torque GREAT WALL HOVER 2006 Service Repair Manual

Brake-7
Air discharge of brake system
Remarks:
It should discharge the air if operate on the brake system or as-
sume the brake system pipeline has the air.
Caution:
Must not keep the brake fluid on the paint surface, wipe off it if
has.
1. Fill the liquid reservoir up with the brake fluid.
Check the liquid level in liquid reservoir after discharge the air of each
wheel pump. Filled with the brake fluid if necessary.
2. Connect the polyethylene resin pipe to the overflow hole plug of
wheel pump;insert the other end of pipe into the container with
half of brake fluid.
Remarks:
When discharge the air of wheel brake pump, it should begin
from the longest pipeline.
3. Air discharge of brake system pipe
a. Step down the brake pedal slowly for several times.
b. Let the assistant presses down the pedal, at the same time screw
off the overflow hole plug until the brake fluid flows out. Then
switch off the overflow hole plug.
c. Repeat the procedure until the liquid is without air bubble.
Tightening torque of overflow hole plug: 11N
m
4. Process the same procedure for each wheel pump.
hexagon flange nut
brake bracket
welded assembly
support sleevereturn spring
bush
screw bar
pin shaft
pedal cover block
rocker arm
welded assembly
Brake pedal

Brake-8
Replacement of pin shaft
Remarks:
When the connecting fork pin shaft and pin hole is over worn, it
should replace the pin shaft bush.
Remarks:
When the clearance between the brake pedal shaft and bush is
large, it should remove the pedal and replace the bush.
push barlock nut
inner distance
fork pin shaft
Parking brake
parking crank assembly
switch assembly
rear parking brake pull wire (R)
rear parking brake pull wire (L)
brake pull wire clip
1. Adjust the parking crank assembly in position, 6
8 teeth.
2. When the parking brake pull wire is tightened, the torque should
be no more than 400N
m.

Brake-9
Front brake
front brake oil pipe
cliper bracket
outer silencing plate combination
lower circlip of
brake block
brake block assembly
lower circlip of brake block
wear limitation alarm plate of brake block
lnner silencing plate combination
Inner brake block
silencing plate
upper circlip of brake block (I)upper circlip of brake block (II)
piston
dustproof cover
guide pin dustproof cover
guide pin rubber covercooper washer
tong
air-bleed
bolt cover
location pin
guide pin dustproof coversquare seal ring
N
m: Specified torque
Piston
Replacement of brake block
Remarks:
When brake during the travel process, if the front wheel has the
continuous screams noise, then it should check the wear limitation
alarm plate of brake block. If the alarm plate has the abrasion
mark with brake disc, then it should replace the brake block .
1. Remove the front wheel
2. Check the thickness of abrasion material of brake block.
Check the thickness of abrasion material of brake block by the watch
hole on the tong.
Replace it if is not within specified range.
Min. thickness : 2.0mm

Brake-13
Check the component of front brake
1. Measure the thickness of the brake block bush.
standard thickness: 9.0mm
minimum thickness: 2.0mm
It should replace the brake block if less than minimum thickness or
has uneven abrasion.
2. Measure the thickness of the brake disc.
standard thickness: 26.0mm
minimum thickness: 24.0mm
It should repair or replace the brake disc if the brake disc is damaged
or worn or its thickness is
less than minimum thickness.
3. Measure the circular runout of the brake disc.
Remarks: It should ensure that the bearing is adjusted correctly
before the measurement . maximum circular runout : 0.11mm
4. Replace the brake disc if necessary.
a. Remove the tong bracket form the steering knuckle.
b. Remove the hub and brake disc. (Refer to section “Front hub”)
c. Install the new brake disc; tighten the connecting bolt to the
specified torque.
Tightening force: 90
100Nm.
d. Install the hub and brake disassembly. (Refer to section “Front
hub”)
e. Install the tong bracket on the steering knuckle; tighten the
connecting bolt to the specified torque.
Tightening torque 140
10Nm.

Brake-14
Assembly of brake pump
1. Preparation work
All components should be washed, dried by wind and without foreign
material before the assembly. During the assembly, cost the guide pin
and location pin with proper vacuum silicon based grease; coat the
working surface of piston and square gasket with proper rubber
lubricant.
2. Install the piston gasket in the tong body.
a. Screw the bleed screw into the bleed hole;
tightening torque 7
10Nm.
b. Install the square gasket in the sealing groove of two cylinders of
pump respectively after coat its working surface with proper
rubber lubricant.
3. Install the piston with dustproof cover in the tong
a. Cover the dustproof cover on the piston.
b. Lengthen the dustproof cover to expose the bottom of piston
from the dustproof cover clip ring; use the tool (for example: steel
wire about
2mm ) to assist insert the clip ring into the cylinder
hole clip ring groove.
Caution: The used tools must not be sharp to prevent the damage
of dustproof cover.
c. Press the piston to the bottom of cylinder hole by hand.
4. Pre Install the guide pin and location pin on the tong bracket.
a. Install the guide pin dustproof cover on the guide pin and location
pin respectively.
b. Screw the guide pin and location pin in the tong bracket
respectively.
Caution: Do not damage the guide pin dustproof cover.

Brake-16
Rear brake (Disk-and-drum type)
tong bracket
pin rubber cover
brake caliper locking bolt 100
silencing plate
combination
outside brake block
inside brake block
brake block wearing
indication plate
cylinder hole
dustproof cover
wire clip
rectangle seal ring
piston
tong body (left)
copper washer
brake oil pipe fastening blot 55
location pin 2530
bleed screw
bleed screw dustproof cover
guide pin 2530
rear brake oil pipeline
N
m: specified torque
peepholesilencing
plate
Replacement of brake block
Remarks: if the rear wheel generates the cheep during the braking,
it should check the abrasion indication plate of brake block. If the
indication plate has the abrasion mark with brake disc, then it
should replace the brake block .
1. Remove the rear wheel
2. Check the thickness of brake block bush.
Measure the thickness of the brake block bush (abrasion material)
from the eyehole of tong. If the thickness is not within the specified
range, then it should replace the brake block.
minimum thickness: 2.0mm.

Brake-22
2. Install the piston gasket in the tong body.
a. Screw the bleed screw into the bleed hole;
b. Install the square gasket in the sealing groove of two cylinders of
pump respectively after coat its working surface with proper
rubber lubricant.
Tightening torque 7
10Nm.
3. Connect the brake pipeline
Connect the brake oil pipe to the tong.
Tightening force: 50
5Nm
4. Fill up the brake system with the brake fluid and drain the air
in the brake system.
5. Check for leakage of brake fluid.
Rear parking brake
pull-out piece
spring draw bar
hand brake
stay wire
front brake shoe
lower tension spring
clearance-adjusting bolt
clearance-adjusting gear
clearance-adjusting
bolt head
pull-out piece
spring seat
pulling arm pin
rear brake shoe
brake shoe pulling arm
saddle type washer
push pedal
push pedal
release spring
stopper
upper release spring
rear brake disc
Used component which can not be used any more.
Removal of rear brake
Remarks: When the brake torque of the hand brake cannot meet
the brake requirement, the thickness of the brake shoe gasket
shall be tested. If it is less than the minimum value of brake show
gasket, the brake shoe shall be replaced.
minimum thickness: 1.0mm

Brake-28
10. Adjust the clearance between the brake drum and brake shoe.
Poke the adjusting hole plug on the brake drum, insert the screwdriver
into the clearance-adjusting hole; rotate the clearance-adjusting gear
to expand the brake shoe until the brake disc can not be rotated by
hand. Then rotate it for 3-5 teeth in anticlockwise, rotate the brake
disc by hand at the same time, it is proper that it can rotate freely
and without the contact between the abrasion and disc. It is allowable
that the non-running-in brake shoe has the slight abrasion sensing.
When adjust the clearance, the left and right wheel must be adjust at
the same, install the adjusting hole plug after the completion of
adjusting .
11.Rear brake caliper assembly
12.Rear wheel assembly
Tighten torque :120N.m

Brake-30
Replace of load-sensing proportional valve
1. Removal
Disconnect the brake pipeline form the valve; remove the lock nut and
remove the adjusting bolt from the suspension arm bracket; remove the
installation bolt and take off the load-sensing proportional valve assembly.
2. Installation
a. Use two installation bolts to fix the load-sensing proportional valve.
The bolt tightening torque is 23N
m,
b. Tighten the adjusting bolt locking nut,
c. Connect each brake pipeline.
The tightening torque of the connector is 16N
m,
d. Filled with the brake fluid, discharge the air from the brake system;
check the brake pressure and leakage. output manometer
input manometer

Steering-5
Technical requirements
1.The fastening torque of the mounting bolts of the integral power
steering gear assembly is
2.The fastening torque of the connecting bolts of the steering drive sub-
assembly and the integral power steering gear assembly is
3. The fastening torque of the connecting bolts of the steering drive
assembly and the left horizontal beam of the frame is
4. The fastening torque of the mounting bolts of the power steering
pump is 40N.m.
5. The tension force of multi-wedge belt 4PK1100 is 4PK1100.
6. Centering fastening of the handwheel: steer the front wheel to the
right front and remove the handwheel without changing the position
of the steering stem, install the handwheel aligning the center, the
radials of the handwheel should be at the left & right centering state;
the symbol of “the Great Wall” on the steering wheel shall be in
driver’s straight view position, secure the nut firmly with the
fastening torque of
7. Inspection of free clearance of the handwheel
Steer the car in a straight direction and stop the engine, apply a 5N force to
the handwheel along the circumference, left turn the handwheel and stop
the turning when the resistance is increasingly felt with each turn; then right
turn the handwheel and stop the turning when the resistance is increasingly
felt with each turn; the angle rotated along the circumference is the free
clearance of the handwheel, whose standard value shall be below 20
, and
the angle from the center to the right shall not be more than 10