lock GREAT WALL SO COOL 2006 Service Manual

B0-48Vehicle Body
Tailgate
Tailgate (
)
Element figure
stop-grade
washer plastic clipes
10 screws
upper position limit adhesive block
tailgate assembly pneumatic ejector rod
tailgate hinge
lock clip
assembly
nut trim panel
at tailgate
tailgate lock
barrel assembly
sealing strip
front wall
plastic clipes
lower
position limit
tailgate lock side lower
position limit
side upper
position limit
SY SJ

B0-49Vehicle Body
Tailgate
Dismantle of Tailgate
1. Tear down the trim panel at tailgate;
Tear down the ten plastic clipes and take down the trim panel
at tailgate.
2. Tear down the tailgate lock barrel and lock from tailgate:
(a) Screw off the nuts of lock barrel from the inside of
tailgate cavity and take down the lock barrel from the
outside.
(b) Tear down the three screws to take down the tailgate lock.
3. Tear down the tailgate lock clip
Take down the tailgate lock clip from the lower beam flange
after tearing down the two screws.
Dismantle of Tailgate
1. Tear down the pneumatic ejector rod;
Tear down the screws and take down the two pneumatic ejector
rod from the tailgate and the body.
2. Tear down the tailgate hinge and the tailgate;
(a) Tear down the eight bolts to take down the right and left
tailgate hinge from the tailgate and the body;
(b) Pull out the plugging element of wire harness to tear
down the tailgate from the body.
3. Tear down the position limit
After tearing down the two bolts, take down the left and right
side upper/lower position limits and the upper/lower position
limit from the tailgate and the body.
Tear down the position limit
Mount of tailgate lock and the tailgate
Mount the tailgate lock and the tailgate in the reverse
order

B0-52Vehicle Body
Instrument Panel
Instrument panel (
)
Element figure
SL SK SY SJ
instrument
panel body
right upper air tunnel
central air tunnel
left upper
air tunnel
combination
instrument
decorative cover
of instrument
lower covering board
at right end
glove box
lower instrument
cover(SY)
air-conditioning
controlling mechanism
assemblylower instrument cover
central cover
CD device
cigarette
lighter seat
lower decorative
frame of
instrument panel
ashtray cluster
glove box lock

B0-53Vehicle Body
Instrument Panel
Dismantle of instrument panel
(Dr SF)
1. Disconnect the cable of accumulator from the negative
polar;
2. Tear down the steering wheel;
3. Tear down the combined switch shell cluster;
4. Tear down the bonnet lock switch;
Tear down the two screws and the sliding fastener of bonnet
lock.
5. Tear down the central bottom-wall (Dr)
Tear down the decorative cover of gearbox (SF)
6. Tear down the instrument cover (SF).
Tear down the two screws and the cover.
7. Tear down the lower instrument cover;
(a) Tear down the ignition lock;
(b) Tear down the five screws and the cover;
Tear down the four screws and the cover;
(c) Disconnect the plugging elements.
8. Tear down the air-conditioner controlling panel;
(a) Pull out the air-conditioner controlling button;
(b) Prize out the A/C switch;
(c) Prize out the air-conditioner panel as shown in the
drawing with screwdriver and take it down.
Notice: the screwdriver should be wrapped with adhesive
strap at its head before using.
(d) Disconnect the plugging elements.
9. Tear down the decorative cover of instrument (Dr)
(a) Tear down the two screws to pull out the decorative cover
of instrument;
(b) Disconnect the plugging elements.E
F

B0-55Vehicle Body
Instrument Panel
19. Tear down the instrument panel body;
(a) Tear down the three screws and the instrument panel.
(b) Disconnect the plugging elements.
SF:
(a) Tear down the fixing bolts at the ends of instrument panel
body to pull out the fixed clipes at the front end.
(b) Disconnect the plugging elements.
SL SK SJ SY
1. Disconnect the cable of accumulator from the negative
polar (-):
2. Tear down the steering wheel;
3. Tear down the combined switch shell cluster;
4. Tear down the bonnet lock switch;
Tear down the two screws and the sliding fastener of bonnet
lock.
5. Tear down the lower instrument cover;
6. Tear down the lower decorative frame of the instrument
panel;
Prize out the decorative frame of instrument with screwdriver
and take it down.
Notice: the screwdriver must be wrapped with adhesive
strap at its head before using.
7. Tear down the decorative cover of instrument;
(a) Tear down the three screws to pull out the decorative
cover of instrument.
(b) Disconnect the plugging elements.
8. Tear down the ashtray cluster;
9. Tear down the central cover;
(a) Tear down the three screws to pull out the central cover;
(b) Disconnect the plugging elements

B0-59Body
Safety Belt
Safety belt
1. Driving test (in the security place);
(a) Fix the safety belt of the front seat.
(b) Drive the vehicle at the speed of 16 km/h and brake it
suddenly;
(c) Check the safety belt, which should be lock tightly
without expansion.
Remark: it is required to tear down the mechanism
fittings of the safety belt to make the following static load
test at the security place, in addition, moderate inspection
for the new safety belt should be conducted before
mounting no matter when the new safety belt fittings is
needed to mount.
2. Static test

a) Tear down the lock-type expansion fittings;
(b) Tilt the expansion fittings slowly;
(c) Check the expansion of safety belt, which should be
pulled out when the tilt angle is no more than 15 but not
be pulled out when the tilt angle is more than 45
.
If the requirement is not met, change the safety belt fittings.
Two-point safety belt
(manually operated)
(a) Adjust the safety belt to the moderate length;
(b) Exert the stable load on the belt;
(c) Check whether the safety belt is elongated or not, in such
case, the belt should not be elongated.

B0-66Body
Reserve Tire Bracket
Reserve tire bracket (
)
Element figure
reserve tire holderbuffer block bracket
buffer block
lock clip bracket
assembly
return spring reserve tire bracket adjusting arm
reserve tire lock
90
SY

specified torque
reserve tire bracket reserve tire holderreserve tire lock
lock clip bracket assembly
adjusting arm
SJ
90
KN
m

B0-67Vehicle Body
Reserve Tire Bracket
Reserve tire bracket (
)
Element figure
buffer blockspringy welt
trim cover of fixed bracket
decorative cover of screw hole reserve tire bracket
nut
SF
Dismantle of reserve tire bracket
1. Tear down the trim cover of fixed bracket;
Tear down the decorative cover of screw hole, and then tear down the
trim cover of fixed bracket.
Tear down the adjusting arm (SY SJ)
Tear down the two bolts to take down the adjusting arm;
2. Tear down the reserve tire bracket;
Tear down the three bolts and take down the reserve tire bracket. (SF)
Tear down the three bolts and take down the reserve tire bracket. (SY
SJ)
Mount of reserve tire bracket
1. Mount the reserve tire bracket;
(a) Stick the springy welt on the corresponding face where the
reserve tire bracket contact with the body; (SF)
(b) Fix the reserve tire bracket on the body with eight bolts (SF).
Fix the reserve tire bracket with three bolts on the right mail sill
and tail beam of the body.
2. Mount the trim cover of fixed bracket;
Mount the trim cover of fixed bracket and the decorative cover of
screw hole.
Mount the adjusting arm (SY SJ)
Fix the adjusting arm on the tail beam bracket of the body by screwing
the two bolts in the fixing hole.
Notice: the paint layer should be well protected during
disassembling and assembling.

B0-74
Body Dimension
Rear Wall (
)
Vehicle Body
Body Dimension
Mark NameBore diameterMark NameBore diameter
J
,j
Connecting part of outer panel of
rear wall with roof
O
,o
Corresponding spots of upper edge


K
,k
Lower edge of outer panel of rear
wall
P
,p
Vertical corresponding spot of
floor

L
,l
Lines and angle of rear side wall

Q
,q


M
,m
Upper angle of rear lamp cavity

R
,r
Outer edge of lock box at tailgate


N
,n
Lower angle of rear lamp cavity


J

k
K
1022j

1270 1202
376
SY SJ
(point size in 3D)
GN O
o
m
Q
q
N

n

P
p
R
r M
900 L

1042
1376 1141l

*1: SY 1376
SJ 1385
SF
(point size in 3D)

A-2
Clutch
Specification
Item Specification
Fastening torque for clutch tube on master cylinder
Fastening torque for clutch tube on wheel-brake cylinder
Fastening torque for clutch pressure plate160
190-200
5-15
0.3
0.8
0.2
0.6
5
Max misplacement
0.5 Pedal height (calculated from front wall
Pedal free stroke
Min depth of clutch-facing rivet
Max radial swing difference of clutch rib
Max radial swing difference of flywheel
Max width of wear of diaphragm spring
Max width of wear of diaphragm spring
Alignment degree of diaphragm spring endApplicable vehicle model
Dr SF
SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Torsion moment
Fastening location (N*m)
15-17
15-17
30 Applicable Vehicle model
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Gearbox
Three-grade maintenance for gearbox
1. Grade I maintenance for gear box
Grade I maintenance: Check the lubricant level to see whether the lubricant level is in alignment with the lower edge of oil
filler; if the lubricant is lower than the oil filler lower edge, add the lubricant; or the insufficient lubricant will lead to the poor
lubrication or burn-out of bearing and teeth; while the over-high lubricant will cause the overheating and oil leakage.
2. Grade II maintenance for gear box
Grade II maintenance: The gear box of a new vehicle should be maintained by exchanging the lubricant during the
first grade II maintenance and should be washed with kerosene; and the lubricant quality should be checked in the
grade II maintenance in later time, if the lubricant is diluted, gumming or over-dirty, it should be changed.
3. Grade III maintenance
The gearbox should be disassembled for inspection, washing and oil change.
Notice: As the new vehicle is in the running-in status, the gearbox should be maintained by exchanging lubricant
after the vehicle covers 1500 km,
Lubricant Type
GL-5 SAE80W/90
Torsion moment of relative connecting elements
Tung Teeth: Tang tooth(5DYA4TWD
5DYA8FWD)
Unit
ãã Specification of Maintenance and Up-Keeping
Clutch and Gearbox
Locating screw of fork axle at first and second gear
Locating screw of yoke block
Screw on baffle of rear bearing of output shaft
Screw of reverse idler shaft
Bolt of gearshift cover
Bolt of front cover
Bolt of rear body
Bolt of clutch shell
Bolt of locating spring13
17
15
20
17
22
17
20
15
20
15
20
30
45
30
45
17
22 Fastening location N*m