Great Wall Sailor (2006 year). Service Manual — part 28
B0-55
Vehicle Body
Instrument Panel
19. Tear down the instrument panel body;
(a)
Tear down the three screws and the instrument panel.
(b)
Disconnect the plugging elements.
SF:
(a)
Tear down the fixing bolts at the ends of instrument panel
body to pull out the fixed clipes at the front end.
(b)
Disconnect the plugging elements.
SL SK SJ SY
1.
Disconnect the cable of accumulator from the negative
polar (-):
2.
Tear down the steering wheel;
3.
Tear down the combined switch shell cluster;
4.
Tear down the bonnet lock switch;
Tear down the two screws and the sliding fastener of bonnet
lock.
5.
Tear down the lower instrument cover;
6.
Tear down the lower decorative frame of the instrument
panel;
Prize out the decorative frame of instrument with screwdriver
and take it down.
Notice: the screwdriver must be wrapped with adhesive
strap at its head before using.
7.
Tear down the decorative cover of instrument;
(a) Tear down the three screws to pull out the decorative
cover of instrument.
(b) Disconnect the plugging elements.
8.
Tear down the ashtray cluster;
9.
Tear down the central cover;
(a) Tear down the three screws to pull out the central cover;
(b)
Disconnect the plugging elements
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B0-56
Vehicle Body
Instrument Panel
10. Tear down the combination instrument;
(a)
Tear down the four screws;
(b)
Disconnect the plugging elements.
(c)
Tear down the combination instrument.
11. Tear down the CD or combined acoustic device;
(a)
Tear down the four screws;
(b)
Disconnect the aerial cable and the plugging elements;
(c)
Tear down the CD or the combined acoustic device.
12. Tear down the central air tunnel;
Tear down the four screws to take out the central air tunnel.
13. Tear down the air-conditioner controlling panel;
(a)
Pull out the air-conditioner controlling button;
(b)
Prize out the A/C switch;
(c)
Prize out the air-conditioner controlling panel as shown
in the drawing with screwdriver and take it down.
Notice: the screwdriver should be wrapped with adhesive
strap at its head before using.
(d)
Disconnect the plugging elements.
14. Tear down the air-conditioning controlling mechanism
assembly;
Tear down the two screws and let the air-conditioner control-
ling mechanism in suspension.
15. Tear down the lower covering board at right end;
Tear down the four screws and take out the lower covering
board at right end.
16. Tear down the glove box;
Tear down the two screws and the glove box
17. Tear down the instrument body;
(a)
Tear down the three bolts and the instrument panel;
(b)
Disconnect the plugging elements.
Mount of instrument panel
Mount the parts of instrument panel in the reverse
approach.
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B0-57
Safety belt (
)
Element figure
Vehicle Body
Safety Belt
Dr SL SK SF SY SJ
SF rear safety belt
N
m
specified torque
43
43
43
43
43
QP
43
43
front safety belt
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B0-58
Safety belt (
)
Element figure
Vehicle Body
Safety Belt
QP
43
QP
43
43
43
43
safety belt in
SY model
vehicle
43
safety belt in SJ
model vehicle
N
m
specified torque
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B0-59
Body
Safety Belt
Safety belt
1. Driving test (in the security place);
(a)
Fix the safety belt of the front seat.
(b)
Drive the vehicle at the speed of 16 km/h and brake it
suddenly;
(c)
Check the safety belt, which should be lock tightly
without expansion.
Remark: it is required to tear down the mechanism
fittings of the safety belt to make the following static load
test at the security place, in addition, moderate inspection
for the new safety belt should be conducted before
mounting no matter when the new safety belt fittings is
needed to mount.
2.
Static test
a) Tear down the lock-type expansion fittings;
(b)
Tilt the expansion fittings slowly;
(c)
Check the expansion of safety belt, which should be
pulled out when the tilt angle is no more than 15 but not
be pulled out when the tilt angle is more than 45
.
If the requirement is not met, change the safety belt fittings.
Two-point safety belt
(manually operated)
(a)
Adjust the safety belt to the moderate length;
(b)
Exert the stable load on the belt;
(c)
Check whether the safety belt is elongated or not, in such
case, the belt should not be elongated.
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B0-60
Seat (
)
Element figure
Vehicle Body
Seat
Dr SL SK SF SY SJ
front seat
seat in SY
model vehicle
N
m
specified torque
37
37
37
37
18
18
18
18
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B0-61
Safety belt (
)
Element figure
Vehicle Body
Safety Belt
Dr rear seat
SL rear seat
N
m
specified torque
18
18
18
18
18
SY small seat
18
18
18
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B0-62
Seat (
)
Element figure
Body
Seat
SF rear seat
18
18
18
18
18
18
18
SJ rear seat
N
m
specified torque
18
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B0-63
Spoiler (
)
Element figure
Vehicle Body
Spoiler
Dismantle of Spoiler
1.
Tear down the spoiler assembly;
(a)
Tear down the four bolts and the spoiler;
(b)
Tear down the three bolts and the spoiler supporter.
2.
Tear down the wire harness of highly-mounted stop-
grade lamp and take it down;
Mount of spoiler
Mount the spoiler in the reverse approach.
SF
spoiler
spoiler supporter
highly mounted stop-grade lamp
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B0-64
Spoiler (
)
Element figure
Vehicle Body
Spoiler
Spoiler disassembly
1.
Tear down the highly-mounted stop-grade lamp;
(a)
Tear down the two screws and disconnect the wire harness
from lamp.
(b)
Tear down the highly-mounted stop lamp from the spoiler.
2.
Tear down the spoiler assembly
(a)
Tear down the rear beam trim panel from the inside of body.
(b)
Tear down the four nuts and disconnect the wire harness
from the spoiler;
(c)
Tear down the spoiler assembly and spoiler gasket from the
outside.
SJ
(a)
Open the two covers of round hole at the top-grade of
spoiler;
(b)
Tear down the two bolts and disconnect the wire harness
from the spoiler.
(c)
Tear down the spoiler assembly and spoiler gasket from the
outside.
Mount of Spoiler
Mount the spoiler in the reverse approach.
SY SJ
spoiler gasket
nut
highly mounted
stop lamp
spoiler
assembly
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B0-65
Luggage rack
Element figure
Vehicle Body
Luggage Rack
bracket fastening
button
main sill
SF SY
antiskid strip
beam
blanking plug of
main sill
adjusting button of antiskid strip
fixed bracket
mounting plate of outer
luggage rack
adhesive strip of mounting plate
luggage rack assembly
SJ
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B0-66
Body
Reserve Tire Bracket
Reserve tire bracket (
)
Element figure
reserve tire holder
buffer block bracket
buffer block
lock clip bracket
assembly
return spring
reserve tire bracket
adjusting arm
reserve tire lock
90
SY
specified torque
reserve tire bracket
reserve tire holder
reserve tire lock
lock clip bracket assembly
adjusting arm
SJ
90
K
N
m
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B0-67
Vehicle Body
Reserve Tire Bracket
Reserve tire bracket (
)
Element figure
buffer block
springy welt
trim cover of fixed bracket
decorative cover of screw hole
reserve tire bracket
nut
SF
Dismantle of reserve tire bracket
1.
Tear down the trim cover of fixed bracket;
Tear down the decorative cover of screw hole, and then tear down the
trim cover of fixed bracket.
Tear down the adjusting arm (SY SJ)
Tear down the two bolts to take down the adjusting arm;
2.
Tear down the reserve tire bracket;
Tear down the three bolts and take down the reserve tire bracket. (SF)
Tear down the three bolts and take down the reserve tire bracket. (SY
SJ)
Mount of reserve tire bracket
1.
Mount the reserve tire bracket;
(a)
Stick the springy welt on the corresponding face where the
reserve tire bracket contact with the body; (SF)
(b)
Fix the reserve tire bracket on the body with eight bolts (SF).
Fix the reserve tire bracket with three bolts on the right mail sill
and tail beam of the body.
2.
Mount the trim cover of fixed bracket;
Mount the trim cover of fixed bracket and the decorative cover of
screw hole.
Mount the adjusting arm (SY SJ)
Fix the adjusting arm on the tail beam bracket of the body by screwing
the two bolts in the fixing hole.
Notice: the paint layer should be well protected during
disassembling and assembling.
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B0-68
Vehicle Body
Body Dimension
Body Dimension
Large lamp seat (
)
SF
(point Size in 3D)
Dr
(point Size in 3D)
Mark
Name
Bore diameter
Mark
Name
Bore diameter
A,a
Radiator mounting hole
M8
B,b
Radiator mounting hole
M8
C,c
Cab mounting hole
10 20
A
B
b
a
603
`
c
573
573
A
B
a
b
c
C
573
573
623
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B0-69
Body Dimension
Large lamp seat (
)
Vehicle Body
Body Dimension
SL SY
(point Size in 3D)
SK SJ
(point Size in 3D)
Mark
Name
Bore diameter
Mark
Name
Bore diameter
A,a
Radiator mounting hole
F,f
Mounting hole of median mesh
B,b
Fixing bolts of front bar
G,g
Vertical projection spot of lower
beam of radiator
C,c
Fixing bolts of front bar
D,d
Radiator mounting hole
E,e
Cab mounting hole
A
B
b
a
C
c
802
d
e
D
E
969
1406
633
B
b
E
F,f
G,g
799
465
e
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B0-70
Body Dimension
Engine Room (
)
Vehicle Body
Body Dimension
Dr SF
(point size in 3D)
SL SY
(point size in 3D)
Mark
Name
Bore diameter
Mark
Name
Bore diameter
H,h
Front locating hole of mudguard
M8
M,m
Locating hole of upper part of
front wall
7
I,i
Hole of fixing nut of large lamp
M8
N,n
First mounting hole of wing panel
J,j
Front locating hole of mudguard
M6
K,k
First mounting hole of engine cover
M6
L,l
First mounting hole of wing panel
10
Remark: the deviation
in length of diagonal
line of engine room
should not be more than
4 mm.
J
K
L
I
H
j
k
l
á
h
1005
1268
582
384
M
N
m
n
728
728
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