2006 GREAT WALL HOVER maintenance

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.

CD Player and Air Conditioning System-13
1 .CC6460K air conditioning system is designed with SD7V16 compressor, whose refrigeration oil type as
specified is SP-10P AG; hence application of other type of refrigeration oil may damage the parts and compo
nents of the compressor. When the
air conditioning system goes through maintenance and replacement of
parts, it should be added with new refrigeration oil, whose volume is listed as follows: the evaporator and
condenser: 30ml; the drier: 20ml; the pipeline: 10ml.
Addition of refrigeration oil can be available with two methods: The direct addition and the vacuum suction
2 .D irect addition method
a. remove the oil filler plug and fill with the specified SP-10P AG refrigeration oil.
b. observe through the hole of oil filter plug and rotate front plate of clutch to make the piston connecting rod right positio n in the
center of the hole of oil filter plug.
c. insert the dipstick along the right side of piston connecting rod till the top of dipstick touches the case of the compresso
r
d. pull out the dipstick and examine the graduations (grooves) of refrigeration oil, the readings shall be within the range of 4-6
scales
.
e. screw firmly the oil filter plug with the fastening torque of 14.7± 4.9N
.m
3. Vacuum suction method:
Firstly pump out the refrigerating system to the vacuum of 0.2x105Pa, and then fill with the specified 0.2x10 5 Pa refrigeration oil;
the detailed steps are as follows:
a. switch off the high-pressure manual valve and the auxiliary valve.
b. dismantle the high-pressure side hose from the manifold pressure gauge and insert it into the oil cu
p
c. open the auxiliary valve and have the refrigeration oil sucked into the refrigerating system from the oil cup.
d. when the refrigeration oil in the oil cup is almost pumped out to the vacuum, then immediately turn off the auxiliary valve
to
prevent the air from being sucked into the system
.
e. secure the hose adapter at high-pressure side to the manifold pressure gauge, start the vacuum pump and turn on the high-
pressure manual valve, then turn on the auxiliary valve to pump the system to the vacuum state of 0.2x10
5Pa, keep such state
for 15mins so as to discharge out the air flowing into the system along with the oil.
V ol ume of Refrigeration Oil Addition and its Methods
2.ai r h eating system
T r oubl e Cau ses o f the trouble
H e ati n g n otsuppl i ed or
no t s
uf f i cientl y suppl i ed 1.
blow erof air c ondition erf ai l u re 2.relay o f the blow erdamage
d
3. heati n g w ater pipe bloc k e d 4 . coo ling water p i pe b lock ed
5. col d/h ot damp erexecutor damage d 6. ins
uf f i cien t c oo ling l iqu id
N o rotation ofblow er 1.
f use burned
down orpoor contac t o f the switch
2. mo tor o f the blowe r burne d d ow
n
3. op en circ uit o f h igh- sp eed relay o f the blow er
4. speed-ad j usti n g m odule d am aged
5. short c ircu it
leak age o f w ater W ater p ipe o f ai rhe ati n g a ged, inse cu re j oi nt
O v erhe at 1.
speed-ad j usti n g r esi sto r o f the f an d am aged
2. col d/h ot damp erexecutor damaged
I nsu f f i cien t h otair
vo lume f or d efro stin
g 1.
mode executor dama ge
d
2. f al li n g o f fof the d riv e ro
d
3. damp ernot in p osi ti o
n
4. air v ent b l ock ed
5. inad equa te heatin g s
upply
6. inst
alla tion ofwind tunn elno t fi t
7. circ uit d i sco nn ecte
d

CD Player and Air Conditioning System-17
Daily Maintenance of Air Conditioning System
In order to ensure normal operation of air conditioning system, maintenance and care services shall be frequently performed for the
air conditioning system. The daily maintenance of air conditioning system is illustrated as follows:
1. Inspect, wash and clean the condenser of air conditioning system, requiring that radiator pins are clean and there is no dirt
between the pins. After the car runs in the rain or on the muddy road, the fan of the condenser should be inspected to find
whether it bears the earth, sand, stone and etc, and remove them if any.
2. Check the quantity of the working media of the refrigerating system; when the compressor set works normally, observe the
liquid viewing glass, under the normal circumstance, there shall be not air bubbles in the glass.
3. Inspect the drive belt. The belt between the compressor and the engine should be tensioned.
4. Check if there is any abnormal noise or odor in the air conditioning system.
5. Check if the temperature difference between the air inlet and outlet of the compressor is normal.
6. Check if the hose of the refrigerating system is in an apparent good condition and connections of all joints are secure.
7. Check if the pipeline of the refrigerating system collides with other parts and components, and if there is any oil leakage trace
left at each joint.
8. Check if the circuit connection of the refrigerating system is secure and if there is an occurrence of short circuit and falling off
9. Check if fastening bolts of the compressor are firmly secured or broken. d. When connecting the pipe, apply little compressor oil to the O-ring and fasten the nut with two wrenches. Attention: never
spatter the compressor oil to the painted parts or the plastic components to avoid the corrosion. If these components are
spattered with the oil, please clean it immediately.
e. When connecting the pipe, please follow the torque listed in the following table to fasten the screws or the nuts:
Diameter of Pipe Fastening Torque (N·m)
￠8mm 12-15
￠16mm 30-35 30－35


At ends of each pipe the protective caps should be installed till the pipe is connected to the refrigerating system.
compressor oil fasten it by using two wrenches at the same time

Safety airbag-2
Table 1 SRS-ECU stitch description
5. The maintenance operation must be started after 60 seconds following the removal of negative connection of
accumulator, wrap the negative with insulating tape for insulation.
Due to the capacitance in SRS-ECU to maintain certain power to make the safety airbag release within a certain time after the
power-off of accumulator, the operation must be started after a while to avoid any possible major damaging accident caused
by the safety airbag’s improper release.
6. The parts such as SRS-ECU, safety airbag module as well as clock spring should be removed off and well preserved
providing the temperature is high enough to cause any damage(above93¡æ) in the painting operation.
The failure codes must be debugged with the diagnostic scanner following the repairing of SRS safety airbag system so as to
make alarm lamp work functionally.
Instructions for maintenance
For your safe operation, please read the following instructions prior to your operation.
1. The maintenance of SRS safety airbag must be operated under the procedure and directions instructed in this
chapter.
2. The operation must be done with the test instruments and special tools designated by the chapter.
3. The following parts must be replaced by new ones providing something wrong with them.
a. SRS safety airbag control unit (SRS-ECU)
b. Clock spring module
c. The driver’s side safety airbag module
d. The passengers’ side safety airbag module.
e. Safety airbag wiring harness.
4. The safety airbag electric principles figure and definitions of connector clips are in Figure 1,SRS-ECU stitch
definition in Table 1 and the position and form of safety airbag failures indicator lamp in combined instrument in
Figure 2.
The driver’s side safety airbag, low position
Wire#Description
Name
Diagnosis request
The driver’s side safety airbag, high position
Passengers’ side safety airbag, high position
Passengers’ side safety airbag, low position
Diagnosis of serial data I/O (K-line)

Safety airbag-5
Test instrument
InstrumentNameUtility
diagnostic scanner
The alarm lamp
keeps illuminating.Failure
handlingDebug the
failure codes
Test the systematic failures in
SRS safety airbag system, debug
ECU. failure codes.
The basic failure diagnosis process
The failure code DTC of both present and history-accumulated failures may co-exist.
Caution
The safety airbag alarm lamp flashes for 6 times and then extinguishes when the ignition switch is in ON
position after the installation of new safety airbag system electronic control unit, which demonstrates the
normal function of SRS safety airbag system. In this case the system does not need to be tested, otherwise it
should be diagnosed and repaired.
If the alarm lamp does not illuminate when the ignition switch is in ON position, repair the alarm lamp relevant
circuit and, then further operate to get it into work.
Scan the ECU by connecting
the scanner with k-lineFailure detection
The test for SRS safety airbag alarm lamp
SRS-ECU will execute a series of diagnosis and test to check whether the function of airbag system is prepares. The check can
prevent the restriction system from mis-explosion and ensure the necessary explosion during collision. If found the failure,
SRS-ECU will save a proper failure code and light the alarm lamp to indicate a failure status for the convenience of maintenance.
If connect the pin 2# wire 488# (diagnosis request wire) on the diagnosis port to the ground (wire 50#) for more than 2s, the
safety airbag alarm lamp will flash the code. For detailed position refer to following figure.safety airbag system alarm lamp

Safety airbag-7
Description of flash code
The failure code transmission is completed by SRS-ECU’s input to the defined diagnostic scanner through the maintenance system’s
serial data interface. (X-431 diagnostic scanner) Failure code of diagnosis
Failure Failure code Flash code
1 No storage error $12
2 Front airbag driver’s, high resistance $9,021 $21
3 Front airbag driver’s , low resistance $9,022 $22
4 Front airbag driver ’s, short-circuit of GND $9,024 $24
5 front airbag driver ’s , short –circuit of VBATT $9,025 $25
6 front airbag passenger, high resistance $9,015 $15
7 front airbag passenger, low resistance $9,016 $16
8 front airbag passenger , short-circuit of GND $9,018 $18
9 Front airbag passenger , short-circuit of VBTT $9,019 $19
10 High voltage of battery $9,031 $31
11 Low voltage of battery $9,032 $32
12 Failure of alarm lamp $9,061 $61
13 Internal failure (replace SDM) $9,071 $71
14 Front collision record $9,051 $51
15 Side collision driver’s record $9,056 $56
16 Side collision passenger record $9,057 $57
17 Retightened safety belt collision $9,058 $58
18 Beyond the allowable repeat usage times $9,054 $54
3. Interior failure
The micro controller can test the following items not only in starting detection but also in cyclic diagnosis detection.
a. Ignition circuit triggers the transistor: The high-side transistor is detected not only in the starting detection but also in the
circulation diagnosis. But for the low-side transistor is opened when is connected to power supply directly, so the low-side
transistor only can be detected in the starting detection to avoid the misexplosion.
b. The ignition voltage is provided by the booster transformer.
c. The acceleration sensor is detected by itself when start the detection.
d. Allowable deviation scope of acceleration sensor in circulation diagnosis.
e. Micro controller includes (AD converter, ROM, RAM etc.)
f. Status of safety sensor
Cautions:
Connector of explosion tube circuit has the short-circuit bar. When the connector is not connected, the end (+) of
explosion tube is connected to end (-) directly to prevent the failure outspread caused by static. When the connector
is bas and short-circuit bar is connected, the failure may not be eliminated.
An external watch dog can detect the operating status of micro controller. It can trigger the watchdog when the micro con
troller has failure. The watch dog will reset the micro-controller and light the alarm lamp.

Safety airbag-20
Wiring harness joint (instrument cluster wiring harness)
Check whether the wiring harness is well installed, the joint is broken and the terminal is deformed.
Warning
The attentions for use and maintenance for SRS safety airbag are displayed in the Figure. Operate according to the sign and, the
destructed and dirty sign must be replaced with a new one steering
wheel in Figure6-1
Driver’s side safety airbag module in Figure 6.2
Clock spring in Figure 6.3
SRS-ECU in Figure 6.4
Sun visor in Figure 6.5
Passengers’ side safety airbag module in Figure 6.6
Passenger side airbag (PAB)

Safety airbag-17
Passengers’ side failure

Failure code
$9015
$9016
$9018
$9019 Passengers’ side safety airbag module (high or low resistance or shorting grounding)
Tes t co n d it i o n Warning
If not correctly handled, the safety airbag module as well as pretension safety belt may possibly be
trigged, released and tensioned, thus make serene damage to people. Therefore, please carefully read the
repairing warning before trouble handling. Please take references in safety airbag system repairing warning
If with passengers’ side safety airbag failure
The resistance between SRS safety airbag system unit connector clip stitch 13 and stitch 14 not within the
designated scope.
The wiring harness shorting between safety airbag system unit stitch 13 and stitch 14
Open loop between SRS safety airbag system unit connector clip stitch 13 and stitch 14,
Possible causes Passengers’ side safety airbag module failure
The failure of connector clip between passengers’ side safety airbag module and SRS safety airbag system
electronic-control unit
The failure of connector clip between SRS safety airbag system unit and grounding jumper.
The circuit shutoff or shorting between passengers’ side safety airbag module and SRS safety airbag system
electronic-control unit
The circuit shutoff or shorting between SRS safety airbag system unit and grounding jumper
SRS safety airbag system unit failure
Procedure Test Operation

Yes Next step
1 Is the vehicle with passengers’ side safety airbag module
No Step 5
Ye s Present failure code
Next step
History- accumulated failure codes
Next step
2 Check passengers’ side safety airbag connector clips
Warning
If not correctly handled, the safety airbag module may possibly be
trigged and released thus cause serene damage to people, therefore,
please carefully read the maintenance warning.
Take references in safety airbag maintenance warning.
Place the ignition switch in LOCK position
Release accumulator negative wire and wait for about 1 minute
plus
Remove the PAB trim cover, glove box (passengers’ side safety
airbag is under the trim cover)
Release passengers’ side safety airbag module connector clip
Is the previous connector clip normal? No Replace the wiring harness
Ye s Next step
3 Confirm whether the failure cause is with passengers’ side safet y
airbag module or some other parts
Connect a better module to the terminal A and B of passengers’
side safety airbag connector clip
Connect the accumulator negative wire
Place the ignition switch in ON position
Any failure code in display? No Replace passengers’ side safety airbag
module
Take references in the
removal/installation of passengers’ side
safety airbag module in safety airbag
system.