2006 GREAT WALL HOVER ESP

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-3
The maintenance procedure is explained in the form step by step:
The illustration shows what to do and where to do.
The topic of maintenance work tells you what to do.
The detailed instruction tells you how to finish the maintenance
work and introduce other related issues, such as specification and
warning, etc.
For example
This format can help the experienced technical personnel to locate the
causes of failure quickly. The maintenance personnel can browse the
work topics, and reference the detailed explanation below it only when
necessary. The important specification and warnings are given in bold
face letter.
Specification
In the whole manual, each maintenance step is given with corresponding
specification in bold face letter, so there is no need to stop working to
look at the specification. All the specification can be located quickly in
Annex A.
Warning, Attention, Remarks:
The Warning is given in bold face letter, which means there is the
possibility of harming both the person himself and others.
The Attention is written in bold face letter, which means there is
the possibility of damaging the parts under maintenance.
The Remarks is written separately in the instruction, it is also in
bold face letter. Its main function is to make some additional
explaining to help you to finish the repair work more efficiently.
3. Check the drive of ball pin
a. Remove the ball pin.
b. As shown in the Figure, shake the ball pin back and forth for
several times before mounting the cap nut,
c. Turn the but with torque meter continuously, turn one cycle
every 2 to 4 seconds, read the torque meter at the fifth cycle.
Tightening torque (for rotary):
Upper ball pin
Lower ball pin 0.1
Specification
Work topics: what to do
Detailed instruction:
How to do

Engine
For the structure and main technical parameter of engine see Table 2.
Table 2 Structure and main technical parameter of engine

Serial No. Item Specification and parameter
1 model 4G64S4M
2 style 4-cylinder, straight-line, water-cooling, single top
cam shaft, 4-stroke engine
3 Fuel oil supply method Multi-point fuel oil injection(MPI)
4 Measuring method of inlet capacity Speed compact style
5 Combustion room style Single-slope roof
6 Cylinder diameter × stroke(mm) 86.5×100
7 Total displacement (L) 2.351
8 Compression ratio 9.5:1
9 Max. power and corresponding speed (kW/r/min) 93/5250
10 Max. torque and corresponding speed (N·m/rpm) 190/2500
11 Min. fuel consumption (g/kW·h) ≤254
12 Idle stable speed(r/min) 750±30
13 Idle-speed control Electronic closed loop control
14 Mean piston speed(m/s) 17.5
15 Mean effective pressure (kPa) 1036
1 6 C y l i n d e r c o m p r e s s i o n p r e s s u r e : i n 250r/min (kPa) 1 3 2 0
17 Ignition sequence and control 1-3-4-2; without distributor block, electronic
controlled direct ignition
18 Spark plug gap(mm) 1.0～1.1
19 Spark plug model BKR5E-11 or K16PR-U11 or RC10YC4
BKR6E-11 or K20PR-U11 or RC8
20 Manufacturer of spark plug NGK or DENSO or Xiang huo ju
21 Valve clearance(mm) 0(hydraulic column )
22 Port timing: Opened inlet/closed inlet
Opened outlet/closed outlet 18 °before upper stop point/ 53 °after lower stop
point
50°before lower stop point/ 18 °after upper stop
point
23 Lubrication method Combined method of pressure and splash
24 Pressure of engine oil of main oil channel, in idle
speed of 3000rpm (kPa) (≥78.5)/(245-490)
25 Max. engine oil temperature(℃) 130
26 Consumption ratio of engine oil(g/kW·h) 2

Front shaft/axle
CC6460K wagon has the two-cross arm, independent suspension, breakaway front axle.
CC6460KY wagon has the two-cross arm, independent suspension, breakaway steering drive axle , hyperbolic gear single-stage main
reducer, plain bevel gear differential mechanism, universal drive semiaxle, Birfield ball-joint, main reduction ratio i
0=4.55, Max. input
torque is 900N
m.
Rear axle
Non-breakaway drive axle, integral stamping-welded axle housing, hyperbolic gear single-stage main reducer, plain bevel gear differential
mechanism, semi-floating semiaxle, main reduction ratio i
0=4.55, Max. input torque is 900Nm.
Wheel and tyre
The type, specification and main parameter of wheel and tyre see Table 4.
Table 4 Type, specification and main parameter of wheel and tyre
Transmission
For the structure and main technical parameter of transmission see Table 3.
Table 3 Structure and main technical parameter

Serial
No. Item Specification and parameter
1 Model SC5M2D-C SC5M4D-C
2 style manual mechanical step
transmission of full synch, 5
forward steps, 1 revers e step, direct
manipulation manual mechanical step transmission with torque
divider of full synch, 5 forward steps, 1 reverse step,
direct manipulation
3 Cent er
distance(mm) 72 72(transmission), 222.25 (torque divider)
4 Max. input torque
(N. m) 196 196
5 Max. input torque
(r/min) 5500
Step
I Step
II Step
III St ep
IV Step
V Step
R(Reverse) Step
H(high) St ep
L(low)
6 Speed ratio

7 Gear pair of
speedometer 8:25
8 To t a l n et
weight(kg) 38 68(include torque divider)
9 Outline
dimension: L×W
×H 1070mm×466mm×
399mm( not include height of
steering level) 1070mm×460mm×380mm( not include height of
steering level)
Drive shaft
The structure of rear drive shaft assembly of CC6460K wagon is the three cross-axle universal joints, two drive shafts with exten
s
intermediat e support free-maint enance segmental structure. The front and rear dr ive shaft assembly of CC6 460KY wa gon has the
universal joints, one drive shaft with extension spline, free-maintenance integral structure respectively.

Electrical system
The structure and parameter of the electrical system are shown in table 7.
Table 7 Structure And Parameter of Electrical System

No. Item Structure and Parameter
1 Power, starting and charging system

1.1 Lines Singe line system, voltage DC 12V, negative earth
1.2 Accumulator 55D26R maintenance free type, voltage 12V, 20 hours capacity 60Ah, storage
capacity 101min, low temperature starting current 475A

1.3 Starter 12V, 1.2kW
1.4 generator Internally furnished with adjustor type generator. 14V, 90A
2 Illumination and signal s ystem

2.1 Front illumination light
white, major high beam 60W,1 on the left and right respectively,
auxiliary high
beam 55W,1 on the left and right respectively, passing
lamp 55W,1 on the left and right respectively. Head light base center
height H: 920mm±20mm

2.2 Position light Front position lamp: white, 5W,1 on the left and right respectively.
Rear parking lights: red, 5W,1 on the left and right respectively.

2.3 turn light Amber。Front and rear turn light: 21W,1 on the left and right
respectively. Side turn light: 5W,1 on the left and right respectively,
2.4 Fog light Front fog light: white, 55W, 1 on the left and right respectively. Rear
fog light: red, LED,1 on the left and right respectively.
2.5 Brake light Red, 21W, 1 on the left and right respectively, high position brake light,
10W, 2 in the middle
2.6 License light White, 5W, 1 on the left and right respectively.
2.7 Backup light White, 21W, 1 on the left and right respectively.
2.8 Danger warning signal light All the turning signal lights, danger alarm switch control
2.9 Back repeating reflector Red, none triangle shape, forming combination light with the rear fog
light
2.10 Front, middle and back ceiling light
in the room White. Front indoor ceiling light: 10W, 2 pieces. Middle indoor ceiling
light: 10W, 1 piece. Back indoor ceiling lights: 5W, 1 piece

2.11 Cigar lighter illumination Blue, 3W, 1 piece
2.12 Ash tray illumination White, 3W, 1 piece
3 Meter system
3.1 Combined instrument Car speed odometer, engine speed indicator , water t emperature met er,
fuel gage
3.2 Indicator lamp Refer to the drawing
4 Auxiliary electrical system
4.1 Rain wiper system Front and rear rain wiper DC motor. Front rain wiper: four rods type,
electric drive three gears (high and low speed + adjustable interval),
scraper 2 pieces, 55W. Rear rain wiper: single arm type, electric drive
one gear, with 1 scraper plate, 21W
4.2 Defogging, defrosting device Front wind window hearing type, back wind window heating type
glass, switch control
4.3 Electric drive glass frame riser Drive side general control, independent control oh other windows and
doors
4.4 Central control lock With r emote control
4.5 Camborne power socket 12V, 2 pieces
4.6 Radio, CD and loudspeaker Stereo radio, six discs CD, four sound channels

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.

Inspection of SC5M2D-C transmission:
1.Check the oil level of transmission:
Screw off the oil discharge plug of the transmission; discharge all lubri-
cate oil; screw on the oil discharge plug to the specified torque; the
torque is: 30
35Nm. Fill the transmission with the transmission
oil through the oil filling port, oil number is hyperbolic gear oil SAE80W/
90, which meet API GL-4, oil capacity are 2.2L. Tighten the oil-filling
plug to the specified torque of 30
35Nm. (for area with high or
low temperature refer to the maintenance specification)
2. Replacement of oil seal of rear hosing:
The replacement of the oil seal of rear housing is shown in figure.
Disconnect the drive shaft from the rear housing; remove the oil seal
by the flat screwdriver, then use the special tools to knock the rear
housing oil seal in the rear housing. It should pay attention to the
installation of oil seal, shown as figure. Coat the lip of oil seal with the
specified transmission oil.
3. Removal, installation and inspection of transmission
The preoperation before removal and after installation of transmission
is: Remove and install the manipulator cover assembly, drain and fill
the transmission oil accordance with the regulation; after remove and
install the drive shaft. Separate each plug-in part from the vehicle
transmission .
4
Inspection of manipulator cover assembly
Shown as figure, remove the adhesive on the surface before installation,
use the screwdriver( M8
1.25) to clean the adhesive in the screw
hole; coat the installed part of bolt screw with the specified screw
adhesive. Firstly, install two positioning bolts A, then install other
two bolt A and bolt C respectively. The tightening torque of all bolts is
15
22Nm.
oil filling screw plug (SC1701005)
oil-drain screw-plug assembly (JK721701071)
rear housing oil seal
bolt C(SC-1704003)bolt A(SC-1704004)

2. Operation of 4WD
The operating auxiliary steering column can be shifted to 4WD status.
For position of auxiliary steering column and corresponding operating
condition refer to table.
3. Caution for operation:
a. Do not use 4WD in good surface, otherwise the tyre and components
of drive system will be damaged easily and increase the consumption
of fuel, and cause the noise of drive system.
b. Please run in 1st-Gear under “4L” gear position when run in very
low speed in field.
Operating instruction of transmission SC5M4D-C
1.The schematic diagram of transmission operating gear position
is on the handle of steering column.
During the process after vehicle is started and in traveling, it must
step the clutch pedal to bottom before the shifting. If need shift from
5
th-Gear to reverse-Gear, it should move the shifting bar to the neutral
position of 3rd/4th-Gear. Shift to R-Gear after stop the vehicle stably,
otherwise, it can not shift.
During the traveling process. It should always pay attention to the
shifting to make the vehicle matches to the speed of engine. The
correct shifting can improve the economical efficiency and prolong
the service life of engine. Do not shift from high-Gear to low-Gear on
the condition that the pointer of tachometer may enter into red area,
otherwise, the engine will be damaged.
Warning: Do not shift to reverse-Gear when the vehicle moves
forwardly, otherwise the transmission will be damaged.
hand hall of main steering column
hand ball of auxiliary steering column
Auxiliary steering
column position drive Operating condition
2H 2WD Use this gear position when run in the general railway and high speed highway.
4H High speed 4WD Use this gear position when run in the deep snowland, sand ground or uneven road
in normal speed.
N Neutral gear When use the gear position during using of winch, it could not drive the vehicle.
4L Low speed 4WD Use this gear-position when run in uneven road such as mud land or climbing or
downward （especially when need increas e the power）.