Great Wall V200. Service Manual — part 2
Overview of the entire car-11
4.7 Cigar
lighter
12V,
1
piece
4.8
Horn
Treble and bass
4.9
Safety airbag
Electric main and auxiliary airbag
Checking and commissioning of the auxiliary components of car body:
1. Stop the car stably, check the doors, engine cover, fuel filling port cover, meter and tools box cover, front and rear ash
tray cover, floor center console sundries box cover, CD disc conveyer (VCD disc conveyer), power socket cover, etc. they
shall be reliable and flexible during starting, opening and closing, without blocking and insufficient closing and
abnormal sound;
2. The major lamp high beam and city beam, the alternating light, taillight, turn light, brake light, front and rear mist
light, malfunction alarm light, indoor light, instrument panel light, ignition switch light, etc. shall operate normally,
without the failure of no lighting,constant lighting and error lighting , etc;
3. Checking the performance of front head light
a. The high beam luminous intensity of each head light
20000 cd/ piece
b. Beam center left and right deviation (when the beam is irradiating on the screen of 10 m away):
Left light high beam: left 17 cm right 35 cm
Right light high beam: left 35 cm right 35 cm
Left light city beam: left 17 cm right 35 cm
Right light city beam: left 17 cm right 35 cm
c. Beam center height (when the beam is irradiating on the screen of 10 m away):
Head light city beam 0.7
0.9 H; head light high beam 0.9
1.0 H
H means the head light center height 920
20mm.
4. The adjustment of multi functional meter:
a. Drive the car onto the trench, insert the car speed transducer, drive the car to open places, press the ADJ switch for no less than
3 seconds, the orientation indicator begins to flash. Drive the car slowly for one circle within 2 minutes, the orientation
indicator will stop flashing, it shall points to the practical normal direction.
Note: E
east, W
west, S
south, N
north.
b. The adjustment of time:
Press the “MODE” switch for over 2 seconds, the time can be adjusted, press the MODE switch to adjust the minute, then
press the MODE again to adjust the hour, adjust the time through pressing the “
”and “
” key. After the time is adjusted,
press the ”MODE” switch for over 2 seconds to quit the time adjustment mode.
c. Check to see whether the absolute altitude meter and the car speed response display are working normally.
d. Drive the car onto the trench again, pull off the car speed transducer plug.
5. The adjustment of rain wiper nozzle cleaning mixture ejection height:
a. Put the ignition switch to the ”ON” position, open the rain wiper nozzle switch, the position of front cleaning mixture nozzle
shall be evenly distributed along the middle height of the front windshield glass from left to right.
b. The position of the rear cleaning mixture nozzle is deviated to right of the center of rear windshield glass for about 20mm-
120mm, and the height is within the scope of 50mm at the center of the glass. If the deviation is large, the nozzle needs to be
adjusted.
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Air-conditioning system
The structure and parameter of the air-conditioning system is shown in table 8.
Table 8 The structure and parameter of the air-conditioning system
Serial No.
Item
Structure and Parameter
1
Structure and
shape
Front and rear heating and cooling air conditioner, vapor compression type
cooling, hot-water heating
2
Performance and
parameters
Refrigerating capacity 3.5kW, heat exchange capacity 3.5kW, fan capacity
350m
3
/h
3
Operation
Control board button type operation, temperature auto control, air door micro
motor drive, the temperature in the car can be controlled automatically, the
fanning position mode, heating/cooling mode, air intern/external cycling mode
and wind speed and temperature can be selected and adjusted
4
Refrigerant
R134a
5
Compressor
SD7V16 variable capacity compressor, with a maximum capacity of 160ml
6
Condenser
Parallel stream mode structure, flat pipe thickness of 26mm
7
Evaporator
Two boxes structure, cascading evaporator, F expansion valve, centrifugal
blower
8
Drying fluid
collector
External diameter φ60.5mm
9
Refrigerating
pipe and
warm water pipe
Refrigerating pipe: complex structure of rubber refrigeration soft tube and
aluminum tube. The warm water pipe: rubber molding pipe
10 Transducer
Outdoor temperature sensor, indoor temperature sensor, evaporator temperature
sensor
11
pressure switch
Three-state pressure switch
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Chapter 2
Fuel supply system and exhaust system
Fuel supply system :
Disassembly of the fuel tank . . . . . . . . . . . . . . . . . . 3
Installation and disassembly of the Fuel pump . . . . . . . . . . . ..4
Disassembly of the components of fuel supply system. . . . . . . . ...4
Disassembly and adjustment of the accelerator pedal operating system . . 5
Exhaust system :
Disassembly of the blast pipe assembly. . . . . . . . . . . . . . .8
Installation of the blast pipe assembly. . . . . . . . . . . . . . . 9
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Fuel supply system
N
m: specified torque
adjustment nut
throttle pull wire
accelerator pedal assembly
carbon tank exhaust rubber tube
snap fitting
steel strip type elastic hoop
generator oil-in rubber tube
generator of return rubber tube
soft tube fixing clipper
carbon
tank
carbon tank
air inlet
rubber tube
b type
worm drive
type hoop
vaporizer tube 2
back part of fuel tank
oil-out tube
back part of fuel tank
oil return tube
fuel filter
filter rubber tube
for gas out
hard tube bracket
vaporizer soft tube 2
cleaner bracket
filter rubber
tube for gas-in
fuel tank vaporizer
rubber tube
front part of the oil-out
tube of fuel tank
vaporizer soft
tube1
vaporizer tube1
fuel tank gland
the middle connection rubber
tube of the oil return tube
front taps of fuel tank
fuel pump
fuel tank gland
fuel tank protection plate
seal packing
ring
fuel tank assembly
fuel tank oil return tube
fuel tank lock
r e f i l l o p e n i n g c u s h i o n
pressing board
refill opening cushion
oil filing port assembly
steel strip type elastic hoop
fuel tank protection plate
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Caution: When maintaining the fuel supply system, if the oil
path needs to be removed, the pressure of the fuel system must
be released to avoid the ejection of high pressure fuel.
Disassembly of the fuel tank
1. First remove the oil-in and oil return hard tube of the
generator, the oil return hard tube of fuel tank, and the
connection rubber tube between the back parts of hard vaporizer
tube. Release the pressure of oil path system slowly, block the
joints with cotton cloth, lest there is ejection of high pressure
oil.
2. Remove the oil filling port at the back of the fuel tank and the
clip of the connection rubber tube of ventilation tube, there are
two clips altogether.
3.
Remove the bolts fixing the fuel tank, there are 6 bolts
altogether;
4. Remove the oil-in and oil-out tube from the fuel tank, remove
the vaporizer tube joints and line bundle connector;
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The disassembly and installation of the fuel pump
Removal of components of fuel supply system
Gasoline filter disassembly
1. Firstly, use the straight screwdriver to remove the hose clamp
and remove the connecting rubber hose on both sides of gasoline
filter;
2. Loose the bolt on the gasoline filter bracket, then
remove the gasoline filter for complete replacement.
Removal of carbon tank
The disassembly of the fuel filler pipe
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Removal of fuel pipe
1. Remove the connection between the in/return fuel connector of
engine fuel track and the fuel supply pipe:
a. Remove the elastic hoop firstly;
b. Remove the package connector; press down the button of package
connector by hand, then pull it out outwardly.
c. Remove the three-line plastic clip.
2. Removal of front section of fuel hard pipe
b. Pull out the fuel pipe form the clip fixing base, then remove the
hard pipe;
c. Remove the fixing base on the longitudinal beam if necessary
rotate the fixing base for 90 degree in clockwise or anticlockwise,
the take out it.
3. Removal of rear section of fuel hard pipe
a. Remove the connecting elastic hoop of two ends of rear section
of fuel hard pipe;
b. Pull out the fuel pipe form the clip fixing base, then remove the
hard pipe ;
Removal and adjustment of throttle control system
1. Removal of accelerator pedal
Remove the two fixed bolts which fix the pedal ;
2. Removal of throttle pull-wire
a. Firstly, disconnect the connection on motor, then loose the fixed
bolt ;
b. Remove the plastic clip of throttle pull-wire on pedal, remove the
end of throttle pull-wire;
c. Use the pliers to clamp the clip on the side of engine compartment
to remove the fixing base of pull-wire on the fa ade of engine
compartment.
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Exhaust system
N.m Specific torque
Used component which can not be used any more.
end washer assembly
exhaust pipe outlet nut
front section of exhaust pipe
hexagon flange nut
cleaner cushion
assembly 1
fastening bolt of hoop
cleaner heat insulation cover clip
cleaner discharge pipe
catalytic converter
three-hole rubber block
cleaner cushion assembly 2
hexagon flange nut
muffler assembly
muffler port decoration cover
hexagon flange nut
rear section assembly
of exhaust pipe
wahser assembly
100
9
63
5
23
m u f f l e r d a m p i n g
ruber block assembly
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Warning : All components of the exhaust air system should be
disassembled 30 minutes after shut down to avoid the human
injury caused by hot parts.
Removal of exhaust pipe assembly
Removal of exhaust tail tube
1. Firstly, use the M15 box spanner, ratchet wrench and extension
bar to remove the connecting nut of the rear flange of muffler
assembly and rear section flange of exhaust pipe, take out
the seal bush between the flanges.
2. Remove the three-hole rubber block on the back of the rear
section of exhaust pipe.
3. Remove the three-hole rubber block on the front of the rear
section of exhaust pipe.
Caution: The bush between the rear flange of muffler and
rear section flange mainly has the function of sealing; it
may cause the great pressure and distortion after one
installation, the sealing effect is worse, and the bush cannot
be used repeatedly.
Removal of the muffler
1. If necessary, dismantle the back section of exhaust pipe
according to the method of dismantling the exhaust pipe, if
not necessary, only remove the coupling nut between the
muffler and back flange of the exhaust pipe;
2. Use the M15 sleeve, ratchet wrench or open-end (box) span-
ner to remove the coupling nut between the front flange of
muffler assembly and the rear flange of the cleaner; when
implementing this operation, there must be somebody to pull
the muffler to prevent it from falling only to cause damage;
brick of the muffler;
3. Use the M13 sleeve, ratchet wrench to loosen the four nuts
fixing the shock absorption rubber
4. Then the muffler assembly can be removed.
Caution: The cleaner cushion assembly 2 between the
cleaner and the front section of the exhaust pipe mainly plays
a role of sealing; there may be great pressure and distortion
after one installation and the sealing effect is worse, this
bush cannot be used repeatedly.
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Removal of cleaner
1
. If necessary, remove the rear section of the exhaust pipe and
the muffler according to the dismantling methods of the
exhaust pipe and muffler; if not necessary, just loosen the two
nuts fixing the shock absorption rubber brick of the muffler;
2. Remove the coupling nut between the front flange and the rear
flange of the front section of exhaust pipe;
3. If the muffler has been removed, the cleaner can be taken out
directly; if the muffler is not removed, push the cleaner
backwards tenderly, keep certain space between the cleaner
and the muffler to make the welding bolt of the cleaner to
quit;
4. At this time, the cleaner can be removed.
Caution: The cleaner cushion assembly 1 between the cleaner
and the front section of the exhaust pipe mainly plays a role of
sealing there may be great pressure and distortion after one
installation, and the sealing effect is worse, this bush cannot
be used repeatedly.
Disassembly of front section of exhaust pipe
1. Remove the cleaner according to method of removal of cleaner;
2. Use the M18 box spanner, heavy-duty extension bar, ratchet
wrench to loose and remove the nut of exhaust pipe outlet,
then takes off the front section of exhaust pipe;
Caution: The two flat flanges use the interface cushion to
ensure the sealing, which is stainless steel punching unit,
and can be used for only once.
Installation of exhaust pipe assembly
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Clutch-1
Chapter 3
Clutch
Troubleshooting. . . . . . . . . . . . . . . . . . 2
Inspection and adjustment of clutch pedal. . . . . . . . ..3
Bleed air of clutch. . . . . . . . . . . . . . . . . .3
Disassembly of clutch master cylinder and clutch cylinder . . ..5
Cautions for installation of clutch operation device. . . . . .5
Disassembly of clutch assembly. . . . . . . . . . . . .6
Inspection of clutch component. . . . . . . . . . . . .7
Installation of clutch. . . . . . . . . . . . . . . . ..9
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Clutch-2
Troubleshooting
failure cause inspection
content
Shift difficulty or can not shift
Large free stroke of clutch pedal clutch Pipe
has air
Failure of clutch cylinder
Failure of clutch master cylinder
The installation position of clutch disc is not
in position; large deviation; oil on the friction
lining or broken
The clutch disc is dirty or with foreign
material
Failure of clutch cover
Adjust the free stroke of pedal
Discharge the air in clutch system
Replace
replace
Inspect the clutch disc; replace
Repair if necessary
Replace
Disengagement of transmission
The clutch guide bearing is worn.
Replace the guide bearing
Slide of clutch
insufficient free stroke of clutch pedal
oil on the clutch disc friction lining or broken
failure of press disc
separation rocker arm assembly is blocked
Adjust the free stroke of pedal
Inspect the clutch disc and replace it
Replace the clutch cover
Check the separation rocker arm assembly
clutch clamping
stagnation/vibration
oil on the clutch disc friction lining or broken
failure of press disc clutch membrane spring
is bend
loose of engine bracket
Inspect the clutch disc and replace
Replace the clutch cover
Correct the clutch membrane
Repair if necessary
Soft of clutch pedal
clutch pipe has air
failure of clutch cylinder
failure of clutch master cylinder
Discharge the air in clutch
replace
replace
Loud noise of clutch
Component in clutch housing is loose
Throw-out bearing is worn or dirty
guide bearing is worn
separation rocker arm assembly or pull-rod is
blocked
Repair if necessary
replace
replace
Repair if necessary
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Clutch-3
Inspection and adjustment of clutch pedal
1. Check the correctness of pedal height and stroke of push rod
The pedal height starting from the meter: LHD 157.5mm
The push pole travel at the top of the pedal: RHD 151.0mm
If not correct, adjust the pedal height and push rod stroke.
2. Adjust the pedal height and stroke of push bar if necessary
a. Screw off the locknut, rotate the locking bolt until to the correct
height.
Screw on the locknut.
b. Screw off the locknut, rotate the push rod until the stroke of push
rod is correct.
Screw on the locknut.
3. Check the correctness of free stroke of pedal
Step on the pedal lightly until fell the clutch start to generate the
resistance.
Free stroke of pedal: 5
15mm
4. Adjust the free stroke of pedal if necessary
a. Screw off the locknut, rotate the push rod until the free stroke is
correct.
b. Tighten the lock nut
c. Check the height of the pedal after adjusts the free stroke of pedal.
d. On the condition that ensure the free stroke of clutch pedal assembly:
The height difference between the brake pedal, clutch pedal and the
front apron is 0
8mm.
Air discharge of clutch
Remarks: It should discharge the air if there is residual air in the
clutch system.
Caution: Do not leave the clutch liquid on the painted surface,
otherwise it should be washed off immediately.
Fill the brake fluid in the clutch storage tank
Check the liquid tank frequently. Filling if necessary.
the adjustment
point of push rod
stroke
t h e a d j u s t m e n t
point of pedal height
pedal height
front wall
free stroke
push rod stroke
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Clutch-4
Cluch control mechanism
clutch master cylinder
N
m: specified torque
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Clutch-5
Removal of clutch master cylinder, clutch cylinder
1. Use the No. 16 open-end wrench to remove the hose connecting
bleed bolt, use the cloth to cover the oil outlet of auxiliary pump
to avoid the splash of 0brake fluid; step on the clutch pedal for
several times to drain the clutch.
Cautions for installation of clutch operation device:
1. Installation of clutch hard pipe : Check the hard pipe for
deformation, check to see whether the curling at the port of
connection pipe is complete and without damage, if there is no
problem after confirmation, it can be installed and fixed in the
front wall clip and hard-tube clip.
2. Coat each rotary parts of peal with the lithium base grease.
3. Check the surface of clutch hoes, no surface cracking, oil leakage
and dog leg is allowed, use the split washer and spring clip to fix
the clutch hose on the support frame of car body.
4. Connect the joints of the general pump oil pipe and the general
2. Remove the split pin and cylinder pin connected the master
pump connecting fork to the pedal; use the No. 13 socket spanner
to remove two nuts Q32008 which is used to install the master
pump. Check the clutch master cylinder, replace the complete
master pump if the internal of master pump has the abnormal
noise and damage of leakage etc.
pump and sub pump according to the required tightening torque.
5. The air in the clutch oil path needs to be exhausted after filling
oil (except the vacuum filling): step on the clutch pedal after
filling the oil tank, when feeling difficult in stepping, use the
open-end wrench with specification of 11 to loosen the air bleed
plug screw to exhaust the air, then tighten the plug screw,
repeat the operation for several times. Tighten the air bleed
plug screw of the sub pump when there is no foam in the
flowing oil liquid. Supplement the oil of the oil tank to the
level between the Max and the Min.
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