2006 GREAT WALL HOVER ABS

Preface
Since the Great Wall Hover is put into the market, it has won the favor from the customers for its
elegant appearance, excellent performance&price ratio,concept of double area and eternal safety.The car is
furnished with Mitsubishi 4G64 engine.It has both the type of five shifts manual transmission and the type of
automatic transmission as an option. At the same time, there are also options of ABS and safety airbag, etc.
Before of its complex structure, high technical intervention and difficulty of maintenance, its maintenance
needs the reference of related documents. Upon the request of the after-sale maintenance technical personnel
of Great Wall, we have prepared this Hover Maintenance Manual. The manual is oriented towards the after-
sale maintenance technical personnel of the Great Wall, and mainly introduces the disassembly of the various
systems of Hover (refer to the maintenance manual of motor for the introduction of the motor), the
troubleshooting, matters needing attention for maintenance and the related technical parameters.
During the preparation of this book, a lot of professional personnel have given support and help, here we
would like to express our sincere thanks.
Though we have made efforts to prepare this manual earnestly, we cannot guarantee that the content in
the manual is totally accurate and without error. The user cannot raise improper request to the Great Wall
Company with the manual as legal basis. We cannot bear any responsibility for the losses caused by using
this manual. Confined to the knowledge of the editor, the fault and errors are inevitable, your advice and
comment are appreciated.
The final authority for the interpretation of this manual belongs to the Great Wall Motor Co., Ltd.

Instroduction-6
9. Determine the necessity of using special maintenance tools and
special maintenance material according to the practical situation
of maintenance. Use them on the necessary position, and go on
with the maintenance according to proper procedures.
10. To replace the fuse, check to see whether the rated current of
new fuse is correct. Do not exceed the rated current of the fuse,
or do not use the fuse with low rated current.
11. When jacking up or supporting the car, lift or support the car on
proper position with care.
a. If only jacking up the car in the front part or rear part, choke up the
wheel to ensure the safety.
b. After the car is jacked up, use frame to support it. It is dangerous to
conduct maintenance on the car that is only jacked up with one
screw jack, even for the minor maintenance that can be finished
quickly.
12. Paying attention to the following matters to avoid the damage
of components:
a. If it is not absolutely necessary, do not open the housing of the
ECU and the computers (if the IC terminals are touched, the IC
may have electrostatic damage).
b. When removing the vacuum tube, pull the end of the tube instead of
the central part of the tube.
c. When pulling the wire terminal, pull the terminal itself instead of
the wire.
d. Take care to not make the electrical components fallen, such as the
sensor or relay.
If they fall to the hard ground, they must be replaced.
e. Never use the striking wrench to remove or install the electric
thermostat or thermostat sensor.
f. When checking the conducting state of the wire connector, insert
the multimeter with care, do not bend the terminal.
g. When using the vacuum meter, do not insert the soft tube onto large
connector. Use the stepped terminal. Once the soft tube is swelled
and tightened, there may be leakage.
error correct

Preface
Table of Contents
Instruction How to use the manual
Chapter 1 Overview of the entire car (parameters)
Chapter 2 Fuel supply system and exhaust air system
Chapter 3 Clutch
Chapter 4 Transmission
Chapter 5 Automatic transmission
Chapter 6 Driving shaft
Chapter 7 Suspension and vehicle axle
Chapter 8 Brake (ABS)
Chapter 9 Steering
Chapter 10 Car body electric appliance
Chapter 11 CD player and air-conditioning system
Chapter 12 Safety airbag
Annex:
Important components guarantee and requirement
List of non-metal material consumption
Special tools
D Important working components and tightening torque
E Electric wiring diagram

Overview of the entire car-7
Suspension
The front suspension is the torsion bar spring, double-cylinder inflatable hydraulic damper, transverse stabilizer rod, double
cross-arm independent suspension. The distance between the center of front shaft of lower arm fixing nut and level ground is
295mm±1mm.
The rear suspension is the four-connecting rod, coil spring, double-cylinder inflatable hydraulic damper, transverse stabilizer
rod, no indep endent suspension.
Carriage
Peripheral trapezoidal structure; welded by two box section longitudinal beams and several box or tube section cross beams.
Steering system
Pinion-and-rack power steering-gear, hydraulic assists steering. Breakaway front steering trapezoidal structure. Diameter of
quadriradistus steering disc φ380mm, adjustable angle, power-absorbing steering pipe. For main technical parameters of
steering s ystem refer to Table 5.
Table 5 Main technical parameter of steering system
Serial No. Item Parameter Serial No. Item Parameter
1 wheel camber 0°±30′ 6 Rotary round of
steering disc n 3.64
2 kingpin inclination 12°30′±30′ 7 Angle drive ratio of
steering system i0ω 18.2
3 kingpin castor 3°30′±30′ 8 Force drive ratio of
steering s ystem i0p 198.0
4 toe (mm) 0～2 9 Normal efficiency of
steering gear η+ ≥75%
5 Steering angle of
internal and external
wheel (°) 32/28 10 Revers e efficiency of
steering gear η- ≥60%
1．Adjustment of .4-Wheel Alignment
Test and adjust the front wheel alignment value and adjust the toe on the 4-Wheel Alignment meter.
a. Adjustment of kingpin castor: The standard value is 3°30′±30′(adjust the difference of left and right kingpin
castor to within 30′);
b. Adjustment of toe: The toe with standard value of 0～2mm is adjusted by rotating the steering cross rod. When adjust
the toe, it should rotate the cross brace in left and right side evenly. Tighten the lock nut after adjustment, the torque is
55 - 65N·m.
c. Centering and fix of steering wheel: according to the display of the alignment gauge, turn the front wheel to right
ahead, after removing the steering wheel without changing the position of steering lever, mount the steering wheel
with center aligned, the radials of the steering wheel shall be in the bilateral symmetry position, and the symbol of
Great wall on the steering wheel shall be in the confrontation position of the driver, tighten the nut, with a tightening
torque of 25 - 35N·m.
Left wheel left steering: 32, right wheel left steering:28;
Left wheel right steering:
28, right wheel right steering: 32;
b. Under the light condition of the car, the height between the center of front axis fixed bolt of the lower suspension arm to the
ground is 295
1mm, if the dimension is not within this scope, reach it through adjusting the torsion bar adjustment arm
bolt;
c. The reference dimension of the height of the car is : the left and right deviation is less than 10mm;
3. Checking the free gap of steering wheel:
Turn the orientation of the car to front, stop the engine, exert a force of about 4.9N on the steering wheel along the circumferential
direction to make the it turning to the left, there is resistance force, stop turning when the resistance force is growing; then turn
the steering wheel to the right, stop turning when the resistance force is felt to be growing; the radian value that the external edge
of steering wheel runs is the free gap of the steering wheel, its standard value shall be less than or equal to 20
, and the corner
from the central position to the left or right shall be no larger than 10.

Overview of the entire car-11
4.7 Cigar lighter 12V, 1 piece
4.8 Horn Treble and bass
4.9 Safety airbag Electric main and auxiliary airbag
Checking and commissioning of the auxiliary components of car body:
1. Stop the car stably, check the doors, engine cover, fuel filling port cover, meter and tools box cover, front and rear ash
tray cover, floor center console sundries box cover, CD disc conveyer (VCD disc conveyer), power socket cover, etc. they
shall be reliable and flexible during starting, opening and closing, without blocking and insufficient closing and
abnormal sound;
2. The major lamp high beam and city beam, the alternating light, taillight, turn light, brake light, front and rear mist
light, malfunction alarm light, indoor light, instrument panel light, ignition switch light, etc. shall operate normally,
without the failure of no lighting,constant lighting and error lighting , etc;
3. Checking the performance of front head light
a. The high beam luminous intensity of each head light
20000 cd/ piece
b. Beam center left and right deviation (when the beam is irradiating on the screen of 10 m away):
Left light high beam: left 17 cm right 35 cm
Right light high beam: left 35 cm right 35 cm
Left light city beam: left 17 cm right 35 cm
Right light city beam: left 17 cm right 35 cm
c. Beam center height (when the beam is irradiating on the screen of 10 m away):
Head light city beam 0.7
0.9 H; head light high beam 0.91.0 H
H means the head light center height 920
20mm.
4. The adjustment of multi functional meter:
a. Drive the car onto the trench, insert the car speed transducer, drive the car to open places, press the ADJ switch for no less than
3 seconds, the orientation indicator begins to flash. Drive the car slowly for one circle within 2 minutes, the orientation
indicator will stop flashing, it shall points to the practical normal direction.
Note: E
east, Wwest, Ssouth, Nnorth.
b. The adjustment of time:
Press the “MODE” switch for over 2 seconds, the time can be adjusted, press the MODE switch to adjust the minute, then
press the MODE again to adjust the hour, adjust the time through pressing the “
”and “” key. After the time is adjusted,
press the ”MODE” switch for over 2 seconds to quit the time adjustment mode.
c. Check to see whether the absolute altitude meter and the car speed response display are working normally.
d. Drive the car onto the trench again, pull off the car speed transducer plug.
5. The adjustment of rain wiper nozzle cleaning mixture ejection height:
a. Put the ignition switch to the ”ON” position, open the rain wiper nozzle switch, the position of front cleaning mixture nozzle
shall be evenly distributed along the middle height of the front windshield glass from left to right.
b. The position of the rear cleaning mixture nozzle is deviated to right of the center of rear windshield glass for about 20mm-
120mm, and the height is within the scope of 50mm at the center of the glass. If the deviation is large, the nozzle needs to be
adjusted.

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

Automatic transmission-23
Figure 4.1 Power flow chart
Torque converter
The torque converter (refer to Figure 4.2) consists of the turbine, stator, impeller and a lock throttle brake and piston assembly.
Same as that of the traditional torque converter, the impeller is connected to the end cover of the torque converter. The turbine is
connected to the input shaft through the spline. The stator is installed on the pump housing through the one-way clutch .
Figure 4.2 Section of torque converter
The buffer and piston assembly can make the torque converter is locked in proper condition. The locking action only occurs
in the condition of specified throttle position opening and vehicle speed. When the hydraulic force makes the buffer and piston
assembly is coupled on the cover of torque converter, it can acquire the locking status. In this status, it can eliminate the
unnecessary sliding. It can increase the economical efficiency of fuel oil when the locking action is generated. When in locking
status, the torque buffer spring in the buffer and piston can absorb the torque fluctuation of engine
.
Clutch assembly
It has four types of clutch assembly (refer to Figure 4.3). All clutch assemblies are composed of several layers of steel plate and
friction disk.
Clutch C1 When it is engaged, the drive shaft drive the planet carrier. The condition occurs in 3
rd and 4th Gear.
Clutch C2 When it is engaged, the drive shaft drive the forward central gear through the 3-4 one-way clutch. The conditio
occurs in 1
st, 2nd and 3rd-Gear condition.
Clutch C3 When it is engaged, the drive shaft drive the backward central gear. The condition occurs in R-Gear position.
Clutch C4 It can provide the brake of engine during overspeed when is engaged, The condition occurs in manual 1
st, 2nd and 3rd
–Gear, also in automatic 2nd and 3rd-Gear to avoid the unfavorable inertia rotation of freewheel.