Vehicle Damage Warnings

Observe the following precautions when handling components used in the air conditioning system:
- Air conditioning units must not be lifted by their hoses, pipes or capillary lines.
- Hoses and lines must not be subjected to any twist or stress - the efficiency of the system will be impaired by kinks or restrictions. Ensure that hoses are correctly positioned before tightening couplings, and ensure that all clips and supports are utilized.
- Flexible hoses should not be positioned close to the exhaust manifold (less than 100mm) unless protected by heat shielding.
- Completed assemblies must be checked for refrigeration lines touching metal panels. Any direct contact of components and panels may transmit noise and so must be eliminated.
- The appropriate torque wrench must be used when tightening refrigerant connections to the stipulated value. An additional spanner must be used to hold the union to prevent twisting of the pipe when tightening connections.
- Before connecting any hose or pipe, ensure that refrigerant oil is applied to the seat of the new 'O' ring seals, BUT NOT to the threads of the connection.
- All protective plugs must remain in place to seal the component until immediately prior to connection.
- Ensure components are at room temperature before uncapping, to prevent condensation of moisture from the air that enters it.
- Components must not remain uncapped for longer than 15 minutes. In the event of a delay, the caps must be fitted.
- When disconnecting, immediately cap all air conditioning pipes to prevent ingress of dirt and moisture into the system.
- The modulator (receiver/drier) contains desiccant which absorbs moisture. It must be positively sealed at all times. A modulator that has been left uncapped must not be used, fit a new unit.
- The modulator should be the last component connected to the system to ensure optimum dehydration and maximum moisture protection of the system.
- Whenever the refrigerant system is opened, the modulator must be renewed immediately before evacuating and recharging the system.
- Use alcohol and a clean lint-free cloth to clean dirty connections.
- Ensure that all new parts fitted are marked for use with R134a.


Refrigerant oil
Use an approved refrigerant lubricating oil
ND Oil 8


CAUTION:
- Do not use any other type of refrigerant oil.
- Refrigerant oil easily absorbs water and must not be stored for long periods. Do not pour unused oil back into the container.


When renewing system components, add the quantities of refrigerant oil recommended in the Air Conditioning section of this manual.

Compressor
A new compressor is sealed and pressurized with Nitrogen gas. When fitting a new compressor, slowly release the sealing cap; gas pressure should be heard to vent as the seal is broken.


CAUTION: A new compressor should always be sealed and could be pressurized with nitrogen gas. To avoid possible oil loss, release the sealing cap(s) slowly. Do not remove the cap(s) until immediately prior to connecting the air conditioning pipes to the compressor.


Rapid refrigerant discharge
If the air conditioning system is involved in accident damage and the system is punctured, the refrigerant will discharge rapidly. The rapid discharge of refrigerant will also result in the loss of most of the oil from the system. The compressor must be removed and all the remaining oil in the compressor drained and refilled in accordance with the 'Air Conditioning Compressor Replacement Procedure'.