87-161

Compressor/engine applications
Engine Manufacturer Engine code USA/Canada 1.8L T 5V Motronic 110 KW 1.8L T 5V Motronic 110 & 125 KW 2.8L V6 Motronic 142 KW 4.0L W8 Motronic 202 KW 10.00: Zexel DCW-17D 10.00 : Denso 7SB-16C Denso 7SB-16C Denso 7SEU16 AEB, ATW AUG, AWM AHA & ATQ BDP

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Condensor, removing
CAUTION! Before beginning repairs on the electrical system: Obtain the anti-theft radio security code. Switch the ignition off. Disconnect the battery Ground (GND) strap. After reconnecting battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows according to Repair Manual and/or Owner's Manual. - Discharge refrigerant system Page 87-173 .

- Bring front end assembly (lock carrier) into service position Repair Manual, Body Exterior, Repair Group 50 . - Vehicles 10.00 : Remove front bumper carrier Manual, Body Exterior, Repair Group 63 (10.00 Repair )

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- Loosen and separate refrigerant pipes/couplings from evaporator. CAUTION! Immediately plug open connections on A/C components and lines to prevent dirt and moisture contamination. 1 - Lock carrier 2 - Clip Vehicles 10.00 3 - Bracket Vehicles 10.00 4 - Grommet, upper 5 - Condensor 6 - Left air guide 7 - Right air guide 8 - Bolt Vehicles 10.00

8 Nm (71 in lb) Qty.: 4

9 - Rubber grommet, lower

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Heating and A/C unit, removing and assembly

CAUTION! Before beginning repairs on the electrical system: Obtain the anti-theft radio security code. Switch the ignition off. Disconnect the battery Ground (GND) strap. After reconnecting battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows according to Repair Manual and/or Owner's Manual. Removing - Discharge refrigerant system Page 87-173 .

- Clamp off and disconnect coolant hoses to heater core Repair Manual, Engine Mechanical, Repair Group 19. - Disconnect refrigerant lines to evaporator.

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CAUTION! Immediately plug open connections on A/C components and lines to prevent dirt and moisture contamination. - Remove instrument panel Interior, Repair Group 70 . Repair Manual, Body Page 87-72 .

- Loosen instrument panel cross-member - Remove heating and A/C unit. Assembly 1 - Heater core

Always use new coolant after replacement. 2 - Housing, upper part 3 - Evaporator Attaching inlet/outlet seal, Fig. Installing seal Fig. 4 - Housing, lower part With fresh/recirculating air flap With central air flap 2 1

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Fig. 1

Evaporator inlet/outlet seal, attaching

- Evaporator inlet -B- and outlet -A- pipes must be insulated between the halves of the housing with seal -C-.

Fig. 2

Evaporator seal, installing

- Foam seal -B- must must be glued around circumference of evaporator -A-. - To allow evaporator water to drain, do not attach foam seal on evaporator in area -C-.

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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. When an additional, rear evaporator is present, additional compressor oil must be added after replacing the compressor. Always replace the accumulator whenever the refrigerant system has been opened. 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.

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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 Page 87-191 . 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.

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A/C refrigerant system pressures and temperatures, checking

The pressures and temperatures in the A/C system will vary depending on engine speed (RPM), coolant fan speed, engine coolant temperature, A/C clutch engagement, outside temperature, humidity, etc. Pressure and temperature specifications are based on the following: Engine speed (RPM) at 1500 Fresh air blower on high speed A/C adjusted to Max. cooling 1 - Compressor, high pressure side 2 - Condenser 3 - Restrictor 4 - Evaporator 5 - Accumulator 6 - Compressor, low pressure side

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Pressure and temperature specifications Refer to pages Page 87-169 and 133 for component identification. Component 1 - Compressor, high pressure side 2 - Condenser Refrigerant state Gas Gas to Vapor to Liquid 3 - Restrictor Liquid to Vapor High pressure side: up to 20 bar (290 psi) High pressure side: up to 60 C (140 F) Approximate pressure (bar/psi) Up to 20 bar (290 psi) Page 87-

Approximate temperature Up to 70 C (158 F)

Low pressure side: greater than 1.5 bar (22 psi)1) 4 - Evaporator Vapor to Gas Greater than 1.5 bar (22 psi)1)

Low pressure side: warmer than -4 C (25 F)

Warmer than -4 C (25 F)

6 - Accumulator 7 - Compressor, low pressure side

1)

Gas Gas

Low side pressure is maintained in the refrigerant system by the variable displacement compressor despite variables in temperature, load and engine speeds (RPM).

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A/C refrigerant system, testing with pressure gauges

Due to the constant temperature/pressure relationship of refrigerant R-134a, approximate high-side system temperature can be determined based on system pressure. Pressure gauges may have one or more temperature scales in addition to the pressure scale. Since various refrigerants have different temperature/pressure relationships, each gauge is specific for a particular refrigerant. Measuring pressure and temperature in a "switched-on" refrigerant system Use the A/C refrigerant high-pressure gauge to measure high pressure between the compressor and restrictor (including condenser) with the A/C switched on. Use the A/C refrigerant low-pressure gauge to measure low pressure between the restrictor and the compressor inlet (including evaporator) with the A/C switched on. The temperature displays of the low- and highpressure gauges apply only to a portion of the low- and high-pressure sides. The low-pressure

gauge displays approximate temperature between the restrictor and evaporator outlet. The high-pressure gauge displays approximate temperature between the compressor outlet and restrictor.

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Note: The temperature/pressure relationship only holds true when the refrigerant system contains liquid and vapor, but not when it contains only gas. In the gaseous state, the temperature is approx. 1030 C (18-54 F) higher than indicated on the pressure gauge. Measuring pressure and temperature in a closed container or "switched-off" refrigerant system Due to the constant temperature/pressure relationship of R-12 and R-134a, approximate temperaturein a closed container or in a switched-off A/C system can be determined based on its pressure. If the temperature displayed on a gauge is lower than the actual temperature of the refrigerant, the refrigerant container or system is empty (discharged). Note: The temperature/pressure relationship only holds true when the refrigerant system contains liquid and vapor, but not when it contains only gas. In the gaseous state, the temperature is approx. 10-

30 C (18-54 F) higher than indicated on the pressure gauge.

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A/C refrigerant system, discharging

WARNING! Always use an Underwriter's Laboratory (UL) approved refrigerant recovery/recycling/recharging unit such as Kent-Moore ACR4, or equivalent, whenever discharging an R-134a A/C system. Any person who services a motor vehicle air conditioner MUST, by law, be properly trained and certified and use approved refrigerant recycling equipment. Technicians must complete an EPA approved recycling course to be certified. State and local governments may have additional requirements regarding air conditioning servicing. Always comply with state and local laws. Always wear safety goggles when charging or discharging system.

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CAUTION! Always use separate refrigerant recovery/recycling/recharging servicing equipment for R-12 and R-134a systems. DO NOT use one piece of equipment for both R12 and R-134a systems. The residual traces of refrigerant inside the equipment will contaminate and damage the equipment. Servicing equipment includes recovery/recycling/recharging unit, charging station, vacuum pump, manifold gauges, etc. DO NOT use R-12 servicing equipment on R134a systems or R-134a equipment on R-12 systems or damage to both the vehicle A/C system and servicing equipment may result. Use only equipment designed to meet Society of Automotive Engineers (SAE) standards. R-134a and R-12 systems use different size service fittings. NEVER use adaptors to convert an R-12 fitting to R-134a size or R134a fitting to R-12 size. Note: Refer to safety measures starting on page

Page 87-1 prior to discharging or charging A/C refrigerant system.

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Note: Make sure that initial set-up of the refrigerant recovery/recycling/recharging unit has been completed before discharging the A/C system. - Connect red high-pressure hose -A- of refrigerant recovery/recycling/recharging unit to high side fitting on vehicle and open coupler valve. - Connect blue low-pressure hose -B- of refrigerant recovery/recycling/recharging unit to low side fitting on vehicle and open coupler valve. CAUTION! Always follow manufacturer's instructions when using a refrigerant recovery/recycling/recharging unit. - Following refrigerant recovery/recycling/recharging unit manufacturer's instructions, discharge A/C system into refrigerant recovery/recycling/recharging unit. - Disconnect power supply from A/C clutch to prevent accidental compressor operation with A/C system discharged.

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A/C refrigerant system, flushing with compressed air and nitrogen

CAUTION! When using compressed nitrogen always use a pressure regulator and the proper adaptor hoses and fittings (available locally). During flushing, use existing exhaust/ventilation systems to draw off the gas mixture escaping from the A/C system. DO NOT flush R-134a refrigerant system with R-11. R-11 is not compatible with R-134a refrigerant and PAG oil and will cause total system contamination. Use compressed air and nitrogen (available locally) to remove moisture, impurities and old refrigerant oil from A/C refrigerant system. First blow out old refrigerant oil and dirt with compressed air, then dry components with nitrogen.

DO NOT blow compressed air and nitrogen through the compressor or expansion valve.

Only blow compressed air and nitrogen through disconnected, free flowing components (i.e. disconnected hose, condenser, evaporator, etc.) DO NOT blow compressed air and nitrogen into a capped off A/C component. Pressurized R134a refrigerant in the presence of oxygen may form a combustible mixture.

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Always flush components in opposite direction of refrigerant flow. Flush evaporator through the low-pressure line with the high-pressure line removed. If any component has dark thick deposits that cannot be removed with compressed air, replace component. Thin light gray deposits in refrigerant lines and hoses are normal and do not impair the function of the system. Always replace receiver drier and restrictor after flushing. Dispose of contaminated refrigerant (PAG) oil following laws governing hazardous waste disposal. Do not combine PAG oil with any other old oils such as engine oil or transmission fluid.

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Flush refrigerant system with compressed air and nitrogen if: Refrigerant oil is dark and viscous (thick) Too much refrigerant oil is in the system following compressor replacement Unclear or do not know how much refrigerant oil is in the system Moisture, dirt or other impurities have entered the refrigerant system (i.e. following an accident) Unable to pull a constant vacuum during evacuation of a leak-free system due to excessive moisture in the system Refrigerant system has been open longer than the time required for normal repairs (i.e. following an accident) Based on temperature and pressure measurements, system is diagnosed with moisture contamination

Compressor is replaced due to noises or internal damage Flushing is required after replacing certain components in certain situations Page 87167

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A/C refrigerant system, evacuating and recharging

WARNING! Always use an Underwriter's Laboratory (UL) approved refrigerant recovery/ recycling/recharging unit such as KentMoore ACR4, or equivalent, when evacuating and recharging an R-134a A/C system. Any person who services a motor vehicle air conditioner MUST, by law, be properly trained and certified and use approved refrigerant recycling equipment. Technicians must complete an EPA approved recycling course to be certified. State and local governments may have additional requirements regarding air conditioning servicing. Always comply with state and local laws. Always wear safety goggles when discharging, evacuating and recharging an A/C system.

CAUTION! Always follow manufacturer's instructions when using a refrigerant recovery/recycling/recharging unit.

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Notes: Refer to R-134a safety measures starting on page prior to discharging or charging A/C refrigerant system. Follow refrigerant recovery/recycling/recharging unit manufacturer's instructions for evacuating and recharging A/C system. Evacuate refrigerant system for a minimum of 30 minutes. When recharging A/C system, add correct amount of refrigerant and PAG oil to system Page 87-191 . After system recharge, manually rotate A/C compressor approx. 10 turns before starting engine. Start engine with A/C OFF. After idle speed has stabilized, switch A/C ON and let engine idle (compressor running) for a minimum of two minutes before raising engine speed.