Gear box GREAT WALL SAILOR 2006 Manual PDF

SR-9Steering System
Manual Steering Gear
Manual steering gear
Disassembly and mount of manual steering gear
steering drive shaft
manual steering gear box
swing arm
N
m
specified torque
245
25(Dr)
assembly mark
SSTPoints on disassembly and mount
1. Disassemble the steering drive shaft:
(a) Loosen the fixing bolts at upper part of steering column;
(b) Tear down the connecting bolts of steering drive shaft;
(c) Mark the assembly marks on the steering drive shaft and
worm shaft;
(d) Slide the shaft backward to tear it down from the worm shaft.
2. Tear down the swing arm from the steering gear:
(a) Loosen the fixing nuts of swing arm;
(b) Tear down the swing arm from the steering gear with SST.
96
10(Dr SL SK SY)
worm shaft

BE-9Body Electric System
Protective Box Position and Content
fuse relay
1. Small lamp 10A A. electromagnetic fan relay
2. Brake 5A B. lasher
3. Ceiling lamp 5A C. electromagnetic fan relay
4. Central control lock 15A D. small lamp relay
5. Electric rocker gear 30A E. electric window relay
6. Dual flasher 10A
7. Cigarette lighter 15A
8. Rear vision mirror 5A (1) plugging elements of ceiling lamp wire harness
9. Unload (2) plugging elements of wire harness at front left door
10. Acoustic device 15A (3)plugging elements of wire harness in engine room
11. Rear window 20A
12. Electromagnetic fan 10A
13. Instrument 5A
14. Back-up lamp 5A
15. Rain brush 10A
16. Steering 5A
17. Unload
18. Unload




A
B
C
E D
123 456
78 9 101112
13 14 15
16 1718
SF
Protective bos I (continued)

BE-38Body Electric System
Backup Radar System
Inspection on Common Trouble
Failure Judgment Methods
No backup radar display (no
system start notification when
the reverse gear is engaged)Check whether the plugging elements of power supply
of back up radar control box are in well connection as
shown in drawing H in next page.(when the reverse
gear is engaged, touch the detector, if there is vibration,
which shows the detector is powered.
Check whether the wire harness of inner mirror in
electric room and that on the top of body are in well
connection as shown in the drawing A in next page
Check whether the wire harness of back up radar
control box is well connected with that of chassis
and that on the top of body.
Rotate the vehicle key to the ACC position and
engage the reverse gear, then measure to see whether
the back up power supply reaches to 12 V with the
multi-meter of 50 V of voltage, refer to the
red
and black
positions shown in the drawing in next
page.
If the voltage reaches 12 V, change the backup
radar control box in trial firstly, then the inner
mirror in electric room, finally change the roof
wire harness and the chassis.
No backup radar display (but
there is start notification when
the reverse gear is engaged)
remark: such trouble occur
under the blocking condition.Check whether the power supply of back up radar
is well located, see the red and position in the
drawing of next page.
Check and align the plugging element.Poor properties of ultrasonic wave
Change the ultrasonic detector heads.
Continuous back up radar red
lamp alarming (remark: there
is no obstacle within 0.5 m away
from the detector head)Check whether the detectors in the two circuit of
back up radar control box is well plugged, see the
marked positions F, G in the drawing of next page.
Check and well connect those plugging elements
Poor connection of the left/right ultrasonic detector head
Poor performance of back up radar control box.Check and well connect those plugging elements
Change the ultrasonic detector head
Change the back up radar control box.
Vehicle modelpc
Alarming by mistake
The rear standby tire is removedConduct the inspection operation for the rear
standby tire at the spacious place
fail to detect the obstacle
The detector head doesn
t workChange the detector head
There is dirt on detector headClean the detector head
Rear standby tire inspection1. engage the reverse gear for five times repeatedly within ten seconds at the spacious place so that the red
lamp on the screen flash three times, the system will automatically remember the standby tire status.
2. When the body height varies or the stand by tire is opened, make a new inspection for the rear stand by
tire to ensure the backup radar in normal operation.
Seven section of lamp display
Column I
1.49m-1.3m Column II
1.29m-1.1m
Column III
1.09m-0.9m Column IV
0.89m-0.75m
Column V
0.74m-0.6m column VI
0.59m-0.45m
Column VII

0.45m
Remark: the right and left LED display the direction and distance of obstacle respectively for driver
reference.If the voltage fails to reach 12 v, check the power
supply system of original vehicle
s large wires
to restore the voltage to 12 V.
Vehicle model SL SK
fail to detect the obstacle
Trouble description Repairing and treatment approaches

BE-50Body Electric System
Central Control Lock and Electric Rocker Gear System
Central control lock and electric rocker gear system
Part Mounting position
SL SK SY SJ Dr SF
Central control lock box
Central control lock box

BE-51Body Electric System
Central Control Lock and Electric Rocker Gear System
Electric circuit diagram of central control lock
aê
pc
fuse
21
6
5
3
4 left front door switchleft front
main lock
control case of central control lock
1 2 3 4 5 6 7 8
fuse
M M M M
to generator
power lead
to left turn
lamp
to right turn
lamp
to door
lamp switch
control case of central control lock
1 2 3 4 5 6
7 8 9 10 a 12 131
6
5
7
10
132 3 12
11
central
controller box
batterylock-head lamp
battery central controller box
central control lock
switch at left front door
four doors locker
8
right front
main lock
left rear
auxiliary lockright rear
auxiliary lock

BE-53Body Electric System
Central Control Lock and Electric Rocker Gear System
Electric circuit diagram of central control lock (continued)
SL SK
pv
fuse
8
76
5
4
3
left front door
main lock
right front door
main lockleft rear door
auxiliary lockright rear door
auxiliary lock
control case of central control lock
123456 78
fuse
ignition switch
ACCONST
111
10
8 91
6
4
5
3
7
12
left front main
lockright front
main lock
left rear
auxiliary lockright rear
auxiliary lock
ignition switchcontrol case of central control lock
1 2 3 4
5 6 7 8123 45
6789101112
battery door lamp switch
speed sensor central
controller box turn lamp
battery central
controller box

BE-54 Body Electric System
CCL and Electric Rocker Gear System
Electric circuit diagram of CCL
SJ Top-grade SY
fuse
ACC ONST
N
ignition switch
11
10
8 9
12745 2 61
left front main lock right front main
lockleft rear auxiliary
lockright rear auxiliary
lock
ignition switch
1 2 3 4
5 6 7 8123 45
6 7 8 9 10 11 12
battery
central controller
box
speed sensor
turn lamp
left front electric rocker gear switch
central controller box
door lamp switch

BE-60
Inspection on Common Trouble
Trouble Possible causes Repairing approaches
Burned out fuse Change and check whether there is
short circuit
Wiring failure
Seize-up of electric rocker gear
or mechanical lock
Failure of brush-rocker or lock
out deviceMake reparation as required.
Make reparation as required.
Change
The indicating lamp of electric rocker gear
switch doesn
t workWiring failure
Failure of indicating lamp locates
interior side of switchMake reparation as required.
Change
There is no electricity in the Change the cell
remote controller
Both remote controller cannot
control the CCL
Glass cannot raise automatically after the
car door is locked (top SY SJ)Wiring failure
Failure of Control case of CCL
Brush-rocker switch failureMake reparation as required.
Change
Change
Body Electric System
CCL and Electric rocker Gear System
Electric rocker gears at four
doors don
t work
The CCL at four doors don
t work Burned out fuse Change and check whether there is
short circuit
The electric rocker gear or
CCL at one
door doesn
t work
One remote controller cannot c
ontrol the CCL
Controller box damage Change

BE-64
Inspection on Common Trouble
k
v
kk
v
ON
OFF
blue screen
black screen
(a) Main engine cannot be opened
Ther is no action when pressing
the
ower
key repeatedlyCheck whether the voltage of
ACC and storage cell reaches
12 VCheck the fuse in power wire
or the power supply of the
entire vehicle
Failure of main
engine
(b) No voice or image when broadcasting

NO CDC
displayed on
screenRe-open the deviceCheck whether there is image
when backing upFailure of main
engine
Be normal after
returning
Check the converter box works
normally (whether the lamp is
light or not)Failure of converter
box
Failure of disc box
(c) There is no image when backing up
There is no image in
video cameraWhether the screen display
is blue screenFailure of video
camera
The backing up wire is not connected
well; reconnect it to the positive polar
of 12V of reverse gear
Body Electric System
Acoustical Equipment System

B0-53Vehicle Body
Instrument Panel
Dismantle of instrument panel
(Dr SF)
1. Disconnect the cable of accumulator from the negative
polar;
2. Tear down the steering wheel;
3. Tear down the combined switch shell cluster;
4. Tear down the bonnet lock switch;
Tear down the two screws and the sliding fastener of bonnet
lock.
5. Tear down the central bottom-wall (Dr)
Tear down the decorative cover of gearbox (SF)
6. Tear down the instrument cover (SF).
Tear down the two screws and the cover.
7. Tear down the lower instrument cover;
(a) Tear down the ignition lock;
(b) Tear down the five screws and the cover;
Tear down the four screws and the cover;
(c) Disconnect the plugging elements.
8. Tear down the air-conditioner controlling panel;
(a) Pull out the air-conditioner controlling button;
(b) Prize out the A/C switch;
(c) Prize out the air-conditioner panel as shown in the
drawing with screwdriver and take it down.
Notice: the screwdriver should be wrapped with adhesive
strap at its head before using.
(d) Disconnect the plugging elements.
9. Tear down the decorative cover of instrument (Dr)
(a) Tear down the two screws to pull out the decorative cover
of instrument;
(b) Disconnect the plugging elements.E
F