2008 GREAT WALL FLORID brake fluid

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 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 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

Downloaded from www.Manualslib.com manuals search engine 37Clutch Operational System
Areas of Importance
1. Clutch Rigid Pipe Installation
Before installing, check to make sure that the rigid pipe flare contact area is in good condition, the pipeline is
clean, and that there is no foreign materials.
2. Clutch Hose Installation
Check the surface of the clutch hose to make sure that there is no scuffing and that the pipeline is clean.
3. Coat grease on the U-joint of the pedal and the master cylinder.
4. Strictly adhere to the set torque guidelines when tightening the pipe fittings.
Rigid pipe and the master cylinder: M10 16±2 N·m
Clutch rigid pipe and hose: M10 16±2 N·m
5. While the clutch system is undergoing the exhausting process, make sure that all the air bubbles in
the pipeline are cleared out. Then check the brake fluid level in the reservoir, it should be between
MIN and MAX.
Troubleshooting
The numbers in the table represent the order of the possible malfunction causes, so be sure to check each part in
turn. If necessary, replace the part.
SymptomsPossible Causes
Clutch vibration1. Engine mounting bracket (loose)
2. Clutch plate (axial runout is too much)
3. Clutch plate (oil build-up)
4. Clutch plate (polished)
5. Clutch plate (hardened)
6. Diaphragm spring (damaged)
Clutch pedal is spongy1. Clutch pipeline (air entering)
2. Clutch master cylinder cup (damaged)
3. Clutch slave cylinder cup (damaged)
Clutch makes abnormal noise1. Clutch release bearing (wear and tear, dirty or damaged)
2. Driven plate torsion damper (damaged)
Clutch slips1. Clutch pedal (free play is out of alignment)
2. Clutch plate (oil build-up)
3. Clutch plate (polished)
4. Diaphragm spring (damaged)
5. Pressure plate (deformed)
6. Flywheel (deformed)
Clutch cannot be disengaged1. Clutch pedal (free play out of alignment)
2. Clutch pipeline (air entering)
3. Clutch master cylinder cup (damaged)
4. Clutch slave cylinder cup (damaged)
5. Clutch plate (axial runout is too much)
6. Clutch plate (wear out from friction)
7. Clutch plate (dirty or burnt)
8. Clutch plate (oil build-up)
9. Clutch plate (lack of grease on the spline)

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual38
Clutch Operational System
Components
Clutch Master Cylinder Removal
1. Use a combination plier to loosen the steel band elastic
hoop, and to remove the clutch feed connecting hose.
Caution: Release the brake fluid in the reservoir before
disconnecting the hose.
Steel band elastic hoop
Clutch feed connecting hose
Reservoir
Steel band elastic hoop
Clutch feed connecting hose
Clutch discharge pipe
Clutch master cylinder
Limit adjusting bolt
Return spring
Lock nut

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual40
Clutch Master Cylinder Installation
Installation of clutch system is reverse to its removal, but
since the whole clutch system uses hydraulic assistance,
make sure to air bleed it after the installation is completed.
Detailed steps as follows:
(a) Plug one end of the long transparent connection hose
(about 0.5 m long) into the bottom of bleed screw, and
the other end into a fixed container.
(b) Loosen the bleed screw via the open end of the M8,
meanwhile ask the assistant to step on the clutch pedal
repeatedly until no air bubbles can be seen in the hose.
R e m a r k : R e s i d u a l a i r i n t h e c l u t c h s y s t e m h a s b e e n
completely exhausted.
(c) Lastly, lock the bleed screw.
Caution: Refilling the brake fluid reservoir should be
performed while air bleeding the clutch.
Clutch Pedal Removal
1. Remove the battery's negative cable.
2. Remove the glove box at the left of the dashboard.
3. Remove the cotter pin at the U-joint of the clutch
master cylinder, and separate the center pin and the
pedal lever.
4. Remove the clutch pedal bracket from the cowl.
5. Remove the clutch pedal.
(a) Move the clutch pedal to the maximum stroke position.
(b) Take down the return spring.
(c) Remove the bolts and nuts.
(d) Take the pedal lever down from the pedal bracket.
Clutch Pedal Installation
1. Install the clutch pedal.
(a) Install the return spring.
(b) Install the clutch pedal lever.
(c) Install the bolts and nuts.
Tightening torque: 30 N·m
(d) Put the pedal lever at the maximum stroke position and
connect it with the spring, in order to set the pedal to its
initial position.
2. Install the clutch pedal onto the 2 studs of the clutch
master cylinder.
Use a M13 wrench to tighten the clutch pedal brackets with
two M8 nuts.
Tightening torque: 23±3 N·m
3. Install the clutch master cylinder push rod with the U-
joint.
(a) Coat the contact areas between the center pin and the
U-joint pedal connector with multi-functional grease.
(b) In succession, join the U-joint (pedal connector) and
the clutch pedal lever with a cotter pin.
Caution: Insert the center pin into the pedal lever from
the left side of vehicle.
(c) Install the cotter pin onto the center pin.
4. Check and adjust the clutch pedal.
5. Connect the negative cable of the battery.
Bleed screw

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual74
3. Remove the wheel speed sensor and the brake hose
Remove the wheel speed sensor's mounting bolts with a M10
sleeve to take off the wheel speed sensor. Remove the front
brake hose's mounting bolts with a M18 sleeve, and then
take off the brake hose.
Caution: When removing the brake hose, brake fluid
may flow out, catch the fluid with a container. Also,
b e c a u s e t h e b r a k e f l u i d i s c o r r o s i v e , p l e a s e p a y
attention to personal protection.
4. Remove the cotter pins and lock nuts of the steering tie
rod and the lower swing arm
Because the ball stud and steering knuckle act in conjunction
with the tapered bore, they can not yet be removed after re-
moving the nuts. Pound the steering knuckle arm (unfinished
surface) with a hammer. Positions are shown on the left.
Shake to loosen.
Caution:
1. To avoid separating the ball studs, do not pound the
tie rod and the lower swing arm with a hammer.
2. To avoid damaging the thread, do not hammer the
ball stud's head.
Front brake hose mounting bolt
Wheel speed sensor mounting bolts
Lightly hammer here