GREAT WALL HOVER 2006 Service Repair Manual

Ball pin
Check of ball pin
1. Check the lower ball pin for loose
a. Raise the front of the car by jack and support it by the frame.
b. Ensure the front wheel is in straight advancing position and step
down the brake pedal.
c. Move the arm upwardly and downwardly; check
the clearance of lower ball pin.
Max. vertical clearance: 0mm
2. Check the upper ball pin for loose move the wheel
upwardly and downwardly and check the gap of
upper ball pin.
Max. vertical clearance: 0mm
3. Check the rotation of ball pin
a. Remove the ball pin.
b. Shown as figure, shake the ball pin stud forwardly and backwardly
for several times before install the nut
c. Rotate the nut continuously by torsion meter and 2-4s for a
cycle; record the readout of torsion meter in the fifth cycle.
Tightening torque (for rotary):
Lower ball pin 0.1
4Nm
Upper ball pin 0.1
4Nm
Disassembly of ball pin
1. Remove the steering knuckle and front hub assembly
(Refer to section “Front Hub and Steering Knuckle”)
2. Remove the lower ball pin form the lower arm
3. Remove the upper ball pin from the upper arm

Installation of ball pin
1. Install the upper ball pin on the upper arm
Tightening force: 785Nm
2. Install the lower ball pin on the lower arm
Tightening force: 14010Nm
3. Install the steering knuckle and front hub assembly
(Refer to section “Front Hub and Steering Knuckle”)

Torsion bar spring
Disassembly of torsion bar spring
1. Make the assembly mark on the torsion bar spring,
torsion base and adjusting arm
2. Measure the length A of extension section of bolt
according to the length shown in figure.
Remarks: The measuring value is for reference when adjust the
ground clearance of chassis.
3. Loose the adjusting bolt until the torsion bar spring
has not the tension.
4. Remove the fixed arm and torsion bar spring
Installation of torsion bar spring
Remarks: There are the L and R indication marks, which must not
be exchanged on the rear end of the torsion bar spring. Mark L
means the left while R for right
1. For reused torsion bar spring
a. Cost the spline of torsion bar spring with grease thin.
b. Align the assembly mark and install the torsion bar spring on the
torsion bar.
c. Align the assembly mark and install the adjusting arm on the
torsion bar spring.

d. Tighten the adjusting bolt and make the extension length of the
bolt equal to the value before disassembly.
2. For new torsion bar spring
a. Remove the wheel.
b. Coat the spline of torsion bar spring with thin grease.
c. Install the torsion bar spring on the torsion bar base.
d. Lower the lower arm to the lower limitation position; install
the adjusting arm in the torsion bar spring with the angle that
the adjusting bolt just can be screwed on the upper adjusting
block.
Remarks: It can repeat for several times until proper when
adjust the angle.
e. Tighten the adjusting bolt to the specified torque.
Nut tightening limitation: A is about 20-35mm; if A>35mm,
then it is adjusted through height of adjusting arm.
f. Install the wheel; remove the bracket; bounce the vehicle for
several times to make the suspension enters into the stable
status.
g. Rotate the adjusting bolt and adjust the ground clearance of
chassis (Refer to 4-Wheel Alignment).

Lower suspension arm
Disassembly of lower suspension arm
1.The disassembly of the front hub and steering knuckle
assembly includes the removal of vibration damper,
stabilizer bar and steering cross rod.
(Refer to the section “Front Hub and SteeringKnuckle”)
2. Disassembly of torsion bar spring
(Refer to section “Torsion Bar Spring”)
3. Remove the front shaft of lower arm
a. Make the assembly mark on the adjusting cam
b. Remove the nut and front shaft of lower arm.
4. Screw off the rear shaft of lower arm
Screw off the nut; remove the rear shaft of lower arm shaft and
remove the lower suspension arm.

Replacement of bush of lower suspension arm
1. Remove the short bush of lower suspension arm
Use the special tools to press out the short bush form
the lower arm.
2. Installation of short bush of lower suspension arm
Use the special tools to press the new short bush into
the lower arm
Remarks: Do not coat the bush with the grease.
3. Removal of long bush of lower suspension arm Use
the special tools to remove the long bush.
special tools
special tools
4. Install of long bush of lower suspension arm Use
the special tools to install the new bush.
Remarks: Do not coat the bush with the grease.
special tools
special tools

Installation of lower suspension arm
1. Installation of lower suspension arm
a. Install the rear shaft of lower arm and tighten the screw to
the specified torque.
Tightening force: 290
25Nm
b. Install the front shaft of lower arm and pretighten the nut.
2. Installation of front hub and steering knuckle
assembly
(Refer to section “Front Hub andSteeringKnuckle”)
3. Install the vibration damper on the lower suspen
sion arm Install the vibration damper on the
lower suspension arm bracket.
Tightening force: 9010Nm
4. Connect the stabi lizer barto the lower susp
ension arm.
Tightening force: 635Nm
5. Connect the steering cross rod to the steering
knuckle arm
a. Connect the steering cross rod to the steering knuckle arm.
Tightening force: 120
10Nm
b. Install the new split pin.
Remarks: It should align the notch of nut with the pinhole
when install the split pin; the nut can be tightened but not
loosed during the alignment.

6. Install the torsion bar spring
(Refer to the section “Torsion Bar Spring”)
7. Tighten the nut of front shaft of lower arm to the
specified torque
a. Install the wheel, remove the bracket and bounce the vehicle
for several times to make the vibration damper enters into the
stable status.
b. Align the assembly mark and tighten the nut to the specified
torque.
Tightening force: 240
20Nm
8. Check the wheel alignment parameter
(Refer to 4-Wheel Alignment)

Upper suspension arm
Disassembly of upper suspension arm
1. Disconnect the upper ball pin form the steering
knuckleRemove the split pin and nut; use the special
tools to disconnect the upper ball pin from the steering
knuckle.
2. Remove the brake oil pipe on the upper arm shaft
a. Use the open-end wrench to screw off the oil pipe tight nut.
b. Pull out the brake oil pipe and plug it by the rubber plug.
Remarks: There are two two-way valves for rear brake oil pipe
beside the right upper arm shaft ; when remove the right upper
suspension arm, it must remove four oil pipe tight nuts in the
place and plug it by the rubber plug to prevent the brake fluid
from overflowing.
3. Disconnect the brake hose form the brake caliper
Remove the hollow bolt and disconnect the brake hose
form the brake caliper
Remarks: Must not lose the copper gasket seal.
4. Disconnect the brake hose from the upper arm oil
pipe bracket.
Use the pliers to pull out the sheet steel spring clip and
disconnect the brake hose from the upper arm oil pipe
bracket.
5. Remove the upper suspension armRemove two bolts
and remove the upper suspension from the armcarriage.
Remarks: Keep the adjusting shim and don’t lose it. Record the
thickness of front and rear adjusting shim for convenience of
reinstalling them in the original position.
special tools

Replacement of upper arm bush
1. Remove the bush
a. Remove the bolt and washer.
b. Use the special tools to push out the bush.
c. Remove the upper arm shaft; remove another bush in same
procedure.
2. Install the bush
a. Use the special tools to press in the bush.
b. Install the upper arm shaft; use the special tools to press in
another bush.
3. Tighten the upper arm shaft to specified torque.
a. Coat the screw of both ends of upper arm shaft with the
screw lock sealant; install the washer and nut.
Remarks: Adjust the position of upper lower; make the
installation plane of ball pin is vertical to the installation
plane of upper arm shaft.
special
special
special