Page 1801 of 2490

Condenser:
Multi-pass fin-over-tube type, mounted in front of the engine cooling pack and directly to the radiator.
Pressure (Bitron) switch:
Located in the discharge pipe. Provides a signal, via the A/CCM, to th e ECM, to disengage the compressor clut ch should the refrigerant pressure be
< 2 bar or > 30 bar.
Provides a hard-wired signal to the ECM, to switch the cool ing fans to HIGH speed at 22 bar rising pressure and to
LOW speed at 17,5 bar falling pressure.
Provides a hard-wired signal to the ECM, to switch the radiator cooling fans to LOW speed at 12 bar rising pressure
and to switch the fans OFF at 8 bar falling pressure.
Expansion Valve
Parts List
The expansion valve is located inside the heater / air conditioning unit and comprises of a diaphragm, connected by a
capillary tube to a temperat ure sensing bulb, which regulates the valve according to temperature variations at the
evaporator outlet pipe. This component is NOT serviceable. See 'Refrigeration Cycle'
Air Conditioning (Heater / Cooler) Unit
ItemPart NumberDescription
1—Valve body
2—Pressure spring
3—Diaphragm
4—Capillary tube
5—Temperature sensing bulb
6—Valve inlet
7—Valve outlet
8—Equalizer pipe
Page 1802 of 2490

Parts List
The air conditioning unit houses the evap orator, heater matrix and their temperatur e sensors. The unit also incorporates
two servo motor operated air distribution flaps which regulate airflow to the front and rear footwells and the quantity of
airflow through the cool air bypass (air which by-passes he ater matrix) up to the upper air distribution box (ADB).
When the footwell flap is open, air is du cted to the front and rear footwell areas via the lower air distribution duct (LADD)
and appropriate ducts. The LADD is clipped to the bottom of the air conditioning unit case an d the front foot ducts clipped
onto the outlets of the LADD.
Condensate (water) which forms on the evaporator fins is drained out of the unit case through two drains, located either
side of the unit underneath the evaporator. The liquid is routed to the vehicle exterior via flexible tubes which are located
behind the firewa ll heatshield.
Refrigeration Cycle
ItemPart NumberDescription
1—Air inlet - LH (RH opposite, not shown)
2—Servomotor - cool air bypass
3—Servomotor - footwell outlet
4—Air outlet - footwell
5—Air outlet - ADB (with foam seal)
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Refrigeration Cycle
The Compressor draws low pressure, lo
w te
mperature, refrigerant from the evaporat or and, by compression, raises the
refrigerant temperature and pressure. High pressure, hot, vaporized refr igerant enters the condenser, where it is cooled by
the flow of ambient air. A change of state occurs as the refrigerant cools in the condense r and it becomes a reduced
temperature, high pressure, liquid.
From the condenser, the liquid passes into the receiver drier which has three functions:
Storage vessel
for varying sy
stem refrigerant demand.
F
ilter to remove sy
stem contaminants.
Mo
isture removal via the dessicant.
With the passage through the receiver drie r completed, the liquid refrigerant, still at high pressure, enters the expansion
valve where it is metered through a contro lled orifice, which has the effect of reducing the pres sure and temperature. The
refrigerant, now in a cold atomized st ate, flows into the evaporator and cools the air passing through the matrix.
As heat is absorbed by the refrigerant, it once again changes state, into a vapor, and returns to the compressor for the
cycle to be repeated.
An automatic safety valve is incorporated in the compressor, which will operate if the system pressure rises above 41 bar.
The valve will reseat when the pressure drops below 27,6 bar.
It
em
Par
t Number
De
scription
1—Compre
ssor
2—Conden
ser
3—Re
ceiver drier
4—Expans
ion valve
5—Evaporator
6—4
-level pressure switch
The terms 'high' and 'low'
pressure (or si
de) refer to the pres sure differential betw een the compressor and expansion valve
ports. This differential is critical to sy stem fault diagnosis and efficiency checks.
Page 1804 of 2490
Air Conditioning - Air Conditioning (A/C) Compressor
Removal and Installation
Removal
1. Disconnect battery ground cable (IMPORTANT, see SRO
86.15.19 for further information).
2. Recover refrigerant from air co nditioning system; refer to
82.30.30.
3. Remove supercharger drive belt (where fitted); refer to
18.50.08.
4. Remove front end accessory dr ive belt; refer to 12.10.40 or
(SC) 12.10.40.
5. NOTE: A commercially availa ble brake pipe clamp is
recommended. Do not over tighten.
Clamp power steering reservoir to pump feed hose.
6. Raise vehicle for access
7. NOTE: Position drain tin to collect the fluid when union nut is
released.
Disconnect steering rack hose from pump. 1. Release union nut.
2. Discard O-ring.
3. Install suitable blanking plugs.
8. Disconnect clutch harness connector from compressor.
1. Disconnect connector.
9. Disconnect lines from compressor.
Discard O-rings.
Install suitable blanking plugs.
Page 1805 of 2490
Installation
10. NOTE: Reposition compressor after releasing the fixings to
allow removal.
Remove compressor.
Remove bolts.
11. NOTE: This step is not necessar y in the case of refrigerant
loss.
Measure amount of oil held in compressor.
Remove blanking plugs from the compressor.
Pour oil from compressor into a suitable measuring
container. Note amount and discard the oil.
Install blanking plugs to compressor.
1. Fill new compressor with correct amount of oil.
Remove blanking plugs from compressor.
Pour oil from compressor into a suitable container.
Fill compressor with the same amount of oil that was
removed from original compre ssor, plus amount recovered from recovery equipment.
Install blanking plugs to compressor.
2. Install compressor.
Tighten fixings.
Page 1806 of 2490
3. Install lines to compressor.
Install new O-ring seal and lubricate with clean
compressor oil.
4. Connect clutch harness connector to compressor.
1. Connect clutch connector.
5. Connect power steering hose to pump.
1. Remove blanking plugs.
2. Install new O-ring seal and lubricate with clean
compressor oil.
3. Tighten union nut.
6. Lower ramp.
7. Unclamp power steering rese rvoir to pump feed hose.
Page 1807 of 2490
8. Install front end accessory drive belt; refer to 12.10.40 or (SC)
12.10.40.
9. Install supercharger drive belt (where fitted); refer to
18.50.08.
10. Reconnect battery ground cable (IMPORTANT, see SRO
86.15.15 for further information).
11. Recharge air conditioning system; refer to 82.30.30.
12. Check / bleed / top up power stee ring fluid reservoir; refer to
211-02.
Page 1808 of 2490

Air Conditioning - Condenser Core
Removal and Installation
Removal
1. Disconnect battery ground cable (IMPORTANT, see SRO
86.15.19 for further information).
2. Drain radiator coolant only; refer to 26.10.01 or (SC)
26.10.01.
3. Recover refrigerant from air co nditioning system; refer to
82.30.30.
4. Release both gas struts, set the engine cover fully forward to
the service access position an d support with a wooden (or
similar) strut.
5. CAUTION: Take care not to damage hood or radiator
grille.
Remove twin fan and motor as sembly; refer to 26.25.12.
6. Disconnect radiator bleed hose.
Release connection.
7. Remove retaining clip which secures transmission oil cooler
upper and lower pipes.
8. Disconnect transmission oil cooler lower pipe from radiator.
1. Release union nut and disconne ct pipe.
Discard O-ring seal.
2. Install suitable blanking plugs.
9. From above the vehicle, discon nect transmission oil cooler
upper pipe from radiator.
1. Release union nut and disconne ct pipe.
Discard O-ring seal.
2. Install suitable blanking plugs.