fuse box GREAT WALL SO COOL 2006 Service Manual

TF-30Transfer Box
Washing, Checking, Up-Keeping and Exchanging (Attachment for Inspection Maintenance or Change of Parts)
Change the parts and fittings as requirement
Attachment for Inspection Maintenance or Change of Parts
Checking items
Acceptance/Refusal
Parts (items)
All parts (including
all springs)Crack inspection, distortion inspection and ero-
sion inspectionAll parts with crack, all parts that are bended,
distorted or poor in round bouncing are refused.
All threaded partsThread inspection for buckle missing or other
damageThose parts cannot be threaded or bottomed in
overlap manner shall be refused.
Flange and fork
flangePlease refer to the paragraph of
inspection
to
check the spline.Please refer to the
inspection paragraph
for
spline inspection.
Velocity sensor, mo-
tor assembly
Parts of electric clutch
systemPlease refer to the part of electric appliance
Sliding bearing Inside surface inspection for the sliding bearing In the case that the bearing has pitting corrosion
or other damage, refuse it.
Ball bearingCheck visually the ball and track of the ball
bearing to see whether there is damage such as
adhesive bonding, pitting corrosion, etc.
Ensure that the bearing are all lubricated, run the
outer race of the bearing while holding the inner
one to feel whether there is poor running or
corrosion, the bearing shall be run smoothly
without excessive clearance.Refuse to use the damaged bearing;
Refuse to use the damaged or loose bearing; or
Check the axial clearance to see whether it
exceeds 0.23mm.
Needle bearing Check the bearing needle roller and track to see
whether there is damage such as adhesive
bonding, pitting corrosion, etc.Refuse to use the damaged bearing.
The rear cover, front
body and front hous-
ing of transfer boxCheck to see whether there is burr on the cou-
pling face or other damage that impedes assem-
bling or sealing.Clear away the burr according to the paragraph
of
inspection
, otherwise, change the dam-
aged element
Rear cover of trans-
fer boxCheck the bearing holeRefuse to use the assembly that has pitting
corrosion
Odometer gear Check the gear teeth referring to the Inspection
ParagraphRefer to the gear or chain sprocket inspection in

inspection paragraph
.
Clutch shell, joint
outer gear sleeve and
joint coverCheck the spline according to the Inspection
paragraphRefer to the spline inspection of
inspection
paragraph

Locking sleeveCheck the wear or damage of the toggle fork
grooveRefuse the parts with step slipping or damage.
Shift guide shaft Check the deformation situation
Check the burr or other damage on outer race
Check the wear of outer raceRefuse to use the bend shaft; clear away the burr
according to the
inspection
paragraph, oth-
erwise refuse to use.
Refuse to use the shaft with step slipping or
other damage.
Shift toggle forkCheck whether there is wear or damage at the
location where the toggle fork combines with
the shifting cam and gear sleeve.If any step slipping or damage is found, refuse
to use it.

TF-31Transfer Box
Washing, Checking, Up-Keeping and Exchanging (Attachment for Inspection Maintenance or Change of Parts)
Attachment for Inspection Maintenance or Change of Parts
Parts (items) Checking items Acceptance/Refusal
Shift toggle fork as-
semblyCheck the wear and damage of the inserted face
that is combined with gear sleeve;
Check to see whether the contact roller can
rotate freely or is damaged or notIf any step wear or damage is found, the inserted
face shall be refused to use.
If the contact runs difficultly or is damaged, a
new pin-contact roller and new cage assembly
shall be used.
Driving and driven
chain sprocketCheck the sprocket teeth according to
the
inspection
paragraphRefer to the sprocket teeth inspection of

inspection
paragraph
Shift toggle fork as-
semblyCheck the inner diameter that matches with the
output shaftIf any pitting corrosion or damage is found,
refuse to use it.
Driving chain Check the step sliding, looseness or damage of
pin or connecting elementRefuse to use the weary or damaged driving
chain
Filtering screenCheck to see the filtering screen is clean or with
small hole or damageClean it where necessary, and abandon the dam-
aged one.

TF-32Transfer Box
Washing, Checking, Up-Keeping and Exchanging (Attachment for Inspection
Maintenance or Change of Parts
Pump shell Check to see whether there is pitting corrosion
or step slippingAbandon it in case it is seriously damaged or
worn
Output shaftCheck the spline, check the surface that matches
with bearing and check the distortion according
to
inspection
paragraphRefer to the spline inspection of
inspection

paragraph;
Refuse to use the one with pitting corrosion or
damage;
Refuse to use the one that is bending or poor in
round bouncing.
Deceleration hubCheck the spline of chain sprocket and check the
wear or damage of the location where matches
with the toggle fork according to the

inspection
paragraphRefer to the spline inspection of
inspection

paragraph; refuse to use the one with step slid-
ing or damage.
Front output shaftCheck the surface where matches with the
bearing;
Check the spline according to the
inspection
:
paragraphRefuse to use the one with pitting corrosion or
damage
Input shaft Check the spline according to the
inspection

paragraph
Check the distortionRefer to the spline inspection of
inspection

paragraph;
Refuse the one that is bending or poor in round
bouncing.
Thrust washer and
thrust discCheck the pitting corrosionRefuse to use the one with pitting corrosion or
damage
Sun wheelCheck the gear teeth and spline according to the

inspection
paragraphRefer to the gear teeth inspection and spline
inspection of
inspection
paragraph.
Planetary mechanism
assemblyCheck the gear teeth according to the

inspection
paragraph;
Check the wear and looseness of the planetary
gear pin; check the wear of thrust gasketRefer to the gear teeth inspection of

inspection
paragraph;
If any step sliding or pitting corrosion is found,
refuse to use it
Electric shifting camCheck to see whether there is step slipping or
pitting corrosionIf any step sliding or pitting corrosion is found,
refuse to use it
Shift guide shaftCheck to see whether there is step slipping or
pitting corrosion
Check the distortion situationIf any step sliding or pitting corrosion is found,
refuse to use it
Refuse to use the bending one
Planetary gear ringCheck the match performance of it with the
transfer box housing
Check the gear teeth according to the

inspection
paragraphCheck the transfer box housing assembly to see
whether the gear ring is loose or not in the
housing
Refer to the gear teeth inspection of

inspection

paragraph
Transfer box housingCheck the holes matches with the bearingAbandon the one with pitting corrosion or
damage.

BE-3Body Electric System
Brief Introduction
pull up
pull up
press down press down
Change of fuse and maxi-fuse
Remark: in case of exchanging the fuse or maxi-fuse, the fuse
or maxi-fuse with same rated current should be used.
Notice:
1. Before exchanging the fuse or maxi-fuse, all electric
appliances and ignition switches should be turned off
firstly. And the rated current of fuse or maxi-fuse should
not be exceeded.
2. When disassembling or assembling the fuse, the
disassembly and assembly tools must be used. And they
must be pulled out or plugged in vertically. No bend is
allowed because the bend will make the connecting
terminals depart away, and thus poor connection will
occur. In case the fuse or maxi-fuse is burned, it shows
there is short circuit. In such situation, the systematic
inspection should be conducted by the qualified
technician.
Remark: the disassembly and assembly tools are put on the
protective box cover.
same rated current 10A
10A

BE-5
If there is diode in the circuit, connect the two leads in reverse
polar and make another inspection. When the cathode lead (-)
is connected with the positive (+) side of diode, and the
positive (+) lead should be connected with the cathode (-) lead
of diode, the diode should conduct, while the two leads
connected to the reverse polar, the diode should not contact.
Remark: the specification may be not same due to different
testing meter types; therefore, the application instruction for
testing meter should be referred before the inspection.
Check the light emitting diode (LED) according to the same
approach for diode inspection.
Remark:
The testing meter should be used the one with 3V voltage or the
one has larger resistance than that in circuit.
If no suitable testing meter is applied, the voltage of accumu-
lator may be added to check the LED to see whether it is
lighted.
(c) Use the voltage or ohmn meter with high-impedance
(min voltage of 10 KV) to diagnose the failure in electric
circuit. Body Electric System
Brief Introduction0

0

K

K
ohmn meter
diode
0
0
K

K





ohmn
LED
digital type
analogue type


DCD
C
V
LG terminal of ignition switch
testing bubblefuse box
short circuit

SW1
short circuit

disconnection
electromagnetic
coil
short circuit

disconnection disconnectiong
Check to see whether there is short circuit
(a) Tear down the burned fuse and remove all loads from
the fuse.
(b) Connect the testing bubble at the fuse position;
(c) Verify the situation of testing bubble position:
For example:

Put the ignition switch of SW at
ON
position;

Put the ignition switch of SW and SW1 at
ON
position;

Put the ignition switch of SW, SW1 and Relay at

ON
position (which connects with the relay), and put
SW2 at
OFF
) position (or disconnect the SW2).
(d) Disconnect or re-connect the plugging elements when
observing the testing bubble. In case the testing bubble
keeps lighting, which shows there is short circuit between
the plugging elements; if the testing bubble extinguishes,
there is short circuit between the plugging elements.
(e) Shake the trouble wire alongside the body to locate the
SW2 electromagnetic
coil

BE-8Body Electric System
Protective Box Position and Content
Content of Protective Box
1 protective box I
fuse
1.Small lamp 10A
2.Rain brus 20A
3.Ceiling lamp 10A
4.(Cigarette lighter) 15A
5.Back -u 15A
6.Brake 10A
7.electric window 30A
8.Instrument 10A
fuel delivery/break electromagnetic valve10A(diesel

9.Central control lock 15A Dr
A
B
C



1
2
3
456
789
SL SK
U
N
O
V
P
Q
R NM
NN
NO
S
T NP
NQ
FUSE
1. Protection 10A
2. Unload
3. Charging 10A
4. Back-up 10A
5. ECU 10A
6. Unload
7. Rain wiper 10A
8. Stop lamp 10A
9. Ceiling lamp 10A
10. Central control lock 15A
11. Dual flasher 10A
12. EC 10A
13. Fuel pump 10A
14. Cigarette lighter 15Arelay
A electric window relay
B. small lamp relay
C.(flasher)

(plugging elements of ceiling
lamp wire harness)

(plugging elements of wire
harness in engine room)

BE-9Body Electric System
Protective Box Position and Content
fuse relay
1. Small lamp 10A A. electromagnetic fan relay
2. Brake 5A B. lasher
3. Ceiling lamp 5A C. electromagnetic fan relay
4. Central control lock 15A D. small lamp relay
5. Electric rocker gear 30A E. electric window relay
6. Dual flasher 10A
7. Cigarette lighter 15A
8. Rear vision mirror 5A (1) plugging elements of ceiling lamp wire harness
9. Unload (2) plugging elements of wire harness at front left door
10. Acoustic device 15A (3)plugging elements of wire harness in engine room
11. Rear window 20A
12. Electromagnetic fan 10A
13. Instrument 5A
14. Back-up lamp 5A
15. Rain brush 10A
16. Steering 5A
17. Unload
18. Unload




A
B
C
E D
123 456
78 9 101112
13 14 15
16 1718
SF
Protective bos I (continued)

BE-10Body Electric System
Protective Box Position Content
FuseVehicle
Model
1. Standby 30A
Standby 20A SJ
2. Standby 15A SY
Standby 10A SJ
3. Standby 10A SY SJ
4. Unload SY
Bass bubble 10A SJ
Power amplification 10 A top SY
5. Unload SY SJ
6. Unload SY SJ
7. Unload SY SJ
8. Air-conditioner 10A SY SJ
9. Charging 10A SY
Instrument 10A SJ
10. ECU 10A SY SJ
11. Back-up lamp 10A SY SJ
12. Cigarette lighter 30A SY SJ
receiver
13. Unload SY
Refrigerant 10A SJ top SY
14. Unload SY SJ
15. Steering electric window 10A SY
Humid display of steering 10A SJ
sindicating lamp
16. Stop lamp 10A SY SJ
17. Power aerial of inside lamp 10A SY SJ
18. Central control lock 20A SY SJ
19. Dual flasher 10A SY SJ
20. Front rain brush 10A SY SJ
21. Rear air-conditioner 15A SY
Unload SJ
22. Rear defroster 15A SY
Unload SJ
23. Rear rain brush 10A SY
Unload SJ
1Protective box I (continued)pv=pg
1
2
3
4
567
8
91011
12 13
14 15
16 17 18 19
20 21 22 23

BE-11Body Electric System
Protective Box Position and Content
Fuse Vehicle model
1. Standby 10A (SL diesel)(SY diesel)
2. Standby 15A (SL diesel) (SY diesel)
3. Standby 30A (SL diesel) (SY diesel)
4. Unload (SL diesel) (SY diesel)
5. Unload (SL diesel) (SY diesel)
6. Unload (SL diesel) (SY diesel)
7. Unload (SL diesel) (SY diesel)
8. Start 10A (SL diesel) (SY diesel)
9. Rear defroster 15A (SY diesel)
Unload (SL diesel)
10.Cigarette lighter
and receiver 30A (SY diesel)
Cigarette lighter 15A (SL diesel)
11.Rear rain brush 10A (SY diesel)
Unload (SL diesel)
12.Front rain brush 15A (SY diesel)
Rain brush 5A (SL diesel)
13.Steering 10A (SY diesel)
Dual flasher 10A (SL diesel)
14.Preheating 15A (SL diesel)(SY diesel)
15.Electric window 30A (SL diesel)(SY diesel)
16.Small lamp 10A (SL diesel)(SY diesel)
17.Stop lamp 10A (SL diesel)(SY diesel)
18.Inside lamp
and electric aerial 15A (SY diesel)
eiling lamp 10A (SL diesel)
19.Central control lock 20A (SY diesel)
Central control lock 15A (SL diesel)
20.Rear air-conditioner 15A (SY diesel)
Unload (SL diesel)
21.Unload (SL diesel)(SY diesel)
Refrigerant 10A (top SY diesel)
22.Unload (SL diesel )(SY diesel)
Power amplification 10A (top SY diesel)
23.Unload (SL diesel)(SY diesel)
1.Protective box I (continued)SLDiesel SYDiesel
1
2
3
4 567
89NM11
12 13 14 15
16 17 18 19
2021
22 23

BE-12
Protective box II
Body Electric System
Protective Box Position and Content
Dr SF
Fuse Vehicle Relay vehicle
1. Front fog lamp 15A Dr A. electromagnetic fan relay Dr
Unload SF charging relay Dr diesel
2. Electromagnetic fan 15A Dr electric horn relay SF
ECU1 10A SF B. large lamp Dr SF
3. Large lamp 10A Dr C. frost relay Dr SF
Horn 15A SF
4. Horn 15A Dr
Lower beam 10A SF
5. ECU1 10A Dr (1) plugging elements of
wire harness in engine room Dr
Charging 10A Dr diesel none SF
Rear frost 5A SF (2) plugging elements of
wire harness in engine room Dr SF
6. Large lamp 10A Dr (3) plugging elements of
wire harness in engine room Dr SF
ECU2 10A SF
7. Rear frost 10A Dr
Upper beam 10A SF
8. ECU2 10A Dr
Preheating 10A Dr diesel
Front fog lamp 10A SF
9. Fuel pump 10A Dr SF
Unload Dr diesel





A
B
C 12 3
45 6
78 9