2006 GREAT WALL HOVER warning

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

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

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.

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

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）.

Brake-12
Removal of brake pump
1. Remove the brake pipeline
Remove the brake pipeline. Use a container to contain the brake fluid.
2. Remove the brake pump from the clamp bracket
a. Remove the hexagon flange bolt, location pin and guide pin.
b. Remove the brake pump.
3. Remove the brake block
a. Two brake blocks
b. One silencing plate
c. Two silencing plate combinations
d. One wear limitation alarm plate of brake block
e. Four brake block circlips
Disassembly of brake pump
1. Remove the piston form the tong
a. Place the wood block between the tong bracket and tong body .
b. Use the air gun or air pipe to aim at the brake oil pipe hole; remove
the piston form the tong.
c. Use the clean rag or soft cloth to take out the piston.
Warning: It must not place the finger in front of the piston when
use the compressed air.
2. Remove the piston gasket from the tong body.
Use the paper clip to remove the piston gasket.
Caution: The used tools must not be sharp to prevent from scratching
the piston gasket.

Brake-19
Removal of brake pump
1.Remove the brake pipeline
Remove the brake pipeline. Use a container to contain the brake fluid.
2. Remove the pump form the bracket
a. Remove the location pin and guide pin.
b. Remove the tong.
3. Remove the brake block
a. Two pieces of brake block
b. Two pieces of silencing plate
c. Two pieces of silencing plate combination
d. One piece of brake block bush abrasion indicating plate
e. Two brake block circlips
Disassembly of brake pump
1. Remove the piston form the tong
a. Insert the cleaning cloth or other soft cloth into the place between
piston and tong.
b. Use the compressed air to remove the piston and cylinder hole
dustproof cover from the tong.
Warning: it must not place the finger in front of the piston when
use the compressed air.
2. Remove the piston gasket form the tong
Use the screwer to remove the piston gasket.

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





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