lock GREAT WALL SAFE 2006 Service Manual

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-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-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

B0-3
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

B0-7
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.

B0-8
Assembly of Front Door
1. Coat the MP lubricant on the parts before mounting.
(a) Coat the MP lubricant on the sliding face and the gear of
glass elevator.
Notice: Do not plaster the MP lubricant on the spring of
glass elevator.
(b) Plaster the MP lubricant on the sliding face of door lock.
2. Mount the outdoor handle with lock barrel and the door
lock;
(a) Mount the lock barrel on the outdoor handle with spring
snapping ring;
(b) Use two bolts to mount the outdoor handle and the lock
barrel;
(c) Mount the door lock with three screws;
(d) Connect the outdoor handle to the control lever.
3. Mount the lock ring inside vehicle
Mount the lock ring inside of vehicle and connect the control
lever.
4. Mount the lower rear glass guide track,
5. Mount the lower front glass guide track;
6. Mount the glass elevator:
(a) Put in the elevator through the auxiliary hole;
(b) Mount on the three fixing bolts of elevator. (manually
operated)
Mount on the four fixing bolts of elevator (electric)
(c) Mount the small sliding track, and screw up the bolts of
small sliding track temporarily.
7. Mount the glass groove on car door;
8. Mount the car door and window glass;
Put the glass in the car door cavity, and then use two bolts to
fix the glass on the elevator. Vehicle Body
Front Door

B0-10
Rear Door (
)
Element Figure
glass
glass channel
Outer auchiglass bracket and glass gasket
door limiting
devicedoor hinge
electric switch
interior trim panel
of electric door (Dr)
interior trim panel
of electric door manual interior
trim panel
sleeve
snapping ring elevator handle door lamp inner cliplower rear glass
guide track
small sliding trackdoor lock assembly
lock clipoutdoor handle
lower dust
strip
indoor handle(Dr) lock ring
Dr SL SK SYVehicle Body
Rear Door
(SL,SY,SK)