torque GREAT WALL HOVER 2006 Service Repair Manual

Instroduction-2
How to use this manual
In order to help you to use this manual, the chapter name and main
topics are given at the upper side of each page.
To introduce to you the maintenance items, there is an index on the first
page of each chapter.
At the beginning of each chapter, there are also the matters needing
attention of all the maintenance operations.
Please read the following matters needing attention before starting the
maintenance work.
The failure diagnostic list of each system can help you to diagnose the
failure of the system and find out the causes of failure.
The maintenance method with regard to the possible causes is given in
the column of maintenance method to facilitate you to acquire the method
of solving the problem quickly.
Maintenance procedure
Most part of the maintenance operation can be started
from referencing the illustration. These illustrations help
you recognize the parts and show the mutual coordination.
For example:
split pin
upper ball pin
upper arm
washer
upper arm bush
upper arm shaft
upper arm bush
washer
Specified torque
Used component which can not be used any more.
.Pregummed components

Instroduction-3
The maintenance procedure is explained in the form step by step:
The illustration shows what to do and where to do.
The topic of maintenance work tells you what to do.
The detailed instruction tells you how to finish the maintenance
work and introduce other related issues, such as specification and
warning, etc.
For example
This format can help the experienced technical personnel to locate the
causes of failure quickly. The maintenance personnel can browse the
work topics, and reference the detailed explanation below it only when
necessary. The important specification and warnings are given in bold
face letter.
Specification
In the whole manual, each maintenance step is given with corresponding
specification in bold face letter, so there is no need to stop working to
look at the specification. All the specification can be located quickly in
Annex A.
Warning, Attention, Remarks:
The Warning is given in bold face letter, which means there is the
possibility of harming both the person himself and others.
The Attention is written in bold face letter, which means there is
the possibility of damaging the parts under maintenance.
The Remarks is written separately in the instruction, it is also in
bold face letter. Its main function is to make some additional
explaining to help you to finish the repair work more efficiently.
3. Check the drive of ball pin
a. Remove the ball pin.
b. As shown in the Figure, shake the ball pin back and forth for
several times before mounting the cap nut,
c. Turn the but with torque meter continuously, turn one cycle
every 2 to 4 seconds, read the torque meter at the fifth cycle.
Tightening torque (for rotary):
Upper ball pin
Lower ball pin 0.1
Specification
Work topics: what to do
Detailed instruction:
How to do

Instroduction-5
e. Mount the cable terminal onto the binding post of the loosened nut,
then tighten the nut. Does not use hammer to knock at the terminal
onto the post.
f. Do remember to check whether the positive pole (
) terminal cap
is in its position.
4. Check all the soft tubes and wire terminal, check to see whether
they are connected correctly and firmly.
5. Used component which can not be used any more.
a. The following spare parts needs always to be renewed: split pin,
seal gasket, O ring and oil seal, etc.
b. For the used component which can not be used any more, it is
indicated by symbol “¦” in elements diagram.
6. Precoated component
The precoated component includes the bolt and nut which is precoated
with the locking sealant in factory.
a. If the precoated component is tightened, loosed or moved by any
reason, it must be recoated with the specified sealant.
b. Coating procedure of precoated component
Remove the old sealant from the screw of component by washing.
Dry it by compressed air.
Coat the screw of components with the specified locking sealant.
c. The precoated component is indicated by symbol “?” in elements
diagram.
7. It can use the sealant or seal ring to prevent the leakage if
necessary.
8. Abide by all specifications for bolt torque strictly. It should use
the torque wrench.
Comprehensive maintenance instruction
1. Use the protection plate, seat and floor covering cloth to make
the car clean and prevent it from being damaged.
2. During the disassembling, place the components in order for the
convenience of assembly.
Observe the following issues:
a. Before conducting the electrical work, remove the negative pole of
the cable from the accumulator terminal.
b. When it is necessary to remove the accumulator for checking or
maintenance, the cable shall be removed from the negative pole
(
) connected to the car body.
c. In order to avoid the damage of accumulator terminal, when removing
the cable, loosen the terminal nut, then pull the cable upwards
vertically, do not twist or pry it.
d. Please use cleaning cloth to clean the accumulator terminal. Do not
use file or other similar tools, which may scuff them.

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

Engine
For the structure and main technical parameter of engine see Table 2.
Table 2 Structure and main technical parameter of engine

Serial No. Item Specification and parameter
1 model 4G64S4M
2 style 4-cylinder, straight-line, water-cooling, single top
cam shaft, 4-stroke engine
3 Fuel oil supply method Multi-point fuel oil injection(MPI)
4 Measuring method of inlet capacity Speed compact style
5 Combustion room style Single-slope roof
6 Cylinder diameter × stroke(mm) 86.5×100
7 Total displacement (L) 2.351
8 Compression ratio 9.5:1
9 Max. power and corresponding speed (kW/r/min) 93/5250
10 Max. torque and corresponding speed (N·m/rpm) 190/2500
11 Min. fuel consumption (g/kW·h) ≤254
12 Idle stable speed(r/min) 750±30
13 Idle-speed control Electronic closed loop control
14 Mean piston speed(m/s) 17.5
15 Mean effective pressure (kPa) 1036
1 6 C y l i n d e r c o m p r e s s i o n p r e s s u r e : i n 250r/min (kPa) 1 3 2 0
17 Ignition sequence and control 1-3-4-2; without distributor block, electronic
controlled direct ignition
18 Spark plug gap(mm) 1.0～1.1
19 Spark plug model BKR5E-11 or K16PR-U11 or RC10YC4
BKR6E-11 or K20PR-U11 or RC8
20 Manufacturer of spark plug NGK or DENSO or Xiang huo ju
21 Valve clearance(mm) 0(hydraulic column )
22 Port timing: Opened inlet/closed inlet
Opened outlet/closed outlet 18 °before upper stop point/ 53 °after lower stop
point
50°before lower stop point/ 18 °after upper stop
point
23 Lubrication method Combined method of pressure and splash
24 Pressure of engine oil of main oil channel, in idle
speed of 3000rpm (kPa) (≥78.5)/(245-490)
25 Max. engine oil temperature(℃) 130
26 Consumption ratio of engine oil(g/kW·h) 2

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.

Fuel supply system
N m: specified torque
adjustment nut
throttle pull wire
accelerator pedal assembly
carbon tank exhaust rubber tube
snap fitting
steel strip type elastic hoop
generator oil-in rubber tube
generator of return rubber tube
soft tube fixing clipper
carbon
tankcarbon tank
air inlet
rubber tubeb type
worm drive
type hoop
vaporizer tube 2
back part of fuel tank
oil-out tube
back part of fuel tank
oil return tubefuel filter
filter rubber tube
for gas out
hard tube bracketvaporizer soft tube 2 cleaner bracket
filter rubber
tube for gas-in
fuel tank vaporizer
rubber tube
front part of the oil-out
tube of fuel tank
vaporizer soft
tube1vaporizer tube1
fuel tank gland the middle connection rubber
tube of the oil return tube
front taps of fuel tankfuel pumpfuel tank gland
fuel tank protection plateseal packing
ringfuel tank assembly
fuel tank oil return tube
fuel tank lock
refill opening cushion
pressing board
refill opening cushion
oil filing port assembly
steel strip type elastic hoop
fuel tank protection plate

Exhaust system
N.m Specific torque
Used component which can not be used any more.
end washer assembly
exhaust pipe outlet nut
front section of exhaust pipe
hexagon flange nut
cleaner cushion
assembly 1
fastening bolt of hoop
cleaner heat insulation cover clip
cleaner discharge pipe catalytic converter
three-hole rubber block
cleaner cushion assembly 2
hexagon flange nut
muffler assembly
muffler port decoration cover
hexagon flange nut
rear section assembly
of exhaust pipe
wahser assembly
100
9
63
5
23muffler damping
ruber block assembly

Clutch-4
Cluch control mechanism
clutch master cylinder
N
m: specified torque