oil pressure GREAT WALL FLORID 2008 Service Manual

Downloaded from www.Manualslib.com manuals search engine 17Overall Parameters
ItemStructure and parameters
Dashboard
system
Combination meter Speedometer, tachometer, odometer, fuel gauge, LCD (electronic clock &
reserved automatic gear indication).
Indicator lamp
Driver's seat belt unfastened warning lamp, charging indicator lamp, low
oil pressure warning lamp, service engine light, ABS malfunction indicator
lamp, EBD indicator lamp, EOBD indicator lamp, door unlock warning
lamp, SRS malfunction indicator lamp, high beam indicator lamp, left
turn signal lamp, right turn signal lamp, parking brake indicator lamp,
brake malfunction warning indicator lamp, front fog lamp indicator, back
fog lamp indicator, fuel warning lamp, engine cooling water high/low
temperature indicator lamp, engine preheating indicator lamp, oil/water
separator indicator lamp, O/D indicator lamp.
Auxiliary
electrical
system
Overhead antenna & interior lighting adjustment switch control.
Windshield system
Front wiper: inching, high speed, low speed, and clearance gear with time
slot adjustment, with reset.
Rear wiper: normal gear with reset.
Defog & defrost deviceRear wiper uses an electrical heated tempered glass with switch control.\
Power window
regulator
D r i v e r ' s s i d e h a s t h e m a s t e r c o n t r o l , o t h e r d o o r s a n d w i n d o w s a r e
independent (left and right front doors are both with door lock controlling
switches), with anti-pinch and automatic closing.
Central door lockRemote central door lock (controlled from the front left door), rear doors
containing children protector.
Backup power supply12 V, 120 W, one
Stereo equipment
Single CD, audio input interface
Multidisc DVD (optional)
There are 4 speakers in the standard configuration, 6 in the luxury and elite
configuration.
Cigarette lighter12 V, 120 W, with lighting, one
HornHigh/low disc type horn
Airbag
Comfort type uses a driver side electronic airbag
Luxury type and elite type uses driver and front passenger electronic
double airbags
EngineWith immobilizer system
Electrical System Structure and Parameters (Continued)

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 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 GWFLORID Maintenance Manual44
Transmission's Proper Use and Care
1. Transmission's proper operation
1.1 Shift the gear gently, not excessively.
1.2 Do not start with high speed.
1.3 To avoid premature abrasion of the gear shift fork, do not rest your hand on the \
gear lever while driving.
2. Model number of the lubricant to be used:
GL-4 80W-90 (For China domestic model)
GL-4 75W-90 (For alpine region model)
GL-5 140 (For high-temperature region model)
Caution: Please only use the lubricant with model numbers specified by t\
he Great Wall Motor Co., Ltd.
Do not mix lubricants with different model numbers. Only fill with clean lubricant.
3. Areas of importance for new vehicle usage:
3.1 Before using a new vehicle, be sure to check the transmission and all exposed connectors and fastening
pieces, so as to avoid failure due to faulty installation or loose conne\
ctions.
3.2 Since the new vehicle is still in the run-in period, the transmission's lubricant should be replaced after 5000 km
distance.
4. Transmission three-level maintenance:
4.1 Transmission level-one maintenance: During the first level of maintenance, the liquid level of the lubricant
should be checked to ensure that it is up to the oil-filling mouth. Add more if insufficient. Excessive low
oil level can lead to ineffective lubrication, as well as burning of the bearings and gears. Excessive high oil
level, however, can overheat the transmission or cause oil to leak. In addition, during the first level of main-
tenance, the breather plug should be checked and cleaned. If the breather plug is clogged, internal pressure
will build up and oil will leak from the transmission.
4.2 Transmission level-two maintenance: The transmission's lubricant should be replaced the first time that the
vehicle undergoes the second level of maintenance. Clean the transmission with kerosene. The quality of the
lubricant should be inspected during the future second level of maintenance practises. The lubricant should
be replaced if diluted, gummy, or dirty.
4.3 Transmission level-three maintenance: During the third level of maintenance, it should be removed for in-
spection, cleaning, and oil changing.
Technical Specifications for Transmission Installation and Adjustment
Inspect the axial play (δ) between the synchronizer ring and the gear shaft
Gear (δ1) (δ2) (δ3) (δ4) (δ5)
Standard axial play (mm)0.7-1.70.7-1.70.7-1.70.7-1.70.7-1.7
Gear (δ1) (δ2) (δ3) (δ4) (δ5)
Standard axial play (mm)0.1-0.40.1-0.60.1-0.40.1-0.60.1-0.55
Check the axial play (δ) between each gear

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 GWFLORID Maintenance Manual50
Transmission Case
Components
Clip
Shift lever assembly
Pressure torsion spring
Reverse gear switch subassembly
Washer
Bush
Oil drain slot
Tapered roller bearings
Adjusting shim
Transmission case
Clip
Clip
Adjusting shim
×8
WasherWasher
Hexagon head plug
39.2
Bolt for flange face12.0
: Specified torqueN·m
Hexagon head plug
39.2
Bolt for flange face
29.4
Position mechanism assembly
36.8

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual64
Disassembling the Shift Cover Subassembly
Components
Shift lever assembly
Dust cover
T oil seal
Gear shifting block
No. 2 spring seat
Pressure spring
Shaft retainer
Gasket
Lock plateShaft retainerElastic cylindrical pin
Shift guide block
Select lever subassembly
Manipulation lid
T oil seal
1. Remove the shift lever's elastic cylindrical pin.
Set bolt38.0
: Specified torqueN·m

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual72
Suspension System Technical Parameters
Main technical parameters
Suspension type and
composition
Front suspension typeMcPherson independent suspension
Front suspension componentsCoil spring, hydraulic telescopic shock absorber, stabilizer bar, lower swing
arm
Rear suspension typeCompound trailing arm semi-independent suspension
Rear suspension componentsCoil spring, hydraulic cylinder damper, & twist beam welded components
Wheel positional
parameters
(no load)
Front wheel camber-0° 43′ ±30′
Front wheel kingpin angle+10° 21′ ±30′
Front wheel kingpin caster+1° 49′ ±30′
Front wheel toe-in-0° 01′ ±15′
Rear wheel camber-0° 43′ ±30′
Rear wheel toe-in+0° 14′ ±15′
Wheel and tire parameters
Tire specifications: 15 × 6J (For 185/65R15 tires), 16 × 4T (For T125/70R16 tires)
Tire specification: 185/65 R15 88H
Spare tire specification: T125/70R16 96M
Tire pressure must be gauged when the tire is cool: Tire inflation pressure: 200±10 KPa
Spare tir e inflation pressure: 420±10 KPa
Tightening torque
PartCodeAssembly locations for
standard components
Tightening
torque
(N·m)
QuantityGlueGrade
Front
suspen-
sion
Q1861455TF2
(M14×1.5) + Q402
(d2=32 t=5) FD
Subframe & vehicle body (rear)145±15 2Red glue10.9
Q1861275TF2
(M12×1.25) + Q402
(d2=32) FD
Subframe & vehicle body (front)120±102Red glue10.9
Q1401020 (M10×1.25) FDSubframe strut bar mounting bolt49±54Red glue10.9
2904011-S08Swing arm & steering knuckle98±102Red glue
Q1401495 (t=4)
(M14×1.5) FDSwing arm & subframe (front)180±102Red glue10.9
Q1401280 (M12×1.25) FDSwing arm & subframe (rear)120±102Red glue10.9
2904013-S08Swing arm & subframe (rear)/2
2905011-S08Front shock upper assembly loca-
tion40±56
Q32014 (M14×1.5) FDFront shock lower assembly loca-
tion132±104Red glue10.9
Q1400830 (d2=13.5)F r o n t s t a b i l i z e r b a r m o u n t i n g
bracket37±44Red glue
Q32608Front stabilizer bar hanger rod16±24
Rear sus-
pension
Q151B12110TF2+Q402
(d2=35 t=5) FDTwist beam & vehicle body80±102Red glue10.9 grade
with guide
Q32012T13F2
(M12×1.25) FDRear shock absorber & twist beam120±102Red glue10 grade
Q341C10Rear shock absorber & vehicle
body64±54
Wheel3101014-K00Wheel nut (M12×1.25)110±1016
Q30612FD (M12×1.25)Wheel nut cone nut110±1016

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 Manual96
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.