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Great Wall. Service manual for chassis and body (2006) - page 23

B0-37

side-window glass

Side-window glass (

)

Element mounting position

Vehicle Body

Side-Window Glass

side-window glass

spilling strip

trim strip of side window

B0-38

Side window glass (

)

Element mounting position

Vehicle Body

Side-Window Glass

side-window glass

spilling strip

trim strip of side

window

Dismantle of side window glass

Tear down the following parts:

(a)

Lower trim panel of rear column;

(b)

Rear side-panel trim

(c)

Roof

Tear down the side window glass

(a)

Tear down the three hex nuts and eight nuts on flange

(SF)

(b)

Cut a small open in the sealing glue between the glass and

body with knife, then insert the steel wire into the small

open and pull it fro and to slowly until the sealing glue

between the glass and body separate completely, and pull

the glass out to take it down.

Notice: be careful not damage the body and glass.

Mount of side window glass

Clean the body and glass;

Clean the contacting face of body and glass completely with

cleaning materials.

Cleaning the sealing strip;

Clean the sealing strip surface with cleaning materials.

B0-39

Vehicle Body

Side Window Glass

Mount the trim strip and spilling strip of side window (SY SJ)

(a)

Assemble the trip strip of side window on the left upper

conner of inner edge of the left side window at 60 mm under

the conner, and encase the roof in the trim strip.

(b)

Stick the spilling strip (4

6) to the center of lower edge of

side window and to the circumference of the glass frame.

4. Mounting of side glass

Coat the cleaning active agent around the inner edge along the

circumference of side window glass (the black glass edge).

Airing for 3 to 5 min, coat the priming agent on the layer of cleaning

active agent and airing for 5 to 30 min.

(SY

SJ)

(a)

Plaster the glass glue with the glue container on the layer of

priming paint of window frame with the initiative location

200 mm under the left upper conner of left side window.

(b)

Stick the glass quickly to the window frame and adjust the

upper, lower, left and right clearance, and fill them with

gasket.

(c)

Exert the pressure of certain degree on the glass circumfer-

ence after adjusting so that the glass contact

Recommended sealing glue for use

Glass glue

U-201 windshield glue

Priming paint 130

Cleaning active agent

C020

(SF)

(a)

Plaster the glass glue alongside the complete circumference

of adhesive strip of side window glass, and the glue section

should be similar to tri-angle after coating.

(b)

Put the side window glass assembly at the corresponding

location on body, fix the upper edge of side window glass with

three hex nuts and others should be fixed with flange nuts.

Recommended sealing glue for use

Glass glue

TS-100 PVC windshield glue

Priming paint TS-5028

Cleaning active agent

TS-7016

Notice:

(a)

When plastering glue, the glue should be plastered continu-

ously and no breakage is allowable at the sealing glue seam.

(b)

Clean the redundant glue on the body;

(c)

The vehicle is not allowed to drive within 4 hours in summer

and 8 hours in winder under common circumstances.

Check whether there is leakage and the leakage reparation;

(a)

Conduct the leakage test;

(b)

Seal the leaking parts with glass glue.

B0-40

Rear door glass

Element mounting position

Vehicle Body

Rear Door Glass

Dismantle of rear door glass

Disconnect the connecting wire of the defroster first, cut a small

open in the sealing agent between the glass and body with knife,

then insert the steel wire into the open and pull the steel wire to

and fro until the sealing glue between the glass and body separates

completely, finally pull the glass outwardly to take it down.

Notice: be careful not to damage the body and glass.

Mount of rear door glass

Seize the wire harness of rear defroster in the plastic clipes

and encase the clipes into the mounting open, then seize the wire

harness of rear defroster in the trim strip at tailgate.

As this mount is the same with that of side window glass, see

the mounting approaches for side window glass.

trim strip at tailgate

SY SJ

plastic clip

spilling strip

wire harness of

rear defroster

rear door glass

B0-41

Vehicle Body

Rear Windshield

Rear windshield

Element mounting position

Dismantle of rear windshield

Tear down the rear windshield:

(a)

Prize up the sealing strip front the body with screwdriver.

Notice: be careful not to damage the paint on body.

(b)

Prize the lips of sealing strip outwardly from the inside

of the body flange.

(c)

Pull the glass outwardly to tear it down together with the

sealing strip.

Dr SL SK

rear windshield

sealing strip of rear windshield

sealing strip

vehicle
body

B0-42

Vehicle Body

Rear Windshield

Mount of rear windshield

Clean the body and glass;

Clean the contacting face of body and glass with the

cleaning materials.

Clean the sealing strip

Clean the sealing strip with cleaning materials;

Mount the rear windshield

(a)

Lay the ready glass against the corresponding position of

rear windshield opens.

(b)

Pull the rope from the inside of body to encase the roof,

the rear column and the door frame within the adhesive

strip, meanwhile push the outside of the glass by hand.

(c)

Tap the four edges of the adhesive strip to ensure that the

adhesive strip contact closely with the body windshield

opened.

(d) Coat the glue from left to right at the upper part of

windshield (location between the adhesive strip and the

body windshield open) and the lower part of windshield

(location between the adhesive strip and glass), and the

remaining glue should be cleared away with abrasive

paper, and the location should be cleaned with cloth.

Notice: there should no breakage at the sealing glue

seam when coating the glue.

Recommended sealing agent for use

Glass glue

XL-1211 acid silicone glass glue

Check whether there is leakage and the leakage

reparation;

(a)

Conduct the leakage test;

(b)

Seal the leaking parts with glass glue.

Mount the rear windshield in the sealing strip

(a)

Coat a layer of silicon oil around the glass circumference

and mount the adhesive strip on the glass according to

the glass shape.

Notice: if the adhesive strip becomes stiffening or

deforming that will lead to water leakage, change with

the new one where possibly.

(b)

Mount a rope alongside the sealing strip channel as

shown in the drawing (fix the rope in the adhesive strip).

B0-43

Cargo body baffle

Element mounting position

Vehicle Body

Cargo Body Baffle

baffle lock

connecting bar

2 screws

baffle lock controller

rear panel of cargo body

buffer block

hinge assembly

inner cover panel

bolt hole

14 screws

Dr SL SK

14 screws

(Dr SK)

specified torque

cargo body

hinge

Dismantle of baffle lock

Tear down the inner cover panel.

(SL)

Tear down the 14 screws and the inner cover panel.

(Dr SK)

Tear down the 12 screws and the inner cover panel.

Disconnect the connecting bar of baffle lock from the

baffle lock controller.

Tear down the baffle slide fastener

(a)

Tear down the baffle lock from the baffle.

(b)

Tear down the two screws and the baffle lock.

Teardown the baffle from the baffle

Teardown the 12 screws and the baffle lock

B0-44

Vehicle Body

Cargo Body Baffle

Mount of Baffle

Mount the baffle lock on the baffle;

Mount the baffle lock with two screws (Dr SK)

Mount the baffle lock with two nuts (SL)

Connect the connecting bar with the baffle lock controller.

Mount the baffle slide fastener;

(a)

Mount the baffle slide fastener and bolts.

Fastening torque

14N

(b)

Connect the baffle slide fastener with the baffle.

Mount the baffle hinge on the baffle

Mount the inner coverpannel

SL)

Mount the inner cover panel with 14 screws;

Dr SK)

Mount the inner cover panel with 12 screws.

Dismantle of baffle lock controller:

Tear down the inner cover panel;

Disconnect the two baffle connecting bar;

Tear down the baffle lock controller

Tear down the two screws and the baffle lock controller; (Dr

SK)

Tear down the two nuts and the baffle lock controller. (SL)

Mount of baffle lock controller

Mount the baffle lock controller in the reverse order for

disassembly.

B0-45

Tailgate (

)

Element figure

Vehicle Body

Tailgate

tailgate glass

outer auchi

inner auchi

tailgate lock

glass elevator at tailgate

tailgate handle

glass bracket

glass supporter

tailgate cover panel

sealing strip at tailgate

trim panel at tailgate I

lock ring

B0-46

Vehicle Body

Tailgate

Dismantle of tailgate

Tear down the trim panel of the tailgate:

(a)

Insert the screwdriver between the fixing clipes and the

trim panel at the tailgate to loose the trim panel.

Notice: the screwdriver should be wrapped at its head

with adhesive strap before using

(b)

Tear down the trim panel at tailgate.

Tear down the tailgate cover panel;

Tear down the three bolts and the tailgate cover panel.

Tear down the tailgate handle and the lock ring:

(a)

Tear down the two bolts on handle.

(b)

Disconnect the controlling bar from the glass elevator

and tear down the tailgate handle.

(c)

Disconnect the controlling bar from the glass elevator to

take down the lock ring.

Tear down the trim panel of tailgate I;

Tear down the six bolts and trim panel of tailgate I;

Tear down the sealing strip at tailgate;

Tear down the two threaded ends and the sealing strip;

Tear down the outer auchi

Tear down the glass elevator at tailgate;

(a)

Tear down the tailgate glass;

(b)

Pull the glass outwardly to take it down.

Tear down the tailgate lock;

Tear down the three bolts and the tailgate lock.

B0-47

Vehicle Body

Tailgate

Tear down the tailgate lock

Tear down the three screws from the tailgate to tear down the

lock

Change of Glass

Tear down the glass bracket with screwdriver or with

similar tool.

Coat the polyurethane glue, seize the gasket on the

glass and coat the glass glue at outside of the gasket.

Encase the glass bracket by tapping it with rubber

hammer.

Tailgate Assembly of

Assembly the tailgate in the reverse order of the disassembly

approaches.

Notice: coat the lubricant on the sliding face, elevator

gear and door lock before mounting the parts.

120mm

105mm

outside

B0-48

Vehicle Body

Tailgate

Tailgate (

)

Element figure

stop-grade
washer

plastic clipes

10 screws

upper position limit

adhesive block

tailgate assembly

pneumatic ejector rod

tailgate hinge

lock clip
assembly

nut

trim panel
at tailgate

tailgate lock
barrel assembly

sealing strip

front wall
plastic clipes

lower
position limit

tailgate lock

side lower
position limit

side upper
position limit

SY SJ

B0-49

Vehicle Body

Tailgate

Dismantle of Tailgate

Tear down the trim panel at tailgate;

Tear down the ten plastic clipes and take down the trim panel

at tailgate.

Tear down the tailgate lock barrel and lock from tailgate:

(a)

Screw off the nuts of lock barrel from the inside of

tailgate cavity and take down the lock barrel from the

outside.

(b)

Tear down the three screws to take down the tailgate lock.

Tear down the tailgate lock clip

Take down the tailgate lock clip from the lower beam flange

after tearing down the two screws.

Dismantle of Tailgate

Tear down the pneumatic ejector rod;

Tear down the screws and take down the two pneumatic ejector

rod from the tailgate and the body.

Tear down the tailgate hinge and the tailgate;

(a)

Tear down the eight bolts to take down the right and left

tailgate hinge from the tailgate and the body;

(b)

Pull out the plugging element of wire harness to tear

down the tailgate from the body.

Tear down the position limit

After tearing down the two bolts, take down the left and right

side upper/lower position limits and the upper/lower position

limit from the tailgate and the body.

Tear down the position limit

Mount of tailgate lock and the tailgate

Mount the tailgate lock and the tailgate in the reverse

order

B0-50

Vehicle Body

Instrument Panel

Instrument panel (

)

Element figure

instrument
panel body

glove box

cover

glove box

lower instrument cover

left air tunnel

combination
instrument

ignition
switch cap

central cover

decorative cover of
instrument

upper instrument
cover

air passage

CD device

air-conditioning

controlling

mechanism

assembly

central lower wall

ashtray

B0-51

Vehicle Body

Instrument Panel

Instrument Panel (

)

Element figure

instrument panel body

lower instrument cover

glove box

central panel

central switch

central air tunnel

combination instrument

instrument cover

cigarette lighter seat

ashtray

combined acoustic

device

ir-conditioner panel

fixed bracket

B0-52

Vehicle Body

Instrument Panel

Instrument panel (

)

Element figure

SL SK SY SJ

instrument
panel body

right upper air tunnel

central air tunnel

left upper
air tunnel

combination
instrument

decorative cover
of instrument

lower covering board
at right end

glove box

lower instrument
cover(SY)

air-conditioning
controlling mechanism
assembly

lower instrument cover

central cover

CD device

cigarette

lighter seat

lower decorative
frame of
instrument panel

ashtray cluster

glove box lock

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