2006 GREAT WALL HOVER Service Repair Manual

Check and replacement of steering knuckle
Use the dye penetrant to check the steering knuckle for
crack.It should replace the steering knuckle if has crack.
Installation of steering knuckle
1. Install the steering knuckle
a. Install the lower ball pin on the steering knuckle and install the
slotted nut temporarily.
b. Press down the upper arm and connect the upper ball pin to the
steering knuckle. Install and tighten the nut to the specified torque.
Tightening force: 145
15Nm
c. Install the new split pin.
Remarks: It should align the notch of nut with the pinhole
when install the split pin; the nut can be tightened but not
loosed during the alignment.
Tightening force: 23020Nm
e. Install the new split pin.
Remarks: It should align the notch of nut with the pinhole
when install the split pin; the nut can be tightened but not
loosed during the alignment.
Tightening force: 635Nm

3. Connect the steering cross rod to the steering
knuckle arm.
a. Tighten the slotted nut according to the specified torque.
Tightening force: 170
15Nm
b. Install the new split pin.
Remarks: It should align the notch of nut with the pinhole
when install the split pin; the nut can be tightened but not
loosedduring the alignment.
Tightening force: 233Nm
5. Install the front hub and disc brake
(see section of front hub)

Front suspension (2WD)
front stabilizer bar
rubber cover
clip
connecting rod of
stabilizer bar
flat shim
front shaft of
lower arm
split pin
adjusting bolt
lower adjusting block
fixed arm
upper adjusting block
lower arm
rear shaft of lower arm
torsion bar base
torsion bar
lower arm long bushsplit pin
upper ball pin
upper arm shaft
upper arm bush
flat shim
lower arm
short bush
eccentric shim
disk shim
fill block
fill block
disk shim shim
shock absorbershimshim
upper arm bush
upper arm shaft
lower ball arm
front wheel hub
and steering
knuckle assy
N m: specified torque
Used component which can not be used any more.
Pregummed component N m: specified torque

Ball pin
Inspection of ball pin
1. Check the lower ball pin for loose
a. Raise the front of the car by jack and support it by the frame.
b. Ensure the front wheel is in straight advancing position and
step down the brake pedal.
c. Move the arm upwardly and downwardly; check the
clearance of lower ball pin.
Max. vertical clearance: 0mm
2. Check the upper ball pin for loose;
move the wheel upwardly and downwardly and check the gap of
upper ball pin.
Max. vertical clearance: 0mm
3. Check the rotation of ball pin
a. Remove the ball pin.
b. Shown as figure, shake the ball pin stud forwardly and
backwardly for several times before install the nut.
c. Rotate the nut continuously by torsion meter and 2-4s for a
cycle; record the readout of torsion meter in the fifth cycle.
tightening torque (for rotary):
lower ball pin 0.1
4Nm
upper ball pin 0.1
4Nm
Disassembly of ball pin
1.Take down the steering knuckle and front wheel hub assy.

Installation of ball pin
1. Install the upper ball pin on the upper arm
Tightening force: 785Nm
2. Install the lower ball pin on the lower arm
Tightening force: 14010Nm
3. Install the steering knuckle and front hub assembly
(Refer to section Front Hub and Steering Knuckle)
Disassembly of ball pin
(Refer to section “Front Hub and Steering Knuckle”)
2. Remove the lower ball pin form the lower arm
3. Remove the upper ball pin from the upper arm.

Torsion bar spring
Disassembly of torsion bar spring
Installation of torsion bar spring
Caution: There are the L and R indication marks, which must
not be exchanged on the read end of the torsion bar spring.
Mark L means the left andRforright
.
1. For reused torsion bar spring
a. Coat thin grease on the spline of torsion bar spring.
b. Align the assembly mark, install the torsion bar spring on the
torsion bar.
c. Align the assembly mark; install the adjusting arm onthtorsion
bar spring.

d. Tighten the adjusting bolt to make the extension length of the bolt
equal to the length before remove.
2. For new torsion bar spring
a. Remove the wheel.
b. Coat thin grease on the spline of the torsion bar spring.
c. Install the torsion bar spring on the torsion bar base.
d. Lower the lower arm to the lower limitation position; install the
adjusting arm in the torsion bar spring with the angle that the
adjusting bolt just can be screwed on the upper adjusting block.
e. Tighten the adjusting bolt to the specified torque.
Nut tightening limitation: A is about 30-35mm; if A>
35mm, then it is adjusted through height of adjusting arm.
f. Install the wheel; remove the bracket; bounce the vehicle for
several times to make the suspension enters into the stable
status.
g. Rotate the adjusting bolt and adjust the ground clearance of
chassis (Refer to 4-Wheel Alignment).

2. Disconnect the vibration damper from the lower
arm.
3. Disassembly of torsion bar spring
(Refer to Section “Torsion Bar Spring”)
Lower suspension arm
Removal of lower suspension arm
1. Disconnect the connecting rod of stabilizer bar
from the lower arm
a. Use the jack to support the lower arm.
b. Remove the connecting nut; disconnect the connecting rod of
sta bilizer bar form the lower arm.
5. Remove the front shaft of lower arm
a. Make the mark on the adjusting cam.
special tools