oil change GREAT WALL FLORID 2008 Service Manual

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Troubleshooting
Common problemsPossible causesSolving methods
Difficult gear
engagement
Not applying clutchUse correct driving methods
Insufficient clutch separation Inspection & adjustment
Serious abrasion of the synchronizer ringReplace component
Positioning spring is too hardReplace component
Noise is too loud or
abnormal
Oil level is too lowFill oil to the specified level
Lubricant is of poor qualityReplace the specified oil
Untimely oil changesReplace oil and damaged part
Improper gear axial position and clearanceInspect and adjust
Damaged bearingReplace component
Gear has a burr or has been knockedRepair or replace gear
Oil leakageToo much oil is added, oil level too high.Fill the oil level to the specified position.
Bolt loose or missingReassemble and screw in according to regu-
lations.
Breather plug failsReplace
Damaged sealReplace
Synchronizer is damagedExcessive gear shifting force Replace synchronizer
Not applying clutchUse correct driving methods
Synchronizer's spring expan-
sion ring is damagedReplace
Gear disengagementControl mechanism malfunctionInspect and adjust
Retaining spring or steel ball missingAdditional assembly
Retaining spring malfunctionReplace
Fork groove of the gear sleeve is worn outReplace
Shifting fork is worn out.Replace
Bearing and gear are burntOil level is too lowReplace part and fill oil
Lubricant is of poor quality.Replace part and lubricant
Untimely oil replacement causes
the oil to be too dirtyReplace part and lubricant
Mixed use of different oils
or use of additivesReplace part and lubricant
Difficulty shifting gearsSynchronizer spring malfunctionReplace
The internal groove of the syn-
chronizer ring is worn outReplace
The synchronizer ring is seized
into the conical surfaceReplace
Deformed shifting fork or
shifting fork shaftReplace
Shifting fork is worn outReplace

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Front shock absorber with coil spring assem-
bly disassembly and installation
1. Compression spring
Use SST to grasp the spring, separated by adhesive tape
at the contact area. Alternately rotate the bolts on the SST
until there is no tension on the spring seat from the spring.
The front coil spring rotating means that the spring has been
compressed (shown on the left).
2. Disassemble the front shock absorber with coil spring
assembly
Remove the dust cover of the front shock absorber. Remove
the nuts on top using a ratchet wrench and M21 sleeve. Re-
move the erection support on the front shock absorber col-
umn, support bearing, the front coil spring's erection support,
front coil spring, dust cover, and the bumper in turn.
Tightening torque: 40-60 N·m
3. Retracting spring
Alternately reversing, rotate the bolts on the SST until all the
spring tension is released, then remove the tool.
4. Change any component that needs to be replaced
5. Installation of the front shock absorber with coil spring
assembly
Installation is in the reverse order of disassembly,
please pay attention to items below:
(a) Use SST to compact the spring.
(b) Steps for the installation of each component of the
front shock absorber with coil spring assembly is the
opposite of the steps for its disassembly.
(c) Pull up the strut piston rod as hard as possible and
make sure not to let it draw back into the strut.
(b) All of the fastening pieces must be tightened to the
required torque, and comply to the standard gluing re-
quirements in this chapter.

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Brake System Maintenance
Brake fluid inspection and replacement
Brake fluid directly influences the brake performance and the operating conditions and use life of the brake
system components. Brake fluid has very strong hygroscopic properties, and thus absorbs water easily,
which will then deteriorate the metal and rubber pieces. Polluted and deteriorated brake fluid or its mixture
would cause the brake fluid to boil and gasify, hence reduces braking efficiency. Therefore, pay attention to
the items below when filling or changing the brake fluid:
1. Containers used to hold brake fluid must be tightly closed and sealed
2. Brake fluid is poisonous and damaging to the paint. Hence if it gets on the vehicle surface, rub it
off at once
3. If water or other contaminates found in the brake fluid, and the brake master cylinder's piston seal
has been broken, then the brake fluid and all the rubber pieces inside the brake system including
the brake hose must be replaced
4. The correct brake fluid level in the reservoir must be between MAX and MIN. After the vehicle has
been driven for over 1000 km, check the brake fluid level in the reservoir. If the brake fluid level is
not up to regulation, more brake fluid should be added to the reservoir \
until it reaches MAX.
Hydraulic component inspection and system flushing
1. If the oil-based solvent gets into the hydraulic system, flush the whole system and change all of
the rubber pieces
2. Clean your hands before installing new rubber pieces or other components
3. Do not use regular solvents (kerosene, gas, etc.) when inspecting or cleaning hydraulic
components, instead use absorbing alcohol or brake fluid
4. After inspecting the components, drain the brake fluid from the system. Use new brake fluid to
flush the system. Afterwards, add new brake fluid to perform hydraulic system exhaust
5. Flushing completion sign: When the brake fluid flowing out of the dump valve is clear from any
contaminate.
Hydraulic pressure system drainage
If the brake fluid inside the whole hydraulic pressure system needs to be emptied, open all the bleed screws
with each connected to a hose, as to allow the brake fluid to flow into a container. Step on the pedal slowly
until only air flows out. During the whole procedure, make sure all the \
valves are open.
Hydraulic pressure system air bleeding
The hydraulic brake system must work under a vacuum environment. The air will cause spongy brake or
overall brake failure when it flows into the hydraulic system. It is extremely necessary to bleed system air
when performing any operation on the brake system or if any air inside t\
he brake system is suspected.
1. Air bleeding sequence
If air inside the brake master cylinder is suspected, first perform air bleeding.
(a) If numerous valves are equipped, air bleed each valve
(b) Another sequence principle is: Air bleed from the wheel brake furthest away from the master cylinder.
The air bleeding sequence for the LHD modules is: rear right wheel - left rear wheel - front right wheel
- front left wheel, Right rudder vehicles: rear right wheel - left rear wheel - front left wheel - front right
wheel.
2. Air bleeding method
(1) Manual air bleeding
Use the brake pedal or pump as the air bleeding power source. When the air bleed screws are open, vent the
brake fluid containing the bubbles from the system. Usually this is simultaneously done by two people. One
steps on the brake pedal and the other operates the air bleed screws. Important points to take note of when
performing the operation:
(a) Place the ignition switch to the off position and step on the pedal repeatedly to remove the
vacuum pressure or hydraulic pressure.
(b) Before and after air bleeding, add clean brake fluid into the master cylinder until it reaches
the correct (stated) level.
(c) Check the fluid level frequently to make sure that more than half of the reservoir's capacity is
available.
(d) Bleed screws should only be opened when the pedal is pressed down, and closed before the
pedal is loosened. Meanwhile, check if the vented brake fluid has bubble\
s inside.

Downloaded from www.Manualslib.com manuals search engine 103Brake System
Vacuum Booster with Brake Cylinder Assembly
Components
Areas of Importance
1. The vacuum booster with brake cylinder assembly is tightly connected with the brake pedal assembly on
the cowl panel using four nuts. It is also connected with the brake pedal push rod via an center pin and
lock pin. Thus before removal of the assembly, first loosen the rigid pipe fitting with an open-end wrench,
disconnect the lock pin and center pin using pliers, loosen the four nuts, and then proceed with the booster.
2. Tighten the lock nuts on brake master cylinder and vacuum booster according to the specified torque,
and coat with signal paint.
3. Dimensions between the rear housing head face and the adjusting fork hole center is adjusted to
standard before it leaves factory. Please do not adjust it again.
4. The vacuum booster valve rod on the vehicle must be in a free state.
5. The brake master cylinder's working agent is DOT4 brake fluid. It must not be mixed with any other
brake fluid.
Problems and symptomsCausesEliminating methods
M a s t e r c y l i n d e r ' s o i l r e s e r v o i r i s severely leakingThe master cylinder, slave cylinder, or hydraulic line is leaking.Eliminate the areas with leaks (in general, it may be that the pipe fitting's tightening torque is not enough, check one by one and tighten as necessary)
1. Vacuum booster not sufficient2. No boost when the engine is off3. May lead to unsteady engine idling when severe
1. Under non-operating conditions, the vacuum booster leaks air.2. Front and rear housing connection are not sealed.3. Booster's front and rear gas seal sealing failure.4. Vacuum check valve leaks.
1. Replace the front and back gas seal and control valve assembly.2. Replace the vacuum booster.3. Replace the vacuum check valve assembly.
Brake pedal is heavy with no boost effect1. Under non-operating conditions, the vacuum booster leaks air.2. Booster diaphragm worn and damaged.3. Control valve ring cup worn and damaged.
1. Replace the front, back gas seal and booster diaphragm.2. Replace the vacuum booster.3. Replace the control valve assembly.
Spongy pedal when braking1. There is air in the brake fluid.2. Cylinder or slave cylinder leaks oil.3. There is brake line seepage.
1. Eliminate the air in the system.2. Inspect the cylinder and sub-pump cup and replace with new parts.3. Inspect the pipeline and eliminate the seepage.
When continuously step on the brake pedal, the pedal will gradually change and expand till the highest extend.
Pump valve opening blockage.Brake fluid cleanliness is insufficient, please replace the brake fluid.
Troubleshooting
Oil cup cover
Oil cup body
Check valve
Check valve seat
Vacuum booster
Pad
Lock nut
Rod clevisCoupling nut
Rectangular sealing ringCylinder body
Fluid supply sealing ring

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not necessarily mean that engine start failure is due to a immobilizer system malfunction. The reasons for start-
ing engine failures are numerous, including factors like fuel, gas, fire, electricity, wires, etc. If the engine cannot
start, first check if the immobilizer system is working normally. This can be judged by looking at the flashing
theft deterrent indicator lamp which is located on the dashboard in front of the driver seat: Insert the key into the
lock cylinder and turn it to the "ON" position. If a legal key is used to start the engine, once the warning lamp is
connected to the ON end and the transponder is confirmed, the LED will remain unlit. Then when the ON end is
disconnected and the key is pulled out, the LED will shine for 0.25 s and darken for 4 s, as to act as a warning.
If an illegal key is used to start up the engine or there is something wrong with the system, the alarm indicator
lamp will shine for 0.25 s and darken for 4 s. If all is normal, then check the other parts of the engine. If abnor-
mal, first perform immobilizer system troubleshooting. A scanner can be used to judge if the immobilizer system
is working normally, but the precondition is that the scanner must be able to establish communication with the
theft deterrent controller.
1. If communication cannot be established, consider the following:
(a) Check whether the battery voltage is higher than 9 V
(b) Check whether the scanner plug is well contacted to the vehicle socket
(c) Use a multimeter to check whether the 7 pin of the OBD-II plug (diagnostic plug) is connected to the theft
deterrent controller's A7 pin
(d) Check whether the power supply of the theft deterrent controller is normal. (Use a multimeter to measure
whether the voltage of the theft deterrent controller's socket A1 pin and A2 pin is higher than 9 V)
(e) Then adopt the substitution method, which is to replace the theft deterrent controller to check if there is
anything wrong with the theft deterrent controller.
• If the failure is related to the theft deterrent controller, change it and initiate re-matching.
• If the failure has nothing to do with the theft deterrent controller, remove the electronic controller which
is connected to the alarm's K wire, such as the ABS controller, engine electrojet controller, airbag ECU
assembly, etc., as to ascertain if the present fault is caused by the wire harness connected with the theft
deterrent controller's K wire.
2. If communication can be established
Connect the scanner to the vehicle diagnostic port. Insert the key into the steering lock, and turn it to the "ON"
position, then select the scanner to check the immobilizer system's trou\
ble code.
3. Security system troubleshooting
Investigate the problem and perform troubleshooting according to the tro\
uble code on the scanner:
Trouble
code
Code
significanceFailure causeTroubleshooting methods
B1000Theft deterrent
controller
internal
malfunction
Theft deterrent coil open
circuit or short circuit. Theft
deterrent controller internal
malfunction.
Check whether the theft deterrent coil's connecting plug and 1.
the theft deterrent controller is well connected.
Check whether the theft deterrent coil's wire harness plug is sliding 2.
or touching each other.
R e m o v e t h e t h e f t d e t e r r e n t c o i l p l u g , a n d t h e n u s e a 3.
multimeter to check the resistance between the B1 and B2
pins. The normal resistance is about 5-30 Ω. If the resistance
is close to zero, that means the coil has been short circuited.
If the resistance is infinite, then it means the coil's circuit is
open. Measure the resistance between pins B1 and B3, and
B2 and B3, normally they are infinite. If the resistance gains
a certain value, then it means the coil is short circuited or
leaking electricity.
If there is nothing wrong with the coil, the next step is to 4.
check the theft deterrent controller. Adopt the substitution
approach, replace it with a non-matched new theft deterrent
controller or an theft deterrent controller which has been
reset (please refer to the immobilizer system component
replacement). Insert the key into the ignition lock and turn it
to the "ON" position and read the trouble code. If there is no
9000 failure, it means the replaced controller has an internal
malfunction, and the new replaced controller must be re-
matched.

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Trouble
code
Code
significanceFailure causeTroubleshooting methods
B3048The LED has
a short circuit
or open circuit
to the power
supply
The wire harness (A3
pin) connecting to the
immobilizer indicator
(LED) has short circuited to
the battery positive.
Check whether the theft deterrent controller's 8-core plug 1.
wire harness is touching each other.
Check whether the wire harness which connects the 8-core 2.
plug's A3 pin and the immobilizer indicator has short
circuited to the battery positive.
B3055Transponder
cannot
modulate
or without
transponder
No transponder inside the
key, transponder damage,
and the theft deterrent coil
damage will lead to theft
deterrent controller receiver
failure of the response
signal from the transponder.
Check whether there is transponder in the key.1.
Check whether the theft deterrent coil is correct as specified 2.
in Article 1.
Replace the transponder (please refer to immobilizer system 3.
component replacement).
B3056No key
message is
stored in the
theft deterrent
controller
The theft deterrent controller
hasn't been matched or
has no key duplicate, thus
there is no transponder
identification code stored
inside the theft deterrent
controller
Re-learn the keys.
B3057PIN is not
recognized
by the theft
deterrent
controller
The theft deterrent controller
is new or has been reset.
Set up the safety code and match the theft deterrent controller
again.
B3059No request
signal from
the electrojet
controller is
received
The theft deterrent
controller doesn't receive
the communication request
signal from the electrojet
controller.
Check whether the theft deterrent controller's 8-core plug is 1.
well connected.
Check whether the wire harness connecting the A5 pin (R 2.
wire) of the 8-core plug and electrojet is well connected, is
not short circuited, and is not poorly connected.
Replace the alarm (please refer to immobilizer system 3.
component replacement). Check whether the above failures
exists. If they do not, the fault most likely exists in the alarm.
Replace the electrojet (please refer to immobilizer system 4.
component replacement). Check whether the above failures
exists. If not, the fault most likely exists in the electrojet.
B3060Illegal key
message is
received
No transponder
identification code stored in
the theft deterrent controller.
Use the scanner to carry out the "learning keys" function.
B3061The
communication
with the key is
interrupted
The transponder
can not establish
communication with the
theft deterrent controller,
the communication
is interrupted, or the
communicating data is
incorrect. The electrojet
key is not identical to the
transponder's.
Check whether the theft deterrent coil is correct as specified 1.
in Article 1.
Check whether the transponder is new or not matching. 2.
Rematch it if it is not matched;
If the transponder has been matched, make sure to check 3.
whether the transponder has been changed, or the electrojet
changed or reset
• If the transponder has been changed, then it cannot be used
again, and must be replaced with a new one and then re-
matched
• If the transponder hasn't been changed and only the
electrojet has been reset, then it only needs to matched again.
• If the transponder has not been changed but the electrojet
has been changed, make sure the replacing electrojet
is new or has been reset. If the substituted electrojet is
matched but not yet reset, then it must be replaced with a
new or reset one and then re-matched.

Downloaded from www.Manualslib.com manuals search engine 191Electrical Accessories
4. Security system component replacement
When a failure appears in one of the immobilizer system components, this component must be replaced. After
the replacement, perform matching on the immobilizer system again.
Only changing the coil
There is no need to match the immobilizer system again.
Only changing the key (theft deterrent transponder assembly)
(a) Get the vehicle's PIN code from the code located inside the burglar-proof classified envelope
(b) Connect the scanner with the vehicle's diagnostic connection
(c) Insert the key into the ignition lock and turn it to the "ON" position
(d) Check whether the key is legal and matched. If it is illegal or already been matched, then it cannot be
matched again, but will have to be replaced
(e) Input the PIN code with the scanner
(f) Erase the damaged lost key's information
(g) Match the new key according to the scanner's prompt
(h) If it is necessary to match another key, insert the key, and after resetting the scanner, operate according to
steps c, d, e, and g.
Caution: Make sure the key is legal and hasn't been matched before learning the key. Otherwise, the
immobilizer system won’t successfully match or the scanner will display that it has been matched but
the electrojet's validation is not available.
Only replacing the theft deterrent controller assembly
(a) Get the vehicle's PIN code from the code inside the burglar-proof classified envelope
(b) Turn off the ignition switch, and replace with an unmatched new theft deterrent controller or reset the theft
deterrent controller
(c) Insert the key into the ignition lock and turn it to the ON position
(d) Input the PIN code with the scanner
(e) Match the theft deterrent controller assembly according to the scanner prompts
(f) Because the theft deterrent controller is new, there is no VIN and original key information stored in it. It
will need the VIN inputted and must be matched with the original key, otherwise the original key will not
work.
Caution:
(a) Replace the new alarm remote controller or reset the alarm remote controller, or the alarm re-
mote controller system matching can not be completed.
(b) Select "Read EMS to alarm remote controller", not "Read alarm remote controller to EMS", or it
will make the transponder inoperable.
Only replacing the engine ECU
(a) Get the vehicle's PIN code from the code inside the burglar-proof classified envelope
(b) Turn off the ignition switch, and replace with a new non-matched or reset ECU
(c) Insert the key into the ignition lock and turn it to the ON position
(d) Input the PIN code with the scanner
(e) Match the ECU according to the prompts on the scanner, and complete the ECU and theft deterrent
controller matching.
Caution:
(a) Make sure to replace it with a new or reset ECU, otherwise the immobilizer system matching can-
not be completed.
(b) Select the menu of "Read EMS to theft deterrent controller", but not "Read theft deterrent control-
ler to EMS", or it will make the transponder inoperable.
Replacing the theft deterrent controller and EMS controller at the same\
time
If both the theft deterrent controller and EMS controller need to be changed at the same time, then the transpon-
der that has been matched must also be replaced, otherwise the immobilizer system matching cannot be com-
pleted. The immobilizer system needs to be re-matched after being replace.
Matching after sales stage
Problems caused by lost keys or immobilizer system failures requires a duplicate key, replaced parts, etc. These
problems cannot be solved without re-matching the immobilizer system's parts. During the matching, input the
correct PIN code with scanner. Specific possible problems and matching methods the maintenance station may
encounter are as follows:
1. Match an empty key:
(a) Properly connect the engine ECU and the theft deterrent controller, and then insert the key to be matched,
and switch the ignition switch to the ON position

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Air Conditioning System Terminal Definition
PinInterface signalPinInterface signal
AEmergency lamp relay2Parking lamp drive +
BPower supply (+)3Safety indicator
lamp drive +
CGround4Blower LO gear drive +
DPower supply5Blower common
terminal GND
EAir conditioner
request signal6Blower HI gear drive +
FBlower relay9Blower M1 gear drive +
10Blower M2 gear drive +
Air conditioner switchHazard warning switch + rear defroster switchBlower + night lighting + safety instruction
Cylinder
Blade
Exhaust valve
Rotor
Exhaust valve
Compressor
Entire outline structure (shown on the left)
Rotary vane compressor’s operation
As the diagram shows, when the rotor is rotating under an
external force, due to the synergism of centrifugal force and the
oil pressure difference on the five vanes of the rotor, their edge
clings to the cylinder wall. Because the fixed cylinder is oval
shaped, while rotating on the rotor, the rotor vanes spread and
retract according to the cylinder's geometrical shape, which in
turn makes the crescent shape consisting of the cylinder, vanes,
etc. to change continuously, so as to achieve the functions of
suction, compression, and exhaustion.

Downloaded from www.Manualslib.com manuals search engine 211Air Conditioning System
Clutch Installation
1. Install the solenoid coil at the place pressing up against the head cover's end surface and pay atten-
tion to insert the dowel pin of the solenoid coil into the bottom hole of the head cover. Put the retaining
ring into the groove with circlip pliers, and press the solenoid coil's connecting wire onto the pressing
line plate on the head cover with a SST.
2. Put the compressor on a specially designed fixture or platform, with its head cover facing upwards.
Press the pulley into the head cover shaft, and put the pulley bearing's retaining ring into the groove
with circlip pliers.
3. Install the armature onto the main shaft's spline and seize the clutch's triangular piece with a clamp.
Then tighten the inner hexagon lock screws and washers with a torque wrench. Screw torque should
be between 150-180 N·m. After installation is done, make sure to check if the clutch's pulley and
armature are able to operate freely, and also check the clearance between the pulley and armature,
which should be 0.3-0.6 mm.
Vacuuming and Charging Refrigerant
Initiate vacuum pumping by using the manifold pressure
gauge connected to the air conditioner (compressor) pipeline
and vacuum pump. When the vacuum pumping starts, open
the manifold pressure gauge's high and low pressure valve,
and open the vacuum pump's end surface valve (if equipped),
then press the "ON" button to start the vacuum pump, and let it
run for at least 20 minutes. When the manifold pressure gauge
shows -760 mmHg or lower, close the high and low pressure
valve, and press the switch to turn off the vacuum pump.
Low pressure gaugeHigh pressure gauge
Manifold gauge
Yellow
BlueYellowRed
Air purge
Blue
Yellow
Red
Close
Refrigerant tank
Refrigerant tank
Blue
Red
Yellow
Low pressureHigh pressure
OpenOpen
Quick coupler
Red
Manifold gauge
Low pressure pipe
Quick couplerHigh pressure pipe
Vacuum pump
Low pressureHigh pressure
Blue
Inspect air tightness
After shutting off the vacuum pump, continue to inspect
the pressure reading of the manifold pressure gauge. If the
pressure reading remains unchanged for 20 minutes after
the vacuum pump stops operating, the refrigeration system
is proven to have no leak. One may continue to the next
step. If the reading changes, the system has a leak. Carry out
an inspection, and after repairing the leaking section, start
vacuum pumping once more.
Charge refrigerant
After verifying the system's air tightness, connect the
refrigerant tank (or gas cylinder) and yellow air supply hose
head. Connect the yellow air supply hose's other head with
the injection port in the middle of the manifold pressure
gauge. Ensure the refrigerant tank and air supply hose's nut
is tightly connected, then open the refrigerant tank's valve.
At this time, the high and low pressure valve is closed. Use
a tip shaped screwdriver or similar instrument and press
the valve core at the side port for 1-2 s, then expel the air
between the air supply hose and manifold gauge.
Perform switch operations according to the
following methods
1. Switch the front and rear blower speed control switch
to the highest settings, and rotate the temperature
control switch to the coldest position.
2. Press down the A/C switch, and set inner/outer circula-
tion to inner circulation mode. Open the doors and win-
dows during this procedure.
3. Adjust the engine's speed to the regulated idle speed.
4. Hold up the refrigerant tank or gas cylinder (emptying