Great Wall Hover. Service Manual - part 2

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  0.9

1.0 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, W

west, S

south, N

north.

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.

Air-conditioning system 

The structure and parameter of the air-conditioning system is shown in table 8. 

Table 8    The structure and parameter of the air-conditioning system 

 

Serial No.

 

Item

 

Structure and Parameter

 

1

 

Structure and 

shape

 

Front and rear heating and cooling air conditioner, vapor compression type 

cooling, hot-water heating

 

2

 

Performance and 

parameters

 

Refrigerating capacity 3.5kW, heat exchange capacity 3.5kW, fan capacity 

350m

3

/h

 

3

 

Operation

 

Control board button type operation, temperature auto control, air door micro 

motor drive, the temperature in the car can be controlled automatically, the 

fanning position mode, heating/cooling mode, air intern/external cycling mode 

and wind speed and temperature can be selected and adjusted

 

4

 

Refrigerant

 

R134a

 

5

 

Compressor

 

SD7V16 variable capacity compressor, with a maximum capacity of 160ml

 

6

 

Condenser

 

Parallel stream mode structure, flat pipe thickness of 26mm

 

7

 

Evaporator

 

Two boxes structure, cascading evaporator, F expansion valve, centrifugal 

blower 

 

8

 

Drying fluid 

collector

 

External diameter  φ60.5mm

 

9

 

Refrigerating 

pipe   and 

warm water pipe

 

Refrigerating pipe: complex structure of rubber refrigeration soft tube and 

aluminum tube. The warm water pipe: rubber molding pipe

 

10 Transducer 

Outdoor temperature sensor, indoor temperature sensor, evaporator temperature 

sensor    

11 

pressure switch 

Three-state pressure switch   

 

Chapter 2

Fuel supply system and exhaust system

Fuel supply system :

Disassembly of the fuel tank ........................................................................3

Installation and disassembly of the Fuel pump ..............................................4

Disassembly of the components of fuel supply system...................................4

Disassembly and adjustment of the accelerator pedal  operating system ........5

Exhaust  system :

Disassembly of the blast pipe assembly.........................................................8

Installation of the blast pipe assembly............................................................9

Fuel supply system

 N 

m:   specified torque

adjustment nut

 throttle pull wire

accelerator pedal assembly

carbon tank exhaust rubber tube

snap fitting

steel strip type elastic hoop
generator oil-in rubber tube

generator of return rubber tube

soft tube fixing clipper

carbon

tank

carbon tank
air inlet
rubber tube

b type
worm drive
type hoop

vaporizer tube 2

back part of fuel tank

oil-out tube

back part of fuel tank

oil return tube

fuel filter

filter rubber tube
for gas out

hard tube bracket

vaporizer soft tube 2

cleaner bracket

filter rubber
tube for gas-in

fuel tank vaporizer
rubber tube

front part of the oil-out
tube of fuel tank

vaporizer soft
tube1

vaporizer tube1

 fuel tank gland

the middle connection rubber
tube of the oil return tube

front taps of fuel tank

fuel pump

fuel tank gland

fuel tank protection plate

seal packing
ring

fuel tank assembly

fuel tank oil return tube

fuel tank lock

r e f i l l   o p e n i n g   c u s h i o n

pressing board

refill opening cushion

oil filing port assembly

steel strip type elastic hoop

fuel tank protection plate

Caution: When maintaining the fuel supply system, if the oil

path needs to be removed, the pressure of the fuel system must

be released to avoid the ejection of high pressure fuel.

Disassembly of the fuel tank

1.  First remove the oil-in and oil return hard tube of the

generator, the oil return hard tube of fuel tank, and the

connection rubber tube between the back parts of hard vaporizer

tube. Release the pressure of oil path system slowly, block the

joints with cotton cloth, lest there is ejection of high pressure

oil.

2.  Remove the oil filling port at the back of the fuel tank and the

clip of the connection rubber tube of ventilation tube, there are

two clips altogether.

3. 

Remove the bolts fixing the fuel tank, there are 6 bolts

altogether;

4.  Remove the oil-in and oil-out tube from the fuel tank, remove

the vaporizer tube joints and line bundle connector;

The disassembly and installation of the fuel pump

Removal of components of fuel supply system

Gasoline filter disassembly

1. Firstly, use the straight screwdriver to remove the hose clamp

and remove the connecting rubber hose on both sides of gasoline

filter;

2.   Loose the bolt on the gasoline filter bracket, then

remove the gasoline filter for complete replacement.

Removal of carbon tank

The disassembly of the fuel filler pipe

Removal of fuel pipe

1.  Remove the connection between the in/return fuel connector of

engine fuel track and the fuel supply pipe:

a. Remove the elastic hoop firstly;

b. Remove the package connector; press down the button of package

           connector by hand, then pull it out outwardly.

c. Remove the three-line plastic clip.

2.  Removal of front section of fuel hard pipe

b.   Pull out the fuel pipe form the clip fixing base, then remove the

      hard pipe;

c.   Remove the fixing base on the longitudinal beam if necessary

            rotate the fixing base for 90 degree in clockwise or anticlockwise,

           the take out it.

3.   Removal of rear section of fuel hard pipe

a.    Remove the connecting elastic hoop of two ends of rear section

            of fuel hard pipe;

b.    Pull out the fuel pipe form the clip fixing base, then remove the

            hard pipe ;

Removal and adjustment of throttle control system

1.   Removal of accelerator pedal

      Remove the two fixed bolts which fix the pedal ;

2.   Removal of throttle pull-wire

  a. Firstly, disconnect the connection on motor, then loose the fixed

      bolt ;

b. Remove the plastic clip of throttle pull-wire on pedal, remove the

end of throttle pull-wire;

c. Use the pliers to clamp the clip on the side of engine compartment

to remove the fixing base of pull-wire on the fa ade of engine

compartment.

Exhaust   system

N.m       Specific torque

Used component which can not be used any more.

end washer assembly

 exhaust pipe outlet nut

  front section of exhaust pipe

hexagon flange nut

cleaner cushion

assembly 1

fastening bolt of hoop

cleaner heat insulation cover clip

cleaner discharge pipe

       catalytic converter

three-hole rubber block

 cleaner cushion assembly 2

 hexagon flange nut

muffler assembly

muffler port decoration cover

hexagon flange nut

rear section assembly

of exhaust pipe

wahser assembly

100

9

63

5

23

m u f f l e r   d a m p i n g

ruber block assembly

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.

Removal of cleaner

1

.  If necessary, remove the rear section of the exhaust pipe and

the muffler according to the dismantling methods of the

exhaust pipe and muffler; if not necessary, just loosen the two

nuts fixing the shock absorption rubber brick of the muffler;

2.  Remove the coupling nut between the front flange and the rear

flange of the front section of exhaust pipe;

3.  If the muffler has been removed, the cleaner can be taken out

directly; if the muffler is not removed, push the cleaner

backwards tenderly, keep certain space between the cleaner

and the muffler to make the welding bolt of the cleaner to

quit;

4.  At this time, the cleaner can be removed.

     Caution:  The cleaner cushion assembly 1 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.

Disassembly of front section of exhaust pipe

1. Remove the cleaner according to method of removal of cleaner;

2. Use the M18 box spanner, heavy-duty extension bar, ratchet

wrench to loose and remove the nut of exhaust pipe outlet,

then takes off the front section of exhaust pipe;

     Caution:   The two flat flanges use the interface cushion to

ensure the sealing, which is stainless steel punching unit,

and can be used for only once.

Installation of exhaust pipe assembly

Clutch-1

Chapter 3

                     Clutch

Troubleshooting........................................................................2

Inspection and adjustment of clutch pedal..................................3

Bleed air of clutch.....................................................................3

Disassembly of clutch master cylinder and clutch cylinder ..........5

Cautions for installation of clutch operation device.....................5

Disassembly of clutch assembly.................................................6

Inspection of clutch component.................................................7

Installation of clutch..................................................................9

Clutch-2

Troubleshooting 

 

failure cause inspection 

content 

Shift difficulty or can not shift 

 

Large free stroke of clutch pedal clutch Pipe 

has air 

Failure of clutch cylinder   

Failure of clutch master cylinder   

The installation position of clutch disc is not 

in position; large deviation; oil on the friction 

lining or broken 

The clutch disc is dirty or with foreign 

material 

Failure of clutch cover   

Adjust the free stroke of pedal 

Discharge the air in clutch system 

Replace 

replace 

Inspect the clutch disc; replace 

Repair if necessary 

Replace 

Disengagement of transmission 

The clutch guide bearing is worn. 

Replace the guide bearing   

Slide of clutch 

 

insufficient free stroke of clutch pedal   

oil on the clutch disc friction lining or broken 

failure of press disc 

separation rocker arm assembly is blocked 

Adjust the free stroke of pedal   

Inspect the clutch disc and replace it   

Replace the clutch cover   

Check the separation rocker arm assembly   

clutch clamping 

stagnation/vibration 

oil on the clutch disc friction lining or broken 

failure of press disc clutch membrane spring 

is bend 

loose of engine bracket 

Inspect the clutch disc and replace 

Replace the clutch cover   

Correct the clutch membrane 

Repair if necessary 

Soft of clutch pedal 

clutch pipe has air 

failure of clutch cylinder   

failure of clutch master cylinder 

Discharge the air in clutch 

replace 

replace  

Loud noise of clutch 

 

Component in clutch housing is loose 

Throw-out bearing is worn or dirty 

guide bearing is worn 

separation rocker arm assembly or pull-rod is 

blocked 

Repair if necessary 

replace 

replace 

Repair if necessary 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

  t h e   a d j u s t m e n t

point of pedal height

pedal height

front wall

free stroke

push rod stroke

Clutch-4

Cluch control mechanism

clutch master cylinder

N 

m:   specified torque

Clutch-5

Removal of clutch master cylinder, clutch cylinder

1. Use the No. 16 open-end wrench to remove the hose connecting

bleed bolt, use the cloth to cover the oil outlet of auxiliary pump

to avoid the splash of 0brake fluid; step on the clutch pedal for

several times to drain the clutch.

Cautions for installation of clutch operation device:

1. Installation of clutch hard pipe :   Check the hard pipe for

deformation, check to see whether the curling at the port of

connection pipe is complete and without damage, if there is no

problem after confirmation, it can be installed and fixed in the

front wall clip and hard-tube clip.

2. Coat each rotary parts of peal with the lithium base grease.

3. Check the surface of clutch hoes, no surface cracking, oil leakage

and dog leg is allowed, use the split washer and spring clip to fix

the clutch hose on the support frame of car body.

4. Connect the joints of the general pump oil pipe and the general

2.  Remove the split pin and cylinder pin connected the master

pump connecting fork to the pedal; use the No. 13 socket spanner

to remove two nuts Q32008 which is used to install the master

pump. Check the clutch master cylinder, replace the complete

master pump if the internal of master pump has the abnormal

noise and damage of leakage etc.

pump and sub pump according to the required tightening torque.

5. The air in the clutch oil path needs to be exhausted after filling

oil (except the vacuum filling): step on the clutch pedal after

filling the oil tank, when feeling difficult in stepping, use the

open-end wrench with specification of 11 to loosen the air bleed

plug screw to exhaust the air, then tighten the plug screw,

repeat the operation for several times. Tighten the air bleed

plug screw of the sub  pump when there is no foam in the

flowing oil liquid. Supplement the oil of the oil tank to the

level between the Max and the Min.