Hover service manual PDF

Preview

Summary

Preface Since the Great Wall Hover is put into the market, it has won the favor from the cus- tomers for its elegant appearance, excellent performance&price ratio,concept of double area and eternal safety. This vehicle is provided with the Mitsubishi engines of 4G63, 4G64 and 4G69 and the Great ...

Description

Preface Since the Great Wall Hover is put into the market, it has won the favor from the customers for its elegant appearance, excellent performance&price ratio,concept of double area and eternal safety. This vehicle is provided with the Mitsubishi engines of 4G63, 4G64 and 4G69 and the Great Wall engines of GW2.8TC, GW2.8TCI, and GW2.5TCI, and also the manual transmissions from Shanghai Gear, TAGC and ZOMAX. ABS and airbags are optional. Before of its complex structure, high technical intervention and difficulty of maintenance, its maintenance needs the reference of related documents. Upon the request of the after-sale maintenance technical personnel of Great Wall, we have prepared this Hover Maintenance Manual. The manual is oriented towards the aftersale maintenance technical 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 troubleshooting, matters needing attention for maintenance and the related technical parameters. During the preparation of this book, a lot of professional personnel have given support and help, here we would like to express our sincere thanks. Though we have made efforts to prepare this manual earnestly, we cannot guarantee that the content in the manual is totally accurate and without error. The user cannot raise improper request to the Great Wall Company with the manual as legal basis. We cannot bear any responsibility for the losses caused by using this manual. Confined to the knowledge of the editor, the fault and errors are inevitable, your advice and comment are appreciated. The final authority for the interpretation of this manual belongs to the Great Wall Motor Co., Ltd.

Editor

Preface Table of Contents Introduction How to use the manual Chapter 1 General Description of Complete Vehicle Chapter 2 Fuel-supply System Chapter 3 Exhaust System Chapter 4 Clutch Chapter 5 Transmission SC5M2D-C SC5M4D-C 038M1 038M ZM001DB ZM001DF ZMOO1M ZMOO1MF

Chapter 6 Chapter 7 Chapter 8 Chapter 9 Chapter 10 Chapter 11

Chapter 12 Chapter 13 Chapter 14 Chapter 15 Chapter 16 Chapter 17

Transfer case(4555)

Drive shaft Suspension and axle Wheels and Tyres Brake Steering System Body Electrical Appliance 05 05 Top model 06 08 K1-NCAP TK

Electric Appliance Air Conditioning System Safety airbag(Siemens) Interior and Exterior Trims of Vehicle Body Body & Stamping Parts Bolt Tightening Torque (Chassis)

Introduction-1

Introduction How to use this manual ................................................... 2 Identification mark............................................................ 4 Comprehensive maintenance instruction ...................... 4

Introduction-2

How to use this manual In order to help you to use this manual, the chapter name and main topics are given at the upper side of each page. To introduce to you the maintenance items, there is an index on the first page of each chapter. At the beginning of each chapter, there are also the matters needing attention of all the maintenance operations. Please read the following matters needing attention before starting the maintenance work. The failure diagnostic 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 maintenance method to facilitate you to acquire the method of solving the problem quickly.

Maintenance procedure

Most part of the maintenance operation can be started from referencing the illustration. These illustrations help you recognize the parts and show the mutual coordination. For example: washer

★upper arm shaft upper arm bush 210

210 upper arm bush

upper arm

washer

upper ball pin 78 ◆split pin N·m :specified torque ◆ Used component which can not be used any more ★ Pregummed components

145

Introduction-3 The maintenance procedure is explained in the form step by step: • The illustration shows what to do and where to do. • The topic of maintenance work tells you what to do. • The detailed instruction tells you how to finish the maintenance work and introduce other related issues, such as specification and warning, etc. For example: Work topics: what to do

illustration: what to do and where to do

3. Check the drive of ball pin (a) Remove the ball pin.

Detailed instruction: How to do

(b)

(c)

As shown in the Figure, shake the ball pin back and forth for several times before mounting the cap nut, Turn the but with torque meter continuously, turn one cycle every 2 to 4 seconds, read the torque meter at the fifth cycle.

Tightening torque (for rotary): Upper ball pin 0.1-4N·m Lower ball pin 0.1-4N·m

Specification

This format can help the experienced technical personnel to locate the causes of failure quickly. The maintenance personnel can browse the work topics, and reference the detailed explanation below it only when necessary. The important specification and warnings are given in bold face letter.

Specification

In the whole manual, each maintenance step is given with corresponding specification in bold face letter, so there is no need to stop working to look at the specification.

Warning, Attention, Remarks •

•

•

The Warning is given in bold face letter, which means there is the possibility of harming both the person himself and others. The Attention is written in bold face letter, which means there is the possibility of damaging the parts under maintenance. The Remarks is written separately in the instruction, it is also in bold face letter. Its main function is to make some additional explaining to help you to finish the repair work more efficiently.

Introduction-4

VIN nameplate nameplate

Identification mark The identification code of the car

The identification code of the car is a unique code of 17 bits to identify the car. Besides appearing 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.

vehicle VIN NO.

Motor serial number

The manufacture number of motor is inscripted on the right side of the cylinder .

Comprehensive maintenance instruction 1. Use the protection plate, seat and floor covering cloth to make the car clean and prevent it from being damaged. 2. During the disassembling, place the components in order for the convenience of assembly. 3. Observe the following issues: (a) Before conducting the electrical work, remove the negative pole of the cable from the accumulator terminal. (b) When it is necessary to remove the accumulator for checking or maintenance, the cable shall be removed from the negative pole (-) connected to the car body. (c) In order to avoid the damage of accumulator terminal, when removing the cable, loosen the terminal nut, then pull the cable upwards vertically, do not twist or pry it. (d) Please use cleaning cloth to clean the accumulator terminal. Do not use file or other similar tools, which may scuff them.

Introduction-5 (e)

locking sealant

Mount the cable terminal onto the binding post of the loosened nut, then tighten the nut. Does not use hammer to knock at the terminal onto the post. (f) Do remember to check whether the positive pole (+) terminal cap is in its position. 4. Check all the soft tubes and wire terminal, check to see whether they are connected correctly and firmly. 5. Used component which can not be used any more. (a) The following spare parts needs always to be renewed: split pin, seal gasket, O ring and oil seal, etc. (b) For the used component which can not be used any more, it is indicated by symbol “◆” in elements diagram. 6. Precoated component The precoated component includes the bolt and nut which is precoated with the locking sealant in factory. (a) If the precoated component is tightened, loosed or moved by any reason, it must be recoated with the specified sealant. (b) Coating procedure of precoated component Remove the old sealant from the screw of component by 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 ring to prevent the leakage if necessary. 8. Abide by all specifications for bolt torque strictly. It should use the torque wrench. 9. Determine the necessity of using special maintenance tools and special maintenance material according to the practical situation of maintenance. Use them on the necessary position, and go on with the maintenance according to proper procedures. 10. To replace the fuse, check to see whether the rated current of new fuse is correct. Do not exceed the rated current of the fuse, or do not use the fuse with low rated current. 11. When jacking up or supporting the car, lift or support the car on proper position with care. (a) If only jacking up the car in the front part or rear part, choke up the wheel to ensure the safety. (b) After the car is jacked up, use frame to support it. It is dangerous to conduct maintenance on the car that is only jacked up with one screw jack, even for the minor maintenance that can be finished quickly.

Introduction-6

error

correct

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 computers (if the IC terminals are touched, the IC may have electrostatic damage). (b) When removing the vacuum tube, pull the end of the tube instead of the central part of the tube. (c) When pulling the wire terminal, pull the terminal itself instead of the wire. (d) Take care to not make the electrical components fallen, such as the sensor or relay. If they fall to the hard ground, they must be replaced. (e) Never use the striking wrench to remove or install the electric thermostat or thermostat sensor. (f) When checking the conducting state of the wire connector, insert the multimeter with care, do not bend the terminal. (g) When using the vacuum meter, do not insert the soft tube onto large connector. Use the stepped terminal. Once the soft tube is swelled and tightened, there may be leakage.

General Description of Complete Vehicle-1

General Description of Complete Vehicle CC6460K and CC6460KY wagon (4G64)....................................... 2 CC6460KM55 and CC6460KM75 wagon (2.5TCI right-hand drive). ............................................................... 12 CC6460KM07 and CC6460KM27 wagon (4G63 left-hand drive)..................................................................... 16 CC6460KM19 and CC6460KM39 wagon (4G69) ........................... 21

General Description of Complete Vehicle-2

CC6460K and CC6460KY Wagon (4G64) Basic Parameters of Complete Vehicle Item Size parameters (no-load) (mm) Length Width Height Axle base Wheel base: Front/Rear Front suspension Rear suspension Quality parameters Loading weight (kg) Curb weight (kg) Max. gross mass (kg) Load distribution on no-load axle : Front/rear (kg) Load distribution on full-load axle load distribution: Front/rear (kg) Trafficability parameters Min. turning diameter (m) Min. ground clearance (mm) Approach angle (°) Departure angle (°) Power performance: Min. stable speed of direct drive (km/h) Accelerating time of direct drive 30km/h~100km/h (s) Accelerating time of initial starting of Gear 1 shifting to 100km/h (s) Top speed (km/h) Max. climbing capacity (%) Economical efficiency Sliding distance with initial speed 50km/h (m) Fuel consumption under 90km/h constant speed driving (L/100km) Fuel consumption under 120km/h constant speed driving (L/100km) Fuel consumption under simulation of urban and suburban comprehensive working conditions (L/100km) Brake performance Service braking distance of initial braking speed of 50km/h (m) Emergency braking distance of initial braking speed of 50km/h (m) Grade parking brake (%) Stability Max. side cross stable angle under no-load and static status (°) Control stability (minute) Smoothness Acceleration weighted mean square valueσw(m/s2) Equivalent mean value Leq (dB) Reducing comfort limit TCD (h) Tightness Dust-proof tightness M (%) Waterproof tightness (minute) Noise Outside noise when driving in acceleration speed dB (A) Inside noise when driving in uniform speed of 50km/h dB(A) Parotid noise beside the driver dB(A)

CC6460K

CC6460KY

4620 1800 1710 (vehicle body)/1775 (plus tail fin, luggage rack)/1810 1700 (vehicle body)/1765 (plus tail fin, luggage rack)/1800 2700 1515/1520 850 1070 5 persons×65kg/person+150kg 1720 1830 2195 2305 890/830 980/850 980/1215

1070/1235 ≤13

≥180

≥175 ≥28 (no-load) ≥27.5 (no-load) ≤25 ≤32 ≤20 ≥160 ≥35 ≥500 ≤10.19 ≤13.24

≤11.9

≤12.5

≤19 (no -load), ≤20 (full load) ≤38 ≥20 (no -load), ≥18 (full load) ≥35 Nan≥60 and NZ≥60 ≤0.6883 ≤116.5 ≥1.2 ≥95 ≥93 ≤74 ≤79 ≤90

General Description of Complete Vehicle-3 Emission Conform to exhaust emission of Euro II Pollutant drainage in low and idle speed: (750±50) r/min Pollutant drainage in high and idle speed: (2000±50) r/min

CO≤2.2g/km, (HC+NOX)≤0.5g/km CO≤0.1%, HC≤50ppm CO≤0.07%, HC≤50ppm

Structure Types and Technical Parameters of Main Systems and Assemblies Engine No. 1

Model

2

Mode

3 4 5 6 7 8

Fuel supply type Measure method of air intake Mode of combustion chamber Cylinder diameter×stroke (mm) Total displacement (L) Compression ratio Max. power and corresponding rotation speed (kW/r/min) Max. torque and corresponding rotation speed (N•m/rpm) Min. fuel consumption (g/kW•h) Stable idle speed (r/min) Idle control Mean speed of piston (m/s) Mean effective pressure (kPa) Cylinder compression pressure: 250r/min (kPa)

9 10 11 12 13 14 15 16

Item

Specifications and parameters 4G64S4M Four-cylinder, in-line, water cooling, single over-head camshaft four-stroke petrol engine Multi-ignition fuel injection (MPI) Speed-intensive Single-slope roof 86.5×100 2.351 9.5:1 93/5250 190/2500

25

≤254 750±30 Electronic closed-loop control 17.5 1036 1320 1-3-4-2; without distributor block, ignition directly through Ignition order and control electronic control Ignition plug clearance (mm) 1.0~1.1 BKR5E-11 or K16PR-U11 or RC10YC4 Ignition plug model BKR6E-11 or K20PR-U11 or RC8 Ignition plug manufacturer NGK or DENSO or Torch Valve clearance (mm) 0 (hydraulic tappet) Valve timing phase: open/closed air intake valve 18°in front of upper dead point/53°back of lower dead point 　　　　　　　　　open/closed exhaust valve 50°in front of lower dead point/18°back of upper dead point Lubrication type Combined type of pressure and splash Oil pressure of main oil way: idle speed/ (≥78.5)/(245~490) 3000rpm (kPa) Max. oil temperature (℃) 130

26

Oil consumption (g/kW•h)

2

27

Oil and fuel consumption ratio (%)

≤0.8

28

Cooling type

Closed-circuit forced water cooling

29

Starting type

Electric starter

30

Net mass (kg)

167

31

Overall dimension: length×width×height (mm)

730×653×667

32

Emission in idle speed: CO(%)/HC(ppm)

33

Emission control level of work condition code

≤0.5/≤100 With three-way catalytic converter, air-fuel ratio closed-loop control, conform to GB18352.2-2001 standard when carrying light vehicle

17 18 19 20 21 22 23 24

Air Intake System Dry-type Air Cleaner.

Exhaust System

It is equipped with first-level silencer, with second-level three-way catalytic device.

Fuel Supply System

Adjustment of accelerator pedal: free play of accelerator pedal is 155mm. If it does not conform to the standard value, adjust the adjusting nut on the cable bracket. Fuel tank is made of plastic, with the capacity of 67L; Fuel supply control is mechanical pedal fuel supply control, with integral electronic fuel pump; The fuel is vaporized to activated carbon pot, and it is controlled by electronic valve.

General Description of Complete Vehicle-4

Cooling System

Forced circulation water cooling, electronic fan, and aluminium ribbon-tubular radiator.

Clutch

It is equipped with friction, disc type, single plate diaphragm spring clutch, hydraulic control mechanism. Outer diameter D and inner diameter d of friction plate is 225mm and 150mm respectively. The material is F810.

Adjustment of Clutch Pedal

1. Measure the height (from pedal cushion to the floor) and free play (fork level pin clearance) of the clutch pedal. The standard value of height of clutch pedal: keep alignment to brake pedal, and the free play of clutch pedal is 5-15mm; 2. Firstly adjust the height of pedal, and then adjust the free play of the pedal. Turn the push rod till it reaches the standard value and fix the bolt and nut; 3. If the free play of the clutch pedal is beyond the standard value, turn the adjusting bolt to the standard value and fix the bolt and nut. When adjusting the free play of the pedal, do not impel the push rod to the master cylinder; 4. If the clearance between the clutch pedal and the floor does not conform to the standard value when the free play of clutch pedal is separated from the clutch, it may be caused by the malfunction of master cylinder or clutch because of entering of air in the hydraulic system. So, conduct deflation for the system or remove and inspect the master cylinder or clutch.

Transmission No. 1 2 3 4 5 6 7 8 9

Item

Specifications and parameters SC5M2D-C SC5M4D-C Manual mechanical step speed A l l s y n c h r o n i z e r w i t h m a n u a l transmission of all synchronizer, 5 mechanical step speed transmission Mode forward gears, 1 reverse gear, and of transfer case, 5 forward gears, 1 direct control reverse gear, and direct control 72 (transmission), 222.25 Central distance (mm) 72 (transfer case) Max. input torque (N·m) 196 Max. input rotation speed (r/min) 5500 Gear Gear Gear R Gear H Gear Gear I Gear II Gear V (reverse) III IV (high) L (low) Speed ratio 3.967 2.136 1.360 1.000 0.856 3.578 1.000 1.925 Gear pair of odometer 8:25 Gross dry mass (kg) 38 68 (including transfer case) Overall dimension: length×width× 1 0 7 0 m m × 4 6 6 m m × 3 9 9 m m 1070mm×460mm×380mm (excluding height (excluding the height of control lever) the height of control lever) Model

Drive Axle

The rear drive axle assembly of CC6460K wagon includes three cross axle universal joints, two drive axles and maintenance-free sectional structure with expansion spline and intermediate support. The front and rear drive axle assembly of CC6460KY wagon includes two cross axle universal joints, a drive axle and maintenance-free integral structure with expansion spline.

Front Axle

The front axle of CC6460K wagon is a double-transverse arm independent suspension breakaway front axle. For CC6460KY wagon, it is equipped with double-transverse arm independent suspension breakaway steering drive axle, hyperbolic gear single-stage main reducing gear, common bevel gear differential, universal drive half axle, ball cage universal joint with constant speed. The main reducing ratio i0=4.55, and the max. input torque is 900N•m.