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Great Wall hover, Service Manual

The Great Wall Hover Service Manual is a comprehensive guide for maintaining and repairing your vehicle. Easily download the manual for free from our website to access detailed instructions and diagrams. Keep your Great Wall Hover running smoothly with the help of this essential resource.

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8. Use the jack to support the front reducer assembly

9. Remove the lifting bolt of front drive axle hanger

plank and carriage.

10. Remove the front drive axle assembly

Caution: Do not damage the drive shaft and front drive

shaft jacket

11. Remove the front drive shaft assembly of both sides

from the front drive axle assembly.

12. Use the wrench to remove the bolt and nut which is

used to fix the front reducer housing.

13. Remove the clump weight assembly and clump

weight bracket welded assembly

(Refer to “Disassembly of Front Reducer Assembly”)

electric clutch connector

N 

m:   specified torque

Summary of Contents for hover

Page 1: ......

Page 2: ...echnical personnel of the Great Wall and mainly introduces the disassembly of the various systems of Hover refer to the maintenance manual of motor for the introduction of the motor the troubleshootin...

Page 3: ...Instroduction 1 Instrodution How to use this mannual 2 Identification mark Instructiontocomprehensivemaintenance 5...

Page 4: ...tic list of each system can help you to diagnose the failure of the system and find out the causes of failure The maintenance method with regard to the possible causes is given in the column of mainte...

Page 5: ...working to look at the specification All the specification can be located quickly in AnnexA Warning Attention Remarks The Warning is given in bold face letter which means there is the possibility of...

Page 6: ...ppearing on the label plate of the entire car it is also inscripted on the external right side of the right stringer chassis number and on the VIN nameplate at the upper left part of the panel Motor s...

Page 7: ...washing Dry it by compressed air Coat the screw of components with the specified locking sealant c The precoated component is indicated by symbol in elements diagram 7 It can use the sealant or seal...

Page 8: ...r maintenance that can be finished quickly 12 Paying attention to the following matters to avoid the damage of components a If it is not absolutely necessary do not open the housing of the ECU and the...

Page 9: ...atic transmission Chapter 6 Driving shaft Chapter 7 Suspension and vehicle axle Chapter 8 Brake ABS Chapter 9 Steering Chapter 10 Car body electric appliance Chapter 11 CD player and air conditioning...

Page 10: ...meter 2 Engine 4 Airinletsystem 5 Exhaustairsystem 5 Fuelsupplysystem 5 Coolingsystem 5 Clutch 5 Transmission 6 Driveshaft 6 Frontshaft axle 6 Rearaxle 6 Wheeltyre 6 Suspension 7 Frame 7 Steeringsyste...

Page 11: ...tion front rear kg 980 1215 1070 1235 Traffic ability parameter Min turning diameter m 13 Min ground clearance mm 180 175 Approach angle 28 no load departure angle 27 5 no load Dynamic parameter Min s...

Page 12: ...arameters 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 tra...

Page 13: ...750 30 13 Idle speed control Electronic closed loop control 14 Mean piston speed m s 17 5 15 Mean effective pressure kPa 1036 16 Cylinder compression pressure in 250r min kPa 1320 17 Ignition sequenc...

Page 14: ...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 2...

Page 15: ...m Specification and parameter 1 Model SC5M2D C SC5M4D C 2 style manual mechanical step transmission of full synch 5 forward steps 1 reverse step direct manipulation manual mechanical step transmission...

Page 16: ...oe with standard value of 0 2mm is adjusted by rotating the steering cross rod When adjust the toe it should rotate the cross brace in left and right side evenly Tighten the lock nut after adjustment...

Page 17: ...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 f...

Page 18: ...nt wind window triplex glass with a thickness of 4 76mm Rear wind window toughened glass with electrical heating defrosting resistance wire with thickness of 3 5mm Other windows toughened glass with t...

Page 19: ...pectively 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 warni...

Page 20: ...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...

Page 21: ...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 varia...

Page 22: ...e 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 syste...

Page 23: ...rn tube fuel filter filter rubber tube for gas out hard tube bracket vaporizer soft tube 2 cleaner bracket filter rubber tubeforgas in fuel tank vaporizer rubber tube front part of the oil out tube of...

Page 24: ...tion 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 th...

Page 25: ...sassembly 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 re...

Page 26: ...egree 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 p...

Page 27: ......

Page 28: ...ut 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...

Page 29: ...orse 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 on...

Page 30: ...f 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 ther...

Page 31: ...ion and adjustment of clutch pedal 3 Bleed air of clutch 3 Disassemblyofclutchmastercylinderandclutchcylinder 5 Cautionsforinstallationofclutchoperationdevice 5 Disassembly of clutch assembly 6 Inspec...

Page 32: ...n 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 co...

Page 33: ...e 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...

Page 34: ...Clutch 4 Cluchcontrolmechanism clutch master cylinder N m specified torque...

Page 35: ...se 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...

Page 36: ...sbestos 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 t...

Page 37: ...Check the guide bearing Rotate the bearing with hand along the direction of the axis If the bearing cannot be rotated or there is great resistance the guide bearing needs to be replaced The bearing i...

Page 38: ...Use caliper to check the wearing depth and width of the diaphragm spring Limit value maximum depth 0 6mm Maximum width 5 0mm 7 Check the throwout bearing Rotate the bearing with hand along the axis di...

Page 39: ...alue use the special tools to adjust the face runout amount of the diaphragm spring clutch finger 4 Coat the following components with the molybdenum disulfide lithium base grease NLGI NO 2 or multi p...

Page 40: ...f transmission SC5M2D C 6 Disassemblyoftransmissionhousingassembly bearinghousingassembly 18 Operating instruction of transmission SC5M4D C 24 Repair of transmission SC5M4D C 25 Disassembly of rear ho...

Page 41: ...Structure diagram of SC5M2D C and SC5M4D C transmission shown in figure Structure diagram of SC5M2D C transmission Structure diagram of SC5M4D C transmission Specification of transmission...

Page 42: ...sted by axial retainer Clearance between bearing block and bearing of Axle 1 mm 0 0 1 Adjusted by adjusting shim End clearance of gear hub of Gear 3 4 synchronizer mm 0 0 08 Adjusted by axial retainer...

Page 43: ...housing It should pay attention to the installation of oil seal shown as figure Coat the lip of oil seal with the specified transmission oil 3 Removal installation and inspection of transmission The...

Page 44: ...on spring 1 0 5 8 41 bush select shift seating N m specified torque Used component which can not be used any more Pregummed component Use the special tools manipulator cover assembly elastic cylindric...

Page 45: ...eter driven gear assembly Use the special tools to remove the odometer driven gear assembly 3 Remove the rear housing assembly a Remove 6 M10 1 25 30 hexagon bolts Caution The tightening torque is 14...

Page 46: ...et N m specified torque Used component which can not be used any more Pregummed component N m specified torque Used component which can not be used any more bush 6 oil guiding plate location pin steel...

Page 47: ...1 2 shift ing block gear 3 4 shifting block earbox assembly three steel ball 4 762 pin 6 22 gear 1 2 shift fork adjusting shim spacing ring reverse drive gear reverse shaft needle bearing reverse gea...

Page 48: ...is 26 36 N m 6 Remove the gearbox a Use the wrench to remove the 5 M8 55 bolts 1 M8 6 bolt and 2 M8 110 bolts Caution When install 5 M8 55 bolts 1 M8 6 bolt and 2 M8 110 bolts tightening torque is b...

Page 49: ...ers to remove the circlip for shaft 9 Use the magnetic rod to take out the steel ball 11 Use the circlip pliers to remove the circlip for shaft Caution It is necessary to circlip for shaft when instal...

Page 50: ...3 locking screw plugs M10 1 25 19 Caution The tightening torque is 14 19N m when install the locking screw plug M10 1 25 19 b Use the magnetic rod to remove 3 springs c Use the magnetic rod to remove...

Page 51: ...mbly a Use the punch to remove the reverse gear 5 shift fork elastic cylindrical pin b Use the punch to remove the Gear 1 2 shift fork elastic cylindrical pin c Use the punch to remove the Gear 3 4 sh...

Page 52: ...fork 18 Remove the lock nut of intermediate shaft Caution When install the lock nut of intermediate shaft the tightening torque is 160 190N m 19 Remove the Gear 1 2 declutch shift shaft assembly inter...

Page 53: ...the thrust plate 23 Use the magnetic rod to remove the steel ball 24 Remove the 5th Gear driven gear assembly Caution When install the 5th Gear driven gear assembly it should use the plug gage to tes...

Page 54: ...que is within 20 60N m 29 Remove the thrust plate 30 Remove the 5th reverse Gear synchronizer assembly a Use the special tools to remove the 5th reverse Gear synchronizer assembly 26 Remove the synchr...

Page 55: ...the reverse gear 32 Remove 2 needle bearings of reverse gear 33 Remove the reverse driven gear 34 Remove the needle bearing of reverse driven gear b Remove the sleeve and 5th reverse Gear synchronizer...

Page 56: ...Remove the intermediate shaft spacing ring 37 Remove 8 countersunk screws Caution when install the countersunk screw the tightening torque is within 15 22N m 38 Remove the support axial lock plate 39...

Page 57: ...tening torque is 10 13N m Clutch housing assembly Bearing housing assembly bush oil seal Used component which can not be used any more throwout bearing assembly washer 8 non standard spring first bear...

Page 58: ...ke out the adjusting shim Caution It should select the adjusting shim when install the adjusting shim 43 Remove the bearing snap ring 44 Remove the intermediate shaft assembly 45 Remove the first shaf...

Page 59: ...ork Remove the second shaft assembly a Use the rubber hammer to knock the second shaft b Remove the needle bearing bushing of reverse driven gear c Remove the double inner race ball bearing assembly d...

Page 60: ...izer gear ring it should use the plug gage to measure the end surface clearance of gear ring to ensure it is within 1 25 1 65mm circlips for shaft 3rd 4th Gear syn chronizer assembly 1st 2nd Gear sync...

Page 61: ...17 0 284mm e Remove the 3rd Gear driven gear needle bearing f Use the special tools to press the second shaft to remove the inner race of double inner race ball bearing Remove the 1st Gear driven gear...

Page 62: ...ve the 1st 2nd Gear synchronizer assembly l Remove the 2nd Gear synchronizer gear ring 2nd Gear driven gear and second shaft Caution When install the 2nd Gear driven gear it should use the plug gage t...

Page 63: ...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 ec...

Page 64: ...he vehicle Inspection of manipulator cover assembly The bolt dimension is different for different installation position Do not confuse it during the installation It should install the fixing bolt Afir...

Page 65: ...g cylindrical pin cylindrical compression spring steel ball 6 35 cylindrical compression spring reverse lamp switch bracket wire clip elastic cylindrical pin manipulator cover assembly washer test swi...

Page 66: ...n 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...

Page 67: ...ven gear assembly Use the special tools to remove the odometer driven gear assembly 3 Remove the rear cover assembly Caution When install 6 M10 1 25 30 hexagon bolts the tightening torque is 14 19N m...

Page 68: ...ermediateshaft high low gear duplicate gear thrust washer lock plate 14 19 high low gear declutch shift shaft high low gear shift fork assembly 2nd 4th drive declutch shift shaft pin 5 26 2nd 4th driv...

Page 69: ...houldered lock screw plug Use the wrench to remove the shouldered lock screw plug M16 1 5 12 Caution The tightening torque is 26 36N m when install the shouldered lock screw plug M16 1 5 12 5 Remove t...

Page 70: ...ldered lock screw plug M12 1 25 10 Caution When install the shouldered lock screw plug M14 1 5 10 the tightening torque is within 26 36N m b Takeout mushroom lock spring c Use the magnetic rod to take...

Page 71: ...d 4th declutch shift shaft elastic cylindrical pin e Use the circlip pliers to remove the bearing snap ring f Use the rubber hammer to knock out the transfer case cover assembly slightly and remove th...

Page 72: ...mbly front output shaft assembly and chain out slightly 13 Remove the second fourth shift block and high and low gear shift fork 14 Remove the housing of transfer case a Use the wrench to remove 4 bol...

Page 73: ...b Remove the housing of transfer case 15 Remove a location pin For the disassembly of gearbox refer to Disassembly of gearbox in SC5M2D C...

Page 74: ...r shaft high and low gear sleeve needle bearing high and low gear hub needle bearing low speed driven gear rear output shaft ballbearing spacing plate second fourth drive gear hub second fourth driveg...

Page 75: ...nd needle bearing Caution When install the drive sprocket it should use the plug gage to measure the drive sprocket axial clearance and ensure within 0 19 0 338mm g Remove the drive geared sleeve h Us...

Page 76: ...ngle when install it m Remove the high and low geared sleeve and gear hub n Remove the low speed driven gear needle bearing and rear output shaft Caution When install the low speed driven gear it shou...

Page 77: ...sion M88 Instruction for automatic transmission 2 Operation and display interface 5 Control system 7 Powertransmissionsystem 22 Power transmission 26 Diagnosis and test 45 Adjustment 53 Disassembly As...

Page 78: ...f opening degree of throttle position opening frequency of throttle position engine speed vehicle speed transmission oil temperature gear position mode selection and forced Gear reduction application...

Page 79: ...hinder the end of the bolt and affect the threads on the case Ensure the proper length and special torque of the bolt 9 Pay attention that the height of the oil has been determined before delivery fr...

Page 80: ...hicle 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...

Page 81: ...maintained in 3rd Gear position Under manual mode the transmission will be kept in 3rd Gear D gear drive It can process the 1st 2nd 3rd and 4th Gear position operation and gear shifting operation of...

Page 82: ...s 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...

Page 83: ...used to control the line pressure operate the shift valve and hydraulic torque converter lock clutch and switch on and off two regulating valves Two regulating valves control the shift feel The seven...

Page 84: ...Automatic transmission 8...

Page 85: ...f temperature resistance Pin No Wire color Connected solenoid valve 1 Red solenoid valve 1 2 Blue solenoid valve 2 3 yellow solenoid valve 3 4 orange solenoid valve 4 5 green solenoid valve 5 6 violet...

Page 86: ...2 Throttle position sensor Figure 3 4 gear sensor solenoid valve 4 orange ground wire 2 solenoid valve 7 power supply connector olenoid valve 6 violet ground wire temperature sensor solenoid valve red...

Page 87: ...release the pressure of gear position shifting It provides the pressure signal to the clutch and brake belt regulator and controls the shifting pressure S5 also provides the pressure single to the tor...

Page 88: ...0mA S3 Off S4 Off 3 4 S1 On S4 On 950mA 550mA S4 Off 4 3 S4 On 950mA 700mA S1 Off S4 Off 4 2 S3 On 800mA 500mA S1 Off S2 On S3 Off 4 1 S3 On S4 On 1000mA 600mA S2 On S3 Off S4 Off 3 2 S2 On S4 On 550m...

Page 89: ...S meanwhile the VPS output pressure equals to the pressure on line 500 always When the VPS is in waiting status it means there is not the generation of shifting action VPS current is 200mA At this tim...

Page 90: ...nsmission fluid will enter into the shift valve 1 2 to make the rear brake belt and C4 overspeed gear clutch is engaged respectively The hydraulic control system is located in the valve pump and main...

Page 91: ...Automatic transmission 15 Figure 3 6 Hydraulic control circulation flow...

Page 92: ...s On Off status During 1 2 shift period drive the transmission fluid from manual operated valve to the 2nd Gear loop During the shifting form 2 to 1 the brake belt is engaged and drain the oil through...

Page 93: ...gulating pressure of clutch C1 to control the change ratio of shifting quality clutch status The ratio is about 2 25 1 When the S3 is opened the oil of 3rd Gear is provided to the valve and adjust the...

Page 94: ...matic transmission 18 Figure 3 11 2 3gear shift valve Figure 3 12 3 4gear shift valve Figure 3 13 4 3sequence valve Figure 3 14 Electromagnetic pressure regulating valve and line pressure impelling va...

Page 95: ...id connect the line pressure to loop B2 The transmission fluid flows to servo internal and external attachment area the B2 is engaged When none of above condition is met TCU control the solenoid valve...

Page 96: ...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...

Page 97: ...Automatic transmission 21 Figure 3 20 torque converter clutch control valve Figure 3 21 C1 eccentrically arranged valve Figure 3 22 BIR blow off valve...

Page 98: ...d and the 1 2 one way clutch is separated OWC During the 2 3 shifting period the clutch C1 is engaged and the B1brake belt is released During the 3 4 shifting period B1brake belt is engaged and 3 4 on...

Page 99: ...his status it can eliminate the unnecessary sliding It can increase the economical efficiency of fuel oil when the locking action is generated When in locking status the torque buffer spring in the bu...

Page 100: ...g ratch refer to Figure 4 5 The ratchet is engaged with the tooth of external gear ring fear to lock the output shaft axle in the transmission When it is not in parking gear the return spring will rel...

Page 101: ...Automatic transmission 25 Figure 4 5 Parking mechanism...

Page 102: ...eed gear X X X Automatic 4th Gear locking X X X X In P Gear or N Gear the planetary gear assembly has not the drive The rear brake belt is used to eliminate the voice generated in engagement with reve...

Page 103: ...ic transmission 27 Refer to Figure 5 1and table 5 2 Table 5 2 The participation status of each unit in parking and neutral position clutch Gear position Name of participated unit Parking and neutral p...

Page 104: ...Automatic transmission 28 Figure 5 1 parking and neutral position...

Page 105: ...ion of solenoid valve and valve is shown as follows A solenoid valve S1 or S2 is closed at least Refer to the part in section 3 3 11 related to condition when S1 and S2 is closed The line pressure rea...

Page 106: ...Automatic transmission 30 Figure 5 2 Reverse Gear...

Page 107: ...d its axial to drive the internal gear ring and output shaft to rotate in clockwise to realize the movement in forward direction In overspeed clutch C4 can provides certain brake force through 3 4 one...

Page 108: ...Automatic transmission 32 Figure 5 2 Reverse Gear...

Page 109: ...he rotation of planetary gear carrier in counteracting force At the same time the long planetary gear rotates around its axial to drive the ring gear and output shaft to rotate in clockwise to realize...

Page 110: ...Automatic transmission 34 Figure 5 4 Automatic 1 st Gear...

Page 111: ...he drive oil line pressure from the manual operated valve makes the engagement of clutch C2 When the solenoid valve S1 is powered off the S1 oil pressure form line pressure 500 pushes the 3 4 Gear shi...

Page 112: ...Automatic transmission 36 Figure 5 5 Automatic 2 nd Gear manual 2 nd Gear...

Page 113: ...ctly and flows into the 2 3 Gear shifting valve The brake belt combination regulating valve provides the 2nd Gear oil controlled by the product of line pressure and valve to the brake belt feed loop B...

Page 114: ...Automatic transmission 38 Figure 5 6 Automatic 3 rd Gear manual 3 rd gear...

Page 115: ...noid valve S7 is opened the variable torque clutch control valve is closed and allow the oil feed of S7 loop pass through the solenoid valve S7 to drainage port It makes the control valve moves to the...

Page 116: ...Automatic transmission 40 Figure 5 7 Automatic 3 rd Gear locking and manual 3 rd Gear locking...

Page 117: ...shifting valve is in 4th Gear position for the pressure of line 500 The 1 2 Gear shifting valve is kept in 4th Gear position for the pressure of S2 oil loop The 2nd Gear loop oil line pressure from t...

Page 118: ...Automatic transmission 42 Figure 5 8 Automatic 4 th Gear overspeed Gear...

Page 119: ...e variable torque clutch control valve is closed and allow the S7 loop oil flows to the drainage port through the solenoid valve S7 then control the valve to move to the clutch engagement position The...

Page 120: ...Automatic transmission 44 Figure 5 9 Automatic 4th Gear locking...

Page 121: ...ype 2WD description A14 Public grounding GND Negative pole of TCU supply connected to negative pole of battery A13 Nonuse A12 Mode indicator lamp Snowland mode OP Indicate that select the Snowland Mod...

Page 122: ...ine the selected gear position B2 Nonuse B1 Return solenoid valve 5 IP Using for grounding of VPS and current of circuit can be detected then process the feedback control for the VPS B14 Gear position...

Page 123: ...ower supply then TCU will start form 4 Gear and is switched to the proper gear to meet the requirement of current work At this time it will not monitor the power supply status b The transmission fluid...

Page 124: ...e pressure is high always Opened always The line pressure is low always So it cause the slide between gears The clutch C1 and brake belt B1 will be burned 7 Closed always The hydraulic torque converte...

Page 125: ...can 2 3 shifting can not realize the 4th Gear and 1st Gear S1 is closed always Test the S1 Repair or replace it if necessary Test the failure of S1 12V power supply voltage or wire bundle Only can 1...

Page 126: ...ear The rear brake belt is loose when the tem perature is high The R G ear Low speed 1 st G ear ball spool has displacem ent The internal O ring of rear servo is lost C4 is invalid D etect the rear br...

Page 127: ...S3 S2 Replace or maintain it if necessary Detect the regulating valve Replace or maintain it if necessary Detect the ball spool Reinstall or replace it if necessary Detect the sealing ring Reinstall o...

Page 128: ...t servo is large and has the possibility of loose The input shaft sealing ring is damaged C1 B1R ball spool has displacement Detect and repair the or replace the spring if necessary Replace the socket...

Page 129: ...ervice 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 inc...

Page 130: ...on 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...

Page 131: ...smission Caution It should remove the gear position sensor before wash the transmission in solvent or hot abluent When need to remove the transmission from the vehicle it should drainage the transmiss...

Page 132: ...ools to take out the cross shaft seal c Take out the circlip from the cross shaft Pull up the cross shaft and take out the drive pin from the sector gear position selection plate d Use the tools press...

Page 133: ...ease refer to Figure 8 4 The procedure is shown as follows Figure 8 4 Assembly of front clutch cylinder a Place the assembly on a level surface b Remove the thrust bearing and adjusting shim from the...

Page 134: ...3 cylinder The procedure of removal of clutch C3 cylinder is shown as follows a Remove the front sun gear assembly thrust bearing and thrust washer from the clutch C3 cylinder asse bly shown as Figure...

Page 135: ...ch piston from the clutch cylinder Refer to Figure 8 8 h Take out the cylinder forms the reverse sun gear and C3 washer 5 Planet carrier and central support The disassembly procedure of planet carrier...

Page 136: ...of pump when replace it 7 Valve The removal procedure of valve is shown as follows a Use the special tools T40 T orxbit to remove the ratchet spring and retainer plate Caution The manual operated val...

Page 137: ...select the quality Torx tools especially for the two screw socket wrench with code of 40 50 8mm 10mm and 12mm to detect the transmission completely 1 Transmission Caution Ensure the BIR retainer is p...

Page 138: ...ns to the correct position g Install the parking brake lever pin and spring Refer to Figure 8 13 Caution ensure the rake lever can rotate freely h Connect the parking brake lever to the manual operate...

Page 139: ...nsor on the box install the screw according to the specified torque Use the tools to press the bolt on the shaft r Check the connection of wire bunch port completely to ensure the normal operation s I...

Page 140: ...t bearing assembly NO 10 on the output shaft h It should be carefully when install the output shaft on the box to avoid the damage of sealing ring 3 Rear brake belt assembly The assembly procedure of...

Page 141: ...ccording to the specification 5 Planet carrier assembly and central support The installation process of planet carrier assembly and central support is shown as follows a Check the bracket and planet a...

Page 142: ...pring fixing plate ensure the ring spring is installed in the box correctly j Remove the central support bolt and provide the Loctite243 or similar material for screw install and tighten the bolt to s...

Page 143: ...ousing O ring and install it on the housing b Use the automatic transmission liquid to lubricate the housing O ring and install it on the piston c Install the piston brake lever spring washer base and...

Page 144: ...the discharge outlet of piston C2 for cleanness use the transmission liquid to lubricate the O ring Caution The O ring must not be winded in groove Figure 8 24 Typical C2 C4clutch assembly b Install t...

Page 145: ...installs the cylinder Install the piston into the cylinder until the external diameter of piston enters into the inner diameter of cylinder Caution The diameter of wire bunch of spring is 5 26mm k Ins...

Page 146: ...ch the correct specification If need to install the new friction disk it should remove the clutch assembly and immerse the friction disk in the automatic transmission fluid for 5 minutes at least befo...

Page 147: ...tion plate to reach the correct specification It should remove the clutch assembly and immerse the friction disk in the automatic transmission fluid for 5 minutes at least before the installation if i...

Page 148: ...e the tools to press down the spring to install the ring spring better Ensure the ring spring is installed in the groove fixedly then remove the tools i Install the C3 wave plate on the C3 piston surf...

Page 149: ...nt sun gear ensure the thrust washer is between the bearing and central gear b Use the Vaseline to lubricate the thrust plate and install it on the reverse sun gear Refer to Figure 8 32 c Adjust and i...

Page 150: ...e sealing ring on its correct position c Install the clutch disk and other disc on the cylinder according to the following sequence steel plate abrasion plate steel plate abrasion plate steel plate st...

Page 151: ...lutch C3 assembly 13 Pump housing and torque support Caution a Do not clean the solenoid valve by solvent b Ensure the O ring is installed in the correct position c Do not blow off the first drop and...

Page 152: ...e spring and O ring Refer to Figure 8 38 pump cover assembly pump housing cover oil seal pump assembly o ring pump n Install the fixed bolt shown as Figure 8 39 o Install the torque converter detectio...

Page 153: ...ut filling metal plate is more than that in instruction then the metal plate should be placed in surface of NO 4 bolt and input shaft bolt Refer to Figure 8 19 if the end float is less than 0 5mm or m...

Page 154: ...Figure 8 39 Valve fixing plug and pin Figure 8 40 Torque converter release ball and spring...

Page 155: ...Figure 8 41 Position of test ball Figure 8 42 Tighten the pump bolt in the sequence shown in figure Figure 8 43 Connect the pump to the housing in the sequence shown in figure...

Page 156: ...6 to wash the upper and lower valve completely and dry it by air check the valve cavity port and hole for damage or block b Install the cushioning baffle positioning bolt and clean all loose parts com...

Page 157: ...Figure 8 45 Lower valve Figure 8 46 Position of upper valve and detection ball Figure 8 47 solenoid valve 5 and damper...

Page 158: ...re 8 48 1 2gear shift valve Figure 8 49 3 4 gear shift valve Figure 8 50 solenoid 2 and 2 3gear shift valve Figure 8 51 4 3sequence valve Figure 8 52 brake belt combination regulating valve and soleno...

Page 159: ...er of upper and lower valve for damage replace it if necessary m Install the upper shim of lower position valve n Install the reverse lock valve spring and fixed disc ensure the correct installation o...

Page 160: ...he manual gear shift valve Refer to Figure 8 57 Figure 8 57 Manual gear shift valve v It should ensure the position lever is in the position of manual 1st Gear before install the valve on the transmis...

Page 161: ...e the filter when a important mechanical component is damaged and assemble a transmission b To assist the assembly of sealing gasket groove please coat the surface of oil pan and washer with thin Vase...

Page 162: ...e 8 60 a Use the automatic transmission liquid to lubricate the spring ring of gasket of lubrication oil b Install the oil filter on the valve carefully During the installation the socket must be incl...

Page 163: ...h o u sin g to h o u sin g M 1 2 3 2 4 8 o r 9 5 4 6 8 4 0 5 0 rea r en d h o u sin g to h o u sin g C h a irm a n M 1 2 3 2 4 5 4 6 8 4 0 5 0 C o n n ec to r h o u sin g to h o u sin g 4 W D M 8 2 5...

Page 164: ...he shim is clamped by the housing correctly c Recheck the stroke of thrust lever 3mm 0 25mm 2 Setting procedure of rear brake belt The setting procedure of rear brake belt is shown as follows a The se...

Page 165: ...Figure 8 62 Setting of brake belt Figure 8 63 External port position of B1 and B2 Figure 8 64 Setting of rear brake belt...

Page 166: ...Reverse gear 2 393 1 1 450 1 1 000 1 0 677 1 2 093 1 Lubricant type dry system alternative of maintenance Castrol TQ95 9 0 L approximation 4 5L approximation Axial movement of gear assembly 0 50 0 65...

Page 167: ...anual 4 2 4 2 direct 68 km h Manual 4 2 sequence of 4 3 2 89 km h Figure 9 4 Special tools for maximum disable speed of manual Gear decreasing Special tools tools Part No Platform bracket of transmiss...

Page 168: ...Annex Description for oil inlet hole of main housing...

Page 169: ...Chapter 6 Drive shaft...

Page 170: ...n The intermediate bearing is worn The cross axle bearing is worn or jammed Replace the universal joint fork Replace the intermediate bearing Replace the cross axle bearing vibration Runout of drive s...

Page 171: ...o r k shim n u t c i r c l i p cross axle assembly r e a rs e c t i o na s s e m b l yo f r e a ra x l ep r o p e l l e rs h a f t f l a n g ef o r k c i r c l i p cross axle assembly axle tube assemb...

Page 172: ...r d a m a g e s p l i n e f o r c o r r o s i o n a n d c o n n e c t i n g s u r f a c e f o r d e f i c i e n c y o f d a m a g e o r s a n d h o l e b y i t s e l f 2 Install the connecting spline...

Page 173: ...Chapter 7 Suspension and vehicle axle Rear suspension 112...

Page 174: ...The steering system is loose or worn The steering mechanism is adjusted badly or damaged Replace the tyre or charge it to the proper pressure Balance all wheels Replace the vibration damper Check the...

Page 175: ...ocessed according to the detailed description of equipment manufacturer 4 Adjust the wheel angle Remove the cover of spacing bolt of steering knuckle check the internal wheel s steering angleA Interna...

Page 176: ......

Page 177: ...ack of tyre to the position of front instrument Remarks if the tyre moves too far repeat the procedure b e Measure the distance A between the marks on front of tyre f Measure the toe of wheel toe B A...

Page 178: ...h Check the sideslip Sideslip Within 5m km...

Page 179: ...sk shim absorber bearing hub cap brake cover spring shim split pin lower suspension arm split pin upper suspension arm spring shim brake caliper assembly steering knuckle tight nut lock washer screw o...

Page 180: ...rake hose 2 Remove the hub cap Use the inner hexagon spanner to screw off the fastening blot and remove the hub cap 3 Remove the hub and brake disc a Use the Philips screwdriver to screw off the lock...

Page 181: ...and check them for damage or wear 2 Replace the bearing outer race a Use the brass bar and hand hammer to knock out the bearing outer race b Use the special tools to knock in the new bearing outer ra...

Page 182: ...Install the hub on the steering knuckle b Install the external bearing diagram of spe cial tools special tools 5 Adjust the pre applied load a Use the special tools to screw on the locknut to specifi...

Page 183: ...the pre applied load does not meet the specified value it must remove the lock washer and adjust it by the adjusting nut 8 Install the hub cap a Coat the silicon rubber surface sealant on the matching...

Page 184: ...ball pin 4 Disconnect the connecting rod of stabilizer bar from lower arm Use the inner hexagon spanner to fix the ball pin remove the self locking nut 5 Remove the steering knuckle a Remove the spli...

Page 185: ...rm and connect the upper ball pin to the steering knuckle Install and tighten the nut to the specified torque Tightening force 145 15N m c Install the new split pin Remarks It should align the notch o...

Page 186: ...pecified torque Tightening force 170 15N m b Install the new split pin Remarks It should align the notch of nut with the pinhole when install the split pin the nut can be tightened but not loosed duri...

Page 187: ...lower arm torsion bar base torsion bar lower arm long bush split pin upper ball pin upper arm shaft upper arm bush flat shim lower arm short bush eccentric shim disk shim fill block fill block disk s...

Page 188: ...or loose move the wheel upwardly and downwardly and check the gap of upper ball pin Max vertical clearance 0mm 3 Check the rotation of ball pin a Remove the ball pin b Shown as figure shake the ball p...

Page 189: ...ll pin on the lower arm Tightening force 140 10N m 3 Install the steering knuckle and front hub assembly Refer to section Front Hub and Steering Knuckle Disassembly of ball pin Refer to section Front...

Page 190: ...h must not be exchanged on the read end of the torsion bar spring Mark L means the left andRforright 1 For reused torsion bar spring a Coat thin grease on the spline of torsion bar spring b Align the...

Page 191: ...stall the adjusting arm in the torsion bar spring with the angle that the adjusting bolt just can be screwed on the upper adjusting block e Tighten the adjusting bolt to the specified torque Nut tight...

Page 192: ...nsion arm Removal of lower suspension arm 1 Disconnect the connecting rod of stabilizer bar from the lower arm a Use the jack to support the lower arm b Remove the connecting nut disconnect the connec...

Page 193: ...1 Removal of short bush of lower suspension arm Use the special tools to press the short bush from the lower arm 2 Installation of short bush of lower suspension arm Use the special tools to press th...

Page 194: ...to the specified torque Tightening force 290 25N m b Install the front shaft of lower arm and screw on the nut temporarily 2 Installation of front hub and steering knuckle assembly Refer to section Fr...

Page 195: ...ecified torque a Install the wheel remove the bracket and bounce the vehicle for several times to make the vibration damper enters into the stable status b Align the assembly mark and tighten the nut...

Page 196: ...must remove four oil pipe tight nuts in the place and plug it by the rubber plug to prevent the brake fluid from overflowing 3 Disconnect the brake hose form the brake caliper Remove the hollow bolt a...

Page 197: ...to press in the bush b Install the upper arm shaft use the special tools to press inanother bush 3 Tighten the upper arm shaft to specified torque a Coat the screw of both ends of upper arm shaft with...

Page 198: ...ified torque Tightening force 15 17N m Remarks It should tighten four connector of two two way valves to the specified torque if disassemble the right upper arm 3 Connect thebrakehosetotheupperarmoilp...

Page 199: ...st discharge the air in the rear brake system if disassemble the right upper arm 7 Check the brake fluid for leakage 8 Tighten the upper arm front shaft nut to the specified torque Install the wheel r...

Page 200: ...stabilizer bar remove the stabilizer bar Installation of stabilizer bar 1 Install the stabilizer bar on the carriage Place the stabilizer bar in position install the stabilizer bar bush and clip on t...

Page 201: ...izer bar hub and brake disc flange adjusting washer circlip hub cap spring shimdisc brake split pin lower suspen sion arm split pin upper suspension arm drive shaft oil seal n e e d l e bearing lock w...

Page 202: ...hub cap and flange a Use the inner hexagon spanner to screw off the fastening blot and remove the hub cap b Use the pliers to remove the circlip and remove the adjusting washer c Remove the flange 3...

Page 203: ...Replace the bearing outer race a Use the brass bar and hand hammer to knock out the bearing outer race Use the special tools to knock in the new bearing outer race Assembly of front hub 1 Coat the in...

Page 204: ...Install the hub on the steering knuckle a Install the hub on the steering knuckle b Install the outer bearing 5 Adjust the pre applied load a Use the special tools to screw on the locknut to specifie...

Page 205: ...plied load Pre applied load for starting 28 56N If the pre applied load does not meet the specified value it must remove the lock washer and adjust it by the adjusting nut 8 Install the ring flange a...

Page 206: ...ols to disconnect the steering cross rod from the steering knuckle arm 4 Disconnect the connecting rod of stabilizer bar from lower arm Use the inner hexagon spanner to fix the ball pin remove the sel...

Page 207: ...he dye penetrant to check the steering knuckle for crack It should replace the steering knuckle if has crack 2 Remove the steering knuckle oil seal Use the screwdriver to pry out the oil seal from the...

Page 208: ...he 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...

Page 209: ...stall the split pin the nut can be tightened but not loosedduringthealignment 2 Connect the stabilizer bar to the lower arm Support the lower arm by jack use the inner hexagon spanner to fix the ball...

Page 210: ...front hub and steering knuckle assembly split pin lower ball pin adjusting bolt lower adjusting block fixed arm upper adjusting block l ower arm rear shaft of lower arm Torsion base torsion bar lower...

Page 211: ...per ball pin Max vertical clearance 0mm 3 Check the rotation of ball pin a Remove the ball pin b Shown as figure shake the ball pin stud forwardly and backwardly for several times before install the n...

Page 212: ...the upper ball pin on the upper arm Tightening force 78 5N m 2 Install the lower ball pin on the lower arm Tightening force 140 10N m 3 Install the steering knuckle and front hub assembly Refer to sec...

Page 213: ...t until the torsion bar spring has not the tension 4 Remove the fixed arm and torsion bar spring Installation of torsion bar spring Remarks There are the L and R indication marks which must not be exc...

Page 214: ...on bar spring with the angle that the adjusting bolt just can be screwed on the upper adjusting block Remarks It can repeat for several times until proper when adjust the angle e Tighten the adjusting...

Page 215: ...ss rod Refer to the section Front Hub and SteeringKnuckle 2 Disassembly of torsion bar spring Refer to section Torsion Bar Spring 3 Remove the front shaft of lower arm a Make the assembly mark on the...

Page 216: ...on arm Use the special tools to press the new short bush into the lower arm Remarks Do not coat the bush with the grease 3 Removal of long bush of lower suspension arm Use the special tools to remove...

Page 217: ...Install the vibration damper on the lower suspen sion arm Install the vibration damper on the lower suspension arm bracket Tightening force 90 10N m 4 Connect the stabi lizer barto the lower susp ensi...

Page 218: ...the specified torque a Install the wheel remove the bracket and bounce the vehicle for several times to make the vibration damper enters into the stable status b Align the assembly mark and tighten th...

Page 219: ...our oil pipe tight nuts in the place and plug it by the rubber plug to prevent the brake fluid from overflowing 3 Disconnect the brake hose form the brake caliper Remove the hollow bolt and disconnect...

Page 220: ...l tools to press in the bush b Install the upper arm shaft use the special tools to press in another bush 3 Tighten the upper arm shaft to specified torque a Coat the screw of both ends of upper arm s...

Page 221: ...fied torque Tightening force 15 17N m Remarks It should tighten four connectors of two two way valves to the specified torque if disassemble the right upper arm 3 Connect the brake hose to the upper a...

Page 222: ...the rear brake system if disassembly the right upper arm 7 Check the brake fluid for leakage 8 Tighten the upper arm front shaft nut to the specified torque a Install the wheel remove the bracket and...

Page 223: ...stabilizer bar 1 Install the stabilizer bar on the carriage Place the stabilizer bar in position install the stabilizer bar bush and clip on the carriage Align the mark on the stabilizer bar to keep...

Page 224: ...versal joint bearing front reducer and electric clutch assembly Power plug of electric clutch circlip hanger plank L constant speed drive shaft circlip lower segment of vent tube of front drive axle c...

Page 225: ...make the car in 2WD status before the disassembly 2 Remove the beam on the lower of front drive axle assembly 3 Disconnect the connection of front drive axle flange and drive shaft and make the assemb...

Page 226: ...and right front drive shaft assembly with the oil seal hanger plank and bearing se the circlip pliers to remove the outside circlip of bearing 15 Use the special tools pull out the bearing 16 Use the...

Page 227: ...arance in radius direction c Check the inner and outer jacket for damage Caution It should use the pad when clamp the front drive shaft to avoid the damage of it 2 Remove the large clip of inner jacke...

Page 228: ...he adz and hand hammer to make the assembly mark on the shaft and three pin section assembly c Use the cooper bar and hand hammer to remove the three pin section Caution Remove the cooper chip on the...

Page 229: ...stall the dustproof cover Caution The dustproof cover should be replaces when itisdeformed heavily 2 Install the large clip of outer jacket outer jacket and small clip of outer jacket Caution The oute...

Page 230: ...is damaged b Align the assembly mark made before disassembly c Use the hand hammer and copper bar to install the three pin sec tion assembly to the front drive shaft d Use the circlip pliers to insta...

Page 231: ...connector c Cover the inner jacket on the inner trumpet connector 7 Use the inner and outer jacket clip pliers to clamp the inner and outer jacket a Use the special non ear clip pliers to lock the lar...

Page 232: ...e the left and right steer ing knuckle of car then disconnect the inner trumpet con nector of front drive shaft assembly then take out the three pin section assembly and shaft from the inner trumpet c...

Page 233: ...e of electric clutch and reducer slowly 6 Drip 1 2 drop of screw lock agent on the middle of screw of connecting bolt of hanger plank andreducer 7 Use the wrench to tighten the connecting bolt of hang...

Page 234: ...t 10 Use the bolt to connect the front drive axle flange and drive shaft according to the mark mage before disassembly and tighten it to the specified torque specified torque 73 83N m 11 Install the b...

Page 235: ...e from the drive shaft and use the jack to remove the front drive axle Caution Make the assembly mark on the reducer and drive shaft before separate them 4 Remove the front differential assembly Cauti...

Page 236: ...dustproof cover assembly 6 Remove the drive gear oil seal Use the special tools to remove the oil seal do not damage the inner wall of reducer housing 7 Install the new drive gear oil seal a Use the s...

Page 237: ...ould be replaced by the thicker washer if the pre ap plied load is more than specified value The step of thickness of washer is 0 03mm c Is should be replaced by the thinner washer if the pre applied...

Page 238: ...force of oil drain plug 30 35N m Model of lubrication oil GL 5 Filling amount Flush to the lower edge of oil filling open 14 Insert the oil filling plug washer and tighten the oil filling plug to the...

Page 239: ...vibration damper front reducer electric clutch assembly Power plug of electric clutch circlip bearing front vibration damper oil seal front vibration damper hanger plank L front drive shaft assembly...

Page 240: ...the steering knuckle of both sides and separate it form the front drive shaft assembly 1 Support the front of the car remove two front wheels and the beam under the front reducer assembly 2 Drain the...

Page 241: ...rive shaft and front drive shaft jacket 11 Remove the front drive shaft assembly of both sides from the front drive axle assembly 12 Use the wrench to remove the bolt and nut which is used to fix the...

Page 242: ...ording to the removal and installation procedure of front drive shaft assembly and install the new side oil seal on the front drive shaft then install them in the front reducer assembly Refer to Remov...

Page 243: ...ing and front drive axle vent tube connector assembly 4 Disconnect the connector between the vent tubes on the electric clutch and vent tube connector assembly 5 Remove the bolt which is used to fix t...

Page 244: ...iaxle oil seal Caution Do not scratch the inner surface of flange 6 Use the circlip pliers to remove the circlip which clamp the major semiaxle bearing outer race 7 Use the special tools to remove the...

Page 245: ...position 11 Insert the spline of small end of major semiaxle in the spline of front reducer half axle gear slightly then use the brass bar and hand hammer to knock it in Caution When knock in the maj...

Page 246: ...nect the electric clutch housing and front axle pipe flange and tighten it to the specified torque In which the bolt should be precoated with the screw locking agent drip one or two drops on the middl...

Page 247: ...e vent tube on the electric clutch housing to the front axle vent tube connector assembly 21 Connect the electric clutch vent tube to the front axle vent tube connector assembly connect the place conn...

Page 248: ...h shift sleeve electric clutch housing oil filling plug circlip major semiaxle oil seal half axle gear thrust plate half axle gear planetary gear shaft planetary gear bolt clump weight bracket clump w...

Page 249: ...nt tube connector assembly 4 Screw off the bolt fixed the electric clutch and use the brass bar to knock down the electric clutch 5 Use the wrench to remove the oil filling plug remove the washer and...

Page 250: ...t the vent tube on the front axle tube 11 Use the circlip pliers to remove the circlip Fasten the major semiaxle bearing inner race 12 Press out the major semiaxle bearing on press machine Or knocked...

Page 251: ...use the dial indicator to measure the run out of driven bel gear Max Runout 0 07mm It should replace the drive and driven bevel gear totally if the run out is more than 0 07mm 19 Check the running cl...

Page 252: ...ween the drive and drivenbevel gear Range of pre applied load 1 2 1 7N m 22 Measure the total pre applied load of drive bevel gear 23 Remove the drive gear flange and dustproof cover assembly a Use th...

Page 253: ...e left and right of the bearing gland when remove it to avoid the confusion Remove the side bearing outer race and marked with L and R 29 Remove the left and right adjusting washer mea sure its thickn...

Page 254: ...replace the drive and driven bevel gear in pair before replace the big bearing if the drive bevel gear is damaged special special special b Install the washer on the drive bevel gear Use the special t...

Page 255: ...ide bearing inner race on the side of differential assembly with bolt b It should pay attention to does not damage the driven bevel gear when use the vice for clamping to remove the bearing inner race...

Page 256: ...to fix the planetary gear shaft and rivet the inserted hole to prevent the loose of pin Remarks The rotation of half axle gear and planetary gear should be smooth and without block push the planetary...

Page 257: ...ld be in the diagonal sequence to tighten the bolt and tighten it for little then tighten it to the specified torque uniformly h On press machine use the special tools to press the inner race of beari...

Page 258: ...e special tools to install the drive bevel gear oil seal Caution It should coat the lip with the oil seal lithium base grease before install it and the rear surface of rear oil seal should flush with...

Page 259: ...gear select out the adjusting shim in the side which meets the rational clearance of 0 15mm 11 Measure the thickness of the adjusting shim 12 After select out one side adjusting shim then select thea...

Page 260: ...the selected adjusting shim is without clearance form front reducer housing 17 Adjust the pre applled axial load of side bearing a Remove two adjusting shim remeasure the thickness of two adjusting s...

Page 261: ...contact dedendum contact 20 Check the meshing mark of drive and driven bevel gear a Paint 3 4 teeth with the red lead in three different positions of driven bevel gear b Hold the flange of drive gear...

Page 262: ...in the reducer housing install the drive gear flange andtighten the nut to the specified torque g Remeasure the pre applied load of drive gear bearing clearance and the total pre applied load of redu...

Page 263: ...washer on the stud tighten the nut to the specified torque The screw of all bolts should be precoated with screw lock agent The specified tightening force of hexagon bolt and spring washer combinatio...

Page 264: ...line of front reducer half axle gear use the brass rod and hand hammer to knock the major semiaxle into the front reducer Caution Does not damage the inside needle bearing On spline of large end of ma...

Page 265: ...h is in 2WD status the indicator lamp is extinguished always If does not reach the 2WD status in the first time then the controller restarts it for 2s after 2 5s delay the lamp flashes at the same tim...

Page 266: ...by bolt tighten the bolt to the specified torque Precoat the medium screw of bolt with one or two drop of screw lock agent Specified torque 23 26N m 47 Screw off the oil filling plug of front drive a...

Page 267: ...ot insert the previous two bolts in reverse direction Specified torque 200 220N m 3 Use the bolt to connect the front drive axle flange to the drive shaft according to the mark made before disassembly...

Page 268: ...ousing a Use the bolt to connect the special tools to the semiaxle flange surface b Use the hammer of special tools to remove the rear axle brake caliper assembly brake disc circlip oil seal base bear...

Page 269: ...hown as figure make the hook holds the bearing tightly then use the bolt to connect the hook to the hammer fixedly at last place it on the pad with halfaxle spline end facing ground c Hold the hammer...

Page 270: ...Assemble the halfaxle spline and halfaxle gear spline firstly then use the brass rod to beat knock the halfaxle assembly into the axle housing Caution Protect the lip of inner external oil seal and pu...

Page 271: ...e the oil seal Use the special tools to remove the oil seal bearing spacer adjusting washer rear bearing drive bevel gear adjusting ring side bearing driven bevel gear differential housing locking pla...

Page 272: ...htening force 78 5N m 8 Check the oil level of reducerReplace the hyperbolic gear oil if necessary Oil number GL 5 hyperbolic gear Viscosity SAE80W 90 Amount Filled with oil until the oil flows out fo...

Page 273: ...tial housing Use the feeler to measure the clearance between the thrust plate of axle shaft gear and differential housing Standard clearance 0 45 0 75mm It should be replaced by the proper thrust wash...

Page 274: ...ut can not be used any more c Remove the flange and dustproof cover assembly 8 Remove the oil seal Use the tools to pry out the oil seal 9 Remove the drive bevel gear and spacer Remove the drive bevel...

Page 275: ...g outer race by press 13 Remove the side bearing form the differential housing Use the special tools to pull out the side bearing from the differ ential housing 14 Remove the driven bevel gear a Remov...

Page 276: ...bevel gear a Place the front bearing inner race in the reducer housing place the oil baffle disc b Coat the position of reducer housing oil seal and lip of oilseal with grease uniformly place the oil...

Page 277: ...usting washer if the measured value is less than standard value b Increase the thickness of adjusting washer if the measured value is more than standard value 8 Install the driven bevel gear on the di...

Page 278: ...outer race in position tighten it properly Adjust the clearance between the drive and driven gear to the proper dimension 12 Install the bearing gland a Align the assembly mark on the bearing cover wi...

Page 279: ...eet the requirement use the special tools to adjust the left and right adjusting ring until it meets the requirement d Recheck the engagement clearance between the drive and driven gear Engagement cle...

Page 280: ...ightening force 18 25N m c Use the punch and hand hammer to knock the lower end of stop plate in the adjusting ring hole Set NO Thickness Set NO Thickness 16 Measure the total pre applied load Pre app...

Page 281: ...educer and differential assembly 1 Install the new stiffening ring 2 Install the reducer and differential assembly Install the reducer and differential assembly in the rear axle housing place the wash...

Page 282: ...emove the planetary gear shaft two half axle gears two planetary gears and two lock washers two thrust plates 2 Assembly of differential a Install the half axle gear and thrust plate of axle shaft gea...

Page 283: ...arance 0 45 0 75mm d Install the straight pin Use the hammer and punch to knock in the pin through the hole on the differential housing and planetary gear shaft Rivet the pin with the differential hou...

Page 284: ...ngitudinal pull rod fixed bolt long longitudinal pull rod assembly long longitudinal pull rod fixed bolt long longitudinal pull rodassembly short longitudinal pull rod assembly rearaxle assembly coil...

Page 285: ...al height Caution If the fixing nut of vibration damper is the lock nut it should be replaced by the new lock nut after replace the vibra tion damper Removal of coil spring 1 Remove the vibration damp...

Page 286: ...ing place between the connecting rod of stabi lizer bar and carriage Need the inner hexagon spanner 2 Screw off the nut connected to stabilizer bar in same method screw off the connecting rod Installa...

Page 287: ...apter 8 Brake Cautions 2 Troubleshooting 2 Check and adjustment 5 Brake pedal 7 Parking brake 8 Front brake 9 Rear brake 16 Rear parking brake 22 Sensor load proportional valve 29 Antilock Braking Sys...

Page 288: ...e adjuster Replace the master pump Brake is stagnant Improper inflation of tyre There is grease spot or lubricant oil on the brake shoe or brake block The brake shoe is deformed the brake pad is worn...

Page 289: ...he squeak continuous scream rattler or vibration noise when use the brake Caution The abrasion material in the brake will generate the inherent noise and heat during the abrasion then emit the heat So...

Page 290: ...aged or under lubricated Check and adjust Check repair or replace Check and fill with lubrication oil if necessary Repair or replacement Repair or replacement Repair or replacement Repair Repair Repai...

Page 291: ...lue lock the block nut tightenedly when reach the standard value c Rotate the brake lamp switch to contact with the limit block of brake pedal then rotate 1 2 1 round continuously tighten the block nu...

Page 292: ...p down the brake pedal and start the engine If the pedal moves downwardly a little then it means the normal operation if the brake pedal moves upwardly then it means the brake assist is damaged 2 Air...

Page 293: ...pipe into the container with half of brake fluid Remarks When discharge the air of wheel brake pump it should begin from the longest pipeline 3 Air discharge of brake system pipe a Step down the brake...

Page 294: ...and bush is large it should remove the pedal and replace the bush push bar lock nut inner distance fork pin shaft Parking brake parking crank assembly switch assembly rear parking brake pull wire R re...

Page 295: ...ong air bleed bolt cover location pin guide pin dustproof cover square seal ring N m Specified torque Piston Replacement of brake block Remarks When brake during the travel process if the front wheel...

Page 296: ...components a Two pieces of brake block b One piece of silencing plate c Two piece of silencing plate combination d One wear limitation alarm plate of brake block e Four brake block circlip plates 5 Me...

Page 297: ...the operating surface of brake block and brake disc is polluted by the grease and paint e Suck a few of brake fluid form the liquid reservoir prevent the brake fluid from overflowing from liquid rese...

Page 298: ...late 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...

Page 299: ...imum thickness 3 Measure the circular runout of the brake disc Remarks It should ensure that the bearing is adjusted correctly before the measurement maximum circular runout 0 11mm 4 Replace the brake...

Page 300: ...e with proper rubber lubricant 3 Install the piston with dustproof cover in the tong a Cover the dustproof cover on the piston b Lengthen the dustproof cover to expose the bottom of piston from the du...

Page 301: ...hexagon flange bolt Tightening force 25 35N m 3 Connect the brake pipeline Connect the brake oil pipe to the tong body Tightening force 50 5N m 4 Fill up the brake liquid reservoir with the brake flui...

Page 302: ...n 25 30 rear brake oil pipeline N m specified torque peephole silencing plate Replacement of brake block Remarks if the rear wheel generates the cheep during the braking it should check the abrasion i...

Page 303: ...g components a Two brake blocks b Two silencing plates c Two silencing plate combinations d One brake block bush wearing indication plate e Two brake block circlips 5 Measuring the depth of brake disc...

Page 304: ...g surface of the brake block and brake disc are not allowed to be contaminated by grease and paint 9 Install the sub pump a Unscrew the release screw absorb some of the brake fluid b Press the plunger...

Page 305: ...lencing 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 o...

Page 306: ...should repair or replacement brake disc if it is scratched or worn or its thickness is less than minimum thickness 3 Measure the circular runout of brake disc Remarks It should ensure that the rear b...

Page 307: ...coat the operating surface of piston and square gasket with proper rubber lubricant 2 Install the piston gasket and piston in the tong 3 Install the cylinder hole dustproof cover and wire clip in the...

Page 308: ...r parking brake pull out piece spring draw bar hand brake stay wire front brake shoe lower tension spring clearance adjusting bolt clearance adjusting gear clearance adjusting bolt head pull out piece...

Page 309: ...ough twisting the clearance adjusting gear 4 Remove the shoe plate pull out the piece spring pull out piece spring seat pull out piece spring draw bar 5 Remove the lower tension spring and clearance a...

Page 310: ...e the thickness of the brake shoe standard thickness 4 0mm minimum thickness 1 0mm If the thickness of the brake shoe is less than the minimum value or there is uneven wearing the brake shoe shall be...

Page 311: ...tact position of brake soleplate and brake shoe b Contacting surface of push plate and shoe plate contacting sur face of clearance adjusting device assembly and shoe plate Assembly of rear parking bra...

Page 312: ...spring base Use the pull out piece spring fork to rotate the pull out piece spring base in position 4 Install the front brake shoe install the front shoe plate insert one of its ends into the fixed pi...

Page 313: ...tall two upper release springs Insert the block into the support pin then install the upper release spring on the place between two brake assemblies 9 Check the operating process of automatic adjustin...

Page 314: ...en rotate it for 3 5 teeth in anticlockwise rotate the brake disc by hand at the same time it is proper that it can rotate freely and without the contact between the abrasion and disc It is allowable...

Page 315: ...ent including driver b Install the brake pressure measuring meter and drain the air c Increase the front brake pressure to 12Mpa the rear brake pressure should be within 8 9 Mpa d If necessary adjust...

Page 316: ...f the load sensing proportional valve assembly 2 Installation a Use two installation bolts to fix the load sensing proportional valve The bolt tightening torque is 23N m b Tighten the adjusting bolt l...

Page 317: ...the small number means the failure which occurs most possibly Check each element according to the sequence and maintain or replace it if necessary 2 Check the following elements for normal operation b...

Page 318: ...Brake 32...

Page 319: ...parking brake brake shoe is out of round 4 parking brake improper adjustment 2 parking brake pull wire lag 3 Assist push bar improper adjustment 5 9 8 Tension or release spring failure 8 8 brake shoe...

Page 320: ...Steering 1 Chapter 9 Steering Precautions 2 Troubleshooting 2 Inspection on vehicle 3 Steering linkage 4 Hydraulic power steering system 6...

Page 321: ...Steering 2...

Page 322: ...Steering 3...

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Page 324: ...sition of the steering stem install the handwheel aligning the center the radials of the handwheel should be at the left right centering state the symbol of the Great Wall on the steering wheel shall...

Page 325: ...Steering 6...

Page 326: ...Steering 7...

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Page 328: ...B Black Br Brown G Green Gr Gray L Lake blue Lg Light green Or Orange P Pink R Red V Violet W White Y Yellow...

Page 329: ...F i g u r eV I I I 2 2 1 Wire Harness Wire harness middle link number pin function diagram 1 l i n k e dt oi n s t r u m e n tw i r eh a r n e s s2 l i n k e dt oe n g i n eb a y 2...

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Page 351: ...ition lock or the door lock the reading light will be off if there is not any action when the door is closed within 1 minute the reading light will automatically turn off 8 ON power supply detection c...

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Page 354: ...CD Player and Air Conditioning System 1 Chapter 11 CD Player and Air Conditioning System...

Page 355: ...of the 20 pin connector plug to the air conditioner ECU then connect the speaker o u t p u t l i n e t o o t h e r l i n e s f i n a l l y c o n n e c t t h e y e l l o w m e m o r y p o w e r s u p...

Page 356: ...solutions No programs received for AM and FM Check if the antenna is pulled out and socket becomes loosened Impurity of sound after radio auto searching Tune to the correct radio station with manual...

Page 357: ...onditioner control unit display unit sensors and executor elements f r e s h a i r d a m p e r e x e c u t o r mode damper executor emperature damper executor i n t e g r a t e dd i s p l a ys c r e e...

Page 358: ...C U i s i n s t a l l e d u n d e r t h e b o t t o m o f C D p l a y e r T h ec o n t r o lp a n e lo fa i rc o n d i t i o n e r i s d e s i g n e d w i t h a n i n t e g r a t e d p a t t e r n w i...

Page 359: ...ailure Step 1 Display 01 set the temperature zone all other display symbols turn off Press down Temp switch Step 2 Display 02 set the temperature zone The inspection procedures During the period of 10...

Page 360: ...the evaporator 002 Short circuit of temperature sensor of the evaporator Step 3 Display 03 set the temperature zone Display the outside temperature value Press down Temp switch Step 4 Display 04 set...

Page 361: ...ernal circulation Temperaturedamper coldend Windamount themaximum Compressor enabled Note X is a digital number without specific meaning the code number is displayed in the outside temperature display...

Page 362: ...Action of the executor mechanism Mode damper wind to the feet and defrost Circulation damper external circulation Temperature damper in the middle Wind amount small Compressor off display 10 set the...

Page 363: ...r Refrigeration of air conditioning systemfailed 3 nowindfromtheblower 1 fuse burneddown 2 motor brushof theblower damaged 3 switch of the blower damaged 4 coming off of distribution wire connectors o...

Page 364: ...r 5 pressure at low pressure side sometime normal sometimes with negative pressure moisture andiceblock inair coolingsystem 6 negative pressure at low pressure side pressure at high pressure side too...

Page 365: ...roduces refrigeration effect while sometimes not compressor works improperly 1 slide of the clutch 2 coming off of the clutch s winding 3 poor earthing of clutch s winding d Noise of the air cooling s...

Page 366: ...auxiliary valve b dismantle the high pressure side hose from the manifold pressure gauge and insert it into the oil cup c open the auxiliary valve and have the refrigeration oil sucked into the refrig...

Page 367: ...p out to the vacuum after the leakage is fixed 2 Injection of the refrigerant Whentheairtightnessofthesystemisverifiedcorrect connecttherefrigerantreservoir orgasbottle withoneendoftheyellow air charg...

Page 368: ...between the internal external air circulation During this process the door and windows will be all opened Adjust the engine s speed to the specified free running speed Erect the refrigerant reservoir...

Page 369: ...fan High gear Temperature controller air return temperature inside the car is between 25 and 30 Fresh air control internal circulation Door all opened Window all opened Repair and replacement of pipe...

Page 370: ...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 join...

Page 371: ...Safety airbag 1 Chapter 12 Safetyairbag...

Page 372: ...ructions for maintenance For your safe operation please read the following instructions prior to your operation 1 The maintenance of SRS safety airbag must be operated under the procedure and directio...

Page 373: ...Safety airbag 3...

Page 374: ...Safety airbag 4 safety airbag system alarm lamp impact sensor and diagnosis module passengers side inflation elements and airbag insulating tape battery wire...

Page 375: ...epaired If the alarm lamp does not illuminate when the ignition switch is in ON position repair the alarm lamp relevant circuit and then further operate to get it into work Scan the ECU by connecting...

Page 376: ...e front airbag grounding Can 4 Ignition loop 1 driver s side front airbag connected to power supply Can 5 Ignition loop 2 passenger side front airbag resistance is too high or open circuit Can 6 Ignit...

Page 377: ...nterior failure The micro controller can test the following items not only in starting detection but also in cyclic diagnosis detection a Ignition circuit triggers the transistor The high side transis...

Page 378: ...en the front airbag releases 14 The ignition of side airbag is not determined Though SRS ECU has received ignition information for 5 times during HSIS cycling ignition the ignition can not be determin...

Page 379: ...ll 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...

Page 380: ...erminal and wiring harness well connected and in good condition If it is not any of previous cases operate according to the following steps Procedure Test Operation Yes Place the ignition switch in LO...

Page 381: ...power supply fuse shutoff or bad contact Misconnection of ECU plug terminal Bad contact between ECU plug terminal and grounding wiring harness Driver s or passengers side safety airbag circuit failur...

Page 382: ...ends of K line No Repair or replace the wiring harness and continue according to step 5 Yes Next step 3 Make sure the shutoff of accumulator negative line and keep the status for at least 1 minute Sh...

Page 383: ...t and the preparatory work must be done before the test because the damage to working personnel or system may be caused by the incorrect operation during the test SRS safety airbag system electronic c...

Page 384: ...Place the ignition switch in ON position Test the potential of two fuse corresponding contactors the potential above 9V No Check the wiring harness Yes Next step 3 Check the wiring harness between fu...

Page 385: ...n the SRS safety airbag system connector clips connectors not within the designated scope SRS safety airbag system driver s side airbag relative wiring harness shorting or shutoff Possible causes Driv...

Page 386: ...harness Normal Next step 6 Check the clock spring connector clip Remove the steering pillar shell Release the clock spring connector clip Is the clock spring connector clip normal Abnormal Replace the...

Page 387: ...s shorting between safety airbag system unit stitch 13 and stitch 14 Open loop between SRS safety airbag system unit connector clip stitch 13 and stitch 14 Possible causes Passengers side safety airba...

Page 388: ...nes providing something wrong with them a Clock spring b Steering wheel steering column bottom steering shaft module 3 Driver s side safety airbag module s installation status towards the steering whe...

Page 389: ...tallation status of safety airbag module Driver s side safety airbag module the following Figure generator bracket connect the horn connect the driver s side module Clock spring right Figure 1 Check w...

Page 390: ...and maintenance for SRS safety airbag are displayed in the Figure Operate according to the sign and the destructed and dirty sign must be replaced with a new one steering wheel in Figure6 1 Driver s s...

Page 391: ...or repaired replace the failed SRS ECU with a new one 3 Prevent the SRS ECU from shock and vibration replace the SRS ECU with depression crack or deformation with a new one 4 Do replace the SRS ECU wi...

Page 392: ...panel d Connect the grounding jumper 4 Some points for installation a SRS ECU installation b Post installation test Place the ignition switch in ON position SRS alarm lamp flashes in 6 seconds and ext...

Page 393: ...ss connector clips in order to avoid the possible improper release caused by static interferences which is reversal to the case of installation 1 Removal and installation Driver s side safety airbag m...

Page 394: ...the vehicle tightly fix the PAB module to the vehicle transverse beam with 2 matted M6 bolts at the glove box site Well mutually plug the PAB module airbag wiring harness connector clip and safety ai...

Page 395: ...a The test before installation The new safety airbag or clock spring must be tested before installation Caution The safety airbag module must be abandoned after its release according to the procedure...

Page 396: ...If without the clock spring central involution the steering wheel will not be able to rotate at midway or the clock spring circuit will be damaged so that jeopardize SRS safety airbag s normal activi...

Page 397: ...e broken and the terminal is deformed Whether the shield is damaged Check the connection between clock spring s upper joint terminal and it s corresponding bottom terminal Plug in a thin probe from th...

Page 398: ...residential area due to the big noise during the safety airbag s release Remove the accumulator positive and negative and remove the accumulator off the vehicle Caution Continue the operation 60 secon...

Page 399: ...f the joint of driver s side safety airbag release wiring harness somewhere far from the vehicle and connects the joint with the accumulator and makes the safety airbag release clock spring connector...

Page 400: ...ly without the joint connection of driver s safety airbag module therefore the possible improper release caused by static interference can be avoided if it improperly releases keep the released side u...

Page 401: ...fixing the driver s side safety airbag module Figure 9 7 wheel hub free old tires release wiring harness Shut off the joint of driver s side safety airbag release wiring harness somewhere far from the...

Page 402: ...ips between clock spring and SRS safety airbag system electronic control unit Shutoff or shorting of wiring harness between clock spring and SRS safety airbag system electronic control unit Misconnect...

Page 403: ...harness Normal Next step 6 Check the clock spring connector clip Remove the steering pillar shell Release the clock spring connector clip Is the clock spring connector clip normal Abnormal Replace the...

Page 404: ...control unit The circuit shutoff or shorting between SRS safety airbag system unit and grounding jumper SRS safety airbag system unit failure Procedure Test Operation Yes Next step 1 Is the vehicle w...

Page 405: ...e previous circuit normal Abnormal Replace the relative wiring harness Impact vehicle diagnosis Test SRS ECU diagnostic signals 1 Connect the X 431 diagnostic test s diagnostic joint 2 Read the diagno...

Page 406: ...important parts assurance and request 1 B non metal materials consumption table 12 C Special tools 14 D importantworkingregionsandtightening torque important working region 17 E Electric wiring diagra...

Page 407: ...Control item fixing to the 23 2N m Torque wrench Steel plate gauge 100mm hexagon flange nut Q32012 hexagon flange nut Q32012 Control item locate the riage and fix it with some bolts Q32012 90 10N m T...

Page 408: ...nut 2 in the Figure is Torque wrench Connection of left right short longitudi nal tie assembly and carriage the fixed torque of nut 3 in the Figure is Torque wrench Connection of cross tie assembly a...

Page 409: ...5N m Torque wrench rear transverse stabilizer rear transverse stabilizer rod connecting bar assembly bush Upper suspension arm and upper suspension arm steering knuckle ball pin Steering gear cross t...

Page 410: ...axle assembly Drive shaft assembly installation Plug the front part of drive shaft into transmission assembly splinded shaft after their good meshing screw the central bearing hexagon bolt into the c...

Page 411: ...of bolt 1 in the Figure is 78 5N m front axle drive shaft assembly transmission assembly rear axle drive shaft assembly rear axle assembly petrollienjoint petrol line joint tightening torque is 16 2 N...

Page 412: ...i wedge belt 4PK1100 tension is 500 50N Torque Torque multi wedge belt 4PK1100 driver steering oil pump cover lock mounting bolt effect cover lock mounting bolt s torque is 9 2N m the cover lock can b...

Page 413: ...no linkage falling off the backup door can be opened and closed freely without any jam nor unlocking Handle confirmation rear door assembly backup door bottom buckle backup door lock backup door out h...

Page 414: ...atilize the washer completely Apply adhesive on front windshield glass Shake the glass base coater to be sufficiently even followed by the even application on the glass frame with the width of about 2...

Page 415: ...width of about 25mm and volatilize it completely Shake the base coater to be sufficiently even followed by the even application on the sticking region with the width of about 20mm and dry it for 2 15...

Page 416: ...he width of about 20mm and dry it for 2 15minutes Viewing confirmation Apply washer on side window glass frame Wash the glass frame with the width of about 25mm and volatilize the washer completely Vi...

Page 417: ...lation order is A C E B D F as showed in the Figure Torque wrench Viewing and handle confirmation The headrest can be up and down smoothly angle adjuster handle can be normally used driver co driver s...

Page 418: ...spline speed shaft L Suitable Glass base coater 5001TF Glass base coat m 0 03 Butyl tape 6 2 700 Air filtering suction tube door seal film L Suitable Attraction steering fluid DEXRON3 ATF 3 Steering f...

Page 419: ...sive 7120 Backup door glass side window glass L 0 9 Clearance adhesive LY 22 Luggage rack Kg Suitable Liquid adhesive LY 609 Warming pipe speed lever L 0 02 Windshield washer Q35 Front and rear window...

Page 420: ...ing or r e p a i r i n gt o o l v a l v e s p r i n g p r e s s e r crankshaft pulley remover c r a n k s h a f t p u l l e y f i x i n g t o o l camshaft bearing removing and r e p a i r i n gt o o l...

Page 421: ...Appendix C 15 c r a n k s h a f tf r o n to i ls e a lr e p l a c i n g t o o l c r a n k s h a f to i ls e a lr e p l a c i n gt o o l...

Page 422: ...o r h i g h s p e e d s m a l l r o t o r f r o n tb e a r i n g i n j e c t i o n p u m p s p l i n e s h a f t r e m o v e r 1 s t a r t e rb e a r i n g 2 h i g h s p e e d s m a l l r o t o r f r...

Page 423: ...5 15 7 front twisted bar pedestal connecting bolt M12 1 25 10 9 140 10 31 steering wheel lock nut M12 1 25 8 30 5 8 upper arm ball channel fixing nut M16 1 5 10 145 15 32 steering gear carriage fixing...

Page 424: ...olt M10 1 25 9 8 63 5 19 cross tie carriage connecting bolt M14 1 5 10 9 200 20 43 Engine oil pan drain bolt 40 5 20 cross tie rear axle fixing nut M14 1 5 8 180 15 44 Transmission transfer case refue...

Page 425: ......

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