2008 GREAT WALL FLORID brake

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 GWFLORID Maintenance Manual2
How to Use This Manual
1. There is a content index on the first page of each
chapter. You can consult the index to see the items
needed for maintenance. In order to make searching
more convenient, the subject of each chapter has been
printed on the page header of each odd page.
2. There is a summary or caution item in the beginning of
each chapter. Please read this content carefully before
any maintenance is performed. Some systems include
a malfunction diagnostic table to help determine ve-
hicle failures and their causes.
3. Throughout the entire manual, each maintenance
step's corresponding specification is highlighted in bold,
so there should be no need to pause maintenance
work in order to find these specifications.
4. Warnings, Cautions & Notes
• Warnings are highlighted in bold, indicating the possibility
of causing injury to oneself or to others.
• Cautions are highlighted in bold, indicating the possibility
of damaging the part being repaired.
• Notes are listed separately from the instructions, not high-
lighted in bold. They are mainly used for additional expla-
nations in order to work more effectively.
5. Maintenance procedures:
Most of the maintenance procedures begin with a high-level
component schematic, which indicates individual vehicle
components and how they are assembled.
For example:
Hollow bolt
Copper washer
Q150B1235
Heavy duty spring washer Q40512
Q43082
Front hub bearing assembly
Left steering
knuckleFront brake disc
cover LH
Q1420612
Front hub flange
Front brake disc
Front brake caliper assembly LH
100±10
9±2
N·m: Specified torque
Disposable parts

Downloaded from www.Manualslib.com manuals search engine 3Overview
Correct vehicle maintenance and repair is very important
to the safety of the maintenance person and the vehicle. If
any vehicle part change is necessary, please use a part with
the same part number or part number specified by the Great
Wall Motor Co., Ltd. Never use a part that has not been au-
thorized by the Great Wall Motor Co., Ltd.
4. Inspect the front brake disc thickness.
Standard thickness: 22.0 mm
Minimum thickness: 20.0 mm
The brake disc must be changed when its thickness falls be-
low the minimum level.
The maintenance procedures are explained step by step:
• The schematics and diagrams illustrate how and where to
operate.
• The titles convey the maintenance content.
• Detailed instruction explains how to perform the maintenance,
as well as introduces other related matters, such as specifications,
warnings, and so on.
For example:
Illustration: How and where to operate.
Work Subject: What to do
Detailed Instruction: How to do it
Specifications
Engine Manufacturing Number
The engine manufacturing number is engraved on the left
side of the engine cylinder block.
Vehicle Nameplate
Every vehicle has a vehicle nameplate, and this vehicle's
nameplate is located at the bottom of the right B-pillar.
Identifying Number Location
Vehicle Identification Number (VIN)
A Vehicle Identification Number is a unique serial number
consisting of 17 characters and used to identify individual
motor vehicles. This number is marked at three different
places: at the nameplate, at the upper-left side of the dash-
board, and at the cross member located under the front pas-
senger seat.
VIN
Vehicle Nameplate

Downloaded from www.Manualslib.com manuals search engine 9Overview
General Repair Methods and Operations
1. If a jack is needed, please kindly comply to the safety procedures liste\
d below.
2. Park the vehicle on a flat surface, stablize the front and the back wheels using any fixed object or tool,
jack up the vehicle, support it with the chassis, and then start the mai\
ntenance.
3. Disconnect the battery's negative cable before maintenance, in order to reduce the possibility of
damaging and burning out the cable due to a short circuit.
4. Cover the vehicle body, seats, and floor to prevent them from being damaged and polluted.
5. Handle brake fluid and antifreeze fluid carefully, because it may damage the vehicle's surface paint
and its surroundings.
6. Using the proper tools or basic tools that have been recommended and are purchasable is very
important in guaranteeing an effective and reliable maintenance result.
7. Dispose the used dowel pins, gaskets, O-rings, oil seals, lock washers, and self-locking nuts. Prepare
new parts for installation. Normal functions are not guaranteed if these\
parts are reused.
8. Store the removed parts in order and in groups to make reassembly more c\
onvenient.
9. Store bolts and nuts separately, because their hardness levels and designs are different according to
the installation locations.
10. Clean parts before they are inspected or reassembled. In addition, parts that come in contact with
engine oil also need to be cleaned, as well as checked for blockage by u\
sing compressed air.
11. Before installation, use engine oil or grease to lubricate the rotating and sliding sides of the necessary
parts.
12. When necessary, use sealant on gaskets to avoid leakage.
13. Please carefully comply to all tightening torque specifications of b\
olts and nuts.
14. After maintenance, check to make sure whether the repairs were performed correctly and whether the
malfunctions have been fixed.
Vehicle Lifting/Lowering Procedures
When lifting the vehicle, the lifter must be placed at the indicated spots. Using these indicated spots
incorrrectly can lead to permanent deformation of the vehicle body. Many vehicle service stations
have autolifts that raise vehicles by supporting certain vehicle parts. If using other types of lifts, be
careful to prevent damages to the fuel tank, oil filler, or the base of the vehicle body.
Frame contact lifting device and basic hand jack
Floor arch jack
Lifting points (left/right) of central threshold

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual14
Chassis' Main Assembly Technical Parameters (Continued)
ItemSpecifications
Wheel and
tire
Wheel specificationsStandard 15 × 6J rim, offset distance: 40 mm
Tire specificationsStandard tire selection 185/65 R15 88H
Spare tire
specificationsSpare tire 185/65 R15 88H, T125/70R16 96M J16 × 4T
Steering
system
Steering gearRack and pinion hydraulic power steering gear, with drive ratio of 19.03,
power steering pump rate of flow is 6.7-8.9 L/min
Steering columnSafe, energy absorbing, angle-adjustable steering column, with an adjustable
range of 3.6°.
Steering wheelA three stage softening type with airbag, diameter of 370 mm, and maximum
steering circle number of 3.08.
Main technical
parameters
Front wheel camber/rear wheel camber-0° 43′ ± 30′ /-0° 43' ± 30'
Kingpin angle+10°21′ ± 30′
Kingpin caster+1°49′ ± 30′
Front wheel toe-in/rear wheel toe-in-0° 01′ ± 15′ /+0° 14' ± 15'
Inside wheel steering angle (°)32°-37°
Outer wheel steering angle (°)28°-30°
Steering wheel rotation number (n)3.08
Steering system angle ratio (i0ω)19.03
Brake
system
Service brake type
The service brake system adopts a hydraulic vacuum power-assisted type.
The front/rear brakes are disc and drum brakes respectively. The front brake
uses a ventilated disc, and the brake pedal is a suspended pedal with vacuum
booster. Brake line is in a dual-circuit diagonal (X type) arrangement,
adopting a ABS + EBD anti-lock and braking force distribution system.
Service brake booster
and master cylinder
Single stage Φ9inch vacuum booster, series dual-chamber brake master
cylinder, cylinder bore Φ22.22 mm, stroke 32 mm
Brake reservoirShares with the clutch master cylinder reservoir and installed with a brake
fluid level alarm.
Brake pedal strokeFree play: 6-9 mm, working stroke: 37-40 mm.
Brake pedal pressure<380 N (no load) <480 N (full load)
Parking brake
The parking brake system uses a mechanical remote ratchet cable control
mechanism to control the rear wheel drum brake. Brake lever's functional
stroke is 5-8 gearteeth.
Brake parameters
Front wheelFloating caliper disc brake
Wheel cylinder
diameterΦ54 mm
Brake disc
diameterΦ255 mm
Rear wheelLeading trailing shoe drum
brake
Wheel cylinder
diameterΦ19.05 mm
Drum brake
diameterΦ200 mm

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 GWFLORID Maintenance Manual18
Torque Specifications for Key Operational Bolts
Any part that has a tightening torque requirement for fastening piece connections should be fastened according
to specifications, the tightening torque of fastening pieces that have no tightening torque specification should
satisfy the QC/T 518—1999 regulations.
Tightening torque for key operational bolts are shown in the table below.
No.Important fastening piece locationsFastening piece name
and model numberQuantity
Tightening
torque
(N·m)
1Chassis
1.01Left mount & left side memberHexagon bolt for flange face1112±10
Left mount & left mounting bracketHexagon bolt for flange face264±5
1.02Left mounting bracket & transmissionHexagon bolt for flange face364±5
Right mount & engineHexagon nut for flange face141±4
1.03Right mount & engineHexagon bolt for flange face264±5
Right mount & vehicle bodyHexagon bolt for flange face 264±5
Grade Specification and Filled Quantity of Each Individual Functioning
Component's Working Agent
No.Functioning
component
QuantitySpecificationsGW413EFGW4G15
1Engine fuel45L
#93 and above high quality unleaded gasoline (GW413EF,
GW4G15 engine)
#-10 light diesel fuel (YC4W75-31 engine)
2Engine
lubricant3.25±0.25 L3.5L
GW413EF
SJ 15W-40/SJ 10W-30
(For China domestic model)
SL 5W-30 (For alpine region model)
GW4G15
SJ 20W-40/SJ 10W-30 (For domestic &
exported high-temperature region model)
SL 10W-30 (For alpine region model)
3Coolant5.5±0.5 L5.4±0.5 L
Ethylene-Glycol-35oC antifreeze fluid
(For China domestic model)
Ethylene-Glycol-45oC antifreeze fluid
(For alpine region model)
4Clutch fluid0.49±0.02 L0.72±0.02 LDOT4 synthetic brake fluid
5Transmission
lubricant1.9±0.1 L1.8L
GL-4 80W-90 (For China domestic model)
GL-4 75W-90 (For alpine region model)
GL-5 140 (For high-temperature region model)
6Power steering
fluid0.65±0.02 L0.75±0.02 LATF DEXRONⅢ Mobil fluid
7Brake fluid0.49±0.02 LDOT4 synthetic brake fluid
8Battery
terminal1.0 gIndustrial vaseline
9Windshield
washer fluid2.8±0.1 L
Room temperature: use clean water with a hardness less
than 205g/1000 kg.
Low temperature (-18oC±3oC): use methanol-water
solution concentration of 50%.
10Air conditioner
refrigerant510±10 gR134a