A/C Refrigerant System, Replacing Components

A/C Refrigerant System, Replacing Components

Replacement A/C compressors, evaporators and condensers supplied by the Parts Dept. are filled with Nitrogen. If gas (Nitrogen) does not escape when component is first opened, the component may be faulty (leaking), do not install.

Replacement A/C compressors are filled with the total refrigerant oil quantity needed for the entire refrigerant system.

Always replace the receiver drier whenever the refrigerant system has been left open. Install immediately after opening to prevent moisture contamination of drier desiccant. Moreover, keep refrigerant system and other replacement components sealed for as long as possible to minimize the chance of dirt and moisture contamination.

Always plug open refrigerant line connections to prevent dirt and moisture contamination.

If the system has been discharged due to a damaged or leaking component (refrigerant hose/line, compressor, evaporator, condenser, etc.), flush the refrigerant system first with compressed air, then with nitrogen (available locally) and collect the oil that runs out. This will remove the refrigerant oil which may be saturated with moisture.

CAUTION: DO NOT flush R-134a refrigerant system with R-11. R-11 is not compatible with refrigerant R-134a and PAG oil and will cause total system contamination.

If the compressor is not replaced after flushing the system, fill compressor with the correct type and quantity of refrigerant oil as specified under A/C system capacities. Fill compressor with the total system oil capacity.

If the compressor is replaced, do not add any additional oil as the total amount of oil required is already in the compressor.

Dispose of contaminated refrigerant oil following laws governing hazardous waste disposal. Do not combine any refrigerant oil with any other old oils such as engine oil or transmission fluid.

Follow all applicable Warnings and Cautions when working on the A/C system.


A/C Refrigerant System, Replacing Components







CAUTION:
Before beginning repairs on the electrical system:
- Obtain the anti-theft radio security code.
- Switch off all electrical consumers.
- Switch off ignition and remove ignition key.
- Disconnect negative ( - ) battery terminal.
- When disconnecting and reconnecting battery terminals, observe all applicable Notes and torque specifications, as well as instructions on performing OBD program and electrical system function checks as specified.
- Immediately plug open connections on A/C components to prevent dirt and moisture contamination.

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 system components illustrated must only be serviced or replaced after discharging refrigerant system.

NOTE: During servicing, all couplings, fittings and related fasteners must be torqued to specifications.

1. Sealing plug
- 15 Nm (11 ft. lb)
2. O-ring
- 10.8 mm; 1.8 mm
3. Receiver drier
4. O-ring
- 10.8 mm; 1.8 mm
5. Refrigerant pipe
- From receiver drier to expansion valve
6. Bolt
- 15 Nm (11 ft. lb)
7. A/C pressure switch -F129- (4-Pin) or high pressure sensor -G65- (3-Pin)
- Depending on engine type, refrigerant systems have either an A/C pressure switch -F129- or high pressure sensor -
- G65- installed. Refer to appropriate wiring diagram.
- Component can be removed without discharging refrigerant system
8. O-ring
- 10.8 mm; 1.8 mm
9. Refrigerant pipe
10. Threaded plate
11. O-ring
- 10.8 mm; 1.8 mm
12. Expansion valve
13. Bolt
- 8 Nm (71 in lb)
14. O-ring
- 14 mm; 1.8 mm
15. High pressure service valve
- Only use Kent Moore ACR4 or equivalent
16. Refrigerant pipe
17. Low pressure service valve
- Only use Kent Moore ACR4 or equivalent
18. O-ring
- 7,6 mm; 1.8 mm
19. Evaporator
- In heater/evaporator unit
- Removing heater/evaporator unit, disassembly and assembly
20. O-ring
- 16.7 mm; 1.8 mm
21. Insulation
22. O-ring
- 7,6 mm; 1,8 mm
23. Bolt
- 8 Nm (71 in lb)
24. Refrigerant hose
- From compressor to condenser
25. Bolt
- 15 Nm (11 ft. lb)
26. O-ring
- 10.8 mm; 1.8 mm
27. Condenser
28. Compressor
- Sanden SD7-V16
- Removing and installing compressor bracket
29. O-ring
- 14.3 mm; 2.4 mm
30. Bolt
- 20 Nm (15 ft. lb)
31. O-ring
- 10.8 mm; 1.8 mm
32. A/C clutch -N25-*
- Sanden
33. Refrigerant hose
34. O-ring
- 10.8 mm; 1.8 mm
35. Damper