Refrigerant Lines, Disconnecting and Connecting From Evaporator Connection

Refrigerant Circuit, Servicing

• No refrigerant must be added into the refrigerant circuit (discharge, evacuate and recharge refrigerant circuit).

• Compressor is always driven when engine is running; there is no magnetic clutch. Engine is therefore not to be started unless refrigerant circuit has been properly assembled. If for example the refrigerant lines are not connected to the compressor and the engine is started then the compressor may be destroyed by the build-up of internal heat. Such internal heat generation results from the fact that - even with delivery approaching 0% - the compressor is confronted with a fixed resistance (sealed circuit).

• To stop the compressor being destroyed when the refrigerant circuit is empty, it is designed such that delivery is reduced to roughly 0% and lubrication is maintained by way of an internal oil circuit with the oil left in the compressor.

• Replacement compressors contain the full quantity of refrigerant oil required for the refrigerant circuit.

• For compressors manufactured by "Zexel", "Sanden ", and "Denso", various refrigerant oils are required.

• The specified diameters for O-rings seals and the tightening torques pertain also to the threaded connections of the refrigerant lines or hoses between the separate components.

• Only install O-rings seals that are approved for Refrigerant R134a.

• Check cooling performance. Refer to => [ A/C Unit, Checking Cooling Output ] A/C Unit, Checking Cooling Output.

• Checking pressures in refrigerant circuit. Refer to =>
Heating and Air Conditioning Heating and Air Conditioning

• All other servicing and testing work not described in this repair information.

Refrigerant Lines, Disconnecting and Connecting from Evaporator Connection

Removing

- Remove the plenum chamber cover.

- Drain refrigerant circuit.

- Remove nut - A - (tightening torque of 25 Nm).





- Detach the refrigerant lines from the evaporator and seal the open connections.

• The cap of a replacement evaporator, for example, can be used to seal open connections at evaporator - D - and the lines (to prevent ingress of dirt and moisture).

Installing

Installation is carried out in the reverse order, when doing this note the following:

- Replace O-ring seals - B - and - C -.





- Install refrigerant pipes such that they are not strained.

- After the refrigerant lines are attached, check grommet - E - and line bushing - F - for correct installation.

- Check position of refrigerant pipes with respect to evaporator.

- Check the type of seal at the connections and the refrigerant lines. These must be designed for the same type of seal. Refer to => [ Refrigerant Line to Component Connections ]

- Evacuate and re-charge refrigerant circuit.