2006 GREAT WALL SO COOL steering wheel adjustment

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

SA-2
Troubleshooting
Suspension System and Automobile Axle
Troubleshooting
Change the tire or inflate to the proper pressure
Balance the wheels
Change vibration damper
Check Alignment of Front Wheel
Change or adjust the wheel bearing
Check ball joint) or liner
Tighten or change steering linkage
Adjust or repair the steering device
Discharge the oil and change with new one
Check the wandering clearance
Check the gears
Change the bearing
Change the bearing
Tighten or change the bearing Trouble Causes
Inspection items
Body wandering/body
draggingTire wear or improper air inflation
Incorrect alignment of front wheel
Over-tightened wheel bearing
Part looseness or damage of front/rear sus-
pension
Wear or looseness of steering rod system
Poor connection or damage of steering de-
viceInflate the tire to the proper pressure or change
the tire.
Check the situation of alignment of front wheel
Adjust the wheel bearing
Tighten or change the suspension element
Tighten or change the steering rod system
Adjust or repair the steering device
Body sink Overloaded vehicle
Wear of vibration damper
Poor spring performanceCheck the loading mass
Change vibration damper
Change spring
Left-right vibration/up-
down bouncingImproper air inflation
Bending or damaged lateral stabilizer
Vibration damper wearInflate the tire to suitable pressure
Change stabilizer
Change vibration damper
Front wheel vibration Tire wear or improper air inflation
Imbalance of wheels
Vibration damper wear)
Improper Alignment of Front Wheel
Wheel bearing wear or improper adjustment
Ball joint or liner wear
Steering linkage looseness or wear
Poor adjustment or damage of steering mecha-
nism
Abnormal tire wear Improper air inflation
Vibration damper wear
Poor Alignment of Front Wheel
Suspension system wearInflate the tire to the proper pressure
Change vibration damper
Check the Alignment of Front Wheel
Change suspension element
Speed reducer leakage Over-high oil level or improper oil quality
Oil seal wear or damage
Flange looseness or damageDischarge the oil for change
Change oil seal
Tighten or change the flange
Noise inside the
axleNoise inside the axleOver-low oil level or inferior oil quality
Over-large wandering clearance between
driving bevel gear and driven bevel gear
Wear and disintegration of driving bevel
gear and driven bevel gear
Bearing wear of driving bevel gear
Bearing wear of rear axle shaft
Bearing looseness or wear of speed reducer

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-4Suspension System and Automobile Axle
Alignment of Front Wheel (Dr SL SK SY SJ)
5. Adjustment for inner tilt angle of kingpin, outer tilt angle
of front wheel and back tilt angle of kingpin
Item
Inner tilt
angle of
kingpin
Outer tilt
angle of
front
wheelApplicable vehicle type
Dr SL SK SY
SJ
Mechanic
steeringDr SL SK SY
Power
steeringDr
SL SK SY
SJ
Back tilt
angle of
kingpinMechanic
steeringDr SL SK SY
Power steer-
ingDr SL SK SY
SJ9
30
45

14
52

0
30
20

0
10
10

0
20
10

0
30
15

2
45
15

3
15
Location parameter
4. Adjust the wheel angle
Take apart the limit bolts of the steering knuckle to check the
steering angle A of inner wheel.
Inner wheel steering angle
Dr SL SK SY
( 36
40
)
SJ
( 32
34
)
Remark: The wheel should not contact the body or brake hose
when the steering wheel reaches the limit position.
In case the steering angle of inner wheel doesnít conform to the
standard value, adjust the wheel angle through adjusting the
limit bolts of the steering knuckle.
Fastening torque
(90
0)N
m(SJ)
If the wheel angle fails to be adjusted within the standard value,
change the weary or damaged parts of steering system.
If the tilt angle fails to fall within the specified values, make an
adjustment through adding or reducing the gaskets on the
location of upper arm.
Gasket thickness: 3.0, 2.0 and 1.0mm
Once the gasket thickness increases by 1mm, the outer tilt
angle of wheel will change by 7', while the back tilt angle of
kingpin will change 20'.
After the wheel outer tilt angle and the back tilt angle of kingpin
are adjusted, if the inner tilt angle of kingpin still fails to the
specified value, check the steering knuckle or front wheel to
see whether they are bending or loose.
1
50
-20

adjusting bolt
outer tilt
angle of
front wheel inner tilt angle of kingpin
back tilt angle of
kingpin
front AB AB
HPM

SA-6Suspension System and Automobile Axle
Alignment of Front Wheel
Alignment of Front Wheel (SF)
Alignment of Front Wheel
(SF)
1. The following items should be checked to remove the
troubles.
(a) Check the tire abrasion and the air inflation to see it is
suitable or not.
Tire inflation pressure: (250
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 through elastic force test to see
whether it is normal in performance.
2. Height adjustment of vehicle
Adjust the vehicle height to the standard value so as to make
the Alignment of Front Wheel inspection.
A-B-58 5mm
A: The height of steering knuckle shaft center.
B: The center height of the adjusting cam bolt at front end
The standard value for the unloaded height is: the
difference of the center height of drive shaft climax and
the front adjusting cam bolt is 58.5mm.
3. Mount on the four wheel locating device
This approach should be conducted according to the detailed
instruction of the equipment manufacturer.
4. Adjust the outer tilt angle of front wheel and the back tilt
angle of kingpin
The outer tilt angle of front wheel: 0
5'
0'
The back tilt angle of kingpin: 2
0'
0'
Outer inclination of front wheel:
BA
the outer tilt angle of
front wheelthe back tilt angle
of kingpin
front

SA-7Suspension System and Automobile Axle
Alignment of Front Wheel
Alignment of Front Wheel (SF)
In case the outer tilt angle of front wheel or the back tilt angle
of kingpin fails to conform to the specified value, adjust the
cam forward or backward may amend them.
5. Wheel angel adjustment
Take apart the limit bolt cap of the steering knuckle to check
the inner wheel steering angle A.
The inner wheel steering angle: =32

Notice:The wheel should not touch the body brake hose
when the steering wheel is rotated to the bottom.
In case the max steering angle is not in the conformity with the
standard value, adjust the wheel angle through the limit bolts
of steering knuckle.
In case the wheel angle still fails to fall within the standard
range, make a inspection and change the weary and damaged
steering mechanism parts.
6. Wheel toe-in adjustment
Adjust the wheel toe-in according to the following approach
(a) Raise or reduce the vehicle until the suspension stands in
balance.
(b) Push the vehicle on the ground 5 meters forward under
the condition that the front wheels locate forward in a
line.front cam adjustment
rear cam adjustment
reduce increaseincrease reduce
A
B
A B
front

SA-13
3. Mount the front wheel hub on the steering knuckle.
Coat a little lubricant at the position of the steering knuckle
where the oil seal locates, mount the front wheel hub and front
brake disc on the steering knuckle, and then mount on the stop
washer.
4. Preload adjustment
(a) Mount on the lock nut and screw up according to the
specified torque.
Fastening torque
(130-150)N
m
(b) Run the front wheel hub about 1/4-1/3 of circle, and
combine it with the bearing seat.
(c) Loosen the locking nut to ensure the front brake disc run
freely, and then screw up the nuts to the specified torque.
Fastening torque
(25-35)N
m
(d) Hook the front wheel hub with the spring-tension meter
and pull the spring-tension meter slowly in the tangential
direction of this spot.
The reasonable range of tension force: (16-33)N.
Remark: if the tension force is larger or smaller of the reason-
able range, screw up the nuts again until the tension force falls
within the reasonable range.
(e) Measure the bouncing value of the front brake disc,
which should not be larger than 0.11mm.
5. Mount on the lock cover and the split pin
Suspension System and Automobile Axle (Dr/2WD)
Front Wheel Hub and Steering Knuckle (Front Wheel Hub)

BR-24
2. Measure the thickness of brake disc;
Standard thickness
20.0mm
Min thickness
18.0mm
If the brake pad is scraped, repair it; where the abrasion is
serious and its thickness is smaller than the min thickness,
change the brake disc.
3. Measure the bounding value of the brake disc face;
Remark: the bearing is required to be verified in the suitable
adjustment before measuring.
Max face bouncing value: 0.11mm;
4. Change the brake disc according to the requirement:
(a) Tear down the hub and the brake disc. (see the paragraph
of front wheel hub)
(b) Mount the new brake disc and screw up the connecting
bolts as the specified torque.
(c) Mount the hub and brake disc assembly. (see the para-
graph of front wheel hub).
Fastening torque
(75
5)N
m
(d) Mount the caliper bracket on the steering knuckle and
screw up the bolts according to the specified torque.
Fastening torque
123N
m.
Assembly of Brake-wheel pump
1. Preparation
All parts shall be washed, dried and cleared away the alien
materials, and coat moderate rubber lubricant on the work
faces of piston, piston dust cover and rectangular sealing ring.
2. Encase the piston sealing ring in the caliper body Braking System
Front Brake(SF)