steering GREAT WALL HOVER 2006 Service Repair Manual

Preface
Table of Contents
Instruction How to use the manual
Chapter 1 Overview of the entire car (parameters)
Chapter 2 Fuel supply system and exhaust air system
Chapter 3 Clutch
Chapter 4 Transmission
Chapter 5 Automatic transmission
Chapter 6 Driving shaft
Chapter 7 Suspension and vehicle axle
Chapter 8 Brake (ABS)
Chapter 9 Steering
Chapter 10 Car body electric appliance
Chapter 11 CD player and air-conditioning system
Chapter 12 Safety airbag
Annex:
Important components guarantee and requirement
List of non-metal material consumption
Special tools
D Important working components and tightening torque
E Electric wiring diagram

Overview of the entire car-1
Chapter 1
Overview of the entire car
Basic parameter....................................................... 2
Engine..................................................................... 4
Air inlet system........................................................ 5
Exhaust air system................................................... 5
Fuel supply system................................................... 5
Cooling system........................................................ 5
Clutch..................................................................... 5
Transmission............................................................ 6
Drive shaft............................................................... 6
Front shaft/axle........................................................ 6
Rear axle................................................................. 6
Wheel tyre............................................................... 6
Suspension.............................................................. 7
Frame..................................................................... 7
Steering system........................................................ 7
Brake system........................................................... 8
Car body................................................................. 9
Electrical system.................................................... 10
Air-conditioning system …………………..............12

Front shaft/axle
CC6460K wagon has the two-cross arm, independent suspension, breakaway front axle.
CC6460KY wagon has the two-cross arm, independent suspension, breakaway steering drive axle , hyperbolic gear single-stage main
reducer, plain bevel gear differential mechanism, universal drive semiaxle, Birfield ball-joint, main reduction ratio i
0=4.55, Max. input
torque is 900N
m.
Rear axle
Non-breakaway drive axle, integral stamping-welded axle housing, hyperbolic gear single-stage main reducer, plain bevel gear differential
mechanism, semi-floating semiaxle, main reduction ratio i
0=4.55, Max. input torque is 900Nm.
Wheel and tyre
The type, specification and main parameter of wheel and tyre see Table 4.
Table 4 Type, specification and main parameter of wheel and tyre
Transmission
For the structure and main technical parameter of transmission see Table 3.
Table 3 Structure and main technical parameter

Serial
No. Item Specification and parameter
1 Model SC5M2D-C SC5M4D-C
2 style manual mechanical step
transmission of full synch, 5
forward steps, 1 revers e step, direct
manipulation manual mechanical step transmission with torque
divider of full synch, 5 forward steps, 1 reverse step,
direct manipulation
3 Cent er
distance(mm) 72 72(transmission), 222.25 (torque divider)
4 Max. input torque
(N. m) 196 196
5 Max. input torque
(r/min) 5500
Step
I Step
II Step
III St ep
IV Step
V Step
R(Reverse) Step
H(high) St ep
L(low)
6 Speed ratio

7 Gear pair of
speedometer 8:25
8 To t a l n et
weight(kg) 38 68(include torque divider)
9 Outline
dimension: L×W
×H 1070mm×466mm×
399mm( not include height of
steering level) 1070mm×460mm×380mm( not include height of
steering level)
Drive shaft
The structure of rear drive shaft assembly of CC6460K wagon is the three cross-axle universal joints, two drive shafts with exten
s
intermediat e support free-maint enance segmental structure. The front and rear dr ive shaft assembly of CC6 460KY wa gon has the
universal joints, one drive shaft with extension spline, free-maintenance integral structure respectively.

Overview of the entire car-7
Suspension
The front suspension is the torsion bar spring, double-cylinder inflatable hydraulic damper, transverse stabilizer rod, double
cross-arm independent suspension. The distance between the center of front shaft of lower arm fixing nut and level ground is
295mm±1mm.
The rear suspension is the four-connecting rod, coil spring, double-cylinder inflatable hydraulic damper, transverse stabilizer
rod, no indep endent suspension.
Carriage
Peripheral trapezoidal structure; welded by two box section longitudinal beams and several box or tube section cross beams.
Steering system
Pinion-and-rack power steering-gear, hydraulic assists steering. Breakaway front steering trapezoidal structure. Diameter of
quadriradistus steering disc φ380mm, adjustable angle, power-absorbing steering pipe. For main technical parameters of
steering s ystem refer to Table 5.
Table 5 Main technical parameter of steering system
Serial No. Item Parameter Serial No. Item Parameter
1 wheel camber 0°±30′ 6 Rotary round of
steering disc n 3.64
2 kingpin inclination 12°30′±30′ 7 Angle drive ratio of
steering system i0ω 18.2
3 kingpin castor 3°30′±30′ 8 Force drive ratio of
steering s ystem i0p 198.0
4 toe (mm) 0～2 9 Normal efficiency of
steering gear η+ ≥75%
5 Steering angle of
internal and external
wheel (°) 32/28 10 Revers e efficiency of
steering gear η- ≥60%
1．Adjustment of .4-Wheel Alignment
Test and adjust the front wheel alignment value and adjust the toe on the 4-Wheel Alignment meter.
a. Adjustment of kingpin castor: The standard value is 3°30′±30′(adjust the difference of left and right kingpin
castor to within 30′);
b. Adjustment of toe: The toe with standard value of 0～2mm is adjusted by rotating the steering cross rod. When adjust
the toe, it should rotate the cross brace in left and right side evenly. Tighten the lock nut after adjustment, the torque is
55 - 65N·m.
c. Centering and fix of steering wheel: according to the display of the alignment gauge, turn the front wheel to right
ahead, after removing the steering wheel without changing the position of steering lever, mount the steering wheel
with center aligned, the radials of the steering wheel shall be in the bilateral symmetry position, and the symbol of
Great wall on the steering wheel shall be in the confrontation position of the driver, tighten the nut, with a tightening
torque of 25 - 35N·m.
Left wheel left steering: 32, right wheel left steering:28;
Left wheel right steering:
28, right wheel right steering: 32;
b. Under the light condition of the car, the height between the center of front axis fixed bolt of the lower suspension arm to the
ground is 295
1mm, if the dimension is not within this scope, reach it through adjusting the torsion bar adjustment arm
bolt;
c. The reference dimension of the height of the car is : the left and right deviation is less than 10mm;
3. Checking the free gap of steering wheel:
Turn the orientation of the car to front, stop the engine, exert a force of about 4.9N on the steering wheel along the circumferential
direction to make the it turning to the left, there is resistance force, stop turning when the resistance force is growing; then turn
the steering wheel to the right, stop turning when the resistance force is felt to be growing; the radian value that the external edge
of steering wheel runs is the free gap of the steering wheel, its standard value shall be less than or equal to 20
, and the corner
from the central position to the left or right shall be no larger than 10.

2. Operation of 4WD
The operating auxiliary steering column can be shifted to 4WD status.
For position of auxiliary steering column and corresponding operating
condition refer to table.
3. Caution for operation:
a. Do not use 4WD in good surface, otherwise the tyre and components
of drive system will be damaged easily and increase the consumption
of fuel, and cause the noise of drive system.
b. Please run in 1st-Gear under “4L” gear position when run in very
low speed in field.
Operating instruction of transmission SC5M4D-C
1.The schematic diagram of transmission operating gear position
is on the handle of steering column.
During the process after vehicle is started and in traveling, it must
step the clutch pedal to bottom before the shifting. If need shift from
5
th-Gear to reverse-Gear, it should move the shifting bar to the neutral
position of 3rd/4th-Gear. Shift to R-Gear after stop the vehicle stably,
otherwise, it can not shift.
During the traveling process. It should always pay attention to the
shifting to make the vehicle matches to the speed of engine. The
correct shifting can improve the economical efficiency and prolong
the service life of engine. Do not shift from high-Gear to low-Gear on
the condition that the pointer of tachometer may enter into red area,
otherwise, the engine will be damaged.
Warning: Do not shift to reverse-Gear when the vehicle moves
forwardly, otherwise the transmission will be damaged.
hand hall of main steering column
hand ball of auxiliary steering column
Auxiliary steering
column position drive Operating condition
2H 2WD Use this gear position when run in the general railway and high speed highway.
4H High speed 4WD Use this gear position when run in the deep snowland, sand ground or uneven road
in normal speed.
N Neutral gear When use the gear position during using of winch, it could not drive the vehicle.
4L Low speed 4WD Use this gear-position when run in uneven road such as mud land or climbing or
downward （especially when need increas e the power）.

Transmission-27
Manipulator cover assembly
Rear housing assembly
nut
reverse lock
assembly
manipulator
cover assembly
ball head
rubber cover
auxiliary steering
column stop platebush
ball head basewasher
pin
auxiliary steering
column assembly
handle of transfer case
ball head
hood
ball head
rubber cover
stop plate of
main bar
bush
ball head base
pin
washer
master control lever assembly
handle of
gearlever
N m: specified torque
Used component which can not be used any more.
odometer driven gear
assembly
odometer seating lock plate
14-19
14-19
oil seal
dustproof seal
guide bushing
rear housing
adjusting shim
24-33
26-36
aluminum gasket
mushroom lock spring
aluminum gasket
24-33
mushroom lock spring
26-3630-42
N m: specified torque
Used component which can not be used any more.
Pregummed component
Use the special tools
steel ball 7.938 (3)

Automatic transmission-24
Front servo and brake belt Rear servo and brake belt
Figure 4.4 brake belt
One-way clutch
The transmission has two one-way clutches, 1-2 one-way clutch and 3-4 one-way clutch (notice that the third one-way clutch is
located on torque converter, also called as retainer)
1-2 one-way clutch is located between the planet carrier assembly and central shaft. The structure makes the planet carrier only
can rotate in single direction around the central shaft. The one-way clutch is only engaged in automatic 1
st-Gear.
3-4 one-way clutch is located between the clutch C4 and clutch C2.The structure makes the clutch C2 drive the front planetary
gear in 1
st, 2nd and 3rd –Gear, but is disengaged in 4th-Gear and overspeed.
Planetary gear assembly
The planetary gear block used in transmission is the traditional lavena gear block consisted of6 pinions.
Parking mechanism
When select the parking-Gear, the steering column will move the parking lever backwardly to engage with the parking ratch
(refer to Figure 4.5). The ratchet is engaged with the tooth of external gear ring fear to lock the output shaft axle in the
transmission. When it is not in parking-gear, the return spring will release the parking ratchet and unlock the output shaft to
prevent the occurrence of accident parking action.
Figure 4.3 Clutch assembly
Brake belt
The transmission has two brake belts, brake belt B1 (named as 2-4 brake belt sometimes ) and brake belt B2 (named as low-speed
– reverse gear brake belt ) refer to Figure 4.4.
The brake belt B1 is a flexible brake belt which is engaged with front servo piston. When it is in 2
nd and 4th –Gear, the brake belt
B1 starts to act. When the brake belt acts, it can prevent the rotation of reverse central gear by maintaining the clutch C3 assembly
is in static. In 2
nd –Gear, only the external surface of piston is used. In 4thGear, both sides are used to acquire more clamping force.
The brake belt B2 is a solid brake belt which is meshed with the rear servo piston. When the B2 acts, it prevents the rotation of
planet carrier assembly. When in manual 1
st-Gear, only the external surface of piston is used. In reverse-Gear, both sides are used
to acquire more clamping force.

Automatic transmission-46
Pin
No. Type 2W D Description
A24 CAN (-ve) I/O ○ CAN hidden communication end
A23 CAN (+ve) I/O ○ CAN exposed communication end
A22 K line communication
connection I/O ● Diagnosis information and car code
A21 Nonuse ―― ○ －－－－－
A20 Nonuse ―― ○ －－－－－
A19 Shaft speed sensor
signal IP ○ The sensor sends the shaft speed signal to T CU
A18 Nonuse ―― ○ －－－－－
A17 Nonuse ―― ○ －－－－－
A16 Nonuse ―― ○ －－－－－
A15 Nonuse ―― ○ －－－－－
B6 Gear-position IP ● T h e sw itch ha s th e variab le-vo ltage ; in dicate the
gear-position steering colum n selected (PRND321). The
vo ltage is variab le in the ran ge o f 0 V --5 V .
B5 transm ission fluid
temperature IP ● The sensor indicates the transmission fluid temperature.
High R=Low temperature
Low R= High temperature
The voltage is variable in the range of 0V to 5V
B 4 so leno id va lve 4 O P ● N /O FF no rm al-op ened so leno id valve , co m b ined w ith the
O N /O FF w itch o f so len oid valve 3; en sure the sh ifting
quality and sequence
B 3 so leno id va lve 1 O P ● ON/OFF normal-opened solenoid valve; combined with
o the r so leno id va lve; u sed to determ ine the selected
gear-position.
B2 Nonuse ―― ○ －－－－－
B1 R e tu rn so len oid va lve
5 IP ● Using for grounding of VPS and current of circuit can be
detected, then process the feedback control for the VPS.
B14 Gear-position －
grounding GND ● PRND321 Gear-position switch grounding
B13 transm ission fluid
temperature －
grounding GND ● Connected to grounding pin of temperature sensor.
B12 solenoid valve 6 OP ● ON/OFF normal-opened solenoid valve, determine the
high or low of line pressure
B11 solenoid valve 2 OP ● O N /O FF norm al-o pened so leno id va lve, co m bined w ith
o the r so leno id valves; u sed to d eterm ine the selected
gear-position.
B10 solenoid valve 3 OP ● O N /O FF norm al-o pened so leno id va lve, co m bined w ith
the O N /O FF sw itch of solenoid valve 4; ensure the
shifting quality and sequence
B 9 so leno id va lve 7 O P ● ON/OFF normal-opened solenoid valve, hydraulic torque
converter locking; increase the efficiency of medium
speed run.
B8 Nonuse ―― ○ －－－－－
B 7 so leno id va lve 5 (+ ve) O P ● It is the so leno id va lve w hich can ch an ge th e p ressu re
d urin g the sh iftin g a nd on /o ff o f so leno id valve .
●= connected line ○= unconnected line ＊=only
OP= output IP=input I/O=input/output
GND=grounding REF=reference PWR=power
Table 6.1.1 Description of TCU pin

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.

Figure 8.56 The tighten sequence of valve bolt from upper to lower
q. Install the solenoid valve 1, 2, 3, 4 and 6. Ensure the solenoid valve is clamped by the clip tightly and the bolt is tightened to
the specified torque.
Caution:
The wire harness ground wire port is protected by the solenoid valve fixing plate
r. Install the solenoid valve 5. Ensure the solenoid valve close to valve through the clip.
s. When install the valve with line pressure relief valve, it should install the tapering port of line pressure relief valve, then install
and fix the spring and disc.
t . Install the pin spring; ensure the screw is tightened to the specified torque. Check the damaged spring.
u. Install the manual gear shift valve .Refer to Figure 8.57.
Figure 8.57 Manual gear shift valve
v. It should ensure the position lever is in the position of manual 1st-Gear before install the valve on the transmission.
w. Adjust the valve on the transfer case and install the connection of manual-operated valve steering column and manual-operated
valve. Make the long end of connecting object is proper for the 1
st manual-operated valve. Install the protecting spring and
tighten it according to the specification. Refer to Figure 8.58.
x. Check the positioning drum and manual-operated valve .
Caution:
All hardware must be installed and meet the specification.
y . Connect the wire of connecting solenoid according to the following details:
Solenoid valve 1
red
Solenoid valve 2
blue
Solenoid valve 3
yellow
Solenoid valve 4
orange
Solenoid valve 5
green
Solenoid valve 6
purple
Refer to Figure 8.58.