dimensions GREAT WALL SO COOL 2006 Service Manual

Preface
With the increase of automobile demand in China, our automobile industry also experiences a rapid
development. The trucks including SUV, manufactured by Great Wall Motor Co., Ltd, which are sold all over
China, are in the leading place in terms of their sales volume, in order to satisfy the demands of various maintain-
ing staff, technicians and managing staff of Changcheng Co., Ltd, we compile this maintenance manual accord-
ing to the latest technological data. This manual covers six vehicle models including Deer, Safe, Sailor, Sing, So
Cool and Pegasus, its main content includes:
Part I is general introduction, which introduces the application index of this manual.
Part II introduces the chassis system, which mainly includes the technologies of dismantle, inspection,
adjustment, repairing, assembly and mount of the clutch, gear box, transfer box, drive shaft, suspension system
and automobile axle, braking system and steering system, etc. each operation approach is illustrated with figure,
which not only presents the maintenance procedure, but also clearly describes the technical requirements and
application limit.
Part III introduces the electric system and air-conditioning system of the automobile body, which mainly
covers such items as the location and content of protective box, power supply system, starting system, lighting
system, combination instrument, backup radar system, wiping and washing system, center control locking and
power window system, acoustical equipment system, full wire harness and air-conditioning system, etc. Electric-
ity diagrams for those electric systems are given in this manual so as to facilitate the maintaining technicians to
find out the problem easily and quickly.
Part IV introduces the external and internal body decoration, which mainly covers the dismantling, inspect-
ing and assembling requirements of the engine cover, front and rear doors, adhesive strip of body collision
avoidance, wheel shield, wrapping angle of wheel-shield and exterior trim panel, front and rear windshields,
side-window glass, rear-door glass, rear platform of cargo compartment, rear door, instrument panel, safety belt,
seat, tail-fin, luggage rack, and reserve tire bracket etc. The dimensions of vehicle body and frame are also given
to maintaining staff for reference during their repairing.
During the narrations of each part, items such as troubleshooting, maintenance notice, maintenance data
and application limit, fastening torques of bolts and nuts for special purpose, SST, SSM and lubricant materials
and so on are also introduced. Various maintenance data are briefed in attachment for reference.
Altogether, this manual is comprehensive in content, visual in illustration, clarifying in requirement and
plain in language. It can be referred by the maintaining staff, technicians and professional managing staff.
Even though we try our best to compile this manual in a strict earnest manner, we cannot guarantee that all
contents in this manual are correct. Therefore, users shall not put forward any claim with Great Wall Company
according to this manual; we are not in the position to hold the responsibility for the loss caused by usage of this
manual. Due to our limited knowledge, it is unavoidable to find error in this manual, any criticism and correction
from you is welcomed.
The final explanation power for this manual is subject to Great Wall Motor Co., Ltd
Compiler
May 2006

TF-17
1.25-1.75mm
23
1
12.70mm
13
2
4
4
2
1
5 6
7
83
(e) In the case that the input shaft is taken apart, what need
to do is to fill the needle bearing as shown in the drawing
and press it in the input shaft, meanwhile, press the new
sliding bearing to complete the whole input shaft assembly.
(f) Raise the planetary mechanism assembly to mount it into
the input shaft assembly; encase the thrust gasket and
press in the bearing through the input shaft end. Encase
the fixed bearing in the snapping ring groove of the input
shaft with a snapping ring.
(g) If the transfer box front body is taken apart, press the new
located pin in the front body, and the pressing dimensions
are shown in the drawing.
(h) Put down the oil seal as the drawing shows, and press it
in the front body according to the dimensions shown in
the drawing.
(i) Put down the front body assembly on two wooden blocks
in the way that the coupling face of the front body and the
housing faces upward, so that there is clearance left
between the input shaft assembly and the worktable. Put
down the input shaft and planetary mechanism assembly
in the front body, in which the input shaft shall be
downward. Open the long ends of the snapping ring to
encase input shaft and planetary mechanism assembly
until the snapping ring enters into the external snapping
ring groove of the bearing.
(j) Coat the sealing glue of 1.6mm on the coupling locations
of the front end cover and transfer box assembly, The
glue shall be coated continuously without break and steer
clear of the screwed hole.
(k) Screw up the six bolts.
Fastening torque
(27
46)N
m
6. Assembly of front output shaft
Mount the following parts:
(a) If the dust cover is taken apart, mount it by pressing.
(b) Encase the input shaft, sealing ring, gasket and nuts in the
transfer front housing.
(c) Insert the torque arm of T-13-54-002 in the flange hole to
screw up the nuts.
Fastening torque
(203
244)N
m Transfer Box
Transfer Box Assembly
1. needle bearing
2. bearing roller
3. input shaft
1. locating pin
2. oil seal
3. front body of transfer box
4. snapping ring
1. fork-type flange
2. dust cover
3. fork-type flange assembly
4. transfer box housing5. output shaft
6. oil seal
7. washer
8. nut

BR-23
Wheel-brake cylinder disassembly:
1. Tear down the dust cover steel gripping hoop and the
dust cover.
Tear down the dust cover steel gripping hoops and piston dust
covers of the four wheel-brake cylinders with the screwdriver.
2. Tear down the piston from the wheel-brake cylinder:
(a) Prepare a wooden block with the dimensions as shown in
the drawing (which is used to support the piston)
(b) Put the wooden block between the pistons and insert one
brake pad on one side of the wooden block.
(c) Tear down the four pistons from the wheel-brake cylin-
der by using the compressed air.
Warning: do not put your fingers in front of the piston
when using the compressed air.
3. Tear down the piston sealing ring.
Tear down the four piston sealing ring from the wheel-brake
cylinder with the screwdriver.
Check the front brake parts
1. Measure the thickness of brake pad liner;
Standard thickness
9.0mm
Min thickness
2.0mm
In case the liner is less than the min thickness or the liner is
worn unevenly, change the brake pad. Braking System
Front Brake(SF)
mm
mm
mm

B0-9
manual indoor plate
Electric indoor plate (Type A)
ten clips
12 clips
Vehicle Body
Front Door
12. Mount the interior trim panel of car door:

Dr)
(a) Connect the handle to the control lever first, then pull it
out from the indoor handle hole.
(b) Fix the clip by tapping to encase the interior trim plate of
car door in the corresponding hole of car door interior
panel.
(c) Use one screw to mount the inner clip.

Dr SF)
(a) Connect the handle to the control lever first, and then pull
it out from the indoor handle hole.
(b) Fix the clip by tapping to encase the interior trim panel in
the corresponding hole of car door interior panel
(c) Mount the inner clip with one screw; and
(d) Mount the electric switch and panel.

SL SK SY SJ)
(a) Connect the handle with the control lever first, then pull
out it from the indoor panel handle.
(b) Connect the plugging elements.
(c) Fix the clip by light tapping to encase the interior trim panel
of car door in the corresponding holes on indoor panel.
(d) Mount the inner clip with two bolts;
(e) Mount the four screws to fasten the interior trim panel of
car door, and cover the nuts.
(f) Mount the electric elevator switch.
13. Mount the indoor handle:
(a) Push the indoor handle into the car door paneling and
make it slide backward.
(b) Screw on the screws;
14. Mount the elevator handle (Dr)
Mount the paneling and elevator handle with spring snapping
ring under the condition the car doors and windows are closed
completely as shown in drawing.
12 clips
9. Adjust the car door and window glass;
Adjust the balance arm upwardly or downwardly until the
dimensions of A and B shown in drawing are equal, and then
fix the balance arm.
10. Mount the outer
Encase the claw of clip into the paneling seam and press the
outer on the paneling.
11. Mount the rear vision mirror
inner panel of electric door (type B)
four sets of bolt and nut
front

B0-18
10. Adjust the door window glass Vehicle Body
Rear Door
Adjust the balance arm upwardly or downwardly until the
dimensions A and B shown in the drawing are equal, and then
fix the balance arm.
11. Mount the outerauchi
8. Mount lower rear glass guide track (Dr SF)
Mount the bolts and guide track.
9. Mount the door window glass;
(Dr SF SL SK SY SJ)
Put the glass in the door cavity and then fix the glass on the
glass elevator with two bolts.
Mount on the tailgate baffle and lower dust strip (Dr) 5. Mount the door glass channel;
6. Mount on the quarter window glass (SF SJ)
7. Mount the upper glass guide track (SF)
Mount the bolts and guide track.
12. Mount the door interior trim panel;
13. Mount the indoor handle:
(a) Push the indoor handle in the door paneling and slide it
backwardly.
(b) Tighten the screws.
ABA=B
SF
SJ