2008 GREAT WALL FLORID Service Manual

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Downloaded from www.Manualslib.com manuals search engine PREFACE
GWFLORID will build 1.3L (GW413EF, GW4G13) or 1.5L (GW4G15) gasoline engines, in which the
GW4G13 and GW4G15 engines will both incorporate the newest VVT technology which meets the Euro IV
emission standards. GWFLORID features McPherson technology on its chassis system. With an ultra light
body made from structural steel and high-intensity front and rear fender impact beams as well as a collision
impact absorption system, it is able to maintain the cab's integrity and safety to greater extent. We wrote this
maintenance manual in order to meet the demand of Great Wall after-sales service technicians. This manual
mainly introduces the areas of importance in regard to maintenance and care, and removal and installation of
each system's assembly and maintenance technical parameters.
To reduce the possibility of injury or property damage, read and follow t\
he instructions carefully:
This manual is provided by the Great Wall Motor Co., Ltd, and is written for the technician use. Any
maintenance or repair without proper prior training and tools or devices may result in personal injury of the
person performing the maintenance or others in the vicinity. It is also possible that damage to the vehicle will
occur or will lead to mechanical failure during normal operation.
Correct vehicle maintenance and repair is essential for the safety of the person performing regular
maintenance as well as the vehicle itself. If there is any component that needs to be replaced, use a
component with the same serial number or a serial number specified by the Great Wall Motor Co., Ltd. Never
use any part that has not been authorized by the Great Wall Motor Co., Ltd.
Any maintenance procedure introduced in this manual is effective for maintenance and repair. Some of
these procedures need specially designed tools.
Therefore, before using any vehicle part following any maintenance procedure or working with a tool
that has not been authorized by the Great Wall Motor Co., Ltd, check to make sure that none of the above
will endanger the safety of the person performing the work or the correc\
t operation of the vehicle.
This manual includes multiple "Warnings" and "Cautions," which should be strictly followed, so as to
reduce the possibility of injury during maintenance or repair. Improper maintenance or repair of the vehicle
may cause potential safety hazards. These "Warnings" and "Cautions" are not exhaustive. It is impossible for
the Great Wall Motor Co., Ltd, to warn against all the potential dangers caused by not properly following the
instructions.
Please read carefully the "Areas of Importance" before carrying out any maintenance or repair on the
airbag system's components or its surrounding electrical components. Action contrary to any of the "Areas of
Importance" may lead to the deployment of the airbag, resulting in injur\
y or unnecessary repair of the airbag.
To avoid accidental deployment of the airbag and its resulting injury, we suggest repairing the airbag
system before other vehicle systems if the airbag and the other vehicle \
systems both need repairing.
We have received generous support and help from many professional technicians during the preparation
of this manual. We would like to express our heartfelt gratitude to all of them.
Although we have tried our best to write this manual well, we do not guarantee that the entire content
in this manual is absolutely correct. Users may not make any legal claim against the Great Wall Motor Co.,
Ltd. in regards to this manual. Any loss caused by using this manual is not our responsibility. Because of
the writer's limited experience, there are likely mistakes in this manual, therefore we welcome any user
comments, suggestions, and corrections.
Great Wall Motor Co., Ltd. reserves the final right of explanation.


\
Editor
May 2008

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Downloaded from www.Manualslib.com manuals search engine Chapter One: Overview ........................................................................\
........................................1
How to Use This Manual ...................................................................................\
...........2
Identifying Number Location ..................................................................................\
......3
Comprehensive Repair Instructions .............................................................................4
General Repair Methods and Operations ....................................................................9
Chapter Two: Overall Parameters ........................................................................\
......................10
Basic Parameters of the Overall Vehicle ...................................................................11
Engine Technical Parameters ..................................................................................\
..12
Chassis’ Main Assembly Technical Parameters .........................................................13
Vehicle Structure Type and Parameters ....................................................................15
Air Conditioning System Structure and Parameters ..................................................16
Electrical System Structure and Parameters .............................................................16
Grade Specification and Filled Quantity of Each
Individual Functioning Component’s Working Agent ..................................................18
Torque Specifications for Key Operational Bolts ........................................................18
Vehicle Body’s Basic Calibration Measurements ......................................................22
Chapter Three: Fuel Supply and Exhaust System .....................................................................29
Fuel Supply System ...................................................................................\
................30
Components ..................................................................................\
..........................30
Fuel Tank Removal ..................................................................................\
................31
Fuel Pump and Charcoal Canister Removal ...........................................................31
Fuel Filter Removal ...................................................................................\
...............31
Fuel Filler Pipe Assembly Removal .........................................................................32
Exhaust System ...................................................................................\
......................33
Components ..................................................................................\
..........................33
Exhaust System Removal ...................................................................................\
.....34
Exhaust System Installation ...................................................................................\
..35
Chapter Four: Clutch Operational System........................................................................\
..........36
Areas of Importance ..................................................................................\
................37
Troubleshooting ..................................................................................\
.......................37
Clutch Operational System ..................................................................................\
......38
Components ..................................................................................\
..........................38
Clutch Master Cylinder Removal .............................................................................38
Clutch Master Cylinder Installation ..........................................................................40
Clutch Pedal Removal ..................................................................................\
...........40
Clutch Pedal Installation ..................................................................................\
........40
Clutch Pedal Examination and Adjustment ..............................................................41
CONTENTS

Downloaded from www.Manualslib.com manuals search engine Chapter Five: Transmission ........................................................................\
................................42
037A Transmission’s Overall External Schematics ....................................................43
Main Technical Parameters ..................................................................................\
....43
Transmission’s Proper Use and Care ........................................................................44
Technical Specifications for Transmission Installation and Adjustment .....................44
Areas of Importance ..................................................................................\
................45
Troubleshooting ..................................................................................\
.......................46
037A Transmission Structural Schematics ................................................................47
Clutch ...................................................................................\
......................................48
Gear Shift Fork and Fork Shaft ..................................................................................49
Transmission Case ..................................................................................\
..................50
Disassembling the Input Shaft Subassembly ............................................................56
Disassembling the Output Shaft Subassembly ..........................................................60
Disassembling the Shift Cover Subassembly ............................................................64
Disassembling the Differential Subassembly .............................................................68
Chapter Six: Suspension System ........................................................................\
.......................71
Suspension System Technical Parameters ...............................................................72
Front Suspension ...................................................................................\
....................73
Subframe and Front Stabilizer Bar ............................................................................77
Lower Swing Arm ...................................................................................\
....................80
Drive Shaft ..................................................................................\
...............................84
Rear Suspension ..................................................................................\
.....................86
Wheel and Tire ...................................................................................\
........................89
Chapter Seven: Brake System ........................................................................\
...........................94
Brake System Components Arrangement Schematics ..............................................95
Brake System Maintenance ...................................................................................\
....96
Brake Pedal ..................................................................................\
.............................98
Parking Brake Control Mechanism Assembly ..........................................................102
Vacuum Booster with Brake Cylinder Assembly ......................................................103
Anti-lock Brake System ...................................................................................\
.........107
ABS General Problem Maintenance and Areas of Importance ................................109
Steering Knuckle and Hub Brake Assembly ............................................................112
Front Brake Caliper ...................................................................................\
...............118
Rear Brake ...................................................................................\
............................124
Rear Support Axle ...................................................................................\
.................131
Chapter Eight: Steering System ........................................................................\
.......................134
Troubleshooting ..................................................................................\
.....................135
Steering System Maintenance .................................................................................137
Power Steering Fluid Instructions ............................................................................141

Downloaded from www.Manualslib.com manuals search engine Technical Requirements ..................................................................................\
........141
Chapter Nine: Vehicle Body Electrical System ........................................................................\
.142
Basic Information on the Electrical System .............................................................143
Fuse Box ...................................................................................\
...............................144
Overall Vehicle’s Grounding Point Schematics ........................................................150
Key Electrical Component’s Module Schematics for the Overall Vehicle ................151
Wire Harness Distribution Chart for the Overall Vehicle ..........................................152
Wire Harness Relationship and Plug-in Connections Numbered Diagram ..............155
Wire Harness Plug-in Connectors and Pin Function Diagram .................................156
Electrical Wiring Diagram for the Overall Vehicle ....................................................167
Chapter Ten: Electrical Accessories ........................................................................\
.................177
Reverse Sensor ..................................................................................\
.....................178
Combination Meter ..................................................................................\
................180
Central Door Lock ...................................................................................\
.................181
Power Windows ..................................................................................\
.....................184
Immobilizer System ..................................................................................\
...............186
CD Player ..................................................................................\
..............................193
DVD Player ..................................................................................\
............................195
Chapter Eleven: Air Conditioning System........................................................................\
........202
Areas of Importance ..................................................................................\
..............203
Technical Parameters ..................................................................................\
............203
Troubleshooting ..................................................................................\
.....................204
Air Conditioning System’s Structure Diagram and Fundamentals ...........................207
Air Conditioning System Overview ..........................................................................207
Air Conditioning System Terminal Definition ............................................................208
Compressor ..................................................................................\
...........................208
Electromagnetic Clutch ...................................................................................\
.........210
Vacuuming and Charging Refrigerant ......................................................................211
Filling Quantity and Method for Refrigerant Oil ........................................................212
Daily Maintenance of the Air Conditioning System .................................................212
Chapter Twelve: Airbags ........................................................................\
...................................213
Airbag Electronic Control Unit ..................................................................................214
Diagnostic Scanner ...................................................................................\
...............215
Troubleshooting ..................................................................................\
.....................216
Vehicle Collision Diagnostics ..................................................................................\
.226
Removal Method for Individual Components ...........................................................227
Driver Side Airbag Module (DAB), Front Passenger Side
Airbag Module (PAB), Clock Spring, and Steering Wheel .......................................228
Airbag Module Disposal ...................................................................................\
........230

Downloaded from www.Manualslib.com manuals search engine Airbag’s Diagnostic Methods Without a Diagnostic Scanner ...................................232
Chapter Thirteen: Vehicle Body ........................................................................\
........................233
Front Door Lock Assembly ...................................................................................\
....234
Rear Door Lock Assembly ..................................................................................\
.....237
Trunk Door Lock Assembly ...................................................................................\
...239
Wiper Arm and Vent Panel Assembly ......................................................................240
Front & Rear Window Glasses ................................................................................241
Dashboard ..................................................................................\
.............................242
Cooling Unit ..................................................................................\
...........................246
Front Door Assembly ..................................................................................\
.............248
Rear Door Assembly ...................................................................................\
.............251
Trunk Door Assembly ...................................................................................\
............254
Front Bumper ...................................................................................\
........................256
Rear Bumper ..................................................................................\
.........................259
Seat Belt ..................................................................................\
................................262
Seats ...................................................................................\
.....................................266
Sunroof Assembly ...................................................................................\
.................268

Downloaded from www.Manualslib.com manuals search engine 1Overview
Overview
How to Use This Manual ....................................................2
Identifying Number Location ...............................................3
Comprehensive Repair Instructions ...................................4
General Repair Methods and Operations ...........................9