2006 GREAT WALL HOVER lock

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;

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.

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

Warning : All components of the exhaust air system should be
disassembled 30 minutes after shut down to avoid the human
injury caused by hot parts.
Removal of exhaust pipe assembly
Removal of exhaust tail tube
1. Firstly, use the M15 box spanner, ratchet wrench and extension
bar to remove the connecting nut of the rear flange of muffler
assembly and rear section flange of exhaust pipe, take out
the seal bush between the flanges.
2. Remove the three-hole rubber block on the back of the rear
section of exhaust pipe.
3. Remove the three-hole rubber block on the front of the rear
section of exhaust pipe.
Caution: The bush between the rear flange of muffler and
rear section flange mainly has the function of sealing; it
may cause the great pressure and distortion after one
installation, the sealing effect is worse, and the bush cannot
be used repeatedly.
Removal of the muffler
1. If necessary, dismantle the back section of exhaust pipe
according to the method of dismantling the exhaust pipe, if
not necessary, only remove the coupling nut between the
muffler and back flange of the exhaust pipe;
2. Use the M15 sleeve, ratchet wrench or open-end (box) span-
ner to remove the coupling nut between the front flange of
muffler assembly and the rear flange of the cleaner; when
implementing this operation, there must be somebody to pull
the muffler to prevent it from falling only to cause damage;
brick of the muffler;
3. Use the M13 sleeve, ratchet wrench to loosen the four nuts
fixing the shock absorption rubber
4. Then the muffler assembly can be removed.
Caution: The cleaner cushion assembly 2 between the
cleaner and the front section of the exhaust pipe mainly plays
a role of sealing; there may be great pressure and distortion
after one installation and the sealing effect is worse, this
bush cannot be used repeatedly.

Clutch-2
Troubleshooting

failure cause inspection content
Shift difficulty or can not shift
Large free stroke of clut ch pedal clutch Pipe
has air
Failure of clutch cylinder
Failure of clutch master cylinder
The installation position of clutch disc is not
in position; large deviation; oil on the friction
lining or broken
The clutch disc is dirty or with foreign
material
Failure of clutch cover Adjust the free stroke of pedal
Discharge the air in clutch system
Replace
replace
Inspect the clutch disc; replace
Repair if necessary
Replace
Disengagement of transmission The clutch guide bearing is worn. Replace the guide bearing
Slide of clut ch
insufficient free stroke of clutch pedal
oil on the clutch disc friction lining or broken
failure of press disc
separation rocker arm assembly is blocked Adjust the free stroke of pedal
Inspect the clutch disc and replace it
Replace the clut ch cover
Check the separation rocker arm assembly
clutch clamping
stagnation/vibration oil on the clutch disc friction lining or broken
failure of press disc clutch membrane spring
is bend
loose of engine bracket Inspect the clutch disc and replace
Replace the clut ch cover
Correct the clutch membrane
Repair if necessary
Soft of clutch pedal clutch pip e has air
failure of clutch cylinder
failure of clutch master cylinder Discharge the air in clutch
replace
replace
Loud noise of clut ch
Component in clutch housing is loose
Throw-out bearing is worn or dirty
guide bearing is worn
separation rocker arm assembly or pull-rod is
blocked Repair if necessary
replace
replace
Repair if necessary

Clutch-3
Inspection and adjustment of clutch pedal
1. Check the correctness of pedal height and stroke of push rod
The pedal height starting from the meter: LHD 157.5mm
The push pole travel at the top of the pedal: RHD 151.0mm
If not correct, adjust the pedal height and push rod stroke.
2. Adjust the pedal height and stroke of push bar if necessary
a. Screw off the locknut, rotate the locking bolt until to the correct
height.
Screw on the locknut.
b. Screw off the locknut, rotate the push rod until the stroke of push
rod is correct.
Screw on the locknut.
3. Check the correctness of free stroke of pedal
Step on the pedal lightly until fell the clutch start to generate the
resistance.
Free stroke of pedal: 5
15mm
4. Adjust the free stroke of pedal if necessary
a. Screw off the locknut, rotate the push rod until the free stroke is
correct.
b. Tighten the lock nut
c. Check the height of the pedal after adjusts the free stroke of pedal.
d. On the condition that ensure the free stroke of clutch pedal assembly:
The height difference between the brake pedal, clutch pedal and the
front apron is 0
8mm.
Air discharge of clutch
Remarks: It should discharge the air if there is residual air in the
clutch system.
Caution: Do not leave the clutch liquid on the painted surface,
otherwise it should be washed off immediately.
Fill the brake fluid in the clutch storage tank
Check the liquid tank frequently. Filling if necessary.
the adjustment
point of push rod
stroke
the adjustment
point of pedal height
pedal height
front wall
free stroke
push rod stroke

1. Speed ratio of transmissio

Gear Ⅰ Ⅱ Ⅲ Ⅳ Ⅴ R
Speed ratio 3.967 2.136 1.360 1.000 0.856 3.578

2. Speed ratio of transfer case SC5M4D-C

Gear synchronizer H L
Speed ratio 1.000 1.925

3. Central distance of main shaft
transmission 72 mm
transfer case 222.25 mm
4. Instruction for repair specification of transmission

Inspection item Repair specification
End clearance of gear of Axle 1 (mm) 0～0.06 Adjusted by axial retainer.
Clearance b etween b earing block and bearing of Axle 1 (mm) 0～0.1 Adjusted by adjusting shim.
End clearance of gear hub of Gear 3/ 4 synchronizer (mm) 0～0.08 Adjusted by axial retainer.
Clearance of rear end cone b earing of int ermediate s haft (mm) 0～0.05 Adjusted by adjusting shim.
End clearance of gear hub of high and low gear (mm)
SC5M4D-C 0～0.08 Adjusted by axial retainer.
Clearance between the rear output shaft rear bearing and back
cover (mm) SC5M4D-C 0～0.1 Adjusted by adjusting shim.
Clearance of rear input shaft bearing (mm) SC5M4D-C 0～0.06 Adjusted by adjusting shim.

SC5M2D-C transmission assembly
handle of gearlever
dustproof seal cover
oil seal 39.65210
odometer driven gear assembly
odometer seating lock plate
cylindrical compression spring
1.05.841
bush
select & shift seating
N m: specified torque
Used component which can not be used any more.
Pregummed component
Use the special toolsmanipulator cover assembly
elastic cylindrical pin 6
22
rear housing assembly spring cylindrical pin
reverse lamp switch bracket
bearing housing assembly
clutch housing assembly
location compression
cylindrical pin