2006 GREAT WALL HOVER brake light

Overview of the entire car-5
The friction, disc, single-diaphragm spring clutch, hydraulic control mechanism. The external diameter of friction disc D=225mm,
internal diameter d=150mm, material is F810.
Adjustment of clutch pedal:
1. Measure the height of clutch pedal (from pedal pad surface to floor) and free stroke of clutch pedal (fork bar pin clearance).
Standard height of clutch pedal: flush with the brake pedal, free stroke of clutch pedal is 5-15mm;
2. Readjust the free stroke of pedal after adjust the height of pedal; rotate the push bar to the standard value, then fix the bolt
and nut;
3. If the free stroke of clutch pedal is not within standard value, it should rotate the adjusting bolt to standard value, then fix
the bolt and nut. Do not move the push bar to main cylinder when adjust the free stroke of pedal;
4. If the free stroke of clutch pedal and clearance between the clutch pedal and floor when the clutch is disengaged de not
consist with the standard, this may by caused by the air in hydraulic system and failure of main cylinder or clutch. It can
discharge the air of system or dissemble and inspect the main cylinder or clutch.
Table 2 Structure and main technical parameter of engine(continued)

Serial No. Item Specification and parameter
27 Consumption ratio of engine oil and fuel oil
(%) ≤0.8
28 Cooling method Closed forced water cooling
29 Starting method Electric motor
30 Net weight(kg) 167
31 Outline dimension: L×W×H (mm) 730×653×667
32 Idle-speed emission CO(%)/HC(ppm) ≤0.5/≤100
33 Emission control degree of operating
condition regulation With three unique catalytic converter, air-fuel
ratio closed loop control, the equipped light
car meets the standard of GB 18352.2－
2001

Air inlet system
Dry-type air cleaner.
Exhaust air system
Primary muffler, with two-stage three-way catalyst device.
Fuel supply system
Adjustment of accelerator pedal
The stroke of accelerator pedal is 155mm; adjust the adjusting nut on wire bracket if it does not consist with the standard.
The fuel tank is plastic tank with capacity of 67L; the oil supply control is the mechanical pedal oil control and
internal-type electric fuel pump; the type of fuel evaporation is the activated carbon can and electric valve control.
Cooling system
Forced circulation water cooling, electric fan and aluminum tube radiator.
Clutch

Brake system
The front wheel brake is ventilation coil type, the rear wheel brake is disk and drum type. The service brake type is that the double-
loop vacuum assist hydraulic brake is applied on the front and rear disc brake. The parking brake is mechanical dragline acting on the
drum brake of the rear wheel.
The free stroke of brake pedal is 20mm
30mm, and the operating stroke of the pedal is 120mm. The operating stroke of the brake
handle is 17
(3 teeth)30(8 teeth).
1. The adjustment of brake pedal
Measure the operating stroke of the brake pedal, the standard value is 120mm. When the eighth is no in compliance with the
requirement, make adjustment according to the following procedures:
a. Separate the brake lamp switch wire connector, loosen the blocking nut, and turn the brake lamp switch to the position that the
stopper is not touched;
b. Unscrew the blocking nut of the operation connecting rod, use the thinnose pliers to turn the operation connecting rod, adjust
the brake pedal height to standard value, after reaching the standard value, tighten the lock nut;
c. Turn the brake lamp switch to the position that the stopper of brake pedal is just touched, continue the turning for 1/2
1 circle,
and tighten the blocking nut;
d. Connect the brake lamp switch wire connector;
e. The brake lamp should not be light when the brake pedal is in release status.
2. Standard value of brake pedal free stroke: 20-30 mm
a. Under the stopping status of the engine, step on the brake pedal for 2
3 times, clear the influence of brake assistor, then use
hand to push the brake pedal to the position that there is resistance, measure the amount of movement (free stroke). It shall
be in compliance with the regulation of standard value;
b. If the gap is less than the regulation value, check to see whether the gap between the carrier rod of brake lamp switch and the
brake pedal is in compliance with the regulation. If this gap is exceeding the regulation, it means that the gap between the drive
rod clevis pin and the brake pedal arm is exceeding the regulated value.
3. Start the engine, step down the brake pedal with a force of about 700N,ehck the main brake pump, whether there is oil
leakage on the connection positions of the brake pipeline. If there is, maintain it.
4. Operating status test of brake assistor
Conduct the operation status test of the brake assistor according to the following methods:
a. Start the engine, stop if after operating for 1
2 minutes. Step on the brake pedal for several times with normal force. Expect
that the pedal can be fully stepped down a the first stepping, the height of the brake pedal shall be raised on and on with the
stepping, thus means that the brake assistor operates normally, if the height of the pedal is not changed, it means that the brake
assistor is damaged;
b. Under the stopping status of the engine, step on the brake pedal for several times, confirms that the height of brake pedal is
elevated on and on, under the status that the brake pedal is stepped down, start the engine. At this time, the brake pedal will
move down a bit, it means that the brake assistor is working normally. If the brake pedal is moving upwards, it means that the
brake assistor is damaged;
c. Under the operation status of the engine, step down the brake pedal to stop the operation of the engine. AT this time, the there
shall be no change of the height of brake pedal within 30 seconds, it means that the brake assistor is working normally. If the
brake pedal is moving upwards, it means that the brake pedal assistor is damaged.
5. Adjustment of the parking brake system:
a.For positioning, pull the brake bar to the limit position for over 3 times, use a force of about 400N to pull the brake parking
lever, count the number of knocking teeth. The standard value of stroke of parking brake : 17
(3 teeth) 30(8 teeth);
b.If the stroke of brake parking lever is too big and not in compliance with the requirement, adjust it with the following methods:
Loosen the brake parking lever, unscrew the adjusting nut.
Remove the adjuster hole cap from the brake assembly, use screwdriver to turn the adjustor in the arrow direction to the limit
that the brake drum cannot turn.
Rotate 5 teeth in the counter arrow direction.
Rotate the adjusting nut, adjust the brake parking lever stroke to the standard value.
c. If the stroke is less than the standard value, unscrew the adjusting nut to make it reach the standard value.
d. Check to see whether the adjusting nut and the rod are loosened, whether the adjusting nut is fixed in the fixed seat.
e. After adjustment, jack up the rear part of the car. Loosen the brake parking lever, the brake disc shall not be dragged when
checking the rear wheel.
f. The breaking in of the parking brake: use the force of about 200-250N to pull the brake parking lever,drive the car for about
400m with a speed of about 60km/h, repeat for 2-3 times, then test on the slope of 30%, the car shall be able to be parked.

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.

Clutch-3
Inspection and adjustment of clutch pedal
1. Check the correctness of pedal height and stroke of push rod
The pedal height starting from the meter: LHD 157.5mm
The push pole travel at the top of the pedal: RHD 151.0mm
If not correct, adjust the pedal height and push rod stroke.
2. Adjust the pedal height and stroke of push bar if necessary
a. Screw off the locknut, rotate the locking bolt until to the correct
height.
Screw on the locknut.
b. Screw off the locknut, rotate the push rod until the stroke of push
rod is correct.
Screw on the locknut.
3. Check the correctness of free stroke of pedal
Step on the pedal lightly until fell the clutch start to generate the
resistance.
Free stroke of pedal: 5
15mm
4. Adjust the free stroke of pedal if necessary
a. Screw off the locknut, rotate the push rod until the free stroke is
correct.
b. Tighten the lock nut
c. Check the height of the pedal after adjusts the free stroke of pedal.
d. On the condition that ensure the free stroke of clutch pedal assembly:
The height difference between the brake pedal, clutch pedal and the
front apron is 0
8mm.
Air discharge of clutch
Remarks: It should discharge the air if there is residual air in the
clutch system.
Caution: Do not leave the clutch liquid on the painted surface,
otherwise it should be washed off immediately.
Fill the brake fluid in the clutch storage tank
Check the liquid tank frequently. Filling if necessary.
the adjustment
point of push rod
stroke
the adjustment
point of pedal height
pedal height
front wall
free stroke
push rod stroke

Automatic transmission-6
Selection of drive mode
The selection of drive mode includes a mode selection switch and indicator lamp. The drive mode selection switch is located
on the operating panel. It can provide the different mode selection according to the different type of car.
It has the optimal fuel economy when select the “normal” mode. At this time, the indicator lamp is not light. When select the
“dynamic” mode, the car will have the maximum dynamic performance and the “dynamic” mode indicator lamp is light. When select
the “snowland” mode, it will realize the starting of “2
nd-Gear”, the “snowland” mode indicator lamp is light, meanwhile the
“dynamic” mode indicator lamp will be closed. When select the manual mode, press down the “snowland” switch firstly, the
“manual” light will be light when the gear is in 3, 2, 1. When in manual mode, 1-2, 2-3, 3-4, 3-2, 2-1, 1-3, 3-1 is shifted by driver
manually and can not be shifted automatically. It can be used in car-racing etc. for the special mode of each model of car refers to
operation manual of user.
Operation instruction
Function
5 Brake function
Can decrease the gear-position in slope to improve the brake effect and increase the vehicle safety.
6 Speed-up function
It can select the manual shifting to increase the vehicle speed completely during the speed-up.
cautions
7 It must place the transmission in the P-Gear or N-Gear when start the engine.
8 It must place the transmission in P-Gear during the parking.
9 It must place the transmission in N-Gear when trail the car.
10 It must be powered off when remove the transmission.
11 It must be powered off when install the transmission.
The transmission processes the communication and calculation with the engine electronic control computer by the precision
central on-line computer. It not only save the fuel, but also provide the maximum mode function, including field, winter and
manual selection. It provides the two conditions, manual and electric for the fast race of racing player. It has racing capacity wh i ch
can compete the speed increasing with the manual transmission.
automatic
Having anti-slide function
It is allowable that the D-Gear
in “W” mode is used in
snowland and M-A integration
mode. automatic
automatic

Automatic transmission-20
Figure 3.17 reverse lock valve
12. Primary regulating valve
Primary regulating valve (PRV) (refer to Figure 3.18) can regulate the line pressure of transmission (or pump output
pressure). The valve can give the high or low line pressure according to the on/off status of S6. When S6 is in on or off status,
the pressure S6 is applied on PRV, move it and has the action of spring force. Open the line pressure loop to turn on the inlet
of pump to reduce the line pressure. Generally, the line pressure is small when the throttle position is opened lightly and in
patrol status. It will cause the closing of S6 when the opening degree of throttle position is large and because the high line
pressure valve
For all shifting pressures are controlled by output of separation brake belt , clutch regulating valve and S5, so all step control
of line pressure has not affect on effect of shifting sensing.
By the oil inlet of torque converter, PRV also adjust the oil supply of hydraulic torque converter. The level effect of PRV
should ensure the priority of valve, i.e. it can keep the line pressure in low engine speed condition. When the speed of engine
is increased and the pump supplies excess oil, the PRV acts to open the torque converter oil inlet cover to increase the pressure
of torque converter. If the oil amount is beyond the requirement of transmission, PRV will act further to allow the oil return
to the suction inlet.
Figure 3.18 Primary regulating valve
Figure 3.19 Torque converter on/off regulating valve
The torque converter regulating valve (refer to Figure 3.19) adjusts the pressure applied on torque converter clutch oil.
According to the signal pressure form loop S5, adjust the oil flow status from line pressure loop in valve. With the change of
pressure signal of loop S5, the engagement and disengagement of torque converter clutch can be finished by electric control.
13. Torque converter on/off regulating valve

3. Oil filling of service after sales
Set the liquid level position correctly; the procedure is shown as follows:
a. Shut down the engine; place the gear-position in the P-Gear.
b . Lift the vehicle (or place it above the trench).
c. Clean the around of plug before remove it. Remove the oil plug and check the O-ring for damage, finally connect the oil filling
pump to the oil filling hole.
d. Lower the vehicle and oil filling pump to the ground; fill with the transmission fluid partially. The general oil filling amount
is shown as follows:
If in the status of transmission hydraulic torque converter is empty: 8.0 L
If in the status of transmission hydraulic torque converter is full: 3.8 L
e. When start the vehicle in P-Gear, rotate the engine in idle speed. Step down the foot brake, pull the shifting lever in each gear-
position in circulation and add the transmission fluid until the action of each gear-position can be sensed.
f. Then fill with 0.5L transmission fluid (ATF) additionally.
g. Shut off the engine, lift the vehicle; take off the pump and replace the plug. Ensure the plug is tightened according to the
specification.
h. Then pull the vehicle throttle position for slight opening to make the vehicle runs for 3.5
4.5km; the rotary speed of engine
is no more than 2500r/min; then the transmission fluid temperature will in the scope of 50
60.
i. The engine is in idle-speed; pull the hand brake to make the shifting lever circuits in each gear-position horizontal status.
k. Remove the filling plug 3 minutes after the engine is shut off, but must be no more than1 hour. At this time, the correct
level position should be in the bottom of oil filling hole. If does not reach the liquid level position, then fill with few
transmission fluid (ATF) to meet the requirement.
l. Reinsert the transmission fluid plug, remove the residual transmission fluid around the vehicle and transmission; tighten the
plug to the specified torque.
4. Replace the ATF
Please notice that the color of TQ95 automatic transmission oil will be faded in the normal operation of transmission; it will be
turn into the deep brown or even in black. It will not affect the performance of ATF. It means that the fading of transmission
fluid not always means to replace the transmission fluid.
If the transmission temperature is raised, the ATF will be burnt. In this condition, ATF will change into black and with special
sulfur smell. The smell of the ATF means the oil is burnt.
If the ATF is burnt, it will cause the damage of transmission (the clutch assembly is damaged at least).At this time, it should
disassembly the transmission and process the necessary detection.
Electronic calibration
1. Idle-speed calibration
The idle-speed calibration is introduced in detail in the vehicle factory manual.
2 Calibration of position of throttle position

If the throttle position information stored in TCU is lost or not in application scope. It can be reestablished according to the
following program as the diagnosis error information.
a. Check whether the engine idle speed is in required range.
b. In the status of shutting off of air-condition, make the engine is in “D” –Gear for 60s,then the reference point with opening
degree of 0
of throttle position is reset in TCU.
Shut off the engine; switch on the ignition device, step the accelerator pedal to bottom for 60s, then the reference point with opening
degree of 100
of throttle position is reset in TCU.
3. Clear of throttle position

The clear process set by learning throttle position is necessary for M88 transmission TCU.
4. Car code

For M88 transmission, the car code is unnecessary.