2006 GREAT WALL SAFE plug

AC-2Air Conditioning System
Introduction
In case the liquid refrigerant enters into the eye or touches the
skin, the following measures shall be taken:

Wash the part where is touched by the refrigerant with a
great deal of water.

Coat the skin with the clean Vaseline.

See the doctor or go to the hospital for treatment; and

Do not try to cure it yourself.
General Introduction
1. Take notice when handling refrigerant General Introduction
(a) Do not handling with refrigerant in the closed room or
near to open fire.
(b) Safety goggles shall be worn when handling
(c) Be careful to avoid the liquid refrigerant from entering
into your eye or touching you skin.
waterair
dust
ÅçåÇÉåëÉêplug
2. Take notice when changing the parts of refrigerant pipes:
(a) The refrigerant shall be exhausted gradually before
changing.
(b) The dismantled parts shall be covered with plug right
away so as to prevent the water or dust from entering into
the system.
(c) Do not store the condenser or liquid tank under the
condition that the plug has been uncovered. and
(d) Refrigerant shall be exhausted before installing the new
condenser, because the refrigerant, if not exhausted, will
eject out in gaseous form with the lubricant oil when the
plug is moved away.
3. Take notice when fastening the connection parts:
(a) Spread a little lubricant oil at the matching position of the
O-type ring to fasten the connection and avoid of gaseous
refrigerant leakage.
(b) Fasten the nut with two spanners so as to avoid of the pipe
deformation.

AC-10Air-conditioning System - Troubleshooting
Troubleshooting
TroubleReparation approachesPage
Lack of cold airNon-pull-in performance of electromagnetic clutch:
(a) Break of ignition switch and fuse;
(b) Trouble of electromagnetic clutch;
(c) Trouble of A/C switch;
(d) Wiring or grounding trouble;
(e) Lack of refrigerant; and
(f) Trouble of pressure switch.
Abnormal operation of compressor:
(a) Looseness or break of driving belt;
(b) Compressor trouble;
Expansion valve trouble;
Systematic leakage;
Liquid tank fusible plug melting or filtering
screen blocking;
Non-work of air blower:
(a) Failure of A/C switch;
(b) Failure of air blower motor, and
(c) Wiring failure.Change the fuse and check to see whether
there is short circuit;
Check the electromagnetic clutch;
Check the A/C switch;
Repair it as requirement;
Check the refrigerant pressure;
Check the pressure switch;
Adjust or change the driving belt;
Check the compressor;
Check the expansion valve;
Conduct lubricating test for the system
Check the liquid tank;
Check the A/C switch;
Check the air blower motor;
Conduct reparation as requirement.
Inconsecutive
cold airElectromagnetic valve slip
Failure of expansion valve;
Wiring or connecting failure;
Over water content in systemCheck the electromagnetic clutch;
Check the expansion valve;
Make reparation as requirement.
Reclaim the water first, then exhaust the
system to vacuum and inflate in the refrigerant.
Cold air occurs in
high-speed conditionBlocking of radiating face of condenser;
Driving belt slip;
Compressor failure;
Insufficient or redundant refrigerant;
Air existing in systemCheck and wash the condenser
Check and change the driving belt;
Check the compressor;
Check the refrigerant quantity;
Vacuumize the system and inflate
the refrigerant;
Insufficient
cold airCondenser blocking;
Driving belt slip;
Electromagnetic clutch failure;
Compressor failure;
Expansion valve failure;
Insufficient or redundant refrigerant;
Air existing in system;
Redundant compressor lubricant;
Liquid tank blockCheck the condenser;
Check and change the driving belt;
Check the electromagnetic clutch;
Check the compressor;
Check the expansion valve;
Check the refrigerant quantity;
Reclaim the air, then vacuumize the sys-
tem and inflate the refrigerant;
Check the compressor lubricant quantity;
Check the liquid tank
Evaporator blocking or frosting
Air leakage in cooling device or air
pipeline;
Air inlet blocking;
Air blower motor failure;Clean the evaporator radiating rib
or filter;
Make reparation as requirement
Make reparation as requirement
Change the air blower motor.
Page AC-4 to 7
Page AC-12
Page AC-4 to 7
Page AC-11
Page AC-13
Page AC-12
Page AC-16
Page AC-14
Page AC-4 to 7
Page AC-12
Page AC-16
Page AC-4 to 7
Page AC-15
Page AC-12
Page AC-12
Page AC-12
Page AC-16
Page AC-11
Page AC-14
Page AC-18
Page AC-20
Possible causes
Page AC-15
Page AC-13
Page AC-12
Page AC-11
Under-speed cold air

AC-14Air-Conditioning System
Liquid Tank
Liquid Tank
Check to see whether there is leakage in observation window,
fusible plug and joints;
Conduct the inspection with the gas leakage detector and, if
necessary, repair or change the liquid tank.
Dismantle of Liquid Tank
1. Exhaust the refrigerant;
2. Tear down the two liquid pipes from the liquid tank;
Remark: the opened joint should be plugged with cork so as to
prevent the humid air from entering into the system.
3. Tear down the liquid tank from the tank bracket.
Mount of Liquid Tank
1. Mount the liquid tank on the liquid tank bracket;
Remark: the cover of joint should not be take down before
connecting the pipe;
2. Connect the two liquid pipes to the liquid tank;
Tightening moment
(See page AC-8)
3. Vacuumize the system and inflate the refrigerant in;
Vacuumizing time:
Dr SL SK SF SJ
Vacuumize for 20 min and main-
tain the pressure for 30min;
SY
Vacuumize for 30 min and maintain the pres-
sure for 30min.
4.
Dr
(600-650)g
SL
700
0g
SK SJ
560
0g
SF
(700-720)g
SY
850
0g
liquid pipe
condenser
liquid tank
liquid pipe
liquid pipe liquid pipe
liquid tankcondenser
SL SK SY SJ
Dr SF

AC-15Air-Conditioning System
Condenser
Condenser
Condenser dismantle
1. Check the radiating ribs of condenser to see whether
there is blocking or damage;
if the radiating rib is blocked, wash it with water and dry it with
compressed air.
Notice: be careful not to damage the radiating rib;
2. Check the condenser joint to see whether there is leakage;
Make reparation as requirement;
Condenser disassembly
1. Exhaust the refrigerant;
2. Tear down the median mesh and the bonnet lock bracket;
3. Disconnect the outlet hose from the entrance joint of
condenser;
4. Tear down the liquid pipe from the outlet of liquid tank;
Remark: the opened joint should be plugged with cork so as to
prevent the humid air from entering into the system.
5. Tear down the condenser:
Tear down the two bolts.
Condenser mount
1. Mount the condenser
Screw on the two bolts so that the rubber washer contacts the
mounting flanges correctly.
2. Connect the liquid pipe to the liquid tank and the outlet
hose to the condenser.
Tightening moment
(See page AC-8)
3. Mount the median mesh and the bonnet lock bracket;
4. vacuumize the air-conditioning system;
Vacuumizing time:
Dr SL SK SF SJ
vaccumize for 20min and main-
tain the pressure for 30min;
SY
vaccumize for 30min and maintain the pres-
sure for another 30min.
5. Inflate the refrigerant in the air-conditioning system and
check to see whether there is air leakage:
Dr
(600-650)g

SL
700
0g
SK SJ
560
0g
SF
(700-720)g
SY
850
0g
liquid pipe
condenser
liquid tank
liquid pipe
condenser
liquid tank
SL SK SY SJ Dr SF
liquid pipe outlet hose
liquid pipe

AC-16Air-Conditioning System
Refrigeration Device
Refrigeration device
On-vehicle inspection on expansion valve
1. Check the gaseous refrigerant quantity in the refrigeration
cycle;
2. Mount the manifold gauge;
(see Page AC-12)
3. Run the engine;
Run the engine at a speed of 2000 r/m for five minutes.
4. Check the expansion valve;
If the expansion valve is blocked, the LP readings will reduce
to 0 kPa, otherwise, the valve is normal.
Disassembly of Refrigeration Device
1. Disconnect the cathode lead from the storage cell;
2. Exhaust the refrigerant;
3. Tear down the suction pipe from the entrance joint of
refrigeration device;
4. Tear down the outlet pipe from the entrance joint of
refrigeration device;
Remark: the opened joint should be sealed with the cork to
prevent the humid air from entering into the system.
5. Tear down the insulation rings from the inlet and outlet
joints.
6. Tear down the right glove box (SY rear air-conditioner:
tear down the interior trim panel at left rear side).
7. Disconnect the plugging element;
8. Tear down the refrigeration device;
Tear down the three nuts.
refrigeration device
SYinterior trim panel
at left rear side
rear evaporator

AC-18Air-Conditioning System
Evaporator
SYrear evaporator
upper housing
air cover
lower housing temperature controller air blowerevaporator core air pipeheat-sensitive resistance
1. Tear down the evaporator housing:
(a) Disconnect the plugging element;
(b) Tear down the two clipes;
(c) Tear down the four screws;
(d) Tear down the upper cluster housing;
(e) Tear down the HP/LP pressure pipe rubber washers; and
(f) Tear down the lower cluster housing.
2. Tear down the expansion valve:
(a) Tear down the liquid pipe from the entrance joint of
expansion valve;
(b) Tear down the sealing washer and thermal bulb from the
suction pipe of evaporator;
(c) Tear down the expansion valve.
expansion valve
HP pipe LP pipe

AC-19Air-Conditioning System
Refrigeration Device
inspectionofevaporator
1. Check the radiating ribs of evaporator to see whether there is
block.
If the radiating rib is blocked, clean it with the compressed air.
Notice: do not wash the evaporator with water.
2. Check the joint to see whether there is crack or scrape.
Make reparation as requirement.
Mount the evaporator parts:
(a) Connect the expansion valve to the entrance joint of evaporator
and screw up the nuts.
Remark: Carefulness should be put on the O-ring seal.
(b) Mount the bracket on the suction pipe with thermal sensor;
(c) Connect the liquid pipe to the entrance joint of expansion
valve and screw up nuts.
(d) Mount the lower cluster housing on evaporator.
(e) Mount the upper cluster housing;
(f) Mount the four screws;
(g) Mount the two clipes;
(h) Mount the HP/LP pressure rubber washer; and
(i) Connect the plugging elements;
1. Mount the refrigeration device.
Mount the refrigeration device with three nuts.
2. Connect the plugging elements;
3. Mount the right glove box (SY rear air-conditioner: mount the
interior trim panel at left rear side).
4. Mount the insulation ring on the inlet and outlet joints;
5. Connect the liquid pipe to the outlet joint of refrigeration device;
Tightening moment
(see page AC-8)
6. Connect the suction pipe to the outlet joint of refrigeration pipe;
Tightening moment
(see page AC-8)
7. Connect the cathode lead to the storage cell.
8. Vacuumize the air-conditioning system:
Vacuumizing time:
Dr SL SK SF SJ
vacuumize for 20min and maintain the
pressure for 30min
SY: vacuumize for 30min and maintain the pressure for
another 30min.
9. Inflate the refrigerant in the air-conditioning system and
check to see whether there is air leakage;
Refrigerant quantity:
Dr
(600-650)g
SL
700
0g
SK SJ
560
0g
SF
(700-720)g
SY
850
0g
expansion valveHP pipe LP pipe

B0-9
manual indoor plate
Electric indoor plate (Type A)
ten clips
12 clips
Vehicle Body
Front Door
12. Mount the interior trim panel of car door:

Dr)
(a) Connect the handle to the control lever first, then pull it
out from the indoor handle hole.
(b) Fix the clip by tapping to encase the interior trim plate of
car door in the corresponding hole of car door interior
panel.
(c) Use one screw to mount the inner clip.

Dr SF)
(a) Connect the handle to the control lever first, and then pull
it out from the indoor handle hole.
(b) Fix the clip by tapping to encase the interior trim panel in
the corresponding hole of car door interior panel
(c) Mount the inner clip with one screw; and
(d) Mount the electric switch and panel.

SL SK SY SJ)
(a) Connect the handle with the control lever first, then pull
out it from the indoor panel handle.
(b) Connect the plugging elements.
(c) Fix the clip by light tapping to encase the interior trim panel
of car door in the corresponding holes on indoor panel.
(d) Mount the inner clip with two bolts;
(e) Mount the four screws to fasten the interior trim panel of
car door, and cover the nuts.
(f) Mount the electric elevator switch.
13. Mount the indoor handle:
(a) Push the indoor handle into the car door paneling and
make it slide backward.
(b) Screw on the screws;
14. Mount the elevator handle (Dr)
Mount the paneling and elevator handle with spring snapping
ring under the condition the car doors and windows are closed
completely as shown in drawing.
12 clips
9. Adjust the car door and window glass;
Adjust the balance arm upwardly or downwardly until the
dimensions of A and B shown in drawing are equal, and then
fix the balance arm.
10. Mount the outer
Encase the claw of clip into the paneling seam and press the
outer on the paneling.
11. Mount the rear vision mirror
inner panel of electric door (type B)
four sets of bolt and nut
front