lock GREAT WALL HOVER 2006 Service User Guide

Exhaust system
N.m Specific torque
Used component which can not be used any more.
end washer assembly
exhaust pipe outlet nut
front section of exhaust pipe
hexagon flange nut
cleaner cushion
assembly 1
fastening bolt of hoop
cleaner heat insulation cover clip
cleaner discharge pipe catalytic converter
three-hole rubber block
cleaner cushion assembly 2
hexagon flange nut
muffler assembly
muffler port decoration cover
hexagon flange nut
rear section assembly
of exhaust pipe
wahser assembly
100
9
63
5
23muffler damping
ruber block assembly

Warning : All components of the exhaust air system should be
disassembled 30 minutes after shut down to avoid the human
injury caused by hot parts.
Removal of exhaust pipe assembly
Removal of exhaust tail tube
1. Firstly, use the M15 box spanner, ratchet wrench and extension
bar to remove the connecting nut of the rear flange of muffler
assembly and rear section flange of exhaust pipe, take out
the seal bush between the flanges.
2. Remove the three-hole rubber block on the back of the rear
section of exhaust pipe.
3. Remove the three-hole rubber block on the front of the rear
section of exhaust pipe.
Caution: The bush between the rear flange of muffler and
rear section flange mainly has the function of sealing; it
may cause the great pressure and distortion after one
installation, the sealing effect is worse, and the bush cannot
be used repeatedly.
Removal of the muffler
1. If necessary, dismantle the back section of exhaust pipe
according to the method of dismantling the exhaust pipe, if
not necessary, only remove the coupling nut between the
muffler and back flange of the exhaust pipe;
2. Use the M15 sleeve, ratchet wrench or open-end (box) span-
ner to remove the coupling nut between the front flange of
muffler assembly and the rear flange of the cleaner; when
implementing this operation, there must be somebody to pull
the muffler to prevent it from falling only to cause damage;
brick of the muffler;
3. Use the M13 sleeve, ratchet wrench to loosen the four nuts
fixing the shock absorption rubber
4. Then the muffler assembly can be removed.
Caution: The cleaner cushion assembly 2 between the
cleaner and the front section of the exhaust pipe mainly plays
a role of sealing; there may be great pressure and distortion
after one installation and the sealing effect is worse, this
bush cannot be used repeatedly.

Clutch-2
Troubleshooting

failure cause inspection content
Shift difficulty or can not shift
Large free stroke of clut ch pedal clutch Pipe
has air
Failure of clutch cylinder
Failure of clutch master cylinder
The installation position of clutch disc is not
in position; large deviation; oil on the friction
lining or broken
The clutch disc is dirty or with foreign
material
Failure of clutch cover Adjust the free stroke of pedal
Discharge the air in clutch system
Replace
replace
Inspect the clutch disc; replace
Repair if necessary
Replace
Disengagement of transmission The clutch guide bearing is worn. Replace the guide bearing
Slide of clut ch
insufficient free stroke of clutch pedal
oil on the clutch disc friction lining or broken
failure of press disc
separation rocker arm assembly is blocked Adjust the free stroke of pedal
Inspect the clutch disc and replace it
Replace the clut ch cover
Check the separation rocker arm assembly
clutch clamping
stagnation/vibration oil on the clutch disc friction lining or broken
failure of press disc clutch membrane spring
is bend
loose of engine bracket Inspect the clutch disc and replace
Replace the clut ch cover
Correct the clutch membrane
Repair if necessary
Soft of clutch pedal clutch pip e has air
failure of clutch cylinder
failure of clutch master cylinder Discharge the air in clutch
replace
replace
Loud noise of clut ch
Component in clutch housing is loose
Throw-out bearing is worn or dirty
guide bearing is worn
separation rocker arm assembly or pull-rod is
blocked Repair if necessary
replace
replace
Repair if necessary

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

1. Speed ratio of transmissio

Gear Ⅰ Ⅱ Ⅲ Ⅳ Ⅴ R
Speed ratio 3.967 2.136 1.360 1.000 0.856 3.578

2. Speed ratio of transfer case SC5M4D-C

Gear synchronizer H L
Speed ratio 1.000 1.925

3. Central distance of main shaft
transmission 72 mm
transfer case 222.25 mm
4. Instruction for repair specification of transmission

Inspection item Repair specification
End clearance of gear of Axle 1 (mm) 0～0.06 Adjusted by axial retainer.
Clearance b etween b earing block and bearing of Axle 1 (mm) 0～0.1 Adjusted by adjusting shim.
End clearance of gear hub of Gear 3/ 4 synchronizer (mm) 0～0.08 Adjusted by axial retainer.
Clearance of rear end cone b earing of int ermediate s haft (mm) 0～0.05 Adjusted by adjusting shim.
End clearance of gear hub of high and low gear (mm)
SC5M4D-C 0～0.08 Adjusted by axial retainer.
Clearance between the rear output shaft rear bearing and back
cover (mm) SC5M4D-C 0～0.1 Adjusted by adjusting shim.
Clearance of rear input shaft bearing (mm) SC5M4D-C 0～0.06 Adjusted by adjusting shim.

SC5M2D-C transmission assembly
handle of gearlever
dustproof seal cover
oil seal 39.65210
odometer driven gear assembly
odometer seating lock plate
cylindrical compression spring
1.05.841
bush
select & shift seating
N m: specified torque
Used component which can not be used any more.
Pregummed component
Use the special toolsmanipulator cover assembly
elastic cylindrical pin 6
22
rear housing assembly spring cylindrical pin
reverse lamp switch bracket
bearing housing assembly
clutch housing assembly
location compression
cylindrical pin

Disassembly of transmission (SC5M2D-C)
1.Remove the hexagon bolt M818 and lock plate.
Caution: The tightening torque is 14-19N
m when install the
hexagon bolt;
2.Remove the odometer driven gear assembly
Use the special tools to remove the odometer driven gear assembly
3.Remove the rear housing assembly
a. Remove 6 M10
1.2530 hexagon bolts
Caution: The tightening torque is 14-19N
m when installs 6
M10
1.2530 hexagon bolts.
b. Use the rubber hammer to knock the rear housing and take out the
rear housing assembly.
4. Remove 2 location pins and bushes.

Manipulator cover assembly
gearbox assembly (one)
reverse lock assembly nut M8
bulbrubber cover
pin 740
master control lever assembly
bulb basebush
stop plate of main rodbush
bulb jacket
N m: specified torque
Used component which can not be used any more.
Pregummed component N
m: specified torque
Used component which can not be used any more.
bush
6
oil guiding plate
location pin
steel ball 7.
938
aluminum gasket
reverse lamp switch
gearbox
selection and shifting
shaft rubber choke plug
bleed plug assembly
bush
selection and shifting block
elastic cylindrical pin 622

N m: specified torque
Used component which can not be used any more.
Pregummed component
Use the special tools
aluminum
washer
lower cover plate assembly
bushgear 5 drive gear ball bearing
circlip for shaft
steel ball
odometer drive gear
circlip for shaft
ball bearing
circlip for shaft
reverse gear 5
shift fork
in 622
declutch shift shaft for
first and secondea
gear 3/4 declutch
shift shaft

declutch shift shaft
pin 522
gear 1/2 shift-
ing block
gear 3/4 shifting
block
earbox assembly (three)
steel ball 4.762
pin 622
gear 1/2 shift fork
adjusting shim
spacing ring
reverse drive gear
reverse shaft
needle bearing
reverse gear thrust washer
split pin
grease baffle of air duct
support axial lock plate
reverse needle bearing bushing
needle bearing
thrust washer
gear 5 needle
bearing bushingsynchronizer gear ring
reverse gear 5 synchronizer assembly
N m: specified torque
Used component which can not be used any more.
Pregummed component
Use the special tools
gear 3/4
shift forkreverse driven gear assembly
needle bearinggear 5 driven
gear assembly

14. Use the opener to pry out the riveted place of lock nut of
intermedi ate shaft
15.Remove the self-locking screw plug, spring, steel ball
a. Use the special tools to remove 3 locking screw plugs M10×
1.25×19
Caution: The tightening torque is 14-19N·m when install the
locking screw plug M10×1.25×19.
b. Use the magnetic rod to remove 3 springs
c. Use the magnetic rod to remove 3 steel balls
Caution: When install 12 bolts M8×16, the tightening torque
is 15-20N·m
16. Remove the lower cover plate assembly
a. Use the wrench to remove the 12
bolt M8×16