heating GREAT WALL HOVER 2006 Service Repair Manual

Overview of the entire car-9
Car body
The structure shape and parameters of the car body is shown in table 6.
Table 6 The structure shape and parameters of the car body
Serial No. Item structure and parameter
1 Car body
1.1 Structure shap e of
car body Long head two boxes five doors five seats totally metal enclosed type hard top no
carrier t yp e car body
1.2 White car body Punching, welding, totally metal enclosed type structure
1.3 Door assembly Frame type, card plate type door lock, hinge type hinges, with side protection rod, four
side doors open outwards by turns, rear door open upwards. Centralized controlled
door lock, electric drive glass frame riser
1.4 Engine bonnet Opening upwards and backwards, single arm hinge
2 Int ernal and external
decoration and
auxiliary
components of car
body
2.1 Internal decoration Softening design, in compliance with the man-machine engineering and comfort ability
requirement
2.2 Meter board Injection molding type structure, metallic framework
2.3 A, B, C pole and
inter door protection
plate Injection molding, set with sundries box on the door protection plate
2.4 Cab handle Metallic frame, PVC surface, PUR foaming layer in the middle
2.5 Windscreen Panorama curved surface windscreen. Front wind window: triplex glass, with a
thickness of 4.76mm. Rear wind window: toughened glass, with electrical heating
defrosting resistance wire, with thickness of 3.5mm. Other windows: toughened
glass, with thickness of 3.5mm
2.6 Rearview mirror External rearview mirror: electric drive, electrical heating defrosting, anti dazzle type,
the left and right side are all convex mirror, with a radius of curvature of 1400mm. The
internal rearview mirror: manual, anti dazzle type, plane endoscope.
2.7 Seat Pilot and co pilot seat: independent seat, front and back position, the backrest angle
and seat headrest, etc. can be adjusted. Back seat: independent seat, the backrest angle
and seat headrest, etc. can be adjusted.
2.8 Safety belt Back seat middle seat two points fixed type, three pointes fixed emergency blocking
mechanical safety belt for other seats.
2.9 Sun visor Luxurious type, with lamp and cosmetic mirror
2.10 Skylight Electric drive skylight
2.11 Front and rear
bumper Overall design type, PP injection molding

Checking and commissioning of the auxiliary components of car body:
Stop the car stably, check the doors, engine cover, fuel filling port cover, meter and tools box cover, front and rear ash tray cover,
floor center console sundries box cover, CD disc conveyer (VCD disc conveyer), power socket cover, etc. they shall be reliable
and flexible during starting, opening and closing, without blocking and insufficient closing and abnormal sound;

Electrical system
The structure and parameter of the electrical system are shown in table 7.
Table 7 Structure And Parameter of Electrical System

No. Item Structure and Parameter
1 Power, starting and charging system

1.1 Lines Singe line system, voltage DC 12V, negative earth
1.2 Accumulator 55D26R maintenance free type, voltage 12V, 20 hours capacity 60Ah, storage
capacity 101min, low temperature starting current 475A

1.3 Starter 12V, 1.2kW
1.4 generator Internally furnished with adjustor type generator. 14V, 90A
2 Illumination and signal s ystem

2.1 Front illumination light
white, major high beam 60W,1 on the left and right respectively,
auxiliary high
beam 55W,1 on the left and right respectively, passing
lamp 55W,1 on the left and right respectively. Head light base center
height H: 920mm±20mm

2.2 Position light Front position lamp: white, 5W,1 on the left and right respectively.
Rear parking lights: red, 5W,1 on the left and right respectively.

2.3 turn light Amber。Front and rear turn light: 21W,1 on the left and right
respectively. Side turn light: 5W,1 on the left and right respectively,
2.4 Fog light Front fog light: white, 55W, 1 on the left and right respectively. Rear
fog light: red, LED,1 on the left and right respectively.
2.5 Brake light Red, 21W, 1 on the left and right respectively, high position brake light,
10W, 2 in the middle
2.6 License light White, 5W, 1 on the left and right respectively.
2.7 Backup light White, 21W, 1 on the left and right respectively.
2.8 Danger warning signal light All the turning signal lights, danger alarm switch control
2.9 Back repeating reflector Red, none triangle shape, forming combination light with the rear fog
light
2.10 Front, middle and back ceiling light
in the room White. Front indoor ceiling light: 10W, 2 pieces. Middle indoor ceiling
light: 10W, 1 piece. Back indoor ceiling lights: 5W, 1 piece

2.11 Cigar lighter illumination Blue, 3W, 1 piece
2.12 Ash tray illumination White, 3W, 1 piece
3 Meter system
3.1 Combined instrument Car speed odometer, engine speed indicator , water t emperature met er,
fuel gage
3.2 Indicator lamp Refer to the drawing
4 Auxiliary electrical system
4.1 Rain wiper system Front and rear rain wiper DC motor. Front rain wiper: four rods type,
electric drive three gears (high and low speed + adjustable interval),
scraper 2 pieces, 55W. Rear rain wiper: single arm type, electric drive
one gear, with 1 scraper plate, 21W
4.2 Defogging, defrosting device Front wind window hearing type, back wind window heating type
glass, switch control
4.3 Electric drive glass frame riser Drive side general control, independent control oh other windows and
doors
4.4 Central control lock With r emote control
4.5 Camborne power socket 12V, 2 pieces
4.6 Radio, CD and loudspeaker Stereo radio, six discs CD, four sound channels

Air-conditioning system
The structure and parameter of the air-conditioning s ystem is shown in table 8.
Table 8 The structure and parameter of the air-conditioning system

Serial No. Item Structure and Paramet er
1 Structure and
shape

Front and rear heating and cooling air conditioner, vapor compression type
cooling, hot-wat er heating

2 Performance and
parameters

Refrigerating capacity 3.5kW, heat exchange capacity 3.5kW, fan capacity
350m
3/h
3 Operation
Control board button type operation, temperature auto control, air door micro
motor drive, the temperature in the car can be controlled automatically, the
fanning position mode, heating/ cooling mode, air int ern/external cycling mode
and wind speed and t emperature can b e selected and adjusted

4 Refrigerant R134a
5 Compressor SD7V16 variable capacity compressor, with a maximum capacity of 160ml
6 Condenser Parallel stream mode structure, flat pipe thickness of 26mm
7 Evaporator Two box es structure, cascading evaporator, F expansion valve, centrifugal
blower

8 Drying fluid
collector
External diameter φ60.5mm
9
Refrigerating
pipe and
wa r m wa t er pi p e

Refrigerating pipe: complex structure of rubber refrigeration soft tube and
aluminum tube. The warm water pipe: rubber molding pipe

10 Transducer Outdoor temp erature sensor, indoor t emperature sensor, evaporator temperature
sensor
11 pressure switch Three-state pressure switch

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.

Shifting point
Opening
degree of
throttle
position Shifting
1/2 2/3 3/4 4L Opening
degree of
throttle
position shifting
1/2 2/3 3/4 4L
0% 10 20 34 63 0% 14 26 41 87
40% 26 47 82 95 40% 30 56 76 113
100% (WOT) 53 93 126 150 100%
(WOT) 53
94 127 152
decreasing 55 89 137 152 decreasing 55 96 137 152
Table 9.3- Shifting point-km/h
Maximum speed of typical Gear-decreasing of vehicle
The Gear-decreasing will be disabled when beyond the following speed.
Gear-decreasing type Speed point for disable of Gear-decreasing
Manual 2-1 In 59 km/h
Manual 3-2 89 km/h
Manual 4-3 119 km/h
Manual 4-2 (4-2 direct) 68 km/h
Manual 4-2 (sequence of 4-3-2) 89 km/h
Figure 9.4 - Special tools for maximum disable speed of manual Gear-decreasing
Special tools
tools Part No.
Platform bracket of transmission
oil pump remover
Cross shaft disassembly /installation
(brake lever)
clutch spring compressing tools
clutch assembly clearance positioning tools
Shaft end floating connector
Shaft end floating measuring tools
cross shaft seal disassembly tools
cross shaft seal installation tools
Pump sealing installation tools
Sealing ring expander extender /compressor
Cross shaft lever disassembly /installation
(disable switch)
solenoid valve /electric heating regulator,
electric meter
solenoid valve, platform meter
Assembly ball spool
Sealing gasket disc
Figure 9.5 Special tools