engine oil GREAT WALL HOVER 2006 Service User Guide

Automatic transmission-35
Power transmission automatic 2nd-Gear and manual 2
In automatic 1st and manual 2nd-Gear, the drive of transmission reaches the front clutch cylinder through the input shaft. In this
condition, the operating principle of each functional unit of transmission is shown as follows:
The engagement of clutch C2 drives the forward central gear.
The forward central gear drives the short planetary gear to rotate in anticlockwise.
The short planetary gear drives the long planetary gear to rotate clockwise.
The engagement of brake belt B1 makes the stop of reverse central gear to make the long planetary gear rotates around the
reverse central gear, then make the internal gear and output shaft rotates in clockwise to make the vehicle moves forwardly.
The clutch C4 is engaged through the 3-4 one-way clutch (OWC) and provides the brake force of engine during overspeed.
Control:
In stable status, the status action of solenoid valve and valve is shown as follows:
The solenoid valve S1 is powered off ; The solenoid valve S2 is powered on.
The drive oil (line pressure) from the manual-operated valve makes the engagement of clutch C2.
When the solenoid valve S1 is powered off, the S1 oil pressure form line pressure 500 pushes the 3-4 Gear shifting valve
moves to left. At the same time, the S1 oil flows into the 1-2 Gear shifting valve to push the 1-2 Gear shifting valve to the
2
nd –Gear.
The line pressure oil from the 1-2 Gear shifting valve flows into the brake belt combination regulating valve, and 2-3 Gar
shifting valve.
The brake belt engagement regulator valve provides the 2nd-Gear oil (controlled by product of line pressure and valve rate)
to brake belt feed loop (BAF).
The brake belt engagement feed loop directly provides the oil to:
External engagement part of front servo piston.
1-2 Gear shifting valve can provide a oil drainage port when the transmission is shifted to 1st-Gear.
Use the 3-4 Gear shifting valve when the transmission is in 4
th-Gear position.
The drive force (line pressure) is sent to the clutch C4 through the 3-4 Gear shifting valve to realize the engagement of
clutch C4.
Refer to Figure 5.5 and table 5.6
Table 5.6The participating condition of each unit in automatic 2nd-Gear and manual 2nd-Gear
Automatic 2nd-Gear and manual
2
nd-Gear

Name of participation unit

Automatic transmission-37
power transmission Automatic 3rd-Gear and manual 3rd-Gear
In automatic and manual 3rd-Gear, the drive of transmission reaches the front cylinder through the input shaft. In this condition,
the operating principle of the transmission is shown as follows:
The engagement of clutch C2 drives the front sun gear
The engagement of clutch C1 drives the planetary gear carrier
The forward central gear and planetary gear carrier rotate in the same speed clockwise. So, there is not relative motion
between the forward central gear and planetary gear.
The gear ring and output shaft rotate in the speed of output shaft, and makes the moves forwardly.
The engagement of clutch C4 is through the 3-4 one-way clutch (OWC) and make the engine to provide the brake force
in overspeed.
Control:
In stable status, the status of solenoid valve and valve is shown as follows:
The solenoid valve S1 is powered off; Solenoid valve S2 is powered off
When the solenoid valve S1 and S2 is powered off, 2-3 and 3-4 shift valve are kept in 3rd-Gear position through the line
pressure 500.
1-2 Gear shifting valve is kept in 3rd-Gear position by the oil pressure of S1 and S2.
The (line pressure)oil form the 1-2 Gear shifting valve flows into the brake belt combination regulating valve directly and
flows into the 2-3 Gear shifting valve.
The brake belt combination regulating valve provides the 2nd-Gear oil (controlled by the product of line pressure and valve)
to the brake belt feed loop(BAF).
The brake belt feed loop directly provides the oil to:
External combination part of front servo
When the transmission is shifted to 1st-Gear, the 1-2 Gear shifting valve provides the oil drainage port.
When the transmission is in 4th –Gear position, it will use the 3-4 Gear shifting valve.
The 2nd-Gear oil of 2-3 Gear shifting valve flows into the 3rd-gear loop directly .
The 3rd-Gear oil from the 2-3 Gear shifting valve flows into the clutch combination regulating valve and sequence valve of
4-3 Gear directly.
The clutch combination regulating valve provides the oil of clutch attachment feed loop (controlled by the product of line
pressure of 500 and valve ratio) (CAF).
CAF directly provides the oil to :
clutch C1
Sequence valve of 4-3 Gear
In 4-3 Gear shifting valve, the CAF oil is changed to the release fluid of B1 (B1R-F), it cause the closing of brake belt 1
through the 3-4 Gear shifting valve to spring bottom of 4-3 gear sequence valve and release side of front servo.
The drive force (line pressure ) is sent to the clutch C4 through the 3-4 Gear shifting valve to engage the clutch C4 .
Refer to Figure 5.6 and Table 5.7.
Table 5.7
Table of participating condition of each unit in automatic and manual 3rd –Gear
Clutch
Name of participation unit
Automatic and manual
3
rd –Gear

Automatic transmission-48
s oleno id
valve Condition Transmission operation
1 Opened
always 1st-Gear replaces 2nd-Gear; 4th-Gear replaces 3rd-Gear. It causes the car form the G ear shift of 1
→1→4→4 when accelerate form static. The transmission stay longer time in Gear; worse 1→4
shift feeling.
Closed always 2nd-Gear replaces 1st-Gear; 3rd-Gear replaces 4th-Gear. It causes the car form the G ear shift of 2
→2→3→3 when accelerate form static. It is said that starts form 2nd-Gear.
2 Closed always 4th-Gear replaces 1st-Gear; 3rd-Gear replaces 2nd-Gear. It causes the car form the G ear shift of 2
→2→3→3 when accelerate form static. That is saying that start form 4th-Gear.
Opened
always 2nd-Gear replaces 3rd-Gear; 1st-Gear replace 4th-Gear.
It cause the car is shifted form 1st-Gear to 2nd-Gear, then from 2nd-G ear to Gear when accelerate
form static. It will feel the transmission is in free gear position after 2→1 Gear shift.
1&2 Opened
always Can not realize the reverse gear; only has 1st-Gear operation.
3 Closed always Following shifts are bad. (2→3 is worst ):1→3, 1→4, 2→3, 2→4, 4→2, 4→1
Opened
always Following gear shifts are worse: 3→4, 4→3, 3→2。
It may cause the gear slide when the hydraulic torque converter is locked.
4 Closed always Following gear shifts are worse:
1→2, 1→3, 1→4, 2→3, 2→4, 3→1, 3→2, (including manual) 3→4, 4→1, 4→3
Opened
always Following gear shifts are worse: (1→2 is worst) 2→4, 3→2 It may cause the gear slide when
the hydraulic torque converter is locked.
6 Closed always The line pressure is high always.
Opened
always The line pressure is low always. So it cause the slide between gears. The clutch C1 and brake belt
B1 will be burned.
7 Closed always The hydraulic torque converter is without lock.
Opened
always The hydraulic torque converter is locked in 3rd-Gear and 4th-Gear. It cause the car generates the
vibration in low-speed status.
Table 6.1.2 Operation of transmission when ON/OFF solenoid valve is faulty
Mechanical detection
1.Inspection of transmission on car
It should process the following detections before disassemble the transmission:
process the on-road drive test to determine the failure cause .(according to requirement)
Detect the standard of transmission fluid. (refer to 7.2.1)
Ensure the transmission fluid in not overheated. (Normal color and smell)
Detect the failure information.
Check the battery terminal and grounding for corrosion or loose.
The engine speed is within the specified value in manual.
Check the cooling system for normal operation.
All power supply and plug wires is tight and not loose.
Check the transmission fluid, ensure the oil pan is without other martial material or pollutant.
2. Oil leakage detection
It should wash the polluted part of the transmission before select the oil leakage part, then drive the car.
When detect the leakage part of the rear servo system, it should lift the car by lifter firstly, then switch the gear to reverse
gear within 10s.
When detect the leakage part of front servo system, it should lift the car by lifter firstly, then switch the gear to gear-2
(winter mode).
The time switched to 2nd-Gear should be no more than 10s to avoid the oil in the torque converter is overheated.
3. FAQ table

Automatic transmission-49
The distribution of FAQ table is shown as follows:
Table 6.2.1 Drive failure Table 6.2.3 Shift quality failure
Table 6.2.2 Shift mode failure Table 6.2.4 Disassembly failure
failure Possible reason Corresponding measure
“D”-Gear operation
has not drive The automatic transmission fluid is insufficient.
The oil-entering of C1/C2 piston is blocked.
The “Z” is assembled incorrectly.
The primary regulating valve plug is opened.
The overspeed shaft or input shaft sealing ring is
failure.
3→4, 1→2 single-way clut ch is installed in revers e or
failure. Check the liquid level. Fill it up if necessary.
Check and wash the C1/C2 oil inlet device.
Reinstall the “Z” connection.
Remove, wash and reinstall the primary
regulating valve.
Check and replace it if necessary.
Check and replace it if necessary.
The reverse shifting
operation is without
drive.
The manual 1
st-Gear
has not engine
brake.
The engine brake is
normal in manual
1
st-Gear. The input shaft oil seal ring is damaged.
The rear brake belt or servo system is faulty.
C3, C3 wheel shaft or C1/C2 cylinder are out of work. Check and replace it if necessary.
Test the servo system or replace the rear brake
belt according to the requirement.
Test the failure C3, C3 wheel axle or C1/C2
cylinder.
Repair it in time if necessary.
“D” –Gear and reverse
–Gear operation is
without drive. The primary regulating valve is blocked.
The pump gear is damaged.
Take out the output shaft clasp. Det ect and clean the primary regulating valve.
Check and replace the pump gear if necessary.
Check and repair it if necessary.
Only can 2→3 shifting
(can not realize the
4
th-Gear and 1st-Gear) S1 is closed always. Test the S1. Repair or replace it if necessary.
Test the failure of S1 12V power supply
voltage or wire bundle.
Only can 1→4 shifting
1→3→4 shifting (1
→2 shifting delay). S1 is opened always Test the S1. Repair or replace it if necessary.
Test the failure of S1 12V power supply
voltage or wire bundle.
Only can 4→3 shifting S2 is closed always.
Test the S2. Repair or replace it if necessary.
Test the failure of circuit break or wire bundle.
1→2→neutral position
shifting (1st-Gear
transition) S2 is opened always Test the S2. Repair or replace it if necessary.
Test the failure of circuit break or wire bundle.
Only can 1→3 shifting B1 is out of work
The brake belt is loose.
The front servo piston or oil s eal is out of work.
S1/S2 ball spool is reinstalled in wrong place. Test and adjust it according to the requirement.
Test and maintain it according to the
requirement. Test and replace or reinstall it according
to the requirement.

Only can 1→3→4
shifting The small O-ring of front s ervo piston is invalid or
lost.
2→3 Gear position shifting valve is blocked. Det ect the O-ring. Process the replacement or
reinstallation if necessary. Detect the 2→3
Gear shifting valve; Process the maintenance
or replacement according to the requirement.
Only can 1→2→1
shifting C1 is invalid or 3rd-Gear and 4th-Gear is loose. (give
to 1st-Gear in 3rd-gear; give to 2nd-Gear in 4th-Gear) Det ect the clutch C1. Repair or replace it if
necessary.
Can not realize the
man ual 4→3, 3→2, 2
→1 Overspeed clutch /ball spool has displacement.
C4 is invalid. Detect the ball spool. Process the replacement
or reinstallation according to the requirement.
Det ect the C4. Repair C4 or r eplace the C4
wave pan according to the necessary.

Automatic transmission-51
Table 6.2.3Shifting quality failure
Bad 1→2 Gear
shifting quality The throttle position sensor has failure.
T he brake b elt is adjusted incorrectly.
The front servo piston O-ring is damaged.
The variable pressure solenoid valve (S5) is damaged or
has failure.
S1, S4 has the failure.
The brake belt combination regulating valve (BAR) has
the failur e.
The front servo release spring is installed incorrectly. Detect the resistance, replace the sensor if
necessary.
Detect and replace the rake belt if necessary.
Detect and r epla ce the O -ring if necessary.
Detect, repair or repla ce the S5 if necessary.
Detect, repair or repla ce the S1, S4 if
necessary.
Detect, repair or repla ce the B AR if
necessary.
Detect and repair it if necessary.
Bad 2→3 Gear
shifting quality B1brake belt release valve is blocked.
S3, S2 has the failure.
The clutch combination regulating valve has failure.
The clutch combination oil feed ball spool is lost or
damaged.
The input shaft oil seal is damaged.
C1 piston O-ring is damaged.
C1 piston oil feed ball spool is damaged. Detect the blow-off valve. Replace or
maintain it if necessary.
Detect the S3, S2.Replace or maintain it if
necessary.
Detect the r egulating valve. R eplace or
maintain it if necessary.
Detect the ball spool .Reinstall or replace it if
necessary.
Detect the sealing ring. Reinstall or replace it
if necessary.
Detect the O -ring .R einstall or replace it if
necessary.
Detect the ball spool .Reinstall or replace it if
necessary.
Bad 3→4 Gear
shifting quality S1, S4 has failure.
B1brake belt release valve is blocked.
T he brake b elt is adjusted incorrectly.
The front servo piston O-ring is damaged.
The variable pressure solenoid valve (S5) is damaged or
has failure.
The brake belt combination regulating valve has failure. Detect the S1, S4.R einstall or replace it if
necessary.
Detect the blow-off valve. Replace or repair
it if necessary.
Detect the brake belt. Adjust it if necessary.
Detect the O -ring .R eplace or maintain it if
necessary.
Detect the S5.R epla ce or maintain it if
necessary.
Detect the r egulating valve. R eplace or
maintain it if necessary.
The engine has
the
extinguishing
co nd itio n
when select
the automatic
gear or R-gear. The torque converter clutch control valve is blocked or
solenoid valve 7 has failure. Detect and clean the torque converter clutch
valve (CCCV)
Has unstable
vibration
co nd itio n. S7 has the failure. Process the necessary detection, maintenance
and replacement according to the
requirem ent.

Adjustment
Hydraulic system
Following parts is the detailed description for self-detection procedure pointed to the condition occurred in chapter
6. including the condition indicated the failure, to point the problem existed in the hydraulic system.
It should select the proper procedure from the following primary detection when adjust the transmission.
Detection process of transmission fluid
Detect the manual linkage adjusting system(refer to factory manual of car)
Detect the engine idle speed
Anchoring test (beyond the scope of the maintenance manual)
On-road test (beyond the scope of the maintenance manual)
Detection procedure of transmission fluid level
1. General

The process is used to detect the level of vehicle transmission fluid. It will cause the failure or delay of transmission shifting if
the level is low than required value and the vehicle does not reach the drive temperature.
Firstly, process the transmission diagnosis information detection for vehicle (refer to chapter 6). If found the failure of sensor,
then it maybe caused by transmission fluid level is less than specified value.
It should detect whether has the abnormal delay and Gear-position condition when select the forward or reverse-gear by driving
the vehicle. One feature of oil level less than normal value is that the vehicle has the gear-position delay and lack condition when
the vehicle is in steering. The previous problem will occur when the transmission fluid temperature is low.
When the oil temperature is medium and vehicle speed failure is recorded, the gear-position lose condition
will not occurs any longer, it means that needs to fill the transmission with the transmission fluid.
2. Detection of transmission fluid level

When fill up or replace the transmission fluid, it must use the Castrol TQ95 automatic transmission fluid (ATF) or other
permissive oil. It will damage the performance and service life of transmission if use the unpermissive transmission fluid.
Please ensure the transmission fluid level is correct. The transmission also can be damaged if the transmission fluid level is
incorrect.
The setting procedure of transmission fluid level is shown as follows:
Caution:
When the transmission is in operating temperature, the hot transmission fluid may flow out form the
housing if remove the filling plug.
a. If the vehicle is in operating temperature, allow two hours time for cooling before add the transmission fluid, but
it must not more than 4 hours (this will make the transmission locate in the correct temperature range). When the
temperature is overheating, the transmission fluid level will higher than the plug port. Removal of plug will cause
the transmission fluid flows out from the oil filling port, then cause the low level of transmission fluid.
b. The gear-position of transmission is in parking-Gear (P-Gear), shut off the engine.
c. Lifting the vehicle (or parking above the trench).
d. Clean the around of plug when remove it. Then remove and clean the plug and check the O-ring for damage. Install
the oil filling pump in the oil filling hole.
e. Lower the vehicle; the oil filling pump will be connected to the vehicle at this time. Fill the transmission with the
oil partially. Then start the vehicle in P-Gear to 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. Shut down the engine; lift the vehicle; ensure the vehicle is always in horizontal.
g. Remove the filling plug 3 minutes after the engine is shut off, but must not 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 to make it reach the correct level.
h. Replace the transmission; clean the residual transmission fluid on the transmission and
vehicle.
i. Tighten the transmission plug to the specified torque of 30
35Nm.

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.

Figure 8.59 Bushing of engine oil filter
Figure 8.60 Installation of engine oil filter
Figure 8.61 Tightening sequence of oil pan bolt
It should abide by follows when assemble the oil filter and oil sump tank (Refer to Figure 8.59and Figure 8.60):
a. Use the automatic transmission liquid to lubricate the spring ring of gasket of lubrication oil.
b. Install the oil filter on the valve carefully. During the installation, the socket must be inclined. Refer to Figure 8.59.
c. Fix the oil cleaner assembly.
d. Check whether the magnet is installed in the recess on the corner of oil bottom shell.
e. Assemble the groove on the oil bottom shell. The groove must be bent during the installation.

Replacement of major semiaxle oil seal
1. Make the electric clutch is in the 4WD status,
them stop the engine and remove the front drive
axle assembly (see the disassembly of front reducer
assembly)
2. Use the wrench to screw off the bolt which fix the
front axle vent tube connectorassemblyonventtubeb
racket bolt
3. Disconnect the connector between vent tube of
electric clutch housing and front drive axle vent tube
connector assembly
4. Disconnect the connector between the vent tubes
on the electric clutch and vent tube connector
assembly.
5. Remove the bolt which is used to fix the electric
clutch housing and front axle tube flange; use the
brass bar to open the electric clutch housing and take
out the mechanical wheel of separator.
Caution: The lubrication oil will flow out when sepa-
rate the electric clutch housing from the front axle
flange. It should use the container to hold it.
mechanical wheel of separator
disconnect the place
disconnect the place

limitationlimitationCheck and repair of rear axle components
1. Check the rear axle and flange for wear, damage
and run-out.
Max. Run-out of axle: 2mm
Max. Run-out of flange: 0.2mm
It should replace the rear axle if the rear axle or flange is worn or
damaged, or the measured run-out is beyond the specified value.
2. Check the external oil seal
a. Check for the wear or damage; especially for the lip of oil seal.
b. Replace it if necessary.
3. Check the bearing and oil seal holder
Check for wear and damage, replace it if necessary.
4. Remove the bearing and oil seal holder
a. Move the brake and oil seal pressing block to the limit position
along flange direction; move the external oil seal to the limit
position of oil seal.
b. Place the hook of the special tools in sequence, the position is
shown as figure; make the hook holds the bearing tightly; then
use the bolt to connect the hook to the hammer fixedly; at last,
place it on the pad with halfaxle spline end facing ground.
c. Hold the hammer to beat downwardly with force for several
times to remove the bearing and oil seal holder.
Caution: Do not damage the oil seal .
5. Install the new external oil seal
a. Clean the semiaxle.
b. Coat the lip of external oil seal with proper HP-R grease.
Caution: When install the oil seal, the lip of oil seal must not
contact the semishaft to avoid scratching the oil seal .
6. Replace the bearing and oil seal holder
a. Heat the oil seal pressing block in 22# engine oil to 100.
Caution: The end of oil seal pressing block with larger chamfer
faces the halfaxle spline. Install it immediately after taken out.
b. Use the hydraulic press to install the new bearing and new oil
seal pressing block by press.
7. Install the circlip
Use the circlip pliers to install the new circlip in the slot of semiaxle.