oil change GREAT WALL SAFE 2006 Workshop Manual

BR-2Braking System
Notice and Troubleshooting
Notice:
1. Carefully change each part where necessary because any
mistake will affect the brake system properties, and will lead
accidents during driving. And the parts to be changed must
be the same in part number or equal in quality.
2. Keep the parts and each position clean when repairing the
braking system.
Troubleshooting
Trouble Causes Inspection items
Lower or soft pedal Abrasion of brake shoe
Abrasion of brake pad
Oil leakage of braking system
Master cylinder failure
Air in braking system
Wheel-brake cylinder failure
Failure in the automatic regulator of rear brake.Change the brake shoe; Change the brake
pad;
Repair the oil leakage;
Change the master cylinder;
Drain out the air from braking system;
Change the wheel-brake cylinder;
Repair or change the regulator
Brake stagnantPoor adjustment of parking brake;
The bracing wire of parking brake is seized;
Poor adjustment of vacuum booster pushrod)
Failure of the drag spring or the return spring
Pipe line blockage
Brake shoe breakage or deformation
Brake pad breakage or deformation
Seizing of the wheel-brake cylinder or the brake
caliper piston
Automatic regulator breakage
Master cylinder failureAdjust the parking brake;
Make repairing according to real situation;
Adjust the drag rod;
Change the drag spring or the return spring
Make repairing according to real situation;
Change the brake shoe
Change the brake pad
Make repairing according to real situation;
Change the regulator
Change the master cylinder
Over large braking
distanceUnsuitable tire inflation
There is oil stain or lubricant on the brake shoe or
brake pad;
Brake shoe deforms, the brake liner is worn or polished;
Brake pad deforms or is worn or polished;
Brake drum or brake disc deforms
Drag spring or return spring has trouble
The wheel-brake cylinder has trouble
The inner piston of wheel-brake cylinder is seized;
The brake pad is seized;Inflate the air to suitable pressure;
Change the brake shoe or the brake pad;
Change the brake shoe;
Change brake pad
Change the brake drum or the brake disc;
Change the spring;
Change the wheel-brake cylinder;
Change the wheel-brake cylinder
Change the brake pad
The brake pedal is hard
but doesn
t work;There is oil stain or lubricant on the brake shoe or
brake pad;
The brake shoe deforms, brake liner is worn or
polished, or the brake wheel is worn;
The brake pad deforms, or is worn or polished;
The piston of wheel brake pump is seized;
The vacuum booster has trouble
The vacuum degree is unsuitable
The brake pipe line is blockedChange the brake shoe brake pad;
Change the brake shoe
Change the brake pad;
Change the wheel-brake cylinder;
Change the vacuum booster;
Make repairing according to real situation;
Make repairing according to real situation;

BR-3
Troubleshooting (continued)
Braking System
Notice and Troubleshooting
Trouble Causes Inspection items
There is clatter noise when using
the brake(Drum-type brake)
The brake shoe is seized on the flange of rear baffle;
The flange of rear baffle is worn;
The pressure spring of brake shoe is loose or missing;
The fixed bolts of brake bottom plate is loose;
(disc type brake)
The brake pad support plate is loose or missing
The mounting bolts are loose;Add lubricant
Change the lubricating flange
Change
Tightening it
Change
Tightening it
There is hoarse noise or quack-
quack when using the brakeThe brake shoe or brake pad is worn;
The brake caliper, the wheel or the rotator interferes each
other.
There is friction between the dust cover and brake disc,
the brake bottom plate and the brake drum;
The other braking part has trouble
There is friction between the tire and bodyChange the part, and re-process
precisely the brake drum or
rotator if the abrasion is serious;
Make change according to real
situation;
repair or change
Make repairing according to
real situation;
Change
Check or maintain the part
There is such noise as
continuous screaming, quack-
quack, oscillating sound, etc.
Notice: the braking materials
may generate the natural noise
and heat during friction, and
thus emit the energy. Therefore,
it is normal to have the
screaming noise. These
phenomena will be more serious
under the condition of frigidity,
torridity, and over humidity,
snowing and mud. the
screaming noise occurring
occasionally will not lead the
fatal brake trouble nor reduce
the effective properties of the
brake.The brake drum, brake liner, liner or brake pad is worn
or scraped
The brake liner or brake pad is dirty or with oil stain or
polished.
The brake liner or brake pad is improperly used.
The brake pedal or vacuum booster drag rod is unsuitably
adjusted.
(disc type brake)
The brake pad silent pad is loss or damaged;
The brake pad is worn to the degree that the abrasion-
indicating lamp of brake pad has friction with the rotator.
There is burr or rust on the brake caliper.
(Drum type brake)
The pressure spring of brake shoe is soft in rigidity, or is
damaged or unsuitable.
The pressure spring pin or spring of brake shoe is loose
or damaged;
There is crack on the brake bottom plate flangeCheck, repair or change
Clean or change
Check or change
Check for adjustment
Change
Change
Clean or polish the burr
Check, repair or change
Check, repair or change
Check, repair or change

BR-6
Operation test of vacuum booster
Remark: check the operation of vacuum booster with the
vacuum booster tester if workable.
1.Operation inspection
(a) Before starting the engine, tread down the brake pedal
several times, and check the pedal reservation distance to
ensure there is no change occurs.
(b) Tread down the brake pedal and start the engine. If the
treaded pedals continue to move downward, which means
the operation is normal.
1. Inspection on Air-tight
(a) Start the engine for 1-2 min and then turn it off. Then
tread down the brake pedal slowly for several times, if the
pedal move downward continuously in the first, but
return gradually in the second or third time, which means
the vacuum booster has a good air-tight.
(b) Tread down the brake pedal when the engine is working,
then stop the engine, but tread the pedal down. If the
reservation distance doesnít change within the 30 seconds,
which shows the air tight of vacuum booster is good.
Air-bleeding of braking system
Remark: air-bleeding is required if any operation for braking
system is conducted or the pipe line is doubted to have air.
1. Fill the oil cup with the brake liquid
Check the liquid level of oil cup after the air in each wheel
brake pump is exhausted. If necessary, add the brake liquid.
2. Connect the vinyl resin pipe with the vent screws.
Insert the other end of pipe into the container with half brake
liquid.
Remark: the air-bleeding shall begin from the longest pipe line
when the wheel-brake cylinder is exhausting the air.
3. Air exhaust of the pipe line in braking system
(a) Tread down brake pedal slowly several times.
(b) Loosen the vent screws until the brake liquid flows out
while letting the assistant tread down the pedal. Then
screw up the vent screws.
(c) Repeat this approach until there is no air in the liquid.
4. Repeat the approach for the wheel-brake cylinder.
normal
abnormal
the third time
the second time
the first time
Braking System
Inspection and Adjustment

BR-14
Brake pad change
Remark: Check the thickness of the friction material of brake
pad through the observation hole on caliper body after the
vehicle covers thirty thousand; if the thickness fails to fall
within the specified range, change is required. (If the brake is
used often, the thickness of friction materials of brake
pad is required to check whether it is within the specified
range after the vehicle covers more than ten thousand,
if not, change it.
1. Tear down the front wheel;
2. Check the thickness of friction material of brake pad:
Check the thickness of friction material of brake pad through
the observation hole on caliper body, if it fails to be within the
specified range, change it.
Min thickness: 2.0mm
3. Raise the wheel-brake cylinder:
(a) Tear down the short bolts of sliding sleeve;
(b) Uplift the wheel brake pump and hang it with rope to
protect the brake oil pipe.
Remark: Do not loosen the brake oil pipe and the bleeding plug.
4. Tear down the following parts:
(a) Two braking pads;
(b) Two silent pad clusters;
(c) Four braking pad lock plates.
Braking System
Front Brake (Dr)

BR-15
5. Brake disc measurement
(See page BR-17)
6. Measure the radial run-out of the brake disc;
(See BR-18)
7. Mount the lock plate of brake pad.
8. Mount the new brake pad.
(a) Mount the silent pad cluster on brake pads of both the
inner and outer sides;
Remark: Pollution of oil stain or coat is not allowed on the
work faces of brake pad or brake disc.
(b) Draw out a little brake liquid from the liquid container to
prevent the brake liquid overflowing from the liquid
container;
(c) Press in the piston with the hammer lever or similar tool.
9. Mount the wheel-brake cylinder;
Mount and screw up the hex bolts (the hex bolts shall be coated
with the thread locking sealing agents.
Fastening torque
(38-50)N
m
Remark: only one brake pad can be changed in one time so as
to prevent the piston of other wheel being shot out.
Braking System
Front Brake (Dr)

BR-21
3. Disassemble the following parts:
(a) Guide pin snapping spring;
(b) Two guide pins;
(c) Brake pad snapping ring
(d) Two brake pads;
(e) Two silent pads; and
(f) Two separation pads
4. Measure the thickness of brake disc.
(See BR-24)
5. Measure the radial swinging of the brake disc.
(see page BR-24)
6. Mount on the new brake pad;
(a) Draw out a little brake liquid from the liquid container.
(b) Press in the piston with the hammer lever and similar tool.
Remark: Only one brake pad of the same wheel can be changed
in one time so as to prevent the piston on the other face ejecting
out.
(c) Mount two silent pads and two separation pads on the
new brake pad.
Remark: coat the brake oil for disc on the inner silent
pads.
(d) Mount the brake pad with the worn limit alarm pad on the
inner side, while the other brake pad on the outer side.
Note: Pollution of oil stain or coat is not allowed on the
work faces of brake pad or brake disc.
7. Mount the brake pad snapping spring;
Brake pad snapping spring shall be mounted at the lower
position;
Braking System
Front Brake(SF)

SR-2
Notice
The parts change should be conducted correctly because
any error will affect the properties of steering system, or lead
to accidental or damage when driving.
Troubleshooting
Trouble Causes Inspection items
Unsuitable tire inflation
Insufficient lubricant
Over-large inclination
Steering gear joint wear
Lower swing arm ball head wear
Steering column seize-up
Steering gear unsuitable adjustment or damage
Power steering conveyer looseness
Over-low liquid level in oil cup of steering pump
Failure in power steering mechanismInflate the tire to specified pressure
Lubricating the hanging devices
Check the Alignment of Front Wheel
Change the Steering gear joint
Change the lower swing arm ball
head;
Check the steering column
Adjust or repair the gear.
Adjust the conveyor.
Check the steering pump oil cup
Check the power steering devices
Poor returning
Unsuitable tire inflation
Insufficient lubricant
Incorrect wheel alignment
Steering column seize-up
Steering gear unsuitable adjustment or damageInflate the tire to specified pressure
Lubricating the hanging devices.
Check the Alignment of Front
Wheel
Check the steering column
Change the steering gear.
Over-large playFront wheel bearing wear
Steering drive shaft yoke wear
Lower swing arm ball head wear
Steering gear joint wear
Steering gear unsuitable adjustment or damageChange the front bearing
Change the steering drive shaft
Change the swing arm ball head
Change the steering gear joint
Change the steering joint
Abnormal noise
Steering drive lever looseness
Steering gear joint wear
Steering gear unsuitable adjustment or damage
Oil lack or poor sealing of steering machine.Tighten the steering drive lever
Change the steering gear joint
Change the steering gear
Add the oil or change the sealing
washer Steering system inspection
on vehicle.
Steering System
Notice and Troubleshooting
Difficulty in steering

SR-14Steering System
Power Steering (On-Vehicle Inspection)
Change of power steering liquid
1. Tear down the oil-returning hose from the oil cup to
drain the liquid into the container;
2. Run the engine in the idle status, and rotate the
steering wheel toward the max rotating angle for
several times in right or left direction while draining the
liquid, until the oil in steering liquid is drained up.
3. Turn off the engine.
4. Connect the oil-returning pipe and inject the new
power steering liquid in the liquid tank;
Hydraulic oil type: No.8 Liquid drive oil (Q/SH003.01.012-88)
5. Start the engine, and make it running in the idle status.
Rotate the steering wheel to the max rotating angle repeatedly
several times, meanwhile, supplement new power steering
liquid in the liquid tank until there is no foam or turbidities in
the liquid tank, and the oil indicating lamp reaches the marked
range when the engine is turned off.
6. Tighten the liquid tank cover
7. Exhaust the air in the power steering system;
Ai-r bleeding in power steering system
1. Check the liquid level height in the liquid tank
Check the liquid level and, if needed, supplement the liquid.
2. Start the engine in the idle status and rotate the
steering wheel repeatedly to the max rotating angle
several times.
3. Turn off the engine and connect the ethane pipe and
bleeding plug.
4. Start the engine and rotate the steering wheel
repeatedly to the max rotating angle several times.
5. Locate the steering wheel at the intermediate position.

SR-15Steering System
Power Steering (On-Vehicle Inspection)
6. Exhaust the air in steering system:
(a) Loosen the bleeding plug;
(b) Screw up the bleeding plug when there is no air bubble
exhausted from the pipeline.
Notice: take care not let the ethane pipe slide from the
bleeding plug, because the liquid is high in temperature
and pressure.
7. Check to see whether there is air bubble or turbidities
in the oil cup, and ensure the liquid level will not
exceed the max value when the engine stops,
Measure the liquid height under the condition of engine running,
then turn off the engine and measure the liquid height again.
In case any problem is found, repeat the approaches of (5) and
(6) in Power Steering Liquid Change. If the problem still
exists, repair the power steering oil pump.
RPM RPM

BE-36Body Electric System
Combination Instrument
Normal indicating range of combination instrument indicator
Speedometer
Real speed Km/h
Displayed speedKm/h
20 40 60 80 100 120 140 160
20
340
056005
Tachometer SY SL
800510005120061400716008
750 1000 2000 3000 4000 5000 6000
750
-10+201000-10+502000
120 3000
150 4000
200 5000
250 6000
300 Real rotating
speedr/min
Displayed rotating
speedr/min
Tachometer Dr SL SK SF
1000 2000 3000 4000 5000 6000 7000
1000
100 2000
200 3000
150 4000
200 5000
250 6000
300 7000
350 Real rotating
speedr/min
Displayed rotating
speedr/min
c. The inaccuracy display of tachometer is usually caused by the interior failures of tachometer, in such situation,
change the combination directly. As for the good-bad shift or out-operation of tachometer, the failures can be judged
according to the following approaches:
1) Start the vehicle, then check the voltage of signal input of tachometer (wire harness with multi-meter, the
voltage should be 6 V or so.
2) In case there is no signal voltage, check the power supply system of the whole vehicle to remove the failures
in circuit.
3) The plugs of wire harness is only allowed to be inserted in the combination instruments under the condition
that the signal voltage is normal, and the instrument is in normal operation.
4) Where the instrument is in abnormal operation, such trouble is caused by the failure of combination
instruments, in such case, change the combination instrument directly.
d. Troubles of fuel gauge and water thermometer
1) In case the instrument indicator points to the large number after it is powered, disconnect the sensor from the
plugging elements of wire harness before judging such kinds of troubles, if the indicator is still at large number,
it can be make a judgment that the trouble is caused by the interior failure of instrument, in such case, change
the combination instrument directly; if the indicator returns to the small number, according to which it can be
judged that the trouble is caused by the sensor failure, therefore, change the sensor directly.
2) where the instrument indicator stands still, such trouble may be caused by three causes probably, interior failure
of sensor, plugging elements of wire harness or interior failure of instrument; the inspection may be conducted
according to the following approaches: disconnect the plugging elements of wire harness from that of sensor,
grounding the wire at the sensor end; in such condition, the indicator should move upwardly to the largest
number; if such phenomena occurs, it can show the trouble is caused by the interior failure of sensor, in such
case, change the sensor directly; if the instrument indicator is still immobilized after it is powered, it can be
judged that the trouble is caused by the interior failure of instrument under the condition that the wire harness
and plugging elements are normal, in such case, change the combination instrument directly.
Fuel gauge Dr SF SY
Displayed oil
volume
Reference
resistance

Permitted
error
E 1/2 F
110 38 7

5
4+3
Fuel gauge SJ
Displayed oil
volume
Reference
resistance

Permitted
error
E 1/2 F
110 38 7

12
4
2
Fuel gauge SL SK
Displayed oil
volume
Reference
resistance

Permitted
error
E 1/2 F
120 45 17

10
10
10