oil GREAT WALL HOVER 2006 Service Manual PDF

2. Place in the bearing inner race; use the fill the gap
between the inner and outer race of the bearing up
with the HP-R grease.grease
grease
3. Install the inner bearing and oil seal
a. Place the inner bearing in the hub.
b. Use the special tools to knock the new oil seal into the hub.
c. Coat the oil seal lip with HP-R grease.
4. Install the hub on the steering knuckle
a. Install the hub on the steering knuckle.
b. Install the external bearing.
diagram of spe-
cial tools
special tools
5. Adjust the pre-applied load
a. Use the special tools to screw on the locknut to specified torque.
Tightening force: 80-100N
m
b. Rotate the hub to right and left 1/3
1/4 round respectively.
c. Screw off the nut until the nut can be loosed by hand.
d. Use the special tools to retighten the lock nut.
Tightening force: 28N
m
e. Use the spring tension meter to check the pre-applied load.
Pre-applied load (for starting): 28-56N
diagram of spe-
cial tools
special tools

special toolsUpper suspension arm
Disassembly of upper suspension arm
1. Disconnect the upper ball pin from the steering
knuckle
Remove the split pin and nut; use the special tools to disconnect
the upper ball pin from the steering knuckle.
2. Remove the brake oil pipe on the upper arm shaft
a. Use the open-end wrench to screw off the oil pipe tight nut.
b. Pull out the brake oil pipe and plug it by the rubber plug.
Remarks: There are two two-way valves for rear brake oil pipe
beside the right upper arm shaft ; when remove the right
upper suspension arm, it must remove four oil pipe tight nuts
in the place and plug it by the rubber plug to prevent the brake
fluid from overflowing.
3. Disconnect the brake hose form the brake caliper
Remove the hollow bolt and disconnect the brake hose form the
brake caliper
Remarks: Must not lose the copper gasket seal.
4. Disconnect the brake hose from the upper arm oil
pipe bracket.
Use the pliers to pull out the sheet steel spring clip and discon-
nect the brake hose from the upper arm oil pipe bracket.
5. Remove the upper suspension arm
Remove two bolts and remove the upper suspension from the
arm carriage.
Remarks: Keep the adjusting shim and don’t lose it. Record
the thickness of front and rear adjusting shim for convenience
of reinstalling them in the original position.

b. Tighten the upper arm shaft nut to specified torque.
Tightening force: 210
10Nm
Installation of upper suspension arm
1. Install the upper suspension arm on the carriage
a. Install the upper suspension arm and camber adjusting shim.
b. Tighten all bolts to the specified torque.
Tightening force: 200
10Nm
Remarks: Install the shim with same quantity and thickness to
the original position.
2. Connect the brake oil pipe of upper arm shaft
Tighten the oil pipe compression nut to specified torque.
Tightening force: 15-17N
m
Remarks: It should tighten four connector of two two-way
valves to the specified torque if disassemble the right upper
arm.
3. Connect thebrakehosetotheupperarmoilpipebracket
a. Thread the brake hose from the hole on upper arm oil pipe
bracket.
b. Use the hand hammer to knock in the sheet steel spring clip to
fix the brake hose.
4. Connect the upper ball pin to the steering knuckle
a. Tighten the slotted nut according to the specified torque.
Tightening force: 145
15Nm
b. Install the new split pin.
Remarks: It should align the notch of nut with the pinhole
when install the split pin; the nut can be tightened but not
loosed during the alignment.

N m: specified torque
Used component which can not be used any more.
precoated component
Front hub and steering knuckle (4WD)
stabilizer bar
flat shim
connecting rod
of stabilizer bar
hub and brake disc
flange
adjusting washer
circlip
hub cap
spring shimdisc brake
split pin
lower suspen-
sion arm
split pin
upper suspension arm
drive shaft
oil seal
needle
bearing
lock washer
steering knuckle
lock nut
lock washer
screw
brake cover
spring shim
flat shim
disk shimShim
fill blockfill block disk shim
oil seal
bearingbearing shock absorber

4. Remove the oil seal and inner bearing
a. Use the screwdriver to pry out the oil seal
b. Remove the inner race of inner bearing form the hub.
Check and repair of front hub
1. Check all bearings
Wash the inner race and outer race of each bearing and check them for
wear and damage.
2. Replace the bearing outer race
a. Use the brass bar and hand hammer to knock out the bearing outer
race.
Use the special tools to knock in the new bearing outer race.
Assembly of front hub
1. Coat the inner surface of hub and bearing outer race
with the grease.
The grease is the Jin HP-R grease or the grease met the requirement
in following table.
special
toolsdiagram of
special tools
grease
Dropping point, C
Leakage amount (104C, 6h), g
EP performance OK value , N
ItemTypical data

2. Place in the bearing inner race; use the fill the gap
between the inner and outer race of the bearing up
with the HP-R grease.grease
grease
3. Install the inner bearing and oil seal
a. Place the inner bearing in the hub
b. Use the special tools to knock the new oil seal into the hub.
c. Coat the oil seal lip with HP-R grease.diagram of
special tools
special tools
4. Install the hub on the steering knuckle
a. Install the hub on the steering knuckle
b. Install the outer bearing.
5. Adjust the pre-applied load
a. Use the special tools to screw on the locknut to specified
torque.
Tightening force: 80-100N
m
b. Rotate the hub to right and left 1/3
1/4 round respectively.
c. Screw off the nut until the nut can be loosed by hand.
d. Use the special tools to retighten the lock nut.
Tightening force: 28N
m
e. Use the spring tension meter to check the pre-applied load.
Pre-applied load (for starting): 28-56N
special
tools
diagram of
special tools

e. Use the jack to raise the lower arm; remove the steering knuckle.
Check and replacement of steering knuckle
1. Check of steering knuckle
Use the dye penetrant to check the steering knuckle for crack.
It should replace the steering knuckle if has crack.
2. Remove the steering knuckle oil seal
Use the screwdriver to pry out the oil seal from the steering knuckle.
3. Take out the thrust plate
4. Remove the needle bearing
Use the copper bar and hand hammer to knock out the needle
bearing.

5. Installation of needle bearing
Use the special tools and hand hammer to knock in the new
needle bearing slightly.
Remarks: The thicker end of needle bearing should be
upwardly when knock in. with thicker end.
chamfer
steering
knuckle
6. Installation of thrust plate
Coat the installation position of thrust plate of steering knuckle
with the HP-R grease; place the thrust plate with the surface
with chamfer facing the steering knuckle.
Remarks: It must measure the thickness of the thrust plate
before the installation; it should install the new thrust plate if
the thickness is less than 1.5mm. The nominal thickness of
the new thrust plate is 2mm.
7. Installation of steering knuckle oil seal
Use the special tools and hand hammer to knock in the new
steering knuckle oil seal slightly.
Installation of steering knuckle
1. Install the steering knuckle
a. Coat the drive shaft and inner of drive shaft dustproof cove
with the lithium base grease.
b. Insert the drive shaft into the steering knuckle, meanwhile
connect the lower ball pin to the steering knuckle and install the
slotted nut temporarily.
special
tools
special
tools

Upper suspension arm
Disassembly of upper suspension arm
1. Disconnect the upper ball pin form the steering
knuckleRemove the split pin and nut; use the special
tools to disconnect the upper ball pin from the steering
knuckle.
2. Remove the brake oil pipe on the upper arm shaft
a. Use the open-end wrench to screw off the oil pipe tight nut.
b. Pull out the brake oil pipe and plug it by the rubber plug.
Remarks: There are two two-way valves for rear brake oil pipe
beside the right upper arm shaft ; when remove the right upper
suspension arm, it must remove four oil pipe tight nuts in the
place and plug it by the rubber plug to prevent the brake fluid
from overflowing.
3. Disconnect the brake hose form the brake caliper
Remove the hollow bolt and disconnect the brake hose
form the brake caliper
Remarks: Must not lose the copper gasket seal.
4. Disconnect the brake hose from the upper arm oil
pipe bracket.
Use the pliers to pull out the sheet steel spring clip and
disconnect the brake hose from the upper arm oil pipe
bracket.
5. Remove the upper suspension armRemove two bolts
and remove the upper suspension from the armcarriage.
Remarks: Keep the adjusting shim and don’t lose it. Record the
thickness of front and rear adjusting shim for convenience of
reinstalling them in the original position.
special tools

b. Tighten the upper arm shaft nut to specified torque.
Tightening force: 210
10Nm
Installation of upper suspension arm
1. Install the upper suspension arm on the carriage
a. Install the upper suspension arm and camber adjusting shim.
b. Tighten all bolts to the specified torque.
Tightening force: 200
10Nm
Remarks: Install the shim with same quantity and thickness to the
original position.
2. Connect the brake oil pipe of upper arm shaft Tighten
the oil pipe compression nut to specified torque.
Tightening force: 15-17Nm
Remarks: It should tighten four connectors of two two-way valves
to the specified torque if disassemble the right upper arm.
3. Connect the brake hose to the upper arm oil pipe
bracket
a. Thread the brake hose through the hole on upper arm oil pipe
bracket.
b. Insert the sheet steel spring clip by the hammer to fix the brake
hose.
4. Connect the upper ball pin to the steering knuckle.
a. Tighten the slotted nut according to the specified torque.
Tightening force: 145
15Nm
b. Install the new split pin.
Remarks: It should align the notch of nut with the pinhole when
install the split pin; the nut can be tightened but not loosed during
the alignment.