2006 GREAT WALL HOVER air conditioning

CD Player and Air Conditioning System-14
Pumping Out of A i r Conditioning System to the Vacuum and Addition of Refrigeration Oil
Connect the manifold pressure gauge with the pipe of air conditioner (compressor) and the multi-purpose adapter of the vacuum
pump for the purpose of pumping out of the system to the vacuum state.
Before pumping out to the vacuum, turn on the high-pressure and low-pressure valve of the
manifold pressure gauge and the end valve
(if provided) of the vacuum pump, then press the button ON to start the vacuum pump, the duration shall be more than 20 minutes
.
When the reading of manifold pressure gauge is -760mmHg or below, turn off the high-pressure and low-pressure valve (if opened)
,
and press the switch to turn off the vacuum pum
p.
1 . check the air tightness
Continue to check the pressure reading of the manifold pressure gauge after turning off the vacuum pump.
If the pressure reading remains unchanged within 20 minutes after the vacuum pump stops running, then it indicates that th
e
refrigerating system has no leakage, the operator can proceed with next work; while change of the reading indicates that the
system has the leakage. Launch the examination and pump out to the vacuum after the leakage is fixed.
2 . Injection of the refrigerant
When the air tightness of the system is verified correct, connect the refrigerant reservoir (or gas bottle) with one end of the yellow
a ir-charging hose, while other end of yellow air-charging hose is connected with the liquid injection port in the middle of the
manifold pressure gauge. Ensure that the refrigerant reservoir is connected firmly with the nut of air-charging hose, then turn on
the valve of refrigerant reservoir; at this time, the high-pressure and low-pressure is closed, use a tip screw driver or other
similar
tools and press the by-pass valve spool for 1~ 2 seconds to discharge out the air in the air-charging hose and the manifold
pressure gauge.
low p ressure
high pressure
manifold pressure gauge
quick coupler
l ow-pressure pump
high-pressure pipe
quick coupler
quick
coupler
red
blue
vacuum pum
p
manifold pressure gauge
low pressure gauge high
pressure gauge
Red
blue
yellow
yellow
4. Attention:
a. when a new compressor is used to substitute for the old one, the oil must be released to some extent that its oil volume is the
same as that of old compressor so as to avoid the influence over the refrigeration effect due to too much oil.
b. when an old or repaired compressor is employed, the volume of the refrigeration oil in the compressor must be kept the sam
e
as that of the replaced
compressor.

CD Player and Air Conditioning System-15
Turn on the high-pressure valve on the manifold pressure gauge and inject the refrigerant to the system from high-pressure pipeline.
At this time, the attention shall be given to the readings of high-pressure meter and low-pressure meter, and make sure that these two
pressure all go up. If the refrigerant is being injected while the pressure does not go up, then the joints of the pipeline may be loosened
or the seals damaged, inject the refrigerant once more after finding out the cause and the fixing. When the increase of pressure stops,
turn off the high-pressure valve of the manifold pressure gauge and then start the engine
.
Operate the switch in a way as follows:
Turn the switch of air conditioner to “ON”
Regulate the temperature controller to the coolest position,
Enable the air conveying to the maximum,
Select the internal air circulation 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 or gas bottle (have the refrigerant injected into the refrigerating system in a gas state), turn on the
low-pressure valve of the manifold pressure gauge.
When the compressor is at work, please do not turn on the high-pressure valve.
Before checking the refrigeration level, please confirm the injection volume of the refrigerant specified for air conditioning system.
When injecting the refrigerant, carefully observe the high-pressure side of the manifold pressure gauge and the flow condition of
the refrigerant (clear, foaming or turbid), all these could be viewed through the inspection window, by which the moment of stop
injecting the refrigerant can be reasonably judged(turning off the low-pressure valve).
air washingoff
off
tip screw driverred
yellow blue
refrigerant reservoirhigh-pressure low-pressure
off
low-pressure pipe
high-pressure pipe
refrigerant reservoiryellowred blueon

CD Player and Air Conditioning System-16
refrigerant reservoir high-pressure pipelow pressure
high pressure
yellowred blueon on
low-pressure pipe
When judging the injection volume of the refrigerant, please make the settings based on the following working conditions:
Water tank temperature of the engine: stable
Speed of the engine: normal free running speed
Switch of air conditioner: ON
Switch of the 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 pipeline
a. Before installation of parts and components, the negative pole of the accumulator must be disconnected.
cut off
b. When the air entries of the refrigerating system, water tank of the engine and the air conditioner are opened, please make sure that
all openings are capped to prevent the penetration of the dust, foreign matters or water.
protective cap protective cap
protective cap must be installed.

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


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

Appendix B-13
Auto gear oil GL-5 140 Transmission L 1.4
For the exported
vehicle for extremely
hot areas
Auto gear oil GL-5 140 Transfer case L 2.7
For the exported
vehicle for extremely
hot areas
Auto gear oil GL-5 140 Rear axle L 2.9
For the exported
vehicle for extremely
hot areas
2.9L=5.14PTS
Auto gear oil GL-5 140 Front axle L 1.4
For the exported
vehicle for extremely
hot areas
1.4L=2.46PTS
Auto gear oil GL-5 75W/90 Front axle L 1.4
Auto gear oil GL-5 80W/90 Front axle L 1.4 1.4L=2.46PTS
Glass adhesive HV3 Front windshield glass L 0.6
Glass adhesive 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 windows L 3
Refrigerant R134a Air-conditioning system Kg 0.73



















Non-metal Materials Consumption Table.

Name Brand, specification and
technical condition Utility Measuring
unit Quantity Note
Engine lubricating
oil SL 10W-40 Oil pan L 4.3 Available for 4G64S4M
engine
Engine lubricating
oil SL 5W-30 Oil pan L Suitable
Available for 4G64S4M
engine and exported
vehicles for extremely
cold areas.
Glass activator VP04604 Glass L Suitable
Lithium base
grease Grease HP-R Front axle,
chassis parts Kg Suitable
Industrial
Vaseline
Seat support,
accumulator
points
Kg Suitable