length GREAT WALL HOVER 2006 Service Repair Manual

Automatic transmission-3
8. Use two bolts to install the back device on the extended case of the transmission, these lengths are important. If it is too long,
it will hinder the end of the bolt and affect the threads on the case. Ensure the proper length and special torque of the bolt.
9. Pay attention that the height of the oil has been determined before delivery from the ION Company. The oil height needs not
checking or correction, except that improper oil is suspected to be used, or additional oil is needed because of leakage.

d. Tighten the adjusting bolt to make the extension length of the bolt
equal to the length before remove.
2. For new torsion bar spring
a. Remove the wheel.
b. Coat thin grease on the spline of the torsion bar spring.
c. Install the torsion bar spring on the torsion bar base.
d. Lower the lower arm to the lower limitation position; install the
adjusting arm in the torsion bar spring with the angle that the
adjusting bolt just can be screwed on the upper adjusting block.
e. Tighten the adjusting bolt to the specified torque.
Nut tightening limitation: A is about 30-35mm; if A>
35mm, then it is adjusted through height of adjusting arm.
f. Install the wheel; remove the bracket; bounce the vehicle for
several times to make the suspension enters into the stable
status.
g. Rotate the adjusting bolt and adjust the ground clearance of
chassis (Refer to 4-Wheel Alignment).

Torsion bar spring
Disassembly of torsion bar spring
1. Make the assembly mark on the torsion bar spring,
torsion base and adjusting arm
2. Measure the length A of extension section of bolt
according to the length shown in figure.
Remarks: The measuring value is for reference when adjust the
ground clearance of chassis.
3. Loose the adjusting bolt until the torsion bar spring
has not the tension.
4. Remove the fixed arm and torsion bar spring
Installation of torsion bar spring
Remarks: There are the L and R indication marks, which must not
be exchanged on the rear end of the torsion bar spring. Mark L
means the left while R for right
1. For reused torsion bar spring
a. Cost the spline of torsion bar spring with grease thin.
b. Align the assembly mark and install the torsion bar spring on the
torsion bar.
c. Align the assembly mark and install the adjusting arm on the
torsion bar spring.

d. Tighten the adjusting bolt and make the extension length of the
bolt equal to the value before disassembly.
2. For new torsion bar spring
a. Remove the wheel.
b. Coat the spline of torsion bar spring with thin grease.
c. Install the torsion bar spring on the torsion bar base.
d. Lower the lower arm to the lower limitation position; install
the adjusting arm in the torsion bar spring with the angle that
the adjusting bolt just can be screwed on the upper adjusting
block.
Remarks: It can repeat for several times until proper when
adjust the angle.
e. Tighten the adjusting bolt to the specified torque.
Nut tightening limitation: A is about 20-35mm; if A>35mm,
then it is adjusted through height of adjusting arm.
f. Install the wheel; remove the bracket; bounce the vehicle for
several times to make the suspension enters into the stable
status.
g. Rotate the adjusting bolt and adjust the ground clearance of
chassis (Refer to 4-Wheel Alignment).

c.Use the special pneumatic pliers to lock the large and small clip of
outer jacket.
d.Ensure the jacket of both sides does not be prolonged or shortened
when the front drive shaft has the standard length.
Standard length: 400.5mm
If only need to replace the outer components of front drive
shaft assembly on car, it can remove the left and right steer-
ing knuckle of car, then disconnect the inner trumpet con-
nector of front drive shaft assembly, then take out the three-
pin section assembly and shaft from the inner trumpet con-
nector for replacement.
Installation of constant-speed drive shaft assem-
bly on front drive axle
1. Insert the hanger plank into the drive shaft, inserted
with oil seal; use the circlip pliers to install the inner
circlip.
Caution: It should replace the oil seal if damaged.
special tools
circlip pliers
support the lower end

Brake-6
4. Adjust the stroke of pedal if necessary
a. Rotate the pedal push bar to adjust the free stroke if the stroke
length is improper.
b. Start the engine to confirm the free stroke of pedal.
c. Check the height of pedal after adjusts the free stroke of pedal.
d. The height difference of brake pedal and clutch pedal to front
apron is 0
8mm.
e. The height difference of brake pedal and accelerator pedal to the
front apron is 45
5mm.
Vacuum assist
Remarks:
Use the vacuum assist tester to check the operation of vacuum
assist if possible.
1. Operation inspection
a. Step on the brake pedal for several times before start the engine
and check the reserved distance which should not be changed.
b. Step down the brake pedal and start the engine. If the pedal
moves downwardly a little, then it means the normal operation;
if the brake pedal moves upwardly, then it means the brake
assist is damaged.
2. Air tightness inspection
a. Start the engine and shut off it after 1
2 minutes. Step down the
brake pedal slowly for several times. If the pedal moves
downwardly all long at the first time, but moves upwardly little
by little after second or third times, then it means the vacuum
assist has the sound air tightness. If the pedal height is without
variety, then it means the brake assist is damaged.
b. Step down the brake pedal when the engine is operating; then shut
off the engine but step down the pedal, if the pedal keeps the
stroke without variety within 30s, then it means the vacuum
assist has the sound tightness; if the brake pedal moves upwardly,
then it means the brake pedal assist is damaged.

Brake-14
Assembly of brake pump
1. Preparation work
All components should be washed, dried by wind and without foreign
material before the assembly. During the assembly, cost the guide pin
and location pin with proper vacuum silicon based grease; coat the
working surface of piston and square gasket with proper rubber
lubricant.
2. Install the piston gasket in the tong body.
a. Screw the bleed screw into the bleed hole;
tightening torque 7
10Nm.
b. Install the square gasket in the sealing groove of two cylinders of
pump respectively after coat its working surface with proper
rubber lubricant.
3. Install the piston with dustproof cover in the tong
a. Cover the dustproof cover on the piston.
b. Lengthen the dustproof cover to expose the bottom of piston
from the dustproof cover clip ring; use the tool (for example: steel
wire about
2mm ) to assist insert the clip ring into the cylinder
hole clip ring groove.
Caution: The used tools must not be sharp to prevent the damage
of dustproof cover.
c. Press the piston to the bottom of cylinder hole by hand.
4. Pre Install the guide pin and location pin on the tong bracket.
a. Install the guide pin dustproof cover on the guide pin and location
pin respectively.
b. Screw the guide pin and location pin in the tong bracket
respectively.
Caution: Do not damage the guide pin dustproof cover.

Brake-27
6Install the lower tension spring
Install the lower tension spring between the front and rear shoe plate.
7. Install the clearance-adjusting device.
Install the clearance-adjusting device after poke the brake shoe by
screwer.
8. Install two upper release springs
Insert the block into the support pin, then install the upper release
spring on the place between two brake assemblies.
9. Check the operating process of automatic adjusting mechanism.
a. Pull the manual brake pill-wire, then release it. Check the clear-
ance-adjusting gear for rotation. If can not rotate, check the rear
brake and find the problem.
b. Adjust the clearance-adjuster to the length as short as possible.

Controller of the Central Door Lock
1. Positive pole of the power supply (12V) is connected to the positive pole of car’s battery through a 15A fuse; when the
engine is started, the voltage is not less than 10V.
2. Output of the central door lock. The unlock cable connected to the executor of the central door lock is usuall
y grounded
through the normally-closed contact of the internal relay; when the door is unlocked by the remote controller or unlocked
manually, the public contact of the relay will get through with the normally-open contact, realizing an output of 12V
voltage.
3. Out
put of the central door lock. The lock cable connected to the executor of the central door lock is usually grounded
through the normally-closed contact of the internal relay; when the door is locked by the remote controller or locked
manually, the public contact of the relay will get through the normally-open contact, realizing an output of 12V voltage.
4. Key detection cable. This cable is connected to the ignition lock of the car and will
get through with the grounding wire
when the key is inserted into. (negative input)
5. Ri
ght direction indicator. The cable is connected to the positive pole of the right direction indicator of the car; an output of
12V voltage will be available when this cable is at work.
6. Left direction indicator. The cable is connected to the
positive pole of the right direction indicator of the car; an output of
12V voltage will be available when this cable is at work.
7. Negative input of door switch, which is connected to the door switch of the car; this cable will be earthed when the door is
opened. (Interior lights will be on)
a. Open the door and then close it, the reading light will be on for 10 seconds; if during this period, it is detected that the key has
been inserted into the ignition lock or the door closed, then the reading light will turn off.
b. When the key is pulled out of the ignition lock, then reading light will turn on, during this period, if the key is reinserted into
the ignition lock or the door lock, the reading light will be off; if there is not any action when the door is closed within 1
minute, the reading light will automatically turn off.
8. ON power supply detection cable. A conductive wire connected to the ON gear of the ignition lock. (When the ke
y is turned
to the ON position, a 12V output will be available)
9. Car s
peedometer detection cable, which is connected to the detection cable of car's speedometer. (When the car is
accelerated to the speed of 15km/h, the instruments unit will out
put a 500mS rectangular positive pulse to the central door
lock controller, which will control the locking of the central door lock when this 500mS rectangular positive pulse signal is
detected by the controller.)
10. Output of window closing si
gnal. When the door is locked by the remote controller, this line will be available with an
output of 12V positive current for one second and then be off. (No output)
11. Locking signal. The locking signal line connected to the central door lock of car's left front door is connected throu
gh with
the grounding line when at work. (Earthing)
12. Unlockin
g signal. The unlocking signal line connected to the central door lock of car's left front door is connected through
with the grounding line when at work. (Earthing)
13. Ne
gative pole of the power supply, which is connected to the car body, (earthing) line shall be as short as possible,
over-length will produce the interference.
Function of controller of the central door lock
1. Locking. When all the car doors are closed, press LOCK button of the remote controller once, at this time, the direction
indicator will flash once and the central door lock is closed.
2. Unlocking. At the locking state, press UNLOCK button of the remote controller once, at this time, the direction indicato
r
will flash two times and the central door lock is opened.
3. Car-findin
g function. At the locking state, press LOCK bottom of the remote controller once, and at this time, the direction
indicator will flash ten times quickly. Press UNLOCK button of the remote controller to quit the car-finding function.
4. Automatic
prevention function. At the locking state, press UNLOCK button of the remote controller to open the lock; if the