air condition GREAT WALL HOVER 2006 Service Owner's Manual

CD Player and Air Conditioning System-10
Refrigeration of air conditioner failed
T rou ble Des crip tion s Ana l ysis o f the Cause
1.No pick -up o f com pressor 1.
fuse burned down , com presso r’s r elay dama ge
d
2. pressu re sw itch contac t d isco nn ected, short c ircu itor open circ uit o f the
ro utin
g
3. open circ ui t o f clutch’ s w indi ng
4. sw itch burned down
5. ma ster relay b urne d d ow
n
6.
s lid e o f the clut ch
7. beltof the c om presso r b roke ortoo l oose
8. comp ressor failur
e
9. sens or failur e(ju dg ed by read ing t he failu recode
)
10. insu ffic ient cold me dia, lowe r system p ress ur e(< 0 .97M Pa
)
11. system pressu re abov e 1 .37M Pa
12. water t em peratu re of the e ngine t oo high
13. V oltag e o f the clut ch below 7
V
2. Pick -up o f Com pressor 1.
norm
ally -ope n c ontact of the c om presso r’s r elay stuc k a nd seriou s leaka ge
of system cold me dia, system runn ing s hortof cold me di
a
2. no wind from the b lowe
r
R e frig eratio n of
ai r c ondition in
g
syst emfaile
d
3.no wind from the b lowe
r 1.
fuse burned down
2. mo tor b rush ofthe b lowe r dam aged
3. sw itch ofthe b lowe r dam aged
4. comi ng off o f d istrib utio n w ire c onnector s o r circu itdisc
onne cted
5. speed-ad justin g m odule d amaged
6. no wind from the b lowe r w hen a t high s peed, h igh- sp ee d r elay dama ge
d
Press down “Temp+” switch
Step 11: display “11”(set the temperature zone)
Action of the executor mechanism
:
M ode damper: defrost
Circulation damper: external circulation
Te mperature damper: cold end
Wind amount: the minimum
Compressor: off
Attention: during the inspection period fr om step 7 to step 11, the controlle r
will for cibly transit the output signal based on
the code number displayed on the integrated display screen to the functioned executor; the inspection must be done with
such
m ethods as visual inspection, listening to abnormal sound or touching the air vent by hand so as to judge whether
there is any improper operation.
T rouble Diagnosis and T roubleshooting of A i r Conditioning System
Air cooling system

CD Player and Air Conditioning System-11
b .Insufficient refrigeration output
T rou ble D escrip tion s Ana l ysis o f the Cause
I nad equate
re fri g eratio
n 1.
wind amount
is no rm al 1.
comp ress or wo rks n orma ll
y
(1 ) low- leve l p ressu reathigh -pressu reand l ow -pressu reside
s
a. bloc k o f exp ansion valv
e
b. op enness of expa nsion v alve too n arro
w
(2 ) h igh- leve l p ressu reathigh -pressu reand l ow -pressu reside
s
a. failur e t o h igh- vo ltag e p ip
elin e,flow not smooth
b. ma lfun ctio n o f the rm o resisto
r
c. op
enne ssof expa nsion v alve too w ide
d. too m uch r efrige ration oi
l
e. too m uch r efrige rant
f. po or heat diss ipatio n o f the cond ense
r
(3 ) p ress ure a t high- vo ltag e s ide t oo lo
w
a. low- pr
essu repipe line dama ged
b. bloc k o f low -pressu repipe lin
e
(4 )pressu reatlow- pr
essu reside too l ow
a. the e vapo rato r f rosted
b. bloc k o f expansion valv
e
c. low- pr
essu repipe line not smo oth
d. ma lfun ctio n o f the rm o resisto
r
(5 )pressu re at low- pr
essu re side some time norm al, s ometim es with negative pressu re,
mo istu re and i ce bloc k i n a irco oling s yste
m
(6 )neg ative p ress ur e a t low -pressu reside , p ressu reathigh -pressu reside too l ow , block ofai
r
co oling s yste
m
(7 )pressu reatlow- pr
essu reside too l ow , pressu reathigh -pressu reside too h i gh
a. intern al bloc k o f drier of f lui d r eservo ir
b. bloc k o f high- pr essu re pipe lin
e
(8 )pressu reatlow- pr
essu reside too h igh, pressu re athigh -press ure s ide t oo low
a. leak ag e o f the comp resso
r
b. dama ged v alve ofcomp resso
r
(9 )poo r h eat r ad iation ofcond enser d ue tosm all w ind a mo unt from t hecond ensing blow er
2. comp ress or wo rks i mp rope rl
y
(1 )int erna l m alfu nc tion ofcomp ress or
(2 )belt o f com pr
esso r too loos e o r slidi ng
(3 )fai lu re of elec trom agnetic c lutc
h
a. low vol tage ofpowe r suppl
y
b. mu tual interfer en ce ofthe s tato r and roto
r
c. ma lfun ctio n o f amp lifier s tabi lizi ng the i dle s peed
d. circ uit d isco nn ected, comi ng off o f the joi n ts
e. po or operatio n o f the sw itch and r elay
f. sh ort c ircu itan d o pen c ircu itof the r outing
g. po or earthi ng
3. othe r c ause
s
ba d s ealin g o f w agon

CD Player and Air Conditioning System-12
e .Precautions for the overhaul of air cooling system
When the air cooling system encounters the trouble, the cause for such trouble shall be analyzed inlightof trouble varieties,
followed with the examination and report work.
c. T he c ooling system some time s w orks wh ile some time s refus es towo rk.
T rou ble Des cri p tion s Ana l ysis o f the C ause
1.comp ress or wo rks n orma l l y 1.
ice b lock i nthe c ool i ng s yste
m
2. failu reof therma l resisto r o r tem perature sens ing b ul
b
3. poor contac t o f A /Cswitch
4. cond ensing blow erdama ge
d
T he c ooling system
so me time s p rodu ce
s
re f ri g eratio n e f f ect whil
e
so me time s not
.
comp resso r w orks i mprop erl y 1.s
lid e o f the clut ch
2. comi ng off o f the clut ch ’ s wind i n
g
3. poor earthi ng ofclut ch ’ s wind i n
g
d. N oise o f the air c oolin g s ystem
T r ou ble Des cription s Ana l ysis o f the C ause
No ise o f the air c ooling system too
lo ud N o
ise t oo l oud (1
) b elt t oo
loos e or w orn t oo mu ch
(2 ) f asteni ng screw o f mounting h olde r o f the comp resso
r
lo os en ed
(3 ) m ounti n g h olde r o f the comp resso r dam aged
(4 ) i nter na l p arts of the c om pr
esso r dam aged
(5 ) t oo mu chref ri g eratio n o ilor none
(6 ) .
slid e o f the clut ch
(7 ) . B e aring o f the clut ch runni ngshort o f o i lor dama ge
d
(8 ) . mo tor b earing ofthe b lowe r dam aged
(9 ) h olde r o f the blow erbrok en or
loos ened
(1 0) blad e o f the blow erbrok en or
loos ened
(1 1) . F rict io n o f the blow er’ s blad e w ith o ther comp onents

CD Player and Air Conditioning System-13
1 .CC6460K air conditioning system is designed with SD7V16 compressor, whose refrigeration oil type as
specified is SP-10P AG; hence application of other type of refrigeration oil may damage the parts and compo
nents of the compressor. When the
air conditioning system goes through maintenance and replacement of
parts, it should be added with new refrigeration oil, whose volume is listed as follows: the evaporator and
condenser: 30ml; the drier: 20ml; the pipeline: 10ml.
Addition of refrigeration oil can be available with two methods: The direct addition and the vacuum suction
2 .D irect addition method
a. remove the oil filler plug and fill with the specified SP-10P AG refrigeration oil.
b. observe through the hole of oil filter plug and rotate front plate of clutch to make the piston connecting rod right positio n in the
center of the hole of oil filter plug.
c. insert the dipstick along the right side of piston connecting rod till the top of dipstick touches the case of the compresso
r
d. pull out the dipstick and examine the graduations (grooves) of refrigeration oil, the readings shall be within the range of 4-6
scales
.
e. screw firmly the oil filter plug with the fastening torque of 14.7± 4.9N
.m
3. Vacuum suction method:
Firstly pump out the refrigerating system to the vacuum of 0.2x105Pa, and then fill with the specified 0.2x10 5 Pa refrigeration oil;
the detailed steps are as follows:
a. switch off the high-pressure manual valve and the auxiliary valve.
b. dismantle the high-pressure side hose from the manifold pressure gauge and insert it into the oil cu
p
c. open the auxiliary valve and have the refrigeration oil sucked into the refrigerating system from the oil cup.
d. when the refrigeration oil in the oil cup is almost pumped out to the vacuum, then immediately turn off the auxiliary valve
to
prevent the air from being sucked into the system
.
e. secure the hose adapter at high-pressure side to the manifold pressure gauge, start the vacuum pump and turn on the high-
pressure manual valve, then turn on the auxiliary valve to pump the system to the vacuum state of 0.2x10
5Pa, keep such state
for 15mins so as to discharge out the air flowing into the system along with the oil.
V ol ume of Refrigeration Oil Addition and its Methods
2.ai r h eating system
T r oubl e Cau ses o f the trouble
H e ati n g n otsuppl i ed or
no t s
uf f i cientl y suppl i ed 1.
blow erof air c ondition erf ai l u re 2.relay o f the blow erdamage
d
3. heati n g w ater pipe bloc k e d 4 . coo ling water p i pe b lock ed
5. col d/h ot damp erexecutor damage d 6. ins
uf f i cien t c oo ling l iqu id
N o rotation ofblow er 1.
f use burned
down orpoor contac t o f the switch
2. mo tor o f the blowe r burne d d ow
n
3. op en circ uit o f h igh- sp eed relay o f the blow er
4. speed-ad j usti n g m odule d am aged
5. short c ircu it
leak age o f w ater W ater p ipe o f ai rhe ati n g a ged, inse cu re j oi nt
O v erhe at 1.
speed-ad j usti n g r esi sto r o f the f an d am aged
2. col d/h ot damp erexecutor damaged
I nsu f f i cien t h otair
vo lume f or d efro stin
g 1.
mode executor dama ge
d
2. f al li n g o f fof the d riv e ro
d
3. damp ernot in p osi ti o
n
4. air v ent b l ock ed
5. inad equa te heatin g s
upply
6. inst
alla tion ofwind tunn elno t fi t
7. circ uit d i sco nn ecte
d

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

Safety airbag-10
1. Extinguishments of safety airbag system alarm lamp
Troubleshooting
Extinguishments or normal-light of alarm lamp
NO . Troubleshooting item Description
1 T he warning la mp of safety a irbag
system is not displayed. Safety airbag system warns circuit failure
2 T he warning la mp of safety a irbag
system is light normally. Safety airbag system warns circuit failure or external
failure.

1 Extinguishments of safety airbag system alarm lamp
Test status Safety airbag system warns circuit failure.
Possible causes No voltage (fuse shutoff)
Combined instrument failure
Failure of wiring harness between instrument cluster and ECU unit

Diagnostic procedure
When first carry out failure test, joggle the wiring harness and plug to test whether there is periodical bad contact in the circuit, if
it so, please confirm whether the plug, terminal and wiring harness well connected and in good condition. If it is not any of previous
cases, operate according to the following steps.
Procedure Te s t Operation
Ye s Place the ignition switch in LOCK
position followed by next step
1 Test other wiring harness and instrument cluster
indicator lamp
·place the ignition switch in ON position
·light other alarm and indicator lamps No Test the instrument cluster power-supply
system and grounding s ystem (fuse), then
go to step 5.
Yes Next step
2 Bulb test
Warning:
Incorrect handling with the safety airbag system
units will cause the safety airbag’s improper
release and pretension of safety belt, which will
lead to serene accidents. Please read safety airbag
service warning before handling the safety airbag
units.
·Place the ignition switch in LOCK position。
·shut off accumulator negative line and keep the
status for at least 60 seconds.
·Remove the combined instrument.
Test the connection between the two
corresponding stitches of safety airbag alarm lamp No





Rep la ce th e b ulb of a larm la mp.

Safety airbag-12
Begin the test with diagnostic communication with special diagnostic device (X-431 diagnostic tester) and ECU
to find out the failure causes, do the next test providing communication is not successful.
Procedure Te s t Operation
Yes Next procedure
1 Test the battery
Test the battery voltage
Is the voltage higher 9V? No Insufficient battery supply.
Test the charging/discharging
system, then go to step 5.
Yes Next step
2 Test the wiring harness connection between ECU and
combined instrument.
Place the ignition switch in LO C K position。
Shut off the battery negative.
O pen the central channel guard plate.
Shut off the instrument combined connector clip
Connect the negative of battery
Place the ignition switch in ON position.
Check whether the instrument connector clip terminal
voltage is 12V(power supply and instrument line) No Check the circuit and continue the
operation according to step 5.
Yes Next step
3 Place the ignition switch in LO C K position。
Check the connection of corresponding terminals between
instrument connector clip and diagnostic interface
(diagnose the two ends of K-line) No Repair or replace the wiring
harness and continue according to
step 5
Yes Next step
3 Make sure the shutoff of accumulator negative line and
keep the status for at least 1 minute.
Shut off ECU connector clip
Shut off the instrument cluster plug.
Connect the ECU plug terminal 5,7,9 and instrument
cluster plug? No Replace the wiring harness and
step 5
Yes Replace ECU
4 Remove EC U to check the condition of term inal and
whether the shorting bar is broken.
No Reconnect EC U connector clip
and next step.
Yes Troubleshooting followed by the
explanations to customers upon
the repair ing pro ced ur e.
5
Make sure that the failure will never reoccur after
repairing.
Place the ignition switch in LO C K position。
Shut off accumulator negative line and keep the status for
at least 1 m in ute.
Connect all ECU plugs
Connect the driver’s side safety airbag combined
instrum ent p lug
Connect the passengers’ side safety airbag combined
instrum ent p lug
Connect the driver and passengers’ side pretension safety
belts plugs.
(Vehicles with pretension safety-b elts)
Connect clock spring plug
Connect the accumulator negative line
Place the ignition switch in ON position
Does the safety airbag alarm lamp work functionally? No Retest the failure symptoms;
repeat from step 1 if the failure
reoccurs.