2006 GREAT WALL HOVER lock

Brake-20
Check the components of rear brake
1. Measure the thickness of the brake block bush.
Standard thickness: 8.0mm
Minimum thickness: 2.0mm
It should replace the brake block if less than minimum thickness or
has uneven abrasion.
2. Measure the thickness of brake disc.
standard thickness: 18.0mm
minimum thickness: 16.0mm
It should repair or replacement brake disc if it is scratched or worn or
its thickness is less than minimum thickness.
3. Measure the circular runout of brake disc.
Remarks: It should ensure that the rear bearing is adjusted
correctly before the measurement.
Maximum circular runout : 0.11mm
4. Replace the brake disc if necessary.
a. Remove the bracket form the rear axle flange.
b. Remove the rear brake disc and install the new brake disc .
c. Install the bracket and tighten the fastening brake caliper bolt.
Tightening force: 100
5Nm

Brake-21
Assembly of pump
1. During the assembly, coat the guide pin with the proper vacuum
sili con based grease; coat the operating surface of piston and
square gasket with proper rubber lubricant.
2. Install the piston gasket and piston in the tong
3. Install the cylinder hole dustproof cover and wire clip in the
tong.
4. Install the rubber pin cover on the tong bracket.
Installation of brake caliper
1. Install the brake block

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.

Brake-28
10. Adjust the clearance between the brake drum and brake shoe.
Poke the adjusting hole plug on the brake drum, insert the screwdriver
into the clearance-adjusting hole; rotate the clearance-adjusting gear
to expand the brake shoe until the brake disc can not be rotated by
hand. Then rotate it for 3-5 teeth in anticlockwise, rotate the brake
disc by hand at the same time, it is proper that it can rotate freely
and without the contact between the abrasion and disc. It is allowable
that the non-running-in brake shoe has the slight abrasion sensing.
When adjust the clearance, the left and right wheel must be adjust at
the same, install the adjusting hole plug after the completion of
adjusting .
11.Rear brake caliper assembly
12.Rear wheel assembly
Tighten torque :120N.m

Brake-30
Replace of load-sensing proportional valve
1. Removal
Disconnect the brake pipeline form the valve; remove the lock nut and
remove the adjusting bolt from the suspension arm bracket; remove the
installation bolt and take off the load-sensing proportional valve assembly.
2. Installation
a. Use two installation bolts to fix the load-sensing proportional valve.
The bolt tightening torque is 23N
m,
b. Tighten the adjusting bolt locking nut,
c. Connect each brake pipeline.
The tightening torque of the connector is 16N
m,
d. Filled with the brake fluid, discharge the air from the brake system;
check the brake pressure and leakage. output manometer
input manometer

Brake-31
Antilock Braking System (ABS)
Cautions
1. It must not remove or install the electric elements and wire bunch plug when the ignition switch is in ON to avoid
the damage of ECU. It should turn off the ignition switch if needs disassembly.
2. Pay attention to do not knock or impact the ABS ECU during the maintenance and repair, for it will damage the
ABS ECU easily.
3. The wheel speed sensor and hydraulic unit (integrated with ECU) of BOSCH ABS8.0 can not be repaired, it should
be replaced in integral if damaged.
4. After the brake system is maintained, the brake pedal maybe soft. Discharge the air according to the normal brake
system.
5. It must use the brake fluid from original manufacturer; the brake fluid of different number cannot be used in mixed,
otherwise it will cause the failure of brake system. Select the tyre of original type as most as possible
Repair of Antilock Braking System (ABS)
1. It should process the failure diagnosis for the brake system before process the ABS failure diagnosis. It can
diagnose out the failure rapidly by using Table 1. In Table 1, the small number means the failure which occurs most
possibly. Check each element according to the sequence and maintain or replace it if necessary.
2. Check the following elements for normal operation before the diagnosis:
Brake fluid level and brake fluid quality
Pressure of tyre, size of tyre, shape and depth of tyre figure
Other brake component
These components will affect the brake effect of the ABS. Check the system sensor, connecting wire and connector for correct
installation, arrangement and connection. Ensure the completeness of fuse, repair or replace it if necessary.
3. Process the analysis and diagnosis according to the ABS advanced by owner. Use the diagnosis instrument (Annex
1) for final check and confirmation. It must process the run inspection after the competition of all ABS maintenance.
The test condition is shown as follows:
a. Confirm the tyre complies with the requirement, the tyre pressure is normal.
b. The brake system (including brake light ) is normal
c. The brake system is without leakage.
d. The position and installation of wheel speed sensor is correct.
e. All fuses are normal.
4. test method:
Run for 1 min at least when the vehicle speed is beyond 40Km/h, process a proper brake. Then read out the failure code to
ensure the ABS is without failure code.

Brake-32
Table 1

Name of element
(failure) Brake is low or
soft Lag of brake Block of brake The brake is very hard
but has bad eff ect Brake
noise
Brake system (leakage of brake
fluid) 1 1
Brake system (with air) 2 2
brake shoe (worn) 3
Piston oil seal (worn or
damaged) 3
brake pedal (small free stroke) 1
Brake mai n p ump (fai lur e) 4 1 1
parking brake (brake shoe is out
of round) 4
parking brake (improper
adjustment) 2
parking brake pull-wire (lag) 3
Assist push bar (improper
adjustment) 5 9 8
Tension or release spring (failure) 8 8
brake shoe (crack or
deformation) 5 5 4 1
Piston (lag) 6 1
brake shoe (with oil) 2 5
Piston (block) 7 3
assist system (vacuum leakage) 10 9
brake shoe support plate (loose) 4
fixed bolt (loose) 2
Slide pin (worn) 5
brake drum (crack) 4 7 3
brake shoe (with foreign
mater ial) 6 6
brake shoe (harden ) 7
Noise reduction plate (worn) 9
Press spring (damaged) 10

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