2006 GREAT WALL HOVER fuel

Chapter 2
Fuel supply system and exhaust system
Fuel supply system :
Disassembly of the fuel tank ........................................................................3
Installation and disassembly of the Fuel pump ..............................................4
Disassembly of the components of fuel supply system...................................4
Disassembly and adjustment of the accelerator pedal operating system ........5
Exhaust system :
Disassembly of the blast pipe assembly.........................................................8
Installation of the blast pipe assembly............................................................9

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

Caution: When maintaining the fuel supply system, if the oil
path needs to be removed, the pressure of the fuel system must
be released to avoid the ejection of high pressure fuel.
Disassembly of the fuel tank
1. First remove the oil-in and oil return hard tube of the
generator, the oil return hard tube of fuel tank, and the
connection rubber tube between the back parts of hard vaporizer
tube. Release the pressure of oil path system slowly, block the
joints with cotton cloth, lest there is ejection of high pressure
oil.
2. Remove the oil filling port at the back of the fuel tank and the
clip of the connection rubber tube of ventilation tube, there are
two clips altogether.
3. Remove the bolts fixing the fuel tank, there are 6 bolts
altogether;
4. Remove the oil-in and oil-out tube from the fuel tank, remove
the vaporizer tube joints and line bundle connector;

The disassembly and installation of the fuel pump
Removal of components of fuel supply system
Gasoline filter disassembly
1. Firstly, use the straight screwdriver to remove the hose clamp
and remove the connecting rubber hose on both sides of gasoline
filter;
2. Loose the bolt on the gasoline filter bracket, then
remove the gasoline filter for complete replacement.
Removal of carbon tank
The disassembly of the fuel filler pipe

Removal of fuel pipe
1. Remove the connection between the in/return fuel connector of
engine fuel track and the fuel supply pipe:
a. Remove the elastic hoop firstly;
b. Remove the package connector; press down the button of package
connector by hand, then pull it out outwardly.
c. Remove the three-line plastic clip.
2. Removal of front section of fuel hard pipe
b. Pull out the fuel pipe form the clip fixing base, then remove the
hard pipe;
c. Remove the fixing base on the longitudinal beam if necessary
rotate the fixing base for 90 degree in clockwise or anticlockwise,
the take out it.
3. Removal of rear section of fuel hard pipe
a. Remove the connecting elastic hoop of two ends of rear section
of fuel hard pipe;
b. Pull out the fuel pipe form the clip fixing base, then remove the
hard pipe ;
Removal and adjustment of throttle control system
1. Removal of accelerator pedal
Remove the two fixed bolts which fix the pedal ;
2. Removal of throttle pull-wire
a. Firstly, disconnect the connection on motor, then loose the fixed
bolt ;
b. Remove the plastic clip of throttle pull-wire on pedal, remove the
end of throttle pull-wire;
c. Use the pliers to clamp the clip on the side of engine compartment
to remove the fixing base of pull-wire on the fa
ade of engine
compartment.

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）.

Automatic transmission-2
Instruction for automatic transmission
1. M88 4-speed automatic transmission is equipped with the hydraulic torque converter and electric control system with locking.
When keep the stable forward status, the hydraulic torque converter can be locked automatically when the engine operates in low
speed, then reduce the unnecessary slide.
Figure 1.1 Electric automatic transmission control system
Figure 1.2 M88 4 speeds automatic transmission appearance figure (applied to 2 wheels driving)
2. The main advantage of the transmission is the application of transmission control unit (TCU). The control unit is the control
system based on the microprocessor system.. TCU control the shifting sensing and realize the Gear position shifting through the
signal of opening degree of throttle position, opening frequency of throttle position, engine speed, vehicle speed, transmission oil
temperature, gear position, mode selection and forced Gear reduction application.
3. TCU drives a variable pressure regulating solenoid valve to control three regulation valves and control the feeling of shifting.
Different transmission fluid temperatures are taken as one the main parameters to control the output pressure of the solenoid
valve, so as to keep consistent feeling of shifting within the normal operation scope.
4. The planning of shifting is very flexible. According to the car model, the different shifting plan is stored in the same TCU.
Generally speaking, the “economical mode” can increase the economical efficiency of the fuel and the driving performance of the
car to the maximum limit. The “dynamic mode” can bring into full play the drive performance of the car to the maximum limit. The
“winter mode” can make the car starting from shift 2.

Automatic transmission-6
Selection of drive mode
The selection of drive mode includes a mode selection switch and indicator lamp. The drive mode selection switch is located
on the operating panel. It can provide the different mode selection according to the different type of car.
It has the optimal fuel economy when select the “normal” mode. At this time, the indicator lamp is not light. When select the
“dynamic” mode, the car will have the maximum dynamic performance and the “dynamic” mode indicator lamp is light. When select
the “snowland” mode, it will realize the starting of “2
nd-Gear”, the “snowland” mode indicator lamp is light, meanwhile the
“dynamic” mode indicator lamp will be closed. When select the manual mode, press down the “snowland” switch firstly, the
“manual” light will be light when the gear is in 3, 2, 1. When in manual mode, 1-2, 2-3, 3-4, 3-2, 2-1, 1-3, 3-1 is shifted by driver
manually and can not be shifted automatically. It can be used in car-racing etc. for the special mode of each model of car refers to
operation manual of user.
Operation instruction
Function
5 Brake function
Can decrease the gear-position in slope to improve the brake effect and increase the vehicle safety.
6 Speed-up function
It can select the manual shifting to increase the vehicle speed completely during the speed-up.
cautions
7 It must place the transmission in the P-Gear or N-Gear when start the engine.
8 It must place the transmission in P-Gear during the parking.
9 It must place the transmission in N-Gear when trail the car.
10 It must be powered off when remove the transmission.
11 It must be powered off when install the transmission.
The transmission processes the communication and calculation with the engine electronic control computer by the precision
central on-line computer. It not only save the fuel, but also provide the maximum mode function, including field, winter and
manual selection. It provides the two conditions, manual and electric for the fast race of racing player. It has racing capacity wh i ch
can compete the speed increasing with the manual transmission.
automatic
Having anti-slide function
It is allowable that the D-Gear
in “W” mode is used in
snowland and M-A integration
mode. automatic
automatic