instrument panel GREAT WALL HOVER 2006 Service Repair Manual

Overview of the entire car-11
4.7 Cigar lighter 12V, 1 piece
4.8 Horn Treble and bass
4.9 Safety airbag Electric main and auxiliary airbag
Checking and commissioning of the auxiliary components of car body:
1. 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;
2. The major lamp high beam and city beam, the alternating light, taillight, turn light, brake light, front and rear mist
light, malfunction alarm light, indoor light, instrument panel light, ignition switch light, etc. shall operate normally,
without the failure of no lighting,constant lighting and error lighting , etc;
3. Checking the performance of front head light
a. The high beam luminous intensity of each head light
20000 cd/ piece
b. Beam center left and right deviation (when the beam is irradiating on the screen of 10 m away):
Left light high beam: left 17 cm right 35 cm
Right light high beam: left 35 cm right 35 cm
Left light city beam: left 17 cm right 35 cm
Right light city beam: left 17 cm right 35 cm
c. Beam center height (when the beam is irradiating on the screen of 10 m away):
Head light city beam 0.7
0.9 H; head light high beam 0.91.0 H
H means the head light center height 920
20mm.
4. The adjustment of multi functional meter:
a. Drive the car onto the trench, insert the car speed transducer, drive the car to open places, press the ADJ switch for no less than
3 seconds, the orientation indicator begins to flash. Drive the car slowly for one circle within 2 minutes, the orientation
indicator will stop flashing, it shall points to the practical normal direction.
Note: E
east, Wwest, Ssouth, Nnorth.
b. The adjustment of time:
Press the “MODE” switch for over 2 seconds, the time can be adjusted, press the MODE switch to adjust the minute, then
press the MODE again to adjust the hour, adjust the time through pressing the “
”and “” key. After the time is adjusted,
press the ”MODE” switch for over 2 seconds to quit the time adjustment mode.
c. Check to see whether the absolute altitude meter and the car speed response display are working normally.
d. Drive the car onto the trench again, pull off the car speed transducer plug.
5. The adjustment of rain wiper nozzle cleaning mixture ejection height:
a. Put the ignition switch to the ”ON” position, open the rain wiper nozzle switch, the position of front cleaning mixture nozzle
shall be evenly distributed along the middle height of the front windshield glass from left to right.
b. The position of the rear cleaning mixture nozzle is deviated to right of the center of rear windshield glass for about 20mm-
120mm, and the height is within the scope of 50mm at the center of the glass. If the deviation is large, the nozzle needs to be
adjusted.

Automatic transmission-7
Indicator lamp
Figure 2.2
control system
General
The transmission has two sets of control system, a electric control system and a hydraulic control system. The electric control
system monitors the vehicle parameter and adjusts the transmission performance; the hydraulic control system executes the
command of electric control system.
Electric control system
The electric control system consists of the sensor, TCU and 7 solenoid valves. TCU read in the data and make the output under the
control of software based on the value stored in Read Only Memory (ROM).
TCU controls the hydraulic control system and the control is realized through the valve and pump assembly. The system includes
7 solenoid valves, in which 6 valves are used to control the line pressure, operate the shift valve and hydraulic torque converter lock
clutch and switch on and off two regulating valves (Two regulating valves control the shift feel). The seventh solenoid valve is the
pressure regulating solenoid valve (VPS) which controls the shift feel with other three regulating valves. Figure 3.1 is the typical TCU
control system plan.
The figure includes all elements of electric control system involved in the section.
throttle position
open sensor
Engine speed
vehicle speed
Transmission
fluid temperature
mode selection
(instrument panel
/console )
Gear sensor
Forced step-
decreasingK line
shifting
logic
shifting
sensing
line
pressurehydraulic
control
system
Solenoid valve 1
Solenoid valve 2
Solenoid valve 3
Solenoid valve 4
Solenoid valve 5
Solenoid valve 6
Solenoid valve 7
pressure regulating
solenoid valve
Mode indicator lamp
Gear indicator lamp
set and other
necessary equipment
indication

Automatic transmission-13
Symbol of solenoid valve (On/off solenoid valve)
Figure 3.5 Normal-opened type
1.Variable pressure regulating valve regulating system
The shifting pressure of abrasion unit is controlled by the variable pressure regulating valve.
The line pressure is independent of the shifting pressure and determined by the thro
position, shifting status and engine speed.
S5 is a proportional or variable pressure regulating valve which provides the pressure signal control shifting pressure for
the clutch and brake belt regulating valve.
In automatic shifting period, it process the integral times enlarging and contracting
regulation for the clutch regulating valve, brake belt regulating valve, torque converter regulating valve and VPS.
The hydraulic pressure generated by variable pressure regulating valve is in inverse ratio with current. During the shifting, TCU
will increase or decrease the current of solenoid valve according to the program. The current is variable in the range of 200mA
to 1000mA. The increasing of the current will decrease the S5 output pressure; the decreasing of current will increase the output
pressure of S5.
Lin 500 pressure (about 440 to 560kPa) is the reference pressure of VPS, meanwhile, the VPS output pressure equals to the
pressure on line 500 always.
When the VPS is in waiting status, it means there is not the generation of shifting action. VPS current is 200mA. At this time,
it gives the maximum output pressure.
In stable status, the brake belt and clutch regulating solenoid valve is in closed status. In this condition, the pressure of line 500
is applied on the piston. For the line 500 pressure is more than S5 pressure always, so it pushed the oil in S5 to the place
between the regulating valve and piston. At this time, oil pressure applied on the friction unit equals to the product of pressure
on line 500 and magnification factor.
During the starting of shifting, the used on/off solenoid valve is in opened status which cut off the oil loop supply from line 500
to piston.
At the same time, VPS pressure is decreased to starting pressure valve, pressure set by regulating valve and pressure setting
value required by execution of VPS by pushing the piston from the valve. The shifting is finished through the on/off solenoid
valve, VPS returns to the waiting status
Pointed to each gear-position, the system can make the brake belt; clutch or both realize
the electronic control.
Mode indicator lamp: the mode indicator lamp can be used to indicate the current selected and whether the overpeed status
exists. The mode indicator lamp is located in instrument panel generally. (Refer to Part 2.3)

Automatic transmission-45
Diagnosis and test
Test system
1. Recommended test equipment and program
The test equipment and control unit for design will be used for the test of all vehicles. The parts for transmission test includes:
Tester for service after sales
Special vehicle for test
2. Tester for service after sales
After the special programming, the tester equipped with special car test software can be used to test the specified system and unit.
The program allows the normal communication between the transmission control units (TCUs) .
The computer needs the required information from the customer and select the necessary data through the manual. For example:
view the code, clear the error code and make the real-time operation. For detailed operating instruction refer to user’s manual.
The equipment can be used by the trained specialized persons, such as technician, machinist to test the electronic and loop
problem related to transmission. The testable information includes: the engine speed, rode (shaft speed), transmission fluid
temperature, position of throttle position, status of solenoid valve and gear and position of operating lever. Additionally, it can be
used to detect the current and stored problem.
3. Description of TCU pin
The description of TCU pin code had been listed in Table 6.1.1
For description of wire bunch refer to Figure 6.1.1
Pin No. Function Type 2WD description
A14 Public grounding GND
● Negative pole of TCU supply, connected to negative pole of
battery.
A13 Nonuse
－－
○ －－－－－
A12 M ode indicator la mp
Snowland mode OP
● Indicate that select the “Snowland M ode” operating method.
A11 Parking-Gear indicator lamp O P
● T he drive instrum ent panel indicator la mp indicates tha t is in
the “Parking G ear”
A10 Reverse-Gear indicator lamp OP
● T he drive instrum ent panel indicator la mp indicates tha t is in
“ Revers e G ear”
A9 N-G ear indicator lamp O P
● T he drive instrum ent panel indicator la mp indicates tha t is in
“Idle N Gear”
A8 Nonuse －－ ○ －－－－－
A7 Nonuse －－ ○ －－－－－
A6 M ode indicator la mp
dynamic mode OP
● Indicate that select the “ dyna m ic mode” operating method.
A5 Nonuse ―― ○ －－－――
A4 Nonuse ―― ○ －－－－－
A3 Nonuse ―― ○ －－－－－
A2 Mode switch IP
● The switch is used to select the “economic mode”, “dynamic
m ode” and “ snowla nd mode”. T he voltage is varia ble in
range of 0 V－2V .
A1 Nonuse ―― ○ －－－－－
A30 Power supply PWR
● Power supply for TCU; is the main power source of drive
unit and solenoid valve.
A29 Nonuse ―― ○ －－－－－
A28 1st-G ear indicator lamp
/1st-G ear position﹡ OP
● Drive the instrument panel indicator lamp indication, indicate
that the gear-position is in “1st-G ear”
A27 2nd-G ear indicator lamp
/2nd-G ear position OP
● Drive the instrument panel indicator lamp indication, indicate
that the gear-position is in “2nd-G ear”
A26 3rd-G ear indicator lamp
/3rd-Gear position﹡ OP
● Drive the instrument panel indicator lamp indication, indicate
that the gear-position is in “3rd-Gear”
A25 Automatic gear indicator
lamp /4th –Gear position OP
● Drive the instrument panel indicator lamp indication, indicate
that the gear-position is in “automatic-Gear”

Safety airbag-18
Impact-vehicle diagnosis
Test SRS-ECU diagnostic signals
1. Connect the (X-431 diagnostic test’s) diagnostic joint
2. Read the diagnostic results with X-431 diagnostic tester
Repairing procedure
1.When safety airbag is released.
The following parts should be replaced with new ones
a. Passengers’ side safety airbag module
b. SRS-ECU
c. Driver’s side safety airbag module
2 Check the following parts; replace them with new ones providing something wrong with them.
a. Clock spring
b. Steering-wheel, steering column, bottom steering shaft module
3.Driver’s side safety airbag module’s installation status towards the steering wheel.
a. Check whether abnormal knocking is with the steering wheel, its activity is in good condition and its clearance is normal.
b. Check whether the wiring harness joint is broken and its terminal is deformed.
Caution: Due to the impact, the diagnostic instrument cannot communicate with SRS-ECU when accumulator is lack of
power, in this case, check and maintain the instrument panel wiring harness or utilize the extension power supply.

Safety airbag-22
1. Operations before removal
a. Place the ignition switch in OFF position.
b. Remove the accumulator negative and well preserve it somewhere or wrap it with tape.
2. Removal procedure.
a. Central channel’s side panel (or remove the co-instrument panel)
b. Remove the connector clip connecting with the safety airbag ECU
3. Installation sequence
a. SRS-ECU;
b. Install the connector clip connecting with the safety airbag ECU
c. Central channel’s side panel (or remove the co instrument panel)
d. Connect the grounding jumper.
4. Some points for installation
a. SRS-ECU installation
b. Post-installation test
Place the ignition switch in ON position
SRS alarm lamp flashes in 6 seconds and extinguishes.
c. If not extinguishes, the failure test and troubleshooting must be done.
5. Test
a. Whether the depression, crack or deformation is with the SRS-ECU shield.
b. Whether the terminal is broken or deformed.
Caution: The SRS-ECU safety airbag will not work normally if the SRS-ECU is not correctly installed.
Caution: The SRS-ECU with depression, crack or deformation must be replaced with a new one.
For the inspection of SRS-ECU besides the previous refer to related item of troubleshooting

Safety airbag-23
Driver’s and passengers’ side safety airbag module (DAB, PAB), clock spring
Caution
1. Continue the operation 60 seconds after the removal of accumulator negative. Wrap the negative with insulating
tape for insulation.
2. Safety airbag module and clock spring must not be separated nor repaired, replace the failed ones with new ones.
3. Please pay high attention when using the safety airbag module and clock spring, do not let them fall on the ground
nor fall into water or oil. Moreover, replace the depressed, crack or deformed ones with new ones.
4. After the safety airbag module is released, keep the released side up, store it somewhere flat and do not lay anything
on it.
5. The safety airbag module must not be stored in a place with the temperature above 93
.
6. The released safety airbag module must be replaced with a new one, at the same time test the clock spring, replace
it with a new one if something unusual with it.
7. Use gloves and protection glasses during operating the released safety airbag.
8. The unreleased safety airbag must be abandoned after its release.
Caution
During the removal, the wring harness connector clip must be removed before the removal of other wring harness
connector clips in order to avoid the possible improper release caused by static interferences, which is reversal to the
case of installation.
1. Removal and installation
Driver’s side safety airbag module, passengers’ side safety airbag module, clock spring.
2. Operations before removal.
a. Take out the ignition switch key after the steering wheel and front wheel in straightforward direction.
b. Remove the connections of accumulator negative
3. Driver’s side safety airbag module removal procedure
a. Screw off the bolts of two sides, as showed in Figure 8-1
b. Shut off the wiring harness connector clip
c. Remove the safety airbag module assembly
d. Remove the steering wheel
4. Passengers’ side safety airbag module removal procedure
a. Remove all the trim covers and glove boxes of instrument panel separate the PAB module’s airbag wiring harness connector
clip from the safety airbag’s PAB side one.
b. Remove M6 bolts and separate PAB module from instrument panel armed beam.
c. Remove the instrument panel itself.
d. Remove the M5bolts of two sides of four PAB modules.
5. Clock spring removal procedure
a. Remove DAB module (shut off the connecting connector clip)
b. Carefully remove the steer
c. Open the combined switch upper shield, find and shut off the bottom wring harness connector clip
d. Remove the clock spring from the steer
6. Driver’s side safety airbag module (DAB) and its installation procedure

Safety airbag-24
Figure 81
The removal of steering wheel (Figure 8.2)
Figure 82
7. Passengers’ side safety airbag module (PAB) and its installation procedure.
a. Test before installation
Carefully take PAB module, justify both of them and plug four trim cover M5bolt into the mounting holes of the module’s
both sides
Well install together the module with trim cover bracket and instrument panel mounting bracket with four M5 bolts.
After the installation of the entire instrument assembly to the vehicle, tightly fix the PAB module to the vehicle transverse
beam with 2 matted M6 bolts at the glove box site.
Well mutually plug the PAB module airbag wiring harness connector clip and safety airbag wiring harness PAB side
connector clip it is the end of PAB module installation.
b. Connection of accumulator terminal
c. Post-installation test
8. Clock spring installation procedure
a. Test before installation
Cross the line of upper clock spring through the hole in steer.
connect and fix the clock spring and steer
install the combined switch upper cover
install the steering wheel
steering wheel and safety module assembly
b. Connect accumulator’s terminal
c. Post-installation test

Safety airbag-28
SRS translation wiring harness
releases wring harnessshorting site
6m plus
the shroud
protection tube
Safety airbag module abandoning instruction
Carry out the operation according to the following procedure to abandon a safety airbag module or a vehicle with the SRS
safety airbag. First of all, release the safety airbag.
Unreleased safety airbag module abandoning
Caution
First release the SRS safety airbag when abdbdon it.
Release the safety airbag outside the vehicle to replace the safety airbag module.
Conduct the operation somewhere next to a smoke tester due to the smoke during the safety airbag’s release.
Tell the people to cover their ears and try to conduct the operation somewhere far away from the residential area due
to the big noise during the safety airbag’s release.
Remove the accumulator positive and negative and remove the accumulator off the vehicle.
Caution
Continue the operation 60 seconds after the removal of accumulator positive and negative.
Release the safety airbag module according to the following procedure.
1. Driver’s side safety airbag module
a. Remove the blocking lever
b. Remove the clock spring 2# joint and instrument panel wiring harness joint (yellow)(figure 8.6)
Caution
The clock spring joint will short automatically after the removal of clock spring from the instrument wiring harness,
which can prevent any possible major accident caused by the incorrect release of driver’s side safety airbag module duo
to the static interference from happening.
c. Connect the SRS safety airbag translation wring harness with 2 6m plus release wiring harnesses, wrap the joint part with
insulating tape for insulation.

Safety airbag-18
Nor mal Present failure code
Replace SRS safety airbag system
unit
Take references in
removal/installation of SRS
safety airbag system unit in safety
airbag system.
History-accumulated failure
codes
The end of failure diagnosis
4 Check the wiring harness between passengers’ side safety airbag
module and SRS safet y airbag system electronic-control unit
Place the ignition switch in LOCK position
Release accumulator negative wire and then wait for about 1
minute plus
Remove steering pillar shell
Release clock spring connector clip
Release driver’s and passengers’ side safety airbag module
connector clips
Release all SRS safety airbag system unit connector clips
Check whether the following troubles are with the circuit of the
connector clips terminals between SRS safety airbag system
electronic-control unit and passengers’ side safety airbag
module
Grounding
Power-supply shorting
Shutoff
Is the previous circuit normal? Abnormal Replace the relative wiring
harness
Impact-vehicle diagnosis
Test SRS-ECU diagnostic signals
1. Connect the (X-431 diagnostic test’s) diagnostic joint
2. Read the diagnostic results with X-431 diagnostic tester
Repairing procedure
1.When safety airbag is released.
The following parts should be replaced with new ones
a. Passengers’ side safety airbag module
b. SRS-ECU
c. Driver’s side safety airbag module
2 Check the following parts; replace them with new ones providing something wrong with them.
a. Clock spring
b. Steering-wheel, steering column, bottom steering shaft module
3.Driver’s side safety airbag module’s installation status towards the steering wheel.
a. Check whether abnormal knocking is with the steering wheel, its activity is in good condition and its clearance is normal.
b. Check whether the wiring harness joint is broken and its terminal is deformed.
Caution: Due to the impact, the diagnostic instrument cannot communicate with SRS-ECU when accumulator is lack of
power, in this case, check and maintain the instrument panel wiring harness or utilize the extension power supply.