Page 1489 of 1954

A/C Syste m Torqu e Specification s
EVAPORATOR PRESSUR E REGULATO R
SUCTION LIN E
EVAPORATO R
CONDENSE R LIN E
Discharg e hos e t o th e compresso r ( 6 x 1. 0 mm ) .................................................................... . 9. 8 N- m (1. 0 kgf-m , 7. 2 Ibf-ft )
Discharg e hos e t o th e condense r ( 6 x 1. 0 mm)...................................................................\
.... . 9. 8 N- m (1. 0 kgf-m , 7. 2 Ibf-ft )
Condense r lin e t o th e condense r ( 6 x 1. 0 mm ) .......................................................................\
. 9. 8 N- m (1. 0 kgf-m , 7. 2 Ibf-ft )
Condense r lin e t o th e receiver/drye r ( 6 x 1. 0 mm ) ................................................................. . 9. 8 N- m (1. 0 kgf-m , 7. 2 Ibf-ft )
Receive r lin e A to th e receiver/drye r ( 6 x 1. 0 mm ) ................................................................. . 9. 8 N- m (1. 0 kgf-m , 7. 2 Ibf-ft )
Receive r lin e A to th e condense r ( 6 x 1. 0 mm ) .......................................................................\
. 9. 8 N- m (1. 0 kgf-m , 7. 2 Ibf-ft )
Receive r lin e B to th e condense r ( 6 x 1. 0 mm)...................................................................\
..... . 9. 8 N- m (1. 0 kgf-m , 7. 2 Ibf-ft )
Receive r lin e B to th e evaporato r ( 6 x 1. 0 mm ) .......................................................................\
. 9. 8 N- m (1. 0 kgf-m , 7. 2 Ibf-ft )
Suctio n lin e t o th e evaporato r ( 6 x 1. 0 mm ) .......................................................................\
.... . 9. 8 N- m (1. 0 kgf-m , 7. 2 Ibf-ft )
Suctio n lin e to th e evaporato r pressur e regulato r ................................................................... . 3 1 N- m (3. 2 kgf-m , 2 3 Ibf-ft )
Suctio n hos e t o th e evaporato r pressur e regulato r ( 6 x 1. 0 mm ) ......................................... . 9. 8 N- m (1. 0 kgf-m , 7. 2 Ibf-ft )
Suctio n hos e to th e compresso r ( 6 x 1. 0 mm ) .......................................................................\
. . 9. 8 N- m (1. 0 kgf-m , 7. 2 Ibf-ft )
Compresso r t o th e oi l pa n ( 8 x 1.2 5 mm ) .......................................................................\
............ . 22N- m (2. 2 kgf-m , 1 6 Ibf-ft )
COMPRESSO R
SUCTION HOS E
DISCHARG E HOS E
RECEIVE R LIN E ARECEIVER/DRYE R
RECEIVER LIN E B
CONDENSE
R
ProCarManuals.com
Page 1490 of 1954

A/C System Service
Recovery
Use only service equipment that is U.L.-listed and is cer-
tified to meet the requirements of SAE J2210 to remove
HFC-134a (R-134a) from the air conditioner system.
CAUTION: Exposure to air conditioner refrigerant and
lubricant vapor or mist can irritate eyes, nose and
throat. Avoid breathing the air conditioner refrigerant
and lubricant vapor or mist.
If accidental system discharge occurs, ventilate work
area before resuming service.
R-134a service equipment or vehicle air conditioner sys-
tems should not be pressure tested or leak tested with
compressed air.
Some mixtures of air and R-134a have been
shown to be combustible at elevated pressures and can
result in fire or explosion causing injury or property dam-
age. Never use compressed air to pressure test R-134a
service equipment or vehicle air conditioner systems.
Additional health and safety information may be obtained
from the refrigerant and lubricant manufacturers.
1. Connect a R-134a refrigerant recovery/recycling/
charging station to the vehicle, as shown, following
the equipment manufacturer's instructions.
2. Measure the amount of refrigerant oil removed from
the A/C system after the recovery process is com-
pleted.
RECOVERY/RECYCLING/CHARGING STATION
LOW-PRESSURE
SIDE
HIGH-PRESSURE
SIDE
NOTE: Be sure to install the same amount of new
refrigerant oil back into the A/C system before charg-
ing.ProCarManuals.com
Page 1491 of 1954

A/C Syste m Servic e
Performanc e Tes t
The performanc e tes t wil l hel p determin e i f th e ai r con -
ditione r syste m is operatin g withi n specifications .
Us e onl y servic e equipmen t tha t i s U.L.-liste d an d i s cer -
tifie d t o mee t th e requirement s o f SA E J221 0 t o remov e
HFC-134 a (R-134a ) fro m th e ai r conditione r system .
CAUTION : Exposur e t o ai r conditione r refrigeran t an d
lubrican t vapo r o r mis t ca n irritat e eyes , nos e an d
throat . Avoi d breathin g th e ai r conditione r refrigeran t
an d lubrican t vapo r o r mist .
I f accidenta l syste m discharg e occurs , ventilat e wor k
are a befor e resumin g service .
R-134 a servic e equipmen t o r vehicl e ai r conditione r sys -
tem s shoul d no t b e pressur e teste d o r lea k teste d wit h
compresse d air .
Som e mixture s o f ai r an d R-134 a hav e bee n
show n to b e combustibl e a t elevate d pressure s an d ca n
resul t i n fir e o r explosio n causin g injur y o r propert y
damage . Neve r us e compresse d ai r t o pressur e tes t R -
134 a servic e equipmen t o r vehicl e ai r conditione r sys -
tems .
Additiona l healt h an d safet y informatio n ma y b e obtaine d
fro m th e refrigeran t an d lubrican t manufacturers .
1 . Connec t a R-134 a refrigeran t recover/recycling /
chargin g statio n t o th e vehicle , a s shown , followin g
th e equipmen t manufacturer' s instructions .
2 . Inser t a thermomete r i n th e cente r ai r vent . Deter -
min e th e relativ e humidit y an d ai r temperature .
3 . Tes t conditions :
Avoi d direc t sunlight .
Ope n hood .
Ope n fron t doors .
Se t th e temperatur e contro l dia l o n MA X COOL ,
th e mod e contro l switc h o n VEN T an d th e recir -
culatio n contro l switc h o n RECIRCULATE.
Tur n th e A/ C switc h on , an d th e fa n switc h o n
MAX .
Run th e engin e a t 1,50 0 rpm .
N o drive r o r passenger s i n vehicl e
4 . Afte r runnin g th e ai r conditionin g fo r 1 0 minute s
unde r th e abov e tes t conditions , rea d th e deliver y
temperatur e fro m th e thermomete r i n th e das h ven t
an d th e hig h an d lo w syste m pressur e fro m th e A/ C
gauges .
RECOVERY/RECYCLING/CHARGIN G STATIO N
LOW-PRESSUR ESIDE
HIGH-PRESSUR ESIDE
ProCarManuals.com
Page 1492 of 1954
5. To complete the charts:
Mark the delivery temperature along the vertical line.
Mark the intake temperature (ambient air temperature) along the bottom line.
Draw a line straight up from the air temperature to the humidity.
Mark a point one line above and one line below the humidity level (10% above and 10% below the humidity level).
From each point, draw a horizontal line across the delivery temperature.
The delivery temperature should fall between the two lines.
Complete the low side pressure test and high side pressure test in the same way.
Any measurements outside the line may indicate the need for further inspection.
DELIVERY
PRESSURE
DELIVERY
PRESSURE
DELIVERY
TEMPERATURE
HUMIDITY
LEVEL
HUMIDITY
LEVEL
HUMIDITY
LEVEL
DELIVERY
TEMPERATURE
INTAKE TEMPERATURE
INTAKE
PRESSUREProCarManuals.com
Page 1493 of 1954

A/C Syste m Servic e
Pressur e Tes t Char t
NOTE : Performanc e Tes t i s o n pag e 22-76 .
Test result s
Discharg e (high )
pressur e abnor -
mall y hig h
Discharg e pres -
sur e abnormall y
low
Suctio n (low )
pressur e abnor -
mally lo w
Suctio n pres -
sur e abnormall y
high
Suctio n an d dis -
charg e pres -
sure s abnormall y
hig h
Suctio n an d dis -
charg e pressur e
abnormall y lo w
Refrigeran t leak s
Relate d symptom s
After stoppin g compressor , pres -
sur e drop s t o abou t 20 0 kP a
(2. 0 kgf/cm
2, 2 8 psi ) quickly , an d
the n fall s gradually .
Reduce d o r n o ai r flo w throug h
condense r
Lin e to condense r i s excessivel y
hot.
Hig h an d lo w pressure s ar e bal -
ance d soo n afte r stoppin g compres -
sor . Lo w sid e is highe r tha n normal .
Outle t o f expansio n valv e is no t
frosted , low-pressur e gaug e indi -
cate s vacuum .
Expansio n valv e is no t frosted , an d
low-pressur e lin e is no t cold . Low -
pressur e gaug e indicate s vacuum .
Discharg e temperatur e is low , an d
th e ai r flo w fro m vent s i s restricted .
Expansio n valv e is frosted .
Receiver/drye r outle t i s cool , an d
inle t i s war m (shoul d b e war m
durin g operation) .
Low-pressur e hos e an d chec k
join t ar e coole r tha n th e tempera -
tur e aroun d evaporator .
Suctio n pressur e is lowere d whe n
condense r i s coole d b y water .
Hig h an d lo w pressur e ar e equal -
ize d a s soo n a s th e compresso r i s
stopped , an d bot h gauge s fluctu -
ate whil e running .
Reduce d ai r flo w throug h con -
denser .
Low-pressur e hos e an d meta l en d
area s ar e coole r tha n evaporator .
Temperatur e aroun d expansio n
valv e i s to o lo w compare d wit h
tha t aroun d receiver/dryer .
Compresso r clutc h i s dirty .
Compresso r bolt(s ) ar e dirty .
Compresso r gaske t i s we t wit h oil . Probabl
e caus e
Ai r i n syste m
• Clogge d condense r o r
radiato r fin s
• Condense r o r radiato r fa n
no t workin g properl y
Restricte d flo w o f refriger -
an t i n syste m
• Fault y compresso r dis -
charg e valv e
• Fault y compresso r sea l
• Fault y expansio n valv e
• Moistur e in syste m
• Froze n expansio n valv e
• Fault y expansio n valv e
Froze n evaporato r
Clogged expansio n valv e
Clogge d receiver/drye r
• Expansio n valv e ope n to o
lon g
• Loos e expansio n capillar y
tub e
Excessiv e refrigeran t i n sys -
tem
• Fault y gaske t
• Fault y high-pressur e valv e
• Foreig n particl e stuc k in
high-pressur e valv e
• Clogge d condense r o r
radiato r fin s
• Condense r o r radiato r fa n
no t workin g properl y
Clogge d o r kinke d low -
pressur e hos e part s
Clogge d high-pressur e lin e
Compresso r shaf t sea l leakin g
Leakin g aroun d bolt(s )
Gaske t leakin g Remed
y
Recover , evacuate , an d
recharg e wit h specifie d amount .
Evacuation : se e pag e 22-8 8
Charging : se e pag e 22-8 9
• Clean .
• Chec k voltag e an d fa n rpm .
• Chec k fa n direction .
Restricte d line s
Replac e th e compressor .
• Replace .
• Recover , evacuate , an d
recharg e wit h specifie d amount .
Replac e th e expansio n valve .
Ru n th e fa n wit h compresso r
off , the n chec k evaporato r
temperatur e sensor .
Clea n o r replace .
Replace .
Repair o r replace .
Recover , evacuate , an d
recharg e wit h specifie d amount .
Replac e th e compressor .
• Clea n condense r an d radia -
tor.
• Chec k voltag e an d fa n rpm .
• Chec k fa n direction .
Repai r o r replace .
Repai r o r replace .
Replac e th e compressor .
Tighte n bolt(s ) o r replac e com -
pressor .
Replace th e compressor .
ProCarManuals.com
Page 1494 of 1954

Compressor
Replacemen t
1. I f th e compresso r i s marginall y operable , ru n th e
engin e a t idl e speed , an d le t th e ai r conditione r
wor k fo r a fe w minutes , the n shu t th e engine off.
2 . Mak e sur e yo u hav e th e anti-thef t cod e fo r th e radio ,
the n writ e dow n th e frequencie s fo r th e radio' s pre -
se t buttons .
3 . Disconnec t th e negativ e cabl e fro m th e battery .
4 . Recove r th e refrigeran t wit h a recovery/recycling /
chargin g statio n (se e pag e 22-75 ).
5 . Loose n th e A/ C compresso r bel t (se e pag e 22-85 ).
A/ C COMPRESSO R BEL T
6. Remov e th e nuts , the n disconnec t th e suctio n lin e
an d th e discharg e lin e fro m th e compressor .
NOTE : Plu g o r ca p th e line s immediatel y afte r dis -
connectin g the m to avoi d moistur e an d dus t con -
tamination .
SUCTION LIN E
DISCHARG E LIN E
6 x 1. 0 m m9.8 N- m (1. 0 kgf-m ,
7 Ibf-ft )
7. Remov e th e mountin g bolt s an d th e compressor .
8 x 1.2 5 mm22 N- m (2. 2 kgf-m , 1 6 Ibf-ft )
8. Remov e th e bolt s an d th e suctio n servic e valv e
fro m th e compressor .
25.5 N- m (2. 6 kgf-m , 18. 8 Ibf-ft )
SUCTIO N SERVIC E
VALV E
O-RIN G
Replace .
ProCarManuals.com
Page 1495 of 1954

Compressor
Replacemen t (cont'd )
9. Remov e th e mountin g bolt s an d th e idle r pulley .
IDLER PULLE Y
MOUNTIN G BOLT S
10. Chec k th e idle r pulle y bearin g fo r pla y an d drag .
Replac e it wit h a ne w on e i f it' s nois y o r ha s exces -
siv e pla y o r drag .
ADJUSTIN GBOLT
IDLE RPULLE YCENTE RBOLT
10 x 1.2 5 mm44 N- m (4. 5 kgf-m , 3 3 Ibf-ft )
11. Instal l i n th e revers e orde r o f removal . Mak e not e o f
th e followin g items .
I f you'r e installin g a ne w compressor , drai n al l
th e refrigeran t oi l fro m th e remove d compressor ,
an d measur e it s volume . Subtrac t th e volum e o f
draine d oi l fro m 14 0 m ( 4 2/ 3 fl-oz , 4. 9 Imp-oz) ;
th e resul t i s th e amoun t o f oi l yo u shoul d drai n
fro m th e ne w compresso r (throug h th e suctio n
fitting).
Replac e th e O-ring s wit h ne w one s a t eac h fitting ,
an d appl y a thi n coa t o f refrigeran t oi l befor e
installin g them .
NOTE : B e sur e t o us e th e righ t O-ring s fo r HFC -
134a (R-134a ) t o avoi d leakage .
Use refrigeran t oi l (ND-OI L 8 ) fo r R-134 a DENS O
piston typ e compressor s only .
To avoi d contamination , d o no t retur n th e oi l t o
th e containe r onc e dispensed , an d neve r mi x i t
wit h othe r refrigeran t oils .
Immediatel y afte r usin g th e oil , reinstal l th e ca p
o n th e container , an d sea l i t t o avoi d moistur e
absorption .
D o no t spil l th e refrigeran t oi l o n th e vehicle ; i t
ma y damag e th e paint ; i f th e refrigeran t oi l con -
tact s th e paint , was h it of f immediately .
Adjus t th e A/ C compresso r bel t (se e pag e 22-85 ).
Charg e th e syste m (se e pag e 22-89 ), an d tes t it s
performanc e (se e pag e 22-76 ).
Th e PC M memor y mus t b e rese t afte r reconnect -
in g th e batter y (se e pag e 11-125 ).
Ente r th e anti-thef t cod e fo r th e radio , the n ente r
th e customer' s radi o statio n presets .
ProCarManuals.com
Page 1496 of 1954
Illustrated Inde x
CENTE R BOL T
PRESSUR E PLAT E
Inspection , pag e 22-8 2
SHIM(S )
SNAP RIN G B
Replace .
PULLE Y
Inspection , pag e 22-8 2
SNA P RIN G A
Replace .
FIEL D COI L
Inspection , pag e 22-8 2
RELIE F VALV E
Replacement ,
page 22-8 4O-RIN GReplace .
SUCTION SERVIC E VALV E
O-RIN
G
Replace . COMPRESSO
R
(Do no t disassemble )
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