GREAT WALL HOVER 2006 Service Repair Manual

Preface
Since the Great Wall Hover is put into the market, it has won the favor from the customers for its
elegant appearance, excellent performance&price ratio,concept of double area and eternal safety.The car is
furnished with Mitsubishi 4G64 engine.It has both the type of five shifts manual transmission and the type of
automatic transmission as an option. At the same time, there are also options of ABS and safety airbag, etc.
Before of its complex structure, high technical intervention and difficulty of maintenance, its maintenance
needs the reference of related documents. Upon the request of the after-sale maintenance technical personnel
of Great Wall, we have prepared this Hover Maintenance Manual. The manual is oriented towards the after-
sale maintenance technical personnel of the Great Wall, and mainly introduces the disassembly of the various
systems of Hover (refer to the maintenance manual of motor for the introduction of the motor), the
troubleshooting, matters needing attention for maintenance and the related technical parameters.
During the preparation of this book, a lot of professional personnel have given support and help, here we
would like to express our sincere thanks.
Though we have made efforts to prepare this manual earnestly, we cannot guarantee that the content in
the manual is totally accurate and without error. The user cannot raise improper request to the Great Wall
Company with the manual as legal basis. We cannot bear any responsibility for the losses caused by using
this manual. Confined to the knowledge of the editor, the fault and errors are inevitable, your advice and
comment are appreciated.
The final authority for the interpretation of this manual belongs to the Great Wall Motor Co., Ltd.

Instroduction-1
Instrodution
How to use this mannual................................................2
Identification mark........................................................
Instruction to comprehensive maintenance......................5

Instroduction-2
How to use this manual
In order to help you to use this manual, the chapter name and main
topics are given at the upper side of each page.
To introduce to you the maintenance items, there is an index on the first
page of each chapter.
At the beginning of each chapter, there are also the matters needing
attention of all the maintenance operations.
Please read the following matters needing attention before starting the
maintenance work.
The failure diagnostic list of each system can help you to diagnose the
failure of the system and find out the causes of failure.
The maintenance method with regard to the possible causes is given in
the column of maintenance method to facilitate you to acquire the method
of solving the problem quickly.
Maintenance procedure
Most part of the maintenance operation can be started
from referencing the illustration. These illustrations help
you recognize the parts and show the mutual coordination.
For example:
split pin
upper ball pin
upper arm
washer
upper arm bush
upper arm shaft
upper arm bush
washer
Specified torque
Used component which can not be used any more.
.Pregummed components

Instroduction-3
The maintenance procedure is explained in the form step by step:
The illustration shows what to do and where to do.
The topic of maintenance work tells you what to do.
The detailed instruction tells you how to finish the maintenance
work and introduce other related issues, such as specification and
warning, etc.
For example
This format can help the experienced technical personnel to locate the
causes of failure quickly. The maintenance personnel can browse the
work topics, and reference the detailed explanation below it only when
necessary. The important specification and warnings are given in bold
face letter.
Specification
In the whole manual, each maintenance step is given with corresponding
specification in bold face letter, so there is no need to stop working to
look at the specification. All the specification can be located quickly in
Annex A.
Warning, Attention, Remarks:
The Warning is given in bold face letter, which means there is the
possibility of harming both the person himself and others.
The Attention is written in bold face letter, which means there is
the possibility of damaging the parts under maintenance.
The Remarks is written separately in the instruction, it is also in
bold face letter. Its main function is to make some additional
explaining to help you to finish the repair work more efficiently.
3. Check the drive of ball pin
a. Remove the ball pin.
b. As shown in the Figure, shake the ball pin back and forth for
several times before mounting the cap nut,
c. Turn the but with torque meter continuously, turn one cycle
every 2 to 4 seconds, read the torque meter at the fifth cycle.
Tightening torque (for rotary):
Upper ball pin
Lower ball pin 0.1
Specification
Work topics: what to do
Detailed instruction:
How to do

Instroduction-4
Identification mark
The identification code of the car is a unique code of 17 bits to identify
the car. Besides appearing on the label plate of the entire car, it is also
inscripted on the external right side of the right stringer (chassis number)
and on the VIN nameplate at the upper left part of the panel.
Motor serial number
The manufacture number of motor is inscripted on the right side of the
cylinder .
nameplate
nameplate
vehicle VIN NO.

Instroduction-5
e. Mount the cable terminal onto the binding post of the loosened nut,
then tighten the nut. Does not use hammer to knock at the terminal
onto the post.
f. Do remember to check whether the positive pole (
) terminal cap
is in its position.
4. Check all the soft tubes and wire terminal, check to see whether
they are connected correctly and firmly.
5. Used component which can not be used any more.
a. The following spare parts needs always to be renewed: split pin,
seal gasket, O ring and oil seal, etc.
b. For the used component which can not be used any more, it is
indicated by symbol “¦” in elements diagram.
6. Precoated component
The precoated component includes the bolt and nut which is precoated
with the locking sealant in factory.
a. If the precoated component is tightened, loosed or moved by any
reason, it must be recoated with the specified sealant.
b. Coating procedure of precoated component
Remove the old sealant from the screw of component by washing.
Dry it by compressed air.
Coat the screw of components with the specified locking sealant.
c. The precoated component is indicated by symbol “?” in elements
diagram.
7. It can use the sealant or seal ring to prevent the leakage if
necessary.
8. Abide by all specifications for bolt torque strictly. It should use
the torque wrench.
Comprehensive maintenance instruction
1. Use the protection plate, seat and floor covering cloth to make
the car clean and prevent it from being damaged.
2. During the disassembling, place the components in order for the
convenience of assembly.
Observe the following issues:
a. Before conducting the electrical work, remove the negative pole of
the cable from the accumulator terminal.
b. When it is necessary to remove the accumulator for checking or
maintenance, the cable shall be removed from the negative pole
(
) connected to the car body.
c. In order to avoid the damage of accumulator terminal, when removing
the cable, loosen the terminal nut, then pull the cable upwards
vertically, do not twist or pry it.
d. Please use cleaning cloth to clean the accumulator terminal. Do not
use file or other similar tools, which may scuff them.

Instroduction-6
9. Determine the necessity of using special maintenance tools and
special maintenance material according to the practical situation
of maintenance. Use them on the necessary position, and go on
with the maintenance according to proper procedures.
10. To replace the fuse, check to see whether the rated current of
new fuse is correct. Do not exceed the rated current of the fuse,
or do not use the fuse with low rated current.
11. When jacking up or supporting the car, lift or support the car on
proper position with care.
a. If only jacking up the car in the front part or rear part, choke up the
wheel to ensure the safety.
b. After the car is jacked up, use frame to support it. It is dangerous to
conduct maintenance on the car that is only jacked up with one
screw jack, even for the minor maintenance that can be finished
quickly.
12. Paying attention to the following matters to avoid the damage
of components:
a. If it is not absolutely necessary, do not open the housing of the
ECU and the computers (if the IC terminals are touched, the IC
may have electrostatic damage).
b. When removing the vacuum tube, pull the end of the tube instead of
the central part of the tube.
c. When pulling the wire terminal, pull the terminal itself instead of
the wire.
d. Take care to not make the electrical components fallen, such as the
sensor or relay.
If they fall to the hard ground, they must be replaced.
e. Never use the striking wrench to remove or install the electric
thermostat or thermostat sensor.
f. When checking the conducting state of the wire connector, insert
the multimeter with care, do not bend the terminal.
g. When using the vacuum meter, do not insert the soft tube onto large
connector. Use the stepped terminal. Once the soft tube is swelled
and tightened, there may be leakage.
error correct

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