PICKUP WULING MAINTENANCE MANUAL

Page |1

Preface
The P&N family of microbuses is the new series of vehicles developed and made by SAIC-GM-Wuling Automobile Co., Ltd., featuring state-of-the-art technologies, stable performance and economy driving. This Manual is specially prepared to facilitate your servicing and maintenance on Wuling P&N series vehicles. The information contained in this Manual is based on the latest products and technologies when it is printed. The configuration of the vehicle you purchase may vary from this Manual to reflect our continuous improvement in product engineering without prior notice. Please pay special attention to such changes to your Wuling vehicle. If you have anything not clear enough, please refer to the latest version of the Service Manual, and you may contact our Technical Center directly. Mechanics may refer to this Manual to service the Wuling vehicle. This Manual may contain errors or improperness. Your comments are highly welcome. SAIC-GM-Wuling Automobile Co., Ltd.: May 2006

Table of Contents
Chapter 1 Basic Information Chapter 2 Heating, Ventilation and A/C System Chapter 3 Steering System Chapter 4 Suspension, wheel and tire Chapter 5 Transmission System Chapter 6 Brake System Chapter 7 Engine Chapter 8 Operation System Chapter 9 Body Chapter 10 Protection Units Chapter 11 Electrical System

PICKUP WULING MAINTENANCE MANUAL

Page |2

Chapter 1 Basic Information

1.1 General information 1.1.1 Diagnosis form 1.1.2 VIN 1.1.3 Nameplate 1.2 Fuel, brake fluid, lubricating oil, fluid sealant, coolant fluid 1.3 Tire pressure 1.4 Vehicle maintenance and servicing 1.4.1 Before inspection 1.4.2 Electrical service 1.4.3 Intermittent fault 1.4.4 Preparations before the disassembly 1.4.4.1 Lift the vehicles 1.4.4.2 Rear axle disassembly 1.4.4.3 Engine disassembly 1.4.4.4 Assemble 1.5 Regular check, service and maintenance 1.5.1 Regular check, service and maintenances

PICKUP WULING MAINTENANCE MANUAL

Page |3

Chapter 1 Basic Information

1.1 General information
1.1.1 Diagnosis form Diagnosis Form records the vehicle services; Customers shall properly fill this Form, which will be used by the ServiceStation to analyze the possible causes to your vehicles fault. Checklist (Sample) Customer: VIN: Purchase Date: Problems
Difficult Startup Poor driving performance Surge Abnormal idle speed Engine stop in one Condition Clutch not disengaged completely Abnormal noises of propeller shaft Tire uneven wear Brake pedal loose Abnormal horn Air conditioner malfunction Window regulator fault Road conditions Cannot start Surging when accelerated Abnormal noises High idle speed After starting When start one system Walking out of meshing Abnormal noises of rear axle Driving deflection Brake fluid leaking Starter motor does not work Air conditioner leaking water Weather performance Sunny /Cloudy /Rainy

Vehicle Model: Mileage: Registration Date:

Cannot ignition No spark

Backfire/ exhaust pipe knock Not enough power Unstable idle speed Low idle speed When treading accelerator pedal Electrical appliance P/S Gear not engaged Steering loose Brake delay Battery charging fault Radio and cassette player not working Door lock fault Temperature Hot/Warm/Cool/Cold Expressway Heating In any condition When accelerating Decelerating moment Fault Indicator Unstable high idle speed (r/min to r/min) Others When releasing accelerator Others Abnormal noises from gear shifting Front wheel vibrating Brake deflection Abnormal light Instruments working abnormally Seats bad Frequency Any condition Mountain areas (upslope Down slope) Starting moment After starting Turning right moment Turning left moment On all the time Light sometimes Second check: No code Normal code Fault code ( )

At any time Sometimes City area Out of city (times/day, month) Engine temperature Cold Preheating No load running Vehicle Running Engine speed ( r/min.) Constant speed Shifting moment Gear Parking moment Not lighting all the time Driving speed when problem arises ( km/h) Troubleshooting code

First check: No code Normal code Fault code ( )

Note: The above form is for reference only, which may be revised as necessary.

PICKUP WULING MAINTENANCE MANUAL

1.1.2 VIN VIN is stamped on the frame under the right seat of driving cab. One vehicle identification plate is riveted on the upper left of dashboard. VIN is indicated on it.

Page |4

1.1.3 Nameplate Nameplate is riveted on the center-pillar on the right of driving cab. The information contained in the nameplate varies with different vehicle.

1.2 Fuel, brake fluid, lubricating oil, fluid sealant, coolant fluid. item Recommended spec. Volume lt.
Gasoline Engine Oil Gearbox Oil Rear Axle Oil Liquid coolant Brake Fluid Brake cylinder grease Chassis Grease Servicing Materials Lead free gas, above 90# 15W40 (-15/40C) GL-4 (75W90 80W90 85W90) GL-5 (75W90 80W90 85W90) Chongqing Yiping 4916 TEEC JG3 automobile brake fluid Above DOT3 degree Chongqing Yiping 7503 40 l truck 3 (3.5 oil filter repl.) 1.0 4th 1.3 5th gear 0.9 4.5 0.5

obs

Chongqing Yiping 7022, #2 Q/SHYPO2.017Z-2000 1.Anaerobic adhesive GY340 2.Baide Adhesive 3.Glue 1201 4.HZ-1 RTv sealant, oil and grease resistant 5. 1406S screw fastening adhesive 6. Lithium based grease ZL-2

Caution:

1. Do not mix two kinds of brake fluid. 2. The coolant should be corrosion prevention, rust proof and frozen proof. 3. The water used to make up coolant must be soft water. 4. Ambient temperature (Lowest) -10C -20C -30C -45C v/s Coolant thickness 30 40 50 60

1.3 Tire pressure (cold conditions) KPa

Tires Front R12 Rear Idle 200 200 Full load 200 300

Date

Caution: After the tire being inflated, take the 4 mounting bolts as fixture center to test the balance on a dynamic balancer. The unbalance should not exceed 10g. Otherwise, attach adequate counter balance onto the wheel rims.

PICKUP WULING MAINTENANCE MANUAL

Page |5

1.4 Vehicle maintenance and servicing

1.4.1 Before inspection Protect components concerned, since some parts may be damaged or stained during the inspection and servicing. Take adequate measures for protection. Properly arrange the parts as per the disassembly sequence. Reasonably identify the parts to be changed and to be reused. Protect parts from damaging. The parts below have to be changed after they are removed. Oil seal Liner Gasket O-ring Locking washer Splint pin Self-locking nut Guard belt and retaining ring Vehicle washing When using a high pressure washing gun to wash your vehicle, always maintain the nozzle 300 mm away from the plastic parts or the openings (such as doors, truck and roof opening). Hose and other rubber parts To avoid any possible damages to the hoses and other rubber parts, be sure not to stain them by gasoline, grease and other fluids. Grease It is highly recommended to only use the specified grease during the assembly. Brake fluid Never spill off the brake fluid or it will damage the finish coating of your vehicle. If there is any spill, you should wash the stained part immediately using clean water. Keep the hose and rubber parts clear form any other parts during the disassembly and reassembly of hose and hose clamp, to avoid damages to them.

Obs.

You should only use the genuine Wu Ling parts

Obs. Identify areas to pressure washing

Obs. Clean them with soap

PICKUP WULING MAINTENANCE MANUAL

1.4.2 Electrical service You should disconnect the negative terminal from the battery before checking the circuit.

Page |6

Caution: Be sure to disconnect the ignition switch and light switch before connecting or removing the negative cable (Or damages may results). Use adequate clamps to tighten the harness to avoid any looseness The harness connected onto such vibrating parts as the engine should be so tightened that the normal vibration of the vibrating parts will not be restrained by the harness connected When using cable clamps to fix them, you should verify that an adequate looseness has been remained If there is a fixing sign indicated on the harness (color strip), at which point you should fix the harness properly If a harness has to contact with any sharp part be sure to protect the harness using ethylene tape to avoid any possible damage Never allow any wiring or harness be pressed under any parts Only use the specified fuse to change the fuse blown. If bigger fused being used, some parts may be blown even accidents such as fire may results Be especially careful with the sensor, relay and other electronic parts, they are extremely vulnerable; do not drop them When using a multi-meter to check the circuit conductivity or the circuit voltage at the connection, only insert the probe from the harness end

PICKUP WULING MAINTENANCE MANUAL

If you need to check a sealed connector, insert the probe from the hole on the cover until touch the connector inside. Be sure not to damage the insulation Disconnect an adapter by pulling both adapter ends. Do not disconnect an adapter by pulling the cable connected Press the locking device as per the direction shown below to disconnect an adapter if a locking device is attached. When you connect the adapter attached with a locking device, plug in the connection until a click sound is heard.

Page |7

1.4.3 Intermittent fault The intermittent fault is mostly resulted from the wire connections or wires itself, sometimes it caused by the faults of the lockup relay or the magnetic coil. Always check the circuit thoroughly if your suspect there is any fault with the circuit. Check the mating connectors The stained contact pin and socket may influence the connection. Contact pin or socket is in poor shape or is damaged. The adapter is damaged or has a poor contact due to the effect of water, oil, grease or any other dirties. Check the contact between plugs (Or connectors) and wires. Check every connector of malfunction circuits for poor contact by shaking wires slightly. Repair them if necessary. Check wires Wires should be completely insulated. If any naked section of a wire contacts with the vehicle body or any other conductors, it will lead to short circuit. Ensure all wires are in good conditions and may function properly.

PICKUP WULING MAINTENANCE MANUAL

If a wire consists of several cords, make sure to check its resistance. If abnormal, repair or replace them as necessary.
Chapter 1 Bascic Information 7

Page |8

1.4.4 Preparations before the disassembly 1.4.4.1 Lift the vehicles Lift or jack up your vehicle to a certain height and the hoisting or supporting point should be reliable with the total weight uniformly distributed. The vehicle height should be suitable and convenient for disassembly. When jacking up your vehicle with a lifting jack, you are advised to follow the instructions provided, to avoid any possible damage to the vehicle body. Using the lifting jack: Using a support:
Chapter 1 Bascic Information 8

Using a hoist:
Chapter 1 Bascic Information 9

1.4.4.2 Rear axle disassembly Properly jack up the vehicle to remove the wheels. Use a suitable support to jack the rear axle up. Remove the parking brake cable, drain the brake fluid and remove the brake hose. Loosen the U bolt and remove the leaf springs on the two sides. Remove the lower connector of the rear shock absorber. Lower the support to separate the rear axle from the vehicle body. When you disassemble some elements from the rear axle or other assemblies, you can lift or jack your vehicle as necessary. 1.4.4.3 Engine disassembly Disassemble the connecting pipes, harness plug, earth cable, odometer flexible axle, cooling water pipe and various cables (clutch, accelerator and choke cable). Remove the locking rod (flexible shaft) of gear shift manipulation and the tie rod of shift lever (flexible shaft). Remove the flange bolt connecting the rear axle and the propeller shaft, and then draw out the propeller shaft. (Use a clean stopper to block the output end of gearbox, preventing the lubricating oil from flowing out.) Remove the intake hose and the exhaust pipe. Use a suitable bracket to support your engine. Remove the hoisting bolt of gearbox (at the point where the gearbox is connected with frame). Remove the bolts connecting the engine suspension and the R&L beam, then lower the bracket to remove the engine from the vehicle.

PICKUP WULING MAINTENANCE MANUAL

Page |9

When standing in a trench to install the engine, make sure to hold the engine firmly to avoid any possible injuries 1.4.4.4 Assemble Lift or jack up the vehicle to a certain height. Please refer to the information concerning the disassembly for reassembly. Caution: During the re-assembling, the unchanged parts should be all cleaned. Fitting parts should be cleaned with gasoline. Lubricate all parts as appropriate. During the re-assembling, tighten all fasteners to the torque specified. The torque value is indicated on the assembly drawing.

1.5 Regular check, service and maintenance

Regular check, service and maintenances refer to the check, service and maintenances you should perform at a regular interval of time or driving mileage. To maintain a proper functioning of your vehicle and to ensure the passengers safety, it is highly recommended that you should perform the regular maintenance as per the schedule
Chapter 1 Bascic Information 10

1.5.1 Regular check, service and maintenances Please refer to the Form below: Regular check, service and maintenance:
Break-in 3 6 12 18 24 Interval (months) Interval (km) Item 2000 5000 10000 20000 30000 40000 Fan belt: check the tightness or damage J. T J. T J. T. G G Timing belt: check tightness or damage J. T. G Bolts of cylinder cover, in.& ex. pipe and engine suspension: check tightness NN Oil-filter: replace G Every 5000km G Oil: change G Every 5000km G Fuel-filter: replace G Filter element of air cleaner: clean and change Q Q G Liquid coolant: replenish and change J. B J. B G Hoseand connectorsofthe cooling system: check theleak age and damage J. T J. T. G Fuel pipe and connections: Check the leakage or damage J. T J. T. G Crankcase ventilation hose and connector: check or change J. T J. T. G PCV valve: check and change J. Q J. Q. G HV damper wire: deteriorate or damage J. T. G Sparkplug: clean and regulate gap J. T Q. T. G Ignition timing: check and regulate J. T J. T In. & ex. valve: gap adjustment J. T J. T Idle speed and emission: check and regulate J. T J. T Fuel injector: clean Q Discharge deposits in the fuel tank Q Cooling jacket, radiator, water pump, and

PICKUP WULING MAINTENANCE MANUAL

P a g e | 10

thermostat: check and clean J. Q Fuel vapor storage vessel: piping and connectors: check J. T. G Fuel vapor canister Chang it one time every 50000km. In the bad conditions, it should be frequently checked. If the liquid fuel is found, it should be changed immediately. Engine EFI system Refer to the indication of trouble light. Operation Accelerator, clutch, gearbox, gearbox control cable, axle: check, adjust, lubricate and change J. T. G Adjust the clutch pedal free travel (15~25mm) J. T Every 5000kmJ.t (May shorten or lengthen as necessary.) Gearbox lubricating oil G J.B G Propeller shaft: check J J. G Speed reducer lubricating oil G J. B G Transmissi on Connecting bolt: fasten as necessary N N

Under hostile conditions, such as in the dusty area, replace all parts at a shorter interval or clean all parts more frequently.
Chapter 1 Bascic Information 11 Interval (months ) Break-in 3 6 12 18 24 Interval (kms) Item 2000 5000 10000 20000 30000 40000 Wheel nut: tightness (As per the specified torque) J. N N Front wheel hub bearing pre-tightening: check: lubricate J. T J. T Q. T Toe-in adjustment J. T J. T Wheel Tire rotation T Rubber cushion for the connections of steering axle and steering gear, ball joint of tie rod and link rod, the wear or rubber aging of steering swing arm, engaging clearance of steering rack and pinion: Check, adjust and replace J. T. G Steering Connecting bolt: fastening N N Check the braking pipe; check, adjust and lubricate the parking brake and brake pedal (including the vacuum booster); check and adjust the free travel of brake pedal J. T J. T. G Check the brake fluid: replenish or change if necessary J. B J. B G Mater cylinder and wheel cylinder rubber cup: change G Check the friction disc for the disc or drum brake J. T. G Braking Connecting bolt: fastening N N Check the performance of front and rear shock absorber J

PICKUP WULING MAINTENANCE MANUAL

Check lower arm bush and ball pin; check strut bar bushing; check the leaf spring hanger inner board, U bolts and rubber lining; check the rubber cushion assembly; check the wear of rubber cushion, front suspension, flat bearing and dust guard; check the breakage and aging of rubber elements. J J. G Check and lubricate the leaf springs; check the coil spring. J. R Suspension Connecting bolt: fastening N N Frame Frame and cab: calibrate and weld J. T. H Check the specific gravity of electrolyte of battery; replenish with distilled water, if necessary. J. B J. B Check and charge battery: grease the pillar as necessary Check the air piping. J Check, adjust and maintain the performance of engine, regulator and the starter motor. J. T. R Check the cable connectors. J Electrical Check the lighting equipment: check all signal lamps; check the indicator, instrument cluster and switch J. G Refrigerant Replenish at any time Refrigeration system J. T Compressor J. T. R. G Condenser Check and wash at any time Air conditioner evaporator J. T Liquid drier G A/C Tighten the refrigeration pipes N N

P a g e | 11

Note: J= Check; J.T.= Check or adjust, change if necessary; J.B= Check and replenish liquid level; "N= Tighten specified torque; R= Lubricate; G=Change; Q"= Clean; H= Weld.

PICKUP WULING MAINTENANCE MANUAL

P a g e | 12

PICKUP WULING MAINTENANCE MANUAL

P a g e | 13

PICKUP WULING MAINTENANCE MANUAL

P a g e | 14

Chapter 3 Steering System Content

3.1 Check and Adjustment of Steering System

PICKUP WULING MAINTENANCE MANUAL 3.1.1 3.1.2 3.1.3 3.1.4 Check of free travel Check of Steering Whee Check of Steering Column Axial Clearance Check of Steering Angle Check of Rubber parts and joints

P a g e | 15

3.2 Steering System Assembly Drawing 3.2.1 Safety Regulations

3.3 Steering Wheel 3.3.1 Specification 3.3.2 Steering Wheel Assembly Drawing 3.3.3 Maintenance Guide 3.4 Steering Column 3.4.1 Specification 3.4.2 Steering Column and Drive Shaft Assembly Drawing 3.4.3 Maintenance Guide 3.5 Steering Gear 3.5.1 Specification 3.5.2 Steering Gear Assembly Drawing 3.5.3 Maintenance Guide 3.6 Steering Tie Rod 3.6.1 Steering Tie Rod Assembly Drawing 3.6.2 Maintenance Guide 3.7 Troubleshooting 3.7.1 Steering System Measurement 3.7.2 Abnormal Noise of Steering Gear 3.7.3 Too Large free travel of Steering or Steering Looseness 3.7.4 Return Difficulty of Steering Wheel 3.7.5 Steering Swing or Unsteadiness 3.7.6 Special Tools

PICKUP WULING MAINTENANCE MANUAL

P a g e | 16