Great Wall Socool (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.
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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.
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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)Nm
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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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.
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