Page 2 Therefore, before using any vehicle part following any maintenance procedure or working with a tool that has not been authorized by the Great Wall Motor Co., Ltd, check to make sure that none of the above will endanger the safety of the person performing the work or the correct operation of the vehicle.
Page 4: Table Of Contents
CONTENTS Chapter One: Overview ........................1 How to Use This Manual ....................2 Identifying Number Location ..................3 Comprehensive Repair Instructions ................4 General Repair Methods and Operations ..............9 Chapter Two: Overall Parameters ....................10 Basic Parameters of the Overall Vehicle ..............11 Engine Technical Parameters ..................12 Chassis’...
Page 5 Chapter Five: Transmission ......................42 037A Transmission’s Overall External Schematics ............43 Main Technical Parameters ..................43 Transmission’s Proper Use and Care ................44 Technical Specifications for Transmission Installation and Adjustment .....44 Areas of Importance ....................45 Troubleshooting ......................46 037A Transmission Structural Schematics ..............47 Clutch .........................48 Gear Shift Fork and Fork Shaft ..................49 Transmission Case ....................50 Disassembling the Input Shaft Subassembly ............56...
Page 6 Technical Requirements ..................141 Chapter Nine: Vehicle Body Electrical System .................142 Basic Information on the Electrical System .............143 Fuse Box ........................144 Overall Vehicle’s Grounding Point Schematics ............150 Key Electrical Component’s Module Schematics for the Overall Vehicle ....151 Wire Harness Distribution Chart for the Overall Vehicle ..........152 Wire Harness Relationship and Plug-in Connections Numbered Diagram ....155 Wire Harness Plug-in Connectors and Pin Function Diagram .........156 Electrical Wiring Diagram for the Overall Vehicle ............167...
Page 7 Airbag’s Diagnostic Methods Without a Diagnostic Scanner ........232 Chapter Thirteen: Vehicle Body ....................233 Front Door Lock Assembly ..................234 Rear Door Lock Assembly ..................237 Trunk Door Lock Assembly ..................239 Wiper Arm and Vent Panel Assembly ..............240 Front & Rear Window Glasses ................241 Dashboard .......................242 Cooling Unit ......................246 Front Door Assembly ....................248...
Page 8: Chapter One: Overview
Overview Overview How to Use This Manual ............ 2 Identifying Number Location ..........3 Comprehensive Repair Instructions ........4 General Repair Methods and Operations ......9...
Page 9: How To Use This Manual
GWFLORID Maintenance Manual How to Use This Manual 1. There is a content index on the first page of each chapter. You can consult the index to see the items needed for maintenance. In order to make searching more convenient, the subject of each chapter has been printed on the page header of each odd page.
Page 10: Identifying Number Location
Great Wall Motor Co., Ltd. Never use a part that has not been au- thorized by the Great Wall Motor Co., Ltd. Identifying Number Location Vehicle Identification Number (VIN)
Page 11: Comprehensive Repair Instructions
GWFLORID Maintenance Manual Comprehensive Repair Instructions 1. Use the splasher, backing, and carpet to keep the vehicle clean and to prevent damage. 2. While removing, mark all vehicle components or place all the components in proper order to make re- assembling more convenient.
Page 12 Overview 7. Pay attention to the "Areas of Importance" below to avoid damaging any part: Do not open the cover or case of the ECU (Electronic Control Unit) unless it's absolutely necessary. (Touching the pin of the IC (Integrated Circuit) may damage the IC due to static electricity.) When unplugging the vacuum hose, make sure to pull from the end of the hose but not the center.
Page 13 GWFLORID Maintenance Manual 2. Inspection procedures for related fuses or fuses in re- Inspection procedures for related fuses or fuses in re- Inspection procedures for related fuses or fuses in re- Same current rating lay boxes. Inspect the battery for damage, the battery's charging state, cleanness, and tightening with the connectors.
Page 14 Overview 5. Maintenance methods for wire harness connector ter- Maintenance methods for wire harness connector ter- for wire harness connector ter- minals. Use an airgun or rag to clean the contact points if the terminals become dusty. Do not use sandpaper to clean it, as that could damage the electroplated layer.
Page 15 GWFLORID Maintenance Manual Continued table Shape Removal / Installation Removal Installation Screwdriver Press Clip extractor Push out the king pin, remove it, and pry the kingpin bush. Removal Installation Press Screwdriver Clip extractor Screw off the king pin and pry the shell. Removal Installation Press...
Page 16: General Repair Methods And Operations
Overview General Repair Methods and Operations 1. If a jack is needed, please kindly comply to the safety procedures listed below. 2. Park the vehicle on a flat surface, stablize the front and the back wheels using any fixed object or tool, jack up the vehicle, support it with the chassis, and then start the maintenance.
Page 17: Chapter Two: Overall Parameters
GWFLORID Maintenance Manual Overall Parameters Basic Parameters of the Overall Vehicle ......11 Engine Technical Parameters ..........12 Chassis' Main Assembly Technical Parameters ....13 Vehicle Structure Type and Parameters ......15 Air Conditioning System Structure and Parameters ... 16 Electrical System Structure and Parameters ......
Page 18: Basic Parameters Of The Overall Vehicle
Overall Parameters Basic Parameters of the Overall Vehicle Item GW413EF GW4G15 YC4W75-31 Length 3907 Width 1694 Size Pa- Height 1521 rameters Wheelbase 2368 (no load) Tread: front/rear 1459/1430 (mm) Front suspension Rear suspension Load capacity (kg) 5 people × (68±7) kg/person Curb weight (kg) 1135 1120...
Page 19: Engine Technical Parameters
GWFLORID Maintenance Manual Outter acceleration noise dB (A) ≤74 ≤75 Ride 60 km/h constant velocity interior noise dB (A) ≤65 ≤65 Performance Driver operating noise dB (A) ≤90 ≤90 CO emission (g/km) ≤2.30 ≤1.00 ≤0.64 HC emission (g/km) ≤0.20 ≤0.10 Emission NOx emission (g/km) ≤0.15...
Page 20: Chassis' Main Assembly Technical Parameters
Overall Parameters Chassis' Main Assembly Technical Parameters Item Specifications Model number GW413EF GW4G15 YC4W75-31 Single chip, dry type, Single chip, dry type, diaphragm spring diaphragm spring Driven disc diameter: Clutch disc diameter: Driven disc diameter: Clutch type Clutch 200 mm 213 mm 212 mm Separating stroke:...
Page 21 GWFLORID Maintenance Manual Chassis' Main Assembly Technical Parameters (Continued) Item Specifications Wheel specifications Standard 15 × 6J rim, offset distance: 40 mm Wheel and Tire specifications Standard tire selection 185/65 R15 88H tire Spare tire Spare tire 185/65 R15 88H, T125/70R16 96M J16 × 4T specifications Rack and pinion hydraulic power steering gear, with drive ratio of 19.03, Steering gear...
Page 22: Vehicle Structure Type And Parameters
Overall Parameters Vehicle Structure Type and Parameters Item Structural parameters & performance descriptions Body type All-metal closed hard surface bearing body. Body in white Pressed and welded, all-metal enclosed structure. Framed door with four-door impact beam, hinged sliding open door, trunk door Door assembly opens upwards, front/rear doors are installed with auto window regulator.
Page 23: Air Conditioning System Structure And Parameters
GWFLORID Maintenance Manual Air Conditioning System Structure and Parameters Item Structure and parameters Structure type Vapor compression refrigeration, water warmer, and water heater Air conditioner refrigerating capacity is 5 kW. Blower's air volume is 450 m /h. Air Performance parameters conditioner heating capacity is 4.5 kW.
Page 24 Overall Parameters Electrical System Structure and Parameters (Continued) Item Structure and parameters Speedometer, tachometer, odometer, fuel gauge, LCD (electronic clock & Combination meter reserved automatic gear indication). Driver's seat belt unfastened warning lamp, charging indicator lamp, low oil pressure warning lamp, service engine light, ABS malfunction indicator lamp, EBD indicator lamp, EOBD indicator lamp, door unlock warning Dashboard lamp, SRS malfunction indicator lamp, high beam indicator lamp, left...
Page 25: Grade Specification And Filled Quantity Of Each Individual Functioning Component's Working Agent
GWFLORID Maintenance Manual Grade Specification and Filled Quantity of Each Individual Functioning Component's Working Agent Quantity Functioning Specifications component GW413EF GW4G15 #93 and above high quality unleaded gasoline (GW413EF, GW4G15 engine) Engine fuel #-10 light diesel fuel (YC4W75-31 engine) SJ 15W-40/SJ 10W-30 (For China domestic model) GW413EF SL 5W-30 (For alpine region model)
Page 26 Overall Parameters Tightening Fastening piece name Important fastening piece locations Quantity torque and model number (N·m) Right mount & vehicle body Hexagon bolt for flange face 64±5 1.04 Right mount & transmission Hexagon bolt for flange face 64±5 Right mount & transmission Hexagon bolt for flange face 64±5 1.05...
Page 27 GWFLORID Maintenance Manual Tightening Fastening piece name Important fastening piece locations Quantity torque and model number (N·m) 1.31 Propeller shaft assembly Front drive shaft nut (M22 × 1.5) 240±20 Hexagon bolt for flange face and flat 1.32 Subframe & vehicle body (rear) 116±10 washer subassembly Hexagon bolt for flange face and flat...
Page 28 Overall Parameters Tightening Fastening piece name Important fastening piece locations Quantity torque and model number (N·m) ABS sensor front wire harness & front Hexagon head bolt and flat washer 1.61 23±3 shock absorber subassembly Hexagon head bolt and flat washer 1.62 ABS &...
Page 29: Vehicle Body's Basic Calibration Measurements
GWFLORID Maintenance Manual Vehicle Body's Basic Calibration Measurements This section shows the basic parameters of the overall vehicle. Please refer to this section when servicing or repairing. • All figures used to express measurements are actual figures. • Measuring points are taken from the center of the mounting holes. •...
Page 30: Engine Compartment
Overall Parameters Engine Compartment Mark Axis (X, Y, Z) Diameter (mm) Mark Axis (X, Y, Z) Diameter (mm) (115.2, 0.4, 701.5) Ф10 (-461.2, -447.6, 627.7) Ф8 (56.5, -520.3, 698.8) Ф11 (-143.9, -645.9, 690.9) Ф8 (-506.2, -45.0, 679.1) Ф9 (-52.3, -681.0, 725.3) Ф10 (-606.8, -464.3, 290.6) Ф8.5...
Page 31 GWFLORID Maintenance Manual Chassis side Upper Lower Front Front Unit: mm...
Page 32 Overall Parameters Chassis (Continued) Axis Axis Ф side Ф Ф Ф Ф Ф Ф Ф Ф Ф Front Unit: mm...
Page 33 GWFLORID Maintenance Manual Subframe ± 1195 1.5 ( Distance between the center points of both shaft's end surfaces ) ± 1381 0.5 ( Distance between points P and Q ) Unit: mm...
Page 34 Overall Parameters Left side panel Mark Name Diameter (mm) Mark Name Diameter (mm) Front door lower hinge mounting via hole Φ13 Process cut Rear door upper hinge mounting via hole Φ15 Process cut Front door upper hinge mounting via hole Φ13 Process cut Front door contact switch via hole...
Page 35 GWFLORID Maintenance Manual Windshield Mark Name Diameter (mm) Mark Name Diameter (mm) Central defroster air duct mounting holes Φ11 Process cut Oblong hole 7×12 Central defroster air duct mounting holes Φ8 Process cut Oblong hole 7×12 Trunk door frame Mark Name Diameter (mm) Mark...
Page 36: Chapter Three: Fuel Supply And Exhaust System
Fuel Supply and Exhaust System Fuel Supply and Exhaust System Fuel Supply System............30 Components ..............30 Fuel Tank Removal ............31 Fuel Pump and Charcoal Canister Removal ....31 Fuel Filter Removal ............31 Fuel Filler Pipe Assembly Removal ........32 Exhaust System..............
Page 37: Fuel Supply System
GWFLORID Maintenance Manual Fuel Supply System Components Desorption hose III Single-hole clamp Fuel filler hose III Canister solenoid valve Canister solenoid valve installation sheath Canister solenoid valve mounting bracket assembly Desorption hose II Fuel hose sheath Fuel filler hose Desorption fuel hose Desorption hose I Three-hole Fuel filler hose II...
Page 38: Fuel Tank Removal
Fuel Supply and Exhaust System Fuel Tank Removal Fuel tank assembly Special note: When maintenance of the fuel supply system requires removal of the fuel line, the pressure Strengthening cushion of the fuel system should first be released, so as to avoid the spraying of high-pressure fuel.
Page 39: Fuel Filler Pipe Assembly Removal
GWFLORID Maintenance Manual Fuel Filler Pipe Assembly Removal Fuel filler cap 1. Remove the oil filler cap. 2. Screw off the fixed bolts connecting the fuel filler pipe assembly bracket and vehicle body. Fuel filler pipe sleeve Fuel filler pipe assembly 3.
Page 40: Exhaust System
Fuel Supply and Exhaust System Exhaust System Components Exhaust manifold Gasket I Exhaust pipe front joint Front heat shield Sealing Air intake and exhaust ring nut components Bolt Q1460612 Spring Hexagon flange nut Gasket II Rear three-way catalytic converter assembly Hexagon flange bolt Middle heat shield Q1460612...
Page 41: Exhaust System Removal
GWFLORID Maintenance Manual Exhaust System Removal Caution: Wait at least 30 minutes between the engine being turned off and the actual removal of any component of the exhaust system, as to avoid personnel injury due to hot components. 1. Main muffler assembly removal First use a No.
Page 42: Exhaust System Installation
Fuel Supply and Exhaust System 4. Front exhaust pipe removal Use a No. 14 wrench (open), sleeve, or ratchet wrench to remove the connecting nut between the front flange of the front exhaust pipe assembly and the flange of the exhaust manifold.
Page 43: Chapter Four: Clutch Operational System
GWFLORID Maintenance Manual Clutch Operational System Areas of Importance ............37 Troubleshooting ..............37 Clutch Operational System ..........38 Components ..............38 Clutch Master Cylinder Removal ........38 Clutch Master Cylinder Installation ........40 Clutch Pedal Removal ............40 Clutch Pedal Installation ........... 40 Clutch Pedal Examination and Adjustment.......
Page 44: Areas Of Importance
Clutch Operational System Areas of Importance 1. Clutch Rigid Pipe Installation Before installing, check to make sure that the rigid pipe flare contact area is in good condition, the pipeline is clean, and that there is no foreign materials. 2. Clutch Hose Installation Check the surface of the clutch hose to make sure that there is no scuffing and that the pipeline is clean.
Page 45: Clutch Operational System
GWFLORID Maintenance Manual Clutch Operational System Components Reservoir Clutch discharge pipe Clutch feed connecting hose Steel band elastic hoop Limit adjusting bolt Clutch master cylinder Return spring Lock nut Clutch Master Cylinder Removal Steel band elastic hoop 1. Use a combination plier to loosen the steel band elastic hoop, and to remove the clutch feed connecting hose.
Page 46 Clutch Operational System 2. Remove the driven clutch discharge pipe with a M10 open-end wrench. Clutch discharge pipe 3. Remove the pedal lock pin. Pedal lock pin 4. Remove the return spring and the connecting pin. Connecting pin Return spring 5.
Page 47: Clutch Master Cylinder Installation
GWFLORID Maintenance Manual Clutch Master Cylinder Installation Bleed screw Installation of clutch system is reverse to its removal, but since the whole clutch system uses hydraulic assistance, make sure to air bleed it after the installation is completed. Detailed steps as follows: Plug one end of the long transparent connection hose (about 0.5 m long) into the bottom of bleed screw, and the other end into a fixed container.
Page 48: Clutch Pedal Examination And Adjustment
Clutch Operational System Clutch Pedal Examination and Adjustment 1. Check if the pedal height is correct. Height from the carpet: 100-110 mm Pedal height 2. Adjust the pedal height. Loosen the lock nut and adjust the clutch pedal limit adjust- ing bolt until its height is correct, and then tighten the lock Limit adjusting bolt nut.
Page 49: Chapter Five: Transmission
GWFLORID Maintenance Manual Transmission 037A Transmission’s Overall External Schematics .... 43 Main Technical Parameters ..........43 Transmission's Proper Use and Care ......... 44 Technical Specifications for Transmission Installation and Adjustment ..............44 Areas of Importance ............45 Troubleshooting ..............46 037A Transmission Structural Schematics ......
Page 50: 037A Transmission's Overall External Schematics
Transmission 037A Transmission’s Overall External Schematics The 037A transmission is a step mechanical transmission with differential, two-shaft front wheel drive application. The forward gear has adopted the inertia synchronizer gear-shifting mechanism, which offers smooth and easy gear shifting, reduces noise dramatically, and improves the service life of the gear - important in achieving the overall economical efficiency.
Page 51: Transmission's Proper Use And Care
GL-4 75W-90 (For alpine region model) GL-5 140 (For high-temperature region model) Caution: Please only use the lubricant with model numbers specified by the Great Wall Motor Co., Ltd. Do not mix lubricants with different model numbers. Only fill with clean lubricant.
Page 52: Areas Of Importance
Transmission Thread fastening piece tightening torque table Tighten- Use parts Bolt code Specifications Quantity ing torque (N·m) Differential case × differential ring gear 037-2303309 M12 × 1.0 123.6 Clutch housing × reverse gear arm 037-1702073 M8 × 1.25 17.2 bracket subassembly No.
Page 53: Troubleshooting
GWFLORID Maintenance Manual Troubleshooting Common problems Possible causes Solving methods Not applying clutch Use correct driving methods Difficult gear engagement Insufficient clutch separation Inspection & adjustment Serious abrasion of the synchronizer ring Replace component Positioning spring is too hard Replace component Oil level is too low Fill oil to the specified level Noise is too loud or...
Page 54: 037A Transmission Structural Schematics
Transmission 037A Transmission Structural Schematics 1. No. 2 gear sleeve 2. Shaft retainer 3. No. 2 Slider (3) 4. Spring expansion ring (2) 5. No. 2 gear hub 6. 3rd gear synchronizer ring 7. 3rd gear gear assembly 8. Needle bearing 9. With washer bolt 10. Clutch slave cylinder subassembly 11. Release fork protective cover 12.
Page 55: Clutch
GWFLORID Maintenance Manual Clutch Components Release bearing Cable bracket Release fork Bolts with washer ×5 11.3 Cable bracket Release fork support nail 29.4 Bolts with washer 11.3 Release fork dust cover Differential assembly Magnetic body Clutch housing Guide nozzle Tapered roller bearings T oil seal Output shaft assembly...
Page 56: Gear Shift Fork And Fork Shaft
Transmission Gear Shift Fork and Fork Shaft Components Clutch housing No. 1 gear shift fork shaft Shaft retainers 15.7 Set bolt Elastic cylindrical pin No. 1 gear shift fork Shaft retainers Elastic cylindrical pin Lock pin No. 1 guide block Pressure spring No.
Page 57: Transmission Case
GWFLORID Maintenance Manual Transmission Case Components Bolt for flange face 12.0 Clip Clip Clip Reverse gear Shift lever assembly switch subassembly Pressure torsion spring Washer Oil drain slot Tapered roller bearings Bush Adjusting shim Transmission case Adjusting shim Position mechanism assembly 39.2 36.8...
Page 58 Transmission Shift System Removal 1. Remove 4 bolts for flange face from the manipulation lid. 2. Remove the set bolts from the sides of the transmis- sion case. 3. Separate the clutch housing and the transmission case. Remove 8 bolts for flange face from the transmission case and clutch housing.
Page 59 GWFLORID Maintenance Manual 5. Remove the reverse gear arm bracket assembly. 6. Remove the No. 1 gear shift fork shaft and the set bolts. 7. Remove the elastic cylindrical pin from the No. 1 guide block. 8. Remove the No. 1 gear shift fork, No. 1 gear shift fork shaft, and No.
Page 60 Transmission 9. Remove the elastic cylindrical pin from the No. 3 gear shift fork. 10. Remove the elastic cylindrical pin from the No. 3 guide block. 11. Remove the No. 3 gear shift fork, compression spring, and No. 3 guide block. 12.
Page 61 GWFLORID Maintenance Manual 13. Remove the No. 2 gear shift fork shaft, No. 2 gear shift fork, and No. 2 guide block. 14. Remove the input and output shaft subassembly. 15. Remove the differential subassembly. 16. Remove the magnetic body from the inside of the clutch housing.
Page 62 Transmission 17. Remove the oil drain slot from the inside of the transmis- sion case. 18. Remove the T oil seal with a screwdriver from the clutch housing. 19. Remove the release fork and the release bearing from the clutch housing. 20.
Page 63: Disassembling The Input Shaft Subassembly
GWFLORID Maintenance Manual Disassembling the Input Shaft Subassembly Components Needle bearing 4th gear subassembly 4th gear synchronizer ring Rear ball bearing Retaining ring Spring expansion Shaft retainer ring Spring expansion ring No. 3 Slider No. 3 gear sleeve/ No. 3 gear hub No.
Page 64 Transmission 2. Remove each component from the 3rd synchronizer. 3. Remove the 5th gear needle bearing. 4. Remove the retaining ring. 5. Remove the shaft retainer.
Page 65 GWFLORID Maintenance Manual 6. Remove the input shaft's 5th gear thrust washer. 7. Remove the steel balls from the 5th gear thrust washer of the input shaft. 8. Remove the 4th gear subassembly, 4th gear needle bearing, 4th gear synchronizer ring, and the 4th gear bearing washer (4 types of part).
Page 66 Transmission 10. Remove each component of the input shaft's No.2 syn- chronizer. 11. Remove the input shaft's 3rd gear synchronizer ring and the 3rd gear subassembly. 12. Remove the needle bearing from the 3rd gear of input shaft.
Page 67: Disassembling The Output Shaft Subassembly
GWFLORID Maintenance Manual Disassembling the Output Shaft Subassembly Components Rear tapered roller bearing 1st gear synchronizer ring Shaft retainer 5th driven gear 1st gear gear subassembly 4th driven gear Needle bearing Spacer 3rd driven gear Retaining ring Shaft retainer Needle bearing Output shaft 2nd gear gear subassembly 2nd gear synchronizer ring...
Page 68 Transmission 2. Remove the output shaft's 5th driven gear shaft retainer. 3. Remove together the output shaft's 5th and 4th gear driven gear. 4. Remove the output shaft spacer. 5. Remove the output shaft's 3rd driven gear and the 2nd gear subassembly spacer.
Page 69 GWFLORID Maintenance Manual 6. Remove the output shaft's 2nd gear synchronizer ring, 2nd gear needle bearing, and the 2nd gear subassem- bly retaining ring. 7. Remove the shaft retainer from the No. 1 synchronizer gear hub of the output shaft. 8.
Page 70 Transmission 10. Remove each component of output shaft's No. 1 syn- chronizer. 11. Remove the front tapered roller bearing.
Page 71: Disassembling The Shift Cover Subassembly
GWFLORID Maintenance Manual Disassembling the Shift Cover Subassembly Components Gear shifting block Shift lever assembly Dust cover T oil seal 38.0 Set bolt No. 2 spring seat Pressure spring Manipulation lid Shaft retainer T oil seal Select lever subassembly Shift guide block Gasket Lock plate Shaft retainer...
Page 72 Transmission 2. Remove the shaft retainer on the shift lever and the se- lect lever. 3. Remove the lock plate. 4. Remove the pressure torsion spring. 5. Remove the No. 2 spring seat.
Page 73 GWFLORID Maintenance Manual 6. Remove the set bolts and the select lever assembly. 7. Remove the select lever subassembly. 8. Remove the shaft retainer on the shift shaft and the se- lect lever. Caution: Use a cord to fasten the shift lever in order to Cord make the operation convenient.
Page 74 Transmission 10. Remove the shaft retainer from the shift shaft. 11. Remove the shift shaft T oil seal from the manipulation lid. 12. Remove the T oil seal from the manipulation lid.
Page 75: Disassembling The Differential Subassembly
GWFLORID Maintenance Manual Disassembling the Differential Subassembly Components T oil seal Clutch housing Tapered roller bearings Differential case Elastic cylindrical pin Odometer drive gear Gasket Planetary gear Differential ring gear Adjusting shim Axle shaft gear Axle shaft gear Planetary gear shaft Bolt for flange face Adjusting shim 123.6...
Page 76 Transmission 1. Remove the tapered roller bearings of the left differen- tial. 2. Remove the odometer drive gear from the differential. 3. Remove the tapered roller bearings of the right differen- tial. 4. Remove the bolts for flange face of the differential ring gear and the differential case.
Page 77 GWFLORID Maintenance Manual 5. After removing bolts for flange face from the differential ring gear and the differential case, gently pound to re- move the differential ring gear with a soft hammer. 6. Remove the elastic cylindrical pins from the differential case and the gear shaft.
Page 78: Chapter Six: Suspension System
Suspension System Suspension System Suspension System Technical Parameters ......72 Front Suspension ............... 73 Subframe and Front Stabilizer Bar ........77 Lower Swing Arm..............80 Drive Shaft ................84 Rear Suspension ..............86 Wheel and Tire ..............89...
Page 79: Suspension System Technical Parameters
GWFLORID Maintenance Manual Suspension System Technical Parameters Main technical parameters Front suspension type McPherson independent suspension Coil spring, hydraulic telescopic shock absorber, stabilizer bar, lower swing Front suspension components Suspension type and composition Rear suspension type Compound trailing arm semi-independent suspension Rear suspension components Coil spring, hydraulic cylinder damper, &...
Page 80: Front Suspension
Suspension System Front Suspension Components Press plate on the front shock absorber column Front shock absorber with coil spring assembly Front stabilizer bar mounting bracket Front stabilizer bar bushing Front stabilizer bar hanger rod subassembly Lower swing arm assembly RH Front stabilizer bar Subframe assembly Lower swing arm...
Page 81 GWFLORID Maintenance Manual 3. Remove the wheel speed sensor and the brake hose Remove the wheel speed sensor's mounting bolts with a M10 sleeve to take off the wheel speed sensor. Remove the front brake hose's mounting bolts with a M18 sleeve, and then take off the brake hose.
Page 82 Suspension System Front shock absorber with coil spring assembly (Image) Front bumper Press plate on the front shock absorber column Dust cover on the front shock absorber Hexagon flange nut Erection support under the front shock absorber Front shock absorber assembly Erection support under the front coil spring Dust cover...
Page 83 GWFLORID Maintenance Manual All of the fastening pieces must be tightened to the required torque, and comply to the standard gluing re- quirements in this chapter. Front shock absorber with coil spring assem- bly disassembly and installation 1. Compression spring Use SST to grasp the spring, separated by adhesive tape at the contact area.
Page 84: Subframe And Front Stabilizer Bar
Suspension System Subframe and Front Stabilizer Bar Components Stabilizer bar bracket Front stabilizer bar Stabilizer bar bushing Lower swing arm RH Subframe Subframe strut bar Lower swing arm LH Subframe removal and installation 1. Remove the engine's rear suspension bolts, coupling bolts between steering propeller shaft and column, and the steering fuel hose.
Page 85 GWFLORID Maintenance Manual Remark: When removing the subframe's front mounting bolt, an extension bar should be inserted through the lower swing Insert extension bar arm's hole. Positions shown on the left. through this hole 5. Subframe installation. Installation follows the reverse removal steps. Caution: Fix the position of the subframe with the position pin, to avoid influencing the four wheels' positioning.
Page 86 Suspension System The sliding side of the hanger rod should face upward, Correct Incorrect so as to make the operation more convenient.
Page 87: Lower Swing Arm
GWFLORID Maintenance Manual Lower Swing Arm Components Lower swing arm Q1401495 Subframe Q1401280 Swing arm removal and installation 1. First, remove the steering knuckle, subframe, and stabilizer bar hanger rod. For detailed steps, please refer to the removal of the steering knuckle, subframe, and stabilizer bar.
Page 88 Suspension System 4. Remove the lower swing arm. Swing the lower swing arm up and down, and pull it out at the same time. Force F shown as in the picture. Pull the front Rear mount point of the swing arm from the subframe, and then take down the lower swing arm.
Page 89 GWFLORID Maintenance Manual On the press, press out the lower swing arm's large shaft sleeve with SST (Special Service Tools), and re- place it with a new one. Check that the mounting holes of the lower swing arm's large shaft sleeve are Φ55 , measure for inaccurate di- -0.2 -0.3...
Page 90 Suspension System On the press, use SST (Special Service Tools) to press the new lower swing arm's small shaft sleeve into the correct position.
Page 91: Drive Shaft
GWFLORID Maintenance Manual Drive Shaft Components Front shock absorber with coil spring assembly LH Front drive shaft nut LH Front drive shaft assembly LH Transmission assembly Wheel assembly Drive shaft removal 1. First use a M32 sleeve, ratchet wrench, and extension bar, to remove front drive shaft nut LH.
Page 92 Suspension System Drive shaft installation 1. Insert the drive shaft. First, align the inner end of the drive shaft and differential spline. Keep the drive shaft axes and the differential axes bases uniform, then hammer towards the direction of the differential drive shaft's outer end until a clear and sharp clicking sound is heard.
Page 93: Rear Suspension
GWFLORID Maintenance Manual Rear Suspension Components Upper mounting rubber cushion for the rear coil spring Rear shock absorber subassembly Rear coil spring Lower mounting rubber cushion for the rear coil spring Hexagon bolt for flange face Rear twist beam assembly Hexagon nut for flange face Large washer Rear shock absorber and...
Page 94 Suspension System 4. Remove the rear shock absorber. Screw down the hexagon nut for flange face Q32012T13F2 Rear shock absorber (M12×1.25) FD linking the rear shock absorber and rear twist beam, and remove the rear shock absorber. Make sure the rear twist beam is firmly supported meanwhile. Tightening torque: 44 54 N·m Hexagon nut for...
Page 95 GWFLORID Maintenance Manual Use SST (Special Service Tools) to clog the shaft sleeve's installation tube. Tighten the two adjusting bolts, use a wrench to twist the middle long bolt, and push out the shaft sleeve. 3. Install the new trailing arm spindle sleeve assembly. Before installing the new trailing arm spindle sleeve assembly, first to distinguish the installation direction for the trailing arm spindle sleeve's nylon bushing as-...
Page 96: Wheel And Tire
Suspension System Wheel and Tire Tire Remark This vehicle's tire is of the tubeless type. The optimal design condition is met when the inflation pressure is at the recommended value, and the tire is under full load. Maintaining suitable tire pressure and proper driving habits greatly influence the tire's use life.
Page 97 GWFLORID Maintenance Manual Tire's abnormal wear and tear Tire's abnormal wear and tear includes uneven and excessive wear of the tire. There are many causes for this. For example, improper tire pressure, tire rotation has not been timely maintained, bad driving habits, abnormal front wheel location, etc.
Page 98 Suspension System Tire rotation For equal wear or tear for the tires, please rotate the tire positions timely. Swapping principle shown on the left. Radial tires should be regularly switched, and add pressure according to the regulations. Front Rear Caution: Due to structural reasons, radial tires usually quickly receive most of its wear on the shoulders, especially the front tires.
Page 99 GWFLORID Maintenance Manual Tire installation and removal • Install or remove tires with a tire changer. When operating machinery, make sure to comply to the machine manufacturers operation manual. Please do not change tires merely with manual hand tools or tire installation crowbars.
Page 100 Suspension System Dynamic balance and static balance There are two types of wheel balance: static and dynamic. Picture 1 shows static balance. Picture 2 shows dynamic balance. Static balance means that the weight distribution around the wheel is equal. If the wheel is static and unbalanced, violent vibrations may be created, called jump vibration.This kind of situation can ultimately lead to the uneven wear and tear of the tires.
Page 101: Chapter Seven: Brake System
GWFLORID Maintenance Manual Brake System Brake System Components Arrangement Schematics..95 Brake System Maintenance..........96 Brake Pedal ................ 98 Parking Brake Control Mechanism Assembly....102 Vacuum Booster with Brake Cylinder Assembly ....103 Anti-lock Brake System ............ 107 ABS General Problem Maintenance and Areas of Importance ............
Page 102: Brake System Components Arrangement Schematics
Brake System Brake System Components Arrangement Schematics Right steering knuckle and hub brake assembly Left steering knuckle and hub brake assembly ABS controller assembly Vacuum booster with brake cylinder assembly Front wheel speed sensor assembly RH Front wheel speed sensor assembly LH Brake pedal assembly Brake line assembly Parking brake control mechanism assembly...
Page 103: Brake System Maintenance
GWFLORID Maintenance Manual Brake System Maintenance Brake fluid inspection and replacement Brake fluid directly influences the brake performance and the operating conditions and use life of the brake system components. Brake fluid has very strong hygroscopic properties, and thus absorbs water easily, which will then deteriorate the metal and rubber pieces.
Page 104 Brake System (e) Make sure not to let the system valves block the air bleeding. (f) When the brake fluid that flows out of the hose or connector has no bubbles, it means that the air in the system has been exhausted. There is still air inside the system if the hose inserted into the brake fluid is still bubbling when pressing down the pedal.
Page 105: Brake Pedal
GWFLORID Maintenance Manual Brake Pedal Components Bushing Brake pedal lever welding assembly Brake pedal bracket welding assembly Limiting stopper Center pin Pedal pad Pedal shaft Cotter pin Return spring Areas of Importance 1. During removal, all components should be gently handled to avoid knocking, especially the junction surface.
Page 106 Brake System Disassembly of the brake pedal assembly Lock nut 1. Remove the lock nut with an outer hexagonal wrench. 2. Remove the pedal shaft. Caution: Please do not place the pedal shaft directly on the ground, as to guarantee its cleanness. Pedal shaft 3.
Page 107 GWFLORID Maintenance Manual 2. Install the pedal pad and limiting stopper to the pedal lever. Pedal pad Limiting stopper 3. Apply lubricant on the inner bushing and the outer pedal shaft. Install the pedal lever assembly, pedal shaft, and brake pedal bracket welding assembly. 4.
Page 108 Brake System 3. Inspect the pedal free play. When the engine is off, step on the brake pedal two to three times, after the brake booster's influence is removed, push the brake pedal by hand until resistance is felt, then measure its movement (free play).
Page 109: Parking Brake Control Mechanism Assembly
GWFLORID Maintenance Manual Parking Brake Control Mechanism Assembly Components Parking brake control mechanism assembly Q1460825 Right parking brake cable assembly Q1420612 Left parking brake cable assembly Q32006 Q1420616 Q1420612 Parking brake lever removal and installation Button 1. Removal Control jacket control lever Remove the auxiliary facia console, and pull the park- ing brake lever to the lowest position.
Page 110: Vacuum Booster With Brake Cylinder Assembly
Brake System Vacuum Booster with Brake Cylinder Assembly Components Oil cup cover Oil cup body Vacuum booster Check valve Check valve seat Fluid supply sealing ring Lock nut Coupling nut Rod clevis Cylinder body Rectangular sealing ring Areas of Importance 1.
Page 111 GWFLORID Maintenance Manual Removal of the vacuum booster Push rod: Stepping onto the pedal in order to pass the force with brake cylinder assembly 1. Discharge the vacuum. If there is vacuum inside of the booster, before removal, step on the brake pedal 3-5 times, so as to discharge the vacuum. 2.
Page 112 Brake System 6. Screw off the coupling bolt between the vacuum booster and the pedal bracket with a M13 sleeve. Bolt 7. Extract the vacuum booster with brake cylinder assem- bly. Removal of the vacuum booster with brake cylinder assembly is now complete.
Page 113 GWFLORID Maintenance Manual 4. Remove the dust cover. If necessary to replace the dust cover, replace it using the Dust cover following steps. Twist off the rod clevis. Screw off the nut. Pull out the split ring. Pull out the dust cover. Removal of the vacuum booster with brake cylinder Rod clevis assembly is now complete.
Page 114: Anti-Lock Brake System
Brake System Anti-lock Brake System ABS/EBD introduction 1. Operation The vehicle's Anti-lock Brake System (ABS) is a type of increasingly popular brake safety device. It detects the wheel's speed using wheel speed sensor detection. After signal processing, the wheel speed will be transferred to the computer, which controls the solenoid valve’s operating condition and the pressure inside the brake wheel cylinder to avoid wheel locking by using certain calculations and control methods based on the wheel speed.
Page 115 GWFLORID Maintenance Manual Vehicle speed Wheel slippage Wheel speed Master cylinder pressure Wheel cylinder brake pressure 4. EBD working process The EBD comes into effect when the wheel brakes are lightly applied. The wheel speed sensor detects the speed of the wheels, and the ECU calculates the speed. If the rear wheel's slip ratio increases, adjust the brake pressure to maintain or reduce the rear wheel's braking force.
Page 116: Abs General Problem Maintenance And Areas Of Importance
Brake System 3. Installing the ABS rear wheel speed sensor with brack- et assembly. Rear wheel speed sensor Use three hexagon head bolts, spring washers, and flat with bracket assembly washer subassembly connecting pieces to connect the sensor Hexagon head bolt, to the rear hub unit, rear twist beam, and vehicle body.
Page 117 GWFLORID Maintenance Manual The X431 scanner possesses a waveform function. Wheel speed signal error (wheel speed sensor failure) only appears when intermittent problems occure, such as high speed. When in use, some signal errors may occasionally appear. Continue observing the waveform to make sure there is nothing abnormal.When driving the vehicle on a flat and straight road, all four wheels' speed sensor waveform are extremely similar.
Page 118 Brake System should also be removed from the ECU. Do not let oil contaminate the ECU. Be especially careful of the ECU terminals, otherwise it might obstruct the connection among terminals of the wire harness plug. Note: The BOSCH ABS8.0 hydraulic pressure unit (integrated into the ECU) is not serviceable. If damaged, the whole unit must be replaced.
Page 119: Steering Knuckle And Hub Brake Assembly
GWFLORID Maintenance Manual Steering Knuckle and Hub Brake Assembly Components Front brake caliper assembly LH Copper washer Front brake disc Hollow bolt Wheel bolt ♦Heavy duty spring washer 100 ± 10 9 ± 2 Front hub flange ♦Hexagon head bolt and spring washer subassembly Left brake disc cover ♦Front hub...
Page 120 Brake System 5. Remove the front brake caliper. Unscrew the fastened front brake caliper's bolt to remove the brake caliper. Caution: Remove the front brake caliper and use wire or similar objects to firmly secure the brake caliper. (Avoid excessive twisting, bending, or pulling off the brake pipeline).
Page 121 GWFLORID Maintenance Manual Measure the front hub bearing's starting torque. Put the SST on the wheel bolts which are at the symmetric locations. Put a dial torque wrench on the SST to slowly rotate the flange assembly (45°/4s), requiring a starting torque range of 0.1-0.3 N·m.
Page 122 Brake System 4. Replace the removed bearing's inner ring back to the bearing's original position. 5. Press out the front hub bearing from inside of the steer- ing knuckle. On the press, withstand the bearing inner ring that was put on with SST, and press out the entire front hub bearing.
Page 123 GWFLORID Maintenance Manual 3. Examine the front hub flange plate surface runout. Examining methods are the same as the methods used during disassembly. Plate surface runout should not exceed 0.03 mm. 4. Examine the front hub bearing assembly's starting torque. Examining methods are the same as the methods used during disassembly.
Page 124 Brake System 9. Examine the front brake disc plate surface runout. When measuring, tighten the two wheel nut's symmetrical locations. The front brake disc's brake linings runout on the two sides should be less than 0.11 mm. 10. Install the brake caliper assembly. Install the brake caliper on the steering knuckle, and tighten the bolt according to the set torque.
Page 125: Front Brake Caliper
GWFLORID Maintenance Manual Front Brake Caliper Components 30 ± 5 Q1840820 Caliper Rectangular sealing ring Air bleed screw Inner brake pad assembly 10 ± 2 Outer brake pad assembly Bleed screw cap Piston Piston dust cover Guide pin dust cover Brake block yoke Inner muffler plate subassembly spring plate...
Page 126 Brake System 3. Remove the caliper assembly. Remove the hexagon bolt for flange face connecting the caliper and caliper frame's lower end. Lift the caliper assembly and use a rope to hang it up to protect the brake pipeline. Remark: Do not unscrew the brake pipeline and bleed screw. 4.
Page 127 GWFLORID Maintenance Manual 8. Install a new inner and outer brake pad assembly and inner and outer muffler plate subassembly. Outer brake disc Inner shim B Outer shim B Install inner shim A and B onto the inner brake disc. Warning device Install outer shim A and B onto the outer brake disc.
Page 128 Brake System 2. Remove the caliper assembly. Remove the two hexagon bolts for flange face connecting the caliper and caliper frame. Remove the caliper assembly from the caliper frame. 3. Remove the following parts. The group of inner and outer shims B. The group of inner and outer shims A.
Page 129 GWFLORID Maintenance Manual Front brake caliper assembly installation 1. Preparations Make sure all parts are clean and free of foreign materials before installation.When installing, apply an appropriate amount of rubber grease to the guide pin and piston's working surface, as well as the rectangular sealing ring and the piston protective cover's working surface.
Page 130 Brake System 7. Install the caliper assembly. Install the caliper assembly. Install and tighten the hexagon bolt for flange face. Tightening torque: 30±5 N·m 8. Connect the brake line. Connect the brake pipeline to the caliper. Tightening torque: 40±4 N·m 9.
Page 131: Rear Brake
GWFLORID Maintenance Manual Rear Brake Components Dust cover Bleed screw Piston Wheel cylinder Bleed screw cap Ring cup Piston spring Rubber plug of the adjuster's observation port Ring cup Adjusting clearance shaft head Piston Rubber plug of the Adjusting clearance wheel observation port gap Dust cover Washer...
Page 132 Brake System Method two: Find two M6×40 (the thread is longer than 25 mm) phillip screws, and screw them into the rear brake drum's two threaded holes. M6×40 Use a screwdriver to tighten the phillip screw, and push out the rear brake drum. Caution: Alternately tighten the two screws.
Page 133: And Maintenance
GWFLORID Maintenance Manual 6. Remove the return spring and ratchet adjuster assem- bly. Remove the adjusting clearance shaft head. Remove the adjusting clearance wheel. Remove the return spring. 7. Remove the parking brake lever. Remove the split ring with pliers. Remove the brake lever rotating shaft.
Page 134 Brake System 3. Measure friction plate thickness. Standard thickness: 4.0 mm Minimum thickness: 1.0 mm If the friction plate thickness is smaller than the minimum value or produces uneven wear and tear, the brake leading and trailing shoe assemblies should be replaced. Remark: If one of the brake shoe assembly needs to be replaced, be sure to replace all the rear brake leading and trailing shoe assemblies to ensure even braking ability.
Page 135 GWFLORID Maintenance Manual Rear Brake Installation Caution: Refer to the diagram for installation directions. Foreward Foreward Left wheel Right wheel 1. Install the brake wheel cylinder. Apply a small amount of lithium grease onto two piston assemblies. Install the wheel cylinder assembly. •...
Page 136 Brake System Apply a small amount of lithium grease on the brake leading shoe assembly and brake trailing shoe assembly (refer to the arrows in the diagram for indicated areas). Remark: Do not contaminate the friction plate. Insert the return spring into the adjusting clearance screw rod and apply an appropriate amount of lithium grease on the adjusting clearance wheel's thread and screw, adjusting clearance screw rod's shaft head,...
Page 137 GWFLORID Maintenance Manual 7. Install the brake cable connector on the brake trailing shoe with brake lever assembly. Install the brake cable connector on the brake trailing shoe with brake lever assembly. Insert the brake trailing shoe with brake lever assembly and the shoe end of the brake leading shoe assembly into the wheel cylinder assembly.
Page 138: Rear Support Axle
Brake System Rear Support Axle Components Left parking brake cable assembly 9±1 Right parking brake Spring cable assembly Rear brake drum Trailing arm spindle sleeve with nylon bushing assembly Rear hub unit 9±1 Rear brake assembly LH Spring 78-98 Rear twist beam assembly Rear brake assembly RH Rear hub unit Rear brake drum...
Page 139 GWFLORID Maintenance Manual 4. Measure the rear brake drum's outer end surface runout. Stick a dial indicator magnet to the rear wheel hub's mounting bracket. Point the dial indicator to the rear brake drum's outer end surface diameter at about a Φ136 mm circumference (refer to diagrams dotted line area).
Page 140 Brake System 2. Remove the trailing arm spindle sleeve. Mark with a white paint pen, and remember the direction of the trailing arm spindle sleeve assembly . The trailing arm spindle sleeve is a disposable part. If it is damaged, first use a pry bar to lift up the edge of the trailing arm spindle sleeve's outer tube in order to install SST.
Page 141: Chapter Eight: Steering System
GWFLORID Maintenance Manual Steering System Troubleshooting ..............135 Steering System Maintenance..........137 Power Steering Fluid Instructions ........141 Technical Requirements ............. 141...
Page 142: Troubleshooting
Steering System Troubleshooting Fault Malfunction Causes Troubleshooting Symptoms 1. Too much clearance between the steering 1. Have the clearance adjusted by professionals, gear and gear rack. and if it cannot be adjusted, replace the steer- ing gear. 2. The inner and outer ball stud of the steering 2.
Page 143 GWFLORID Maintenance Manual Fault Malfunction Causes Troubleshooting Symptoms 1. Tire pressure insufficient. 1. Inflate according to the specified pressure. 2. Wheel counterweight falls off or other fac- 2. Recalibrate the wheel's dynamic balance. tors cause extremely poor wheel balance. 3. Lower swing arm's rubber bushing is too old, 3.
Page 144: Steering System Maintenance
Steering System Steering System Maintenance Structure Introduction The steering wheel has an airbag module which should only be inspected and repaired by a professional. The steering column's upper section adopts a steel deformation and energy absorbing crumple structure which ensures collision protection for the driver. The lower section uses a high precision sliding spline structure, which can effectively eliminate structural interference caused by body deformation.
Page 145 GWFLORID Maintenance Manual 2. Remove the steering wheel. Q32012 (M12×1.25) Remove the lock nut Q32012 (M12×1.25) of steering wheel with a M18 socket wrench in the counterclock- wise direction. Grip the entire steering wheel and shake it several times, and then to pull out the steering wheel upwards. 3.
Page 146 Steering System 7. Manually rotate the two plastic buckles 3412012-S08 in the counterclockwise direction, and remove the steer- ing dust cover installed on the steering propeller shaft. 3412012-S08 8. Remove the bolt 3404202-S08 connecting the steering propeller shaft and steering drive connection shaft with a M13 socket wrench, and then pull out the propeller shaft.
Page 147 GWFLORID Maintenance Manual 4. Screw off the two bolts Q1840816 of the steering Q1840816 gear protection plates installed on the subframe with a M10 socket wrench, and remove the steering gear protection plate. 5. First fasten four hexagon nuts 2904013-S08 with a 3411013-S08 M18 socket wrench, then screw off the four hexagon 3411014-S08...
Page 148: Power Steering Fluid Instructions
Install the steering wheel in the center. The steering wheel's radial should be in the middle, and the Great Wall logo should be in the direct sight of the driver, then tighten nuts. Tightening torque: 50±5 N·m 4.
Page 149: Chapter Nine: Vehicle Body Electrical System
GWFLORID Maintenance Manual Vehicle Body Electrical System Basic Information on the Electrical System ......143 Fuse Box ................144 Overall Vehicle’s Grounding Point Schematics ....150 Key Electrical Component’s Module Schematics for the Overall Vehicle.............. 151 Wire Harness Distribution Chart for the Overall Vehicle ..152 Wire Harness Relationship and Plug-in Connections Numbered Diagram ............
Page 150: Basic Information On The Electrical System
Vehicle Body Electronic System Basic Information on the Electrical System Electrical system schematics reading instructions 1. Configuration introduction The GWFLORID comes in three configurations: comfort, luxury and elite. The wire harness has two types of configurations: One is a non jam protection comfort model, which is a combination of both comfort and luxury type, the other type is called elite.
Page 151: Fuse Box
GWFLORID Maintenance Manual Double-colored wire: Primary color is Red, secondary color is Blue, marked as RBl. 0.5BrGr means Brown wire with a Gray fine wire, and sectional area is 0.5 mm Areas of importance in circuit maintenance 1. Before operating any electronic devices, and when tools or maintenance devices may easily make contact with an uncovered electronic terminal, please make sure to turn the ignition switch to the LOCK position, and then disconnect the battery's negative cable to avoid injury or vehicle damage.
Page 152 Vehicle Body Electronic System Fuse number and bearer circuit Fuse number Current rating Fuse type Power Bearer circuit Reserve 25 A Sunroof (Elite) Parking lamp relay, front fog lamp 10 A switch, rear fog lamp switch 30 Battery (+) 15 A Reserve 15 A Hazard warning lamp...
Page 153 GWFLORID Maintenance Manual Engine compartment No.2 fuse box Main relay Compressor relay Horn relay 10A backup 15A backup 25A backup Fan relay Low Fuel pump Horn Reserve Reserve Fan relay Low Fan relay High Reserve Main High Starter relay Engine ECU relay beam beam...
Page 154 Vehicle Body Electronic System Cab No.1 fuse box back side pin diagram Connected dashboard's Connected dashboard's wire harness A wire harness B Eilte Connected dashboard's Connected dashboard's wire harness C wire harness D (Elite) Connected dashboard's Connected dashboard's wire harness E wire harness H...
Page 155 GWFLORID Maintenance Manual Plug-in connector pin's function Pin number Function Pin number Function Rear fog lamp Empty Internal lighting Empty Empty Empty Combination switch Empty (front fog lamp) Combination meter Empty Front fog lamp Empty Empty Empty Empty Empty Central lock controller Empty Combination switch Empty...
Page 156 Vehicle Body Electronic System Plug-in connector pin's function (Continued) Pin number Function Pin number Function Combination switch Ignition switch (AM1) (right turn) Combination switch Combination switch (left turn) (parking lamp) Parking lamp, meter Right turn signal lamp brightness Ground Sunroof (Elite) Hazard warning switch Empty Empty...
Page 157: Overall Vehicle's Grounding Point Schematics
GWFLORID Maintenance Manual Overall Vehicle’s Grounding Point Schematics...
Page 158: Key Electrical Component's Module Schematics For The Overall Vehicle
Vehicle Body Electronic System Meaning of each number representation: Number Grounding position Remark Inside the engine compartment's G01, G02 Engine compartment's wire harness left side fender Inside the engine compartment's Engine compartment's wire harness right side fender Wire harness fixture un- G04, G05 Engine &...
Page 159: Wire Harness Distribution Chart For The Overall Vehicle
GWFLORID Maintenance Manual Key Electrical Component’s Module Schematics for the Overall Vehicle (Continued) Positive fuse box ABS ECU No. 2 fuse box Reverse sensor Wire Harness Distribution Chart for the Overall Vehicle Engine compartment wire harness Starter, starter excitation, knock sensor Injector Brake fluid level switch Speed sensor...
Page 160 Vehicle Body Electronic System Dashboard wire harness Air conditioner speed adjuster, AC switch, rear defroster switch Theft deterrent indicator lamp Combination meter Air conditioner CD/DVD Front Passenger side Central lock controller temperature sensor airbag assembly Acceleration pedal Diagnostic port Blower Glove box lighting Airbag ECU assembly 2 Power rearview mirror switch, light...
Page 161 GWFLORID Maintenance Manual Front & rear door wire harnesses High tone speaker Outer power rearview mirror Window regulator motor Door lock motor Window regulator switch Window regulator motor Door lock Door and window Middle & low Middle & low motor main switches tone speaker tone speaker...
Page 162: Wire Harness Relationship And Plug-In Connections Numbered Diagram
Vehicle Body Electronic System Connected 4th cylinder injection nozzle Connected 3rd cylinder injection nozzle Connected 2nd Connected glove box lamp cylinder injection nozzle Connected 1st cylinder injection nozzle Connected ABS ECU Front door lock motor LH Front tweeter LH Front medium woofer LH Rear medium woofer LH Left outer electric mirror...
Page 163: Wire Harness Plug-In Connectors And Pin Function Diagram
GWFLORID Maintenance Manual Wire Harness Plug-in Connectors and Pin Function Diagram Connector 1 Connected engine Connected engine compartment wire harness wire harness Connected cab fuse box Connected engine compartment wire harness (Luxury) (Luxury) (Elite) (Elite) (Comfort) (Comfort) Connected cab fuse box A-20 Connectied dashboard wire harness...
Page 164 Vehicle Body Electronic System Connector 2 (Comfort) (Comfort) (Elite) (Elite) (Luxury) (Luxury) Connected cab fuse box B-18 Connected dashboard wire harness (Comfort) / (Luxury) (Comfort) / (Luxury) (Elite) (Elite) Connected cab fuse box C-14 Connected dashboard wire harness (Comfort) / (Luxury) (Comfort) / (Luxury)
Page 165 GWFLORID Maintenance Manual Connector 3 (Elite) (Elite) Connected cab fuse box D-16 Connected dashboard wire harness (Comfort) / (Luxury) (Comfort) / (Luxury) (Elite) (Elite) Connected cab fuse box E-8 Connected dashboard wire harness Connected cab fuse box H-1 Connected dashboard wire harness...
Page 166 Vehicle Body Electronic System Connector 4 (Elite) (Elite) (Comfort) (Comfort) (Luxury) (Luxury) Connected dashboard Connected engine wire harness A compartment wire harness A (Luxury) (Luxury) (Comfort) (Comfort)
Page 167 GWFLORID Maintenance Manual Connector 5 (Elite) (Elite) Connected dashboard Connected engine compartment wire harness B wire harness B Connected dashboard Connected engine wire wire harness A harness A (white) Connected dashboard Connected engine wire harness B wire harness B (Elite) (Elite)
Page 168 Vehicle Body Electronic System Connector 6 (Comfort) / (Luxury) (Comfort) / (Luxury) Connected meter Connected front left door wire harness A wire harness A (white) (Elite) (Elite) (Luxury) (Luxury) (Comfort) (Comfort) Connected meter Connected front left wire harness B door wire harness B (Elite) (Elite)
Page 169 GWFLORID Maintenance Manual Connector 7 (Comfort)/(Luxury) (Comfort)/(Luxury) Connected dashboard Connected vehicle body wire harness A wire harness A (Elite) (Elite) (Luxury) (Luxury) (Comfort) (Comfort) Connected dashboard Connected vehicle wire harness B body wire harness B Connected vehicle Connected engine body wire harness compartment wire harness...
Page 170 Vehicle Body Electronic System Connector 8 (Elite) (Elite) (Comfort) / (Luxury) (Comfort) / (Luxury) Connected meter Connected front right wire harness A door wire harness A (Elite) (Elite) (Luxury) (Luxury) (Comfort) (Comfort) Connected meter Connected front right wire harness B door wire harness B...
Page 171 GWFLORID Maintenance Manual Connector 9 (Elite) (Elite) (Comfort) / (Luxury) (Comfort) / (Luxury) Connected vehicle Connected rear left body wire harness door wire harness (Elite) (Elite)
Page 172 Vehicle Body Electronic System Connector 10 (Comfort) / (Luxury) (Comfort) / (Luxury) Connected vehicle Connected rear right body wire harness door wire harness Connected vehicle body Connected trunk wire harness A wire harness A Connected vehicle body Connected trunk wire harness B wire harness B...
Page 173 GWFLORID Maintenance Manual Connector 11 Connected trunk wire harness 2 Connected trunk wire harness 1 Connected rear defroster "+" Connected rear defroster "-"...
Page 174: Electrical Wiring Diagram For The Overall Vehicle
Vehicle Body Electronic System Electrical Wiring Diagram for the Overall Vehicle Power & start-up system Connected ABS #1 Theft deterrent ECU 6 Main relay position Shift position Engine ECU 74 pin Generator regulator Ignition switch...
Page 175 GWFLORID Maintenance Manual Airbag & ABS Engine ECU 72 Central control ECU #17 Theft deterrent controller A7 Airbag electric control module ABS electric control module Driver seat belt Front passenger seat pretensioner belt pretensioner Front wheel Front wheel Rear wheel Rear wheel speed Driver side airbag Front passenger side airbag...
Page 176 Vehicle Body Electronic System Combination meter system Connected engine ECU #8 Connected engine ECU #59 To light brightness Connected central regulator switch control ECU #18 Connected coolant temperature sensor LCD display IC module Odometer Low fuel alarm Fuel gauge Tachometer Connected combination meter A Connected combination meter B Brake fluid level warning switch...
Page 177 GWFLORID Maintenance Manual Blower high speed relay Rear defroster indicator Blower regulate module Blower relay To flasher relay Right outer rearview mirror defroster Left outer rearview mirror defroster Rear window defroster Defroster relay Rear defroster indicator Defroster switch Front passenger seat belt switch Front passenger seat belt unfastened indicator lamp Air conditioner panel lighting Blower relay...
Page 178 Vehicle Body Electronic System spiral coil Shift switch Mirror adjustment switch Foldable motor Fold switch...
Page 179 GWFLORID Maintenance Manual To meter brightness switch Rear wiper motor Rear wiper relay Rear washer motor Front washer motor Front wiper motor Front wiper switch Rear wiper switch...
Page 180 Vehicle Body Electronic System Engine Inlet temperature pressure sensor Connected combination meter Spark plug Ignition coil Injection nozzle Scanner Coolant temperature sensor Electric control module Rediator fan motor Engine speed sensor Rear oxygen sensor Front oxygen sensor Inlet pressure & tem. sensor Coolant temperature sensor Accelerator pedal module Electronic throttle...
Page 181 GWFLORID Maintenance Manual Central door locking, window regulator system Jam protection window regulator control system Non jam protection window regulator control system Connected combination meter Connected combination meter Connected combination meter Connected high beam relay Connected airbag ECU Front window regulator mainly control switch LH Front window regulator mainly switch LH Terminal Rise...
Page 182 Vehicle Body Electronic System Light, signal alarm system Steering & alarm lamp control system Electric horn Lighting system Interior lighting system Connected combination meter A18 Connected central control ECU #8 Connected central control ECU #1 Connected central control ECU #2 Connected central control ECU #14 position...
Page 183 GWFLORID Maintenance Manual Auxiliary system To diagnostic port To ECU 29# To ECU 71# Ignition switch IG1 Buzzer Theft deterrent controller Reverse sensor controller Theft deterrent coil Connected theft deterrent ECU Connected theft deterrent indicator Connected reverse sensor controller Connected reverse sensor buzzer Detector No.
Page 184: Chapter Ten: Electrical Accessories
Electrical Accessories Electrical Accessories Reverse Sensor ..............178 Combination Meter ............180 Central Door Lock............. 181 Power Windows ..............184 Immobilizer System ............186 CD Player ................. 193 DVD Player ............... 195...
Page 185: Reverse Sensor
GWFLORID Maintenance Manual Reverse Sensor Reverse sensor operation (ultrasonic wave distance-measurement) Sound is a kind of wave. Sound frequency that can be heard by human beings range from 20 Hz 20 KHz. Those that exceed 20 KHz are called ultrasonic waves. Since an ultrasonic wave is also a kind of sound, its velocity in the air also equals the sound velocity of 340 m/s.
Page 186 Electrical Accessories Functional description and display program 1. This system will be activated within the first second after engaging the reverse gear. There will be two beeps indicating the system is working properly. 2. After the self-check, it will start its normal detection mode. The relationship between the obstacle distance and the alarm frequency is as follows: A Zone B Zone...
Page 187: Combination Meter
GWFLORID Maintenance Manual Combination Meter If something is wrong with the meter, check the relevant component and circuit according to the connector defi- nition. If the failure still cannot be eliminated, check whether the instrument itself has malfunctioned in the fur- ther steps.
Page 188: Central Door Lock
Electrical Accessories Central Door Lock 1. Lock After closing the door (when unlocked), press the LOCK button once on the remote controller, the car lamp flashs once, and all five doors will be locked. 2. Unlock When locked, press the UNLOCK button once on the remote controller, the car lamp will flash twice, and all four front doors will be unlocked.
Page 189 GWFLORID Maintenance Manual VA-882 remote controller central door lock's connection wire definition Controller plug front view Controller socket front view The door lamp signal and side window signal uses a triode transistor emitter open-drain output. The door lamp signal and side window signal uses a triode transistor emitter open-drain output. Power supply positive pole Headlight switch Headlight (+) test...
Page 190 Electrical Accessories 6. Central door lock locking output Connected to the locking wire of the central door lock actuator, this wire will output 12 V when locking. 7. Key insert diagnostic Connected to the detecting wire of the lock head, the electric potential of this wire will lower when a key being inserted into the lock is detected.
Page 191: Power Windows
GWFLORID Maintenance Manual Power Windows The GWFLORID electric power window actuator consist of a motor and module. Its functions include: jam protection, centralized control rise, soft-stop, characterized by easy control, long life, etc. The functions of electric power window actuator 1.
Page 192 Electrical Accessories cut off. Before sending out any new input instructions, the software will first detect whether the adhesive contact point of the relay has been released. If it has been released, then all the operations, including the sleep pattern, will once again be executable. If the contact point is still adhered, then only operations going in one direction have the possibility of execution (depending on which direction the relay contact is adhered).
Page 193: Immobilizer System
GWFLORID Maintenance Manual Immobilizer System Immobilizer system composition This vehicle's engine immobilizer system consists of a theft deterrent ECU assembly, a theft deterrent coil as- sembly, and two theft deterrent converter assemblies. The theft deterrent coil assembly is put on the head of ignition lock cylinder, with the other end connected to the theft deterrent ECU assembly.
Page 194 Electrical Accessories 5. Immobilizer system wire connection diagram Battery Ignition switch Battery Ground 620 Ω W wire Engine ECU R wire ANTA ANTB K wire Diagnostic Coil scanner 6. Theft deterrent controller's connecting plug The theft deterrent controller has two connecting plugs: an 8-core A plug and a 3-core B plug. Theft deterrent controller Coil 3-core B plug pin definition 8-core A plug...
Page 195 GWFLORID Maintenance Manual not necessarily mean that engine start failure is due to a immobilizer system malfunction. The reasons for start- ing engine failures are numerous, including factors like fuel, gas, fire, electricity, wires, etc. If the engine cannot start, first check if the immobilizer system is working normally. This can be judged by looking at the flashing theft deterrent indicator lamp which is located on the dashboard in front of the driver seat: Insert the key into the lock cylinder and turn it to the "ON"...
Page 196 Electrical Accessories Trouble Code Failure cause Troubleshooting methods code significance B3040 W wire failure, There is no response from First check whether the two failures B043 and B0422 communication the electrojet controller after coexist. If so, first solve these two problems. the theft deterrent controller Check whether the 8-core plug of the theft deterrent sends out communication...
Page 197 GWFLORID Maintenance Manual Trouble Code Failure cause Troubleshooting methods code significance B3048 The LED has The wire harness (A3 Check whether the theft deterrent controller's 8-core plug a short circuit pin) connecting to the wire harness is touching each other. or open circuit immobilizer indicator Check whether the wire harness which connects the 8-core...
Page 198 Electrical Accessories 4. Security system component replacement When a failure appears in one of the immobilizer system components, this component must be replaced. After the replacement, perform matching on the immobilizer system again. Only changing the coil There is no need to match the immobilizer system again. Only changing the key (theft deterrent transponder assembly) Get the vehicle's PIN code from the code located inside the burglar-proof classified envelope Connect the scanner with the vehicle's diagnostic connection...
Page 199 GWFLORID Maintenance Manual Input the PIN code and the key matching instructions with the scanner If the PIN code is correct, after receiving the key matching instructions, transponder learning will be complete Switch off the ignition switch 2. Check the key quantity: Check the alarm's currently matched key quantity and matchable key quantity with the scanner.
Page 200: Cd Player
Electrical Accessories CD Player CD player outside view ISO pin definition Function Linear control ground Rear horn RH (+) (Violet) cable Rear horn RH (- ) (Violet/Black Mute (Pink) striped) Linear control Front horn RH (+) (Grey) Connected ignition Front horn RH (-) (Grey/Black striped) switch (Red) Automatic antenna Front horn LH (+) (White)
Page 201 GWFLORID Maintenance Manual Causes Solutions Symptoms Speaker's connection wire touches the Check the speaker's connection wire vehicle body "MUTE" wire touches the metal parts Ensure the telephone silence control wire is The sound quality is poor or of the vehicle body insulated from the vehicle body distorted A connection error between the...
Page 202: Dvd Player
Electrical Accessories DVD Player Head unit outside view Head unit ISO interface definition Pin definition Power supply ground cable Headlight diagnostic Ignition diagnostic Mute diagnostic Power supply + Radio antenna power supply control Key-drive Key-drive ground cable 15 A fuse 15 A fuse Pin definition Pin definition...
Page 203 GWFLORID Maintenance Manual Pin definition Pin definition Brake diagnostic Rearview mirror power supply Rearview mirror power supply ground Reverse diagnostic cable Disc changer video input (reserve) Rearview mirror video input Video ground cable Video ground cable Head unit 36 PIN socket definition Pin definition Pin definition Pin definition...
Page 204 Electrical Accessories Common faults and solutions If the following faults occur while using this machine, please refer to the troubleshooting guide. General problems Symptoms Causes Solutions Replace with a new fuse of the same Burnt fuse specification Cannot start Vehicle supply battery fuse is burnt Replace the vehicle supply battery fuse Illegal operation and other factors Press the reset button to reset the system...
Page 205 GWFLORID Maintenance Manual TFT display screen common faults and solutions Symptoms Causes Solutions No image is shown on the Parking control wire "PRK SW" is not Please refer to the "Equipment connection display screen, only a warning properly connected drawing" to correct the connection image The DVD output image format does not Change the screen format to automatic...
Page 206 Electrical Accessories Symptoms Causes Solutions The player is compatible with the copy system, so if the disc is copy protected, it Image is blurred and distorted The disc is copy protected may not be able to play, and is not a problem with the player PBC function has no effect The disc contains no PBC function...
Page 207 GWFLORID Maintenance Manual Equipment connection drawing Rear view mirror power supply ground wire AUX IN VIDEO Rear view mirror power supply ground wire CAMERA—B+ Rear view mirror power supply ground wire CAMERA—GND Rear view mirror audio input CAMERA—VIDEO Power amplifier control P.CONT Brake diagnosis...
Page 208 Electrical Accessories Control wire connection areas of importance 1. This player is used on vehicles with a 12 V battery and negative ground. If this player is to be installed on a vehicle with a 24 V battery, please install voltage reduction equipment. 2.
Page 209: Chapter Eleven: Air Conditioning System
GWFLORID Maintenance Manual Air Conditioning System Areas of Importance ............203 Technical Parameters ............203 Troubleshooting ..............204 Air Conditioning System's Structure Diagram and Fundamentals ..............207 Air Conditioning System Overview ........207 Air Conditioning System Terminal Definition ....... 208 Compressor ................
Page 210: Areas Of Importance
Air Conditioning System Areas of Importance 1. When putting in a new compressor, adjust the new compressor's inner lubricant to make it the same level as of the old compressor's. 2. When the air conditioner malfunctions, if the pipeline, condenser or evaporator is the source of the damage leading to its replacement, just add model number RS20 professional lubricant 5 10 ml.
Page 211: Troubleshooting
GWFLORID Maintenance Manual Troubleshooting Failure Symptoms Cause analysis Air con- Compressor Blown fuse, compressor relay damaged ditioning does not work Pressure switch contact broken, short circuited, or open circuit system fails Compressor electromagnetic clutch open circuit to produce Switch burnt out cold air Main relay burnt out Clutch slips...
Page 212 Air Conditioning System Troubleshooting (Continued) Failure Symptoms Cause analysis Insufficient Wind vol- Compressor operates normally cooling ume normal (3) High pressure side pressure is too low (a) Low pressure pipeline damaged (b) Low pressure pipeline blocked (4) Low pressure side pressure is too low (a) Evaporator frost (b) Expansion valve is blocked (c) Low pressure pipeline not clear...
Page 213 GWFLORID Maintenance Manual Troubleshooting (Continued) Failure Symptoms Cause analysis Heating sys- No or insuffi- Air conditioner blower malfunction cient heating Blower relay damaged Hot air duct blockage Cooling water pipe blockage Temperature change throttle actuator damaged Coolant insufficient Blower does Fuse blown or ill switch contact not work Blower motor burnt out...
Page 214: Air Conditioning System's Structure Diagram And Fundamentals
Air Conditioning System Air Conditioning System's Structure Diagram and Fundamentals Expansion valve Condenser Pipeline Accumulating dehydrator Air conditioner Compressor Condenser fan Air Conditioning System Overview Basic composition Composed of air conditioner, compressor assembly, condenser assembly, pipeline, defroster system, heating & ventilation system, etc.
Page 215: Air Conditioning System Terminal Definition
GWFLORID Maintenance Manual Air Conditioning System Terminal Definition Air conditioner switch Hazard warning switch + rear defroster switch Blower + night lighting + safety instruction Interface signal Interface signal Emergency lamp relay Parking lamp drive + Safety indicator Power supply (+) lamp drive + Ground Blower LO gear drive +...
Page 216 Air Conditioning System Compressor Removal 1. Hoist the vehicle with a jack. 2. Remove the bottom mudguard. 3. Remove the compressor. Compressor Installation Before installing, manually rotate the compressor several circles, allowing each component in the relative motion to be covered with lubricant.
Page 217: Electromagnetic Clutch
GWFLORID Maintenance Manual Electromagnetic Clutch Clutch composition Electromagnetic clutch consists of an armature, a solenoid, and a pulley. Areas of importance during clutch usage Because the joint of the electromagnetic clutch operates under high speeds, separation-joint marks on the pulley and armature are completely normal, and do not harm clutch usage.
Page 218: Vacuuming And Charging Refrigerant
Air Conditioning System Clutch Installation 1. Install the solenoid coil at the place pressing up against the head cover's end surface and pay atten- tion to insert the dowel pin of the solenoid coil into the bottom hole of the head cover. Put the retaining ring into the groove with circlip pliers, and press the solenoid coil's connecting wire onto the pressing line plate on the head cover with a SST.
Page 219: Filling Quantity And Method For Refrigerant Oil
GWFLORID Maintenance Manual the refrigerant into the refrigeration system in the gas form), and open the manifold pressure gauge's low pressure valve. 5. When charging the refrigerant, carefully observe the high pressure side of the manifold pressure gauge as High pressure well as the refrigerant's rate of flow (limpid, foamy, hazy) side pressure (MPa)
Page 220: Chapter Twelve: Airbags
Airbags Airbags Airbag Electronic Control Unit .......... 214 Diagnostic Scanner ............215 Troubleshooting ..............216 Vehicle Collision Diagnostics ..........226 Removal Method for Individual Components....227 Driver Side Airbag Module (DAB), Front Passenger Side Airbag Module (PAB), Clock Spring, and Steering Wheel ..228 Airbag Module Disposal............
Page 221: Airbag Electronic Control Unit
GWFLORID Maintenance Manual Airbag Electronic Control Unit Driver side airbag assembly Front passenger side airbag assembly Diagnostic interface position Airbag ECU assembly 2 Driver side electronic pretensioner Front passenger side electronic pretensioner Areas of Importance 1. While performing maintenance on the SRS airbag, make sure to work in accordance with this chapter's steps and notes.
Page 222: Diagnostic Scanner
Airbags Airbag electronic control interface and interface-pin definition Name Description DRV A/B + Driver side airbag assembly, high end DRV A/B - Driver side airbag assembly, low end PSG A/B + Front passenger side airbag assembly, high end PSG A/B - Front passenger side airbag assembly, low end PSG PRETENSIONER - Front passenger seat belt pretensioner, low end...
Page 223: Troubleshooting
GWFLORID Maintenance Manual Troubleshooting Basic processes of the malfunction diagnostic There are two SRS-ECU malfunctions types classified by time: current malfunction and history malfunction. The malfunction types categorized by property are: external malfunction and internal malfunction. Current malfunction trouble codes and history malfunction trouble codes may exist at the same time. External malfunction trouble codes can be eliminated with a diagnostic instrument, but the internal malfunction trouble codes cannot be cleared unless the SRS-ECU is changed.
Page 224 Airbags Malfunction judgment 1. Malfunction record (trouble code storage) After the ECU performs the diagnostic test cycle in order to verify a malfunction, the SRS-ECU will store the relevant code, the initial detection time, the final detection time, and the number of times it occurred in the EEPROM.
Page 225 GWFLORID Maintenance Manual detection but also during the diagnostic detection cycle. However, if a short circuit on the power supply causes a malfunction, and the low-end transistor is opened while malfunctioned, the low-end transistor can only be detected when starting up detection, as to avoid faulty execution. Ignition voltage is provided by a pressure increase converter.
Page 226 Airbags Malfunction diagnosis and troubleshooting 1. Warning lamp is not on or always on Troubleshooting list Explanation Airbag system warning lamp not lit Airbag system warns of circuit malfunction Airbag system warns of circuit Airbag system warning lamp is always on malfunction or external malfunction 2.
Page 227 GWFLORID Maintenance Manual 3. Airbag system warning lamp is always on Airbag system warning lamp is always on Inspection Airbag system warning lamp is always on status Possible • Battery power supply is insufficient causes • ECU internal malfunction • Combination meter airbag warning lamp malfunction •...
Page 228 Airbags Steps Inspection Operation Check and make sure the malfunction symptom does not After the malfunction appear again after they are repaired is removed, explain the • Set the ignition switch to the LOCK position maintenance procedure • Disconnect the battery's negative cable and maintain for at to the client least 1 min •...
Page 229 GWFLORID Maintenance Manual Steps Inspection Operation Inspect the wire harness between the fuse box and SRS airbag system unit connectors Warning If not handled properly, the airbag module and stretch tension type seat belt may open or tense up, causing serious operator Yes Go to the next step injury.
Page 230 Airbags Diagnostic procedures Steps Inspection Operation Inspect the clock spring Warning If not handled properly, the airbag module may deploy Normal Go to the next step and cause serious operator injury. Therefore, before maintenance, please read the maintenance warnings carefully. Replace the clock spring See also airbag system maintenance warning See also airbag system and clock...
Page 231 GWFLORID Maintenance Manual Steps Inspection Operation Inspect the clock spring Normal Go to the next step Take the clock spring off See also airbag system and clock spring removal/ Replace the clock spring installation See also airbag system and clock Abnormal Inspect the clock spring spring removal/installation...
Page 232 Airbags Diagnostic procedures Steps Inspection Operation Is the vehicle equipped with a front passenger side Go to the next step airbag module? Line fault, inspect the wire harness Check the front passenger side airbag module connec- [Current trouble code] tor warning Go to the next step •...
Page 233: Vehicle Collision Diagnostics
GWFLORID Maintenance Manual Vehicle Collision Diagnostics Whether the airbag is deployed or not, vehicle collision diagnostic and maintenance must be conducted according to the following procedures. 1. Check the SRS-ECU diagnostic signal Connect the diagnostic connector (X-431 diagnostic scanner). Read the diagnostic result with the X-431 diagnostic. Caution: Due to impact, and when the battery's power supply is insufficient, the scanner will be unable to communicate with the SRS-ECU.
Page 234: Removal Method For Individual Components
Airbags Removal Method for Individual Components SRS airbag system electronic control component (SRS-ECU) 1. Areas of Importance After taking off the battery's negative (-) terminal, wait for 60 s before operating. Wrap the removed negative (-) terminal in tape to insulate it. The SRS-ECU can not be dismantled or repaired.
Page 235: Driver Side Airbag Module (Dab), Front Passenger Side Airbag Module (Pab), Clock Spring, And Steering Wheel
GWFLORID Maintenance Manual Driver Side Airbag Module (DAB), Front Passenger Side Air- bag Module (PAB), Clock Spring, and Steering Wheel Areas of Importance 1. Take off the battery's negative (-) terminal, and wait for 60 s before operating. Wrap the removed negative (-) terminal in tape to insulate it.
Page 236 Airbags 3. Driver side airbag module installation sequence (after steering wheel installation is completed) Install the horn's wire harness. Install the airbag module executing equipment's (gas generator) wire harness. Place the airbag module onto the steering wheel's proper installation position (avoid heavy knocking while placing).
Page 237: Airbag Module Disposal
GWFLORID Maintenance Manual Whether there are broken connectors or protective pipes and deformed terminals. Whether the housing is damaged. Inspect whether the clock spring's upper connector terminal and lower corresponding connector terminal is conducting. Clock spring central involution Screw in the clock spring clockwise all the way, and then turn it 3.5 circles in the reverse direction, until the position pin's block boss matches the block hole (as shown on the left).
Page 238 Airbags 4. Deploy the wire harness after removing the No. 2 Wire harness used connector of the clock spring. for deployment Prepare two wire harnesses longer than 6 m for deployment, Short circuit area and connect one of their ends together (to short circuit). Caution: When deploying the airbag, make sure to maintain a distance of at least 6 m away from objects or people, and perform the deployment on a flat sur-...
Page 239: Airbag's Diagnostic Methods Without A Diagnostic Scanner
GWFLORID Maintenance Manual Airbag’s Diagnostic Methods Without a Diagnostic Scanner Airbag indicator lamp warning Check the airbag ECU connectors for looseness, check for warnings after correct installation. Disconnect the driver side airbag line and Inspect whether the clock spring is replace it with a 2 Ω...
Page 240: Chapter Thirteen: Vehicle Body
Vehicle Body Vehicle Body Front Door Lock Assembly ..........234 Rear Door Lock Assembly ..........237 Trunk Door Lock Assembly ..........239 Wiper Arm and Vent Panel Assembly ....... 240 Front & Rear Window Glasses ......... 241 Dashboard ................ 242 Cooling Unit ..............
Page 241: Front Door Lock Assembly
GWFLORID Maintenance Manual Front Door Lock Assembly Components Inside handle assembly Front door locking cable installing buckle Front door unlock cable Front door lock cable Front door outside handle framework Gasket Front door lock assembly LH Front door outside handle Lock mounting screw Front door tie rod assembly Lock cylinder decorative cap...
Page 242 Vehicle Body 4. Separate installation for the front door lock assembly. Separately install the front door lock, lock cable, unlock cable, cable installing buckle, and side door inside handle assembly. On the left is the schematic diagram after installa- tion. 5.
Page 243 GWFLORID Maintenance Manual 10. Install the door lock latch. Door lock latch Q2580820 + Q141F32 11. Front door lock removal. For the removal, please simply reverse the installation steps. Caution: The front door tie rod can be removed following the outside handle framework. The front door tie rod can be removed after the removal of the outside handle framework.
Page 244: Rear Door Lock Assembly
Vehicle Body Rear Door Lock Assembly Components Rear door inside handle assembly LH Rear door outside handle Rear door outside handle gasket Rear door outside handle framework LH Rear door handle decorative cap Rear door lock cable installing buckle Rear door outside handle gasket 2 Lock mounting screw Rear door lock assembly LH...
Page 245 GWFLORID Maintenance Manual 5. Install the rear door lock assembly. Install the assembled assembly, tighten the lock mounting screws (pay attention to put the outwardly open swing arm lever clip of the lock onto the outer opened fork of the out- side handle framework), and then insert the wire harness plug-in into the door lock socket.
Page 246: Trunk Door Lock Assembly
Vehicle Body Trunk Door Lock Assembly Components Trunk door lock assembly Q2580820 + Q141F32 Trunk door lock latch Q1460620 (Q402) F3 Connect the door lamp indicator Q1840616F3 Connect the central door lock controller Trunk door outside handle assembly Trunk door lock installation and removal 1.
Page 247: Wiper Arm And Vent Panel Assembly
GWFLORID Maintenance Manual Wiper Arm and Vent Panel Assembly Components Right vent panel Left wiper arm Right wiper arm Screw Wiper arm bolt cover Wiper arm bolt Left vent panel Engine hood rear weatherstrip Screw Wiper arm and vent panel removal and in- stallation Wiper arm bolt cover 1.
Page 248: Front & Rear Window Glasses
Vehicle Body Front & Rear Window Glasses Windshield trim strip Windshield removal Inner rearview 1. Use steel wire to strip the glass sealant from the four mirror sides of the windshield. 2. Remove the windshield and trim strip from the vehicle. 3.
Page 249: Dashboard
GWFLORID Maintenance Manual Dashboard Components Air-conditioner air outlet tray assembly Air-conditioner air outlet wind-ball assembly Side air outlet decorative cap Combination meter hood assembly Dashboard top assembly Dashboard lower framework assembly Glove box assembly Air-conditioner center right air outlet Air-conditioner left air tray assembly outlet tray assembly Small glove...
Page 250 Vehicle Body 3. Remove the dashboard center console left & right side trim strip assembly. Right trim strip Left trim strip 4. Remove the glove box assembly. Glove box assembly 5. Remove the combination switch cover assembly. Remove the three screws. Pry the upper and lower cover off, and remove the up- per and lower cover of the combination switch.
Page 251 GWFLORID Maintenance Manual 11. Remove the dashboard top assembly. Dashboard top assembly Remove the four screws. Remove the dashboard top assembly. Screw 12. Remove the air conditioner controller (refer to air con- ditioner controller removal for details). Screw 13. Remove the small glove box assembly. Remove the four screws.
Page 252 Vehicle Body 18. Remove the dashboard bottom and brace reinforce- ment assembly. Remove the engine hood handle assembly (refer to engine hood handle removal for details). Remove the ten bolts. Pull the electrical connector out, and remove the dash- board bottom and brace reinforcement assembly. Bolt 19.
Page 253: Cooling Unit
GWFLORID Maintenance Manual Cooling Unit Components Radiator inlet connecting pipe Radiator upper mount Radiator filler assembly Radiator assembly Overflow pipe Attachment clip Radiator inlet pipe Electronic fan with overflow tank assembly Radiator lower mount Mounting bolt Attachment clip Radiator outlet pipe Radiator removal Radiator upper cross member...
Page 254 Vehicle Body 8. Remove the radiator and electronic fan with overflow Mounting bolt tank assembly. Use a No. 10 wrench to remove the three mounting bolts of Mounting bolt the electronic fan with overflow tank assembly. Radiator examination 1. Check for impurities between the radiator pipes. 2.
Page 255: Front Door Assembly
GWFLORID Maintenance Manual Front Door Assembly Components Front door window LH Front door glass run LH Front door window rear guide rail assembly LH Front door window front guide rail assembly LH Left external rearview Front door mirror assembly weatherstrip LH Front door triangular protector LH Front door upper...
Page 256 Vehicle Body 2. Remove the front door external weatherstrip. Front door glass run LH Front door Lower the window and manually grasp the weatherstrip window LH Front door firmly, then pull it up to remove. window front Front door external 3.
Page 257 GWFLORID Maintenance Manual 4. Install the window regulator. Window regulator Install the regulator via the auxiliary hole. assembly Install the six mounting bolts of the regulator. 5. Install the guide rail and bolts on the front door window guide rail assembly. Front door assembly LH 6.
Page 258: Rear Door Assembly
Vehicle Body Rear Door Assembly Components Rear door glass run LH Rear door weatherstrip LH Rear door window LH Rear door outside triangu- lar protector assembly LH Rear door inner triangular protector assembly LH Rear door external weatherstrip LH Rear door window rear guide rail LH Rear door outside handle assembly LH...
Page 259 GWFLORID Maintenance Manual 2. Remove the rear door external weatherstrip. Rear door glass run LH Rear door window LH Lower the window and manually grasp the weatherstrip Rear door window rear firmly, then pull it up to remove. guide rail LH 3.
Page 260 Vehicle Body 5. Install the guide rail and bolts on the rear door window Rear door window LH Rear door glass run LH guide rail assembly. Rear door window 6. Install the rear door glass run. rear guide rail LH 7.
Page 261: Trunk Door Assembly
GWFLORID Maintenance Manual Trunk Door Assembly Components Spoiler panel assembly Trunk door glass weatherstrip Trunk door glass weatherstrip Trunk door assembly High mount brake lampshade High mount brake lamp cap High mount brake lamp assembly 2 High mount brake lamp assembly Rear wiper assembly Trunk door main lock assembly Trunk door right side air spring...
Page 262 Vehicle Body Trunk door removal 1. Remove the door inner decoration board. Trunk door Remove the inside handle. assembly Insert the buckle screwdriver between the fixed buckle and the door inner decoration board to pry them loose. Trunk door protector assembly Caution: Before using a buckle screwdriver, make sure to wrap its head in tape.
Page 263: Front Bumper
GWFLORID Maintenance Manual Front Bumper Components 1. Front bumper plastic support 2. Front bumper energy absorbing block 3. Cross slot & concave hexagon head self-tapping screw and large washer subassembly (Q2754819+Q422) 4. Front bumper left mounting bracket 5. Cross slot & concave hexagon head self-tapping screw and large washer subassembly (Q2756319+Q421) 6.
Page 264 Vehicle Body Front bumper removal 1. Remove nut seat 2. Screw off the lower air guide plate mounting screws below Front bumper body the vehicle body from left & right front bumper plastic nut seat 2, and remove left & right front bumper plastic nut seat 2. Front bumper plastic nut seat 2 2.
Page 265 GWFLORID Maintenance Manual 7. Disconnect the wire harness of the left & right fog lamps. Front bumper plastic 8. Remove the bumper attachments. support Remove the front bumper plastic support and energy absorb- ing block from the vehicle body respectively. Front bumper energy absorbing block Front bumper body...
Page 266: Rear Bumper
Vehicle Body Rear Bumper Components 1. Cross slot & concave hexagon head self-tapping screw and large 10. Front mounting bracket RH of the rear bumper washer subassembly 11. Rear bumper trim panel buckle 2. Rear mounting bracket LH of the rear bumper 12.
Page 267 GWFLORID Maintenance Manual 2. Remove the nut and gasket. Screw off the hexagon nut for flange face from the rear bum- Hexagon nut for flange face per left & right side central mounting bolt, and the rubber Rubber cushion of the rear bumper central cushion of the rear bumper left &...
Page 268 Vehicle Body 7. Remove the front bracket. Cross slot & concave hexagon head self- Screw off the cross slot & concave hexagon head self-tap- tapping screw and large washer subassembly ping screw and large washer subassembly on the left & right front mounting bracket of the rear bumper, and pull the left &...
Page 269: Seat Belt
GWFLORID Maintenance Manual Seat Belt Components Front seat belt Rear seat belt guide ring guide ring 45±5 45±5 Rear seat belt retractor 45±5 Front seat belt retractor 45±5 45±5 Seat belt lower mounting bolt Seat belt lower mounting bolt Guide ring mounting bolt 45±5 45±5 Guide ring...
Page 270 Vehicle Body 2. Remove the seat belt lower mounting bolt and B-pillar lower decoration board. 3. Remove the guide ring cover. Seat belt upper mounting bolt Remove the seat belt guide ring cover, and expose the seat belt upper set mounting bolt. 4.
Page 271 GWFLORID Maintenance Manual 5. Install the seat belt guide ring. Fix the seat belt upper mounting bolt onto the vertical ad- juster. Seat belt upper mounting bolt torque is 45±5 N·m. Seat belt upper mounting bolt 6. Install the B-pillar lower trim panel. 7.
Page 272 Vehicle Body 3. Install the C-pillar protector. Side sheet metal C-pillar protector 4. Install the seat belt lower mounting bolt. Lower mounting bolt General Instructions and Operations of Seat Belt Front seat belt warning: The front seat belts are equipped with seat belt indicator. The driver seat belt indicator is located on the dash- board and that of the front passenger is on the air conditioner panel.
Page 273: Seats
GWFLORID Maintenance Manual Seats Components Rear seat Front passenger seat Driver seat Backrest regulating lever Areas of Importance 1. Pay attention to safety in the process of removal, transportation, and installation, as to avoid scratching or crushing injury caused by the seat. 2.
Page 274 Vehicle Body Rear seat removal and installation Removal 1. Remove the mounting bolts (5) on the 40% of the rear seat backrest (3). 2. Remove the mouting bolts (6) on the 60% of the rear seat backrest (4). 3. Lift the rear seat cushion up and make hook 11 slide out of clamping frame 9.
Page 275: Sunroof Assembly
GWFLORID Maintenance Manual Sunroof Assembly Components Sunroof panel Sunroof window weatherstrip Movable sun visor Slider Upper trim strip Spacing tube Lower trim strip Bolt Air guide plate Rear guide device Roof drip channel Wind guard Guide device latch hook Spring End piece Guide rail assembly Drive device...
Page 276 Vehicle Body Troubleshooting Fault classification Fault symptom Fault diagnosis Fault maintenance Window panel Window panel (sunroof) Check if anything is blocking the guide rail Replace the sunroof guide rail assem- motion failure cannot open, rise, or close for window panel movement. Check whether bly.
Page 277 GWFLORID Maintenance Manual Sunroof panel removal Upper trim strip 1. Move sun visor to the back position. 2. Open sunroof in the slanted position. 3. Adjust the lower trim strip. Loosen the front part of the lower trim strip in the direction of car's interior to take the rear part off the hook.
Page 278 Vehicle Body 2. Adjust the rear part. b = 0-1 mm, higher than the level position of the sunroof. The arrow refers to the driving direction (facing forward). 3. Adjust the window panel weatherstrip. Use a sheet of paper of 0.3 mm thickness to check whether the prestress between the weatherstrip and vehicle body is consistent.
Page 279 GWFLORID Maintenance Manual Wind deflector removal and installation 1. Remove the wind deflector. Completely open the sunroof. Pry the wind guard mounting bracket on the left and right side guide rails out with a small screwdriver (according to direction indicated by the arrow). Pull out the wind deflector.
Page 280 Vehicle Body Adjust the initial position of drive device Precondition: Remove the drive device, but leave the electric plug-in connected. The sunroof is on the initial position. Sunroof panel has been installed correctly. Caution: The gear of drive device cannot contact anything while adjusting.

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