Great Wall - X240 - Workshop Manual - 2004 - 2011

Towbar Fitting Instructions To Suit GREAT WALL X240 04-2011 On GREAT WALL X200 11-2011 On Part Number QTGW006L Rating 1800-180 kg (X240) 1700-170 kg (X200) WARNING: Do not, drill, cut, weld or otherwise modify the tow bar .If you are using electric welding on a motor vehicle, always check that the vehicle is not equipped with electronic engine or instrument management equipment. Failure to do so could destroy any onboard computers. If in doubt, check with the vehicle's manufacturer. General: 1. Ensure all hardware items have been included refer to assembly diagram. 2. It is recommended that the instructions are read through and completely understood before making any attempt to fit this product. 3. Be wary of any changes to vehicle designs or other accessories that may conflict with the installation of this product. 4. Before drilling ensure that the area is clear of fuel, electrical & other components. 5. All holes drilled into the body panels shall have all burrs & swarf removed then coated with a suitable rust preventative paint. 6. For vehicles that require the bumper to be cut. Ensure cut out area is in correct position on the vehicle prior to cutting the bumper. 7. The high tensile fasteners supplied with this product were used to achieve the specified rating. If replacement is required ensure that fasteners of the same rating & quality are used. Contact an authorized Trailboss dealer if further information is required. 8. Ensure that all hardware is fastened to torque list below check fasteners on regular basis. 9. Tow bar load rating sticker provided with this product shall be conspicuously located on inside rear end of the driver's door. (See diagram below). 10. Trailboss recommends that you check your tow ball to ensure that it complies with the Australian standards AS 4177.2. 11. PLEASE NOTE: It is advised to remove your lug or tbm when not actually towing so as to produce a clear view of the vehicles registration plate if obscured, and to also provide maximum available departure angle FOR TOWING PURPOSES ONLY For towing capacity details please refer to vehicle owner’s manual or to the manufacturer. Overloading can void your warranties. Place load rating sticker inside driver’s door here Tow bar Maintenance and Care. RECOMMENDED ASSEMBLY TORQUE LISTING Diameter Grade 8.8 Bolt M6 M8 M10 M12 M14 M16 9.5 Nm 21.7 Nm 43.4 Nm 77.3Nm 146 Nm 189.8 Nm Trailboss recommends that bolt torque’s, as listed below, are routinely and regularly inspected and checked for correct tension. Replace any worn or defective parts. We recommended to remove Tow Ball Mounts (TBM’s, tongues or lugs) when not being used for any considerable length of time. So as to avoid injury, when not towing it is suggested that the tongue, Pull Pin and R-clip are removed then stored in a safe, clean and dry place, away from excessive moisture. Hitch Pull Pins and spring “R” clips are regularly checked for proper installation. Replace any worn or defective parts. Page 1 of 2 Issue Date 14-02-2012 Cequent Customer Service Ph: 1800 812 017 Fax: 03 9898 3299 Email: [email protected] Post: PO Box 4050, Dandenong South VIC 3175 Towbar Fitting Instructions To Suit GREAT WALL X240 04-2011 On GREAT WALL X200 11-2011 On Part Number QTGW006L Rating 1800-180 kg (X240) 1700-170 kg (X200) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Lift tailgate and remove 8 plastic scrivets. Remove 6 screws under the bumper. Remove 2 nuts behind mud flab on both sides. Remove 1 vertical screw inside wheel well. Release bumper via pulling outward, disconnect any wiring attaching to bumper bar. Remove 4 nuts holding step support bracket. Remove 2 screws on each side of chassis rails connecting to impact beam, remove impact beam and discard. Insert towbar into chassis rails and secure it using M12x40 bolts, fitting plates, spring washers and flat washers according to diagram on page 3. Torque all fasteners to specifications. Remove centre screw holding parking light wiring before attempting bumper cutting, Cut 70mm wide by 110 mm deep from centre of the bumper. Using masking tape to secure wiring back to the bumper. Refit step support bracket. Refit bumper bar. Page 2 of 2 Issue Date 14-02-2012 Cequent Customer Service Ph: 1800 812 017 Fax: 03 9898 3299 Email: [email protected] Post: PO Box 4050, Dandenong South VIC 3175 Wiring Loom Fitting Instructions To Suit GWM H5 X240/X200 Part Number 100706-WL Wiring Loom Installation Instructions GWM H5 X240 /X200 Part No: 100706-WL Tail Harness Length Required: 1200mm ECU Required: 04826 RPA Override Switch Part No: 04848 (If Fitted) Wiring Loom Installation Time: Approx 50 Mins Page 1 of 5 Issue Date 15-02-12 Cequent Customer Service Ph: 1800 812 017 Fax: 03 9797 3299 Email: [email protected] Post: PO Box 4050, Dandenong South VIC 3175 Wiring Loom Fitting Instructions To Suit GWM H5 X240/X200 Part Number 100706-WL TRAILER PATCH HARNESS DIAGRAM for GWM X240 / X200. POWER HARNESS (04825) NOT SHOWN. Page 2 of 5 Issue Date 15-02-12 Cequent Customer Service Ph: 1800 812 017 Fax: 03 9797 3299 Email: [email protected] Post: PO Box 4050, Dandenong South VIC 3175 Wiring Loom Fitting Instructions To Suit GWM H5 X240/X200 Part Number 100706-WL 1. At the rear of the vehicle, remove the rear bumper fascia. 2. Remove the lower RHS tail light assembly by first removing the two fasteners. 3. Remove the LHS tail light assembly fasteners. 4. Remove and disconnect the upper tail light assembly section and then the lower tail light assembly. 5. Drill a Ø20mm hole (1) into the vehicle just below the RHS lower tail light connector entrance, as shown below. 6. File down any rough edges and then spray on rust inhibitor. 7. Drill a Ø20mm hole (1) into the lower RHS rear quarter cavity, as shown below. 8. File away any rough edges and spray on rust inhibitor. 9. On the LHS of the vehicle, push the LHS vehicle tail light connector into the vehicle cavity. Page 3 of 5 Issue Date 15-02-12 Cequent Customer Service Ph: 1800 812 017 Fax: 03 9797 3299 Email: [email protected] Post: PO Box 4050, Dandenong South VIC 3175 Wiring Loom Fitting Instructions To Suit GWM H5 X240/X200 Part Number 100706-WL 10. In the luggage compartment area, remove enough fasteners from the LHS luggage compartment trim to gain access to the area behind the jack plate. 11. In the luggage compartment jack cavity area, find and remove the grommet located behind the jack tray and remove. 12. Drill out the grommet hole to Ø30mm. 13. File down any rough or sharp edges and then spray on rust inhibitor. 14. On the RHS of the vehicle, connect the trailer patch harness (P/No: 100706-WL) RHS patch connector to the vehicle tail light connector. 15. Route the trailer patch harness RHS patch connector into the previously drilled hole, feeding in the harness grommets until the second grommet is seated correctly. Note: This connector has two grommets. 16. On the LHS of the vehicle, connect the LHS trailer patch connector into the vehicle harness connector. 17. Route the trailer patch harness connector into the pushed-in tail light connector grommet hole. 18. Connect the pushed-in vehicle tail light connector to the trailer patch centre harness mating connector. 19. Connect the trailer patch LHS connector to the trailer patch centre harness connector. 20. Route the rest of the trailer patch centre harness (tail harness connector and power harness (04825) connector) through the grommet hole located behind the jack. 21. Continue routing the trailer patch centre harness along the underside of the vehicle ensuring that the harness is secured away from the exhaust. 22. Using silicone or electrical grease, waterproof the back of the tail harness connector (tail length: 1200mm) and mating connector and then connect the tail harness connector and trailer patch centre harness connector together. 23. Mount the trailer socket to the towbar mounting bracket using M4 fasteners (not supplied). 24. Route the trailer patch centre harness across and towards the RHS and then retrieve it around to the outer side of the sheet metal. 25. Route the trailer patch harness RHS patch connector through the lower drilled out hole and then connect the RHS patch connector to the trailer patch centre harness connector. 26. Inside the LHS tool access cavity area, connect the trailer patch centre harness ECU connector to the ECU. Page 4 of 5 Issue Date 15-02-12 Cequent Customer Service Ph: 1800 812 017 Fax: 03 9797 3299 Email: [email protected] Post: PO Box 4050, Dandenong South VIC 3175 Wiring Loom Fitting Instructions To Suit GWM H5 X240/X200 Part Number 100706-WL 27. Secure the ECU into place on the sheet metal area behind the jack, using double sided tape (not supplied). 28. Secure the trailer patch centre harness ground ring terminal to the vehicle grounding location, just above the LHS tail light cavity area. 29. Underneath the rear of the vehicle, connect the trailer patch centre harness power connector to the power harness (P/No: 04825). 30. Route the power harness along the LHS chassis rail and up into the engine bay. Secure the power harness to the positive battery terminal. 31. Secure all harnesses into place using cable ties (not supplied) ensuring that all harnesses are clear of moving parts, sharp edges and sources of high heat. 32. Test the Trailer socket using a light board or multi-meter. 33. Secure all harnesses using cables ties (not supplied). 34. Re-fit all removed parts and secure all fasteners. 35. Place the instructions in the glove box after fitment. Page 5 of 5 Issue Date 15-02-12 Cequent Customer Service Ph: 1800 812 017 Fax: 03 9797 3299 Email: [email protected] Post: PO Box 4050, Dandenong South VIC 3175