air condition GREAT WALL FLORID 2008 Service Manual

Downloaded from www.Manualslib.com manuals search engine Chapter One: Overview ........................................................................\
........................................1
How to Use This Manual ...................................................................................\
...........2
Identifying Number Location ..................................................................................\
......3
Comprehensive Repair Instructions .............................................................................4
General Repair Methods and Operations ....................................................................9
Chapter Two: Overall Parameters ........................................................................\
......................10
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
Chapter Three: Fuel Supply and Exhaust System .....................................................................29
Fuel Supply System ...................................................................................\
................30
Components ..................................................................................\
..........................30
Fuel Tank Removal ..................................................................................\
................31
Fuel Pump and Charcoal Canister Removal ...........................................................31
Fuel Filter Removal ...................................................................................\
...............31
Fuel Filler Pipe Assembly Removal .........................................................................32
Exhaust System ...................................................................................\
......................33
Components ..................................................................................\
..........................33
Exhaust System Removal ...................................................................................\
.....34
Exhaust System Installation ...................................................................................\
..35
Chapter Four: Clutch Operational System........................................................................\
..........36
Areas of Importance ..................................................................................\
................37
Troubleshooting ..................................................................................\
.......................37
Clutch Operational System ..................................................................................\
......38
Components ..................................................................................\
..........................38
Clutch Master Cylinder Removal .............................................................................38
Clutch Master Cylinder Installation ..........................................................................40
Clutch Pedal Removal ..................................................................................\
...........40
Clutch Pedal Installation ..................................................................................\
........40
Clutch Pedal Examination and Adjustment ..............................................................41
CONTENTS

Downloaded from www.Manualslib.com manuals search engine Technical Requirements ..................................................................................\
........141
Chapter Nine: Vehicle Body Electrical System ........................................................................\
.142
Basic Information on the Electrical System .............................................................143
Fuse Box ...................................................................................\
...............................144
Overall Vehicle’s Grounding Point Schematics ........................................................150
Key Electrical Component’s Module Schematics for the Overall Vehicle ................151
Wire Harness Distribution Chart for the Overall Vehicle ..........................................152
Wire Harness Relationship and Plug-in Connections Numbered Diagram ..............155
Wire Harness Plug-in Connectors and Pin Function Diagram .................................156
Electrical Wiring Diagram for the Overall Vehicle ....................................................167
Chapter Ten: Electrical Accessories ........................................................................\
.................177
Reverse Sensor ..................................................................................\
.....................178
Combination Meter ..................................................................................\
................180
Central Door Lock ...................................................................................\
.................181
Power Windows ..................................................................................\
.....................184
Immobilizer System ..................................................................................\
...............186
CD Player ..................................................................................\
..............................193
DVD Player ..................................................................................\
............................195
Chapter Eleven: Air Conditioning System........................................................................\
........202
Areas of Importance ..................................................................................\
..............203
Technical Parameters ..................................................................................\
............203
Troubleshooting ..................................................................................\
.....................204
Air Conditioning System’s Structure Diagram and Fundamentals ...........................207
Air Conditioning System Overview ..........................................................................207
Air Conditioning System Terminal Definition ............................................................208
Compressor ..................................................................................\
...........................208
Electromagnetic Clutch ...................................................................................\
.........210
Vacuuming and Charging Refrigerant ......................................................................211
Filling Quantity and Method for Refrigerant Oil ........................................................212
Daily Maintenance of the Air Conditioning System .................................................212
Chapter Twelve: Airbags ........................................................................\
...................................213
Airbag Electronic Control Unit ..................................................................................214
Diagnostic Scanner ...................................................................................\
...............215
Troubleshooting ..................................................................................\
.....................216
Vehicle Collision Diagnostics ..................................................................................\
.226
Removal Method for Individual Components ...........................................................227
Driver Side Airbag Module (DAB), Front Passenger Side
Airbag Module (PAB), Clock Spring, and Steering Wheel .......................................228
Airbag Module Disposal ...................................................................................\
........230

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual10
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 15Overall Parameters
Vehicle Structure Type and Parameters
ItemStructural parameters & performance descriptions
Body
Body typeAll-metal closed hard surface bearing body.
Body in whitePressed and welded, all-metal enclosed structure.
Door assemblyFramed door with four-door impact beam, hinged sliding open door, trunk door
opens upwards, front/rear doors are installed with auto window regulator\
.
Engine hoodOpens up/downwards using a single arm hinge.
Closure part
parameters
Front door opening
angle35°/60°Engine hood
opening angle74.5°
Rear door opening
angle36°/64°Trunk door max.
opening angle96°
Vehicle
interior/
exterior and
accessories
Interior Satisfies ergonomic and comfort requirements. Fire resistance complies to regulatory
requirements.
Dashboard
Uses an injected molding structure with brace reinforcement, built in multifunctional
combination meter, knob plus button-press air conditioning controller, CD player
(DVD and GPS LCD are optional), and auxiliary facia console which adopts a gear
shift control mechanism.
A, B, C, and D
pillars and door's
inner decoration
board
Uses injected molding and front door guard plates equipped with package tray, four-
door guard plates are all installed with window regulator switches.
Automobile
glass
Windshield is laminated glass, front and rear door glass is tempered glass, trunk door
glass is heating & defrosting tempered glass with resistance wire.
Outer rearview
mirror
Elite type: electrically actuated convertible body and electronically controlled mirror
with defroster.
Luxury type: manually folded body and electronically controlled mirror without
defroster.
Comfort type: manually folded body and manually adjusted mirror without \
defroster.
Inner rearview
mirrorFlexible with anti-glare function
Seats
Driver & front passenger seats, independent seats. For front and rear seats, backrest
angle and seat headrest are both manually adjustable. Second row seats use a three-
seat arrangement. The seats' front and back positions and backrest angles are
nonadjustable. Seat headrests are both manually adjustable, back of the seat can be
folded forward, and the middle seat includes a child seat belt.
Seat belt
The front seat has two kinds of seat belts, complex equipment type being an
electronic preload three-point seat belt, and simple equipment type a non-preload
three-point seat belt. Advanced configuration uses the electronic preload three-point
seat belt, while simple configuration uses the non-preloaded three-point seat belt.
The rear seat belt uses a normal three-point seat belt.
Sun visor
Left and right sun visors both have cosmetic mirrors, and the sun visors can be
rotated up and down and from side to side, the up and down rotation can be held at
any position.
Front and rear
bumperBumper assembly can withstand collision speeds of 8 km/h.
Washer
Equipped with front and rear wiper, one 5th gear thrust washer reservoir, two motors,
two sets of pipelines in the front and rear, two washing nozzles with one in the front,
and the other in the back.

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual16
Air Conditioning System Structure and Parameters
ItemStructure and parameters
Structure typeVapor compression refrigeration, water warmer, and water heater
Performance parametersAir conditioner refrigerating capacity is 5 kW. Blower's air volume is 450 m3/h. Air
conditioner heating capacity is 4.5 kW.
Controls
Control panel knob, button, manual shift lever control, position gate and temperature
threshold cable drive, new damper micro-motor drive, able to select and adjust air
outlet position, heating/cooling mode, air inner/outer circulation mode and wind speed,
temperature, and more advanced selections and adjustables.
RefrigerantR134a, 510±10g
CompressorModel number: JSS-96TV4-4
CondenserAdvective and subcooling structure with flat tube thickness of 16 mm and dry reservoir
Φ34 mm × L280 mm.
Heating, Ventilating
and Air Conditioning
(HVAC)
Heating, Ventilating and Air Conditioning (HVAC): Of a three-box type consisting of
a layered evaporator, advective heater, H-shaped expansion valve, centrifugal blower,
and air outlet distributing box. Contains cooling, heating, defrosting and air freshening
functions, and operated by a link mechanism driving air valve.
Refrigeration line &
water heating tube
Refrigeration line: a compound structure using a rubber cooling pipe and an aluminum
pipe. Water heating pipe: molded rubber pipe.
SensorsEvaporator temperature sensor
Pressure switchHigh/Mid/Low three position pressure switch
Electrical System Structure and Parameters
ItemStructure and parameters
Power, start
up, and
electronic
charging
system
CircuitSingle wire system, voltage of DC12 V, negative ground
Battery12 V/60 Ah, maintenance-free battery
Starter1.2 kW
Alternator14 V/90 A
Lighting and
signaling
system
Headlight2 white (high beam 55 W, low beam 60 W) H4, height is electrically
adjustable.
Parking lamp2 front parking lamp: white, 5 W. 2 rear parking lamp: red, 5W
Turn signal lampAmber colored. 21W, 2 in the front and 21W, 2 in the back. Turn signal
lamps: 0.3W, 4 LED.
Fog lamp2 front fog lamps: 55W. 2 rear fog lamps: 7.5 W
Brake lamp2 red 21 W. high mounted brake lamps 3 W
License plate lamp2 white 5 W
Reverse lamp2 white 21 W
Hazard warning signal
lampAll turn signal lamps and switch controls
Rear reflectorsRed and non-triangular, inside the rear combination lamps.
Front reading lamp &
interior dome lamp
Front reading lamp: one white 10 W or one white 10 W, two 5 W (with
sunroof).
Interior dome lamp: White, 10 W.
Cigarette lighter
lightingBlue, 3 W, one

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual18
Torque Specifications for Key Operational Bolts
Any part that has a tightening torque requirement for fastening piece connections should be fastened according
to specifications, the tightening torque of fastening pieces that have no tightening torque specification should
satisfy the QC/T 518—1999 regulations.
Tightening torque for key operational bolts are shown in the table below.
No.Important fastening piece locationsFastening piece name
and model numberQuantity
Tightening
torque
(N·m)
1Chassis
1.01Left mount & left side memberHexagon bolt for flange face1112±10
Left mount & left mounting bracketHexagon bolt for flange face264±5
1.02Left mounting bracket & transmissionHexagon bolt for flange face364±5
Right mount & engineHexagon nut for flange face141±4
1.03Right mount & engineHexagon bolt for flange face264±5
Right mount & vehicle bodyHexagon bolt for flange face 264±5
Grade Specification and Filled Quantity of Each Individual Functioning
Component's Working Agent
No.Functioning
component
QuantitySpecificationsGW413EFGW4G15
1Engine fuel45L
#93 and above high quality unleaded gasoline (GW413EF,
GW4G15 engine)
#-10 light diesel fuel (YC4W75-31 engine)
2Engine
lubricant3.25±0.25 L3.5L
GW413EF
SJ 15W-40/SJ 10W-30
(For China domestic model)
SL 5W-30 (For alpine region model)
GW4G15
SJ 20W-40/SJ 10W-30 (For domestic &
exported high-temperature region model)
SL 10W-30 (For alpine region model)
3Coolant5.5±0.5 L5.4±0.5 L
Ethylene-Glycol-35oC antifreeze fluid
(For China domestic model)
Ethylene-Glycol-45oC antifreeze fluid
(For alpine region model)
4Clutch fluid0.49±0.02 L0.72±0.02 LDOT4 synthetic brake fluid
5Transmission
lubricant1.9±0.1 L1.8L
GL-4 80W-90 (For China domestic model)
GL-4 75W-90 (For alpine region model)
GL-5 140 (For high-temperature region model)
6Power steering
fluid0.65±0.02 L0.75±0.02 LATF DEXRONⅢ Mobil fluid
7Brake fluid0.49±0.02 LDOT4 synthetic brake fluid
8Battery
terminal1.0 gIndustrial vaseline
9Windshield
washer fluid2.8±0.1 L
Room temperature: use clean water with a hardness less
than 205g/1000 kg.
Low temperature (-18oC±3oC): use methanol-water
solution concentration of 50%.
10Air conditioner
refrigerant510±10 gR134a

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 37Clutch Operational System
Areas of Importance
1. Clutch Rigid Pipe Installation
Before installing, check to make sure that the rigid pipe flare contact area is in good condition, the pipeline is
clean, and that there is no foreign materials.
2. Clutch Hose Installation
Check the surface of the clutch hose to make sure that there is no scuffing and that the pipeline is clean.
3. Coat grease on the U-joint of the pedal and the master cylinder.
4. Strictly adhere to the set torque guidelines when tightening the pipe fittings.
Rigid pipe and the master cylinder: M10 16±2 N·m
Clutch rigid pipe and hose: M10 16±2 N·m
5. While the clutch system is undergoing the exhausting process, make sure that all the air bubbles in
the pipeline are cleared out. Then check the brake fluid level in the reservoir, it should be between
MIN and MAX.
Troubleshooting
The numbers in the table represent the order of the possible malfunction causes, so be sure to check each part in
turn. If necessary, replace the part.
SymptomsPossible Causes
Clutch vibration1. Engine mounting bracket (loose)
2. Clutch plate (axial runout is too much)
3. Clutch plate (oil build-up)
4. Clutch plate (polished)
5. Clutch plate (hardened)
6. Diaphragm spring (damaged)
Clutch pedal is spongy1. Clutch pipeline (air entering)
2. Clutch master cylinder cup (damaged)
3. Clutch slave cylinder cup (damaged)
Clutch makes abnormal noise1. Clutch release bearing (wear and tear, dirty or damaged)
2. Driven plate torsion damper (damaged)
Clutch slips1. Clutch pedal (free play is out of alignment)
2. Clutch plate (oil build-up)
3. Clutch plate (polished)
4. Diaphragm spring (damaged)
5. Pressure plate (deformed)
6. Flywheel (deformed)
Clutch cannot be disengaged1. Clutch pedal (free play out of alignment)
2. Clutch pipeline (air entering)
3. Clutch master cylinder cup (damaged)
4. Clutch slave cylinder cup (damaged)
5. Clutch plate (axial runout is too much)
6. Clutch plate (wear out from friction)
7. Clutch plate (dirty or burnt)
8. Clutch plate (oil build-up)
9. Clutch plate (lack of grease on the spline)

Downloaded from www.Manualslib.com manuals search engine 89Suspension System
Wheel and Tire
Tire
Remark
This vehicle's tire is of the tubeless type. The optimal design condition is met when the inflation pressure is at
the recommended value, and the tire is under full load. Maintaining suitable tire pressure and proper driving
habits greatly influence the tire's use life. For the vehicle, it improves riding comfort, stability, and handling. For
the tire, it reduces tread wear, damage to the tire and extends tire life. Overloading, speeding, and unnecessary
emergency braking will all add to the tire's wear and tear.
Tire pressure measurements should be taken under normal temperature. If the tire pressure rises due to motion
generated heat when driving, cooling it will return to the normal temperature. Therefore, do not deflate the tire
when the air pressure has risen to this point. The tire's air pressure will naturally and slowly decrease when used
under normal conditions. Hence please inspect the air pressure regularly (suggested once a month). The spare
tire should be kept in a useable condition at all times.
Inspect the tire pressure when it is cool monthly or before a long drive. Adjust the tire pressure to the recom-
mended level. The air pressure will normally rise because the tire warms up due to movement. Therefore, after
driving, you absolutely must not deflate or reduce the tire's air pressure, as deflating could reduce the cool tire's
air pressure.
Tire inflation
During a new tire's initial stage of use, warning due to bending motions will cause the tire to swell, and thus
reduce the corresponding air pressure. After 24 hours or 2000-3000 km worth of drive, charge the air pressure.
After inflating, check if the air nozzle core is leaking air with soapy \
water, then lock on the cap.
Possible problems caused by tire pressure
Exceeding the recommended air
pressure
Below the recommended air pressureSame vehicle axle, different
air pressure
Possible problems it
can create
1. Bumpy ride
2. The tear or rupturing of the tire
3. Rapid wear of the tire tread's center
1. Noisy turns
2. Uneasy turns
3. Tread edge wear is accelerated and uneven
4. The tire's rim is damaged or ruptured
5. The tire cord ruptures
6. High tire temperature
7. Steering failure
8. Large oil consumption
1. Uneven braking
2. Over steering
3. Steering failure
4. Deviation while accelerating
Tire and wheel (steel wheel) installation instructions
When installing the tire and wheel, the tire's radial hardware components, also called "high spot", should be at
the same level of the wheel's minimum radius or so called "low spot".
The "high spot" of the tire is initially marked by the paint spot on the side of the tire's surface. This paint will
eventually be washed away.
The "low spot" of the wheel is initially marked by a paint spot on the wheel flange. Whenever the tire is
removed from the wheel, the tire and wheel need re-balancing to make sure the vehicle runs smoothly. If no
paint spot is found on the tire, draw a line on the tire and the wheel before they are removed, in order to make
sure that the tire and the wheel will be re-assembled at the same place.\

Tire replacement
When a tire needs to be replaced, make sure to use a tire with the same specification as the original one. A new
tire used for replacement must be of the same dimension, load area, and structure as the original one. Using tires
that are different in dimension or type will influence the vehicle's riding comfort, handling, speedometer and
odometer calibration, vehicle ground clearance, and the clearance between the tire or the tire's snow chain and
the vehicle body or chassis.
It is suggested to use a new pair of tires on the same axle. If only one tire is needed to be replaced, make sure to
use a tire with a tread most similar to the original, so as to keep brak\
e power and traction balanced.
Warning: Do not mix radial tires, bias tires, bias belted tires, etc., which are of different structure on the
same vehicle unless it is an emergency. Mixing different tires would seriously influence the vehicle's
handling and stability, and even possibly lead to losing control of the vehicle.

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual90
Vehicle road test methods
1. Drive the vehicle and find out if the swaying is coming from the front tires or the back tires. Then replace the
identified problem tire with a good tire (one that has been tested on t\
he same model of vehicle).
2. If unable to determine the problem tire, replace the rear wheels. Continue with the road test. If the driving
condition obviously changes, replace the original tires, and only switch one at a time until the problem tire is
identified.
3. If no obvious improvement, replace all four tires with good tires, and then replace the original tires one by
one following the steps mentioned above.
Tire's abnormal wear and tear
Tire's abnormal wear and tear includes uneven and excessive
w e a r o f t h e t i r e . T h e r e a r e m a n y c a u s e s f o r t h i s . F o r
example, improper tire pressure, tire rotation has not been
timely maintained, bad driving habits, abnormal front wheel
location, etc.
Change the tires when the below situations happen:
1. When the extents of wear and tear of the front and rear
tires are different.
2. When any of the tire's tread has uneven wear and tear.
3. When the extents of the wear and tear of the left and right
front tires are different.
4. When the extents of wear and tear of the left and right rear
wheels are different.
5. When the groove of the tire tread wear appears abnormal
and the tire's contact area starts to flatten.
Inspect the front wheel alignment when the following
situations occur:
1. When the extents of the wear and tear of the left and right
front tires are different.
2. When any of the tire's tread has uneven wear and tear.
3. When the tread pattern strip or pattern block of a front
tire's single side is badly worn.
[A]
[B]
[A]: Steering problems, air pressure not sufficient, or tire rotation has not been timely maintained. [B]: Abnormal front wheel alignment, tire or wheel structure is not the same.
Radial tire sway
Here the sway means the vehicle's front or rear part shakes
from side to side, together or individually. Tire sway is
caused by the steel wire belt inside the tire not being straight.
The sway is the most obvious when the vehicle runs at the
speed of 8-48 km/h.
Road tests can help finding malfunctioning tires. If the
malfunction is with the rear tires, then left and right shaking
or "swaying" would take place at the back of the vehicle.
Here the driver of the vehicle would feel as if someone were
pushing from one side of the vehicle.
If the malfunction is with the front tires, swaying would be
even more obvious. The metal plate in the front may seem
moving back and forth, and the driver feels as if he/she were
at the vehicle's center of rotation.
Wear marks
There are several tread wear marks (refer to location A in the
diagram shown on the left) inside of the tire's pattern groove.
These marks indicate that the tire has been worn to the point
of replacing.
Before the tire's usage limit, indicated by the remaining
pattern's depth, reaches 1.6 mm (and its main pattern groove
bottom protrudes to the same level), for your safety, please
replace the tire.
When serious eccentric wear leads to the partial protrusion
of the cord fabric level, or outside objects damage the tire to
a depth that reaches the cord fabric level or steel band level,
stop using the tire.
A