engine GREAT WALL SAFE 2006 User Guide

TF-8Transfer Box
Disassembly and Mount of Transfer Box
2. Transfer box mount
a) Coat the lubricant grease on the output axial
spline of the gearbox with a thin sleeve contain-
ing lubricant grease.
b) Mount a new gasket on the mounting face of the
transfer box.
c) Lift the lifting bracket of transfer box and align
it to the same axle with the gearbox.
Notice: The transfer shall be guaranteed to flush
with the gearbox before connecting the spline.
Do not handle it forcefully to press the transfer
box spline into the gearbox. Otherwise, damage
will be caused, run the rear output shaft where
necessary to aim at the spline.
(d) Move the transfer box forward slowly so that
the spline and pin of the input shaft of gearbox
reach the front body of the transfer box, and the
gasket attaches on the gearbox completely.
(e) Ensure that the mounting holes of the front
body of transfer box, gasket, and gearbox are in
alignment and then mount the sets of bolt and
nut.
Fastening torque
(35-48)N
m
(f) Connect the rear drive shaft and the rear output
flange of the transfer box.
(g) Connect the front drive shaft and the front
output fork flange of the transfer box.(h) Connect the venting valve and the soft ventila-
tion pipe.
(i) Connect the cables of odometer that locates
nearby the transfer box.
(j) Connect all wire harnesses that connected with
the transfer box, and
(k) Add the lubricant of right brand.
Notice: when starting the engine, if the lubricant
is added incorrectly or in unsuitable volume,
which may lead the transfer box to damage.
Notice: as for the transfer box mounted on
vehicle, oil pump shall be used when adding oil
for it.
Notice: In case the transfer box is taken apart for
maintenance or inspection, there will be no
lubricant supplied by oil pump in the oil passage
on the top of transfer box. Therefore, it is not
accurate to control the oil volume by opening the
oil filling plug, in such condition, the oil passage
will be filled with oil once the oil pump runs. If the
wheel can run, such operation can be conducted
on the lifting jack. The oil level shall be rechecked
once the oil pump runs.
(l) Put down the vehicle after finishing the lubri-
cant inspection, and connect the cell cathode.

BR-5Braking System
Inspection and Adjustment
pedal push rodbraking lamp switch
pedal push-rod
free stroke of
pedal: (3-6) mm
Inspection and adjustment
Inspection on and adjustment of brake pedal
1. Check the pedal height as shown in the drawing to
whether it is correct,
The height from the pedal to the front floor:
Dr SF
160mm
SL SK SY SJ
(190-200)mm
2. Adjust the pedal height if necessary:
(a) Loosen the locking nuts of braking lamp switch;
(b) Loosen the braking lamp switch to the most degree.
(c) Loosen the locking nuts of drag rod;
(d) Adjust the pedal height through rotating the pedal drag
rod;
(e) Rotate the stop light switch reversibly until it contact
with the stop baffle of pedal.
(f) Screw up the two locking nuts.
(g) Check the braking lamp is lightened or not when tread
down the brake pedal.
(h) Check and adjust the pedal free stroke after adjusting the
pedal height
QKAdjust the free stroke of pedal if necessary:
(a) Loosen the locking nuts of the pedal drag rod and rotate
the pedal drag rod to adjust the pedal free stroke.
(b) Start the engine to confirm the free stroke.
(c) Check the pedal height after adjusting the pedal free
stroke. 3. Inspection on Pedal Free Stroke:
(a) Stop the engine working and tread down the brake pedal
several times until the vacuum booster is not in the stage
of vacuum.
(b) Tread down the pedal until the resistance occurs, and
measure the distance shown in the drawing.
Pedal free stroke
(3-6)mm
pedal height

BR-6
Operation test of vacuum booster
Remark: check the operation of vacuum booster with the
vacuum booster tester if workable.
1.Operation inspection
(a) Before starting the engine, tread down the brake pedal
several times, and check the pedal reservation distance to
ensure there is no change occurs.
(b) Tread down the brake pedal and start the engine. If the
treaded pedals continue to move downward, which means
the operation is normal.
1. Inspection on Air-tight
(a) Start the engine for 1-2 min and then turn it off. Then
tread down the brake pedal slowly for several times, if the
pedal move downward continuously in the first, but
return gradually in the second or third time, which means
the vacuum booster has a good air-tight.
(b) Tread down the brake pedal when the engine is working,
then stop the engine, but tread the pedal down. If the
reservation distance doesnít change within the 30 seconds,
which shows the air tight of vacuum booster is good.
Air-bleeding of braking system
Remark: air-bleeding is required if any operation for braking
system is conducted or the pipe line is doubted to have air.
1. Fill the oil cup with the brake liquid
Check the liquid level of oil cup after the air in each wheel
brake pump is exhausted. If necessary, add the brake liquid.
2. Connect the vinyl resin pipe with the vent screws.
Insert the other end of pipe into the container with half brake
liquid.
Remark: the air-bleeding shall begin from the longest pipe line
when the wheel-brake cylinder is exhausting the air.
3. Air exhaust of the pipe line in braking system
(a) Tread down brake pedal slowly several times.
(b) Loosen the vent screws until the brake liquid flows out
while letting the assistant tread down the pedal. Then
screw up the vent screws.
(c) Repeat this approach until there is no air in the liquid.
4. Repeat the approach for the wheel-brake cylinder.
normal
abnormal
the third time
the second time
the first time
Braking System
Inspection and Adjustment

BR-11Brake System
Vacuum Booster
Inspection on Vacuum booster parts
Operation for one-way valve inspection
(Gasoline engine)
(a) Tear down the one-way valve;
(b) Check the air to see whether it flows from the vacuum
booster side toward the engine side.
(c) Check the air, change the one-way valve if the air flows
from the side of engine toward the vacuum booster.
(d) Mount the one-way valve in the right place.
(a) Tear down the one-way valve from the vacuum pipe.
(b) Check the air to see whether it flows from the side of
vacuum room to the hose.
(c) Check the air, and change the one-way valve if the air
flows to the hose to the vacuum room.
air
engine side booster side
air airless
air
hose side vacuum side
airairless
Mount of Vacuum Booster
1. Adjust the length of vacuum booster pushrod:
(a) Mount the sealing washer on the master cylinder;
(b) Put SST on the sealing washer and descend the pin rod
until it contact lightly the piston with its top;
(c) Put top of SST downward ,and mount it on the vacuum
booster.
(d) Check the clearance between the vacuum booster pushrod
and the head of pin on SST.
(e) Adjust the length of vacuum booster pushrod until the
pushrod touches the pinhead.
2. Mount the vacuum booster, sealing washer and Ushaped
clip head.
(a) Mount the vacuum booster and sealing washer.
(b) Mount the U-shaped clip head.
(c) Mount and tighten the assembling nuts of vacuum booster.
3. Connect the U-shaped clip head and the brake pedal:
Encase the U-shaped clamping pin in the hole of U-shaped clip
head and the brake pedal, and then mount the spring pin on the
U-shaped clamping pin.SST
washer
SST
(Diesel engine)

SR-11Steering System
Power Steering (General Introduction)
power steering oil pump
power steering gear steering drive shaft
oil cup
Power steering
Introduction
Principal of Power Steering
The power steering is a kind of hydraulic device that use
the engine power to steer. The engine drive the power
steering oil pump to generate the hydraulic pressure, which
actuates the piston in steering gear, so that the worm shaft
can provide to the piston with a supplementary force, which
has relation with the pressure actuated on the piston.
Therefore, pressure increase is required if larger steering
force is needed, and the pressure variation is accomplished
through the control valve.
Intermediate position (forward straightly)
The liquid from the power steering oil pump is sent to
the control valve, which, if locates at the intermediate, will
allow the liquid to pass and enter into the drain outlet, finally
return the pump. At this time, it is difficult to increase the
pressure; meanwhile, due to the equal pressures at the both
sides of the power piston, it cannot move toward either side.
Steering time
When the steering drive shaft move toward either side,
the control valve will move together with it, in case one oil
passage is shut off, meanwhile open the other larger, the
liquid flow variation will increase the pressure, as result, the
unequal pressure at both sides of piston will make the piston
move toward the side of smaller pressure, therefore, the
liquid is pressed in the pump through the control valve.
pump control valve
drain outlet
power cylinde
power piston
segmental gear shaft worm shaftsteering gear
Pump

SR-13Steering System
Power Steering (On-Vehicle Inspection)
tensioning wheelpower steering oil
pump
crankshaftOn-vehicle inspection
Inspection on tension of driver conveyor
Measure the tension of drive conveyor.
Drive conveyor tension: under the condition of 98 N.
New conveyor: (5-7)mm
Old conveyor:
(7-9)mm
Remark:
ìnew conveyorî means the conveyor that is used on the
machine less than five minutes;
ìold conveyorî means the conveyor that is used on machine
more than five minutes
Check for height of liquid level
1. Keep the body in horizontal status
2. Increase the liquid temperature
When the engine runs idly by 1000 r/m or less, rotate the
steering wheel several times from the locking position to the
reverse locking position to increase the liquid temperature.
3. Check to see whether there is foam or emulsification;
Remark: the foam or emulsification shows there is air in the
system or the liquid level is over-low.
4. Check the liquid level height in oil cup;
Check the liquid level height and, if needed, add the oil.

SR-14Steering System
Power Steering (On-Vehicle Inspection)
Change of power steering liquid
1. Tear down the oil-returning hose from the oil cup to
drain the liquid into the container;
2. Run the engine in the idle status, and rotate the
steering wheel toward the max rotating angle for
several times in right or left direction while draining the
liquid, until the oil in steering liquid is drained up.
3. Turn off the engine.
4. Connect the oil-returning pipe and inject the new
power steering liquid in the liquid tank;
Hydraulic oil type: No.8 Liquid drive oil (Q/SH003.01.012-88)
5. Start the engine, and make it running in the idle status.
Rotate the steering wheel to the max rotating angle repeatedly
several times, meanwhile, supplement new power steering
liquid in the liquid tank until there is no foam or turbidities in
the liquid tank, and the oil indicating lamp reaches the marked
range when the engine is turned off.
6. Tighten the liquid tank cover
7. Exhaust the air in the power steering system;
Ai-r bleeding in power steering system
1. Check the liquid level height in the liquid tank
Check the liquid level and, if needed, supplement the liquid.
2. Start the engine in the idle status and rotate the
steering wheel repeatedly to the max rotating angle
several times.
3. Turn off the engine and connect the ethane pipe and
bleeding plug.
4. Start the engine and rotate the steering wheel
repeatedly to the max rotating angle several times.
5. Locate the steering wheel at the intermediate position.

SR-15Steering System
Power Steering (On-Vehicle Inspection)
6. Exhaust the air in steering system:
(a) Loosen the bleeding plug;
(b) Screw up the bleeding plug when there is no air bubble
exhausted from the pipeline.
Notice: take care not let the ethane pipe slide from the
bleeding plug, because the liquid is high in temperature
and pressure.
7. Check to see whether there is air bubble or turbidities
in the oil cup, and ensure the liquid level will not
exceed the max value when the engine stops,
Measure the liquid height under the condition of engine running,
then turn off the engine and measure the liquid height again.
In case any problem is found, repeat the approaches of (5) and
(6) in Power Steering Liquid Change. If the problem still
exists, repair the power steering oil pump.
RPM RPM

SR-16Steering System
Power Steering (Oil Pump of Power Steering)
Oil Pump of Power Steering
Dismantle and Mount of Oil Pump of Power Steering
Gasoline Engine Series
Diesel Engine Series
power steering oil pump
power steering oil pump bracket
belt pulley
driving beltLP oil pipeHP oil pipe
power steering oil pump bracketHP oil pipe
LP oil pipebelt pulley oil cup
power steering oil pump

BE-2
Brief Introduction
1. Power supply system
The power supply system includes accumulator, generator and its adjustor. Generator is the main power supply; the
accumulator is the auxiliary power supply. The generator, parallel with the accumulator, is equipped with the
adjustor, which is used to maintain the voltage of generator stable when the rotating velocity and the load varies.
2. Starting System
Which includes the direct current motor, drive mechanism and control device, etc. its performance is to start the
engine.
3. Lighting system
Which includes various lighting lamps inside and outside of the body and their control device; they are used mainly
to guarantee safety driving in night.
4. Alarming System
Which includes the electric horn, flasher and various service signal indicating lamps, etc. they are mainly used to
guarantee the physical and driving safe when driving.
5. Auxiliary Electric Appliance System
It includes the electric wiper, air-conditioner, recorder and cigarette lighter, etc.
R
red
R/G
redgreen
socket plugging element plug plugging elementN
2 3
4 5 6 123
4
5
S
socket plugging
elementplug plugging element
1. The codes of sockets of socket plugging element are
complied from left to right.
2. The codes of sockets of socket plugging element are
compiled from right to left.
Remark: all of plugging elements are watched from the in-
wiring direction.
3. Comparison between plug and socket plugging elements
The plug and socket plugging elements are classified accord-
ing to their in-built socket shape.
(a) All of plugging element are marked according to the
opening end and are locked at their tops.
(b) When pulling the plugging element, pull the plugging
element itself instead of wire.
Remark: before pulling the plugging element, check the
plugging element that you want to disconnect first to verify
their classifications.
English letters for wiring colors code:
B =black Bl =blue R =red Br =brown
Lg =reseda V =purple G =green O =orange
W =white Gr =gray P =pink Y =yellow
First letter stands for the basic color, while the second for the
stripe color.
Body Electric System
Brief Introduction