GREAT WALL PEGASUS 2006 Service Manual

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

AC-20Air-Conditioning System
Refrigerant Pipe
Refrigerant pipe
On-vehicle inspection
1. Check the pipelines of each part to see whether there is
leakage:
Make the inspection with the gas leakage detector and, if
necessary, change them.
2. Check the clamping parts of the pipelines to see whether
there is looseness;
Make a new fastening or change as requirement.
Change of refrigerant pipeline
1. Exhaust the refrigerant;
2. Change the damaged pipe or hose
Remark: the opened joint should be sealed right away with
cork so as to prevent the humid from entering into the system.
3. Screw up the O-ring seal joint and threaded joint according
to the Tightening moment;
4. Vacuumize the air-conditioning system:
Vacuumizing time:
Dr SL SK SF SJ
Vacuumize for 20min and main-
tain the pressure for 30min;
SY
Vacuumize for 30min and maintain the pres-
sure for another 30min.
5. Inflate the refrigerant in the air-conditioning system and
check the system 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

B0-1
Vehicle Body
Page
Introduction ................................................................. BO-2
Engine cover ............................................................... BO-3
Front door .................................................................... BO-4
Rear car Door .............................................................. BO-10
Body collision avoidance adhesive strip ...................... BO-20
Wheel-trims ................................................................. BO-24
Wheel-trims wrapping angle and exterior trim panel ... BO-26
Front Windshield ......................................................... BO-32
Side-window glass ...................................................... BO-37
Rear-door glass ........................................................... BO-40
Rear windshield ........................................................... BO-41
Load-compartment baffle ............................................ BO-43
Tail door ....................................................................... BO-45
Instrument panel ......................................................... BO-50
Safety belt ................................................................... BO-57
Seat ............................................................................. BO-60
Spoiler ......................................................................... BO-63
Luggage rack .............................................................. BO-65
Reserve tire bracket .................................................... BO-66
Body dimension ........................................................... BO-68
Frame dimension ........................................................ BO-78
BO

B0-2
General Introduction
In case there is damage to body and/or part, protection measures
should be taken first to prevent the vehicle from damaging before
repairing them.
Example:
1. Protection adhesive strap should be contacted on the relative
part of body when conduct the disassembling and mounting
operation.
2. When prizing the body parts with screwdriver or scraper, those
body parts head or the edge of screwdriver or scraper should
be wrapped with adhesive strap to prevent paint layer and the
body from damaging.
If the antirust is damaged when repairing other parts, it should be
recoated in time.
Example:
1. In case the sealing agent, paint layer or priming coat on the
body is damaged due to peel-off or crack, etc. the correspond-
ing antirust shall be used for reparation.
2. If the hinge or plate is loosened or torn down, the antirust
should be re-coated after repairing them.
adhesive strap
Vehicle Body
General Introduction
peel-off
crack
anti-rust agent

B0-3
Engine cover
Adjustment of engine cover
Remark
as the centering bolt are used as the fixing bolt to fix the
hinge of engine cover, the engine cover cannot be adjusted when
mounting, in such case, the bolt with a washer should be used to
substitute the centering bolt.
1. Adjust the engine cover in front-back and right-left
direction.
Loosen the hinge bolts on engine cover to adjust the engine
cover.
2. Adjust the engine cover leading edge vertically;
Rotate the buffer block to adjust the engine cover.
3. Adjust the lock clips on engine cover Loosen the bolt to
adjust the lock clip. Vehicle Body
Engine Cover
centering bolt
bolt with washer

B0-4Vehicle Body
Front Door
Front door
Element figure
(glass)
glasschannel
outer auchi
inner tri-angle trim panel
door limiting device
door hinge
indoor handle
seal strip on
door plate
electric switch
and panel
interior trim panel
of electric door
(Dr)
interior trim panel
of electric door
(SF) interior trim panel of
electric door
sleeve
snapping ring elevator handle
(SL SK SY SJ)
door lamp
inner clip
lower rear glass
guide track sliding channelsmall sliding track door lock assembly
lower front glass
guide track lock cliplock ringlock barreloutdoor handle
manual interior
trim panel(Dr) snapping ring
glass bracket and glass gasket
rear vision mirror

B0-5
Adjustment of front door
1. Adjust the car door in the front-back and vertical direction;
Adjust the car door under the condition that the bolts of body
side hinge are loosened.
2. Adjust the car door in left-right and vertical direction
Adjustment should be made after the bolts of side hinge of
body are loosened.
3. Adjust the clip of door lock:
(a) Check whether the car door assembly and the match of
door lock are adjusted correctly.
(b) Loosen the lock clip lightly to mount the screws and tap
the lock clip with hammer to adjust their positions.
(c) Screw off the fixing screws of lock clip.
Disassembly of front door
1. Tear down the elevator handle (Dr)
Pull out the snapping ring of spring with dishcloth and tear
down the elevator handle and the sleeve.
2. Tear down the indoor handle
3. Tear down the inner triangle trim panel;
Loosen the clip open with a screwdriver to tear down the inner
triangle trim panel.
Notice: before using the screwdriver, wrapping the
screwdriver head with adhesive strap.
4. Tear down the rear vision mirror;
Tear down the three screws and rear vision mirror. Vehicle Body
Front Door

B0-6
5. Tear down the interior trim panel of car door:
(a) Tear down the inner clip bolts and the inner clip.
(b) Tear down the door lamp bolts and the door lamp;
(c) Insert the screwdriver into seam between fixing clip and
interior trim panel of car door to loosen the interior trim
panel.
Notice: before using the screwdriver, wrap its head with
adhesive strap.
(d) Tear down the interior trim panel of car door.
(Dr SF)
(a) Tear down the inner clip bolts and the inner clip;
(b) Tear down the door lamp bolts and the door lamp;
(c) Tear down the electric switch and panel.
(d) Insert the screwdriver into the seam between fixing clip
and the interior trim panel of car door to loosen the
interior trim panel.
Remark: use the adhesive strap to wrap the screwdriver
head before using.
(e) Tear down the interior trim panel of car door.

SL SK SY SJ)
(a) Tear down the door lamp bolts and the door lamp;
(b) Tear down the electric switch and the panel;
(c) Tear down the screw covers and screws on the indoor
trim panel
(d) Insert the screwdriver into the seam between the fixing
clip and the interior trim panel of car door to loosen it.
Notice: use the adhesive strap to wrap the screwdriver
head before using.
(f) Tear down the interior trim panel of car door.manually operated indoor plate
inner plate of electric door (type A)
inner plate of electric door (type B)12 clips
ten clips
four sets of bolt and nut
Vehicle Body
Front Car Door
12 clips
6. Tear down the outer auchi
Loosen the clip along the edge of paneling to tear down the
outer
7. Tear down the door and window glass;
(a) Tear down the fixing bolts in the two glass sliding-
grooves.
(b) Pull up the glass to take it down.
8. Tear down the glass groove on car door.

B0-7
Change of Glass
(Dr SF)
1. Tear down the glass bracket with screwdriver or similar
tool;
2. Coat the black glue on the inside of glass bracket liner;
3. Tap the glass bracket with rubber hammer to encase it in.
(SL SK SY SJ)
1. Tear down the bolts on gear plate with pliers or similar
tool;
2. Tear down the bolts of glass bracket of car door to take
out the glass. Vehicle Body
Front Car Door170mm
Dr. SF
SL. SK. SY. SJ
9. Tear down t the lower rear glass guide track:
Tear down the bolts and guide track.
10. Tear down the lower front glass guide track;
Tear down the bolts and guide track.
11. Tear down the glass elevator:
(a) Tear down the two fixing bolts of small sliding track;
(b) Tear down the fixing bolts of three elevators (manually
operated)
Tear down the fixing bolts of four elevators. (electric)
(c) Tear down the elevator through the auxiliary hole.
12. Tear down the lock ring inside the vehicle;
Disconnect the control lever to tear down the lock ring inside
the vehicle.
13. Tear down the door lock and outdoor handle with lock
barrel;
(a) Disconnect the control lever from the outdoor handle
with lock barrel.
(b) Tear down the 3 bolts and door lock.
(c) Tear down the two bolts and outdoor handle with lock
barrel.
(d) Tear down the spring snapping ring and lock barrel.