air conditioning GREAT WALL HOVER 2006 Service Repair Manual

Preface
Table of Contents
Instruction How to use the manual
Chapter 1 Overview of the entire car (parameters)
Chapter 2 Fuel supply system and exhaust air system
Chapter 3 Clutch
Chapter 4 Transmission
Chapter 5 Automatic transmission
Chapter 6 Driving shaft
Chapter 7 Suspension and vehicle axle
Chapter 8 Brake (ABS)
Chapter 9 Steering
Chapter 10 Car body electric appliance
Chapter 11 CD player and air-conditioning system
Chapter 12 Safety airbag
Annex:
Important components guarantee and requirement
List of non-metal material consumption
Special tools
D Important working components and tightening torque
E Electric wiring diagram

Overview of the entire car-1
Chapter 1
Overview of the entire car
Basic parameter....................................................... 2
Engine..................................................................... 4
Air inlet system........................................................ 5
Exhaust air system................................................... 5
Fuel supply system................................................... 5
Cooling system........................................................ 5
Clutch..................................................................... 5
Transmission............................................................ 6
Drive shaft............................................................... 6
Front shaft/axle........................................................ 6
Rear axle................................................................. 6
Wheel tyre............................................................... 6
Suspension.............................................................. 7
Frame..................................................................... 7
Steering system........................................................ 7
Brake system........................................................... 8
Car body................................................................. 9
Electrical system.................................................... 10
Air-conditioning system …………………..............12

Air-conditioning system
The structure and parameter of the air-conditioning s ystem is shown in table 8.
Table 8 The structure and parameter of the air-conditioning system

Serial No. Item Structure and Paramet er
1 Structure and
shape

Front and rear heating and cooling air conditioner, vapor compression type
cooling, hot-wat er heating

2 Performance and
parameters

Refrigerating capacity 3.5kW, heat exchange capacity 3.5kW, fan capacity
350m
3/h
3 Operation
Control board button type operation, temperature auto control, air door micro
motor drive, the temperature in the car can be controlled automatically, the
fanning position mode, heating/ cooling mode, air int ern/external cycling mode
and wind speed and t emperature can b e selected and adjusted

4 Refrigerant R134a
5 Compressor SD7V16 variable capacity compressor, with a maximum capacity of 160ml
6 Condenser Parallel stream mode structure, flat pipe thickness of 26mm
7 Evaporator Two box es structure, cascading evaporator, F expansion valve, centrifugal
blower

8 Drying fluid
collector
External diameter φ60.5mm
9
Refrigerating
pipe and
wa r m wa t er pi p e

Refrigerating pipe: complex structure of rubber refrigeration soft tube and
aluminum tube. The warm water pipe: rubber molding pipe

10 Transducer Outdoor temp erature sensor, indoor t emperature sensor, evaporator temperature
sensor
11 pressure switch Three-state pressure switch

CD Player and Air Conditioning System-1
Chapter 11
CD Player and Air Conditioning System

CD Player and Air Conditioning System-2
CD Player
Function Overview
This product is a kind of car audio system with VFD multi-information integrated display screen with such functions as PLL
electronic tuning radio, CD playing and operation & control of air conditioning system, it can receive AM, FM and FM stereo
radio broadcast programs, play CDs, electronically operate and control the air conditioning system of the car. The integrated
display screen can display the working state of the radio, CD player, air conditioning system, operating mode as well as
information concerning the equalizer, clock and the temperature inside and outside.
Wiring Instructions(see the diagram)
with the speakers: the amplifier of main unit of this system is designed with 4-channel BTL output, each speaker must
be wired individually; the phase position and place of the speaker must be connected correctly; please disconnect the
player from the power supply before connecting the speaker so as to avoid the short-circuit.
2. Connecting main unit with the integrated display screen:
Use the specially-supplied 12-pin connector cable to connect the VFD integrated display screen and main unit.
3. Connection of power supply, output and communication line of main unit:
At first, connect the communication cable of the 20-pin connector plug to the air conditioner ECU, then connect the speaker
output line to other lines, finally connect the yellow memory power supply cord (10A fuse tube) directly to the positive role of
accumulator; when all the wiring is completed, connect the red power supply cord (1A fuse tube) to the positive power supply
of the ignition lock.
4. Connecting main unit with the antenna
T ypical antenna: insert the plug of coaxial cable of car’s antenna into the antenna socket of main unit.
Automatic antenna: insert the plug of coaxial cable of car’s antenna into the antenna socket of main unit, then connect the blue
antenna control cable in the 20-pin connector to the automatic antenna control end, connect the positive pole line of power
supply of automatic antenna to the positive pole of accumulator and the negative pole line to the earth.
5. Connecting main unit with CD-change box
CD player and the CD-change box are connected with the signal cables.
Prior to the installation, please be sure to remove three protective screws on the CD-change box and have it pasted with
ant-dust paper. If the protective screws are not removed, CD can not be played normally.
Attention: Improper wiring may result in the damage to the player!
(Figure 7-1) Wiring Diagram integrated display screen 12-pin connector cable20-pin connector cable
antenna adaptor
main unit

CD Player and Air Conditioning System-3
(Figure 7-2) cable position of 2-pin connector socket

Pos. No. Color Function Pos. No. Color Function
1 Whit e Send the data (TX) 11 Shielded cable Earthing of data cable
2 Red Receive the data (RX) 12 — —
3 Brown Telephone mute (TEL) 13 Blue Automatic antenna (ANT )
4 Orange Lighting (LAMP) 14 Red Ignition power supply (ACC)
5 — — 15 Grounding wire
6 — — 16 Yellow Memory power supply B+
7 Whit e and
black Front left speak (-FL-) 17 Green and black Rear left speak (-RL-)
8 White Front left speak (+FL+) 18 Green Rear left speak (+RL+)
9 Gray and
black Front right speak (-FR-) 19 Violet and black Rear right speak (-RR-)
10 Gray Front right speak (-FR+) 20 Violet {Rear right speak (+RR+)

Possible Troubles of CD Player, Inspection and Analysis

Trouble Descriptions Possible causes, inspection and solutions
No programs received for AM and FM Check if the antenna is pulled out and socket becomes
loosened.
Impurity of sound after radio auto-searching Tune to the correct radio station with manual tuning method
No sound of one speaker Check the speaker a nd the socket or adjust the balance(front,
back, left and right)
Refuse to work Check the power supply, or disconnect and connect the power
supply and restart the player.
No power supply Check if the plug-in fuse and output plug is loosened and if the
fuse is burned down.
Single channel when played Check if the speaker is in open-circuit and examine its plug
Not read CD Check the CD type and if it is placed in reverse or scratched.
Display screen displaying bad Check the connecting wire of display screen or adjust the
brightness level higher
Air conditioner refuses to start Inspect the ECU of air conditioner and air conditioning system
Button failure of air conditioner Inspect the ECU of air conditioner and air conditioning system

A-side V iew

CD Player and Air Conditioning System-4
Air Conditioning System
Composition of Air Conditioning System
Air conditioning system mainly consists of air conditioner control unit, display unit, sensors and executor elements.
fresh air damper executor
mode damper executor
emperature damper executor
integrated display screen
CD Player
outside temperature sensor
inside temperature sensor
temperature sensor
of the evaporator
of the air conditioner

CD Player and Air Conditioning System-5
1. integrated display screen 2. CD player 3. Air conditioner ECU 4. Temperature sensor the evaporator 5. Outside
temperature sensor
6. Outside temperature sensor 7. Speed-adjusting module 8. Temperature damper executor 9. Mode damper executor
10. Fresh air damper executor
Definition of each button on CD player of air conditioner panel
[1] Button to increase the temperature [7] wind conveying mode button
[2] Button to decrease the temperature[8] button to start air conditioner
[3] automatic operation button[9] button to decrease the wind amount
[4] front-defrost button[10] power-off button of air conditioner
[5] rear-defrost button[11] button to increase the wind amount
[6] external circulation button
Definition of each button in air conditioning display zone of the integrated display screen
[1] display of inside temperature setting of air conditioner[5] switch button of outside temperature display
[2] display of automatic operation of air conditioner[6] display zone of outside temperature
[3] display zone of wind conveying mode of air conditioner[7] clock display zone
[4] display zone of wind amount of air conditioner
Control and display unit:Control and display unit of the air conditioner mainly consists of:
Air conditioner ECU: The CC6460K model is designed with the individual air conditioner ECU to control the overall operation
of air conditioning system; Air conditioner ECU is installed under the bottom of CD player.The control panel of air conditioner
is designed with an integrated pattern with the control panel of CD player: to regulate, control and set the operation of the air
conditioning system.
Integrated display screen: display the working condition of air conditioning system of the car; relevant functions of air
conditioning system can be found to be displayed in different zone in the integrated display screen.
The sensor
Sensors of CC6460K Model automatic air conditioning system include: inside temperature sensor, outside temperature
sensor, temperature sensor executor of the evaporator.
Executor components include: mode selection executor motor, cold & hot executor motor, internal & external circulation
executor motor.
Trouble Diagnosis and Repair of Automatic Air Conditioning System
1. Self-diagnosis of the system
CC6460K air conditioning system is designed with the system self-diagnosis function. When the air conditioning system fails to
work, the self-diagnosis function designed for the car can be activated for the initial trouble diagnosis.
Operating directions:
At first, start the engine (turn the ignition switch from OFF to ON) and press OFF , A U T O, RR and MODE successively and the
pressing of MODE switch shall last at least 2 seconds. The button must be pressed down within 10 seconds when the engine is
started (the ignition switch is turned to ON position).If the system is supposed to be released, then press A U T O switch or turn
off the ignition switch (OFF) .If one step is supposed to switch to another step, then press TEMP (HOT) or TEMP (COLD)
switch based on the needs.

CD Player and Air Conditioning System-6
Turn the ignition switch from OFF to ON
The display symbols all light up
failure of the switch or display tune
NO
Press down “Temp+” switch
Enter into self-diagnosis procedur1?
NO“ Te mp +” switch failure
Step 1:
Display “01”
(set t he temperature zone)
all other display symbols turn of
f
Press
down
“Temp+” switch
Step 2: Display
“02”(set the
temperature
z one)
The inspection procedures
During the period of 10 seconds after the engine is started(turn the ignition switch from OFF to ON), press OF F, A U T O ,
RR and MODE once more, and the pressing of MODE switch shall last at least 2 seconds
.
A ll sensors are good.
Display
“000”(outsidetemperature)

CD Player and Air Conditioning System-7
C ode off ailu re S ensor f ai lure
10 0 O pen c ircu itof outsid e t em perature sens or
20 0 S hortcirc uit o f o utside temp eratur e s ensor
01 0 O pen c ircu itof i nside temp eratur e s ensor
02 0 s hortcirc ui t o f ins ide t em perature sens or
00 1 O pen c ircu itof temp erat ur e s ensor o f the evap orator
00 2 S hortcirc uit o f tem perature sens or ofthe e vapo rator
Step 3: Display “03”(set the temperature zone)
Display the outside temperature value
Press down “Temp+” switch
Step 4: Display “04”(set the temperature zone
)
Sensor
failure
The code of the sensor with failure
is showed on the display screen
.
Press down
“Temp+” switch
Press down
“Temp+” switch
Step 5:
Display “05”
(set t he temperature zone)
Display the inside temperature value
Display the temperature value of the evaporator
Press down
“Temp+” switch