warning GREAT WALL FLORID 2008 Service Manual

Downloaded from www.Manualslib.com manuals search engine PREFACE
GWFLORID will build 1.3L (GW413EF, GW4G13) or 1.5L (GW4G15) gasoline engines, in which the
GW4G13 and GW4G15 engines will both incorporate the newest VVT technology which meets the Euro IV
emission standards. GWFLORID features McPherson technology on its chassis system. With an ultra light
body made from structural steel and high-intensity front and rear fender impact beams as well as a collision
impact absorption system, it is able to maintain the cab's integrity and safety to greater extent. We wrote this
maintenance manual in order to meet the demand of Great Wall after-sales service technicians. This manual
mainly introduces the areas of importance in regard to maintenance and care, and removal and installation of
each system's assembly and maintenance technical parameters.
To reduce the possibility of injury or property damage, read and follow t\
he instructions carefully:
This manual is provided by the Great Wall Motor Co., Ltd, and is written for the technician use. Any
maintenance or repair without proper prior training and tools or devices may result in personal injury of the
person performing the maintenance or others in the vicinity. It is also possible that damage to the vehicle will
occur or will lead to mechanical failure during normal operation.
Correct vehicle maintenance and repair is essential for the safety of the person performing regular
maintenance as well as the vehicle itself. If there is any component that needs to be replaced, use a
component with the same serial number or a serial number specified by the Great Wall Motor Co., Ltd. Never
use any part that has not been authorized by the Great Wall Motor Co., Ltd.
Any maintenance procedure introduced in this manual is effective for maintenance and repair. Some of
these procedures need specially designed tools.
Therefore, before using any vehicle part following any maintenance procedure or working with a tool
that has not been authorized by the Great Wall Motor Co., Ltd, check to make sure that none of the above
will endanger the safety of the person performing the work or the correc\
t operation of the vehicle.
This manual includes multiple "Warnings" and "Cautions," which should be strictly followed, so as to
reduce the possibility of injury during maintenance or repair. Improper maintenance or repair of the vehicle
may cause potential safety hazards. These "Warnings" and "Cautions" are not exhaustive. It is impossible for
the Great Wall Motor Co., Ltd, to warn against all the potential dangers caused by not properly following the
instructions.
Please read carefully the "Areas of Importance" before carrying out any maintenance or repair on the
airbag system's components or its surrounding electrical components. Action contrary to any of the "Areas of
Importance" may lead to the deployment of the airbag, resulting in injur\
y or unnecessary repair of the airbag.
To avoid accidental deployment of the airbag and its resulting injury, we suggest repairing the airbag
system before other vehicle systems if the airbag and the other vehicle \
systems both need repairing.
We have received generous support and help from many professional technicians during the preparation
of this manual. We would like to express our heartfelt gratitude to all of them.
Although we have tried our best to write this manual well, we do not guarantee that the entire content
in this manual is absolutely correct. Users may not make any legal claim against the Great Wall Motor Co.,
Ltd. in regards to this manual. Any loss caused by using this manual is not our responsibility. Because of
the writer's limited experience, there are likely mistakes in this manual, therefore we welcome any user
comments, suggestions, and corrections.
Great Wall Motor Co., Ltd. reserves the final right of explanation.


\
Editor
May 2008

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual2
How to Use This Manual
1. There is a content index on the first page of each
chapter. You can consult the index to see the items
needed for maintenance. In order to make searching
more convenient, the subject of each chapter has been
printed on the page header of each odd page.
2. There is a summary or caution item in the beginning of
each chapter. Please read this content carefully before
any maintenance is performed. Some systems include
a malfunction diagnostic table to help determine ve-
hicle failures and their causes.
3. Throughout the entire manual, each maintenance
step's corresponding specification is highlighted in bold,
so there should be no need to pause maintenance
work in order to find these specifications.
4. Warnings, Cautions & Notes
• Warnings are highlighted in bold, indicating the possibility
of causing injury to oneself or to others.
• Cautions are highlighted in bold, indicating the possibility
of damaging the part being repaired.
• Notes are listed separately from the instructions, not high-
lighted in bold. They are mainly used for additional expla-
nations in order to work more effectively.
5. Maintenance procedures:
Most of the maintenance procedures begin with a high-level
component schematic, which indicates individual vehicle
components and how they are assembled.
For example:
Hollow bolt
Copper washer
Q150B1235
Heavy duty spring washer Q40512
Q43082
Front hub bearing assembly
Left steering
knuckleFront brake disc
cover LH
Q1420612
Front hub flange
Front brake disc
Front brake caliper assembly LH
100±10
9±2
N·m: Specified torque
Disposable parts

Downloaded from www.Manualslib.com manuals search engine 3Overview
Correct vehicle maintenance and repair is very important
to the safety of the maintenance person and the vehicle. If
any vehicle part change is necessary, please use a part with
the same part number or part number specified by the Great
Wall Motor Co., Ltd. Never use a part that has not been au-
thorized by the Great Wall Motor Co., Ltd.
4. Inspect the front brake disc thickness.
Standard thickness: 22.0 mm
Minimum thickness: 20.0 mm
The brake disc must be changed when its thickness falls be-
low the minimum level.
The maintenance procedures are explained step by step:
• The schematics and diagrams illustrate how and where to
operate.
• The titles convey the maintenance content.
• Detailed instruction explains how to perform the maintenance,
as well as introduces other related matters, such as specifications,
warnings, and so on.
For example:
Illustration: How and where to operate.
Work Subject: What to do
Detailed Instruction: How to do it
Specifications
Engine Manufacturing Number
The engine manufacturing number is engraved on the left
side of the engine cylinder block.
Vehicle Nameplate
Every vehicle has a vehicle nameplate, and this vehicle's
nameplate is located at the bottom of the right B-pillar.
Identifying Number Location
Vehicle Identification Number (VIN)
A Vehicle Identification Number is a unique serial number
consisting of 17 characters and used to identify individual
motor vehicles. This number is marked at three different
places: at the nameplate, at the upper-left side of the dash-
board, and at the cross member located under the front pas-
senger seat.
VIN
Vehicle Nameplate

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 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 GWFLORID Maintenance Manual34
Exhaust System Removal
Caution: Wait at least 30 minutes between the engine
being turned off and the actual removal of any component
of the exhaust system, as to avoid personnel injury due to
hot components.
1. Main muffler assembly removal
(a) First use a No. 13 wrench (open), sleeve, or ratchet
spanner to remove the connecting spring bolt between
the front flange of the main muffler assembly and the
rear flange of the sub-muffler. Then take out the gasket
between the flanges.
(b) Remove the two rubber hangers on the main muffler.
(c) Take down the main muffler assembly.
Caution: The sealing ring between the front flange of
the main muffler assembly and the rear flange of the
sub-muffler is used only for sealing. If reused, it may
cause large deformations and result in a poor sealing
effect. Accordingly, it is suggested not to use a sealing
ring repeatedly. If necessary, only one repetition should
be allowed.
Warning: While performing this kind of maintenance
work, a person should be present to support the main
muffler to avoid injury in case the muffler falls.
2. Sub-muffler assembly removal
(a) Use a No. 14 wrench (open), sleeve, or ratchet wrench
to remove the connecting bolt between the front flange
of the sub-muffler assembly and the rear flange of the
catalyst assembly.
(b) Remove the support of the sub-muffler plate bracket.
(c) Remove the two two-hole rubber hangers between the
sub-muffler and the frame.
(d) Take down the sub-muffler assembly.
Caution: The sealing ring between the front flange of
the sub-muffler and the rear flange of the catalyst as-
sembly is used only for sealing. If reused, it may cause
large deformations and result in a poor sealing effect.
Accordingly, it is suggested not to use a sealing ring
repeatedly. If necessary, only one repetition should be
allowed.
Warning: While performing this kind of maintenance
work, a person should be present to support the sub-
muffler to avoid injury in case the muffler falls.
3. Rear catalytic assembly removal
(a) Remove the connecting spring bolt between the front
flange of the sub-muffler assembly and the rear flange
of the rear catalytic assembly. Then take out the sealing
ring between the flanges.
(b) Take off the rear catalytic assembly.

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 Manual92
Wheel
General tire balancing procedures
Clean out the accumulated dirt and debris from the inside of the rim.
Warning:
The gravel on the tread must be eliminated to avoid flying out and injuring the operator when
undergoing rotational balancing. This is also a good way to acquire better balance. First thoroughly
inspect the tire's damaged condition, then according to the balancing device manufacture's
recommendations, carry out the balancing operation.
Off-vehicle balancing
Most off-vehicle balancers are more accurate and convenient than on-vehicle rotational balancers. They are
also able to perform dynamic (two sided) balancing. Although it does not correct drum brake and brake disc
imbalance like on-vehicle balancing, it achieves the same effect based on its accuracy.
On-vehicle balancing
On-vehicle balancing is different based on equipment and tool manufacturer. Therefore, when performing
balancing operations, be sure to comply to each manufacturer's operating\
instructions.
Warning: Control the wheel rotation speed to make sure the speedometer stays within 55 km/h.
This restriction is necessary because when a driven wheel slides while the other one stays still, the
speedometer will display only half of the actual wheel speed. When a wheel is sliding, be extremely
careful, because sliding wheels can reach very high speeds. This may lead to the tire rubber peeling
or differential damage, which may cause serious personal injury, or damage to the vehicle.
Tire installation and removal
• Install or remove tires with a tire changer. When operating machinery, make sure to comply to the machine
manufacturers operation manual. Please do not change tires merely with manual hand tools or tire installation
crowbars. This will damage the tire chafer or the vehicle wheel's rim.
• Use a wire brush or coarse steel wool to clean off grease and old rubber, as well as light rust or corrosion from
the rim tire bead's tire chafer seat. Before tire installation or removal, first use the indicated tire lubricant to
thoroughly lube the tire chafer portions one time.
• After installing the tire, inflate it to the specified pressure and make\
sure the tire bead is properly seated.
Warning: Do not over-inflate the tire. If the tire bead severally expands and exceeds the safety limit,
it may burst and cause serious personal injury. While inflating, do not exceed the specified pressure.
If the specified pressure does not allow the tire bead to sit properly, deflate the tire, re-lubricate, and
then re-inflate.
Spare tire usage
• Spare tire standard inflation pressure: 420 kPa.
• Spare tire pressure measurements should be taken under normal temperatur\
e conditions.
• After inflating the spare tire, soapy water should be used to check if the air nozzles core is leaking air, then
lock on the air nozzle cap.
• The spare tire should always be kept in a useable state. Check the air p\
ressure at least once a month.
• When the spare tire's working limit, indicated by the remaining pattern's depth, reaches 1.6 mm (and its pat-
tern groove bottom protrudes to the same level), for your safety, please stop using the spare tire.
Caution:
• The "" symbol on the tire bead of the spare tire in-
dicates the set position of the wear index (shown on
the left).
• The spare tire's maximum driven speed is 80 km/h,
and maximum distance 200 km per trip.
• Each vehicle is allowed to use only one spare tire.
• The spare tire is only used as a temporary backup.
Please go to a professional service station immediately
to get the initial tire repaired or replaced.

Downloaded from www.Manualslib.com manuals search engine 97Brake System
(e) Make sure not to let the system valves block the air bleeding.
(f) When the brake fluid that flows out of the hose or connector has no bubbles, it means that the air
in the system has been exhausted. There is still air inside the system if the hose inserted into the
brake fluid is still bubbling when pressing down the pedal.
(g) Keep the free end of the hose immerged in the brake fluid to avoid air from flowing into the
system while opening the screw.
(h) While air bleeding, hammer the casting part of the vibrating brake device with a rubber hammer.
This is helpful for removing bubbles deep in the brake fluid.
(i) If air in the master cylinder is suspected, then perform air bleeding on the master cylinder first,
then the wheel cylinder or brake caliper.
(j) When releasing air from the tires, generally make sure to release air out of all the tires.
(k) To avoid the possibility of air reversely entering into the system, a bleeder hose that has a check
valve could be used.
(2) Pressure blow-off
Under the proper conditions, a pressure blow-off device can be used to release the air inside the brake system.
3. Air releasing sequence
(1) Master cylinder air bleeding
If the master cylinder does not have air bleed screws, perform the follo\
wing steps:
(a) Check the brake fluid level inside the master cylinder’s reservoir and add to it if necessary.
(b) Slowly take off the front brake pipe connector until the brake fluid flows out from the end.
(c) Reconnect the brake pipe, but do not tighten it.
(d) Slowly step down and press on the brake pedal, check if the brake fluid flowing out of the connector
contains bubbles.
(e) Tighten the pipe fitting.
(f) Have the assistant loosen the pedal, wait for 15 s.
(g) Repeat the above steps until all the air is released.
(h) Take off the rear brake pipe connector, repeat the above steps.
(2) Wheel brake air releasing
(a) Check the brake fluid level inside the master cylinder’s reservoir and add to it if necessary. During the
entire air releasing period, check repeatedly and add promptly.
(b) Connect one end of the bleeder hose with the bleed screw and the other end immerged in the brake fluid.
(c) Have the assistant step on the pedal several times, raise the pedal gradually until it cannot be stepped on
any more, then forcibly press on the pedal once more.
(d) Loosen the bleed screw, check if there are any bubbles in the brake fluid flowing out. Meanwhile, slowly
lower the pedal.
(e) When the brake pedal is close to the stroke end or the out flowing brake fluid does not have any bubbles,
tighten the bleed screw.
(f) Have the assistant release the pedal and wait for 15 s.
(g) Repeat the above steps until there are no bubbles in the flowing brake fluid when the screw is loosened.
(h) Release the air for all the wheels in turn using the same method.
(i) After releasing the air from the entire system, switch the ignition to the on position.
(j) Inspect the stroke of the brake pedal and its reaction.
(k) Inspect the lighting condition of the brake warning lamp, and repeatedly perform maintenance or air
bleeding if necessary.
( l ) Add brake fluid to the reservoir until the specified fluid level, air bleeding is complete.

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual110
The X431 scanner possesses a waveform function. Wheel speed signal error (wheel speed sensor failure)
only appears when intermittent problems occure, such as high speed. When in use, some signal errors may
occasionally appear. Continue observing the waveform to make sure there is nothing abnormal.When driving
the vehicle on a flat and straight road, all four wheels' speed sensor waveform are extremely similar. One can
compare the two front wheels' with the two rear wheels' signal wave at t\
he same time.
Mechanical causes:
Signal gear distortion, loosened hub bearings, smudges on the sensor surface, etc, all may lead to wheel speed
signal intermittency and inaccuracy. Failure examples:
As shown above, once the intermittent failures with the wheel's speed sensor signal are detected, the ABS
control unit records the sensor problems and lights up the warning lamp.\
4. Wheel speed sensor velocity failure (ECU detects an excessive difference between the two wheels'
speed sensor signals).
Possible causes are the gear's wheel speed sensor gap is overly large, or the wheel speed sensor signal is
experiencing interference. For this, first determine which sensor is emitting the signal, and then use failure
three's maintenance methods.
Areas of Importance
1. Sometimes, in order to determine whether there is a common brake system problem or an ABS
problem, the ABS must be terminated by pulling out its ABSECU connector or fuse. At this time the
ABS/EBD loses function as well. On muddy, icy, or snowy roads, the vehicle may fishtail or slide, in
which cases one must be extremely careful to avoid hard braking.
2. The ABS malfunction rate is extremely low, when the brake system shows any problem (before the
warning lamp goes on), first eliminate the normal brake system problems, then consider the ABS mal-
functions.
3. When raining or on gravel, this adjusting process is longer than the standard process, because this
kind of road's unstable adhesion coefficient will lead to a difference between the sliding measurement
and calculation procedures, thus it is necessary to remind drivers to be especially careful when driving
under the circumstances mentioned above.
4. ABSECU Areas of Importance:
(a) The ABSECU is easily damaged from impacts or collisions, thus pay attention to ensure the ECU avoids
such incidents.
(b) High temperature environments can also easily damage the ECU, so when the vehicle undergoes hot paint
work, make sure to first take the ECU out of the vehicle.
(c) When the power switch is ON, do not disassemble the system's electrical elements and wire harness plugs,
in order to avoid damage to the ECU. If removal or installation must be carried out, be sure to disconnect
the ignition switch firstly. When welding components or circuits to the system, the wire harness plug
V( Km/h)
60
30
Signal interrupt
t