Great Wall. Service manual for chassis and body (2006) — page 32

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.

B0-7

Change of Glass

(Dr SF)

1.

Tear down the glass bracket with screwdriver or similar

tool;

2.

Coat the black glue on the inside of glass bracket liner;

3.

Tap the glass bracket with rubber hammer to encase it in.

(SL SK SY SJ)

1.

Tear down the bolts on gear plate with pliers or similar

tool;

2.

Tear down the bolts of glass bracket of car door to take

out the glass.

Vehicle Body

Front Car Door

170mm

Dr. SF

SL. SK. SY. SJ

9.

Tear down t the lower rear glass guide track:

Tear down the bolts and guide track.

10. Tear down the lower front glass guide track;

Tear down the bolts and guide track.

11. Tear down the glass elevator:

(a)

Tear down the two fixing bolts of small sliding track;

(b)

Tear down the fixing bolts of three elevators (manually

operated)

Tear down the fixing bolts of four elevators. (electric)

(c)

Tear down the elevator through the auxiliary hole.

12. Tear down the lock ring inside the vehicle;

Disconnect the control lever to tear down the lock ring inside

the vehicle.

13. Tear down the door lock and outdoor handle with lock

barrel;

(a)

Disconnect the control lever from the outdoor handle

with lock barrel.

(b)

Tear down the 3 bolts and door lock.

(c)

Tear down the two bolts and outdoor handle with lock

barrel.

(d) Tear down the spring snapping ring and lock barrel.

B0-8

Assembly of Front Door

1.

Coat the MP lubricant on the parts before mounting.

(a)

Coat the MP lubricant on the sliding face and the gear of

glass elevator.

Notice: Do not plaster the MP lubricant on the spring of

glass elevator.

(b)

Plaster the MP lubricant on the sliding face of door lock.

2.

Mount the outdoor handle with lock barrel and the door

lock;

(a)

Mount the lock barrel on the outdoor handle with spring

snapping ring;

(b)

Use two bolts to mount the outdoor handle and the lock

barrel;

(c)

Mount the door lock with three screws;

(d)

Connect the outdoor handle to the control lever.

3.

Mount the lock ring inside vehicle

Mount the lock ring inside of vehicle and connect the control

lever.

4.

Mount the lower rear glass guide track,

5.

Mount the lower front glass guide track;

6.

Mount the glass elevator:

(a)

Put in the elevator through the auxiliary hole;

(b)

Mount on the three fixing bolts of elevator. (manually

operated)

Mount on the four fixing bolts of elevator (electric)

(c)

Mount the small sliding track, and screw up the bolts of

small sliding track temporarily.

7.

Mount the glass groove on car door;

8.

Mount the car door and window glass;

Put the glass in the car door cavity, and then use two bolts to

fix the glass on the elevator.

Vehicle Body

Front Door

B0-9

manual indoor plate

Electric indoor plate (Type A)

ten clips

12 clips

Vehicle Body

Front Door

12. Mount the interior trim panel of car door:

Dr)

(a)

Connect the handle to the control lever first, then pull it

out from the indoor handle hole.

(b)

Fix the clip by tapping to encase the interior trim plate of

car door in the corresponding hole of car door interior

panel.

(c)

Use one screw to mount the inner clip.

Dr SF)

(a)

Connect the handle to the control lever first, and then pull

it out from the indoor handle hole.

(b)

Fix the clip by tapping to encase the interior trim panel in

the corresponding hole of car door interior panel

(c)

Mount the inner clip with one screw; and

(d)

Mount the electric switch and panel.

SL SK SY SJ)

(a)

Connect the handle with the control lever first, then pull

out it from the indoor panel handle.

(b)

Connect the plugging elements.

(c)

Fix the clip by light tapping to encase the interior trim panel

of car door in the corresponding holes on indoor panel.

(d)

Mount the inner clip with two bolts;

(e)

Mount the four screws to fasten the interior trim panel of

car door, and cover the nuts.

(f)

Mount the electric elevator switch.

13. Mount the indoor handle:

(a)

Push the indoor handle into the car door paneling and

make it slide backward.

(b)

Screw on the screws;

14. Mount the elevator handle (Dr)

Mount the paneling and elevator handle with spring snapping

ring under the condition the car doors and windows are closed

completely as shown in drawing.

12 clips

9.

Adjust the car door and window glass;

Adjust the balance arm upwardly or downwardly until the

dimensions of A and B shown in drawing are equal, and then

fix the balance arm.

10. Mount the outer

Encase the claw of clip into the paneling seam and press the

outer on the paneling.

11. Mount the rear vision mirror

inner panel of electric door (type B)

four sets of bolt and nut

front

B0-10

Rear Door (

)

Element Figure

glass

glass channel

Outer auchi

glass bracket and glass gasket

door limiting

device

door hinge

electric switch

interior trim panel

of electric door

(Dr)

interior trim panel

of electric door

manual interior

trim panel

sleeve

snapping ring

elevator handle

door lamp

inner clip

lower rear glass

guide track

small sliding track

door lock assembly

lock clip

outdoor handle

lower dust
strip

indoor handle

(Dr)

lock ring

Dr SL SK SY

Vehicle Body

Rear Door

(SL,SY,SK)

B0-11

Vehicle Body

Rear Door

Rear Door (

)

Element Figure

glass

glass channel

Outer auchi

glass bracket and

glass gasket

door limiting
device

door hinge

electric switch

door lamp

inner clip

lower rear glass
guide track

small

sliding

track

door lock assemblyn

lock clip

outdoor handle

upper glass guide track

indoor handle

lock ring

quarter window glass

sliding

channel

SF

B0-12

Vehicle Body

Rear Door

Rear door(

)

Element figure

glass

glass channel

outer auchi

door limiting device

door hinge

electric switch

inner clip

door lock assembly

lock clip

outdoor handle

lock ring

quarter

window glass

screw cap

glass supporter

indoor handle

SJ

B0-13

Adjustment of Rear Door

(Dr SL SK SF SY SJ)

1.

Adjust the door along the front-back and vertical direction;

(upper side)

Screw off the hinge nuts on the body side for the adjustment.

(lower side)

Screw off the hinge nuts on the side body for the adjustment.

2.

Adjust the door along the left-right and vertical direction.

3.

adjust the door lock clip

(a)

Screw off the mounting bolts of lock clip and tap the lock

clip with hammer to adjust its position.

(b)

Screw on the fixing nuts of lock clip.

Disassembly of Rear Door

1.

Tear down the elevator handle (Dr)

Pull out the spring snapping ring with dishcloth and tear down

the elevator handle and sleeve.

2.

Tear down the indoor handle;

(a)

Take spart the screw and slide the handle forwardly.

(b)

Take down the handle from the controlrod

Vehicle Body

Rear Door