GREAT WALL FLORID 2008 Service Manual

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Steering System
Troubleshooting ..................................................................135
Steering System Maintenance............................................137
Power Steering Fluid Instructions .......................................141
Technical Requirements .....................................................141

Downloaded from www.Manualslib.com manuals search engine 135Steering System
Troubleshooting
Fault
SymptomsMalfunction CausesTroubleshooting
Steering wheel
free play too
big / abnormal
noise
1. Too much clearance between the steering
gear and gear rack.
2. The inner and outer ball stud of the steering
tie rod ball is worn out.
3. Steering joint is worn out.
4. Steering propeller shaft and steering gear
connection is loose.
5. Steering wheel and steering column connec-
tor is loose.
6. Steering gear mounting bolt is loose.
7. The sliding spline of the lower propeller
shaft is worn and loose.
1. Have the clearance adjusted by professionals,
and if it cannot be adjusted, replace the steer-
ing gear.
2. After inspection, replace the ball stud if nec-
essary.
3. Replace the lower section of steering column.
4. Fasten the connection bolts in accordance
with the specified torque.
5. Fasten the lock nut of the steering wheel.
When the spline is damaged, make sure to re-
place the steering wheel or steering column.
6. Fasten the mounting bolts of the steering
gear.
7. Replace the lower section of steering column.
Hard steering
1. Tire pressure insufficient.
2. Front wheel alignment angle incorrect.
3. Clearance between the steering gear presses
too small.
4. Steering column's spider bearing broken.
5. Steering tie rod ball stud lacks oil or is dam-
aged.
6. Front shock absorber's support bearing bro-
ken.
7. Damaged lower swing arm ball end.
8. Damaged steering pump leads to insufficient
output volume and output pressure.
9. Power steering pump belt slides.
10.Power steering gear internal leakage too
much.
11. Power steering contains air bubbles and pro-
duces irregular noise.
12. Power steering insufficient.
1. Inflate according to the specified pressure.
2. Check and adjust the front wheel alignment
angle.
3. Replace the steering gear or have profession-
als adjust the clearance between the presses.
4. Replace the lower section of steering column.
5. Replace the lower section of the steering tie
rod ball.
6. Replace the connecting components of the
front shock absorber (refer to the front sus-
pension maintenance section).
7. Replace the lower swing arm (refer to the
front suspension maintenance section).
8. Replace the power steering pump.
9. Adjust the belt's tension.
10. Replace the power steering gear.
11.In place, repeatedly turn, exhaust the air
bubble, then after leaving it stationary for one
hour, replenish the power steering according
to the specific model number.
12.Fill the power steering (with specific model
number) until it reaches the PS fluid reser-
voir's specified scale mark.

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Fault
SymptomsMalfunction CausesTroubleshooting
Poor steering
return
Straight
movement
stability poor
1. Tire pressure insufficient.
2. Wheel counterweight falls off or other fac-
tors cause extremely poor wheel balance.
3. Lower swing arm's rubber bushing is too old,
big difference between the left and right's
rigidity.
4. The front shock absorber's support bearing
and lower swing arm ball lacks sufficient lu-
brications.
5. The four wheels' positional parameters incor-
rect.
6. Steering gear's gear rack meshing condition
worsens and causes intense reverse resis-
tance.
7. Steering column bearing and spider bearing
damaged.
8. Power steering pump's oil supply insuffi-
cient.
9. Inner portion of the steering gear's control
valve performance degradation.
1. Inflate according to the specified pressure.
2. Recalibrate the wheel's dynamic balance.
3. Replace the lower swing arm.
4. Fill with grease of the specified model num-
ber.
5. Re-measure and adjust the four wheels' posi-
tional parameters.
6. Replace the steering gear.
7. Replace the steering column assembly.
8. Replace the power steering pump.
9. Replace the power steering gear.

Downloaded from www.Manualslib.com manuals search engine 137Steering System
Steering System Maintenance
Structure Introduction
The steering wheel has an airbag module which should only be inspected and repaired by a professional. The
steering column's upper section adopts a steel deformation and energy absorbing crumple structure which
ensures collision protection for the driver. The lower section uses a high precision sliding spline structure,
which can effectively eliminate structural interference caused by body deformation. The steering column angle
is adjustable, which can more easily adapt to the driver, and at the same time possesses reasonable reverse
efficiency to ensure the driver has a good feel for the road. Steering sys\
tem is as shown below:
Steering column assembly removal and
installation
1. Remove the airbag.
(a) Disconnect the battery's negative cable, and wait for
one minute before canceling the airbags function in
order to avoid unnecessary injury.
(b) To ensure steering column's proper installation, during
the entire removal process, the front tires must keep
straight.
(c) Remove the two hexagon screws and the airbag module.
Hexagon screw
Steering wheel
Steering column
Steering propeller shaft
PS fluid reservoir
Power steering pumpBelt
Power steering gearSteering combination pipe
Steering propeller shaft connector jacket assembly
Steering dust cover
Steering protection plate

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2. Remove the steering wheel.
(a) Remove the lock nut Q32012 (M12×1.25) of steering
wheel with a M18 socket wrench in the counterclock-
wise direction.
(b) Grip the entire steering wheel and shake it several
times, and then to pull out the steering wheel upwards.
3. Remove the upper and lower trim cover of the combina-
tion switch.
4. Remove the left and right combination switch and the
ignition lock.
(a) Pull out the wire harness on the left and right
combination switch and the ignition lock.
(b) Remove the left and right combination switch and the
ignition lock.
5. Screw off the bolt 3404202-S08 connected the steering
column and steering propeller shaft with a M13 socket
wrench in the counterclockwise direction.
6. Screw off the two flange bolts Q1840820 (d2=22) which
are in the upper part of steering column connected
to instrument brace reinforcement with a M13 socket
wrench in the counterclockwise direction, and screw
off one flange bolt Q1840850 which is in the lower
part of steering column connected to instrument brace
reinforcement with a M10 socket wrench in the counter-
clockwise direction. Follow the column's upper axes
and pull out the steering column assembly.
Q32012 (M12×1.25)
Lower trim cover
Upper trim cover
3404202-S08
Q1840820 (d2=22)
Q1840850
Right combination switch
Left combination switch
Ignition lock

Downloaded from www.Manualslib.com manuals search engine 139Steering System
7. Manually rotate the two plastic buckles 3412012-S08 in
the counterclockwise direction, and remove the steer-
ing dust cover installed on the steering propeller shaft.
8. Remove the bolt 3404202-S08 connecting the steering
propeller shaft and steering drive connection shaft with
a M13 socket wrench, and then pull out the propeller
shaft.
9. Pull out the steering propeller connection shaft's jacket
assembly 3412100-S08. Remove the bolts 3404202-
S08 which are on the steering propeller connection
shaft and steering gear with a M13 socket wrench, and
then pull out steering propeller connection shaft.
10. Install the steering column assembly by reversing the
removal steps. Pay attention to items below:
(a) While installing the steering column and propeller
shaft, and propeller shaft and steering gear, after insert-
ing the screw into the threaded hole, the screw should
align perfectly with the circular groove, as shown on
the left:
(b) When installing the steering wheel, ensure that the
front tires are in a straight line, make the vehicle logo
on the top of the steering wheel face straight ahead, and
ensure the inner steering spine and steering shaft spline
are aligned.
(c) Fasten the bolts and nuts according to the specified
torque.
3412012-S08
Circular groove
3412100-S08
3404202-S08
Power steering gear removal and installation
1. Screw off the flange bolt connecting the steering col-
umn's lower section and the power steering small gear
shaft with a M13 socket wrench, and then pull out
steering column’s lower section.
2. Remove the steering tie rod ball assembly.
Loosen the hexagon slotted nuts (thread space: 1.25)
Q387B12 with a M18 socket wrench.
3. Hammer the circumference of the steering knuckle arm
with a hammer along the direction of the taper bores
until the tie rod ball and steering knuckle arm's taper
fittings loosen, then pull out the tie rod ball downwards.
Q5003220
Q387B12
3404202-S08

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4. Screw off the two bolts Q1840816 of the steering
gear protection plates installed on the subframe with
a M10 socket wrench, and remove the steering gear
protection plate.
5. First fasten four hexagon nuts 2904013-S08 with a
M18 socket wrench, then screw off the four hexagon
bolt gasket groups 3411013-S08 and 3411014-S08
installed on the subframe with a M14 socket wrench.
6. Remove and replace the steering tie rod ball assembly.
Fasten the hexagon nuts in the cotter pins with a M12 socket
wrench, then loosen the steering tie rod ball with a M19
socket wrench, and then finally pull out steering tie rod ball
assembly.
2. Unscrew the hexagon bolts for flange face Q32008
connecting to the vehicle and low pressure pipe with a
M13 socket wrench. When installing, tightening torque
for this bolt is 9±2 N·m.
3. A f t e r r e m o v i n g t h e p o w e r s t e e r i n g g e a r a n d t h e
steering pipeline together with the subframe from the
overall vehicle, disconnect the coupling nut of steering
pipeline and steering gear's high-low pressure oil
port with a M19 wrench. The removal of the steering
pipeline is then complete. While installing this area,
please ensure the two O-rings are in good condition,
and connect the high and low pressure pipeline and
steering gear low pressure oil port according to the
locations shown in the diagram. The tightening torque
of the two nuts is 46±2 N·m.
C a u t i o n : T h e e l a s t i c c l a m p m e n t i o n e d d u r i n g t h e
removal process is disposable, please replace it with a
new one after removal.
Q1460616
Q32008
Q1840816
2904013-S08
3411014-S08
3411013-S08
Hexagon nut
Ball stud
Steering pipeline removal and installation
1. Disconnect the hollow bolt which connects the high
pressure oil pipe and the power steering pump with a
M22 socket wrench. When installing, please take note
of the two seal gaskets and do not allow the oil pump
port to loosen. Each of the seal gaskets should be
positioned at either side of the high pressure oil ring.
Tightening torque for the hollow bolt is 30±4 N·m.
Hollow bolt

Downloaded from www.Manualslib.com manuals search engine 141Steering System
Removal and installation of the power
steering pump on the engine:
Remove the power steering pump after removing the high
pressure port of the power steering pipeline and steering
pump, as well as the inlet hose.
1. Loosen and adjust the bracket's hexagon bolts
Q1401025 (M10×1.25) with a M13 socket wrench,
l o o s e n t h e p u m p b e l t a r e a , a n d t h e n r e m o v e t h e
steering pump belt.
2. Loosen the hexagon flange mounting bolt Q1841090
(M10×1.25). After pulling out the hexagon flange mounting
bolt, complete the disassembly of the steering pump.
3. Tightening torque for installing the tension regulator
bracket: 40±4 N·m.
Install the tightening torque of the steering pump
mounting bracket: 25±3 N·m
4. After the installation of the power steering pump and
steering pump belt is completed, adjust the tension
of the entire power steering pump belt. Belt tension
should be 450±50 N.
Use an exertion force of 98 N in the middle of the belt.
Belt deflection should be 4-6 mm.
Power Steering Fluid Instructions
Replace the power steering fluid in the following situations:
1. After driving a new vehicle for 6000 km.
2. After replacing any part of the power steering gear, power steering pump and steering pipeline.
3. Driving 6000 km after replacing power steering gear and power steering p\
ump.
Caution:
1. The expelled power steering fluid after replacing power steering compone\
nts cannot be reused.
2. Only use ATF DEXRON III power steering fluid.
3. No matter when the PS fluid reservoir level drops, check the PS fluid reservoir, steering pump, power
steering gear, and steering pipeline, as well as all the connections.
Methods:
Two people are required to add power steering fluid. With the engine off, one person pours the fluid
into the PS fluid reservoir, while the other repeatedly turns the steering wheel from lock to lock for
more than 10 laps, until the steering fluid level is between MAX and MIN. Start the engine and turn
the wheel from lock to lock again (Caution: Do not leave it at the two extreme points for more than 5s).
When the fluid level goes down, refill the steering fluid until it is be\
tween MAX and MIN.
Technical Requirements
1. Mounting bolts with thread fastening glue for the power steering gear, tightening torque is 107±7 N·m
The coupling torque for the steering gear's tie rod and tie rod ball is \
74±7 N·m
The coupling torque for the steering tie rod ball stud and steering knuc\
kle is 49±5 N·m
2. The tightening torque for the steering column assembly and steering gear assembly's secure coupling
bolt is 25±3 N·m
The coupling bolt torque for the steering column and dashboard brace rei\
nforcement is 25±3 N·m
Torque for the fixed steering wheel nut on the upper section of the steer\
ing column is 50±4 N·m
3. Fasten the steering wheel center
Keep the front wheel pointed straight ahead, make sure not to change the direction of the steering rod, and
take down the steering wheel. Install the steering wheel in the center. The steering wheel's radial should be
in the middle, and the Great Wall logo should be in the direct sight of the driver, then tighten nuts.
Tightening torque: 50±5 N·m
4. Steering wheel free clearance inspection
Keep the vehicle centered, stop the engine, and turn the wheel left with a force of about 5 N. If
resistance is felt, stop when the resistance increases. Then turn right and stop under the same
situation. Measure the angle that the steering wheel turns along the outer edge. The angle value
measured is the steering wheel's free clearance. Its standard value should be less than 20°, and from
the middle position it should not turn at a left or right angle larger t\
han 10°.
Q1401025 (M10×1.25)Q1841020 (M10×1.25)
Q1841025 (M10×1.25)
Q1840825Q1841090 (M10×1.25)

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual142
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
Vehicle Body Electrical System

Downloaded from www.Manualslib.com manuals search engine 143Vehicle Body Electronic System
Basic Information on the Electrical System
Electrical system schematics reading instructions
1. Configuration introduction
The GWFLORID comes in three configurations: comfort, luxury and elite. The wire harness has two types of
configurations: One is a non jam protection comfort model, which is a combination of both comfort and luxury
type, the other type is called elite. These two configurations are universally used in most of this manual. The
parts that are only available for the non jam protection comfort type have been marked in this manual, please
pay attention to these sections while performing maintenance.
2. Fuse box and power supply introduction
The fuse box located inside the left side of the dashboard is No. 1 Fuse Box, the other one inside the left side of
the engine compartment is No. 2 Fuse Box.
• 30 represents a power cord for normal power, which is from the battery positive fuse box-60 A.
• 30a represents a power cord for normal power, which is from the battery positive fuse box-120 A.
• 30b represents a power cord for normal power, which is from the battery positive fuse box-120 A.
• 15 represents a power cord for small capacity electronics. When the ignition switch is at the "ON" position,
power is supplied by relay IG.
• 15a represents a power cord for small capacity electronics. When the ignition switch is at the "ON"
position, power is directly supplied by ignition switch IG1.
• 15b represents a power cord for small capacity electronics. When the ignition switch is at the "ON"
position, power is directly supplied by ignition switch IG2.
• X represents a power cord for small capacity electronics. When the ignition switch is at the "ACC"
position, power is supplied by relay ACC.
4. Wire's color and sectional area (mm2)
B-BlackW-WhiteR-RedBl-BlueBr-BrownY-Yellow
G-GreenP-PinkOr-OrangeV-VioletLg-Light greenGr-Gray
Mark the solid-colored wires with the letters in the above table. Double-colored wires' first letter is the primary
color, second letter is the secondary color.
For example:
Solid-colored wire: Red, marked as R.
3. Connector
(a) Negative connector pin number
Arranged from upper left to lower right.
(b) Positive connector pin number
Arranged from upper right to lower left.
Example:
Example:
Negative connector
Negative connector
Positive connector
Positive connector
(c) D i f f e r e n c e s b e t w e e n t h e p o s i t i v e a n d n e g a t i v e
connectors.
Mainly lies in their different types of interior pins.
• Every connector is indicated by its engaging part and
locked on the top.
• Please pull out the connector, insted of its wires.
Note: Before pulling out the connector, please check its
type first.