Great Wall. Service manual for chassis and body (2006) — page 2

IN-2

How to use this manual

In order to help you to look in this manual, we marked the chapter

name and main theme at the top of each page.

In order to introduce the repairing items to you, we make the

index

on

the first page of each chapter, and

notices

need to be taken during all

repairing operation are also given in the related chapter.

Please read these notices carefully before the repairing work.

The troubleshooting form for each system will help you to diagnose

the system trouble and its cause.

We furnish with the repairing approaches for each possible cause in

the repairing approach column, which will help you to acquire the

solution in a short time.

Introduction

How to Use This Manual

Repairing approach

Most repairing operation can begin with referring to these illustrations.

These illustrations can help you identify the parts and their coordina-

tion situation

Example

snapping ring

front minor half-shaft

front speed reducer

and differential

oil seal-front semi-axle

front long

semi-axis

snapping ring

88

N*m

specified torque

Parts that cannot be reused after being used

IN-3

Introduction

How to Use This Manual

Introductionóhow to use this manual

The repairing approaches are described step by step:

The illustrations show you what to do and at which position.

The theme of repairing operation tell you what you need to do.

The detailed instruction show you how to accomplish the repairing and

introduce to you other related affairs, such as specification, warning etc.

Example:

Check and adjust the flange bounce

(a) Attach the dial indicator seat to the reducer housing, and touch the

flange face with the measuring head of dial indicator, run the flange

and observe the pendular range of the indicator carefully.

Full bounce tolerance of face : 0.10mm

Illustration:

what to do and at which position

Specification

This formula can help the experienced technicians find out the failure

causes in short time. Overhauling staff can browse the operation theme

and refer to the detailed description thereunder where necessary; impor-

tant specifications and warnings are written out in boldface.

Specification

The corresponding specifications are given in boldface in each repairing

approach of this manual, which allows the overhauling staff to check the

specification while keeping on repairing work.

Warning, Notice and Remark

Warning written out in boldface means there is possibility of self-

injury or harm to others.

Notice written out in boldface means there is possibility of damage

to parts under repairing.

Remarks singled out independently, but not in boldface, serve as

supplementary descriptions to help you accomplish the work more

efficiently.

Vehicle Code

There are six vehicle models in this manual, the model codes are as follows:

Deer model

Dr

Sailor model

SL

SO COOL model

SK

Safe model

SF

Sing model

SY

PEGASUS model

SJ

Abbreviation used in this manual

A/C

air-conditioner

ECU

electronic controller unit

SST

special service tool

2WD

two-wheel drive

4WD

four-wheel drive

PMãã

Topic:what to do ?

Detailed introductionz;How to do?

IN-4

Overall Repairing Description

1. Keep the vehicle clean and prevent it from

damage with guard plate, seat and floor cover

cloth.

2. Put down the dismantled parts in order during

the dismantle process so as to facilitate the re-

assembly

3. Observe the following items:

a) Disconnect the cable cathode from the

accumulator terminal before the electric

operation;.

b) Disconnect the cable from the cathode

connected to the vehicle body when check-

ing or repairing the accumulator where

necessary.

c) In order to avoid the damage of terminal

post of accumulator, loose the bolts first,

then pull up the cable vertically when

dismantling, don

t wring it or prize it.

d) Clean the terminal posts of the accumula-

tor with dishcloth, and do not scrape them

with file or other similar tools to avoid

damage.

e) Mount the cable terminal on the post with loosened nut, then

fasten the nut. donít tap the terminal onto the post with

hammer.

f) Be sure to check whether the cover of positive terminal (+) is

well located or not.

4. Check all hoses and wire plugs to verify whether they are

connected solidly and correctly.

5. Parts that cannot be reused after being used.

a) The following parts should be changed with new one regularly:

split pin, sealing washer, O-ring and oil seal, etc.

b) parts that cannot be reused after being used is marked with

in the element figure.

6. Pre-coated parts

The pre-coated parts including the bolt and nut are coated with

locking seal glue in factory.

a) In case the pre-coated parts are moved due to its fastening,

loosening or other causes, they must be coated again with the

specified seal glue.

b) Coating procedure of pre-coated parts

1) Clear away the former seal glue from the screw thread of

the said parts.

2) Dry the parts with compressed air.

3) Coat the screw thread of the parts with the specified

locking seal glue.

c) The pre-coated parts are marked with the

in element

figure.

7. When necessary, sealing agent or sealing ring to prevent the

leakage.

8. Each specification shall be followed strictly. And the torque

spanners should be used.

9. Determine the necessity of using the special service tools (SST)

or special service materials (SSM) according to the real situation.

SST and SSM must be used where necessary and the repairing

should be in accordance with the repairing approach. SST list

and SSM list are attached to this manual.

10. Be sure to check whether the rated current of the new fuse is

correct when changing the fuse. The fuse rated current should

not larger than that of securing fitting and the fuse of smaller

rated current must not be used.

11. Be careful to hang or support the vehicle on the suitable place

when propping up or raising it.

a) In case prop up the vehicle at the front or back part, the wheels

must be blocked to guarantee the safety work.

Introduction

Overall Repairing Rescription

tighten seal glue

IN-5

Body lifting height and supporting position

wrong

correct

Introduction

Body Lifting Height and Supporting Position

Jack lifting position

. . . . . . . . . . . . . . . . . . . . . . . . . . ...

Front. ..the front the beam center

Rear. .rear differential

Supporting position

safety bracket . . . . . . . . . . . . . . . . . . . . . . . .

front

123456

123456

123456

123456

123456

12345

12345

12345

12345

b) The raised vehicle must be supported with the bracket; it is

dangerous to conduct the repairing work on the vehicle propped

up with one jack, even though such repairing can be finished in

short time.

12. The following items shall be taken notice to avoid the parts damage:

a) Do not open the covers of ECU and various computers where not

necessary absolutely. (if the IC terminal is touched, it be leaded

into static damage) .

b) Pull the hose at its ends when dismantling it, do not pull it at the

center section.

c) Pull the wire joint instead of the wire when pulling the joint

away.

d) Take notice to avoid of the drop of electric parts such as the

sensors or repeaters. In case those parts drop to the hard ground,

they must be changed instead of being reused.

e) Do not use the striking spanner to dismantle or mount the

thermostatic switch or thermostatic sensor.

f) Plug the needles of the multi-meter into the wire connector

carefully when checking its conductance and do not bend the

terminals.

g) Do not sheath the hose of the vacuum gauge into the very large

connector when using the gauge, instead, the stage joint shall be

used because once the hose expands, it is possible to lead into

the leakage.

SA-95

Rear Differential

Element Figure

half axle gear
thrust gasket

differential housing

pin

planetary
gear shaft

planetary gear
stop gasket

half-axle gear

planetary gear

1.

Tear down the speed reducer and the differential

assembly.

2.

Tear down the differential from the speed reducer and

differential assembly.

Change of Differential Parts

1.

Disassembly of Differential

(a)

Tap out the pin with hammer and pinch.

Suspension System and Automobile Axle (Rear)

Rear differential

(b)

Tear down the planetary gear shaft, the planetary gear,

planetary gear stop gasket, half-shaft gear and half axle

gear thrust gasket.

SA-96

2.

Assembly of Differential

(a)

Put the half-axle gear thrust gasket on the half-axle gear

and then encase them in the differential housing.

(b)

Encase the planetary gear stop gasket, planetary gear and

encase the planetary gear shaft.

(c)

Check the clearance between the half-axle gear thrust

gasket and the differential housing.

Remark: the half-axle gear and the planetary gear should run

freely without stagnant, push the planetary gear inside, then

measure the clearance between the half-axle gear thrust gasket

and the differential housing with dial indicating lamp.

Reasonable clearance range: (0.45-0.75)mm.

Remark: if the clearance value fails to fall within the above

range, change the half axle gear thrust gasket, at the same time,

ensure the left and right half axle gear thrust gasket are same

in thickness.

(d)

Tap the pin in the pinhole, and rivet the end of the pinhole

so as to prevent from the pin missing.

Mount of Differential

1.

Encase the differential assembly in the speed reducer

housing.

2.

Mount the speed reducer and differential.

Suspension System and Automobile Axle (Rear)

Rear differential

SA-97

Suspension System and Vehicle Axle

Rear Suspension (Leaf Spring Type)

Rear suspension(leaf spring)

Leaf spring and shock absorber

N

m

specified torque

90

10

110

10

liner

rront ear pin

rear ear pin

liner

u-shaped bolt

spring seat

90

10

Dismantle of leaf spring and vibration

damper

1.

Raise the vehicle body with a jack and support it with a

bracket;

(a)

Raise the vehicle body with a jack and support it with a

bracket;

(b)

Lower the axle housing until the leaf spring is loosened

to the degree there is no tension existing. Keep the leaf

spring in such status.

2.

Tear down the vibration damper.