wheel alignment GREAT WALL SO COOL 2006 User Guide

SA-9Suspension System and Automobile Axle
Alignment of Front Wheel (SF)
(j) Tighten the clamping bolts and lock them with split pin.
Remark: the clamping bolt should face the front of the vehicle.
(k) Side-slip inspection
Sideslip: =5m/km
front

SA-15
Mount the steering knuckle
1. Mount the steering knuckle
(a) Support the lower arm of the steering knuckle with a jack.
(b) Mount the steering knuckle on the lower ball stud and
screw on the nuts.
(c) Press the upper arm to mount on the steering knuckle and
screw on the nuts.
(d) Screw up the nuts of the upper ball stud according to the
specified torque.
Fastening torque
(100-120)N
m
(e) Screw up the nuts of the lower ball stud according to the
specified torque.
Fastening torque
(98-118)N
m
(f) Mount on the split pin between the upper and lower ball
studs.
2. Mount the steering knuckle arm and the front brake shell;
(a) Screw up the two bolts of M8X16.
Fastening torque
(25-28)N
m
(b) Screw up the two bolts and groove nuts (M12X67) to the
specified torque.
Fastening torque
(98-118)N
m
(c) Mount on the two split pins.
In case the pin hole in the ball stud are not in alignment with
the groove nut, adjust the fastening torque and the rotating
angle under the condition that satisfying the minimum torque,
so as to ensure the torque falls within the specified range, if
cannot, mount the split pin with the minimum torque beyond
the range
3. Mount the front wheel hub and the front brake disc.
4. Check the Alignment of Front Wheel.
(See SA-3)
Suspension System and Automobile Axle (Dr/2WD)
Front Wheel Hub and Steering Knuckle (Front Wheel Hub)

SA-23
3. Mount the guide lever on the lower arm
Fastening torque
(96
0)N
m
4. Link the transverse stabilizer rod with the lower arm.
Fastening torque
(23
3)N
m
5. Mount the vibration damper.
6. Mount the ending part of the drag rod:
(a) Link the drag rod end to the steering knuckle arm, mount
and screw up the nuts according to the specified torque.
Fastening torque
(91
0)N
m
(b) Lock the nut with the new split pin.
7. Mount the torsion rod spring.
8. Check the Alignment of Front Wheel.
(See the page SA-3)
Suspension System and Automobile Axle (Dr/2WD)
Front Suspension (Lower Arm and Vibration Damper)

SA-25
2. Mount the upper arm
(a) Mount on the upper arm and the regulating gasket.
(b) Screw up the bolts according to the specified torque.
Fastening torque
(96
0)N
m
Remark: Mount back the gaskets of the same thickness in the
same number on the original locations.
3. Connect the upper ball stud and upper arm together.
Fastening torque
26N
m
4. Check the Alignment of Front Wheel
(See page SA-3)
Suspension System and Automobile Axle (Dr/2WD)
Front Suspension (Upper Arm)

SA-26Suspension System and Automobile Axle (Dr/ 2WD)
Front Suspension (Guide Lever)
Guide Lever
Disassembly of Guide Lever
1. Mark the assembly mark on the guide lever.
2. Tear down the front fixing nuts from the guide lever.
3. Tear down the guide lever from the lower arm.
Tear down the nuts that fix the guide lever on the lower
swimming arm, and then tear down the guide lever.
Mount of Guide Lever
1. Mount on the front fixing nuts
Mount on the front fixing nuts and meanwhile align the
assembly marks on the guide lever.
4. Screw up the fixing nuts according to the specified torque,
(a) Dismantle the bracket so that make the vehicle bounce
sever times to put the suspension in balance.
(b) Screw up the front fixing nut.
5. Check the Alignment of Front Wheel
(See Page SA-3) 2. Mount the guide lever on the bracket
(a) Mount the washer and liner on the guide lever, and then
mount the guide lever on bracket.
(b) Mount the sleeve ring, the liner and the washer on the
guide lever.
(c) Screw up the fixing nuts with finger.
3. Mount the guide lever on the lower swing arm.
Screw up the fixing nuts according to the specified torque.
Fastening torque
(96
)N
m
assembly mark
assembly mark

SA-41
4. Mount the transverse stabilizer rod on the lower arm;
Fastening torque
(23
)N
m
5. Check the Alignment of Front Wheel;
(See Page SA-6)
Suspension System and Automobile Axle (SF/2WD)
Front Suspension (Lower Arm and Vibration Damper)

SA-43
Mount of Upper Arm
1. Screw up the axle nut of upper arm according to the
specified torque;
Fastening torque
(225
)N
m
2. Mount on the upper arm;
Screw up the three bolts of the upper swing arm shaft according
to the specified torque;
Fastening torque
(178
5)N
m
3. Connect the upper arm ball stud with the upper arm;
Use four sets of bolt and nut to connect the upper arm ball stud
and the upper arm.
Fastening torque
(27
)N
m
4. Mount the torsion rod spring;
5. Check the Alignment of Front Wheel:
(See Page SA-6)
Suspension System and Automobile Axle (SF/2WD)
Front Suspension \(Lower arm, Guide Lever and Transverse Stabilizer Rod)
Guide Lever
(See page SA-26)
Transverse Stabilizer rod
(See page SA-27)

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-20Steering system - Steering Linkage
Steering Linkage
Dismantle and mount of steering linkage
N
m
specified torque

Parts that cannot be reused after being used
side drag rod assembly
joint clip






intermediate lateral drag rod assembly






auxiliary steering arm
80
10(Dr)
83
10(SL SK SY)
142
10(SF)
78
10(SJ)
91
10(Dr)
59
5(SF)
91
10(Dr SF)
90
10(SL SK SY)
78
10(SJ)
Remark
(a) Where the bolts of recirculating ball are connected with
the arm or lever, the lubricant on its surface should be
cleaned.
(b) Screw up the bolts and nuts of re-circulating ball to the
specified torque, and then screw the nut forward to the
degree that the split pin can be encased in.
(c) Check the Alignment of Front Wheel and side slip after
any part of steering linkage is mounted.

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