GREAT WALL PEGASUS 2006 Service Manual

B0-38
Side window glass (
)
Element mounting position
Vehicle Body
Side-Window Glass
SJ
side-window glass
spilling strip
trim strip of side
window
Dismantle of side window glass
1. Tear down the following parts:
(a) Lower trim panel of rear column;
(b) Rear side-panel trim
(c) Roof
2. Tear down the side window glass
(a) Tear down the three hex nuts and eight nuts on flange
(SF)
(b) Cut a small open in the sealing glue between the glass and
body with knife, then insert the steel wire into the small
open and pull it fro and to slowly until the sealing glue
between the glass and body separate completely, and pull
the glass out to take it down.
Notice: be careful not damage the body and glass.
Mount of side window glass
1. Clean the body and glass;
Clean the contacting face of body and glass completely with
cleaning materials.
2. Cleaning the sealing strip;
Clean the sealing strip surface with cleaning materials.

B0-39Vehicle Body
Side Window Glass
3. Mount the trim strip and spilling strip of side window (SY SJ)
(a) Assemble the trip strip of side window on the left upper
conner of inner edge of the left side window at 60 mm under
the conner, and encase the roof in the trim strip.
(b) Stick the spilling strip (4
6) to the center of lower edge of
side window and to the circumference of the glass frame.
4. Mounting of side glass
Coat the cleaning active agent around the inner edge along the
circumference of side window glass (the black glass edge).
Airing for 3 to 5 min, coat the priming agent on the layer of cleaning
active agent and airing for 5 to 30 min.
(SY
SJ)
(a) Plaster the glass glue with the glue container on the layer of
priming paint of window frame with the initiative location
200 mm under the left upper conner of left side window.
(b) Stick the glass quickly to the window frame and adjust the
upper, lower, left and right clearance, and fill them with
gasket.
(c) Exert the pressure of certain degree on the glass circumfer-
ence after adjusting so that the glass contact
Recommended sealing glue for use
Glass glue U-201 windshield glue
Priming paint 130
Cleaning active agent C020
(SF)
(a) Plaster the glass glue alongside the complete circumference
of adhesive strip of side window glass, and the glue section
should be similar to tri-angle after coating.
(b) Put the side window glass assembly at the corresponding
location on body, fix the upper edge of side window glass with
three hex nuts and others should be fixed with flange nuts.
Recommended sealing glue for use
Glass glue TS-100 PVC windshield glue
Priming paint TS-5028
Cleaning active agent TS-7016
Notice:
(a) When plastering glue, the glue should be plastered continu-
ously and no breakage is allowable at the sealing glue seam.
(b) Clean the redundant glue on the body;
(c) The vehicle is not allowed to drive within 4 hours in summer
and 8 hours in winder under common circumstances.
5. Check whether there is leakage and the leakage reparation;
(a) Conduct the leakage test;
(b) Seal the leaking parts with glass glue. SJ
SY
SF

B0-40
Rear door glass
Element mounting position
Vehicle Body
Rear Door Glass
Dismantle of rear door glass
Disconnect the connecting wire of the defroster first, cut a small
open in the sealing agent between the glass and body with knife,
then insert the steel wire into the open and pull the steel wire to
and fro until the sealing glue between the glass and body separates
completely, finally pull the glass outwardly to take it down.
Notice: be careful not to damage the body and glass.
Mount of rear door glass
Seize the wire harness of rear defroster in the plastic clipes
and encase the clipes into the mounting open, then seize the wire
harness of rear defroster in the trim strip at tailgate.
As this mount is the same with that of side window glass, see
the mounting approaches for side window glass.
trim strip at tailgate
SY SJ
plastic clip
spilling stripwire harness of
rear defroster rear door glass

B0-41Vehicle Body
Rear Windshield
Rear windshield
Element mounting position
Dismantle of rear windshield
1. Tear down the rear windshield:
(a) Prize up the sealing strip front the body with screwdriver.
Notice: be careful not to damage the paint on body.
(b) Prize the lips of sealing strip outwardly from the inside
of the body flange.
(c) Pull the glass outwardly to tear it down together with the
sealing strip.
Dr SL SK
rear windshield
sealing strip of rear windshield
sealing strip
sealing strip
vehicle
body

B0-42Vehicle Body
Rear Windshield
Mount of rear windshield
1. Clean the body and glass;
Clean the contacting face of body and glass with the
cleaning materials.
2. Clean the sealing strip
Clean the sealing strip with cleaning materials;
4. Mount the rear windshield
(a) Lay the ready glass against the corresponding position of
rear windshield opens.
(b) Pull the rope from the inside of body to encase the roof,
the rear column and the door frame within the adhesive
strip, meanwhile push the outside of the glass by hand.
(c) Tap the four edges of the adhesive strip to ensure that the
adhesive strip contact closely with the body windshield
opened.
(d) Coat the glue from left to right at the upper part of
windshield (location between the adhesive strip and the
body windshield open) and the lower part of windshield
(location between the adhesive strip and glass), and the
remaining glue should be cleared away with abrasive
paper, and the location should be cleaned with cloth.
Notice: there should no breakage at the sealing glue
seam when coating the glue.
Recommended sealing agent for use
Glass glue XL-1211 acid silicone glass glue
5. Check whether there is leakage and the leakage
reparation;
(a) Conduct the leakage test;
(b) Seal the leaking parts with glass glue. 3. Mount the rear windshield in the sealing strip
(a) Coat a layer of silicon oil around the glass circumference
and mount the adhesive strip on the glass according to
the glass shape.
Notice: if the adhesive strip becomes stiffening or
deforming that will lead to water leakage, change with
the new one where possibly.
(b) Mount a rope alongside the sealing strip channel as
shown in the drawing (fix the rope in the adhesive strip).

B0-43
Cargo body baffle
Element mounting position
Vehicle Body
Cargo Body Baffle
baffle lock
connecting bar
2 screws
baffle lock controller
rear panel of cargo body
buffer block
hinge assembly
inner cover panel
bolt hole
14 screws
Dr SL SK
14 screws
(Dr SK)
14
N
m
specified torquecargo body
hinge
Dismantle of baffle lock
1. Tear down the inner cover panel.
(SL)
Tear down the 14 screws and the inner cover panel.
(Dr SK)
Tear down the 12 screws and the inner cover panel.
2. Disconnect the connecting bar of baffle lock from the
baffle lock controller.
3. Tear down the baffle slide fastener
(a) Tear down the baffle lock from the baffle.
(b) Tear down the two screws and the baffle lock.
4. Teardown the baffle from the baffle
Teardown the 12 screws and the baffle lock

B0-44Vehicle Body
Cargo Body Baffle
Mount of Baffle
1. Mount the baffle lock on the baffle;
Mount the baffle lock with two screws (Dr SK)
Mount the baffle lock with two nuts (SL)
2. Connect the connecting bar with the baffle lock controller.
3. Mount the baffle slide fastener;
(a) Mount the baffle slide fastener and bolts.
Fastening torque
14N
m
(b) Connect the baffle slide fastener with the baffle.
4. Mount the baffle hinge on the baffle
5. Mount the inner coverpannel

SL)
Mount the inner cover panel with 14 screws;

Dr SK)
Mount the inner cover panel with 12 screws.
Dismantle of baffle lock controller:
1. Tear down the inner cover panel;
2. Disconnect the two baffle connecting bar;
3. Tear down the baffle lock controller
Tear down the two screws and the baffle lock controller; (Dr
SK)
Tear down the two nuts and the baffle lock controller. (SL)
Mount of baffle lock controller
Mount the baffle lock controller in the reverse order for
disassembly.

B0-45
Tailgate (
)
Element figure
Vehicle Body
Tailgate
tailgate glass
SF
outer auchi
inner auchi
tailgate lock glass elevator at tailgatetailgate handleglass bracket glass supporter
tailgate cover panel
sealing strip at tailgate
sealing strip at tailgatetrim panel at tailgate I lock ring

B0-46Vehicle Body
Tailgate
Dismantle of tailgate
1. Tear down the trim panel of the tailgate:
(a) Insert the screwdriver between the fixing clipes and the
trim panel at the tailgate to loose the trim panel.
Notice: the screwdriver should be wrapped at its head
with adhesive strap before using
(b) Tear down the trim panel at tailgate.
2. Tear down the tailgate cover panel;
Tear down the three bolts and the tailgate cover panel.
3. Tear down the tailgate handle and the lock ring:
(a) Tear down the two bolts on handle.
(b) Disconnect the controlling bar from the glass elevator
and tear down the tailgate handle.
(c) Disconnect the controlling bar from the glass elevator to
take down the lock ring.
4. Tear down the trim panel of tailgate I;
Tear down the six bolts and trim panel of tailgate I;
5. Tear down the sealing strip at tailgate;
Tear down the two threaded ends and the sealing strip;
6. Tear down the outer auchi
7. Tear down the glass elevator at tailgate;
(a) Tear down the tailgate glass;
(b) Pull the glass outwardly to take it down.
8. Tear down the tailgate lock;
Tear down the three bolts and the tailgate lock.

B0-47Vehicle Body
Tailgate
9. Tear down the tailgate lock
Tear down the three screws from the tailgate to tear down the
lock
Change of Glass
1. Tear down the glass bracket with screwdriver or with
similar tool.
2. Coat the polyurethane glue, seize the gasket on the
glass and coat the glass glue at outside of the gasket.
3. Encase the glass bracket by tapping it with rubber
hammer.
Tailgate Assembly of
Assembly the tailgate in the reverse order of the disassembly
approaches.
Notice: coat the lubricant on the sliding face, elevator
gear and door lock before mounting the parts.
120mm
105mm
outside