engine 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

CL-2Clutch
Troubleshooting
Troubleshooting
Trouble Causes Repairing approaches
Difficulty in gearshift
or non-gearshiftOverlarge free stroke of clutch pedal
There is air in clutch pipe
Failure of clutch brake-wheel cylinder
Failure of clutch master cylinder
Overlarge clutch pendulum difference due to incorrect mounting, the
friction liner is stained with oil or is breaking
There is dirty or adhesive materials on spline of input shaft or clutch rib
Failure of clutch pressure plateAdjust the free stroke of pedal
Exhaust the air in clutch pipe
Change the clutch brake-wheel cylinder
Change the master cylinder
Check the clutch rib
Repair according to requirement
Change the clutch pressure plate
Disengagement of gear
box or clutch slipAbrasion of clutch guide shaft
Insufficient free stroke of clutch pedal
The friction liner of clutch rib is stained with oil or is worn
Failure of clutch pressure plate
Seize up of separation forkChange the guide shaft
Adjust the free stroke of pedal
Check the clutch rib
Change the clutch pressure plate
Check the separation fork
Clutch seize-up or
shakingThe friction liner of clutch rib is stained with oil or is worn
Failure of clutch pressure plate
Looseness of engine seatCheck the clutch rib
Change the clutch pressure plate
Repair according to requirement
Looseness of clutch
pedalThere is air in clutch pipe
Failure of clutch brake-wheel cylinder
Failure of clutch master cylinderExhaust the air in clutch pipe
Change the clutch brake-wheel cylinder
Change the master cylinder
Over-loud clutch noiseSeize up of separation fork;
Abrasion or stained spot of separation bearing
Abrasion of guide bearing
Parts looseness in clutch pressure plateRepair according to requirement
Change the separation bearing
Change the guide bearing
Change the clutch pressure plate

MT-5Gearbox
Dismantle of Gear Box
4WD
11. Tear down the wheel-brake cylinder of clutch.
(a) Dismantle the setting bolts of the wheel-brake cylinder of
clutch with spanner.
(b) Hang the wheel-brake cylinder with a thread on the side
of engine without oscillation.
Remark: Do not disconnect the pipeline of the wheel-brake
cylinder.
12. Tear down the pawl washer and bracket of the rear part
of gearbox:
Two-wheel driving:
(a) Dismantle the four bracket bolts (skip over this process
for the wielding structure).
(b) Lift the engine with jack to raise the gearbox a little.
(c) Dismantle the pawl washer from the rear part of gearbox.
Four-wheel driving:
Dismantle the bolts from the pawl washer and bracket of the
rear part of gearbox to tear down the pawl washer and bracket.
13. Insert the wooden plate between the bottom frame and
the beam.

MT-6Gearbox
Dismantle of Gear Box
4WD14. Dismantle the eight bolts that fasten the beam of gearbox.
15. Tear down the starter
Put the starter on the side of engine.
16. Dismantle the bolts of clutch frame and bracket (wrapping
angle).
17. Tear down the remaining bolts of gear box
18. Tear down the gear box
(a) Pull out the gear box in backward direction;
(b) Put down the engine at the front and tear down the
gearbox from the vehicle.
Notice: be careful not to damage the dust cover of
expansion shell.

MT-7Gear Box
Mount of Gear Box
Mount of gear box
1. Put down the gearbox at the mounting place.
2. Mount the bolts of gearbox, clutch bracket and starter.
Tightening moment:
(a) Setting bolt of gear box (82
10)N
m
(b) Enforcement plate bolt (37
5)N
m
(c) starter bolt (39
5)N
m
Notice: the bolts of gear box and clutch shall be mounted
with the clutch pipe clip together.
3. Mount the pawl washer and bracket of gearbox
Two-gear driving:
(a) Mount the gearbox pawl washer and fasten the relative
bolts.
Tightening moment: 23
3)N
m
(b) Lift the rear part of engine with jack and wooden block so
that the gearbox is raised a little.
(c) Mount the bracket of gear box on beam and fasten the
relevant bolts (this process may skip over in wielding
structure)
Tightening moment
(23
3)N
m
(d) Connect the gearbox bracket and supporter with bolts,
then tighten the bolts.
Tightening moment: (23
3)N
m

MT-8Gear Box
Mount of Gear Box
4WD:
(a) Mount the bracket and supporter of leg washers of rear
engine in 4WD vehicle;(SF)
(b) Mount and tighten the third beam of 4WD vehicle. (SF)
4. Remove the wooden spill.
5. Mount exhaust pipe.
Mount the exhaust pipe on the branch exhaust pipe.
Tightening moment
(62
3)N
m
6. Mount the wheel-brake cylinder of clutch.
Tightening moment
(18
2)N
m
7. Mount odometer sensor and plugging elements of backup
switch.
8. Connect the drive shaft.
(See page PR-12)
9. Add oil into the gearbox.
Lubricating oil grade: GL-5 85W/90
Volume: 2.4L(dry)
Remark: the Tightening moment of oil filling/draining
plug: (30
50)N
m
4WD
4WD

TF-3Transfer Box
Troubleshooting
Common troubles Causes Resolving approaches
Change the lubricant or supplement the
lubricant volume.
Guarantee the torque of all connecting
elements stand at the specified value.
Open the transfer case to check the
bearing and othe parts whether is weared
or daamaged,if this happened,change
the parts.
Difficulty in mechanic gearshift or
outplace gear engagement
Troubleshooting
Incorrect lubricant or insufficient
lubricant volume.
Looseness of connecting bolt or other
connecting element.
Noise from the transfer box bearing Noise, which is spreader by the transfer
box instead of clutch, engine, drive shaft
and other parts, occurs in each speed. No driving of front wheel in the four-
gear engagementDrive chain breakDisassemble and check the damage of
inner parts, and change the chain. Adjust or repair shift lever.Open the
transfer box to check the toggle fork and
guide shaft, and change the parts as
requirement.Open the transfer box to
check whether the parts is wearied or not,
and, if any, change the weary parts.Open
the transfer box to check whether the
parts is wearied or not, and, if any, change
the weary parts.Open the transfer box to
check whether the parts is wearied or not,
and, if any, change the weary parts. Overlarge loose fit clearance of the
shift toggle fork on the shift guide
shaft.
Wear of the shift toggle fork
assembly including pin and contact
roller.
Wear of the shift cam hub and the
liner.
Attainment of coupling gear Mechanic gearshift seizing at a certain
location Engagement failure of the mechanically
shift transfer boxDamage or unsuitable adjustment of
the shifting mechanism.
Damage or serious wear of the inner
shifting parts, or looseness or
attainment of the shift toggle fork
assembly on the guide shaft.
Unsuitable adjustment of shift lever.Adjust or repair the shift lever mechanism.
Change the seriously wearied parts.
Change the loose or weary parts. Refer to the vehicle manual for correct
operation.
Add the specified oil of given volume.
Open the rear cover of transfer box to check
and changer the damaged parts.
Open the rear cover of the transfer box to
check whether the sliding parts can slide
freely along the axle, if not, dismantle it and
change the damaged parts. Incorrect operation.
Lubricant of inferior quality or
insufficient volume.
Adhesive bonding of shift toggle fork.
Adhesive bonding of the sliding joint
cover, locking sleeve or gear. Mechanic gearshift failure under the
movement of shifting handleBreak or damage of the shift rocker
arm or shift lever.
Damage of the guide plate of shifting
cam;Change the damaged element.
Open the rear cover of the transfer box to
check the damaged element and change
it. Electric gearshift troubleDamage or failure of electrically
controlled element, electric module,
speed sensor, electric motor, electric
clutch, or built-in wire harness.
Damage or worn of shifting cam,
joint cover, locking sleeve, toggle
fork or shift guide axle.Adhesive
bonding shiftRefer to the vehicle usage manual to
diagnose the failure element and change
it as requirement.
Dismantle the weary or damaged parts
and change it as requirement.
Dismantle and check the free movement
of sliding element, and change it as
requirement

TF-4Transfer Box
Troubleshooting
Common troubles CausesResolving approaches
Unsuitable tire pressure.
Noise, which is spread by the transfer
box instead of the clutch, engine or other
parts, occurs at each speed.Gear noise.
Damage or wear of chain gear or
chain.Open to check whether there is weary
element or damaged element (including
the odometer gear) and, if any, change
them
Noise occurs in the high-speed or low-
speed four-gear driving.Open to check whether there is wear or
damage, and if any, adjust the tire pressure
to suitable value.
Oil leakage in transfer box. Frame Break of transfer box.
Oil leakage of other element.
Ventilation pipe block
Over-added lubricant or lubricant of
unsuitable brand
Looseness of the bolts on sealing
face.
Sealing glue of different brand or
unused sealing glue.
Oil seal wear or damage.Change the frame.
Check the leakage by wiping dry.
Open and clean it and, if necessary,
change it.
Use the specified lubricant and adjust the
lubricant to suitable volume.
Propel the bolts tightly as requirement.
Use the specified sealing glue and propel
the bolts tightly as required.

TF-65D5D-Oil filling plug
5L-Oil drain plug5L2. Regular lubricant change
(a) The oil level of lubricant in transfer box shall be checked
when exchanging the engine lubricant or after the vehicle
covers 8000 kilometers, and the lubricant shall be added
as requirement.
(b) The lubricant shall be changed with the specified one
every year or after the vehicle covers 48000 kilometers.
3. Lubricant inspection approach
(a) Clean the oil filling plug and the around area.
(b) Open the oil-filling plug to check whether the lubricant
can flows out or not.
(c) if the lubricant can flow out, which means the real
lubricant volume is under the prescribed value, and the
specified lubricant shall be added into the transfer box
until the lubricant can flow from the oil filler hole.
(d) Propel the oil-filling plug tightly according to the given
Tightening moment.
Tightening moment
(19
30)N
m
Notice: The vehicle shall run for a certain time before
checking or exchanging the lubricant so that the
temperature of lubricant in transfer box may be a little
higher. Do not use hammer or other punching tools to
open or propel the oil drain plug or oil filling plug, otherwise,
the thread hole on the frame will be damaged
4. Lubricant change
(a) Clean the oil filling plug and oil drain plug and the around
area.
(b) Put down a oil container under the transfer box.
(c) Open the oil drain plug.
(d) Open the oil-filling plug.
(e) Drain the lubricant up.
(f) Mount the oil drain plug and screw it up according to the
given Tightening moment.
Tightening moment
(19
30)N
m
(g) Add the lubricant through the oil filler hole until the
lubricant overflows. Mount the oil-filling plug and tighten
it according to the Tightening moment.
Tightening moment : (19
30)N
m Transfer Box
lubricant grade: ATF--3Product Description and Simple Maintenance

TF-7Transfer Box
Disassembly and Mount of Transfer Box
Disassembly and Mount of Transfer Box
1. Transfer Box Disassembly
(a) Drive the vehicle on the lifting jack.
(b) Locate the gear of transfer box at the neutral
position, shift the transfer box to the 2H and
extinguish the engine.
(c) Disconnect the cell cathode.
(d) Lift the vehicle.
(e) Put down an oil disc under the transfer box, tear
down the oil drain plug and oil filling plug of the
transfer to drain all the lubricant up, then re-
mount the two plugs.
(f) Disconnect all wires and wire harnesses that
connected with the transfer box.
(g) Take apart the hose on the venting valve of
transfer shaft.
(h) Disconnect the linkage of the front drive shaft
with the front flange of the transfer box.
(i) Disconnect the linkage of the rear drive shaft
with the rear flange of the transfer box.
(j) Raise the transfer box up with the jack.Notice: The transfer box shall be guaranteed to
support by the lifting jack before tearing down
the sets of bolt and nut that connected with the
transfer box and gearbox. The transfer box is
not allowed to hang directly on the gearbox
through spline because such operation will
damage the transfer box parts.
(l) Tear down the connecting nuts between the
transfer box and gearbox and take down the
transfer box.
(m) Move the transfer box backward directly until
the linkage between the input shaft of transfer
box and the gearbox spline.
(n) Put down the lifting jack of the transfer box, and
(o) Tear down the gasket between the transfer box
and gearbox. Clean the gasket or glue on the
coupling face of front body of transfer box with
rear body of the gearbox. Take notice not to
damage the coupling face.
1234
5 6 7
8
9
1. input shaft
2. front frame of transfer box
3. rear cover of transfer box
4. flange
5. front output fork flange
6. venting valve
7. gasket
8. rear body of gearbox
9. bolt