air condition GREAT WALL HOVER 2006 Service Repair Manual

Preface
Table of Contents
Instruction How to use the manual
Chapter 1 Overview of the entire car (parameters)
Chapter 2 Fuel supply system and exhaust air system
Chapter 3 Clutch
Chapter 4 Transmission
Chapter 5 Automatic transmission
Chapter 6 Driving shaft
Chapter 7 Suspension and vehicle axle
Chapter 8 Brake (ABS)
Chapter 9 Steering
Chapter 10 Car body electric appliance
Chapter 11 CD player and air-conditioning system
Chapter 12 Safety airbag
Annex:
Important components guarantee and requirement
List of non-metal material consumption
Special tools
D Important working components and tightening torque
E Electric wiring diagram

Overview of the entire car-1
Chapter 1
Overview of the entire car
Basic parameter....................................................... 2
Engine..................................................................... 4
Air inlet system........................................................ 5
Exhaust air system................................................... 5
Fuel supply system................................................... 5
Cooling system........................................................ 5
Clutch..................................................................... 5
Transmission............................................................ 6
Drive shaft............................................................... 6
Front shaft/axle........................................................ 6
Rear axle................................................................. 6
Wheel tyre............................................................... 6
Suspension.............................................................. 7
Frame..................................................................... 7
Steering system........................................................ 7
Brake system........................................................... 8
Car body................................................................. 9
Electrical system.................................................... 10
Air-conditioning system …………………..............12

Overview of the entire car-5
The friction, disc, single-diaphragm spring clutch, hydraulic control mechanism. The external diameter of friction disc D=225mm,
internal diameter d=150mm, material is F810.
Adjustment of clutch pedal:
1. Measure the height of clutch pedal (from pedal pad surface to floor) and free stroke of clutch pedal (fork bar pin clearance).
Standard height of clutch pedal: flush with the brake pedal, free stroke of clutch pedal is 5-15mm;
2. Readjust the free stroke of pedal after adjust the height of pedal; rotate the push bar to the standard value, then fix the bolt
and nut;
3. If the free stroke of clutch pedal is not within standard value, it should rotate the adjusting bolt to standard value, then fix
the bolt and nut. Do not move the push bar to main cylinder when adjust the free stroke of pedal;
4. If the free stroke of clutch pedal and clearance between the clutch pedal and floor when the clutch is disengaged de not
consist with the standard, this may by caused by the air in hydraulic system and failure of main cylinder or clutch. It can
discharge the air of system or dissemble and inspect the main cylinder or clutch.
Table 2 Structure and main technical parameter of engine(continued)

Serial No. Item Specification and parameter
27 Consumption ratio of engine oil and fuel oil
(%) ≤0.8
28 Cooling method Closed forced water cooling
29 Starting method Electric motor
30 Net weight(kg) 167
31 Outline dimension: L×W×H (mm) 730×653×667
32 Idle-speed emission CO(%)/HC(ppm) ≤0.5/≤100
33 Emission control degree of operating
condition regulation With three unique catalytic converter, air-fuel
ratio closed loop control, the equipped light
car meets the standard of GB 18352.2－
2001

Air inlet system
Dry-type air cleaner.
Exhaust air system
Primary muffler, with two-stage three-way catalyst device.
Fuel supply system
Adjustment of accelerator pedal
The stroke of accelerator pedal is 155mm; adjust the adjusting nut on wire bracket if it does not consist with the standard.
The fuel tank is plastic tank with capacity of 67L; the oil supply control is the mechanical pedal oil control and
internal-type electric fuel pump; the type of fuel evaporation is the activated carbon can and electric valve control.
Cooling system
Forced circulation water cooling, electric fan and aluminum tube radiator.
Clutch

Air-conditioning system
The structure and parameter of the air-conditioning s ystem is shown in table 8.
Table 8 The structure and parameter of the air-conditioning system

Serial No. Item Structure and Paramet er
1 Structure and
shape

Front and rear heating and cooling air conditioner, vapor compression type
cooling, hot-wat er heating

2 Performance and
parameters

Refrigerating capacity 3.5kW, heat exchange capacity 3.5kW, fan capacity
350m
3/h
3 Operation
Control board button type operation, temperature auto control, air door micro
motor drive, the temperature in the car can be controlled automatically, the
fanning position mode, heating/ cooling mode, air int ern/external cycling mode
and wind speed and t emperature can b e selected and adjusted

4 Refrigerant R134a
5 Compressor SD7V16 variable capacity compressor, with a maximum capacity of 160ml
6 Condenser Parallel stream mode structure, flat pipe thickness of 26mm
7 Evaporator Two box es structure, cascading evaporator, F expansion valve, centrifugal
blower

8 Drying fluid
collector
External diameter φ60.5mm
9
Refrigerating
pipe and
wa r m wa t er pi p e

Refrigerating pipe: complex structure of rubber refrigeration soft tube and
aluminum tube. The warm water pipe: rubber molding pipe

10 Transducer Outdoor temp erature sensor, indoor t emperature sensor, evaporator temperature
sensor
11 pressure switch Three-state pressure switch

Clutch-3
Inspection and adjustment of clutch pedal
1. Check the correctness of pedal height and stroke of push rod
The pedal height starting from the meter: LHD 157.5mm
The push pole travel at the top of the pedal: RHD 151.0mm
If not correct, adjust the pedal height and push rod stroke.
2. Adjust the pedal height and stroke of push bar if necessary
a. Screw off the locknut, rotate the locking bolt until to the correct
height.
Screw on the locknut.
b. Screw off the locknut, rotate the push rod until the stroke of push
rod is correct.
Screw on the locknut.
3. Check the correctness of free stroke of pedal
Step on the pedal lightly until fell the clutch start to generate the
resistance.
Free stroke of pedal: 5
15mm
4. Adjust the free stroke of pedal if necessary
a. Screw off the locknut, rotate the push rod until the free stroke is
correct.
b. Tighten the lock nut
c. Check the height of the pedal after adjusts the free stroke of pedal.
d. On the condition that ensure the free stroke of clutch pedal assembly:
The height difference between the brake pedal, clutch pedal and the
front apron is 0
8mm.
Air discharge of clutch
Remarks: It should discharge the air if there is residual air in the
clutch system.
Caution: Do not leave the clutch liquid on the painted surface,
otherwise it should be washed off immediately.
Fill the brake fluid in the clutch storage tank
Check the liquid tank frequently. Filling if necessary.
the adjustment
point of push rod
stroke
the adjustment
point of pedal height
pedal height
front wall
free stroke
push rod stroke

Automatic transmission-50
Only can 1→3→4
shifting The sm all O -ring of front servo piston is invalid or lost.
2→3 G ear psition shifting valve is blocked. D etect the O -ring. P rocess the replacem ent or
reinstallatio n if n ecessary. D etect th e 2→3
G ear shifting valve; Process the maintenance
or replacem ent according to the requirem ent.
Only can 1→2→1
shifting C1 is invalid or 3rd-G ear and 4th- G ea r is lo o s e . (g iv e t o
1st-G ear in 3rd-gear; give to 2nd-G ear in 4th-G ear) D etect th e clutch C 1 . R ep air or rep la ce it if
necessary.
Can not realize the
manual 4→3, 3→2, 2
→1 O verspeed clutch /ball spool has displacem ent.
C4 is invalid. D etect the ball spool. Process the replacem ent
or reinstallation according to the req uirem ent.
D etect the C4. R epair C4 or replace the C 4
wave pan according to the necessary.
W itho ut m an ual
1st-G ear The rear brake belt is loose when the tem perature is
high.
The R -G ear/Low speed 1
st-G ear ball spool has
displacem ent.
The internal “O ” –ring of rear servo is lost.
C4 is invalid. D etect the rear brake b elt, adjust id necessary.
D et e ct t h e b a ll sp o o l, R ein s ta ll o r r ep la c e it if
necessary.
D etect the O -ring, R einstall or replace it if
necessary.
D et e ct th e C 4 . R ep a ir o r r ep la c e it if n e c ess a r y.
Only can 1→2→2→4
gear. The dim ension of socket of front servo is large. H as the
possibility of loose of plug.
It has the trend that ca n n ot realize th e reverse-G ear if
drive the vehicle in this condition continuously. Repair or replace it if necessary.
Detect the C3 piston O -ring, replace it if
necessary.
Only an 1st-gear,
2nd-G ear, 4th-G ear or
1st-G ear, 2nd-G ear an d
3rd-G ear.(3rd-G ear is
tightened) The gear sensor has failure, only can1→2→3 shifting.
3→4 Gear shifting valve is blocked. D etect the gear-position sensor. R epair or
replace it if necessary. D etect the 3→4 gear
shiftin g va lv e. R ep air or r ep la ce it if
necessary.

3. Oil filling of service after sales
Set the liquid level position correctly; the procedure is shown as follows:
a. Shut down the engine; place the gear-position in the P-Gear.
b . Lift the vehicle (or place it above the trench).
c. Clean the around of plug before remove it. Remove the oil plug and check the O-ring for damage, finally connect the oil filling
pump to the oil filling hole.
d. Lower the vehicle and oil filling pump to the ground; fill with the transmission fluid partially. The general oil filling amount
is shown as follows:
If in the status of transmission hydraulic torque converter is empty: 8.0 L
If in the status of transmission hydraulic torque converter is full: 3.8 L
e. When start the vehicle in P-Gear, rotate the engine in idle speed. Step down the foot brake, pull the shifting lever in each gear-
position in circulation and add the transmission fluid until the action of each gear-position can be sensed.
f. Then fill with 0.5L transmission fluid (ATF) additionally.
g. Shut off the engine, lift the vehicle; take off the pump and replace the plug. Ensure the plug is tightened according to the
specification.
h. Then pull the vehicle throttle position for slight opening to make the vehicle runs for 3.5
4.5km; the rotary speed of engine
is no more than 2500r/min; then the transmission fluid temperature will in the scope of 50
60.
i. The engine is in idle-speed; pull the hand brake to make the shifting lever circuits in each gear-position horizontal status.
k. Remove the filling plug 3 minutes after the engine is shut off, but must be no more than1 hour. At this time, the correct
level position should be in the bottom of oil filling hole. If does not reach the liquid level position, then fill with few
transmission fluid (ATF) to meet the requirement.
l. Reinsert the transmission fluid plug, remove the residual transmission fluid around the vehicle and transmission; tighten the
plug to the specified torque.
4. Replace the ATF
Please notice that the color of TQ95 automatic transmission oil will be faded in the normal operation of transmission; it will be
turn into the deep brown or even in black. It will not affect the performance of ATF. It means that the fading of transmission
fluid not always means to replace the transmission fluid.
If the transmission temperature is raised, the ATF will be burnt. In this condition, ATF will change into black and with special
sulfur smell. The smell of the ATF means the oil is burnt.
If the ATF is burnt, it will cause the damage of transmission (the clutch assembly is damaged at least).At this time, it should
disassembly the transmission and process the necessary detection.
Electronic calibration
1. Idle-speed calibration
The idle-speed calibration is introduced in detail in the vehicle factory manual.
2 Calibration of position of throttle position

If the throttle position information stored in TCU is lost or not in application scope. It can be reestablished according to the
following program as the diagnosis error information.
a. Check whether the engine idle speed is in required range.
b. In the status of shutting off of air-condition, make the engine is in “D” –Gear for 60s,then the reference point with opening
degree of 0
of throttle position is reset in TCU.
Shut off the engine; switch on the ignition device, step the accelerator pedal to bottom for 60s, then the reference point with opening
degree of 100
of throttle position is reset in TCU.
3. Clear of throttle position

The clear process set by learning throttle position is necessary for M88 transmission TCU.
4. Car code

For M88 transmission, the car code is unnecessary.

connecting housing (4WD)connecting housing
Figure 8.20 planet carrier assembly and central support
eCheck whether the socket has the proper central support, then install the central support on the one-way clutch, ensure the
support can rotate in anticlockwise. Refer to Figure 8.20
f. Use the Vaseline to lubricate the NO.9 needle thrust bearing and thrust washer, and install it on the rear of planet carrier. Refer
to Figure 8.19
g. Install the planet assembly and central support on the box and align the central support installation bolt hole.
h. Install and tighten the central support bolt.
i. Install the ring spring fixing plate; ensure the ring spring is installed in the box correctly.
j. Remove the central support bolt and provide the Loctite243 or similar material for screw; install and tighten the bolt to
specified standard.
6.Ttransmission rear housing assembly
The installation procedure of transmission rear housing assembly is shown as follows:
a. Check the condition of transmission rear housing roller bearing (2WD and Chairman mode), replace it if necessary (rear drive
mode). Install the new bearing form the end of transmission rear housing; only can press the bearing side with mark.
b. Install the new sealing material on the transmission rear housing or adaptor rear housing. Refer to Figure 8.21.
Figure 8.21 Connecting and extension housing
output shaft
o-ring
locking nut
oil seal
needle bearing oil seal
gasket

Troubleshooting
Failure Cause Repair cont ent
Floating/pulling The t yre is worn or charged improperly.

The front wheel alignment is incorrect.

The wheel bearing is adjusted too tightened.
The front /rear suspension components is loose or
damaged
The steering linkage is loose or worn
The steering device is connect ed unsound or worn. Charge the t yre to the prop er pressur e or
repla ce the t yre.
Check the condition of front wheel
alignment.
Adjust the wheel bearing
Tighten or replace the suspension
partTighten or replace the steering
linkage
Adjust or replace the steering device
Subsidence of vehicle body Overload of vehicle
vibration damper is worn
spring is weak Check the load weight
Replace the vibration damper
Replace the spring
Left-right swing/up-down
bounce The t yre is charged improperly
The stabilizer bar is bend or damaged
The vibration damper is worn Charge the t yre to the prop er pressur e
Replace the stabilizer bar
Replace the vibration damper
Front wheel vibration The t yre is worn or is charged improperly

Unbalance of each wheel
The vibration damper is worn
The front wheel alignment is incorrect

The wheel bearing is worn or adjusted badly
The ball joint or bushing is worn
The steering system is loose or worn
The steering mechanism is adjusted badly or damaged Repla ce the t yr e or char ge it to the prop er
pressure.
Balance all wheels
Replace the vibration damper
Check the condition of front wheel
alignment
Replace or adjust the wheel bearing
Check the ball joint or bushing
Tighten or replace the steering linkage
Adjust or repair the steering device
Abnormal abrasion of tyre The t yre is charged improperly
The vibration damper is worn
The front wheel alignment is badly

The suspension part is worn Charge the t yre to the prop er pressur e
Replace the vibration damper
Check the condition of front wheel
alignment
Replace the suspension part
Oil leakage of differential High oil level or incorrect oil grade

The oil seal is worn or damaged
The matching flange is loose or damaged Drain the oil to the specified level or
repla ce the oil
Replace the oil seal
Tighten or replace the flange
The axle has the nois e The oil grade is low or incorrect

The clearance of the pinion, ring gear or side gear is
large.
The ring, pinion gear or side gear is worn or broken
The pinion gear bearing is worn
The b earing of rear axle half shaft is worn.
The differential b earing is loos e or worn Fill with the lubrication oil or replace the
oil according to the specification
Check the clearance

Check each gear
Replace the bearing
Replace the bearing
Tighten or replace the bearing

Brake-3
Troubleshooting (continued)

failure caus e Inspection content


The brake generates the
crack clatter during
operation. (drum brake)
The brake shoe is blocked in the rear apron flange
The rear apron flange is worn
The brake shoe pull-out piece spring is loose or lost
The fixed bolt of rear apron is loose (disc brake )
Brake block support plate is loose or lost
Installation bolt is loose
Filled with lubricated oil
Replace the lubricant flange
Replace
tighten
replace
tighten



It has the rustle or rattler
when use the brake The brake shoe gasket or brake block is worn
The brake caliper and wheel or rotor are disturbed
mutually
The dustproof cover and rotor, rear apron and brake
drum are disturbed mutually
Failure of other brake system component
Tyre generates the abrasion with the tyre and chassis Replace, if the scratch is heavy,
then fine machine the brake drum or
rotor again
Replace it according to requirement
Correct or replace
Repair or replace it according to
requirement
Check or maintain
It has the squeak, continuous
scream, rattler or vibration
noise when use the brake .
Caution: The abrasion
material in the brake will
generate the inherent noise
and heat during the
abrasion, then emit the
heat. So it is normal that
generate the squeak by
accident. The condition
will be serious in extreme
environment, such as cold,
hot, high humidity,
snowing, saliferous and
mud. The accident squeak
will not cause the fatal
failure of the brake, and
will not reduce the effective
performance of the brake. The brake drum and brake shoe gasket, rotor and
brake block is worn or scratched.
The brake pad or block is dirty, with oil or smoothed.
The brake pedal or assistor push bar is adjusted
incorrectly
(dis c brake )
The brake block silencing plate is lost or damaged.
The abrasion of the brake block makes the brake
block abrasion indication plate contacts the rotor
The brake ca lip er has burr or is corrosive
(drum brake)
The pull-out piece spring of brake shoe is soft,
damaged or improper. The pull-out piece spring pin
and spring of brake shoe is loose or damaged; and
rear apron flange has crack Check, repair or replace
clean or replace
check, replace
check and adjust
replace
replace
clean or remove the flash
check, repair or replace