oil change GREAT WALL PEGASUS 2006 Workshop Manual

AC-12Air-Conditioning System
Compressor
Installation of manifold gauge
Remark: Connect the manifold gauge to the auxiliary valve of
compressor.
1. Turn off the manual valve of manifold gauge.
2. Mount the packing hose of manifold gauge on the packing
valve.
Mount the LP hose to the LP packing valve and the HP hose to
HP packing valve. Then screw up the nuts for hose joint by
hand.
Remark: Do not coat the compressor lubricant on the connec-
tion positions.
packing hose
efrigeration system
connected to mani-
fold gauge
connect to compressor
turn offturn offCompressor
On vehicle inspection
1. Mount the manifold gauge;
(see manifold gauge mount)
2. Run the engine at the speed of 1500 r/m or so;
3. Check the compressor according to the following items:
(a) The HP gauge readings under the normal system should
satisfy the specified value of (1.4-1.7)MPa , that of LP
gauge should meet the specified value of (0.15-0.2)MPa .
(b) Whether there is abnormal sound;
(c) Whether there is leakage at the shaft oil seal.
If any problem is found, repair or change the compressor.
4. Check the electromagnetic clutch:
(a) Check to see whether there is lubricant trace on the
pressing plate and rotor;
(b) Check to see whether there is noise or lubricant leakage
at the clutch bearing;
(c) Measure the resistance between the stator coils that is set
between the clutch lead and the grounding lead with the
ohmn meter.
Standard resistance:
SL SK SJ
(3.2
.2)
Ω
Dr SF SY
(3.5
.2)Ω
In case the requirement is not satisfied, change the compressor.

B0-34Vehicle Body
Front Windshield
(a) Prize the lips of sealing strip from the inside of body
flange outwardly;
(b) Pull out the glass to take it down together with the
sealing strip.
(c) Take out the glass from the sealing strip.
sealing strip
In case new sealing strip is used:
(a) Prize the lips of the sealing strip from the inside of body
flange outwardly;
(b) Pull out the glass to take it down;
(c) Tear down the old sealing strip.
Notice: be careful not to damage the body and glass.
Cut a small open in the sealing agent between the glass and the
vehicle body, then insert a steel wire in the open to pull is to and
fro slowly until the sealing agent is separated completely, then
pull out the glass to take it down.
Notice: be careful not to damage the body and glass.
Mount of front windshield
1. Clean the body frame and the glass.
Clear away the sealing agent on the body surface completely,
then clean the contacting face of body and glass with cleaning
materials.
2. Clean the sealing strip;
Clean the sealing strip surface with cleaning materials.
3. Encase the front windshield in the sealing strip (Dr)
(a) Coat the silicon oil around the glass, and mount the
adhesive strip on the glass according to the glass shape.
Notice: if the adhesive is stiffening or deforming, it may
result the water leakage, therefore, change with the
new one where possibly.
(b) Mount a rope alongside the sealing strip groove as
shown in the drawing for operation,(fasten the rope
inside of the adhesive strip, rope diameter:
=4mm)

B0-42Vehicle Body
Rear Windshield
Mount of rear windshield
1. Clean the body and glass;
Clean the contacting face of body and glass with the
cleaning materials.
2. Clean the sealing strip
Clean the sealing strip with cleaning materials;
4. Mount the rear windshield
(a) Lay the ready glass against the corresponding position of
rear windshield opens.
(b) Pull the rope from the inside of body to encase the roof,
the rear column and the door frame within the adhesive
strip, meanwhile push the outside of the glass by hand.
(c) Tap the four edges of the adhesive strip to ensure that the
adhesive strip contact closely with the body windshield
opened.
(d) Coat the glue from left to right at the upper part of
windshield (location between the adhesive strip and the
body windshield open) and the lower part of windshield
(location between the adhesive strip and glass), and the
remaining glue should be cleared away with abrasive
paper, and the location should be cleaned with cloth.
Notice: there should no breakage at the sealing glue
seam when coating the glue.
Recommended sealing agent for use
Glass glue XL-1211 acid silicone glass glue
5. Check whether there is leakage and the leakage
reparation;
(a) Conduct the leakage test;
(b) Seal the leaking parts with glass glue. 3. Mount the rear windshield in the sealing strip
(a) Coat a layer of silicon oil around the glass circumference
and mount the adhesive strip on the glass according to
the glass shape.
Notice: if the adhesive strip becomes stiffening or
deforming that will lead to water leakage, change with
the new one where possibly.
(b) Mount a rope alongside the sealing strip channel as
shown in the drawing (fix the rope in the adhesive strip).

A-2
Clutch
Specification
Item Specification
Fastening torque for clutch tube on master cylinder
Fastening torque for clutch tube on wheel-brake cylinder
Fastening torque for clutch pressure plate160
190-200
5-15
0.3
0.8
0.2
0.6
5
Max misplacement
0.5 Pedal height (calculated from front wall
Pedal free stroke
Min depth of clutch-facing rivet
Max radial swing difference of clutch rib
Max radial swing difference of flywheel
Max width of wear of diaphragm spring
Max width of wear of diaphragm spring
Alignment degree of diaphragm spring endApplicable vehicle model
Dr SF
SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Torsion moment
Fastening location (N*m)
15-17
15-17
30 Applicable Vehicle model
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Gearbox
Three-grade maintenance for gearbox
1. Grade I maintenance for gear box
Grade I maintenance: Check the lubricant level to see whether the lubricant level is in alignment with the lower edge of oil
filler; if the lubricant is lower than the oil filler lower edge, add the lubricant; or the insufficient lubricant will lead to the poor
lubrication or burn-out of bearing and teeth; while the over-high lubricant will cause the overheating and oil leakage.
2. Grade II maintenance for gear box
Grade II maintenance: The gear box of a new vehicle should be maintained by exchanging the lubricant during the
first grade II maintenance and should be washed with kerosene; and the lubricant quality should be checked in the
grade II maintenance in later time, if the lubricant is diluted, gumming or over-dirty, it should be changed.
3. Grade III maintenance
The gearbox should be disassembled for inspection, washing and oil change.
Notice: As the new vehicle is in the running-in status, the gearbox should be maintained by exchanging lubricant
after the vehicle covers 1500 km,
Lubricant Type
GL-5 SAE80W/90
Torsion moment of relative connecting elements
Tung Teeth: Tang tooth(5DYA4TWD
5DYA8FWD)
Unit
ãã Specification of Maintenance and Up-Keeping
Clutch and Gearbox
Locating screw of fork axle at first and second gear
Locating screw of yoke block
Screw on baffle of rear bearing of output shaft
Screw of reverse idler shaft
Bolt of gearshift cover
Bolt of front cover
Bolt of rear body
Bolt of clutch shell
Bolt of locating spring13
17
15
20
17
22
17
20
15
20
15
20
30
45
30
45
17
22 Fastening location N*m

A-3
Fastening location N*m
Upper tooth(JK72TWD)
Fastening location N*m
Specification of Maintenance and Up-Keeping
Transfer Box
Maintenance and Up-keeping of Transfer Box
1. The oil level of transfer box should be checked when exchanging the engine lubricant or the vehicle
covers more than 8000 km
and add the lubricant where necessary.
2. Change with the appointed lubricant each year or after the vehicle covers more than 48000 km.
Notice: lubricant brand: 85W/90 GL-5.
Fastening torque of relative connecting elements
15
20
10
15
12
17
15
20
15
20
15
20
15
20
30
40
60
70
30
40
30
40
17
22
30
50
20
40
30
40
90
125 Toggle fork at first, second and fifth gears and the screw of
toggle fork
Bolt on odometer pressure plate
Screw on baffle of rear bearing of output shaft
Screw on baffle of reverse idler shaft
Locating screw of gearshift yoke block
Bolt of front cover
Bolt of gearshift cover
Pillar of clutch toggle fork
Bolt of clutch cover
Bolt of rear body (M10X1.25X130)
Bolt of rear body (M10X1.25X80)
Plug of locating spring
Oil filling/draining plug
Reverse gear switch assembly
Location mechanism cluster
Locking nut at rear end of countershaft
Fastening location N*m
Flange nut
Oil drain plug
Bolt of motor clip
Fixing bolt of motor
Clutch coil nut
Housing bolt
Oil pump bolt
Venting valve
Bolt of front connecting body203
244
19
30
8
11
8
11
8
11
27
46
4.0
8.5
8
19
27
46 Oil filling/draining plug
Location mechanism cluster
Pillar of clutch toggle fork
Bolt on odometer pressure plate
Reverse gear switch assembly30
50
30
50
30
50
10
15
30
50

B-5
3916031
Press fitting tool of long
semi-axis bearing
3916032
Electric cutch tester
3916033

Disassembling tool of
half-shaft bearing
3916034

Press fitting casing of
half-shaft bearing and oil
seal
3916035

Mounting tool of rear
axle oil seal
3916036

Mounting tool of main
teeth oil seal
3916037

Change oil seal of rear
axle main teeth on
vehicle
3916038

Mounting tool of main
teeth oil seal
3916039

Mounting tool of main
teeth oil seal
3916040

Spanners of adjusting
ring of side bearing of
differentialUse with torsion
spanner togetherChange oil seal of
rear axle main teeth
on vehicle
SSTSpecial Service tool
Diagram Tool name tool number
SST Special Tool
Special Service Tool
Application position
Front axle
Rear axle
2WD 4WDRemark