A/C Refrigerant System From 10.00, Servicing
A/C Refrigerant System From 10.00, Servicing
NOTE:
- Before carrying out any work on the A/C refrigerant system, refer to all CAUTIONS and WARNINGS in A/C refrigerant system safety measures.
- Service refrigerant system using Kent More ACR 4 or equivalent
- Only system components identified with * can be serviced or replaced without discharging refrigerant system.
- During servicing, all couplings, fittings and related fasteners must be torqued to specifications.
1. Refrigerant pipe/hose
- Between accumulator and compressor
2. Hex socket bolt
- M8X28
- 15 Nm(11 ft.lb.)
3. O-ring
- 17.2 mm; 1.8 mm
4. Refrigerant pipe/hose
- Between evaporator and condenser
5. Coupling
- Thread 0 20 mm; pitch 1.5 mm
- 15 Nm (11 ft. lb.)
6. O-ring
- 10.8 mm; 188 mm
7. Restrictor
- Removing and installing, see Fig. 6
8. O-ring
- 7.5 mm; 1.5 mm
9. O-ring
- 10.8 mm; 1.8 mm
10. High pressure service valve
- Only use Kent Moore ACR4 or equivalent.
- Removing and installing, see Fig. 1.
- Refrigerant system capacities
11. Cap*
12. O-ring
- 10.8 mm; 1.8 mm
13. O-ring
- 17.2 mm; 1.8 mm
14. Evaporator
- In heating and A/C unit
- Removing/assembly.
15. Socket head bolt
- 10 Nm (89 in. lb.)
16. Cap*
17. Low pressure service valve
- Only use Kent Moore ACR4 or equivalent.
- Removing, see Fig. 2
- Refrigerant system capacities
18. O-ring
- 7.6 mm; 1.8 mm
19. Refrigerant pipe/hose
- Between accumulator and evaporator
20. Compressor
- Denso 7SB-16C
- With A/C clutch -N25-
- Compressor/engine applications
21. Pressure relief valve
- Checking, see Fig. 8
22. O-ring
- 23.8 mm; 2.4 mm
23. Socket head bolt
- 25 Nm (18 ft. lb.)
- Qty.2
24. O-ring
- 11.1 mm; 1.8 mm
25. A/C clutch -N25-*
- Manufacturer: Denso
- Repairing A/C clutch with compressor installed is not recommended.
- Servicing
26. Compressor
- Denso 7SEU16
- Without A/C clutch
- Compressor/engine applications
27. A/C compressor regulator valve -N280-
- Denso 7SEU16 only.
28. O-ring
- 23.8 mm; 2.4 mm
29. Pressure relief valve
- Checking, see Fig. 8
30. Socket head bolt
- 25 Nm (18 ft. lb.)
- Qty. 2
31. O-ring
- 11.1 mm; 1.82 mm
32. Refrigerant pipe/hose
- Between compressor and evaporator.
33. Condenser
- Removing/assembly
34. O-ring
- 14 mm; 1.8 mm
35. O-ring
- 17.2 mm; 1.8 mm
36. Hex socket bolt
- 15 Nm(11 ft.lb.)
37. O-ring
- 4-cyl. & 6-cyl. engine: 7.6 mm; 1.8 mm
38. A/C pressure switch -F129- or high pressure sensor -G65-
NOTE:
- Application is engine dependent.
- Always confirm system use of -F129- or -G65- and applicable wiring circuit using applicable "Engine" and "Climatronic" wiring diagrams.
- -F129- function
- -F129- checking
- -F129- replacing
- -G65- function
- -G65- checking, use VAS 5051/5052tester in mode "Guided Fault Finding".
- -G65-, replacing
- Switch or sensor can be removed without discharging refrigerant system.
- Tightening torque 8 Nm (71 in lb)
- Always replace O-ring (note Part No.).
39. Accumulator
- Always replace whenever refrigerant system has been opened
40. O-ring
- 17.2 mm; 1.82 mm
Fig. 1 High pressure service valve, removing
NOTE: Before carrying out any work on the A/C refrigerant system, refer to A/C system safety measures WARNINGS. and CAUTIONS.
- Discharge refrigerant system.
- Unscrew and remove high pressure service valve -3-
1. Connection with internal thread
2. O-ring, 10.8 mm; 1.8 mm
3. High pressure service valve, with groove for O-ring and internal thread for cap
4. O-ring, 10.8 mm; 1.8 mm
5. Cap
Fig. 2 Low pressure service valve, removing
NOTE: Before carrying out any work on the A/C refrigerant system, refer to A/C system safety measures WARNINGS. and CAUTIONS.
- Discharge refrigerant system.
- Unscrew and remove low pressure service valve -3-.
1. Connection with external thread and groove for O-ring
2. O-ring, 7.6 mm; 1.8 mm
3. Low pressure service valve
4. O-ring, 7.6 mm; 1.8 mm
5. Cap
Fig. 3 A/C pressure switch -F129-, checking
NOTE: Before carrying out any work on the A/C refrigerant system, refer to A/C system safety measures WARNINGS. and CAUTIONS.
- The pressure switch can be removed without discharging refrigerant system.
- Visually check that O-ring 10,8 mm x 1,8 mm is positioned correctly in the groove.
Function
Switch part between terminals 1 and 2 switches off the A/C clutch -N25- when the system pressure is too high or when there is not enough refrigerant in the system.
- Switch opens when the pressure is below 1.2 bar and closes again above 2.4 bar (switch point).
- Switch opens above 32 bar and closes again below 24 bar (switch point).
Switch part between terminals 3 and 4 switches coolant fan -W- (via the coolant fan control module -J293-) to the next higher fan speed when system pressures increase.
- Switch closes above 16 bar and opens again below 12.5 bar (switch point).
- Checking, continued
Checking:
- With the engine running, briefly bridge terminal 1 and 2 of connector. If the A/C clutch -N25- engages, the refrigerant circuit is empty.
-F129- functional checks
To determine proper A/C system performance, perform the following functional checks with the switch installed and connected.
- Check refrigerant capacity (fill). If system pressure is too low (refrigerant leakage), -F129- switches A/C clutch off.
- Check cooling fan function. When system pressure increases, -F129- causes coolant fan -V7- to switch to next higher fan speed.
- Check if A/C system switches off. At excessive system pressures (e.g.: caused by high ambient temperatures or if condenser is blocked), -F129- switches A/C clutch off.
Fig. 5 A/C pressure switch -F129- from 10.00 or high pressure sensor -G65-, replacing
NOTE: Before carrying out any work on the A/C refrigerant system, refer to A/C system safety measures WARNINGS. and CAUTIONS.
1. Connector
2. Switch/sensor (8 Nm)
3. Hex (to counter-hold)
4. Condenser connection
- Remove front bumper
- Remove front bumper carrier
- Separate electrical connection -1-
To prevent damage to condenser pipe connection -4- counter-hold hex fitting -3- with appropriate wrench when loosening switch.
- Remove switch/sensor -2-.
Fig. 6 Restrictor, removing and installing
NOTE: Before carrying out any work on the A/C refrigerant system, refer to A/C system safety measures WARNINGS. and CAUTIONS.
Removing
- Discharge refrigerant system
- Loosen and separate coupling -A- on evaporator inlet pipe.
Tightening torque 15 Nm (11 ft lb)
- Replace O-ring -D-
O-ring -D- = 10.7 mm, 1.8 mm
- Remove restrictor -B- using long nose pliers
CAUTION: Immediately plug open connections on A/C components and lines to prevent dirt and moisture contamination.
Installing
- Insert restrictor -B- into evaporator inlet pipe with arrow pointing in direction of refrigerant flow (towards evaporator).
NOTE:
- Ensure proper positioning of O-ring -C-
- Restrictor must fit tight in inlet pipe (push in as far as it will go)
- Assemble to allow stress free mounting of evaporator pipes
Fig. 7 Pressure relief valve - Zexel compressor, checking
NOTE: Before carrying out any work on the A/C refrigerant system, refer to A/C system safety measures WARNINGS. and CAUTIONS.
- Function: Protects refrigerant circuit from over-pressure.
- Refrigerant oil deposited on rear of compressor indicates pressure relief valve has opened to release pressure -arrow-. An adhesive plate is pushed out.
Fig. 8 Pressure relief valve - Denso compressor, checking
NOTE: Before carrying out any work on the A/C refrigerant system, refer to A/C system safety measures WARNINGS. and CAUTIONS.
- Function: Protects refrigerant circuit from over-pressure.
- Refrigerant oil deposited in area of compressor manifold indicates pressure relief valve has opened to release pressure -arrow-. An adhesive plate is pushed out.