2006 GREAT WALL SAILOR Steering box

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

SR-9Steering System
Manual Steering Gear
Manual steering gear
Disassembly and mount of manual steering gear
steering drive shaft
manual steering gear box
swing arm
N
m
specified torque
245
25(Dr)
assembly mark
SSTPoints on disassembly and mount
1. Disassemble the steering drive shaft:
(a) Loosen the fixing bolts at upper part of steering column;
(b) Tear down the connecting bolts of steering drive shaft;
(c) Mark the assembly marks on the steering drive shaft and
worm shaft;
(d) Slide the shaft backward to tear it down from the worm shaft.
2. Tear down the swing arm from the steering gear:
(a) Loosen the fixing nuts of swing arm;
(b) Tear down the swing arm from the steering gear with SST.
96
10(Dr SL SK SY)
worm shaft

BE-9Body Electric System
Protective Box Position and Content
fuse relay
1. Small lamp 10A A. electromagnetic fan relay
2. Brake 5A B. lasher
3. Ceiling lamp 5A C. electromagnetic fan relay
4. Central control lock 15A D. small lamp relay
5. Electric rocker gear 30A E. electric window relay
6. Dual flasher 10A
7. Cigarette lighter 15A
8. Rear vision mirror 5A (1) plugging elements of ceiling lamp wire harness
9. Unload (2) plugging elements of wire harness at front left door
10. Acoustic device 15A (3)plugging elements of wire harness in engine room
11. Rear window 20A
12. Electromagnetic fan 10A
13. Instrument 5A
14. Back-up lamp 5A
15. Rain brush 10A
16. Steering 5A
17. Unload
18. Unload




A
B
C
E D
123 456
78 9 101112
13 14 15
16 1718
SF
Protective bos I (continued)

BE-10Body Electric System
Protective Box Position Content
FuseVehicle
Model
1. Standby 30A
Standby 20A SJ
2. Standby 15A SY
Standby 10A SJ
3. Standby 10A SY SJ
4. Unload SY
Bass bubble 10A SJ
Power amplification 10 A top SY
5. Unload SY SJ
6. Unload SY SJ
7. Unload SY SJ
8. Air-conditioner 10A SY SJ
9. Charging 10A SY
Instrument 10A SJ
10. ECU 10A SY SJ
11. Back-up lamp 10A SY SJ
12. Cigarette lighter 30A SY SJ
receiver
13. Unload SY
Refrigerant 10A SJ top SY
14. Unload SY SJ
15. Steering electric window 10A SY
Humid display of steering 10A SJ
sindicating lamp
16. Stop lamp 10A SY SJ
17. Power aerial of inside lamp 10A SY SJ
18. Central control lock 20A SY SJ
19. Dual flasher 10A SY SJ
20. Front rain brush 10A SY SJ
21. Rear air-conditioner 15A SY
Unload SJ
22. Rear defroster 15A SY
Unload SJ
23. Rear rain brush 10A SY
Unload SJ
1Protective box I (continued)pv=pg
1
2
3
4
567
8
91011
12 13
14 15
16 17 18 19
20 21 22 23

BE-11Body Electric System
Protective Box Position and Content
Fuse Vehicle model
1. Standby 10A (SL diesel)(SY diesel)
2. Standby 15A (SL diesel) (SY diesel)
3. Standby 30A (SL diesel) (SY diesel)
4. Unload (SL diesel) (SY diesel)
5. Unload (SL diesel) (SY diesel)
6. Unload (SL diesel) (SY diesel)
7. Unload (SL diesel) (SY diesel)
8. Start 10A (SL diesel) (SY diesel)
9. Rear defroster 15A (SY diesel)
Unload (SL diesel)
10.Cigarette lighter
and receiver 30A (SY diesel)
Cigarette lighter 15A (SL diesel)
11.Rear rain brush 10A (SY diesel)
Unload (SL diesel)
12.Front rain brush 15A (SY diesel)
Rain brush 5A (SL diesel)
13.Steering 10A (SY diesel)
Dual flasher 10A (SL diesel)
14.Preheating 15A (SL diesel)(SY diesel)
15.Electric window 30A (SL diesel)(SY diesel)
16.Small lamp 10A (SL diesel)(SY diesel)
17.Stop lamp 10A (SL diesel)(SY diesel)
18.Inside lamp
and electric aerial 15A (SY diesel)
eiling lamp 10A (SL diesel)
19.Central control lock 20A (SY diesel)
Central control lock 15A (SL diesel)
20.Rear air-conditioner 15A (SY diesel)
Unload (SL diesel)
21.Unload (SL diesel)(SY diesel)
Refrigerant 10A (top SY diesel)
22.Unload (SL diesel )(SY diesel)
Power amplification 10A (top SY diesel)
23.Unload (SL diesel)(SY diesel)
1.Protective box I (continued)SLDiesel SYDiesel
1
2
3
4 567
89NM11
12 13 14 15
16 17 18 19
2021
22 23

B0-53Vehicle Body
Instrument Panel
Dismantle of instrument panel
(Dr SF)
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 central bottom-wall (Dr)
Tear down the decorative cover of gearbox (SF)
6. Tear down the instrument cover (SF).
Tear down the two screws and the cover.
7. Tear down the lower instrument cover;
(a) Tear down the ignition lock;
(b) Tear down the five screws and the cover;
Tear down the four screws and the cover;
(c) Disconnect the plugging elements.
8. 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 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.
9. Tear down the decorative cover of instrument (Dr)
(a) Tear down the two screws to pull out the decorative cover
of instrument;
(b) Disconnect the plugging elements.E
F

A-1
Specifications of Maintenance
and Up-keeping
page
Clutch .......................................................................... A-2
Gear box ..................................................................... A-2
Transfer box ................................................................ A-3
Drive shaft ................................................................... A-4
Suspension system and automobile axle .................... A-4
Braking system ............................................................ A-5
Steering system .......................................................... A-6
A