Rf valve GREAT WALL SAILOR 2006 Owner's 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-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

AC-17Air-Conditioning System
Refrigeration Device
evaporator housing
Dr SF
SL SK SY SJ
evaporator housing
residual liquid pipe
heat-sensitive
resistance
pressure switch
evaporator core
expansion valve
heat-sensitive
resistanceevaporator upper
housingevaporator core
evaporator lower
housingexpansion valve HPpressure rubber
LPpressure rubber
HP/LP pressure rubber

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

A-3
Fastening location N*m
Upper tooth(JK72TWD)
Fastening location N*m
Specification of Maintenance and Up-Keeping
Transfer Box
Maintenance and Up-keeping of Transfer Box
1. The oil level of transfer box should be checked when exchanging the engine lubricant or the vehicle
covers more than 8000 km
and add the lubricant where necessary.
2. Change with the appointed lubricant each year or after the vehicle covers more than 48000 km.
Notice: lubricant brand: 85W/90 GL-5.
Fastening torque of relative connecting elements
15
20
10
15
12
17
15
20
15
20
15
20
15
20
30
40
60
70
30
40
30
40
17
22
30
50
20
40
30
40
90
125 Toggle fork at first, second and fifth gears and the screw of
toggle fork
Bolt on odometer pressure plate
Screw on baffle of rear bearing of output shaft
Screw on baffle of reverse idler shaft
Locating screw of gearshift yoke block
Bolt of front cover
Bolt of gearshift cover
Pillar of clutch toggle fork
Bolt of clutch cover
Bolt of rear body (M10X1.25X130)
Bolt of rear body (M10X1.25X80)
Plug of locating spring
Oil filling/draining plug
Reverse gear switch assembly
Location mechanism cluster
Locking nut at rear end of countershaft
Fastening location N*m
Flange nut
Oil drain plug
Bolt of motor clip
Fixing bolt of motor
Clutch coil nut
Housing bolt
Oil pump bolt
Venting valve
Bolt of front connecting body203
244
19
30
8
11
8
11
8
11
27
46
4.0
8.5
8
19
27
46 Oil filling/draining plug
Location mechanism cluster
Pillar of clutch toggle fork
Bolt on odometer pressure plate
Reverse gear switch assembly30
50
30
50
30
50
10
15
30
50