2006 GREAT WALL PEGASUS seat

Preface
With the increase of automobile demand in China, our automobile industry also experiences a rapid
development. The trucks including SUV, manufactured by Great Wall Motor Co., Ltd, which are sold all over
China, are in the leading place in terms of their sales volume, in order to satisfy the demands of various maintain-
ing staff, technicians and managing staff of Changcheng Co., Ltd, we compile this maintenance manual accord-
ing to the latest technological data. This manual covers six vehicle models including Deer, Safe, Sailor, Sing, So
Cool and Pegasus, its main content includes:
Part I is general introduction, which introduces the application index of this manual.
Part II introduces the chassis system, which mainly includes the technologies of dismantle, inspection,
adjustment, repairing, assembly and mount of the clutch, gear box, transfer box, drive shaft, suspension system
and automobile axle, braking system and steering system, etc. each operation approach is illustrated with figure,
which not only presents the maintenance procedure, but also clearly describes the technical requirements and
application limit.
Part III introduces the electric system and air-conditioning system of the automobile body, which mainly
covers such items as the location and content of protective box, power supply system, starting system, lighting
system, combination instrument, backup radar system, wiping and washing system, center control locking and
power window system, acoustical equipment system, full wire harness and air-conditioning system, etc. Electric-
ity diagrams for those electric systems are given in this manual so as to facilitate the maintaining technicians to
find out the problem easily and quickly.
Part IV introduces the external and internal body decoration, which mainly covers the dismantling, inspect-
ing and assembling requirements of the engine cover, front and rear doors, adhesive strip of body collision
avoidance, wheel shield, wrapping angle of wheel-shield and exterior trim panel, front and rear windshields,
side-window glass, rear-door glass, rear platform of cargo compartment, rear door, instrument panel, safety belt,
seat, tail-fin, luggage rack, and reserve tire bracket etc. The dimensions of vehicle body and frame are also given
to maintaining staff for reference during their repairing.
During the narrations of each part, items such as troubleshooting, maintenance notice, maintenance data
and application limit, fastening torques of bolts and nuts for special purpose, SST, SSM and lubricant materials
and so on are also introduced. Various maintenance data are briefed in attachment for reference.
Altogether, this manual is comprehensive in content, visual in illustration, clarifying in requirement and
plain in language. It can be referred by the maintaining staff, technicians and professional managing staff.
Even though we try our best to compile this manual in a strict earnest manner, we cannot guarantee that all
contents in this manual are correct. Therefore, users shall not put forward any claim with Great Wall Company
according to this manual; we are not in the position to hold the responsibility for the loss caused by usage of this
manual. Due to our limited knowledge, it is unavoidable to find error in this manual, any criticism and correction
from you is welcomed.
The final explanation power for this manual is subject to Great Wall Motor Co., Ltd
Compiler
May 2006

IN-3Introduction
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 positionSpecification
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

CL-2Clutch
Troubleshooting
Troubleshooting
Trouble Causes Repairing approaches
Difficulty in gearshift
or non-gearshiftOverlarge free stroke of clutch pedal
There is air in clutch pipe
Failure of clutch brake-wheel cylinder
Failure of clutch master cylinder
Overlarge clutch pendulum difference due to incorrect mounting, the
friction liner is stained with oil or is breaking
There is dirty or adhesive materials on spline of input shaft or clutch rib
Failure of clutch pressure plateAdjust the free stroke of pedal
Exhaust the air in clutch pipe
Change the clutch brake-wheel cylinder
Change the master cylinder
Check the clutch rib
Repair according to requirement
Change the clutch pressure plate
Disengagement of gear
box or clutch slipAbrasion of clutch guide shaft
Insufficient free stroke of clutch pedal
The friction liner of clutch rib is stained with oil or is worn
Failure of clutch pressure plate
Seize up of separation forkChange the guide shaft
Adjust the free stroke of pedal
Check the clutch rib
Change the clutch pressure plate
Check the separation fork
Clutch seize-up or
shakingThe friction liner of clutch rib is stained with oil or is worn
Failure of clutch pressure plate
Looseness of engine seatCheck the clutch rib
Change the clutch pressure plate
Repair according to requirement
Looseness of clutch
pedalThere is air in clutch pipe
Failure of clutch brake-wheel cylinder
Failure of clutch master cylinderExhaust the air in clutch pipe
Change the clutch brake-wheel cylinder
Change the master cylinder
Over-loud clutch noiseSeize up of separation fork;
Abrasion or stained spot of separation bearing
Abrasion of guide bearing
Parts looseness in clutch pressure plateRepair according to requirement
Change the separation bearing
Change the guide bearing
Change the clutch pressure plate

CL-10Clutch
Clutch Cluster
3. Check the alignment of the diaphragm spring end.
Check the alignment of diaphragm spring end with SST.
Max dislocation: 0.5mm
if the difference is more than the specified value, adjust the
alignment of diaphragm spring end with SST.
4. Coat the lithium base grease;
Coat the lithium base grease on the following parts:

Contact spot of separation fork and bearing

Contact spot of separation fork and push-rod;

Support spots of separation fork

Spline of clutch rib
5. Encase the dust cover, separation fork, separation bearing
seat and bearing into the gearbox;
6. Mount the gearbox.
SST

MT-10Gearbox
Disassembly of Gear Box
Disassembly of Gear Box
1. Tear down the separation toggle fork and separation
bearing.
2. Tear down the backup switch, the driven gear of
speedometer.
3. Tear down the clutch from the gearbox frame.
Take apart the nine boits.
4. Tear down bolts of locating spring of the five-speed
toggle fork, locating spring and locking ball.
(a) Dismantle the bolts from the rear cover with the torque
socket spanner.
(b) Take out the spring and locking ball with magnetic rod.
5. Tear down the operating seat of gear change lever.
(a) Dismantle the setting bolts of the operating seat of gear
change lever.
(b) Take away the operating seat lightly and put it at the
suitable place.
6. Tear down axial locating pin assembly of shifting gear.
7. Tear down the fastening nuts of extension frame.
(a) Tear down the fixing bolts of gearshift shaft.
(b) Tear down the fastening nuts of expansion shell.

PR-12Drive Shaft
Drive Shaft
Mount of Drive Shaft
(2WD)
1. Insert the universal joint yoke in the gearbox.
(a) Tear down the SST tools.
(b) Push the universal joint yoke into the gearbox.
2. Connect the universal joint flange of the rear joint of rear
axle drive shaft and the relative the differential flange.
(a) Align the assembly marks on the two flanges and connect
the flanges with four sets of bolt and nut.
(b) Screw up the sets of bolt and nut according to the
specified torque.
Fastening torque
(74
5)N
m
3. Mount the center support bearing on the frame beam
(three-joint type)
(a) Use two bolts to mount the center support bearing on the
frame beam and tighten them manually.
(b) Check the bearing seat, which shall be vertical with the
drive shaft, and change it where necessary.
(c) Check the central line of the central bearing and ensure
that the central lines of the central bearing and the bear-
ing seat shall be the same when the vehicle is in the non-
loaded stage. And adjust the bearing seat only it is
necessary.
(d) Screw up the mounting bolts according to the specified
torque.
Fastening torque
(40
5)N
m
(4WD)
1. Connect the universal joint flange fork of the front axle
drive shaft with the flange that matches with the transfer
box.
Align the assembly marks and use four sets of bolt and nut to
connect the flange fork with the flange, screw up the sets of bolt
and nut according to the specified torque.
Fastening torque
(74
5)N
m
forward
SST
assembly mark
assembly mark

PR-13Drive Shaft
Drive Shaft
2. Mount on the front axle drive shaft.
Mount on it and screw up the four bolts according to the
specified torque.
Fastening torque
(74
5)N
m
3. Connect the universal joint flange fork of the rear axle
drive shaft on the relative differential flange.
(a) Align the assembly marks on flanges and connect the
flanges with four sets of bolt and nut, and
(b) Tighten the sets of bolt and nut according to the specified
torque.
Fastening torque
(74
5)N
m
4. Mount the center support bearing on the frame beam
(three joint type)
(a) Use two mounting bolts to mount the center support
bearing on the frame beam and screw up them manually.
(b) Check the bearing seat, which shall be vertical with the
drive shaft, and adjust the bearing seat when necessary.
(c) Check the central line of the central bearing. The central
line of the central bearing shall be the same with that of
the bearing seat when vehicle is in the non-loaded stage.
(d) Adjust the bearing seat if necessary, and
(e) Screw up the mounting bolts according to the specified
torque.
Fastening torque
(40
5)N
m
assembly mark
forward