2006 GREAT WALL HOVER Service Repair Manual

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.

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.

Removal of cleaner
1. If necessary, remove the rear section of the exhaust pipe and
the muffler according to the dismantling methods of the
exhaust pipe and muffler; if not necessary, just loosen the two
nuts fixing the shock absorption rubber brick of the muffler;
2. Remove the coupling nut between the front flange and the rear
flange of the front section of exhaust pipe;
3. If the muffler has been removed, the cleaner can be taken out
directly; if the muffler is not removed, push the cleaner
backwards tenderly, keep certain space between the cleaner
and the muffler to make the welding bolt of the cleaner to
quit;
4. At this time, the cleaner can be removed.
Caution: The cleaner cushion assembly 1 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.
Disassembly of front section of exhaust pipe
1. Remove the cleaner according to method of removal of cleaner;
2. Use the M18 box spanner, heavy-duty extension bar, ratchet
wrench to loose and remove the nut of exhaust pipe outlet,
then takes off the front section of exhaust pipe;
Caution: The two flat flanges use the interface cushion to
ensure the sealing, which is stainless steel punching unit,
and can be used for only once.
Installation of exhaust pipe assembly

Clutch-1
Chapter 3
Clutch
Troubleshooting........................................................................2
Inspection and adjustment of clutch pedal..................................3
Bleed air of clutch.....................................................................3
Disassembly of clutch master cylinder and clutch cylinder ..........5
Cautions for installation of clutch operation device.....................5
Disassembly of clutch assembly.................................................6
Inspection of clutch component.................................................7
Installation of clutch..................................................................9

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