2006 GREAT WALL HOVER service

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.

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）.

Automatic transmission-45
Diagnosis and test
Test system
1. Recommended test equipment and program
The test equipment and control unit for design will be used for the test of all vehicles. The parts for transmission test includes:
Tester for service after sales
Special vehicle for test
2. Tester for service after sales
After the special programming, the tester equipped with special car test software can be used to test the specified system and unit.
The program allows the normal communication between the transmission control units (TCUs) .
The computer needs the required information from the customer and select the necessary data through the manual. For example:
view the code, clear the error code and make the real-time operation. For detailed operating instruction refer to user’s manual.
The equipment can be used by the trained specialized persons, such as technician, machinist to test the electronic and loop
problem related to transmission. The testable information includes: the engine speed, rode (shaft speed), transmission fluid
temperature, position of throttle position, status of solenoid valve and gear and position of operating lever. Additionally, it can be
used to detect the current and stored problem.
3. Description of TCU pin
The description of TCU pin code had been listed in Table 6.1.1
For description of wire bunch refer to Figure 6.1.1
Pin No. Function Type 2WD description
A14 Public grounding GND
● Negative pole of TCU supply, connected to negative pole of
battery.
A13 Nonuse
－－
○ －－－－－
A12 M ode indicator la mp
Snowland mode OP
● Indicate that select the “Snowland M ode” operating method.
A11 Parking-Gear indicator lamp O P
● T he drive instrum ent panel indicator la mp indicates tha t is in
the “Parking G ear”
A10 Reverse-Gear indicator lamp OP
● T he drive instrum ent panel indicator la mp indicates tha t is in
“ Revers e G ear”
A9 N-G ear indicator lamp O P
● T he drive instrum ent panel indicator la mp indicates tha t is in
“Idle N Gear”
A8 Nonuse －－ ○ －－－－－
A7 Nonuse －－ ○ －－－－－
A6 M ode indicator la mp
dynamic mode OP
● Indicate that select the “ dyna m ic mode” operating method.
A5 Nonuse ―― ○ －－－――
A4 Nonuse ―― ○ －－－－－
A3 Nonuse ―― ○ －－－－－
A2 Mode switch IP
● The switch is used to select the “economic mode”, “dynamic
m ode” and “ snowla nd mode”. T he voltage is varia ble in
range of 0 V－2V .
A1 Nonuse ―― ○ －－－－－
A30 Power supply PWR
● Power supply for TCU; is the main power source of drive
unit and solenoid valve.
A29 Nonuse ―― ○ －－－－－
A28 1st-G ear indicator lamp
/1st-G ear position﹡ OP
● Drive the instrument panel indicator lamp indication, indicate
that the gear-position is in “1st-G ear”
A27 2nd-G ear indicator lamp
/2nd-G ear position OP
● Drive the instrument panel indicator lamp indication, indicate
that the gear-position is in “2nd-G ear”
A26 3rd-G ear indicator lamp
/3rd-Gear position﹡ OP
● Drive the instrument panel indicator lamp indication, indicate
that the gear-position is in “3rd-Gear”
A25 Automatic gear indicator
lamp /4th –Gear position OP
● Drive the instrument panel indicator lamp indication, indicate
that the gear-position is in “automatic-Gear”

Adjustment
Hydraulic system
Following parts is the detailed description for self-detection procedure pointed to the condition occurred in chapter
6. including the condition indicated the failure, to point the problem existed in the hydraulic system.
It should select the proper procedure from the following primary detection when adjust the transmission.
Detection process of transmission fluid
Detect the manual linkage adjusting system(refer to factory manual of car)
Detect the engine idle speed
Anchoring test (beyond the scope of the maintenance manual)
On-road test (beyond the scope of the maintenance manual)
Detection procedure of transmission fluid level
1. General

The process is used to detect the level of vehicle transmission fluid. It will cause the failure or delay of transmission shifting if
the level is low than required value and the vehicle does not reach the drive temperature.
Firstly, process the transmission diagnosis information detection for vehicle (refer to chapter 6). If found the failure of sensor,
then it maybe caused by transmission fluid level is less than specified value.
It should detect whether has the abnormal delay and Gear-position condition when select the forward or reverse-gear by driving
the vehicle. One feature of oil level less than normal value is that the vehicle has the gear-position delay and lack condition when
the vehicle is in steering. The previous problem will occur when the transmission fluid temperature is low.
When the oil temperature is medium and vehicle speed failure is recorded, the gear-position lose condition
will not occurs any longer, it means that needs to fill the transmission with the transmission fluid.
2. Detection of transmission fluid level

When fill up or replace the transmission fluid, it must use the Castrol TQ95 automatic transmission fluid (ATF) or other
permissive oil. It will damage the performance and service life of transmission if use the unpermissive transmission fluid.
Please ensure the transmission fluid level is correct. The transmission also can be damaged if the transmission fluid level is
incorrect.
The setting procedure of transmission fluid level is shown as follows:
Caution:
When the transmission is in operating temperature, the hot transmission fluid may flow out form the
housing if remove the filling plug.
a. If the vehicle is in operating temperature, allow two hours time for cooling before add the transmission fluid, but
it must not more than 4 hours (this will make the transmission locate in the correct temperature range). When the
temperature is overheating, the transmission fluid level will higher than the plug port. Removal of plug will cause
the transmission fluid flows out from the oil filling port, then cause the low level of transmission fluid.
b. The gear-position of transmission is in parking-Gear (P-Gear), shut off the engine.
c. Lifting the vehicle (or parking above the trench).
d. Clean the around of plug when remove it. Then remove and clean the plug and check the O-ring for damage. Install
the oil filling pump in the oil filling hole.
e. Lower the vehicle; the oil filling pump will be connected to the vehicle at this time. Fill the transmission with the
oil partially. Then start the vehicle in P-Gear to 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. Shut down the engine; lift the vehicle; ensure the vehicle is always in horizontal.
g. Remove the filling plug 3 minutes after the engine is shut off, but must not 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 to make it reach the correct level.
h. Replace the transmission; clean the residual transmission fluid on the transmission and
vehicle.
i. Tighten the transmission plug to the specified torque of 30
35Nm.

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.

CD Player and Air Conditioning System-17
Daily Maintenance of Air Conditioning System
In order to ensure normal operation of air conditioning system, maintenance and care services shall be frequently performed for the
air conditioning system. The daily maintenance of air conditioning system is illustrated as follows:
1. Inspect, wash and clean the condenser of air conditioning system, requiring that radiator pins are clean and there is no dirt
between the pins. After the car runs in the rain or on the muddy road, the fan of the condenser should be inspected to find
whether it bears the earth, sand, stone and etc, and remove them if any.
2. Check the quantity of the working media of the refrigerating system; when the compressor set works normally, observe the
liquid viewing glass, under the normal circumstance, there shall be not air bubbles in the glass.
3. Inspect the drive belt. The belt between the compressor and the engine should be tensioned.
4. Check if there is any abnormal noise or odor in the air conditioning system.
5. Check if the temperature difference between the air inlet and outlet of the compressor is normal.
6. Check if the hose of the refrigerating system is in an apparent good condition and connections of all joints are secure.
7. Check if the pipeline of the refrigerating system collides with other parts and components, and if there is any oil leakage trace
left at each joint.
8. Check if the circuit connection of the refrigerating system is secure and if there is an occurrence of short circuit and falling off
9. Check if fastening bolts of the compressor are firmly secured or broken. d. When connecting the pipe, apply little compressor oil to the O-ring and fasten the nut with two wrenches. Attention: never
spatter the compressor oil to the painted parts or the plastic components to avoid the corrosion. If these components are
spattered with the oil, please clean it immediately.
e. When connecting the pipe, please follow the torque listed in the following table to fasten the screws or the nuts:
Diameter of Pipe Fastening Torque (N·m)
￠8mm 12-15
￠16mm 30-35 30－35


At ends of each pipe the protective caps should be installed till the pipe is connected to the refrigerating system.
compressor oil fasten it by using two wrenches at the same time

Safety airbag-9
Project 3 functional working (neither possible explosion failure or historical failure).
Table 4.9 indicator lamp’s activities after ignition
2.Failure indication
The alarm lamp will indicate it in case any failure arises. If the external failure is a historical one, the indication will be called off. If
the number of history-accumulated failures is or more than 5, the alarm lamp will keep illuminating albeit no failure emerges. The
case of low power will be excluded.
A displayed or historical failure can but only be reconfigured by the service personnel. An internal failure or impact record can not
be reconfigured, in these cases, SRS-ECU must be replaced.
3.Micro controller-independent alarm lamp illumination
The micro-controller in clear failure status can not work therefore can not control the alarm lamp. In this case, the alarm lamp
will be directly lighted via suitable circuit despite of the micro-controller. As following,
The battery for SRS-ECU fails, the alarm lamp will be continuously lighted through the lamp drive function.
b. No internal working voltage, the alarm lamp keeps illuminating
c. Reconfiguration caused by watchdog’s trigging failure, the alarm lamp flashes.
d. No work of micro-controller, the alarm lamp keeps illuminating
e. Incomplete plugging-in of SRS-ECU connector, the alarm lamp keeps illuminating via shoring bar Next explain the diagnostic
procedure by taking some examples
If the alarm lamp is found keeping illuminating, please test it according to the following procedure even it extinguishes finally.
First test the failure region with the scanner followed by the test in the failure region with the corresponding approaches and
steps.
a If an internal failure or the explosion of safety airbag is scanned, replace the SRS-ECU
b.Troubleshooting Project 2. The number of history- accumulated failures is or more than one and less than 5. (The case of low power is excluded)

Safety airbag-10
1. Extinguishments of safety airbag system alarm lamp
Troubleshooting
Extinguishments or normal-light of alarm lamp
NO . Troubleshooting item Description
1 T he warning la mp of safety a irbag
system is not displayed. Safety airbag system warns circuit failure
2 T he warning la mp of safety a irbag
system is light normally. Safety airbag system warns circuit failure or external
failure.

1 Extinguishments of safety airbag system alarm lamp
Test status Safety airbag system warns circuit failure.
Possible causes No voltage (fuse shutoff)
Combined instrument failure
Failure of wiring harness between instrument cluster and ECU unit

Diagnostic procedure
When first carry out failure test, joggle the wiring harness and plug to test whether there is periodical bad contact in the circuit, if
it so, please confirm whether the plug, terminal and wiring harness well connected and in good condition. If it is not any of previous
cases, operate according to the following steps.
Procedure Te s t Operation
Ye s Place the ignition switch in LOCK
position followed by next step
1 Test other wiring harness and instrument cluster
indicator lamp
·place the ignition switch in ON position
·light other alarm and indicator lamps No Test the instrument cluster power-supply
system and grounding s ystem (fuse), then
go to step 5.
Yes Next step
2 Bulb test
Warning:
Incorrect handling with the safety airbag system
units will cause the safety airbag’s improper
release and pretension of safety belt, which will
lead to serene accidents. Please read safety airbag
service warning before handling the safety airbag
units.
·Place the ignition switch in LOCK position。
·shut off accumulator negative line and keep the
status for at least 60 seconds.
·Remove the combined instrument.
Test the connection between the two
corresponding stitches of safety airbag alarm lamp No





Rep la ce th e b ulb of a larm la mp.