A/C Refrigerant System, Servicing
A/C Refrigerant System, Servicing
NOTE:
- Before carrying out any work on the A/C refrigerant system, refer to A/C refrigerant system safety measures.
- Except where indicated with *, all components illustrated must only be serviced or replaced after discharging refrigerant system. Use Kent Moore ACR4 or equivalent.
- O-rings used on R-134a systems may be red, green, violet or black.
- Always plug open refrigerant line connections to prevent dirt and moisture contamination.
Pressures and temperatures, checking
Testing with pressure gauges
Discharging
Evacuating and recharging
Troubleshooting
1. Bolt
- 15 Nm (11 ft lb)
2. O-ring
- Always replace
- 10.8 mm; 1.8 mm
3. Receiver drier
- Always replace
4. O-ring
- Always replace
- 10.8 mm; 1.8 mm
5. Refrigerant line
- From receiver drier to expansion valve
6. Bolt
- 15 Nm (11 ft lb)
7. A/C pressure switch -F129-* or high pressure sensor -G65-*
- 15 Nm (11 ft lb)
- Tightening torque 8 Nm (71 in.lb)
- Always replace O ring (note Part No.).
- -F129- checking
- -G65- checking
- -F129- and -G65- can also be checked using VAS 5051 in mode "Guided Fault Finding".
- -G65- monitored by On Board Diagnostic of Engine Control Module (ECM).
Function:
- -F129- switches the coolant fan -V7- to next higher speed when pressure increases in refrigerant circuit.
- -F129- switches off A/C clutch whenever excessive refrigerant system pressure is present (e.g.: insufficient air flow over condensor or if system is overcharged).
- -F129- switches off A/C clutch whenever insufficient refrigerant system pressure is present (e.g.: refrigerant has leaked out).
- -G65- supplies refrigerant system pressure signal to coolant fan control module -J293- and ECM.
8. O-Ring
- Always replace
- 10.8 mm; 1.8 mm
9. Schrader valve
10. Threaded plate
11. O-ring
- Always replace
- 10.8 mm; 1.8 mm
12. Expansion valve
- Located in right side of engine compartment
- Hole for refrigerant lines at bulkhead must be must be sealed against splash water
13. Bolt
- 8 Nm (71 in. lb)
14. O-ring
- Always replace
- 14 mm; 1.8 mm
15. Damper
16. Low pressure service valve
- Only use Kent Moore ACR4 or equivalent.
- R-134a capacity
17. Refrigerant hose
- From expansion valve to compressor
- With damper
18. High pressure service valve
- Only use Kent Moore ACR4 or equivalent.
- Removing and installing see Fig. 2
- R-134a capacity
19. O-ring
- Always replace
- 10.8 mm; 1.8 mm
20. Evaporator
- In heating and A/C unit (in passenger compartment)
21. O-ring
- Always replace
- 16.7 mm; 1.8 mm
22. Insulation*
23. O-ring
- Always replace
- 7.6 mm; 1.8 mm
24. Bolt
- 8 Nm (71 in. lb)
25. Refrigerant hose
- From compressor to condenser
26. Bolt
- 15 Nm (11 ft lb)
27. O-ring
- Always replace
- 10.8 mm; 1.8 mm
28. Condenser
29. Compressor
- Manufacturer: Sanden, designation: SD7V16
- Manufacturer: Zexel, designation: DCW-17D
- With A/C clutch -N25-
30. O-ring
- Always replace
- 14.3 mm; 2.4 mm
31. Bolt
- 20 Nm (15 ft lb)
32. O-ring
- Always replace
- 10.8 mm; 1.8 mm
33. Pressure relief valve
- Checking see Fig. 3
34. A/C clutch -N25-*
- Sanden, servicing.
- Zexel, servicing.
Fig. 1 Low pressure service valve, removing
- Discharge refrigerant system before replacing valve -3-. Only use Kent Moore ACR4 or equivalent.
NOTE: Protect all opened components against contamination of dirt and moisture with suitable plastic caps.
1. Base with outside thread and groove for -O-ring
2. O-ring
Always replace
7,6 mm; 1,8 mm
3. Service valve
4. O-ring
Always replace
7,6 mm; 1,8 mm
5. Cap
Fig. 2 High pressure service valve, removing
- Discharge refrigerant system before replacing valve -3-. Only use Kent Moore ACR4 or equivalent.
NOTE: Protect all opened components against contamination of dirt and moisture with suitable plastic caps.
1. Base with inside thread
2. O-ring
Always replace
10,8 mm; 1,8 mm
3. Service valve with groove and inside thread for cap.
4. O-ring
Always replace
10,8 mm; 1,8 mm
5. Cap
Fig. 3 Pressure relief valve, checking
- Function: Protects refrigerant circuit from excessive pressure.
- The pressure relief valve shows whether valve has opened. An adhesive sticker is pushed out.