Great Wall Sing (2006 year). Service Manual - part 24

AC-11

Air-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 tank

observation window

observation window

No.

1

2

3

4

5

6

Symptoms

Refrigerant quantity

Repairing 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

Normal

Check 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-12

Air-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 off

turn off

Compressor

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-13

Air-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 
 0g

correct

incorrect

incorrect

98N

AC-14

Air-Conditioning System

 Liquid Tank

Liquid Tank

Check to see whether there is leakage in observation window,

fusible plug and joints;

Conduct the inspection with the gas leakage detector and, if

necessary, repair or change the liquid tank.

Dismantle of Liquid Tank

1.

Exhaust the refrigerant;

2.

Tear down the two liquid pipes from the liquid tank;

Remark: the opened joint should be plugged with cork so as to

prevent the humid air from entering into the system.

3.

Tear down the liquid tank from the tank bracket.

Mount of Liquid Tank

1.

Mount the liquid tank on the liquid tank bracket;

Remark: the cover of joint should not be take down before

connecting the pipe;

2.

Connect the two liquid pipes to the liquid tank;

Tightening moment

(See page AC-8)

3.

Vacuumize the system and inflate the refrigerant in;

Vacuumizing time:

Dr SL SK SF SJ

Vacuumize for 20 min and main-

tain the pressure for 30min;

SY

Vacuumize for 30 min and maintain the pres-

sure for 30min.

4.

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

liquid pipe

liquid pipe

liquid tank

condenser

SL SK SY SJ

Dr SF

AC-15

Air-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-16

Air-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

SY

interior trim panel
at left rear side

rear evaporator

AC-17

Air-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

resistance

evaporator upper

housing

evaporator core

evaporator lower

housing

expansion valve

HPpressure rubber

LPpressure rubber

HP/LP pressure rubber

AC-18

Air-Conditioning System

 Evaporator

SYrear evaporator

upper housing

air cover

lower housing

temperature controller

air blower

evaporator core

air pipe

heat-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-19

Air-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 valve HP pipe 

LP pipe

AC-20

Air-Conditioning System

 Refrigerant Pipe

Refrigerant pipe

On-vehicle inspection

1.

Check the pipelines of each part to see whether there is

leakage:

Make the inspection with the gas leakage detector and, if

necessary, change them.

2.

Check the clamping parts of the pipelines to see whether

there is looseness;

Make a new fastening or change as requirement.

Change of refrigerant pipeline

1.

Exhaust the refrigerant;

2.

Change the damaged pipe or hose

Remark: the opened joint should be sealed right away with

cork so as to prevent the humid from entering into the system.

3.

Screw up the O-ring seal joint and threaded joint according

to the Tightening moment;

4.

Vacuumize the air-conditioning system:

Vacuumizing time:

Dr SL SK SF SJ

Vacuumize for 20min and main-

tain the pressure for 30min;

 SY

Vacuumize for 30min and maintain the pres-

sure for another 30min.

5.

Inflate the refrigerant in the air-conditioning system and

check the system 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

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

B0-2

General Introduction

In case there is damage to body and/or part, protection measures

should be taken first to prevent the vehicle from damaging before

repairing them.

Example:

1.

Protection adhesive strap should be contacted on the relative

part of body when conduct the disassembling and mounting

operation.

 2.

When prizing the body parts with screwdriver or scraper, those

body parts head or the edge of screwdriver or scraper should

be wrapped with adhesive strap to prevent paint layer and the

body from damaging.

If the antirust is damaged when repairing other parts, it should be

recoated in time.

Example:

1.

In case the sealing agent, paint layer or priming coat on the

body is damaged due to peel-off or crack, etc. the correspond-

ing antirust shall be used for reparation.

2.

If the hinge or plate is loosened or torn down, the antirust

should be re-coated after repairing them.

adhesive strap

Vehicle Body

 General Introduction

    peel-off

crack

anti-rust agent

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

B0-4

Vehicle 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 channel

small sliding track

door lock assembly

lower front glass
guide track

lock clip

lock ring

lock barrel

outdoor 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

B0-6

5. Tear down the interior trim panel of car door:

 (a)

Tear down the inner clip bolts and the inner clip.

 (b)

Tear down the door lamp bolts and the door lamp;

 (c)

Insert the screwdriver into seam between fixing clip and

interior trim panel of car door to loosen the interior trim

panel.

Notice: before using the screwdriver, wrap its head with

adhesive strap.

(d)

Tear down the interior trim panel of car door.

(Dr

SF)

(a)

Tear down the inner clip bolts and the inner clip;

(b)

Tear down the door lamp bolts and the door lamp;

(c)

Tear down the electric switch and panel.

(d)

Insert the screwdriver into the seam between fixing clip

and the interior trim panel of car door to loosen the

interior trim panel.

Remark: use the adhesive strap to wrap the screwdriver

head before using.

(e)

Tear down the interior trim panel of car door.

SL SK SY SJ)

(a)

Tear down the door lamp bolts and the door lamp;

(b)

Tear down the electric switch and the panel;

(c)

Tear down the screw covers and screws on the indoor

trim panel

(d)

Insert the screwdriver into the seam between the fixing

clip and the interior trim panel of car door to loosen it.

Notice: use the adhesive strap to wrap the screwdriver

head before using.

(f)

Tear down the interior trim panel of car door.

manually operated indoor plate

inner plate of electric door (type A)

inner plate of electric door (type B)

12 clips

ten clips
four sets of bolt and nut

Vehicle Body 

 Front Car Door

12 clips

6.

Tear down the outer auchi

Loosen the clip along the edge of paneling to tear down the

outer

7.

Tear down the door and window glass;

(a)

Tear down the fixing bolts in the two glass sliding-

grooves.

(b)

Pull up the glass to take it down.

8.

Tear down the glass groove on car door.