Rf valve GREAT WALL SAILOR 2006 Service Manual

CL-3Clutch
Inspection and Adjustment of Clutch Pedal, Air Exhausting of Clutch
Air-exhausting of clutch
Remark: in case operation needs to be conducted for the clutch
system or if there is air in clutch, exhaust the air.
Notice : Do not stain the painted surface with brake liquid,
if any brake liquid is left, wash it away immediately.
1.
Fill the brake liquid into the oil cup of clutch master cylinder;
The oil cup of master cylinder shall often be checked and, if
necessary, added with brake liquid.
2.
Connect the ethene resin pipe to the air-exhausting valve.
Insert the other end of the pipe into the container, half of which
is filled with brake liquid.
3. Air-exhausting in clutch system
a) Move the clutch pedal up and down slowly for several times.
b) Loosen the air-exhausting valve when pressing the pedal
increasingly until there is brake liquid overflowing, then
tighten the air-exhausting valve.
c)
Repeat this operation until the bubble in brake liquid disappears.
Inspection on and adjustment
of clutch pedal
1. Check whether the pedal height is correct
Pedal height that begins from front wall board:
Dr SF
(165
5)mm
SL SK SY SJ
(190-200)mm
2. Adjust the pedal height where necessary
Loosen the locking nut and screw off the adjusting bolts until
the pedal height is correct. Then screw up the locking nut.
Pedal free stroke
3. Check whether the pedal free stroke is correct
Press the pedal lightly until the resistance generated by clutch
occurs.
pedal free stroke: (5-15)mm
4. Adjust the pedal free stroke where necessary;
a) Loosen the locking nut and rotate the push-rod until the
stroke is correct;
b) Screw up the locking nuts;
c) Check the pedal height after the adjustment of pedal free
stroke.
adjusting spot in
pedal height
pedal height
pedal free stroke

TF-7Transfer Box
Disassembly and Mount of Transfer Box
Disassembly and Mount of Transfer Box
1. Transfer Box Disassembly
(a) Drive the vehicle on the lifting jack.
(b) Locate the gear of transfer box at the neutral
position, shift the transfer box to the 2H and
extinguish the engine.
(c) Disconnect the cell cathode.
(d) Lift the vehicle.
(e) Put down an oil disc under the transfer box, tear
down the oil drain plug and oil filling plug of the
transfer to drain all the lubricant up, then re-
mount the two plugs.
(f) Disconnect all wires and wire harnesses that
connected with the transfer box.
(g) Take apart the hose on the venting valve of
transfer shaft.
(h) Disconnect the linkage of the front drive shaft
with the front flange of the transfer box.
(i) Disconnect the linkage of the rear drive shaft
with the rear flange of the transfer box.
(j) Raise the transfer box up with the jack.Notice: The transfer box shall be guaranteed to
support by the lifting jack before tearing down
the sets of bolt and nut that connected with the
transfer box and gearbox. The transfer box is
not allowed to hang directly on the gearbox
through spline because such operation will
damage the transfer box parts.
(l) Tear down the connecting nuts between the
transfer box and gearbox and take down the
transfer box.
(m) Move the transfer box backward directly until
the linkage between the input shaft of transfer
box and the gearbox spline.
(n) Put down the lifting jack of the transfer box, and
(o) Tear down the gasket between the transfer box
and gearbox. Clean the gasket or glue on the
coupling face of front body of transfer box with
rear body of the gearbox. Take notice not to
damage the coupling face.
1234
5 6 7
8
9
1. input shaft
2. front frame of transfer box
3. rear cover of transfer box
4. flange
5. front output fork flange
6. venting valve
7. gasket
8. rear body of gearbox
9. bolt

TF-8Transfer Box
Disassembly and Mount of Transfer Box
2. Transfer box mount
a) Coat the lubricant grease on the output axial
spline of the gearbox with a thin sleeve contain-
ing lubricant grease.
b) Mount a new gasket on the mounting face of the
transfer box.
c) Lift the lifting bracket of transfer box and align
it to the same axle with the gearbox.
Notice: The transfer shall be guaranteed to flush
with the gearbox before connecting the spline.
Do not handle it forcefully to press the transfer
box spline into the gearbox. Otherwise, damage
will be caused, run the rear output shaft where
necessary to aim at the spline.
(d) Move the transfer box forward slowly so that
the spline and pin of the input shaft of gearbox
reach the front body of the transfer box, and the
gasket attaches on the gearbox completely.
(e) Ensure that the mounting holes of the front
body of transfer box, gasket, and gearbox are in
alignment and then mount the sets of bolt and
nut.
Fastening torque
(35-48)N
m
(f) Connect the rear drive shaft and the rear output
flange of the transfer box.
(g) Connect the front drive shaft and the front
output fork flange of the transfer box.(h) Connect the venting valve and the soft ventila-
tion pipe.
(i) Connect the cables of odometer that locates
nearby the transfer box.
(j) Connect all wire harnesses that connected with
the transfer box, and
(k) Add the lubricant of right brand.
Notice: when starting the engine, if the lubricant
is added incorrectly or in unsuitable volume,
which may lead the transfer box to damage.
Notice: as for the transfer box mounted on
vehicle, oil pump shall be used when adding oil
for it.
Notice: In case the transfer box is taken apart for
maintenance or inspection, there will be no
lubricant supplied by oil pump in the oil passage
on the top of transfer box. Therefore, it is not
accurate to control the oil volume by opening the
oil filling plug, in such condition, the oil passage
will be filled with oil once the oil pump runs. If the
wheel can run, such operation can be conducted
on the lifting jack. The oil level shall be rechecked
once the oil pump runs.
(l) Put down the vehicle after finishing the lubri-
cant inspection, and connect the cell cathode.

TF-12
110
9
8
6
5
4
3
2
11
15
14
13
12
17
18
19
207
16
Transfer Box
Disassembly of Transfer Box
1. fork-type flange
2. dust cover
3. fork-type flange assembly
4. transfer box front housing
8. Take apart the following parts from the remaining trans-
fer box housing assembly
(a) Fasten the front fork-type flange with the torque arm of
T-13-54-002 and screw off the nuts to take apart the
gasket, pull out the front fork-type flange assembly and
sealing ring.
(b) The dust cover may also be pressed down from the front
fork-type flange where necessary, and
(c) Take apart the front output shaft.
1. planetary mechanism
assembly
2. gasket
3. snapping ring
4. thrust disc
5. sun wheel
6. planetary bracket
7. input shaft assembly
8. input shaft
9. needle bearing
10. bearing shell
11. transfer box front
body assembly
9. Tear down the front body, input shaft assembly and
planetary mechanism assembly
Tear down the following parts from the remaining transfer box
housing assembly
(a) Take apart the venting valve.
(b) Take apart the six bolts to separate the front body from
the transfer box housing and take down the front body
(take notice not to damage the front-end cover and the
transfer housing).
(c) Take apart the front body assembly, input shaft assembly
and planetary mechanism assembly in grouping manner
(loose the snapping ring to take apart the input shaft from
the front end cover).
(d) Hold one end of the input shaft on the worktable while
open the long end of the snapping ring, press the front
body tightly to disassemble the front body assembly from
the remaining assembly.
(e) Take apart the snapping ring and oil seal from the front
body, the pin is only be taken apart where change is
necessary.
(f) Take apart the bearing and gasket from the input shaft
assembly after the bearing gripping loop is taken apart;
and take apart the input shaft assembly from the planetary
mechanism assembly.
(g) Take apart the needle bearing and bearing shell from the
input shaft assembly, and
(h) Take apart the snapping ring, thrust disc and sun wheel
from the planetary assembly, and
(i) Do not try to disassemble the planetary bracket.
4
2
1
5 6
7
83
5. front output shaft
6. oil seal
7. washer
8. nut
12. oil seal
13. locating pin
14. transfer box front
body
15. snapping ring
16. transfer box front
housing
17. bearing
18. bearing gripping
loop
19. bolt
20. vent

BR-1
Braking System
Notice .......................................................................... BR-2
Troubleshooting .......................................................... BR-2
Inspection and Adjustment .......................................... BR-5
Master Cylinder ........................................................... BR-8
Vacuum Booster .......................................................... BR-10
Front Brake ................................................................. BR-13
Dr .......................................................................... BR-13
SF .......................................................................... BR-20
Rear Brake .................................................................. BR-26
Dr .......................................................................... BR-26
SF .......................................................................... BR-34
Load sensing proportion valve .................................... BR-42Page
BR

BR-8Braking System
Master Cylinder
Master Cylinder
Disassembly of Master Cylinder
1. Tear down the alarm joint for liquid level;
2. Exhaust the brake liquid with the injector:
Notice: brake liquid must not be left on the paint surface,
if any, clear it away.
3. Tear down the pipeline of braking system;
Tear down the pipeline of braking system from the master
cylinder with SST.
4. Take apart the master cylinder:
(a) Tear down the four nuts and the three-way joint.
(b) Tear down the master cylinder and sealing washer from
the vacuum booster
cup cap
filtering screen
oil cup
vacuum booster assembly
sealing liner
master cylinder bodyfront three-way valve
SST
SST

BR-10Brake System
Vacuum Booster
Vacuum booster
Disassembly of Vacuum Booster
1. Take apart the master cylinder
2. Tear down the vacuum hose from the vacuum booster
3. Tear down the return spring
4. Tear down the clamping pin and U-shaped clamping pin
5. Tear down the vacuum booster, sealing washer and U-
shaped clamping head
U-shaped clip head
shock pad
adjusting shim
shock pad
vacuum booster
front three-way valve master cylinder bodybracket
one-way valve
sealing liner
Disassembly of Vacuum Booster

BR-11Brake System
Vacuum Booster
Inspection on Vacuum booster parts
Operation for one-way valve inspection
(Gasoline engine)
(a) Tear down the one-way valve;
(b) Check the air to see whether it flows from the vacuum
booster side toward the engine side.
(c) Check the air, change the one-way valve if the air flows
from the side of engine toward the vacuum booster.
(d) Mount the one-way valve in the right place.
(a) Tear down the one-way valve from the vacuum pipe.
(b) Check the air to see whether it flows from the side of
vacuum room to the hose.
(c) Check the air, and change the one-way valve if the air
flows to the hose to the vacuum room.
air
engine side booster side
air airless
air
hose side vacuum side
airairless
Mount of Vacuum Booster
1. Adjust the length of vacuum booster pushrod:
(a) Mount the sealing washer on the master cylinder;
(b) Put SST on the sealing washer and descend the pin rod
until it contact lightly the piston with its top;
(c) Put top of SST downward ,and mount it on the vacuum
booster.
(d) Check the clearance between the vacuum booster pushrod
and the head of pin on SST.
(e) Adjust the length of vacuum booster pushrod until the
pushrod touches the pinhead.
2. Mount the vacuum booster, sealing washer and Ushaped
clip head.
(a) Mount the vacuum booster and sealing washer.
(b) Mount the U-shaped clip head.
(c) Mount and tighten the assembling nuts of vacuum booster.
3. Connect the U-shaped clip head and the brake pedal:
Encase the U-shaped clamping pin in the hole of U-shaped clip
head and the brake pedal, and then mount the spring pin on the
U-shaped clamping pin.SST
washer
SST
(Diesel engine)

BR-42Braking System
Load Sensing Proportion Valve
Load Sensing Proportion Valve
Element figure
Inspection on and Adjustment of hydraulic
pressure
1. Adjust the load on rear shaft
Load on rear shaft (including the vehicle weight): 800kg
2. Mount the load sensing proportion valve instruments
(SST) and exhaust the air.
location plate
valve bracket
load inductive valvebraking hose bracket
flat washerflat washer
load inductive spring
assembly
inductive spring bracketclaming head I
claming head II

split pin
shaft bush

Parts that cannot be reused after being usedsnapping ring

BR-43Braking System
Load Sensing Proportion Valve
3. Check the rear brake pressure on the condition that
the front brake pressure increases to 7,845kPa
Rear brake pressure: (4,315
490)kPa
If the brake pressure is incorrect, adjust the hydraulic pressure.
4. Adjust the hydraulic pressure if necessary:
(a) Adjust the length of claming head II.
When lengthen the A distance, the rear brake pressure; if A
distance is shortened, the rear brake pressure reduces.
Initial adjustment: 78mm
Adjust range: (72-84)mm
(b) In case no even brake pressure is obtained after adjusting
the claming head, raise the valve or move it downward.
If the valve moves forward, the rear brake pressure will reduce;
if the valve moves downward, rear brake pressure will increase.
(c) Screw up the nuts.
(d) Adjust the length of claming head II again.
If it is unsuitable after re-adjustment, change the valve.
Disassembly of load sensing proportion valve
1. Tear down the claming head II from the bracket;
2. Tear down the load sensing proportion valve cluster:
(a) Tear down the brake pipeline from the valve with SST.
A
SST
kPakPa