engine coolant GREAT WALL FLORID 2008 Service Manual

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual12
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 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 155Vehicle Body Electronic System
Condenser fan motor
Connected compressor
Oil pressure switch
Front oxygen sensor
Connected reverse switch
Connected engine speed sensor Connected
ignition coil
Connected speed sensor Connected coolant temp. sensor
Canister control valve
Connected combination meter A
Connected antenna
Diagnostic port
Connected AC switch Connected air conditioner temperature sensor
Front passenger side airbag
Connected speed adjustive resistance, blower
Front window regulator RH
Front window regulator switch RH
Front medium woofer RH
Front tweeter LH Right outer electric mirror
Front passenger side central door lock switch
Front door lamp switch RH
Front passenger seat belt pretensioner Front door lock motor RH
Ground
plate 3
Connected cigarette lighter (lighting)
Connected cigarette lighter
Front passenger seat belt switch
Connected parking brake switch Connected air conditioner governor & front
passenger seat belt unfastened indicator lamp
Connected CD player
Connected engine ECUConnected ground P1#
Connected ground P2#
Connected starter
Connected knock sensor
Connected starter field coil
Connected inlet
temperature pressure
sensor
connected
electronic throttle
Rear oxygen sensor
Connected 4th
cylinder injection
nozzle
Connected 3rd
cylinder injection
nozzle
Connected 2nd
cylinder injection
nozzle
Connected 1st
cylinder
injection nozzle
Connected generator
Connected engine armature Connected front combination lamp RH
Connected front fog lamp RH
Connected rear washer motor
Connected front washer motor
Connected front wheel speed sensor RH
Right ground
Connected A/C pressure switch
Connected phase sensor
Connected low
pitched horn
Connected front
combination lamp LH
Rediator fan motor
Connected front
fog lamp LH
Connected high pitched horn
Battery
negative
Body
ground
Battery
Left ground Connected
brake lamp
switch Connected brake fluid warning switch
Connected theft deterrent indicator Theft deterrent ECU 1Connected lock
cylinder lightConnected ignition
switch (white)
The key is inserted into the switch
Right combination switch (wiper) Connected airbag ECU (yellow)Ground
plate 2
Ground
plate 4
Connected accelerator pedal
Ground plate 1
Left outer electric mirror
Front medium woofer LH Front door lock motor LH
Rear medium woofer LH
Rear window regulator switch LH
Rear door lock motor LH Rear door lamp switch LH
Ground point ACapacitor
Vehicle power supply
Rear fog lamp LH Left license plate lamp
High mounted brake lamp
Ground point Trunk opener switch
Trunk motorRear wiper motor
Rear windshield defroster “-”
Trunk lamp switch Right license plate lamp
Rear fog lamp RH
Rear combination lamp RHRear wheel speed sensor RH
Rear window
regulator RH
Rear window
regulator switch RH
Rear door lock motor RH
Rear door lamp switch RH Rear medium woofer RH
Ground point B
Rear combination lamp LH
Rear windshield defroster “+”
Rear wheel speed
sensor LH
Rear window regulator LH
Fuel pump, fuel sensor
Rear interior dome lamp
Front door lamp
switch LH
Driver seat belt pretensioner Driver seat belt switch
Front tweeter LH
Connected light brightness regulator switch
Connected rearview mirror switch (white)
Connected glove box lamp
Front window regulator LH Left combination switch (light)
Connected main airbag, horn switch
Window regulator mainly
control switch, central door
lock mainly control switch Connected central door lock controller (white)
Connected front wiper motor
Connected clutch
switch
Connected ABS ECUBattery
positive
Connected front wheel
speed sensor LH Engine groud
Starter connect to
battery positive
Generator connect to
battery positive
Wire Harness Relationship and Plug-in Connections Numbered Diagram

Downloaded from www.Manualslib.com manuals search engine 169Vehicle Body Electronic System
Combination meter system
Connected engine ECU #8
Connected engine ECU #59
To light brightness
regulator switch
Parking brake lamp
Parking brake switch
Brake fluid level switch
Oil pressure switch
Driver seat belt switch
Fuel sensor
Speed sensor
Connected combination meter A
Driver seat belt switch Connected parking brake switch Fuel pump, fuel sensor Coolant temperature sensor Engine speed sensor
Speed sensor Connected combination meter B
Brake fluid level warning switch
Brake warning lamp
Low oil pressure indicator
Seat belt unfastened indicator
Low fuel alarm Fuel gauge
High water temperature alarm
Low water temperature alarm
Connected coolant
temperature sensor Connected central
control ECU #18
IC module
LCD display
Odometer
Tachometer

Downloaded from www.Manualslib.com manuals search engine 173Vehicle Body Electronic System
Engine
Connected generator
Canister control valve
Rear oxygen sensor
1st cylinder injection nozzle
Phase sensor Electronic throttle AC pressure switchConnected clutch switch
Air conditioner
temperature sensor
Connected accelerator pedal Front oxygen sensorRear oxygen sensorKnock sensorCondenser fan motor
Connected brake lamp switch
Engine ECU
2nd cylinder injection
nozzle 3rd cylinder injection
nozzle 4th cylinder injection
nozzle Connected oil
pressure switch Canister control
valve
Front oxygen sensor
Inlet pressure & tem. sensor
Coolant temperature sensor Accelerator pedal module Electronic throttle AC temperature
sensor Knock sensor
Engine speed sensor
Phase sensor
Fuel pump relay
Connected combination meter Connected speed sensor
Engine malfunction indicator lamp Engine service indicator lamp
Compressor relay
Compressor clutch
Central pressure switch Starter relay 86
Connected AC switch AC pressure switch
Connected brake lamp switch
Connected brake lamp switch Condenser fan
Rediator fan Fan relay lowScanner
Fan relay high
Connected airbag
Connected theft deterrent controller A8
Connected
combination meter
Ignition coil
Coolant temperature sensor
Rediator fan motor
Engine speed sensor Wheel speed sensor
Fuel pump, fuel sensor Inlet temperature
pressure sensor
Connected ABS
Spark plug
Fuel pump
Electric control module
Ignition coil
Main relay
Injection nozzle
IG1 relay

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual204
FailureSymptoms Cause analysis
Air con-
ditioning
system fails
to produce
cold air
Compressor
does not work
Blown fuse, compressor relay damaged
Pressure switch contact broken, short circuited, or open circuit
Compressor electromagnetic clutch open circuit
Switch burnt out
Main relay burnt out
Clutch slips
Compressor belt broken or loose
Compressor failure
Insufficient coolant, system pressure below 0.196 MPa
System pressure exceeds 3.14 MPa
Engine water temperature is too high
Clutch voltage is below 7 V
Compressor
pulling in
Compressor relay often open contact bond, system coolant leaks severely,
system has no coolant
Blower does not work
Blower has no windBlown fuse
Blower motor brush damaged
Blower switch damaged
Wiring connector detached or open circuit
Speed regulation module damaged
Blower has no wind at high speeds, high speed relay damaged
Note: Blower's non operational process has a resistance value of 0, with a
open circuit resistance value of
The cool-
ing system
sometimes
works, some-
times not
Compressor operates
normally
Cooling system has ice blockage
Thermistor or thermometer bulb malfunction
Abnormal A/C switch contact
Condenser blower damaged
Compressor operates
abnormally
Clutch slides, clutch coil loose, clutch coil bad connection
Insufficient
cooling




Low wind volume

Blower fan normal: air pipe damaged
Cooling fan operates abnormally:
(1) Blower switch abnormal
(2) Supply voltage low
(3) Speed regulation module damaged
Wind vol-
ume normal

Compressor operates normally
(1) High and low pressure side's pressure is low
(a) Expansion valve is blocked
(b) Expansion valve opening is too small
(2) High and low pressure pipe's pressure is high
(a) High pressure pipeline malfunction, uneven flow
(b) Thermistor failure
(c) Expansion valve opening is too big
(d) Too much refrigerant oil
(e) Too much refrigerant
(f) Poor condenser heat dissipation
Note: When the speed is at 2000 r/min, cooling fan at max gear, and air tem-
perature at 30-35oC, the system's low pressure side pressure should be 147-
192 KPa, and high pressure side pressure 1373-1668 KPa

Troubleshooting

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual206
FailureSymptoms Cause analysis
Heating sys-
tem
No or insuffi-
cient heating
Air conditioner blower malfunction
Blower relay damaged
Hot air duct blockage
Cooling water pipe blockage
Temperature change throttle actuator damaged
Coolant insufficient
Blower does
not work
Fuse blown or ill switch contact
Blower motor burnt out
Blower's high speed relay broken
Speed adjustive resistance damaged
Open circuit
Water leakageHeater water pipe degradation, poor connection
Over heatedFan's speed adjustive resistance damaged
Temperature change throttle actuator damaged
Defroster’s hot
air insufficient
Mode cable damaged
Vent is not in place
Air outlet blockage
Insufficient heating
Air duct mounting
Open circuit
Troubleshooting (Continued)

Downloaded from www.Manualslib.com manuals search engine 247Vehicle Body
8. Remove the radiator and electronic fan with overflow
tank assembly.
Use a No. 10 wrench to remove the three mounting bolts of
the electronic fan with overflow tank assembly.
Radiator examination
1. Check for impurities between the radiator pipes.
2. Check whether the radiator is broken, and repair it if
necessary.
3. Check whether the radiator core is corroded, broken,
or corroded, and change it if necessary.
4. Check whether the pipe is cracked or broken.
5. According to the device circuit, check the operation
conditions of the electronic fan and change it if neces-
sary.
Electronic fan operation conditions:
Direction of rotation
(looking from the radiator)
Low rotational speed
(r/min)
High rotational speed
(r/min)
Counterclockwise1850±250 2250±250
6. Check the sealing conditions of the radiator filler cap:
Connect the diagnostic scanner of the radiator filler
cap, and pressurize until the scanner indicator stops. If
the indicator does not stop at the specified point within
10 s, replace the filler cap.
C a u t i o n : O p e n i n g p r e s s u r e o f p r e s s u r e v a l v e i s
108±14.7 KPa.
Radiator installation
1. Install the electronic fan onto the radiator assembly
with three mounting bolts.
2. Install four radiator mounts onto the four radiator instal-
lation points.
3. Install the radiator and electronic fan assembly be-
tween the upper and lower radiator cross member.
4. Install the inlet and outlet pipes connecting the radiator
and engine.
5. Fill up the radiator with coolant.
6. Check whether leakage exists in the radiator assembly,
the hose, and the connection.
Mounting bolt
Mounting bolt
Mounting bolt