AIR CONDITIONING
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING 82-1
AIR CONDITIONING REFRIGERANT RECOVERY, RECYCLING AND RECHARGING
Refrigerant recovery - recycling and
recharge
$% 82.30.02
Refrigerant recovery
WARNING: Servicing must only be carried
out by personnel familiar with both the
vehicle system and the charging and testing
equipment. All operations must be carried
out in a well ventilated area away from open
flame and heat sources.
1.Remove dust caps from high and low pressure
connectors.
2.Connect high and low pressure hoses to
appropriate connections.
3.Open valves on connectors.
4.Turn valves on refrigerant station to correct
positions.
5.Turn process switch to correct position.
6.Turn main switch to 'ON'.
7.Allow station to recover refrigerant from
system.
WARNING: Refrigerant must always be
recycled before re-use to ensure that the
purity of the refrigerant is high enough for
safe use in the air conditioning system.
Recycling should always be carried out with
equipment which is in compliance with SAE
J2210. Other equipment may not recycle
refrigerant to the required level of purity. A
R134a Refrigerant Recovery Recycling
Recharging Station must not be used with
any other type of refrigerant. Refrigerant
R134a from domestic and commercial
sources must not be used in motor vehicle
air conditioning systems.
8.Close valves on refrigerant station.9.Turn main switch to 'OFF'.
10.Close valves on connectors.
11.Disconnect high and low pressure connectors.
12.Fit dust caps to connectors.
13.Open tap at rear of station to drain refrigerant
oil.
14.Measure and record quantity of refrigerant oil
recovered from system.
15.Close tap at rear of station.
Evacuation
1.Remove dust caps from high and low pressure
connectors.
2.Connect high and low pressure hoses to
appropriate connections.
3.Open valves on connectors.
4.Turn valves on refrigerant station to correct
positions.
5.Turn Process switch to correct position.
6.Turn main switch to 'ON'.
7.Allow station to evacuate system.
Recharging
CAUTION: The system must be evacuated
immediately before recharging
commences. Delay between evacuation and
recharging is not permitted.
1.Close valves on refrigerant station.
2.Close valve on oil charger.
3.Disconnect yellow hose from refrigerant
station.
4.Remove lid from oil charger.
5.Pour correct quantity of refrigerant oil into oil
charger.
+ GENERAL DATA, Air Conditioning.
6.Fit lid to oil charger.
7.Connect yellow hose to refrigerant station.
8.Open valve on oil charger.
9.Move pointer on refrigerant gauge to mark
position of refrigerant drop.
10.Slowly open correct valve on refrigerant station
and allow vacuum to pull refrigerant into
system.
11.Close valve on refrigerant station when correct
amount of refrigerant has been drawn into air
conditioning system.
+ GENERAL DATA, Air Conditioning.
12.Turn main switch to 'OFF'.
13.Close valves on connectors.
14.Disconnect high and low pressure connectors.
15.Fit dust caps to connectors.
M82 0728
AIR CONDITIONING
ADJUSTMENTS 82-3
ADJUST ME NTS
Drive belt - compressor - Td4
$% 82.10.01
Check
1.Disconnect battery earth lead.
2.Remove underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
3.Turn steering on RH lock.
4.Remove 3 bolts and RH splash shield.
5.Check condition of drive belt. Renew a drive
belt that shows signs of wear and splitting.Adjust
1.Loosen clamp and pivot bolts of compressor
drive belt tensioner.
2.Apply an anti-clockwise torque of 38 Nm (28
lbf.ft) for an existing belt and 47 Nm (35 lbf.ft)
for a new belt to tensioner plate hexagon.
3.Tighten tensioner clamp bolt to 24 Nm (18
lbf.ft).
4.Tighten tensioner pivot bolt to 24 Nm (18 lbf.ft).
5.Fit splash shield and tighten bolts to 10 Nm (7.5
lbf.ft).
6.Fit underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
7.Connect battery earth lead.
M82 0721
AIR CONDITIONING
REPAIRS 82-5
REPAIRS
Drive belt - compressor - Td4
$% 82.10.02
Remove
1.Disconnect battery earth lead.
2.Remove ancillary drive belt.
+ CHARGING AND STARTING,
REPAIRS, Ancillary drive belt - Td4.
3.Loosen clamp and pivot bolts of compressor
drive belt tensioner.
4.Remove compressor drive belt.Refit
1.Ensure compressor drive belt and compressor,
crankshaft and tensioner pulleys are clean.
2.Fit compressor drive belt.
3.Adjust compressor drive belt.
+ AIR CONDITIONING,
ADJUSTMENTS, Drive belt - compressor -
Td4.
4.Fit ancillary drive belt.
+ CHARGING AND STARTING,
REPAIRS, Ancillary drive belt - Td4.
5.Connect battery earth lead.
M82 0721
AIR CONDITIONING
82-6REPAIRS
Compressor - Td4
$% 82.10.20
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Disconnect battery earth lead.
3.Recover refrigerant from A/C system.
+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery -
recycling and recharge.
4.Remove compressor drive belt.
+ AIR CONDITIONING, REPAIRS,
Drive belt - compressor - Td4.
WARNING: Under no circumstances should
refrigerant hoses be disconnected without
first discharging the system.
5.Remove 2 bolts securing A/C pipes to
compressor. Release pipes from compressor.
CAUTION: Before disconnecting or
removing components, ensure the
immediate area around joint faces and
connections are clean. Plug open
connections to prevent contamination.
6.Remove and discard 'O' rings from A/C pipes.7.Loosen bolt securing compressor support
bracket to sump, do not remove.
8.Remove 3 bolts and remove compressor from
mounting bracket. Move support strap aside,
disconnect compressor multiplug and remove
compressor.
Refit
1.If a new compressor is being installed, drain the
required amount of refrigerant oil from the new
compressor.
+ GENERAL INFORMATION, Air
conditioning compressor replacement.
2.A new compressor is sealed and pressurised
with Nitrogen gas, slowly release the sealing
cap, gas pressure should be heard to release
as the seal is broken.
3.Ensure mating faces of A/C pipes and
compressor are clean.
4.Fit A/C compressor to mounting bracket, align
support strap and tighten bolts to 25 Nm (18
lbf.ft).
5.Connect multiplug to compressor.
6.Lubricate new 'O' rings with clean refrigerant oil
and fit to evaporator pipes
7.Position A/C pipes to compressor, fit bolts and
tighten to 22 Nm (16 lbf.ft).
8.Replace receiver drier.
+ AIR CONDITIONING, REPAIRS,
Receiver drier.
9.Fit compressor drive belt.
+ AIR CONDITIONING, REPAIRS,
Drive belt - compressor - Td4.
10.Recharge A/C system.
+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery -
recycling and recharge.
11.Connect battery earth lead.
12.Remove stands and lower vehicle.
AIR CONDITIONING
REPAIRS 82-7
Compressor - KV6
$% 82.10.20
Remove
1.Disconnect battery earth lead.
2.Recover refrigerant from A/C system.
+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery -
recycling and recharge.
3.Remove underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
4.Remove RH front road wheel.
5.Remove 3 bolts securing RH splash shield to
body and remove shield.
6.Using a 3/8” square drive socket bar, raise
ancillary drive belt tensioner and release drive
belt from A/C compressor pulley.7.Remove 2 bolts securing high and low pressure
pipes to compressor. Release pipes from
compressor, remove and discard 'O' rings.
CAUTION: Before disconnecting or
removing components, ensure the
immediate area around joint faces and
connections are clean. Plug open
connections to prevent contamination.
8.Disconnect multiplug from compressor.
9.Note fitted position of heat shield on
compressor and remove 3 bolts securing
compressor to front mounting plate and
cylinder block. Remove compressor and heat
shield.
M12 6614
AIR CONDITIONING
82-8REPAIRS
Refit
1.If a new compressor is being installed, drain the
required amount of refrigerant oil from the new
compressor.
+ GENERAL INFORMATION, Air
conditioning compressor replacement.
2.A new compressor is sealed and pressurised
with Nitrogen gas, slowly release the sealing
cap, gas pressure should be heard to release
as the seal is broken.
3.Clean compressor and mating face on front
mounting plate and cylinder block.
4.Position compressor, fit but do not fully tighten
lower bolt.
5.Position heat shield and fit compressor upper
securing bolts. Tighten compressor upper and
lower securing bolts to 25 Nm (18 lbf.ft).
6.Remove caps from compressor and high
pressure pipe.
7.Clean compressor high pressure pipe
connection.
8.Lubricate new 'O' ring with refrigerant oil and fit
to high pressure pipe.
9.Connect high pressure pipe to compressor, fit
and tighten bolt to 25 Nm (18 lbf.ft).
10.Connect multiplug to compressor.
11.Remove caps from compressor and low
pressure pipe.
12.Clean compressor low pressure pipe
connection.
13.Lubricate new 'O' ring with refrigerant oil and fit
to low pressure pipe.
14.Connect low pressure pipe to compressor, fit
and tighten bolt to 25 Nm (18 lbf.ft).
15.Clean pulley 'V's and tensioner pulley running
surface.
16.Using a 3/8” square drive socket bar, raise
ancillary drive belt tensioner and fit drive belt to
pulleys.
17.Fit splash shield and secure with bolts.
18.Fit RH road wheel and tighten nuts to 115 Nm
85 lbf.ft).
19.Replace receiver drier.
+ AIR CONDITIONING, REPAIRS,
Receiver drier.
20.Recharge A/C system.
+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery -
recycling and recharge.
21.Connect battery earth lead.
22.Fit underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
Compressor - K1.8
$% 82.10.20
Remove
1.Disconnect battery earth lead.
2.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
3.Remove underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
4.Recover refrigerant from A/C system.
+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery -
recycling and recharge.
5.Remove alternator.
+ CHARGING AND STARTING,
REPAIRS, Alternator - K1.8.
6.Disconnect multiplug from compressor.
7.Remove 2 bolts securing A/C pipes to
compressor, release A/C pipes from
compressor.
CAUTION: Before disconnecting or
removing components, ensure the
immediate area around joint faces and
connections are clean. Plug open
connections to prevent contamination.
8.Remove and discard 'O' rings from A/C pipes.
M82 0730
AIR CONDITIONING
REPAIRS 82-9
9.Remove 3 bolts securing compressor to
mounting bracket.
10.Release compressor from mounting bracket
and remove from under vehicle.
11.Drain oil from old compressor and record the
amount drained.Refit
1.If a new compressor is being installed, drain the
required amount of refrigerant oil from the new
compressor.
+ GENERAL INFORMATION, Air
conditioning compressor replacement.
2.A new compressor is sealed and pressurised
with Nitrogen gas, slowly release the sealing
cap, gas pressure should be heard to release
as the seal is broken.
3.Ensure mating faces of A/C pipes and
compressor are clean.
4.Lubricate new A/C pipe 'O' rings with clean
refrigerant oil.
+ GENERAL DATA, Air Conditioning.
5.Fit 'O' rings to A/C pipes.
6.Fit A/C compressor to mounting bracket. Fit
and tighten bolts to 25 Nm (18 lbf.ft).
7.Position compressor mounting bracket, fit bolts
and tighten to 25 Nm (18 lbf.ft).
8.Connect A/C compressor multiplug.
9.Fit alternator.
+ CHARGING AND STARTING,
REPAIRS, Alternator - K1.8.
10.Replace receiver drier.
+ AIR CONDITIONING, REPAIRS,
Receiver drier.
11.Recharge A/C system.
+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery -
recycling and recharge.
12.Remove stands and lower vehicle.
13.Connect battery earth lead.
14.Fit underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
M82 0731
AIR CONDITIONING
82-10REPAIRS
Condenser
$% 82.15.07
Remove
1.Disconnect battery earth lead.
2.Recover refrigerant from A/C system.
+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery -
recycling and recharge.
3. Td4 models: Remove intercooler.
+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Intercooler.
4. Remove bumper valance.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
5. KV6 models: Remove 2 bolts securing PAS
fluid cooler to armature.
6. Up to 04MY: Remove 4 nuts and 4 bolts
securing armature to body, remove armature.
7. 04MY on: Remove 4 bolts securing armature to
crash cans and remove armature.8.If fitted, remove 4 scrivets securing LH and RH
air deflectors, remove both deflectors.
9.Remove 2 bolts securing condenser to radiator.
10.Remove 2 bolts securing receiver drier
mounting brackets to radiator.
M76 4176