2008 GREAT WALL FLORID cooling

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 GWFLORID Maintenance Manual12
Ride
Performance
Outter acceleration noise dB (A)≤74≤75
60 km/h constant velocity interior noise dB (A)≤65≤65
Driver operating noise dB (A)≤90≤90
Emission
CO emission (g/km)≤2.30≤1.00≤0.64
HC emission (g/km)≤0.20≤0.10/
NOx emission (g/km)≤0.15≤0.08≤0.5
Particle emission (g/km)//≤0.05
Smoke density//≤4.0
Engine Technical Parameters
ItemUnitSpecifications and Parameters
Model numberGW413EFGW4G15YC4W75-31
Model
Inline four cylinder, 4-stroke, water cooling, dual
overhead camshaft, petrol engine
Inline four cylinder,
4-stroke, water cooled,
dual overhead camshaft,
diesel engine
Fuel supply typeElectronic controlled, multi-points ordinal injection
High pressure electronic
controlled common-rail
fuel injection
Cylinder bore ×
strokemm × mm78.7 × 69.075 × 84.771.0 × 77.0
DisplacementL1.3421.4971.219
Compression ratio9.3:110.5: 118.5:1
Number of valves/
cylinder16/4
Lowest rate of fuel
consumption g/(kW·h)<260≤260215
Maximum power/
rotation speed kW/(r/m)65/600077/600050/4200
Max. torque/
rotation
speed
N·m/(r/m)115/4400-5200138/4200153/2000-2400
Total net weightkg11596142±2
Idle speedr/min800±50800750±50
Fuel type and
gradeRON/MONUnleaded gasoline, #93Euro diesel fuel
Cooling style and
performance
parameters
Forced water circulation
cooling, the opening
temperature of the
thermostat is 82±2oC, the
water temperature under
normal working condition
is 90-100oC, the opening
pressure of the coolant
compensation box's
pressure limiting valve is
108±14.7 kpa
Forced water circulation
cooling, the opening
temperature of the
thermostat is 82±2oC, the
water temperature under
normal working condition
is 80-90oC, the opening
pressure of the coolant
compensation box’s
pressure limiting valve is
108±15 kpa
Forced water circulation
cooling, the thermostat
starts to open at 75oC and
is fully open at 85oC, the
opening pressure of the
coolant compensation
box's pressure limiting
valve is 108±14.7 kpa
Starting style and
performance
Motor starting, starting performance complies with GB18297
requirements 8.1.2 and 8.1.3
Lubricating
methodPressure and splash combination

Downloaded from www.Manualslib.com manuals search engine 13Overall Parameters
Chassis' Main Assembly Technical Parameters
ItemSpecifications
Model numberGW413EFGW4G15YC4W75-31
ClutchClutch type
Single chip, dry type, diaphragm springSingle chip, dry type,
diaphragm spring
Driven disc diameter:
200 mm
Clutch disc diameter:
213 mm
Driven disc diameter:
212 mm
Maximum stroke: 9 mm, separating stroke: 7.5 mmSeparating stroke:
7.5 mm
Clutch hydraulic pressure
control systemClutch pedal total stroke: 116.5mm
Transmission
Transmission
model number037ACC0011AZM007QZM007W
Transmission typeMechanical 5-gear manual transmission
Main speed
reduction ratio3.9444.31254.2673.937
Gear
transmission
ratio
1st gear3.5453.5453.3643.182
2nd gear1.9131.9051.8951.895
3rd gear1.3101.3101.2861.25
4th gear0.9730.9700.9690.91
5th gear0.8040.8160.8000.703
Reverse
gear3.2143.2503.2143.08
Maximum bearing
torque (N·m)130160153153
Maximum input speed
(r/min)6000
Propeller shaft
The input end of the propeller shaft adopts a widely used, near constant
velocity, retractable spherical roller wheel joint. The output end adopts a
Rzeppa joint.
Air intake systemDry air filter, paper filtering element.
Exhaust system
Equipped with GW413EF engine, two grade muffler with two grade three-
way catalytic converter. Front/rear oxygen sensors.
Equipped with YC4W75-31 engine, two grade muffler with one grade three-
way catalytic converter and oxygen sensor.
Fuel supply system
Equipped with GW413EF engine. The 45L metal fuel tank includes an
electronic fuel pump and a charcoal canister. An electronic accelerator pedal
controls the fuel supply. The fuel evaporation control system controls the
charcoal canister through a solenoid valve
Equipped with the YC4W75-31 engine. High pressure electronic common-
rail fuel injection and dual fuel pipeline. The 45L metal fuel tank includes an
electronic fuel pump and a charcoal canister, electronic accelerator pedal, a
fuel line is connected with the fuel-water separator and diesel fuel filter.
Cooling system
The cooling system uses the enclosed forced water circulation cooling
system, the heat dissipating electronic fan uses a two level speed controller.
The electronic fan and overflow tank are combined in one. The radiator is
equipped with upper and lower water chamber aluminum pipe. The system
pressure is 90 kPa.

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual16
Air Conditioning System Structure and Parameters
ItemStructure and parameters
Structure typeVapor compression refrigeration, water warmer, and water heater
Performance parametersAir conditioner refrigerating capacity is 5 kW. Blower's air volume is 450 m3/h. Air
conditioner heating capacity is 4.5 kW.
Controls
Control panel knob, button, manual shift lever control, position gate and temperature
threshold cable drive, new damper micro-motor drive, able to select and adjust air
outlet position, heating/cooling mode, air inner/outer circulation mode and wind speed,
temperature, and more advanced selections and adjustables.
RefrigerantR134a, 510±10g
CompressorModel number: JSS-96TV4-4
CondenserAdvective and subcooling structure with flat tube thickness of 16 mm and dry reservoir
Φ34 mm × L280 mm.
Heating, Ventilating
and Air Conditioning
(HVAC)
Heating, Ventilating and Air Conditioning (HVAC): Of a three-box type consisting of
a layered evaporator, advective heater, H-shaped expansion valve, centrifugal blower,
and air outlet distributing box. Contains cooling, heating, defrosting and air freshening
functions, and operated by a link mechanism driving air valve.
Refrigeration line &
water heating tube
Refrigeration line: a compound structure using a rubber cooling pipe and an aluminum
pipe. Water heating pipe: molded rubber pipe.
SensorsEvaporator temperature sensor
Pressure switchHigh/Mid/Low three position pressure switch
Electrical System Structure and Parameters
ItemStructure and parameters
Power, start
up, and
electronic
charging
system
CircuitSingle wire system, voltage of DC12 V, negative ground
Battery12 V/60 Ah, maintenance-free battery
Starter1.2 kW
Alternator14 V/90 A
Lighting and
signaling
system
Headlight2 white (high beam 55 W, low beam 60 W) H4, height is electrically
adjustable.
Parking lamp2 front parking lamp: white, 5 W. 2 rear parking lamp: red, 5W
Turn signal lampAmber colored. 21W, 2 in the front and 21W, 2 in the back. Turn signal
lamps: 0.3W, 4 LED.
Fog lamp2 front fog lamps: 55W. 2 rear fog lamps: 7.5 W
Brake lamp2 red 21 W. high mounted brake lamps 3 W
License plate lamp2 white 5 W
Reverse lamp2 white 21 W
Hazard warning signal
lampAll turn signal lamps and switch controls
Rear reflectorsRed and non-triangular, inside the rear combination lamps.
Front reading lamp &
interior dome lamp
Front reading lamp: one white 10 W or one white 10 W, two 5 W (with
sunroof).
Interior dome lamp: White, 10 W.
Cigarette lighter
lightingBlue, 3 W, one

Downloaded from www.Manualslib.com manuals search engine 17Overall Parameters
ItemStructure and parameters
Dashboard
system
Combination meter Speedometer, tachometer, odometer, fuel gauge, LCD (electronic clock &
reserved automatic gear indication).
Indicator lamp
Driver's seat belt unfastened warning lamp, charging indicator lamp, low
oil pressure warning lamp, service engine light, ABS malfunction indicator
lamp, EBD indicator lamp, EOBD indicator lamp, door unlock warning
lamp, SRS malfunction indicator lamp, high beam indicator lamp, left
turn signal lamp, right turn signal lamp, parking brake indicator lamp,
brake malfunction warning indicator lamp, front fog lamp indicator, back
fog lamp indicator, fuel warning lamp, engine cooling water high/low
temperature indicator lamp, engine preheating indicator lamp, oil/water
separator indicator lamp, O/D indicator lamp.
Auxiliary
electrical
system
Overhead antenna & interior lighting adjustment switch control.
Windshield system
Front wiper: inching, high speed, low speed, and clearance gear with time
slot adjustment, with reset.
Rear wiper: normal gear with reset.
Defog & defrost deviceRear wiper uses an electrical heated tempered glass with switch control.\
Power window
regulator
D r i v e r ' s s i d e h a s t h e m a s t e r c o n t r o l , o t h e r d o o r s a n d w i n d o w s a r e
independent (left and right front doors are both with door lock controlling
switches), with anti-pinch and automatic closing.
Central door lockRemote central door lock (controlled from the front left door), rear doors
containing children protector.
Backup power supply12 V, 120 W, one
Stereo equipment
Single CD, audio input interface
Multidisc DVD (optional)
There are 4 speakers in the standard configuration, 6 in the luxury and elite
configuration.
Cigarette lighter12 V, 120 W, with lighting, one
HornHigh/low disc type horn
Airbag
Comfort type uses a driver side electronic airbag
Luxury type and elite type uses driver and front passenger electronic
double airbags
EngineWith immobilizer system
Electrical System Structure and Parameters (Continued)

Downloaded from www.Manualslib.com manuals search engine 89Suspension System
Wheel and Tire
Tire
Remark
This vehicle's tire is of the tubeless type. The optimal design condition is met when the inflation pressure is at
the recommended value, and the tire is under full load. Maintaining suitable tire pressure and proper driving
habits greatly influence the tire's use life. For the vehicle, it improves riding comfort, stability, and handling. For
the tire, it reduces tread wear, damage to the tire and extends tire life. Overloading, speeding, and unnecessary
emergency braking will all add to the tire's wear and tear.
Tire pressure measurements should be taken under normal temperature. If the tire pressure rises due to motion
generated heat when driving, cooling it will return to the normal temperature. Therefore, do not deflate the tire
when the air pressure has risen to this point. The tire's air pressure will naturally and slowly decrease when used
under normal conditions. Hence please inspect the air pressure regularly (suggested once a month). The spare
tire should be kept in a useable condition at all times.
Inspect the tire pressure when it is cool monthly or before a long drive. Adjust the tire pressure to the recom-
mended level. The air pressure will normally rise because the tire warms up due to movement. Therefore, after
driving, you absolutely must not deflate or reduce the tire's air pressure, as deflating could reduce the cool tire's
air pressure.
Tire inflation
During a new tire's initial stage of use, warning due to bending motions will cause the tire to swell, and thus
reduce the corresponding air pressure. After 24 hours or 2000-3000 km worth of drive, charge the air pressure.
After inflating, check if the air nozzle core is leaking air with soapy \
water, then lock on the cap.
Possible problems caused by tire pressure
Exceeding the recommended air
pressure
Below the recommended air pressureSame vehicle axle, different
air pressure
Possible problems it
can create
1. Bumpy ride
2. The tear or rupturing of the tire
3. Rapid wear of the tire tread's center
1. Noisy turns
2. Uneasy turns
3. Tread edge wear is accelerated and uneven
4. The tire's rim is damaged or ruptured
5. The tire cord ruptures
6. High tire temperature
7. Steering failure
8. Large oil consumption
1. Uneven braking
2. Over steering
3. Steering failure
4. Deviation while accelerating
Tire and wheel (steel wheel) installation instructions
When installing the tire and wheel, the tire's radial hardware components, also called "high spot", should be at
the same level of the wheel's minimum radius or so called "low spot".
The "high spot" of the tire is initially marked by the paint spot on the side of the tire's surface. This paint will
eventually be washed away.
The "low spot" of the wheel is initially marked by a paint spot on the wheel flange. Whenever the tire is
removed from the wheel, the tire and wheel need re-balancing to make sure the vehicle runs smoothly. If no
paint spot is found on the tire, draw a line on the tire and the wheel before they are removed, in order to make
sure that the tire and the wheel will be re-assembled at the same place.\

Tire replacement
When a tire needs to be replaced, make sure to use a tire with the same specification as the original one. A new
tire used for replacement must be of the same dimension, load area, and structure as the original one. Using tires
that are different in dimension or type will influence the vehicle's riding comfort, handling, speedometer and
odometer calibration, vehicle ground clearance, and the clearance between the tire or the tire's snow chain and
the vehicle body or chassis.
It is suggested to use a new pair of tires on the same axle. If only one tire is needed to be replaced, make sure to
use a tire with a tread most similar to the original, so as to keep brak\
e power and traction balanced.
Warning: Do not mix radial tires, bias tires, bias belted tires, etc., which are of different structure on the
same vehicle unless it is an emergency. Mixing different tires would seriously influence the vehicle's
handling and stability, and even possibly lead to losing control of the vehicle.

Downloaded from www.Manualslib.com manuals search engine 93Suspension System
Dynamic balance and static balance
There are two types of wheel balance: static and dynamic.
Picture 1 shows static balance. Picture 2 shows dynamic
balance.
Static balance means that the weight distribution around the
wheel is equal. If the wheel is static and unbalanced, violent
vibrations may be created, called jump vibration.This kind
of situation can ultimately lead to the uneven wear and tear
of the tires. Shown in diagram 1.
Dynamic balance means that the weight distribution on the
two sides of the medium plane of the wheel is equal, so
during the rotation process, the tire assembly cannot create a
tendency for the medium plane of the wheel to shift from one
side to the other. If the wheel is dynamic and unbalanced, it
can create a shimmying effect. Shown in diagram 2.
1. Wheel shimmy important points[C]: Counterweight not yet added
2. Locations to add counterweight[D]: Counterweight added
3. Axis
Wheel maintenance
Do not use welding, heating, or hammering to repair wheels. All damaged wheels must be replaced.
If the vehicle's wheel is twisted or deformed, sunken or depressed, having too much horizontal or radial hop,
leaking air from the welded parts, stretched out at the bolt holes , having flimsy nut bolt lock, or severely rusty,
the wheel must be replaced. When the wheel is hopping too much, it will lead to undesirable vibratio\
ns.
When replacing the tire, be sure that the load capacity, diameter, rim width, offset distance, and the installation
structure of it, are equal to the settings of original wheel. If the wheel dimensions are not appropriate, this will
influence the wheel and bearing's life, brake cooling effect, speedometer and odometer calibration, vehicle
ground clearance, as well as the clearance between the tire and the vehi\
cle body, and the tire and vehicle chassis.
Wheel (steel wheel) removal
1. Remove the wheelhouse and loosen the nuts, 1-2 turns is
enough.
2. Hoist the vehicle.
3. Screw off the nuts and remove the wheel.
Nut tightening torque: 110±10 N·m
Caution: Heating methods absolutely must not be used
to loosen tightened wheels, otherwise the heat will
reduce its use life and damage the hub bearing.
Wheel (steel wheel) installation
Installation according to the reversed instructions used for
removal, and pay attention to the following requirements:
Wheel nuts must be tightened in proper order and according to
the specified torque, as to avoid wheel or brake disc deformity.
When installing the wheel house, be sure to line up the wheel
housing notch locations with the inflation nozzle.
Tightening sequence: A – C – B – D
Caution: Before installing the wheel, first clean off the
corrosion on the wheel's mounting surface and drum
brake or brake disc's installation surface with a wire
brush, in order to make the wheel installing easier by
making the space between its metal firmly connect
to the mounting surface, otherwise it may lead to the
wheel nuts loosening to the extent that the vehicle's
wheel may come off while driving some day.
1
3
2[A][B]
1. Wheel hop important points[A]: Counterweight not yet added
2. Locations to add counterweight[B]: Counterweight added
3. Axis
Diagram 1
Diagram 2
[C][D]
1
3
2
AB
CD

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual204
FailureSymptoms Cause analysis
Air con-
ditioning
system fails
to produce
cold air
Compressor
does not work
Blown fuse, compressor relay damaged
Pressure switch contact broken, short circuited, or open circuit
Compressor electromagnetic clutch open circuit
Switch burnt out
Main relay burnt out
Clutch slips
Compressor belt broken or loose
Compressor failure
Insufficient coolant, system pressure below 0.196 MPa
System pressure exceeds 3.14 MPa
Engine water temperature is too high
Clutch voltage is below 7 V
Compressor
pulling in
Compressor relay often open contact bond, system coolant leaks severely,
system has no coolant
Blower does not work
Blower has no windBlown fuse
Blower motor brush damaged
Blower switch damaged
Wiring connector detached or open circuit
Speed regulation module damaged
Blower has no wind at high speeds, high speed relay damaged
Note: Blower's non operational process has a resistance value of 0, with a
open circuit resistance value of
The cool-
ing system
sometimes
works, some-
times not
Compressor operates
normally
Cooling system has ice blockage
Thermistor or thermometer bulb malfunction
Abnormal A/C switch contact
Condenser blower damaged
Compressor operates
abnormally
Clutch slides, clutch coil loose, clutch coil bad connection
Insufficient
cooling




Low wind volume

Blower fan normal: air pipe damaged
Cooling fan operates abnormally:
(1) Blower switch abnormal
(2) Supply voltage low
(3) Speed regulation module damaged
Wind vol-
ume normal

Compressor operates normally
(1) High and low pressure side's pressure is low
(a) Expansion valve is blocked
(b) Expansion valve opening is too small
(2) High and low pressure pipe's pressure is high
(a) High pressure pipeline malfunction, uneven flow
(b) Thermistor failure
(c) Expansion valve opening is too big
(d) Too much refrigerant oil
(e) Too much refrigerant
(f) Poor condenser heat dissipation
Note: When the speed is at 2000 r/min, cooling fan at max gear, and air tem-
perature at 30-35oC, the system's low pressure side pressure should be 147-
192 KPa, and high pressure side pressure 1373-1668 KPa

Troubleshooting