engine GREAT WALL SAFE 2006 Owner's Guide

AC-4Electric Circuit Diagram of Air
Conditioning System
Electric circuit diagram of air-conditioning system (continued)
Dr
fuseA/C switch pressure switch
engine wire
harness
air blower
speed-adjusting
module
wind speed switch M2 2
2
2 2
2
2
O 24 4 4 4
4
Q 4
44 3 3
3
3 3 3 3
3
P 5 5
5
5 5 5
5
R 1
1
N 1
1
1
1
N6
6 6
6
6
S 7
7
TU 8
8 9
9 10
10 11 12 13
ignition switch pressure switchA/C switchspeed adjusting
module of air blower
socket connectors of engine wire harnesswind speed switch
lk ^`` p q
fuse ignition switchair-conditioning relayfuse
battery

AC-9Air-conditioning System - General introduction
General introduction
Refrigeration cycle
1. The refrigerant at the lower pressure side is condensed by the
compressor into the HT and HP gaseous refrigerant.
2. These gaseous refrigerant flows into the condenser, where it is
turned into liquid refrigerant.
3. Those liquid refrigerant flows into the liquid tank, where the
liquid refrigerant is stored and filtered so as to satisfy the
requirement of evaporator.
diaschage vent indraft vent
compressor
curent direction
evaporator heat
heat expansionvalve
liquid tank
4. The liquid refrigerant is throttled by the expansion valve to reduce the pressure, so that the liquid refrigerant is turned
into the LT and LP mixture of liquid and gaseous refrigerant.
5. The cold and fog-like refrigerant flows into the evaporator, where it is vaporized with the given heat, which is
absorbed from the hot air flow by the evaporator core. All liquid refrigerants are turned into the gaseous refrigerant
in the evaporator, and only the heated gaseous refrigerant is absorbed into the compressor. Then repeat the above-
mentioned cycling approach.
The refrigerant released from
the evaporator expands and
inflows through the evapora-
tor pipe. During this process,
the refrigerant absorbs the
heat in the air around the ra-
diating rib and pipe and
vaporizes, so that the tem-
perature inside the vehicle
reduces gradually.
The condenser allows the heated gas-
eous refrigerant to release heat to the
cooling air of engine, therefore, the gas-
eous refrigerant is cooled and turned
into liquid state again.
The expansion valve is used
to measure the gaseous re-
frigerant entered into evapo-
rator core, which reduces the
pressure and temperature of
refrigerant gradually.
The liquid tank is used to exhaust
the water in system and to filter
the dust and dunghill. It serves as
the store to store the redundant
refrigerant.
The compressor absorbs the
gaseous refrigerant emitted
from the evaporator and com-
presses it. In doing so, the tem-
perature and pressure of gas-
eous refrigerant increases
rapidly.

AC-11Air-Conditioning System
Inspection On Refrigerant Quantity
Inspection on Refrigerant Quantity
1. Run the engine at the speed of 1500 r/m or so (the
atmospheric temperature should be above 35
);
2. Start the air-conditioner in the max cold air status for
several minutes;
3. Check the refrigerant quantity.
Watch the observation window on liquid tank.
Dr SF
SL SK SY SJ
liquid tank
liquid tankobservation window
observation window
No.
1
2
3
4
5
6
Symptoms
Refrigerant quantityRepairing approaches
Air bubble occurs in the observa-
tion window
No air bubble in observation win-
dow
No temperature difference between
the inlet and outlet of compressor
Obvious temperature difference be-
tween the inlet and outlet of compressor.
Observation window is in clear status
once the air-conditioner is turned off
There is refrigerant foam on observa-
tion window after the air-conditioner
is turned off, then the observation
window becomes clear.Insufficient
No, normal or redundant
No, or almost no
Normal or redundant
Redundant
NormalCheck to see whether there is leakage with the
gas leakage detector
Refers 3 and 4.
Vacuumize the system and inflate the
refrigerant, then check to see whether there is
leakage with the gas leakage detector.
Refer 5 and 6
Exhaust the redundant refrigerant until the speci-
fied quantity is satisfied.

AC-12Air-Conditioning System
Compressor
Installation of manifold gauge
Remark: Connect the manifold gauge to the auxiliary valve of
compressor.
1. Turn off the manual valve of manifold gauge.
2. Mount the packing hose of manifold gauge on the packing
valve.
Mount the LP hose to the LP packing valve and the HP hose to
HP packing valve. Then screw up the nuts for hose joint by
hand.
Remark: Do not coat the compressor lubricant on the connec-
tion positions.
packing hose
efrigeration system
connected to mani-
fold gauge
connect to compressor
turn offturn offCompressor
On vehicle inspection
1. Mount the manifold gauge;
(see manifold gauge mount)
2. Run the engine at the speed of 1500 r/m or so;
3. Check the compressor according to the following items:
(a) The HP gauge readings under the normal system should
satisfy the specified value of (1.4-1.7)MPa , that of LP
gauge should meet the specified value of (0.15-0.2)MPa .
(b) Whether there is abnormal sound;
(c) Whether there is leakage at the shaft oil seal.
If any problem is found, repair or change the compressor.
4. Check the electromagnetic clutch:
(a) Check to see whether there is lubricant trace on the
pressing plate and rotor;
(b) Check to see whether there is noise or lubricant leakage
at the clutch bearing;
(c) Measure the resistance between the stator coils that is set
between the clutch lead and the grounding lead with the
ohmn meter.
Standard resistance:
SL SK SJ
(3.2
.2)
Ω
Dr SF SY
(3.5
.2)Ω
In case the requirement is not satisfied, change the compressor.

AC-13Air-Conditioning System
Compressor
Disassemble of compressor
1. Run the engine in the idle status for ten minutes under
the air-conditioning situation;
2. Turn off the engine;
3. Disconnect the cathode lead from the storage cell;
4. Disconnect the electromagnetic clutch lead from the
matching wire;
5. Exhaust the refrigerant from the refrigeration system;
6. Disconnect the two hoses from the auxiliary valve of
compressor;
Cover the opening joint with cork right away to prevent the wet
gas entering in to the system.
7. Tear down the compressor:
(a) Tear down the fan cover;
(b) Loosen the driving belt;
(c) Tear down the fixing bolts of compressor bracket and the
compressor.
Mount of compressor
1. Mount the compressor with fixing bolts;
Tightening moment
(25-30)N
m
2. Mount the driving belt correctly;
Requirement for belt tension: the tension belt is allowed
to reduce (9-13)mm under 98N after the compressor
runs for five minutes;
3. Connect the two hoses to the auxiliary valve of
compressor;
Tightening moment
(see page AC-8)
4. Connect the clutch lead to the matching wire;
5. Connect the cathode lead of storage cell to the storage
cell, and
6. Vacuumize the system and inflate the refrigerant:
Vacuum time:
Dr SL SK SF SJ
Vacuumize for 20min and main-
tain the pressure for 30min;
SY
Vacuumize for 30min and maintain for 30min
Inflated refrigerant quantity:
Dr
(600-650)g
SL
700
0g
SK SJ
560
0g
SF
(700-720)g
SY
850
0gcorrect incorrect incorrect
98N

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

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

B0-3
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

B0-70
Body Dimension
Engine Room (
)
Vehicle Body
Body Dimension
Dr SF
(point size in 3D)
SL SY
(point size in 3D)
Mark NameBore diameterMark NameBore diameter
H,h Front locating hole of mudguard M8 M,mLocating hole of upper part of
front wall
7
I,iHole of fixing nut of large lamp
M8 N,nFirst mounting hole of wing panel


J,jFront locating hole of mudguard
M6
K,k First mounting hole of engine cover M6
L,lFirst mounting hole of wing panel

10
Remark: the deviation
in length of diagonal
line of engine room
should not be more than
4 mm.
J
K
LIHj
k
l áh
1005
1268582
384
M
Nm
n 728 728

B0-71Body-Body Dismension
SK SJ
(point size in 3D)
O,o
Mark NameBore diameterMark Name Bore diameter
M,m Hole of fixing nut of large lamp
7
N,n First mounting hole of engine cover

O,o Vertical face of median mesh

P,pProjection line of vertical face of
median mesh

Remark: the deviation in length
of diagonal line of engine room
should not be more than 4 mm.
M
Nm
n 845
P,p 711
711
Body Dimension
Engine Room (
)