GREAT WALL FLORID 2008 User Guide

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Comprehensive Repair Instructions
1. Use the splasher, backing, and carpet to keep the vehicle
clean and to prevent damage.
2. W h i l e r e m o v i n g , m a r k a l l v e h i c l e c o m p o n e n t s o r
place all the components in proper order to make re-
assembling more convenient.
3. Disposable parts:
(a) Always use new parts to replace cotter pins, gaskets, O-
rings, and oil seals.
(b) Disposable parts will be marked with a "" in the
components schematics section.
4. Precoated components.
The precoated components include bolts and nuts which
have been coated with locking sealant in the factory.
(a) If the precoated part is tightened, loosened, or moved
for certain reason, it must be coated with prescriptive
sealant again.
(b) When reused, the original sealant should first be
cleaned and dried using compressed air. Afterwards,
use the required locking sealant to coat the bolts, nuts,
or threads.
(c) Precoated parts are marked with "" in the components
schematics section.
5. All rules regarding a bolt's tightening torque must be
seriously obeyed, and a torque wrench must be used.
6. Be careful when using a jack to raise and support the
vehicle. Make sure to jack up and support the vehicle
at proper locations.
(a) To ensure safety, chock up the wheels of the opposite
side if the place to be jacked up is either the front or
back of the vehicle.
(b) After lifting the vehicle, make absolutely sure to
support it with a bracket. It's extremely dangerous to
perform maintenance using merely a jack, even if to
finish the small matter quickly.
Torque wrench indication type
Torque wrench scale indication type
Hydraulic jackScissor type jack

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The white side
The black side
7. Pay attention to the "Areas of Importance" below to
avoid damaging any part:
(a) Do not open the cover or case of the ECU (Electronic
Control Unit) unless it's absolutely necessary. (Touching
the pin of the IC (Integrated Circuit) may damage the
IC due to static electricity.)
(b) When unplugging the vacuum hose, make sure to pull
from the end of the hose but not the center.
IncorrectCorrect
(c) To make hose reassembly more convenient, label the
unplugged portions for easier recognition later. After
performing this task, check carefully to make sure the
hose is connected correctly.
(d) Be careful! Do not drop any electrical components (like
sensors or relay connectors). Replace them at once
if they have been dropped onto a hard surface. They
cannot be used for the second time.
(e) When cleaning the engine with a steam, make sure to
properly protect the ignition coil and air filter as to
prevent water from seeping in.
(f) D o n o t f o r c e f u l l y t r y t o c o n n e c t a h o s e i n t o a n
oversized tube while using a vacuum gauge. Instead,
use a stepped connector. If the hose is stretched, it may
lead to leaking.
8. All resistors must be measured at below 20oC room
temperature unless special situations arise. This is
because resistance value measured under higher
temperature may exceed standard requirements, espe-
cially if measured after driving the vehicle. All measures
should be taken after the engine has cooled down.
Circuit Maintenance Instructions
1. Rules to be obeyed before a circuit is repaired:
(a) Make sure to disconnect the negative (-) cable from the
battery before electrical maintenance is performed.
(b) W h e n i n s p e c t i o n a n d m a i n t e n a n c e w o r k r e q u i r e s
disconnecting the battery, make absolutely sure to
disconnect the negative (-) cable of the battery and that
it is connected to the vehicle body as grounding.
(c) To prevent damaging the wiring terminal of the battery,
loosen the cable's fixing nut and lift up the cable, but
do not forcefully twist or press the cable.
(d) When cleaning up the battery's and the cable's connecting
terminals, make sure to use a special rag, and do not use a
file or other rough material to wipe them.
(e) While connecting the connecting terminals of the cable
and battery, loosen the nuts first, then tighten them
after installation. Do not hammer the cable's connecting
terminals into the battery with a hammer.
(f) I f t h e b a t t e r y ' s g r o u n d c a b l e h a s n o t y e t b e e n
disconnected, please do not try to speed charge the
battery, as this could damage the alternator's diode.
(g) Should the battery's ground cable be disconnected,
please do not try to start the engine, as this could
seriously damage the wire.
(h) Make sure to properly cover the battery's positive (+)
end cover.

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2. Inspection procedures for related fuses or fuses in re- Inspection procedures for related fuses or fuses in re-Inspection procedures for related fuses or fuses in re-
lay boxes. Inspect the battery for damage, the battery's
charging state, cleanness, and tightening with the
connectors.
Before changing a fuse, make sure to check if the fuse's cur-
rent rating meets the required standards. You must not use a
fuse with a current rate that is higher or lower than required
standards.
Same current rating
3. Binding wire harness connectors.
(a) When disconnecting the connections, first press the two
ends of the connectors together, then loosen the lock
and press the lock pawl to release the connector.
(b) When disconnecting the connector, do not pull on its
wire harness. Grasp the joint directly.
(c) Check if the joint is deformed, damaged, or port lost
before connecting the connector.
(d) The connector is not successfully connected until it
makes a click sound.
4. Wire harness connector inspection.
(a) Check while connecting the connectors.
Squeeze both ends of the connectors to make sure it is com-
pletely plugged in and tightly locked.
(b) Check when disconnecting the connectors.
Check by lightly pulling the wire harness behind the connec-
tor's joint. Look for any unconnected or dropped terminals,
loose clamps, or broken wires.
Visually inspect for instances of corrosion, metal fragments,
oddities, and water, as well as bending, rust, overheating,
pollution or deformed terminals, etc.
(c) Check the contact pressure of the terminals.
Prepare a plug that matches the connector's port, plug it into
the socket, then check for the proper rate of tension after
they are fully engaged.
Loosen crimp
Core
Deformed terminal
Pull lightly
The terminal is similar to a plug
Incorrect

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Protection band
Screwdriver
5. Maintenance methods for wire harness connector ter-Maintenance methods for wire harness connector ter- for wire harness connector ter-
minals.
(a) Use an airgun or rag to clean the contact points if the
terminals become dusty. Do not use sandpaper to clean
it, as that could damage the electroplated layer.
(b) If the contact pressure seems unusual, change it to a
socket of the same type.
(c) Any terminal that has been damaged, deformed, or
corroded must be changed. If the terminal is not locked
to the case, then the case needs to be replaced too.CorrectIncorrect
6. Clip removal and installation.
Methods for removal and installation of the vehicle's body part clips ar\
e shown in the table below.
Remark: If the clip is damaged during operation, it must be replaced wit\
h a new one.
ShapeRemoval / Installation
Vise
Clip extractor
Protection band
Screwdriver

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ShapeRemoval / Installation
Continued table
Removal
Screwdriver
Installation
Press
Clip extractor
Push out the king pin, remove it,
and pry the kingpin bush.
Screw off the king pin and pry the shell.
Pry out the king pin, remove the rivet,
and then pry off the shell.
Removal
Screwdriver
Clip extractor
Press
Installation Removal
Screwdriver
Press
Small clip extractor
Installation
Clip extractor

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General Repair Methods and Operations
1. If a jack is needed, please kindly comply to the safety procedures liste\
d below.
2. Park the vehicle on a flat surface, stablize the front and the back wheels using any fixed object or tool,
jack up the vehicle, support it with the chassis, and then start the mai\
ntenance.
3. Disconnect the battery's negative cable before maintenance, in order to reduce the possibility of
damaging and burning out the cable due to a short circuit.
4. Cover the vehicle body, seats, and floor to prevent them from being damaged and polluted.
5. Handle brake fluid and antifreeze fluid carefully, because it may damage the vehicle's surface paint
and its surroundings.
6. Using the proper tools or basic tools that have been recommended and are purchasable is very
important in guaranteeing an effective and reliable maintenance result.
7. Dispose the used dowel pins, gaskets, O-rings, oil seals, lock washers, and self-locking nuts. Prepare
new parts for installation. Normal functions are not guaranteed if these\
parts are reused.
8. Store the removed parts in order and in groups to make reassembly more c\
onvenient.
9. Store bolts and nuts separately, because their hardness levels and designs are different according to
the installation locations.
10. Clean parts before they are inspected or reassembled. In addition, parts that come in contact with
engine oil also need to be cleaned, as well as checked for blockage by u\
sing compressed air.
11. Before installation, use engine oil or grease to lubricate the rotating and sliding sides of the necessary
parts.
12. When necessary, use sealant on gaskets to avoid leakage.
13. Please carefully comply to all tightening torque specifications of b\
olts and nuts.
14. After maintenance, check to make sure whether the repairs were performed correctly and whether the
malfunctions have been fixed.
Vehicle Lifting/Lowering Procedures
When lifting the vehicle, the lifter must be placed at the indicated spots. Using these indicated spots
incorrrectly can lead to permanent deformation of the vehicle body. Many vehicle service stations
have autolifts that raise vehicles by supporting certain vehicle parts. If using other types of lifts, be
careful to prevent damages to the fuel tank, oil filler, or the base of the vehicle body.
Frame contact lifting device and basic hand jack
Floor arch jack
Lifting points (left/right) of central threshold

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Overall Parameters
Basic Parameters of the Overall Vehicle ............................11
Engine Technical Parameters .............................................12
Chassis' Main Assembly Technical Parameters .................13
Vehicle Structure Type and Parameters .............................15
Air Conditioning System Structure and Parameters ...........16
Electrical System Structure and Parameters ......................16
Grade Specification and Filled Quantity of Each
Individual Functioning Component's Working Agent ..........18
Torque Specifications for Key Operational Bolts ................18
Vehicle Body's Basic Calibration Measurements ..............22

Downloaded from www.Manualslib.com manuals search engine 11Overall Parameters
ItemS08 S16S12
GW413EFGW4G15YC4W75-31
Size Pa-
rameters
(no load)
(mm)
Length3907
Width1694
Height1521
Wheelbase2368
Tread: front/rear1459/1430
Front suspension813
Rear suspension726
Quality
Parameters
Load capacity (kg)5 people × (68±7) kg/person
Curb weight (kg)113511201118
Gross vehicle weight (kg)151014951493
Unload axle load distribution: front/rear (kg)646/434669/451689/429
Unload centroid location (x, y, z) (mm)951/27/285.9954/27/285.9909/27/285.9
Full load axle load distribution: front/rear (kg)748/707770/725791/702
Full load centroid location (x, y, z) (mm)1151/22/375.51148/22/375.51114/22/375.5
Passing
Ability
Parameters
Minimum turning diameter (m)11
Minimum ground clearance (mm)127 (full load)
Approach angle (°)17 (full load)
Departure angle (°)20 (full load)
Breakover angle (°)16 (full load)
Dynamic
Performance
Minimum stable speed of the direct gear (km/h)≤25
Direct drive 25 km/h - 100 km/h acceleration
time (s)≤32
Acceleration time from standstill with the first
gear to shifting gears until reaching 100 km/h (s)≤19
Maximum speed (km/h)162178152
Maximum climbing capacity (%)30.63434.3
Economy
Sliding distance (m) of 50 km/h initial speed≥500
F u e l c o n s u m p t i o n o f 9 0 k m / h s p e e d w i t h
constant velocity (L/100 km)5.796.14.25
Fuel consumption of 120 km/h speed with
constant velocity (L/100 km)≤8.5
U n d e r t h e u r b a n a n d s u b u r b d r i v i n g c y c l e
simulation (L/100 km)≤7.5≤8.1≤7.5
Braking
Performance
Service braking distance (m) of 50 km/h initial
braking speed19.0≤ (no load) ≤ 20 (full load)
Emergency braking distance (m) of 50 km/h
initial braking speed ≤38
Grade braking (%)≥18
Stability
Maximum angle of rolling stability when empty
or inactive (°)≥35
Handling stability (min)Nan≥60 and NZ≥60
Basic Parameters of the Overall Vehicle

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Ride
Performance
Outter acceleration noise dB (A)≤74≤75
60 km/h constant velocity interior noise dB (A)≤65≤65
Driver operating noise dB (A)≤90≤90
Emission
CO emission (g/km)≤2.30≤1.00≤0.64
HC emission (g/km)≤0.20≤0.10/
NOx emission (g/km)≤0.15≤0.08≤0.5
Particle emission (g/km)//≤0.05
Smoke density//≤4.0
Engine Technical Parameters
ItemUnitSpecifications and Parameters
Model numberGW413EFGW4G15YC4W75-31
Model
Inline four cylinder, 4-stroke, water cooling, dual
overhead camshaft, petrol engine
Inline four cylinder,
4-stroke, water cooled,
dual overhead camshaft,
diesel engine
Fuel supply typeElectronic controlled, multi-points ordinal injection
High pressure electronic
controlled common-rail
fuel injection
Cylinder bore ×
strokemm × mm78.7 × 69.075 × 84.771.0 × 77.0
DisplacementL1.3421.4971.219
Compression ratio9.3:110.5: 118.5:1
Number of valves/
cylinder16/4
Lowest rate of fuel
consumption g/(kW·h)<260≤260215
Maximum power/
rotation speed kW/(r/m)65/600077/600050/4200
Max. torque/
rotation
speed
N·m/(r/m)115/4400-5200138/4200153/2000-2400
Total net weightkg11596142±2
Idle speedr/min800±50800750±50
Fuel type and
gradeRON/MONUnleaded gasoline, #93Euro diesel fuel
Cooling style and
performance
parameters
Forced water circulation
cooling, the opening
temperature of the
thermostat is 82±2oC, the
water temperature under
normal working condition
is 90-100oC, the opening
pressure of the coolant
compensation box's
pressure limiting valve is
108±14.7 kpa
Forced water circulation
cooling, the opening
temperature of the
thermostat is 82±2oC, the
water temperature under
normal working condition
is 80-90oC, the opening
pressure of the coolant
compensation box’s
pressure limiting valve is
108±15 kpa
Forced water circulation
cooling, the thermostat
starts to open at 75oC and
is fully open at 85oC, the
opening pressure of the
coolant compensation
box's pressure limiting
valve is 108±14.7 kpa
Starting style and
performance
Motor starting, starting performance complies with GB18297
requirements 8.1.2 and 8.1.3
Lubricating
methodPressure and splash combination

Downloaded from www.Manualslib.com manuals search engine 13Overall Parameters
Chassis' Main Assembly Technical Parameters
ItemSpecifications
Model numberGW413EFGW4G15YC4W75-31
ClutchClutch type
Single chip, dry type, diaphragm springSingle chip, dry type,
diaphragm spring
Driven disc diameter:
200 mm
Clutch disc diameter:
213 mm
Driven disc diameter:
212 mm
Maximum stroke: 9 mm, separating stroke: 7.5 mmSeparating stroke:
7.5 mm
Clutch hydraulic pressure
control systemClutch pedal total stroke: 116.5mm
Transmission
Transmission
model number037ACC0011AZM007QZM007W
Transmission typeMechanical 5-gear manual transmission
Main speed
reduction ratio3.9444.31254.2673.937
Gear
transmission
ratio
1st gear3.5453.5453.3643.182
2nd gear1.9131.9051.8951.895
3rd gear1.3101.3101.2861.25
4th gear0.9730.9700.9690.91
5th gear0.8040.8160.8000.703
Reverse
gear3.2143.2503.2143.08
Maximum bearing
torque (N·m)130160153153
Maximum input speed
(r/min)6000
Propeller shaft
The input end of the propeller shaft adopts a widely used, near constant
velocity, retractable spherical roller wheel joint. The output end adopts a
Rzeppa joint.
Air intake systemDry air filter, paper filtering element.
Exhaust system
Equipped with GW413EF engine, two grade muffler with two grade three-
way catalytic converter. Front/rear oxygen sensors.
Equipped with YC4W75-31 engine, two grade muffler with one grade three-
way catalytic converter and oxygen sensor.
Fuel supply system
Equipped with GW413EF engine. The 45L metal fuel tank includes an
electronic fuel pump and a charcoal canister. An electronic accelerator pedal
controls the fuel supply. The fuel evaporation control system controls the
charcoal canister through a solenoid valve
Equipped with the YC4W75-31 engine. High pressure electronic common-
rail fuel injection and dual fuel pipeline. The 45L metal fuel tank includes an
electronic fuel pump and a charcoal canister, electronic accelerator pedal, a
fuel line is connected with the fuel-water separator and diesel fuel filter.
Cooling system
The cooling system uses the enclosed forced water circulation cooling
system, the heat dissipating electronic fan uses a two level speed controller.
The electronic fan and overflow tank are combined in one. The radiator is
equipped with upper and lower water chamber aluminum pipe. The system
pressure is 90 kPa.