lock GREAT WALL FLORID 2008 User Guide

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual20
No.Important fastening piece locationsFastening piece name
and model numberQuantity
Tightening
torque
(N·m)
1.31Propeller shaft assemblyFront drive shaft nut (M22 × 1.5)2240±20
1.32Subframe & vehicle body (rear)Hexagon bolt for flange face and flat
washer subassembly2116±10
1.33Subframe & vehicle body (front)Hexagon bolt for flange face and flat
washer subassembly270±5
1.34Subframe strut bar & vehicle bodyHexagon head bolt and flat washer
subassembly447±5
1.35Swing arm & steering knuckleSwing arm ball end nut (M12 × 1.25)298±10
1.36Swing arm & subframeHexagon nut for flange face (M12 × 1.25)2\
1.37Swing arm & subframeHexagon head bolt and flat washer
subassembly2136±10
1.38Swing arm & subframeHexagon head bolt and flat washer
subassembly2107±10
1.39Front shock absorber & vehicle bodyHexagon nut for flange face (M8)639±4
1.40Front shock absorber & steering knuckleHexagon bolt for flange face (M14 × 1.5)4\
1.41Front shock absorber & steering knuckleHexagon nut for flange face4132±10
1.42Front stablizer bar bracket & frameHexagon head bolt and flat washer
subassembly423±3
1.43Hanger rod, swing arm & stablizer barType 2 non-metal insert lock nut223±3
1.44Trailing arm spindle sleeve assemblyHexagon head bolt and flat washer
subassembly282±5
1.45Rear shock absorber support shaftHexagon nut for flange face249±5
1.46Rear shock absorber componentsI type hexagon nut464±5
1.47Hub Wheel nut (M12 × 1.25)16103±10
1.48Steering wheel & steering column
mounting nutHexagon nut for flange face150±4
1.49Steering column & beam mounting boltHexagon bolt for flange face123±3
1.50Steering column & beam mounting boltHexagon head bolt and flat washer
subassembly223±3
1.51Steering pump adjustable bracket &
engine mounting boltHexagon bolt for flange face339±4
1.52Powr steering pump & bracket mounting
boltHexagon bolt for flange face164±5
1.53S t e e r i n g p u m p m o u n t i n g b r a c k e t
&engine mounting boltHexagon bolt for flange face235±3
1.54Steering gear & subframe mounting
bolt
Hexagon head bolt and flat washer
subassembly (M12 × 1.25 × 80)2107±7
1.55Steering gear & subframe mounting
bolt
Hexagon head bolt and flat washer
subassembly (M13 × 1.25 × 100)2107±7
1.56S t e e r i n g g e a r & s t e e r i n g k n u c k l e
mounting nutHexagon castle thin-nut250±10
1.57Steering protection plate & subframe
mounting boltHexagon bolt for flange face223±3
1.58ABS sensor & steering knackleHexagon head bolt and spring washer
subassembly29±2
1.59Rear brake & rear axleBolt: for installing brake850±5
1.60Brake pedal & boosterNut423±3

Downloaded from www.Manualslib.com manuals search engine 21Overall Parameters
No.Important fastening piece locationsFastening piece name
and model numberQuantity
Tightening
torque
(N·m)
1.61ABS sensor front wire harness & front
shock absorber
Hexagon head bolt and flat washer
subassembly223±3
1.62ABS & vehicle body Hexagon head bolt and flat washer
subassembly323±2
1.63Parking brake cable & vehicle bodyH e x a g o n h e a d b o l t a n d s p r i n g w a s h e r
subassembly69±2
1.64Parking brake cable & rear brakeH e x a g o n h e a d b o l t a n d s p r i n g w a s h e r
subassembly29±2
1.65ABS sensor rear wire harness, vehicle
body & rear brake
H e x a g o n h e a d b o l t a n d s p r i n g w a s h e r
subassembly69±2
1.66Parking brake fixed cable braket &
vehicle body
H e x a g o n h e a d b o l t a n d s p r i n g w a s h e r
subassembly19±2
1.67ABS sensor front wire harness & vehicle
body
Hexagon head bolt, spring washer and flat
washer subassembly29±2
1.68Parking brake control mechanismHexagon head bolt, spring washer and flat
washer subassembly223±3
1.69Rear brake pipe connector & vehicle
bodyHexagon bolt for flange face19±2
1.70Seven-hole tube clamp & vehicle bodyHexagon bolt for flange face19±2
1.71Brake pedal & vehicle bodyHexagon bolt for flange face123±3
1.72Brake cable & rear axleHexagon nut for flange face29±2
1.73All of the brake line connectors M1016±2
1.74All of the brake line connectors M1216±2
2Vehicle body
2.1Connected seat belt Front seat belt upper mounting bolt (7/16.)242±5
2.2Connected seat belt Seat belt lower mounting bolt (7/16.)438±5
2.3Connected seat belt retractorFront seat belt retractor lower bolt (7/16.)238±5
2.4Connected seat belt retractorHexagon bolt for flange face29±3
2.5Connected seat belt Rear seat belt upper mounting bolt (7/16.)238±5
2.6Connected seat belt retractorRear seat belt retractor bolt (7/16.)238±5
2.7Connected seat belt Mounting bolts on the middle seat belt
(7/16.)138±5
2.8Connected front seat belt mortise lockFront seat belt mortise lock bolt (7/16.)260±5
2.9Connected rear seat belt lockRear seat belt lock bolt (7/16.)238±5
3Air conditioner
3.1Compressor bracket & engineHexagon bolt for flange face Q1841030FD
(M10 × 1.25)464±5
3.2Comperssor bracket & compressorHexagon bolt for flange face-oversize
Q1860890FD423±3
3.3Condensor fan mounting boltHexagon head bolt and flat washer
subassembly Q1400630 (Q402) F3219±2
3.4Condensor mounting boltHexagon bolt for flange face223±3
3.5Compressor suction hose & HVAC
refrigeration line portHexagon bolt for flange face Q1460640F3219±2
3.6Air conditioner hose, compressor, and
condenser coupling boltHexagon bolt for flange face Q1840625F3249±2
3.7Expansion valve & HVAC refrigeration line portHexagon bolt for flange face Q1840630F3229±2

Downloaded from www.Manualslib.com manuals search engine 31Fuel Supply and Exhaust System
Fuel Tank Removal
Special note: When maintenance of the fuel supply
system requires removal of the fuel line, the pressure
of the fuel system should first be released, so as to
avoid the spraying of high-pressure fuel.
1. Pull out the electrical connector of the fuel pump on the
top of the fuel tank.
2. Pull out the quick connectors of fuel filler hose II and
the inlet rigid pipe, as well as desorption hose I and
the desorption rigid pipe. Afterwards, use a cotton cloth
to block the mouthpiece to avoid the spraying of high-
pressure fuel.
3. Remove the fuel filler pipe connecting hose, air pipe,
and air return hose (two attachment clips and one
clamp) at the rear of the fuel tank.
4. Use specified torque of 26±3 N·m to remove the four
bolts and the strengthening cushion.
Fuel Pump and Charcoal Canister Removal
1. Assembly removal
(a) Remove the pipeline connected to the fuel pump.
(b) Clean any accumulated dirt from the flange of the fuel
pump.
(c) Starting diagonally, use a wrench to successively
remove the small bolts on the install panel of the fuel
pump in diagnostic mode.
(d) Pay careful attention not to damage the fuel level
sensor when taking the assembly out from the fuel
tank.
2. Assembly installation
(a) Carefully install the fuel pump and charcoal canister
assembly, as well as the oil level sensor, ensuring they
will not be damaged.
(b) Ensure that the port of the pipeline between the fuel
pump and charcoal canister is correct.
(c) Install the weatherstrip and install panel using specified
torque of 3-4 N·m to tighten the bolts.
Fuel Filter Removal
1. Pull out the two quick connectors which connect to the
fuel filter.
2. Loosen the bolts on the fuel filter mounting bracket in
order to take out the filter. The entire filter should be
replaced.
Air return hose
Fuel filler pipe connecting hose
Fuel filler pipe assembly
Q1461025Q67639
Q673B20
Q67639
Q673B20
Fuel filler hose I1400616F3
Fuel filter mounting bracket assembly
Fuel filterFuel filler hose II
1400616F3
Desorption hose II
Fuel filler hose II
Fuel filler hose I
Charcoalcanister
Fuel pump and oil level sensor assembly
Q1400508F3
Strengthening cushion
Heat shield front install buckle
Fuel tank heat shield assembly
Heat shield rear install buckle
Fuel tank assembly
Q1400835FD(Q402)

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual38
Clutch Operational System
Components
Clutch Master Cylinder Removal
1. Use a combination plier to loosen the steel band elastic
hoop, and to remove the clutch feed connecting hose.
Caution: Release the brake fluid in the reservoir before
disconnecting the hose.
Steel band elastic hoop
Clutch feed connecting hose
Reservoir
Steel band elastic hoop
Clutch feed connecting hose
Clutch discharge pipe
Clutch master cylinder
Limit adjusting bolt
Return spring
Lock nut

Downloaded from www.Manualslib.com manuals search engine 39Clutch Operational System
2. Remove the driven clutch discharge pipe with a M10
open-end wrench.
3. Remove the pedal lock pin.
4. Remove the return spring and the connecting pin.
5. Remove the lock nuts of the clutch pedal with a M13
sleeve and an extension bar.
6. Remove the clutch master cylinder.
Clutch discharge pipe
Pedal lock pin
Return springConnecting pin
Lock nut
Clutch master cylinder

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual40
Clutch Master Cylinder Installation
Installation of clutch system is reverse to its removal, but
since the whole clutch system uses hydraulic assistance,
make sure to air bleed it after the installation is completed.
Detailed steps as follows:
(a) Plug one end of the long transparent connection hose
(about 0.5 m long) into the bottom of bleed screw, and
the other end into a fixed container.
(b) Loosen the bleed screw via the open end of the M8,
meanwhile ask the assistant to step on the clutch pedal
repeatedly until no air bubbles can be seen in the hose.
R e m a r k : R e s i d u a l a i r i n t h e c l u t c h s y s t e m h a s b e e n
completely exhausted.
(c) Lastly, lock the bleed screw.
Caution: Refilling the brake fluid reservoir should be
performed while air bleeding the clutch.
Clutch Pedal Removal
1. Remove the battery's negative cable.
2. Remove the glove box at the left of the dashboard.
3. Remove the cotter pin at the U-joint of the clutch
master cylinder, and separate the center pin and the
pedal lever.
4. Remove the clutch pedal bracket from the cowl.
5. Remove the clutch pedal.
(a) Move the clutch pedal to the maximum stroke position.
(b) Take down the return spring.
(c) Remove the bolts and nuts.
(d) Take the pedal lever down from the pedal bracket.
Clutch Pedal Installation
1. Install the clutch pedal.
(a) Install the return spring.
(b) Install the clutch pedal lever.
(c) Install the bolts and nuts.
Tightening torque: 30 N·m
(d) Put the pedal lever at the maximum stroke position and
connect it with the spring, in order to set the pedal to its
initial position.
2. Install the clutch pedal onto the 2 studs of the clutch
master cylinder.
Use a M13 wrench to tighten the clutch pedal brackets with
two M8 nuts.
Tightening torque: 23±3 N·m
3. Install the clutch master cylinder push rod with the U-
joint.
(a) Coat the contact areas between the center pin and the
U-joint pedal connector with multi-functional grease.
(b) In succession, join the U-joint (pedal connector) and
the clutch pedal lever with a cotter pin.
Caution: Insert the center pin into the pedal lever from
the left side of vehicle.
(c) Install the cotter pin onto the center pin.
4. Check and adjust the clutch pedal.
5. Connect the negative cable of the battery.
Bleed screw

Downloaded from www.Manualslib.com manuals search engine 41Clutch Operational System
Clutch Pedal Examination and Adjustment
1. Check if the pedal height is correct.
Height from the carpet: 100-110 mm
2. Adjust the pedal height.
Loosen the lock nut and adjust the clutch pedal limit adjust-
ing bolt until its height is correct, and then tighten the lock
nut.
Tightening torque: 20 N·m
3. Check if the pedal free play is correct.
Step on the pedal until one can feel the resistance.
Pedal free play: 13.7 mm
4. Adjust the free play.
(a) Loosen the lock nuts of the clutch master cylinder and
rotate the push rod until the pedal reaches the correct
free play.
(b) Tighten the lock nuts.
Tightening torque: 20 N·m
(c) Recheck the clutch pedal height.
Pedal height
Lock nut
Limit adjusting bolt
Lock nut
Free play

Downloaded from www.Manualslib.com manuals search engine 43Transmission
Main Technical Parameters
Basic parameters of the 037A transmission
Max. input torque115 N·m/4400-5200 rpm
Speed ratio for each gear3.5451.9131.3100.9730.8043.214
Main deceleration ratio3.944
Odometer speed ratio31/35 (currently no driven gear)
Center distance (mm)65
Lubricant capacity (L)1.8
Control methodRemote cable control
Netweight (kg)28
Match engineGW413EF
037A Transmission’s Overall External Schematics
The 037A transmission is a step mechanical transmission with differential, two-shaft front wheel drive
application. The forward gear has adopted the inertia synchronizer gear-shifting mechanism, which offers
smooth and easy gear shifting, reduces noise dramatically, and improves the service life of the gear - important
in achieving the overall economical efficiency. Regarding its control mechanism, the set steel ball and spring
allow the shifting gear to be quick, accurate with solid handling. The 5th gear transmission is equipped with an
interlocking mechanism to prevent accidental switching to reverse, to im\
prove driving comfort and reliability.

Downloaded from www.Manualslib.com manuals search engine 45Transmission
Areas of Importance
Removal
During removal, all components should be gently handled to avoid knocking, especially the joint surface.
All components should be placed in the proper order to avoid misplacing \
and mistaking.
Installation
1. Clean all parts before installation (except rubber pieces and gaskets)\
.
2. All oil seals, shaft retainers, and elastic pins should not be reused.
3. All rubbing surfaces should be coated with lubricant, and the lips of all oil seals should be coated with
grease.
4. During installation of the bearings, do not use any kind of rolling element to transmit pressure, and
make sure not to tilt it.
5. During the installation of synchronizer components, the two sides of the spring piston's openings
should alternate.
6. When the transmission is operating under normal working conditions, there should be no lubricant
leakage from any of the parts.
Transportation and storage
1. When transporting a transmission, make sure the conditions are dustproof and rainproof, as well as
take proper care not to damage it due to jolting, shaking, removal, or i\
nstallation.
2. Transmission assembly should be stored in a ventilated, dustproof, and dr\
y place.
3. Users with special transportation or storage requirements should have another discussion to reach an
agreement on this matter in the supply contract.
Use partsBolt codeSpecificationsQuantity
Tighten-
ing torque
(N·m)
Differential case × differential ring gear037-2303309M12 × 1.06123.6
C l u t c h h o u s i n g × r e v e r s e g e a r a r m
bracket subassembly037-1702073M8 × 1.25217.2
No. 1 gear shift fork shaft × No. 1 gear
shift fork037-1702056M6 × 0.75115.7
No. 2 gear shift fork shaft × No. 2 gear
shift fork037-1702056M6 × 0.75115.7
Transmission case × clutch housing037-1701012M8 × 1.251329.4
Transmission case × manipulation lid
subassembly037-1702051M8 × 1.25412.0
Transmission case × position mechanism
component037-1702042M18 × 1.5136.8
Transmission case × reverse gear idler
shaft × sealing ring037-1701404M8 × 1.25129.4
Transmission case × hexagon head plug037-1701016M18 × 1.5239.2
Transmission case × reverse gear switch
subassembly037-1701022M18 × 1.5140.2
Transmission case × cable bracket037-1701019M8 × 1.25411.3
Clutch housing × clutch slave cylinder
subassembly037-1601019M8 × 1.25211.3
Select lever assembly × gear shifting
block037-1702027M8 × 1.25138.0
Clutch housing × release fork support
nail037-1601011M10 × 1.25136.8
Counterweight component × shift lever
component037-1702030M8 × 1.25220.0
Release fork support nail129.4
Thread fastening piece tightening torque table

Downloaded from www.Manualslib.com manuals search engine 49Transmission
Gear Shift Fork and Fork Shaft
Components
Clutch housing
No. 1 gear shift fork shaft
Shaft retainers
Set bolt
Elastic cylindrical pin
No. 1 gear shift fork
Elastic cylindrical pin
No. 1 guide block
Lock pin
Pressure spring
Shaft retainers
Lock pin
No. 3 gear shift fork shaft
No. 2 gear shift fork shaft
No. 3 guide block
No. 3 gear shift fork
Set bolt
Output shaft assembly
Input shaft assembly
Gasket
Reverse gear idler shaft
Reverse gear idler assembly
No. 2 gear shift fork
Bracket bolt
Reverse gear arm bracket assembly
Reverse gear gear shift fork
Shaft retainers
Shaft retainers
15.7
15.7
Bolt for flange face
29.4
17.2
: Specified torqueN·m