technical specifications 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 Chapter Five: Transmission ........................................................................\
................................42
037A Transmission’s Overall External Schematics ....................................................43
Main Technical Parameters ..................................................................................\
....43
Transmission’s Proper Use and Care ........................................................................44
Technical Specifications for Transmission Installation and Adjustment .....................44
Areas of Importance ..................................................................................\
................45
Troubleshooting ..................................................................................\
.......................46
037A Transmission Structural Schematics ................................................................47
Clutch ...................................................................................\
......................................48
Gear Shift Fork and Fork Shaft ..................................................................................49
Transmission Case ..................................................................................\
..................50
Disassembling the Input Shaft Subassembly ............................................................56
Disassembling the Output Shaft Subassembly ..........................................................60
Disassembling the Shift Cover Subassembly ............................................................64
Disassembling the Differential Subassembly .............................................................68
Chapter Six: Suspension System ........................................................................\
.......................71
Suspension System Technical Parameters ...............................................................72
Front Suspension ...................................................................................\
....................73
Subframe and Front Stabilizer Bar ............................................................................77
Lower Swing Arm ...................................................................................\
....................80
Drive Shaft ..................................................................................\
...............................84
Rear Suspension ..................................................................................\
.....................86
Wheel and Tire ...................................................................................\
........................89
Chapter Seven: Brake System ........................................................................\
...........................94
Brake System Components Arrangement Schematics ..............................................95
Brake System Maintenance ...................................................................................\
....96
Brake Pedal ..................................................................................\
.............................98
Parking Brake Control Mechanism Assembly ..........................................................102
Vacuum Booster with Brake Cylinder Assembly ......................................................103
Anti-lock Brake System ...................................................................................\
.........107
ABS General Problem Maintenance and Areas of Importance ................................109
Steering Knuckle and Hub Brake Assembly ............................................................112
Front Brake Caliper ...................................................................................\
...............118
Rear Brake ...................................................................................\
............................124
Rear Support Axle ...................................................................................\
.................131
Chapter Eight: Steering System ........................................................................\
.......................134
Troubleshooting ..................................................................................\
.....................135
Steering System Maintenance .................................................................................137
Power Steering Fluid Instructions ............................................................................141

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 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 13Overall Parameters
Chassis' Main Assembly Technical Parameters
ItemSpecifications
Model numberGW413EFGW4G15YC4W75-31
ClutchClutch type
Single chip, dry type, diaphragm springSingle chip, dry type,
diaphragm spring
Driven disc diameter:
200 mm
Clutch disc diameter:
213 mm
Driven disc diameter:
212 mm
Maximum stroke: 9 mm, separating stroke: 7.5 mmSeparating stroke:
7.5 mm
Clutch hydraulic pressure
control systemClutch pedal total stroke: 116.5mm
Transmission
Transmission
model number037ACC0011AZM007QZM007W
Transmission typeMechanical 5-gear manual transmission
Main speed
reduction ratio3.9444.31254.2673.937
Gear
transmission
ratio
1st gear3.5453.5453.3643.182
2nd gear1.9131.9051.8951.895
3rd gear1.3101.3101.2861.25
4th gear0.9730.9700.9690.91
5th gear0.8040.8160.8000.703
Reverse
gear3.2143.2503.2143.08
Maximum bearing
torque (N·m)130160153153
Maximum input speed
(r/min)6000
Propeller shaft
The input end of the propeller shaft adopts a widely used, near constant
velocity, retractable spherical roller wheel joint. The output end adopts a
Rzeppa joint.
Air intake systemDry air filter, paper filtering element.
Exhaust system
Equipped with GW413EF engine, two grade muffler with two grade three-
way catalytic converter. Front/rear oxygen sensors.
Equipped with YC4W75-31 engine, two grade muffler with one grade three-
way catalytic converter and oxygen sensor.
Fuel supply system
Equipped with GW413EF engine. The 45L metal fuel tank includes an
electronic fuel pump and a charcoal canister. An electronic accelerator pedal
controls the fuel supply. The fuel evaporation control system controls the
charcoal canister through a solenoid valve
Equipped with the YC4W75-31 engine. High pressure electronic common-
rail fuel injection and dual fuel pipeline. The 45L metal fuel tank includes an
electronic fuel pump and a charcoal canister, electronic accelerator pedal, a
fuel line is connected with the fuel-water separator and diesel fuel filter.
Cooling system
The cooling system uses the enclosed forced water circulation cooling
system, the heat dissipating electronic fan uses a two level speed controller.
The electronic fan and overflow tank are combined in one. The radiator is
equipped with upper and lower water chamber aluminum pipe. The system
pressure is 90 kPa.

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual14
Chassis' Main Assembly Technical Parameters (Continued)
ItemSpecifications
Wheel and
tire
Wheel specificationsStandard 15 × 6J rim, offset distance: 40 mm
Tire specificationsStandard tire selection 185/65 R15 88H
Spare tire
specificationsSpare tire 185/65 R15 88H, T125/70R16 96M J16 × 4T
Steering
system
Steering gearRack and pinion hydraulic power steering gear, with drive ratio of 19.03,
power steering pump rate of flow is 6.7-8.9 L/min
Steering columnSafe, energy absorbing, angle-adjustable steering column, with an adjustable
range of 3.6°.
Steering wheelA three stage softening type with airbag, diameter of 370 mm, and maximum
steering circle number of 3.08.
Main technical
parameters
Front wheel camber/rear wheel camber-0° 43′ ± 30′ /-0° 43' ± 30'
Kingpin angle+10°21′ ± 30′
Kingpin caster+1°49′ ± 30′
Front wheel toe-in/rear wheel toe-in-0° 01′ ± 15′ /+0° 14' ± 15'
Inside wheel steering angle (°)32°-37°
Outer wheel steering angle (°)28°-30°
Steering wheel rotation number (n)3.08
Steering system angle ratio (i0ω)19.03
Brake
system
Service brake type
The service brake system adopts a hydraulic vacuum power-assisted type.
The front/rear brakes are disc and drum brakes respectively. The front brake
uses a ventilated disc, and the brake pedal is a suspended pedal with vacuum
booster. Brake line is in a dual-circuit diagonal (X type) arrangement,
adopting a ABS + EBD anti-lock and braking force distribution system.
Service brake booster
and master cylinder
Single stage Φ9inch vacuum booster, series dual-chamber brake master
cylinder, cylinder bore Φ22.22 mm, stroke 32 mm
Brake reservoirShares with the clutch master cylinder reservoir and installed with a brake
fluid level alarm.
Brake pedal strokeFree play: 6-9 mm, working stroke: 37-40 mm.
Brake pedal pressure<380 N (no load) <480 N (full load)
Parking brake
The parking brake system uses a mechanical remote ratchet cable control
mechanism to control the rear wheel drum brake. Brake lever's functional
stroke is 5-8 gearteeth.
Brake parameters
Front wheelFloating caliper disc brake
Wheel cylinder
diameterΦ54 mm
Brake disc
diameterΦ255 mm
Rear wheelLeading trailing shoe drum
brake
Wheel cylinder
diameterΦ19.05 mm
Drum brake
diameterΦ200 mm

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual42
Transmission
037A Transmission’s Overall External Schematics ............43
Main Technical Parameters ...............................................43
Transmission's Proper Use and Care .................................44
Technical Specifications for Transmission Installation
and Adjustment ...................................................................44
Areas of Importance ...........................................................45
Troubleshooting ..................................................................46
037A Transmission Structural Schematics .........................47
Clutch ........................................................................\
.........48
Gear Shift Fork and Fork Shaft...........................................49
Transmission Case .............................................................50
Disassembling the Input Shaft Subassembly .....................56
Disassembling the Output Shaft Subassembly ..................60
Disassembling the Shift Cover Subassembly .....................64
Disassembling the Differential Subassembly .....................68

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 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