and mount the five screws at lower part from the

inside, then stick the luminous strip. (top-grade SY)

Change of rear Wheel-trims

1.

Tear down the rear Wheel-trims;

Tear down the three screws and take down the rear Wheel-

trims and the adhesive strip of Wheel-trims. (SY)

Take down the rear Wheel-trims after tearing down the three

screws. (SJ)

Tear down the three screws and uncover the luminous strip on

rear Wheel-trims, take down the rear Wheel-trims after tearing

down the two screws. (top-grade SY)

Change of trim panel at rear door

1.

Tear down the trim panel at rear door

Take down the trim panel at rear door after tearing down one

screw and four clipes. (SJ)

Uncover the luminous strip to tear down the four screws, and

then open the rear door to tear down the four screws inside so

as to take down the trim panel at rear door. (top-grade SY)

Top-grade SY

2.

Mount the trim panel at rear door

Tap the positions of four clipes of trim panel at rear door

manually to mount it on, meanwhile mount the one screw at

upper part of rear edge. (SJ)

Mount the four screws at upper part after aligning the holes,

and mount the four screws at lower part from the inside, then

stick the luminous strip. (top-grade SY)

2.

Mount the front Wheel-trims

(a)

Flush the front end of rear Wheel-trims with the edge line

of rear door, the rear end of the Wheel-trims with the rear

wrapping angle, the seam should be smooth with even

transmission. (top-grade SY SJ)

(b)

Mount the three screws (and mount two screws at the

position where the luminous strip is stickled).

B0-31

Top-grade

SY

Vehicle Body

Wheel-Trims Wrapping Angle and Exterior Trim Panel

Change of rear wrapping angle

1.

Tear down the rear wrapping angle;

Tear down the three nuts, one screw and one self-drilling

screw, and then take down the rear wrapping angle, the rear

mudguard and the adhesive strip. (SY)

Tear down the four screws and then take down the rear small

Wheel-trims. (SJ)

Tear down one screw and three bolts to take down the rear

wrapping angle (top-grade SY)

2.

Mount the rear wrapping angle

(a)

Parallel the rear wrapping angle with the body waist line,

and contact the body with rear bar closely. (the adhesive

strip of wheel trims of SY model vehicle should be

pressed tightly and evenly)

(b)

Mount two bolts through the body bracket, wrapping

angle and mudguard, and another bolts should be mounted

to connect the rear bar bracket and the wrapping angle.

Then mount on one screw and one self-drilling screw.

(SY)

Flush the rear small Wheel-trims and the rear Wheel-

trims, then mount on the four screws (SJ)

Mount on one screw and the other three bolts through the

body bracket, rear bar and wrapping angle. (top-grade

SY)

Notice: the parts mentioned above should be carefully

disassemble or assemble to avoid of paint face scrape

B0-32

Front Windshield (

)

Element mounting position

Vehicle Body

Front Windshield

wiper arm

luminous strip

front ventilating cover board

front windshield

sealing strip of front windshield

Dr

front windshield

wiper arm

luminous strip

front ventilating cover board

SF

B0-33

Front windshield (

)

Element mounting position

Vehicle

Body

Front Windshield

Dismantle of front windshield

1.

Tear down the following parts:

(a)

The wiper arm;

(b)

The front ventilating cover board;

2.

Tear down the front windshield;

(a)

Use the screwdriver to prize the sealing element from the

body.

Notice: be careful not to damage the paint on body.

sealing strip

wiper arm

front ventilating cover board

front windshield

upper trim strip of windshield

right trim strip of

windshield

left trim strip of windshield

SL SK SY SJ

ower limit stop-grade

vehicle
body

B0-34

Vehicle Body

Front Windshield

(a)

Prize the lips of sealing strip from the inside of body

flange outwardly;

(b)

Pull out the glass to take it down together with the

sealing strip.

(c)

Take out the glass from the sealing strip.

sealing strip

In case new sealing strip is used:

(a)

Prize the lips of the sealing strip from the inside of body

flange outwardly;

(b)

Pull out the glass to take it down;

(c)

Tear down the old sealing strip.

Notice: be careful not to damage the body and glass.

Cut a small open in the sealing agent between the glass and the

vehicle body, then insert a steel wire in the open to pull is to and

fro slowly until the sealing agent is separated completely, then

pull out the glass to take it down.

Notice: be careful not to damage the body and glass.

Mount of front windshield

1.

Clean the body frame and the glass.

Clear away the sealing agent on the body surface completely,

then clean the contacting face of body and glass with cleaning

materials.

2.

Clean the sealing strip;

Clean the sealing strip surface with cleaning materials.

3.

Encase the front windshield in the sealing strip (Dr)

(a)

Coat the silicon oil around the glass, and mount the

adhesive strip on the glass according to the glass shape.

Notice: if the adhesive is stiffening or deforming, it may

result the water leakage, therefore, change with the

new one where possibly.

(b)

Mount a rope alongside the sealing strip groove as

shown in the drawing for operation,(fasten the rope

inside of the adhesive strip, rope diameter:

=4mm)

B0-35

Vehicle Body

Front Windshield

4.

Mount of front windshield.

Dr

(a)

Lay the ready glass against the corresponding position of front

windshield opens.

(b)

Pull the rope from the inside of body to encase the roof, the front

column and the door frame within the adhesive strip, meanwhile

push the outside of the glass by hand.

(c)

Tap the four edges of the adhesive strip to ensure that the

adhesive strip contact closely with the body windshield opened.

(d) Coat the glue from left to right at the upper part of windshield

(location between the adhesive strip and the body windshield open)

and the lower part of windshield (location between the adhesive

strip and glass), and the remaining glue should be cleared away with

abrasive paper, and the location should be cleaned with cloth.

Notice: there should no breakage at the sealing glue seam

when coating the glue.

SL SK SF SY SJ

(a)

Suck the front windshield with two sucking discs and put the

glass on the worktable in reverse dirdction.

(b)

Seize the upper trim strip of front windshield at the position of

upper glass edge.

(c)

Coat the cleaning active agent on the inside edges around the

front windshield (the black glass edges), airing for 3~5 min, then

coat the priming paint on the layer of cleaning active agent, and

airing for 5 to 30 min, finally coat the sealing agent.

Notice: no breakage should be allowable at the sealing glue

seam when coating.

Recommended sealing agent for use:

(SF)

Glass glue

TS-100 PVC windshield glue

Priming paint

TS-5028

Cleaning active agent

TS-7016

(SL SK SY SJ)

Glass glue

TEROSTAT-8590 windshield glue

Priming paint

TEROSTAT-8511

(d)

Clean the body windshield open completely with cotton cloth to

coat the priming glue, airing for 5 min or so, and then stick the

front windshield to the windshield open.

(e)

Fix the left/right trim strip of front windshield at the edges of

windshield open.

(f)

Fix the lower trip strip of front windshield with screw at the

clipes of lower glass edge. (SF)

(g)

Stick the upper edge of front windshield to the body with

transparent adhesive strip so as to prevent the glass from lowering.

B0-36

Vehicle Body

Front Windshield

Notice:

(a)

Clear away the redundant glue from the body

completely.

(b)

The vehicle should not be driven after 4 hours in

summer and 8 hours in winter under common

circumstances.

5.

Mount the following parts:

(a)

Front ventilating cover board;

(b)

Wiper arm.

6.

Check whether there is leakage and the leakage repara-

tion

(a)

Conduct the leakage test.

(b)

Seal the leaking parts with vehicle glass glue.