2006 GREAT WALL HOVER roof

Overview of the entire car-3
Stability:
Max. side rotary stable angle in no-load and static(°) ≥35
Operating stabilit y(miniture0 Na
n≥60 and N
Z≥60
Smooth characteristic:
Weighted mean square value of acceleration
σ
w(m/s2
) ≤0.6883
Equivalent mean value L
eq(dB)
≤116.5
Decreased comfortable limitation T
CD(h)
≥1.2
Basic parameters of the complete vehicle of CC6460K and CC6460KY (continued)

Item CC6460K CC6460KY
Tightness:
Dust-proof tightness M(%) ≥95
Rain-proof tightness(miniature) ≥93
Noise:
Exterior noise of accelerating travel dB(A) ≤74
Interior noise of 50km/h constant speed travel dB(A) ≤79
Noise around ear of diver dB(A) ≤90
Emission:
Meet Europe II emission standard CO≤2.2g/km, (HC＋NOx)≤0.5 g/km
Low idle-speed emission of pollutant: (750±50)r/min CO≤0.1%, HC≤50ppm
High idle-speed emission of pollutant: (2000±50)r/min CO≤0.07%, HC≤50ppm

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

Clutch-6
Clutch
4. Disassembly procedure:
a. Clutch cover assembly, clutch disc assembly
b. Profile spring, throwout bearing assembly
c. Dustproof cover, separation rocker arm assembly
d. Separation rocker arm ball support
Warning: When maintaining the clutch assembly, it is now
allowed to use the sand mill or dry brush and compressed air for
cleaning, lest there is powder (use wet cloth). The clutch disc
has the “asbestos fiber”, if there is powder scrap during
maintaining, the asbestos fiber in the powder scrap will floats in
the air, when human inhales the air containing the asbestos
fiber, it will cause great damage to human health.
Removal of clutch assembly
1.Remove the transmission
Remarks: Do not dry the transmission oil.
2.Remove the clutch cover and clutch disc
a. Make the alignment mark on the clutch cover and flywheel
b. Remove the fixed bolt gradually, until release the tension of spring
c. Remove the fixed bolt, pull out the clutch cover and clutch disc.
3. Remove the bearing and separation fork form the transmission
a. Remove the clip and pull out the bearing .
b. Remove the separation rocker arm assembly and leather cup.
clutch disc assembly
clutch cover assembly
bolt, spring and
washer assembly release bearing
assembly
profile spring
separation rocker arm assembly
separation rocker arm ball support
leather cup
N m: specified torque

SC5M2D-C transmission assembly
handle of gearlever
dustproof seal cover
oil seal 39.65210
odometer driven gear assembly
odometer seating lock plate
cylindrical compression spring
1.05.841
bush
select & shift seating
N m: specified torque
Used component which can not be used any more.
Pregummed component
Use the special toolsmanipulator cover assembly
elastic cylindrical pin 6
22
rear housing assembly spring cylindrical pin
reverse lamp switch bracket
bearing housing assembly
clutch housing assembly
location compression
cylindrical pin

Transmission-27
Manipulator cover assembly
Rear housing assembly
nut
reverse lock
assembly
manipulator
cover assembly
ball head
rubber cover
auxiliary steering
column stop platebush
ball head basewasher
pin
auxiliary steering
column assembly
handle of transfer case
ball head
hood
ball head
rubber cover
stop plate of
main bar
bush
ball head base
pin
washer
master control lever assembly
handle of
gearlever
N m: specified torque
Used component which can not be used any more.
odometer driven gear
assembly
odometer seating lock plate
14-19
14-19
oil seal
dustproof seal
guide bushing
rear housing
adjusting shim
24-33
26-36
aluminum gasket
mushroom lock spring
aluminum gasket
24-33
mushroom lock spring
26-3630-42
N m: specified torque
Used component which can not be used any more.
Pregummed component
Use the special tools
steel ball 7.938 (3)

dustproof seal
guide bushingoil seal
transfer case housingball bearingfront output shaft
ball bearing
bowel patch
circlips for hole
rear input shaft
auxiliary gear
disk spring
circlips for shaft
spacing ring
duplicate ball bearing
circlips for
shaft oil seal
back plate
Transfer case assembly (three)
Disassembly of transfer case assembly
4.Remove the shouldered lock screw plug
Use the wrench to remove the shouldered lock screw plug M16
1.512
Caution: The tightening torque is 26-36N
m when install the
shouldered lock screw plug M16
1.512.
5.Remove the upper and lower drive switch M12
1.25
Caution: When install the upper and lower drive switch M12
1.
25, the tightening torque is within 26-36N
m
6.Remove the 2nd/4th drive switch M14
1.25
Caution: When install the 2nd/4th drive switch M14
1.25, the
tightening torque is with in 26-36N
m
N m: specified torque
Used component which can not be used any more.

Automatic transmission-4
10. The gross weight of the transmission is 76kg; mostly weight is on the front of the transmission (side of torque converter). This
should be considered when design the handling/assembly tools.
11. The crankshaft speed/position sensor is installed on the top of transmission torque converter housing which must be installed
after the transmission is installed on the engine. The sensor will be damaged if it is installed before the installation of
transmission.
12. The transmission use the breathing tube connected to rear end of transmission. The tube must not be restricted or blocked
otherwise the air pressure in transmission will be increased. It is unallowable that the water/dirty/dust enters into the
breathing tube; otherwise the transmission will be damaged.
Removal of transmission
If the transmission needs removing for any reasons, following is the preventive measure to help the remove.
1. Must not only support the oil pan in middle of transmission for it will be deformed and leaked. The oil pan will not be deformed
when supports its external edge.
2. It must not allow the transmission to connect to the engine when the rear end is without connection, otherwise the exhaust
system of vehicle will be damaged.
3. Remove all torque converter bolts and push back the torque converter before remove the bolt connected the torque converter
housing to engine. Once all bolts connected the torque converter housing to engine are removed, use the torque converter the
push the transmission from the location pin, then ensure the torque converter is on the transmission and the transmission is
separated form location pin.
4. Install the dustproof cover on the cooler connector rapidly after open the oil cooler pipe; otherwise the oil leakage from the
torque converter will be 2L. The odometer dustproof cover can prevent the dirty from entering into the transmission and avoids
the leakage of oil form transmission.
5. The engine speed sensor is installed on the top of transmission and should be removed before the transmission is removed form
the engine, for the sensor will be damaged during the removal process of the transmission.
Figure 2.1 Gear selection interface
mode selection
gear selection
indicationgear slide way
Operation and display interface
The four-speed automatic transmission has three types of operation display interface which are shown as follows:
Gear selection
The transmission uses the traditional gear selection shifting handle, which is shown in figure. The gear rod can be moved on the gear
slide way according to the requirement. The relationship between the related gear and its function.

5. Installation of needle bearing
Use the special tools and hand hammer to knock in the new
needle bearing slightly.
Remarks: The thicker end of needle bearing should be
upwardly when knock in. with thicker end.
chamfer
steering
knuckle
6. Installation of thrust plate
Coat the installation position of thrust plate of steering knuckle
with the HP-R grease; place the thrust plate with the surface
with chamfer facing the steering knuckle.
Remarks: It must measure the thickness of the thrust plate
before the installation; it should install the new thrust plate if
the thickness is less than 1.5mm. The nominal thickness of
the new thrust plate is 2mm.
7. Installation of steering knuckle oil seal
Use the special tools and hand hammer to knock in the new
steering knuckle oil seal slightly.
Installation of steering knuckle
1. Install the steering knuckle
a. Coat the drive shaft and inner of drive shaft dustproof cove
with the lithium base grease.
b. Insert the drive shaft into the steering knuckle, meanwhile
connect the lower ball pin to the steering knuckle and install the
slotted nut temporarily.
special
tools
special
tools