Great Wall Hover. Service Manual - part 25

Safety airbag-18

Impact-vehicle diagnosis

Test SRS-ECU diagnostic signals

1.  Connect the  (X-431 diagnostic test’s) diagnostic joint

2.  Read the diagnostic results with X-431 diagnostic tester

Repairing procedure

1.When safety airbag is released.

The following parts should be replaced with new ones

a. Passengers’ side safety airbag module

b. SRS-ECU

c. Driver’s side safety airbag module

2 Check the following parts; replace them with new ones providing something wrong with them.

a. Clock spring

b. Steering-wheel, steering column, bottom steering shaft module

3.Driver’s side safety airbag module’s installation status towards the steering wheel.

a. Check whether abnormal knocking is with the steering wheel, its activity is in good condition and its clearance is normal.

b. Check whether the wiring harness joint is broken and its terminal is deformed.

Caution: Due to the impact, the diagnostic instrument cannot communicate with SRS-ECU when accumulator is lack of

power, in this case, check and maintain the instrument panel wiring harness or utilize the extension power supply.

Safety airbag-19

1. Check whether depression, crack or deformation is with the SRS-ECU bracket.

2. Check whether the joint is broken and terminal is deformed

3. Check SRS-ECU bracket’s installation status

a. Check whether depression, crack or deformation is with the shroud

b. Check whether the joint is broken, terminal is deformed and wiring harness is meshed.

c. Check whether depression, crack or deformation is with the gas generator shield.
d. Make sure the direction of the arrow is straightforward

4. Check the installation status of safety airbag module.

Driver’s side safety airbag module (the following Figure)

generator

bracket

connect the horn

connect the driver’s side

module

Clock spring (right Figure)

1.

Check whether the joint and protecting tube are broken and the terminal is deformed.

2.

Check whether the shield is deformed.

Steering wheel, steering column and bottom steering shaft module

1.

Check the installation status of driver’s side safety airbag module

2.

Check whether abnormal knocking is with the steering wheel and its clearance is normal

Passengers’ side safety airbag module (the following Figure)

1.    Check the installation status of passengers’ side safety airbag module

2.    Check whether the shield is deformed

Safety airbag-20

 

Wiring harness joint (instrument cluster wiring harness)

Check whether the wiring harness is well installed, the joint is broken and the terminal is deformed.

Warning

The attentions for use and maintenance for SRS safety airbag are displayed in the Figure. Operate according to the sign and, the
destructed and dirty sign must be replaced with a new one steering

 wheel in Figure6-1

Driver’s side safety airbag module in Figure 6.2

Clock spring in Figure 6.3

SRS-ECU in Figure 6.4

Sun visor in Figure 6.5

Passengers’ side safety airbag module in Figure 6.6

Passenger side airbag (PAB)

Safety airbag-21

Removal methods for all the parts

Safety airbag electronic-control unit

Caution

  Continue the operation 60 seconds after the removal of accumulator negative. Wrap the removed negative with

insulating tape for insulation.

2. The SRS-ECU must not be separated nor repaired replace the failed SRS-ECU with a new one.

3. Prevent the SRS-ECU from shock and vibration, replace the SRS-ECU with depression, crack or deformation with a

new one.

4. Do replace the SRS-ECU with a new one after the safety airbag is released.

5. Do not damage the SRS-ECU when removing or maintaining the parts next to it.

Figure 6

1

Figure 6

2

Figure 6

3

Figure 6

4

Figure 6

5

Figure 6

6

warning signs

warning signs

passengers’ side safety airbag module

warning signs

Safety airbag-22

1.

Operations before removal

a. Place the ignition switch in OFF position.

b. Remove the accumulator negative and well preserve it somewhere or wrap it with tape.

2.

Removal procedure.

a. Central channel’s side panel (or remove the co-instrument panel)

b. Remove the connector clip connecting with the safety airbag ECU

3.

Installation sequence

a. SRS-ECU;

b. Install the connector clip connecting with the safety airbag ECU

c. Central channel’s side panel (or remove the co instrument panel)

d. Connect the grounding jumper.

4.

Some points for installation

a. SRS-ECU installation

b. Post-installation test

Place the ignition switch in ON position

SRS alarm lamp flashes in 6 seconds and extinguishes.

c. If not extinguishes, the failure test and troubleshooting must be done.

5.

Test

a. Whether the depression, crack or deformation is with the SRS-ECU shield.

b. Whether the terminal is broken or deformed.

Caution: The SRS-ECU safety airbag will not work normally if the SRS-ECU is not correctly installed.

Caution: The SRS-ECU with depression, crack or deformation must be replaced with a new one.

For the inspection of SRS-ECU besides the previous refer to related item of troubleshooting

Safety airbag-23

Driver’s and passengers’ side safety airbag module (DAB, PAB), clock spring

Caution

1. Continue the operation 60 seconds after the removal of accumulator negative. Wrap the negative with insulating

tape for insulation.

2. Safety airbag module and clock spring must not be separated nor repaired, replace the failed ones with new ones.

3. Please pay high attention when using the safety airbag module and clock spring, do not let them fall on the ground

nor fall into water or oil. Moreover, replace the depressed, crack or deformed ones with new ones.

4. After the safety airbag module is released, keep the released side up, store it somewhere flat and do not lay anything

on it.

5. The safety airbag module must not be stored in a place with the temperature above 93

.

6. The released safety airbag module must be replaced with a new one, at the same time test the clock spring, replace

it with a new one if something unusual with it.

7. Use gloves and protection glasses during operating the released safety airbag.

8. The unreleased safety airbag must be abandoned after its release.

Caution

During the removal, the wring harness connector clip must be removed before the removal of other wring harness

connector clips in order to avoid the possible improper release caused by static interferences, which is reversal to the

case of installation.

1. Removal and installation

  Driver’s side safety airbag module, passengers’ side safety airbag module, clock spring.

2. Operations before removal.

a. Take out the ignition switch key after the steering wheel and front wheel in straightforward direction.
b. Remove the connections of accumulator negative

3. Driver’s side safety airbag module removal procedure

a. Screw off the bolts of two sides, as showed in Figure 8-1
b. Shut off the wiring harness connector clip
c. Remove the safety airbag module assembly
d. Remove the steering wheel

4. Passengers’ side safety airbag module removal procedure

a. Remove all the trim covers and glove boxes of instrument panel separate the PAB module’s airbag wiring harness connector

clip from the safety airbag’s PAB side one.

b. Remove M6 bolts and separate PAB module from instrument panel armed beam.
c. Remove the instrument panel itself.
d. Remove the M5bolts of two sides of four PAB modules.

5. Clock spring removal procedure

a. Remove DAB module (shut off the connecting connector clip)
b. Carefully remove the steer
c.  Open the combined switch upper shield, find and shut off the bottom wring harness connector clip
d.  Remove the clock spring from the steer

6. Driver’s side safety airbag module (DAB) and its installation procedure

Safety airbag-24

Figure 8

1

The removal of steering wheel (Figure 8.2)

Figure 8

2

7. Passengers’ side safety airbag module (PAB) and its installation procedure.

a. Test before installation

Carefully take PAB module, justify both of them and plug four trim cover M5bolt into the mounting holes of the module’s
both sides
Well install together the module with trim cover bracket and instrument panel mounting bracket with four M5 bolts.
After the installation of the entire instrument assembly to the vehicle, tightly fix the PAB module to the vehicle transverse
beam with 2 matted M6 bolts at the glove box site.
Well mutually plug the PAB module airbag wiring harness connector clip and safety airbag wiring harness  PAB side
connector clip it is the end of PAB module installation.

b. Connection of accumulator terminal
c. Post-installation test

8. Clock spring installation procedure

a. Test before installation

Cross the line of upper clock spring through the hole in steer.
connect and fix the clock spring and steer
install the combined switch upper cover
install the steering wheel
steering wheel and safety module assembly

b. Connect accumulator’s terminal
c. Post-installation test

Safety airbag-25

Figure 8.3

d. Remove the steering wheel by removing the mounting screw from the mid-position. (Shut off the horn connector)

Caution

It is difficult to separate the steer from steering column due to the over meshing between spline and steering column,

in this case, do not forcibly remove the steer but screw off the bolt on the steering column and lift up the steer instead

(the forced removal will damage the clock spring since the connection between the steer and the spring)

Caution

Diagnose the safety airbag module circuit with electric diagnostic instrument without separating it.

Let the removed driver’s side safety airbag module bottom-side up and store it at a clean and dry place.

Store the clock spring in a clean and dry place.

9. Installation operation instructions

a.  The test before installation

The new safety airbag or clock spring must be tested before installation.

Caution

The safety airbag module must be abandoned after its release according to the procedure

Connect the accumulator negative

Connect the K-431 diagnostic instrument with the diagnostic interface (16 plug)

Caution

Place the ignition switch in OFF place when connect or shut off the 

 diagnostic instrument.

Place the ignition switch in ON position

Read the diagnostic circuit, check whether the safety airbag module is in normal condition except the failure regions.

Place the ignition switch in OFF position

Remove accumulator negative and wrap it with the tape for insulation.

Caution

Continue the operation 60 seconds after the removal of accumulator negative

Install the clock spring to the steer after its involution

 Clock spring’s central involution, clockwise screw the clock spring to the end, then turn it for 3 circles anticlockwise and make

    the involution with the marked sites

Safety airbag-26

Do the troubleshooting if the alarm lamp re-illuminates after its extinguishments following the 6-second-flashing (or it keeps

 illuminating from the very beginning)

10. Test

a. Driver’s side airbag module test (Figure8-3)

Check the following items and replace the corresponding safety airbag module part with anything abnormal with a new one.
Abandon the safety airbag’s old parts after its release according to the instructed procedure.

Caution

Do not jam the clock spring wiring harness during the steering wheel and safety airbag module assembly installation.

After the installation, rotate the steering wheel to left and right positions as enough as possible to confirm whether something

 abnormal is with it.

d. Post-installation test.

lightly rotate the steering wheel to the left and right to confirm whether something abnormal and noises will arise.(Driver’s side

safety airbag module, clock spring)

Place the ignition switch in ON place.

SRS alarm lamp flashes in 6 seconds and then extinguishes.

Caution

If without the clock spring central involution, the steering wheel will not be able to rotate at midway, or the clock spring

circuit will be damaged so that jeopardize SRS safety airbag’s normal activities.

The spacer must be removed after replacing a clock spring with a new one, otherwise it will damage the clock spring.

c.   Steering wheel and safety airbag module assembly installation.

Install the steering wheel and safety airbag module assembly after clock spring’s central involution.

safety airbag system failure alarm lamp

Caution

The safety airbag module (squib) circuit resistance can even not be tested by the designated tester.

When testing the resistance with an experimental instrument, sometimes the improper release will be caused by the

static interference because of the current in explosion pipe and cause some major damaging accidents.

Whether depression, crack or deformation is with the shroud.

 Whether the joint is broken and the terminal is deformed.

Whether depression, crack or deformation is with the gas generator shield.

Safety airbag module. Installation status.

Caution

Replace the safety airbag with depression, crack or deformation with a new one. Its old parts must be abandoned after

its release.

Safety airbag-27

b. Clock spring test (figure 8.5,figure 8.6)

Check the following items and replace the clock spring with anything abnormal (even it is quite tiny) with a new one

Whether the joint and protection tube are broken and the terminal is deformed.

Whether the shield is damaged.

Check the connection between clock spring’s upper joint terminal and it’s corresponding bottom terminal.

Plug in a thin probe from the 3# joint of clock spring.

Caution

Do not directly plug in the probe from the bottom of the joint.

Figure 8

5 As showed in Figure 8.5,Plug a thin probe into the current tester to check the connection of the terminal.

Safety airbag-28

SRS translation wiring harness

releases wring harness

shorting site

6m plus

the shroud

protection tube

Safety airbag module abandoning instruction

Carry out the operation according to the following procedure to abandon a safety airbag module or a vehicle with the SRS

safety airbag. First of all, release the safety airbag.

Unreleased safety airbag module abandoning

Caution

First release the SRS safety airbag when abdbdon it.

Release the safety airbag outside the vehicle to replace the safety airbag module.

Conduct the operation somewhere next to a smoke tester due to the smoke during the safety airbag’s release.

Tell the people to cover their ears and try to conduct the operation somewhere far away from the residential area due

to the big noise during the safety airbag’s release.

Remove the accumulator positive and negative and remove the accumulator off the vehicle.

Caution

Continue the operation 60 seconds after the removal of accumulator positive and negative.

Release the safety airbag module according to the following procedure.

1. Driver’s side safety airbag module

a.  Remove the blocking lever
b. Remove the clock spring 2# joint and instrument panel wiring harness joint (yellow)(figure 8.6)

Caution

The clock spring joint will short automatically after the removal of clock spring from the instrument wiring harness,

which can prevent any possible major accident caused by the incorrect release of driver’s side safety airbag module duo

to the static interference from happening.

c.  Connect the SRS safety airbag translation wring harness with 2 6m plus release wiring harnesses, wrap the joint part with

    insulating tape for insulation.

Safety airbag-29

auto body outer panel.

release wiring harness

auto body outer panel.

releases wring harness.

Mutually connect (short) the other end of release wring harness to avoid the possible incorrect release caused by the static

interference.

d.    At the clock spring’s 2# joint, tract the translation wiring harness out of the vehicle with the release wiring harness (Figure 9.2)

e. Close all the windows and doors and wear the guard to reduce the noises.

Caution

The guard should be worn because the glass with cracks is very fragile.

f. Shut off the joint of driver’s side safety airbag release wiring harness somewhere far from the vehicle, and connects the joint

with the accumulator and makes the safety airbag release.

clock spring connector clip

clock spring

srs translation wiring harness

release wiring harness

Caution

Continue the operation after the confirmation of nobody is in or next to the vehicle.

Its gas generator is quite hot after the driver’s side safety airbag’s release, it can be used after its cooling down for more

than 30 minutes.

Contact with the local service station of the Great Wall Auto Stock Corporation if the driver’s side safety airbag module

cannot be released.

g. Abandon the released driver’s side safety airbag module according to the instructions.

Safety airbag-30

wiring harness for release

shorting site

 6m plus

2.   Release outside the vehicle

Caution

Release the safety airbag somewhere open and plain as well as 6m plus from the obstacles and people

When release the safety airbag outdoors, try to avoid the strong wind and ignite windward in the breeze.

a. Remove the accumulator negative and positive and remove the accumulator.

Caution

Continue the operation 60 seconds after the removal of the accumulator.

b. Release the safety airbag module according to following procedure

driver’s  side safety airbag module

remove the driver’s side safety airbag module off the vehicle.

Caution

The two ends of the terminal will short automatically without the joint connection of driver’s safety airbag module,

therefore the possible improper release caused by static interference can be avoided; if it improperly releases, keep the

released side up and store it somewhere plain, do not lay anything on it.

Prepare 2 6m plus release wiring harnesses and mutually connect the other ends(short-circuit) of them to avoid the possible

improper release caused by static interference.( refer to figure 9-4)

Touch the vehicle with your hands to eliminate the static electricity.

Caution

Strictly execute the previous procedure for it can prevent the possible incorrect release caused by the static interference

from happening.

Shut off the driver’s side safety airbag module wiring harness and connect it with two release wiring harnesses( refer to figure

9-5)

release wiring harness

passengers’ side safety airbag module

shoring site

insulating tape

Safety airbag-31

release wiring harness.

driver’s side safety airbag module

release wiring harness

Installed the stand-by bolts on the driver’s side safety airbag module’s inside bolt and fasten a thick wire to the wheel rim to

fix it.

Connect the release wiring harness connecting with the driver’s side safety airbag module with the low part of an old tire loading

the wheel rim. ( refer to figure 9-6)

Lay three wheel-hub-free old tires on the tire fixing the driver’s side safety airbag module (Figure 9-7).

wheel-hub-free old tires

release wiring harness

Shut off the joint of driver’s side safety airbag release wiring harness somewhere far from the vehicle, and connect the joint with

the accumulator and make the safety airbag release (Figure9-8).

Caution

Release the driver’s side safety airbag module after the confirmation of nobody close to it.

Its gas generator is quite hot after the driver’s side safety airbag’s release, it can be used after its cooling down for more

than 30 minutes.

Contact with the local service station of the Great Wall Auto Stock Corporation if the driver’s side safety

Safety airbag-15

Y es

Present failure codes
R eplace SR S safety airbag system unit
See he removal/installation of SRS
safety airbag system unit
History accumulated failure codes
T he end of failure diagnosis

4

Place the ignition switch in L OC K position
Release accumulator negative wire and wait for 1 minute
plus
Remove the left trim cover
Shut off SRS safety airbag system unit translation
connector clips
Install back the accumulator negative wire, place the
ignition switch in ON position
Is the potential of SRS safety airbag system unit connector
clips stitch 5,6(grounding) above 9V ?

No

R eplace wiring harness

Drive side failure 

Failure code 
$9021 
$9022 
$9024 
$9025 

Driver’s side safety airbag failure (high or low resistance, shorting grounding, etc.) 

Test 

condition 

Warning 
If not correctly handled, the safety airbag module as well as pretension safety belt may possibly be trigged, released 
and tensioned, thus make serene damage to people. Therefore, please carefully read the repairing warning before 
trouble handling. Please take references in safety airbag system repairing warning   
Driver’s side safety airbag 
The resistance between the SRS safety airbag system connector clips connectors not within the designated scope 
SRS safety airbag system driver’s side airbag relative wiring harness shorting or shutoff 

Possible 

causes 

Driver’s side safety airbag module failure 
Clock spring internal failure 
Failure of circuit connector clips between clock spring and SRS safety airbag system electronic-control unit   
Shutoff or shorting of wiring harness between clock spring and SRS safety airbag system electronic-control unit. 
Misconnection of SRS safety airbag system driver’s side airbag generator connector clip 

Procedure 

Test 

Operation 

Normal 

Next step 

1 

Check the clock spring   
Warning 
If  not  correctly  handled,  the  safety  airbag  module  may  possibly  be 
trigged  and  released  thus  make  serene  damage  to  people.  Therefore, 
please  carefully  read  the  repairing  warning  before  trouble  handling. 
Please take references in safety airbag system repairing warning. 

Are the relative parts of clock spring normal? (The relation between 

stitches, unnecessary shutoff or shorting?) if the present clock spring can 
be replaced by a better one. 

Abnormal 

Replace the clock spring 
Take  references  in  the 
removal/installation  for 
safety  airbag  system  and 
clock spring 

Can 

Replace  the  driver’s  side 
safety airbag module 
Take  references  in  the 
removal/installation  for 
driver’s side safety airbag 
in safety airbag system 

2 

Confirm the failure in driver’s side safety airbag module or other parts. 
Replace the DAB module with a better one 
Install back accumulator negative wire 
Place the ignition switch in ON position   
Is the failure code still in display or can be debugged? 

No 

Next step 

Normal 

Next step   

 

3 

Check clock spring wiring harness connector clip 
Place the ignition switch in LOCK position 
Release accumulator negative wire and wait for 1 minute plus 
Remove steering pillar shell 
Release the clock spring connector clip, is it in normal condition? 

Abnormal 

Replace 

the 

wiring 

harness 

 

Safety airbag-16

Yes Next 

step 

4 

Confirm the failure in clock spring or other parts 
configure the special tools fuel and temperature diagnostic instrument 
at 2Ω position   
Install back the accumulator negative wire 
Place the ignition switch in ON place 
Any failure code in display? 

No 

Replace clock spring 
Take references in the removal 
and installation for safety airbag 
system and clock spring. 

Normal 

Replace SRS safety airbag 
system unit; take references in 
removal/installation of SRS 
safety airbag system unit. 

5 

Check the wiring harness between clock spring and SRS safety airbag 
system electronic-control unit 
Place the ignition switch in LOCK position   
Release accumulator negative wire and wait for 1 minute plus 
Remove PAB trim cover, glove box (passengers’ side safety airbag is 
under the trim cover) 
Release the passengers’ side safety airbag module connector clip 
Release all SRS safety airbag system unit connector clips 
Check whether the following troubles are with the harness between 
connector clips terminals of SRS safety airbag system unit and clock 
spring  
Grounding  
Power-supply shorting 
Shutoff  
Is the previous wiring harness normal? 

Abnormal 

Replace the wire harness 

Normal Next 

step 

6 

Check the clock spring connector clip 
Remove the steering pillar shell 
Release the clock spring connector clip 
Is the clock spring connector clip normal? 

Abnormal 

Replace the wiring harness or 
connector clips 
 

Normal Next 

step 

7 

Check clock spring   
Remove clock spring   
Take references in removal/installation of safety airbag system as 
well as clock spring 
Check clock spring   
Take references in the test for safety airbag system and clock spring. 
Is the clock spring normal? 

Abnormal 

Replace clock spring 
Take references in the 
removal/installation of safety 
airbag system and clock spring. 

Normal Next 

step 

8 

Check the wiring harness between clock spring and SRS safety airbag 
system electronic-control unit 
Place the ignition switch in LOCK position 
Release accumulator negative wire and wait for 1 minute plus 
Remove PAB trim cover, glove box (passengers’ side safety airbag is 
under the trim cover) 
Release the passengers’ side safety airbag module connector clip 
Release all SRS safety airbag system unit connector clips. 
Check whether the following troubles are with the harness between 
connector clips terminals of SRS safety airbag system unit and spring 
clock. 
Grounding  
Power-supply shorting 
Shutoff  
Is the previous harness normal? 

Abnormal 

Replace clock spring 
Take references in the 
removal/installation of safety 
airbag system, and clock spring