2006 GREAT WALL SAILOR Chassis

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

Service manual for
chassis and body
GeneralIN
ClutchCL
Gear boxMT
Transfer boxTF
Drive shaftPR
Suspension system and automobile axleSA
Braking systemBR
Steering systemSR
Body electric systemBE
Air-conditioning systemAC
Vehicle bodyBO
Maintenance and Up-keepingA
Special ToolB

SA-3Suspension System and Automobile Axle
Alignment of Front Wheel (Dr SL SK SY SJ)
Alignment of Front Wheel
(Dr SL SK SY SJ)
1. Inspection should be conducted for the following items to
remove the trouble
(a) Check the tire abrasion and air inflation situation
Tire inflation pressure:
Front (220
0)kPa
Back (240
0)kPa
(b) Check the front wheel bearing to see whether it is loose.
(c) Check the front suspension to see whether it is loose.
(d) Check the steering driving device to see whether it is
loose, and
(e) Check the front vibration damper work to see whether it
is loose.
2. Measure the ground clearance of the chassis.
Chassis ground clearance:
Dr
295
0+5mm
SL SK
(255
2)mm
SY
(310
2)mm
SJ
(295
1)mm
If the chassis ground clearance of the vehicle is sub-standard,
push down the body or raise it for a trial adjustment, if fails,
check the spring or suspension element to see whether they are
normal.
Remarks: adjust the chassis ground clearance to a specified
value before checking the Alignment of Front Wheel
parameters.
3. Mount on the four-wheel locating device.
The mount should be conducted according to the manufacturerís
instructions.

SA-19
Torsion Rod Spring
Dismantle of Torsion Rod Spring
1. Use the jack to raise up the frame and support it with the
bracket.
2. Take apart the locking nuts to measure the length of the
projecting end of the bolts, as shown in the drawing.
Remark: This measuring value can be referred when adjusting
the chassis ground clearance.
3. Take apart the dust cover.
4. Loosen the regulating nut until there is no tension on the
torsion rod spring.
5. Take apart the torsion arm, torsion rod spring and the
torsion regulating arm.
(a) Tear down the mounting nuts of the torsion rod arm.
(b) Take apart the torsion regulating arm from the adjusting
bolt, the torsion regulating arm should be taken apart with
the torsion rod spring and the torsion rod arm together.
Dr SL SK SY
SJ
SFSuspension System and Automobile Axle (Dr/2WD)
Front Suspension (Torsion Rod Spring)

BE-38Body Electric System
Backup Radar System
Inspection on Common Trouble
Failure Judgment Methods
No backup radar display (no
system start notification when
the reverse gear is engaged)Check whether the plugging elements of power supply
of back up radar control box are in well connection as
shown in drawing H in next page.(when the reverse
gear is engaged, touch the detector, if there is vibration,
which shows the detector is powered.
Check whether the wire harness of inner mirror in
electric room and that on the top of body are in well
connection as shown in the drawing A in next page
Check whether the wire harness of back up radar
control box is well connected with that of chassis
and that on the top of body.
Rotate the vehicle key to the ACC position and
engage the reverse gear, then measure to see whether
the back up power supply reaches to 12 V with the
multi-meter of 50 V of voltage, refer to the
red
and black
positions shown in the drawing in next
page.
If the voltage reaches 12 V, change the backup
radar control box in trial firstly, then the inner
mirror in electric room, finally change the roof
wire harness and the chassis.
No backup radar display (but
there is start notification when
the reverse gear is engaged)
remark: such trouble occur
under the blocking condition.Check whether the power supply of back up radar
is well located, see the red and position in the
drawing of next page.
Check and align the plugging element.Poor properties of ultrasonic wave
Change the ultrasonic detector heads.
Continuous back up radar red
lamp alarming (remark: there
is no obstacle within 0.5 m away
from the detector head)Check whether the detectors in the two circuit of
back up radar control box is well plugged, see the
marked positions F, G in the drawing of next page.
Check and well connect those plugging elements
Poor connection of the left/right ultrasonic detector head
Poor performance of back up radar control box.Check and well connect those plugging elements
Change the ultrasonic detector head
Change the back up radar control box.
Vehicle modelpc
Alarming by mistake
The rear standby tire is removedConduct the inspection operation for the rear
standby tire at the spacious place
fail to detect the obstacle
The detector head doesn
t workChange the detector head
There is dirt on detector headClean the detector head
Rear standby tire inspection1. engage the reverse gear for five times repeatedly within ten seconds at the spacious place so that the red
lamp on the screen flash three times, the system will automatically remember the standby tire status.
2. When the body height varies or the stand by tire is opened, make a new inspection for the rear stand by
tire to ensure the backup radar in normal operation.
Seven section of lamp display
Column I
1.49m-1.3m Column II
1.29m-1.1m
Column III
1.09m-0.9m Column IV
0.89m-0.75m
Column V
0.74m-0.6m column VI
0.59m-0.45m
Column VII

0.45m
Remark: the right and left LED display the direction and distance of obstacle respectively for driver
reference.If the voltage fails to reach 12 v, check the power
supply system of original vehicle
s large wires
to restore the voltage to 12 V.
Vehicle model SL SK
fail to detect the obstacle
Trouble description Repairing and treatment approaches

BE-70
SF
1
2 P
4 5 6
7
8 9 10
11 12 13
14
15 16 1718 19
20
21
22
23
2425262728
29
30 3132
33
34
3536
37
38
39
40
41
42
43
44 45 46 47
48
49 50 51
52
53
54
555657 5859
Housing wire harness (continued)
60 61
1 left door lamp switch
2 defrost switch at tail door
3 window regulator at tail door
4 parking brake switch
5 ignition lock
6 combined switch
7 instrument
8 combined switch shell
9 grounding wire
10 amplifying plate of air-conditioner
11 heat-sensitive resistance
12 control panel of air-conditioner
13 A/C Switch
14 glove-box lamp switch
15 glove-box lamp
16 speed-adjusting resistance
17 blower
18 indoor temperature sensor
19 right front loudspeaker
20 brush motor
21 turn lamp on right side22 electric fan relay
23 maxi-fuse
24 joint of wire harness at right front door
25 right front door lamp switch
26 right electric back-up mirror
27 grounding wire
28 rear sound box wire
29 ashtray lamp
30 CD Device wire
31 cigarette lighter A
32 cigarette lighter B
33 dual flasher switch
34 fog lamp switch
35 temperature indicator
36 stop lamp switch
37 brake liquid level sensor
38 control case of central control lock
39 left front loudspeaker
40 automatic aerial
41 turn lamp on left side
42 generator43 left front conner lamp
44 left front lever-shaped lamp
45 front fog lamp
46 left headlamp
47 temperature control switch
48 connected to wire of 220
49 spraying motor A
50 spraying motor B
51 right front conner lamp
52 right headlamp
53 horn A
54 horn B
55 right front lever-shaped lamp
56 right front fog lamp
57 electric fan
58 outdoor temperature sensor
59 connected to chassis wire harness
anright central wire harness
60 connected to left central wire harness
61 connected to engine wire harness
Body Electric System
Wire Harness Distribution

BE-72
pi=ph
1 grounding wire
2 wire harness at right front door
3 warm air motor
4 wire harness at right front door
5 control case of central control lock
6 heat-sensitive resistance
7 speed-adjusting resistance
8 connected to housing wire harness
9 connected to housing wire harness
10 A/C switch
11 air-volume switch
12 ashtray luminous lamp
13 ECU
14 receiver
15 rear loudspeaker
16 cigarette lighter
17 cigarette lighter grounding wire
18 cigarette lighter luminous lamp
19 fog lamp switch
20 dual flasher switch21 luminous lamp on air-conditioner panel
22 combined switch
23 instrument
24 instrument
25 stop lamp switch
26 connected to roof wire harness
27 connected to housing wire harness
28 connected to housing wire harness
29 connected to housing wire harness
30 connected to wire harness at left front door
31 connected to wire harness at left front door
32 connected to wire harness at left front door
33 protective box I
34 grounding wire
35 wire harness at left front door
36 connected to wire harness at left rear door
37 parking brake switch
38 connected to wire harness at right rear door
39 right front door lamp switch
40 connected to chassis wire harness
1
2
3
4
5
6
7
8
910
11
12
13 14
1516
17
18 19
20
21
2223
24
25
26
27
28
2930
31
32
33
343536 37 38
39
Cab Wire harness (continued)
40
Body Electric System
Wire Harness Distribution

BE-73
SY SJ
1 grounding wire
2 wire harness at right front door
3 warm air motor
4 connected to wire harness at right front door
5 control case of central control lock
6 electric aerial
7 heat-sensitive resistance
8 speed-adjusting resistance
9 connected to housing wire harness
10 connected to housing wire harness
11 A/C switch
12 air-volume switch
13 ashtray luminous lamp
14 grounding wire
15 ECU
16 CD device
17 CD device
18 cigarette lighter
19 cigarette lighter grounding wire
20 cigarette lighter luminous lamp
21 combined switch
22 fog lamp switch
23 dual flasher switch
24 rear defroster switch
25 rear brush switch
26 rear washer switch27 combination instrument
28 combination instrument
29 stop lamp switch
30 roof wire harness
31 connected to housing wire harness
32 connected to housing wire harness
33 connected to housing wire harness
34 connected to wire harness at left front door
35 connected to wire harness at left front door
36 connected to wire harness at left front door
37 protective box
38 rear defrost relay
39 connected to wire harness of rear air-conditioner
40 grounding wire
41 parking brake switch
42 connected to chassis wire harness
43 wire harness at right rear door
44 right front door lamp switch
45 right rear loudspeaker
46 rear washer motor
47 connected to wire harness at tail door
48 left front door lamp switch
49 wire harness at left rear door
50 left rear loudspeaker
51 standby power seat
1
2
3
4
5
6
7
8
9
101112
13
14
15
1617
181920
21 22232425262728
29
30
31
32
3334
35
36
37
38
39
4041 4243 444546
47
48495051
Cab wire harness (continued)
Body Electric System
Wire Harness Distribution