air suspension GREAT WALL DEER 2006 Service Manual

Preface
With the increase of automobile demand in China, our automobile industry also experiences a rapid
development. The trucks including SUV, manufactured by Great Wall Motor Co., Ltd, which are sold all over
China, are in the leading place in terms of their sales volume, in order to satisfy the demands of various maintain-
ing staff, technicians and managing staff of Changcheng Co., Ltd, we compile this maintenance manual accord-
ing to the latest technological data. This manual covers six vehicle models including Deer, Safe, Sailor, Sing, So
Cool and Pegasus, its main content includes:
Part I is general introduction, which introduces the application index of this manual.
Part II introduces the chassis system, which mainly includes the technologies of dismantle, inspection,
adjustment, repairing, assembly and mount of the clutch, gear box, transfer box, drive shaft, suspension system
and automobile axle, braking system and steering system, etc. each operation approach is illustrated with figure,
which not only presents the maintenance procedure, but also clearly describes the technical requirements and
application limit.
Part III introduces the electric system and air-conditioning system of the automobile body, which mainly
covers such items as the location and content of protective box, power supply system, starting system, lighting
system, combination instrument, backup radar system, wiping and washing system, center control locking and
power window system, acoustical equipment system, full wire harness and air-conditioning system, etc. Electric-
ity diagrams for those electric systems are given in this manual so as to facilitate the maintaining technicians to
find out the problem easily and quickly.
Part IV introduces the external and internal body decoration, which mainly covers the dismantling, inspect-
ing and assembling requirements of the engine cover, front and rear doors, adhesive strip of body collision
avoidance, wheel shield, wrapping angle of wheel-shield and exterior trim panel, front and rear windshields,
side-window glass, rear-door glass, rear platform of cargo compartment, rear door, instrument panel, safety belt,
seat, tail-fin, luggage rack, and reserve tire bracket etc. The dimensions of vehicle body and frame are also given
to maintaining staff for reference during their repairing.
During the narrations of each part, items such as troubleshooting, maintenance notice, maintenance data
and application limit, fastening torques of bolts and nuts for special purpose, SST, SSM and lubricant materials
and so on are also introduced. Various maintenance data are briefed in attachment for reference.
Altogether, this manual is comprehensive in content, visual in illustration, clarifying in requirement and
plain in language. It can be referred by the maintaining staff, technicians and professional managing staff.
Even though we try our best to compile this manual in a strict earnest manner, we cannot guarantee that all
contents in this manual are correct. Therefore, users shall not put forward any claim with Great Wall Company
according to this manual; we are not in the position to hold the responsibility for the loss caused by usage of this
manual. Due to our limited knowledge, it is unavoidable to find error in this manual, any criticism and correction
from you is welcomed.
The final explanation power for this manual is subject to Great Wall Motor Co., Ltd
Compiler
May 2006

Service manual for
chassis and body
GeneralIN
ClutchCL
Gear boxMT
Transfer boxTF
Drive shaftPR
Suspension system and automobile axleSA
Braking systemBR
Steering systemSR
Body electric systemBE
Air-conditioning systemAC
Vehicle bodyBO
Maintenance and Up-keepingA
Special ToolB

SA-2
Troubleshooting
Suspension System and Automobile Axle
Troubleshooting
Change the tire or inflate to the proper pressure
Balance the wheels
Change vibration damper
Check Alignment of Front Wheel
Change or adjust the wheel bearing
Check ball joint) or liner
Tighten or change steering linkage
Adjust or repair the steering device
Discharge the oil and change with new one
Check the wandering clearance
Check the gears
Change the bearing
Change the bearing
Tighten or change the bearing Trouble Causes
Inspection items
Body wandering/body
draggingTire wear or improper air inflation
Incorrect alignment of front wheel
Over-tightened wheel bearing
Part looseness or damage of front/rear sus-
pension
Wear or looseness of steering rod system
Poor connection or damage of steering de-
viceInflate the tire to the proper pressure or change
the tire.
Check the situation of alignment of front wheel
Adjust the wheel bearing
Tighten or change the suspension element
Tighten or change the steering rod system
Adjust or repair the steering device
Body sink Overloaded vehicle
Wear of vibration damper
Poor spring performanceCheck the loading mass
Change vibration damper
Change spring
Left-right vibration/up-
down bouncingImproper air inflation
Bending or damaged lateral stabilizer
Vibration damper wearInflate the tire to suitable pressure
Change stabilizer
Change vibration damper
Front wheel vibration Tire wear or improper air inflation
Imbalance of wheels
Vibration damper wear)
Improper Alignment of Front Wheel
Wheel bearing wear or improper adjustment
Ball joint or liner wear
Steering linkage looseness or wear
Poor adjustment or damage of steering mecha-
nism
Abnormal tire wear Improper air inflation
Vibration damper wear
Poor Alignment of Front Wheel
Suspension system wearInflate the tire to the proper pressure
Change vibration damper
Check the Alignment of Front Wheel
Change suspension element
Speed reducer leakage Over-high oil level or improper oil quality
Oil seal wear or damage
Flange looseness or damageDischarge the oil for change
Change oil seal
Tighten or change the flange
Noise inside the
axleNoise inside the axleOver-low oil level or inferior oil quality
Over-large wandering clearance between
driving bevel gear and driven bevel gear
Wear and disintegration of driving bevel
gear and driven bevel gear
Bearing wear of driving bevel gear
Bearing wear of rear axle shaft
Bearing looseness or wear of speed reducer

SA-3Suspension System and Automobile Axle
Alignment of Front Wheel (Dr SL SK SY SJ)
Alignment of Front Wheel
(Dr SL SK SY SJ)
1. Inspection should be conducted for the following items to
remove the trouble
(a) Check the tire abrasion and air inflation situation
Tire inflation pressure:
Front (220
0)kPa
Back (240
0)kPa
(b) Check the front wheel bearing to see whether it is loose.
(c) Check the front suspension to see whether it is loose.
(d) Check the steering driving device to see whether it is
loose, and
(e) Check the front vibration damper work to see whether it
is loose.
2. Measure the ground clearance of the chassis.
Chassis ground clearance:
Dr
295
0+5mm
SL SK
(255
2)mm
SY
(310
2)mm
SJ
(295
1)mm
If the chassis ground clearance of the vehicle is sub-standard,
push down the body or raise it for a trial adjustment, if fails,
check the spring or suspension element to see whether they are
normal.
Remarks: adjust the chassis ground clearance to a specified
value before checking the Alignment of Front Wheel
parameters.
3. Mount on the four-wheel locating device.
The mount should be conducted according to the manufacturerís
instructions.

SA-6Suspension System and Automobile Axle
Alignment of Front Wheel
Alignment of Front Wheel (SF)
Alignment of Front Wheel
(SF)
1. The following items should be checked to remove the
troubles.
(a) Check the tire abrasion and the air inflation to see it is
suitable or not.
Tire inflation pressure: (250
0)kPa
(b) Check the front wheel bearing to see whether it is loose.
(c) Check the front suspension to see whether it is loose.
(d) Check the steering driving device to see whether it is
loose, and
(e) Check the front vibration through elastic force test to see
whether it is normal in performance.
2. Height adjustment of vehicle
Adjust the vehicle height to the standard value so as to make
the Alignment of Front Wheel inspection.
A-B-58 5mm
A: The height of steering knuckle shaft center.
B: The center height of the adjusting cam bolt at front end
The standard value for the unloaded height is: the
difference of the center height of drive shaft climax and
the front adjusting cam bolt is 58.5mm.
3. Mount on the four wheel locating device
This approach should be conducted according to the detailed
instruction of the equipment manufacturer.
4. Adjust the outer tilt angle of front wheel and the back tilt
angle of kingpin
The outer tilt angle of front wheel: 0
5'
0'
The back tilt angle of kingpin: 2
0'
0'
Outer inclination of front wheel:
BA
the outer tilt angle of
front wheelthe back tilt angle
of kingpin
front

SA-55
3. Tear down the retainer ring from the drive shaft with the
calipers, and take down the washer-steering knuckle
shaft spline.
4. Tear down the front wheel hub and the steering knuckle
together.
5. Screw off the nuts that connect the constant speed drive
shaft to take down the constant speed drive shaft.
6. Check and repair the constant speed drive shaft
Inject the molybdenum disulphide lithium grease of 100-110
g in the end of ball-cage type universal joint and the end of
axially movable tripod universal joint.
The ball-cage type universal joint and the axially movable
tripod universal joint should swing freely, and no clipping
stagnant is allowed. The dust cover should be prevented from
deformation and every gripping loop shall be clamping tightly.
Disassembly of Constant Speed Driving
Shaft
1. Tear down the brake caliper.
2. Tear down the free hub Suspension System and Automobile Axle (SF/4WD)
Constant Speed Driving Shaft

SA-80
Dismantle of Rear half Axle Shaft
1. Tear down the wheels.
2. Tear down the rear brake drum.
3. Tear down the grab end of the bracing wire of hand brake
from the rear brake.
4. Tear down the half-shaft and the rear brake assembly
from the rear axle housing.
5. Tear down the flat steel retainer ring for shaft from the
half-shaft;
Tear down the flat steel retainer ring for shaft with the ring
calipers.
6. Tear down the half-shaft:
Put down a wooden plate on the flat ground, and thrust the end
of spline of half-shaft and rear brake assembly toward the
wooden plate to separate the shaft and the rear brake assembly.
Inspection on and repairing of half-shaft parts
1. Check the wear, damage and swing difference half-shaft
and the flange.
Max shaft run-out: 2 mm
Max flange run-out: 0.2 mm
In case the half-shaft is damaged, or wearied or the measuring
value of the swing difference is excessive, change the half-
shaft.
2. Check he oil seal of rear wheel bearing:
Check to see whether there is wear or damage, and change the
oil seal if necessary.
3. The disassembly of the outer oil seal of rear wheel
bearing;
Tear down the outer oil seal of rear wheel bearing with SST. Suspension System and Automobile Axle (rear)
Rear Half Axle Shaft

SA-85
Dismantle of Rear Speed Reducer
1. Take out the oil drain plug to drain the oil in the speed
reducer up.
2. Tear down the rear axle shaft.
3. Disconnect the drive shaft from the speed reducer.
4. Tear down the nuts on the bolts that connect the rear axle
housing and the speed reducer.
5. Tear down the rear speed reducer.
Disassembly of Rear Speed Reducer
Remark: in case the noise is over loud, the following item
should be checked before taking apart it to find out the causes.
If the speed reducer has serious drawback, take it apart for
repairing where necessary.
1. Check the play between the axle driven bevel gear;
In case the play value fails to be within the specified range,
adjust the preload of bearing 200719E or repair it where
necessary.
(see page SA-91)
Standard play: (0.13-0.25)mm
2. Check the teeth engagement of the driving bevel gear
with the axle driven bevel gear.
(See Page SA-92)
Record the teeth engagement positions.
3. Check the clearance between the half-shaft gear thrust
gasket and the differential housing.
Check the clearance between the half-shaft gear thrust gasket
and the differential housing with the feeler.
Standard clearance
(0.45-0.75)mm
Remark: in case the clearance value fails to fall within the
above range, change the half-shaft gear stop gasket, and
ensure the half-shaft gear stop gaskets on the left and right
sides are same in thickness.
(See Page SA-95)
Suspension System and Automobile Axle (Rear)
(Dismantle of Rear Speed Reducer)

B0-54Vehicle Body
Instrument Panel
10. Tear down the combination instrument;
(a) Tear down the four screws;
Tear down the two screws;
(b) Disconnect the plugging elements;
(c) Tear down the combination instrument.
11. Tear down the ashtray cluster;
12. Tear down the central cover;
(a) Tear down the decorative frame;
(b) Tear down the three screws to pull out the central cover;
(c) Disconnect the plugging elements.
13. Tear down the central panel;
(a) Prize out the central panel as shown in the drawing with
screwdriver to take it down.
Notice: the screwdriver must be wrapped with adhesive strap
at its head before using.
(b) Disconnect the plugging elements.
14. Tear down the air-conditioning controlling mechanism
assembly;
Tear down the two screws, which will let the air-conditioning
controlling mechanism in suspension.
15. Tear down the air-controlling panel;
(a) Tear down the four screws to pull out the air-condition-
ing panel;
(b) Disconnect the plugging element;
16. Tear down the CD device or the combined acoustic
device;
(a) Tear down the four screws.
(b) Disconnect the aerial cable and the plugging elements.
(c) Tear down the CD device or the combined acoustic device.
17. Tear down the glove box;
Tear down the two screws and the glove box.
SF
Seize the flanges at two ends of glove box into the sliding
channel of the glove box.
18. Tear down the central air tunnel;
Tear down the four screws and the central air tunnel.

B0-56Vehicle Body
Instrument Panel
10. Tear down the combination instrument;
(a) Tear down the four screws;
(b) Disconnect the plugging elements.
(c) Tear down the combination instrument.
11. Tear down the CD or combined acoustic device;
(a) Tear down the four screws;
(b) Disconnect the aerial cable and the plugging elements;
(c) Tear down the CD or the combined acoustic device.
12. Tear down the central air tunnel;
Tear down the four screws to take out the central air tunnel.
13. 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 controlling 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.
14. Tear down the air-conditioning controlling mechanism
assembly;
Tear down the two screws and let the air-conditioner control-
ling mechanism in suspension.
15. Tear down the lower covering board at right end;
Tear down the four screws and take out the lower covering
board at right end.
16. Tear down the glove box;
Tear down the two screws and the glove box
17. Tear down the instrument body;
(a) Tear down the three bolts and the instrument panel;
(b) Disconnect the plugging elements.
Mount of instrument panel
Mount the parts of instrument panel in the reverse
approach.