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HEATING AND VENTILATIONCONTENTS

and Operationescription PageHeater UnitBlower UnitOperation

23.. 4Repairs PaseHeater unit and matrix - renew .... r",...............,Heater blower, recirc(!lation flap, fan and motor - renew .......... 3Heater control and cabr.,s - renew ....... '. ~ 6Resistor/harness - renew .... ...... ,' , , . . 7Vacuum servo -' renew .... , ................... 8Solenoid valve - renew .........,...... ...... , . 9Blower relay - renew .......... "c'" .:;,. , ,.... 10

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NOTESSymbols have the following meanings:

~. WARNING a CAUTION... NOTEm TORQUE WRENCH FIGURE

o SERVICE TOOL.m FASTCHECK EQUIPMENTI!NON REUSABL.E ITEMIiNFORMATION~;A/C

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i,iA/C HEATING AND VENTILATIONDESCR IP TION AND OPERAT ION

XM0289

HEATERUNff1. Heater unit2. Caseclip3. Blend lever4. Distribution lever5. Heat exchanger matrix6. Duct. left-hand footwall7. Duc:1.right-hand footwall8. Duc:1.floor9. Heater/floor duct joint

2 Description and Operation

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HEATING AND VENTILATION ~';A/C

BLOWERUNff1. Motor and fan assembly2. Relay3. Air box4. Vacuum actuator5. Vacuum solenoidS. Freshair inlet seal7. Harness8. Gasket - resistor board9. Flap and seals10. Duct. blower/heater unit11. Control assembly12. Distribution cable13. Temperature cable

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i;A/C HEATING AND VENTILATIONDESCRIPTION AND OPERAnON

OPERATIONAir is drawn through the intake scuttl., b.lowt~. wl~(fs~re.n and .nters the blower unit (1),whether fanassistedor not, the air will passthrough'~biae ~oth~h"ter .unit"located in the centre of the car ,under the fascia. The heater unit "(2) ~ fttt@dwith ta_,t-.mpeflatur.flap (3) and a distribution flap (4'whilst the blow.r unit carries a singI. r,circulation ffap 15~ ", . - 1 , ' - . 'Th. temperature flap (3) is used to dii;e~a.IL or"a , : p .~portion of the int~ke air through a matrix whichf, ... ....~~ -~recaiv.. a constant supply of hqt water from the angina, thus governing the temperatura of air entering the

~

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HEATING AND VENTILATION4t ~f: ~RE~P.~~~RS~'';A/C

4t

HEATER UN" AND MATRIX - RENEWActIonSlactenPositionReleaseRemoveDisconnect

1

Ref. Detail Special Instructions1. clips - heater hoses

drain trayheater hosesclosing panelscontrol cables - heater levers

2 off

Left and right hand under fascia

Repairs

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~;A/CR e m c M tCollectRemove :

SlideRemove:

SeparateRemoveReuaembleTop-up

2 Repairs

HEATING AND VENTILATIONREPAIRS

2 offduct - heater, blowerseals2. stud - right hand footwen duct3. duct.... studs - couplingcoupling5. clips - heater8. screws - heater7. heater assembly

seal - heater top8. screw - left hand duct

duct9. clips - face aperture10. aperture11. clips - heater casecase halves12. matrixcomponents

cooling system

.. ;.

" '

2 offRearwards2 off "

)_."

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,

HEATING AND VENTILATIONREPAIRS ~/A/C

Action Ref. Detail Spacial InstructionsDisconnect earth lead - batteryRemove .. closing panel Passenger side under fasciaOpen .~ gloveboxRemove : screws - glovebox bar 2 offglovebox assembly

1. ductCollect 2. seals 2 off Remove : bolt cover - fascia3. bolts Fascia retaining, left side 2 offDiIcoRnect : 4. multiplug5. vacuum pipe - 'servoRepairs 3

HEA TER BLOWER, RECIRCULA TlON FLAP , FAN AND MOTOR - RENEW

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~';A/C HEATING AND VENTILATION~~~p~~~~---------------------------t

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?11 124 Repairs

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HEATING AND VENTILATI ONREPA IRS

Remove :

Disconnect :Remove :

Re.....Remove:

Reauemble

6 . bolts. nut - blower unitblower unitclips' - blower unitseparator plate - fan. motor assemblynut - fanfan - motorcooling hose - motormultiplug - motorscrews - motor housinqmotorwashergasketretaining washer - servoservo - leverscrews. washers - bearingsbearingsflapcomponents

>. 3 off r, .

. ,~,'.>

. : > ; : , ' ; .~t'

~';A/C7 .8.9.10.11.1 2 .1 3 .14.1 5 .1 6 .17.18.19.

,.

Repairs 5

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ActIon Ref . DetailRemove : drivers closing panelinstrument cowlRaIeaae : 1. inner cables - heater leversouter cables - bracketRemove : 2 - screws - fasciacontrol and cables assemblyRelease: 3. cable outers - control unit4- cable inners - spring clipsRemove cablesReassemble componentsOperate controls

HEATING AND VENTILATIONREPAIRS

1

HEA T ERCONTROL AND CABLES - RENEWSpecia l Ins truc tionsUnder fasciaSee 1nstruments'

Through their full travel to set cables

6 Repairs

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RESISTOR / HARNESS - RENEWAction R ef. Detail Special Instructions','Disconnect earth lead - batteryRemoYe clqsing panel Passenger side under fasciaOpen gloveboxRemcwe : screws - glovebox bar : 2 offglovebox assembly

duct - blower, heaterCollect .eals :2 offRemove 1. cooling hoseDisconnect : 2. multiplug - relay3. multiplug - motor4. multiplug - solenoid switchS. multiplug - main harness. Re lease harness From around housingRemove : 8. screw - P clip

7 . screws - resistor 3 offresistor, harness assembly 8. gasleet

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HEATING AND VENTILATIONREPAIRS ~';A/C

Repairs

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(}iA/C1

:

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SOLENO ID VALVE - RENEW Action Ref . Detail'Diaconnect earth lead ~ batteryRemow closing pane'Open glovebolCRamo": screws - glovebolC barglovebolCaSSemblyduct - blower, heaterCollect als. Disconnect: 1 . vacuum pipe - solenoid2. multiplug - solenoidRemove: 3. screw - solenoidsolenoidReassemble components

HEATING AND VENTILATIONREPAIRS ~';A/C

8",c181 InstructionsPassenger side2 off

2 off

Repairs 9

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;.HEATINGAND VENTILATION

BLOWER RELA Y - RENEWActIon Ref. Detail Special InstructionsDisconnect earth lead - batteryRemove closing panel Passenger sideOpen glolleboleRemove : screws - glollebox bar 2 off

glollebole assemblvduct - blower, heaterCollect. se81s 2 offDisconnect 1. multiplug - relav emove: 2. screw - relavrelavReasaemble componentsRepairs

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AIR CONDITIONINGCONTENTS

Descr ip tion and Operation PageAir conditioning system components - 2.0 engine 2Air conditioning system components - V6 engine 3Air conditioning electrical components - 2.0 engine bay .4Air conditioning electrical components - 2.7 engine bay 5Air conditioning electrical components - interior 7Compressor components - 2.0 engine with front mounted power steering pump 8Compressor components - V6 engine 9Receiver/drier components ; 9Condenser components ~ ~ 10Evaporator components ; 11Heater distribution and blend unit components : , 12Blower unit components 13Schematic layout of the air conditioning system ; 14-Air conditioning system operation : 15Air conditioning system electrical connections 17Air conditioning cut - outs ; 17Air conditioning control system : 18

Adjustments PageGeneral precautions . : 1~~~~:~=.:~:i. . . . . , ~ ? - : : ~ : : : ~ : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : ~Chargmg cyllnd'er;";'~'b"""""'''''''''''''''''''''''''''''''''''' 5System flushing ; ~~.;;;.::;~ .., 6Air conditioning system - ,~ .1 f . ; , , , 7Air conditioning system - e : a= .-.E(;~i.: ~ 8Air conditioning system ' c;haqje .~::;,.;.;".~.J ; _ _ , 9Compressor/alternator drivcfbelt- ad~~~~,O,engine 11Compressor/alt~rnator/steeri!'g pump dt'itt.~~.~.iij)ust - 2.0 engine 12Compressor dnve belt - adjUst - V6 en4Ine ..;.~ : ~ 13

RepairsReceiver/drier _; renew 1Thermostatic switches - radiator and condenser coolil'lg fan - renew 2Condenser - renew 3Pipes and hoses - renew 4Compressor and tensioner pulley - renew - 2.0 with rear mounted rear mountedsteering pump 5Compressor and tensioner pulley - renew - V6 7High pressure and dual pressure switches - renew 9Blower motor - renew 10Recirculated air mode motor - renew 11Evaporator - renew 12Blower unit - renew 13Thermostatic expansion valve - renew 14Heater distribution and blend unit renew 15Condenser cooling fan motor - renew 16Air conditioning mode unit - renew 17Compressor and tensiOner pulley - renew - 2.0 with front mounted powersteering pump : 18

NOTESSymbols have the following meanings:

~ = WARNI NGA = CAUTI ON = N O T EI i J = TORQUE WRENCH FIGUREo = SERVICE TOOLC D = F AS TC HE CK TO OLfI = NON REUSABLE ITEM1I = INFORMATION

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~;A/C AIR CONDITIONINGDESCRIPTION AND OPERATION

.:AIR CONDITIONING SYSTEM COMPON,NTS - 2.0 ENGINE

1. Compressor2. Condenser3. Cooling tans, behind radiator4. Receiveridrier5. Evaporator6. Thermostatic expansion valve

7. Thermistor8. Heater distribution and blend unit9. Blower unit10. High and low pressure servicing connections11. High pressure switch12. Dual pressure switch


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AIR CONDITIONINGDESCRIPTION AND OPERATION ~';A/C

AIR CONDITIONING SYSTEM COMPONENTS - V6 ENGINE1. Compressor2. Condenser3. Cooling fans, behind radiator4. Receiver/drierS . Evaporator6. Thermostatic expansion valve

7. Thermistor8. Heater distribution and blend unit9. Blower unit10. High and low pressure servicing connections11. High pressure switch

12. Dual pressure switch

Descnption and Operation 3

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A IR CONDITIONINGDESCRIPTION AND OPERATION

XM1090AIR CONDITIONING ELECTRICAL COMPONENTS - 2.0 ENGINE BAY

1. Relay - compressor clutch2. Relay - cooling fan3. Relay - fan change over 14. Relay - fan change over 2

5. High pressure switch6. Dual pressure switch7. Temperature switch - engine cooling system8. Temperature switch - air condit ioning


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XM1088

AIR CONDITIONING ELECTRICAL COMPONENTS - 2.7 ENGINE BAY

1. Relay - compressor clutch2. Diode - hot restart E.C.U.3. Engine oil temperature sensor4. Relay - cooling fan5. Relay - blowerlchange over 16. Relay - blower',.change over 27. High pressure switch

8. Dual pressure switch9. Temperature switch - air conditioning10. Temperature switch - engine cooling11. Coolant temperature thermistor - coolant tophose12. Engine overheat E.C.U.

Description and Operation 5

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"AIR CONDITIONINGDESCRIPTION AND OPERATION

6 DescriptionandOperation

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AIR CONDITIONING, . , , ' C t ; . . : D _ E _ S _ C _ R _ I P _ T _ I O _ N _ A _ N _ D _ O _ P _ E _ R _ A _ T _ I O _ N _: ' , r t : 1 . ,; ,, ; ' ; ' "~..

5. Speed control transistor6. Blower motor7. Mode motor - air recirculationa Air conditioning amplifier9. Mode motor - temperature control10. Fan speed interface unit11. Function control unit',2. Mode motor - air distribution

AIR CONDITIONING ELECTRICAL COMPONENTS - INTERIOR

'.

. " . ' _

1. Hot restart E.C.U:Below l.H. front seat - 2.5Below R.H. front seat - 2.72. Engine overheat e .c . u . - 2.53. Adaptor - low voltage isolation unit2.5 - centre console2.7 - adjacent to fusebox4. Relays - blower motor

If fitted

Description and Operanon 1

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_, -4t;A/C A1R;CONDIT IONINGDESCRIPTION AND OPERATION

COMPRESSOR COMPONENTS - 2.0 ENG IN E 'W ITH FRONT MOUNTED POWERSTEERING PUMP

1. Compressor2. Tensioner pulley"3. Drive belt

r '\1 .. 4. low pressure line. evaporator to compressor". 6. HJ,ghpressure line, compressor tothermostatic expansion valve and condenser

, ,.Po"",,.-.,._


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,; ,4.,ioowpressure line. condenser to compressor,I, '~ ' High pressure line. compressor to "th~rmostatic expansion valve

. " . . . . . . , , " f t .COMPRESSOR COMPONeNtS;': V E N G 'N \:,~t\ :.~~~:j.:' "

1. Compressor2. Tensioner pulley3. Drive belt,.~.

XM0736

RECEIVER/DRIER COMPONENTS1. Receiver/drier2. Sight glass3. Safety plug

4. High pressure line - receiver to evaporator5. High pressure line - condenser to receiver6. Drying agent

XM0731


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i;A/C AIR CONDITIONINGDESCRIPTION AND OPERATION

XM0790

CONDENSER COMPONENTS1. Condenser.2. Condenser fan3. Condenser fan thermostatic switch

~ ~ , ". , . , ' I I '4. Radiator fan thermostatic switch5. Radiator. behind condenser6. Radiator fan

10 Descnonon and Operation

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EVAPORATOR COMPONENTS1. Evaporator2. Thermostatic expansion valve 3. Thermistor4. Drain tube

DeSCription and Operation 11

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AIR CONDITIONINGDESCRIPTION AND OPERATION

HEATER DISTRIBUTION AND BLEND UNIT COMPONENTS1. Heater matrix2. Heater air distribution mode motor3. Heater control mode motor4. Vacuum control switch. coolant5. Heater control amplifier

6. Fan spee,d interface7. Heater sub - harnessa Air mode lever9. Air mode plate10. Vent mode lever


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,< AIR CONDITIONINGDESCRIPTION AND OPERATION

BLOWER UNIT COMPONENTS1. Blower casing2. Fan .3. Blower motor4. Blower motor cooling connection5. Relays

6. Blower motor speed circuit power transistor7. Fresh/recirculated air mode motor8. Air conditioning amplifier9. Blower sub - harness

XM0463


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AlA CONDITIONINGDESCRIPTION AND OPERATION

tF3

A1 XM0726

SCHEMATIC LAYOUT OF n.tE AIR CONDITIONING -SYSTEMA2. A ir flow through fan and evaporatorA3. Air flow to vehicle interiorF1. High pressure high temperatureR12 vapourF2. High pressure slightly cooledR12 liquidF3. High pressure slightly cooledA12 liquid withmoisture, vapour bubbles andforeign matter removedF4. Low pressure low temperatureatomised liquid R12F5. Low pressure high temperatureR12 vapour

1. Compressor2. Condenser3. Receiver/drier4. Thermostatic expansion valve5. Evaporator6. Capillary tube7. Dual pressure switch8. High pressure switch9. Cooling fans to increase airflow10. Drying agent11. Filter12. Sight glass13. Fan motorA1. Air flow through condenser

14 Desenonon and Operation

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AIR CONDITIONINGDESCRIPTION AND OPERATION i,JA/C

AIR CONDITIONING SYSTEM OPERATIONThe air conditioning system provides the means of supplying cooled and dehumidified, fresh or recirculated airto the interior of the vehicle. The cooling effect is obtained by blowing air through the matrix of an evaporatorunit and when required, mixing that air with heated air by means' of the heater distribution and blend unit, toprovide the conditions required inside the vehicle. The volume of cOnditioned air being supplied is controlled bya variable speed blower.Sealed refrigerantA sealed system, charged with Freon Refrigerant R12, together with a blower unit. blend unit and controlsystem combine to achieve the cooled air condition.The sealed system comprises the following main components:1. Compressor2. Condenser3. Receiver/drier4. Thermostatic expansion valve5. EvaporatorThe compressor (1), belt driven from the crankshaft pulley, pressurises and circulates the refrigerant throughthe system. MOl,lnted on the compressor, an electro - mech'Wcal clutch maintains the correct temperature andpressure by engaging or disengaging to support the syste",,srequirements. The clutch action is normally .controlled by a thermistor located at the evaporator (5). A radial tYpe compressor is fitted to the V6 engine anda swashplate type is fitted-.to the 2.0 litre engine.Should the temperature 'at .the evaporator (5) fall low enough for ice to begin to form on the fins, the thermistorsignals the ECU to disengage .the clutch and also isolates the coolfng fans relays. When the temperature at theevaporator (5) rises to the contr-ol temperature, the system is reactivated. .Should the system pressure I : > ~ c ~ m ~xcessive or drop suffiCiently to cause damage to the compressor (1) adual pressure switch (7), located in the highFpressore line. signals the ECU to disengage the clutch. Excessivepressure also activates the high pressure swi,C1'I(8). the cooling f e n s (9) are then switched to high speed.From the compressor. high pressure vapouri~tid Rl'~"(F1) .gas~e~ to the condenser (2), which is mounted infront of the engine coolant radiator. Ram~r(A!I:.)passing: through'the condenser (2) supplemented whenrequired, by two cooling fans (9) mounted on the r e a r of the engine coolant radiator. cools the R12 vapoursufficiently to form a high pressure slightly cooled liquid (F2). TIlis liquid then passes to a receiver/drier (3)which fulfils five functions. It acts as a reservoir. moisture extractor (10), filter (11). has an emergency pressurerelief plug fitted behind the pipe adaptors and by means of a sight glass (12) provides a method of determiningthe state of the R12 without breaking into the system.From the receiver/drier (3) the moisture free R12 liquid passes through a thermostatic expansion valve (4). Thisvalve. converts the liquid R12 to a low temperature, low pressure vapour (F4).To prevent liquid passing through the valve. a capillary tube (6), attached to the outlet pipe of the evaporator (5)and connected to the thermostatic expansion valve (4), controls the amount that the valve opens and closes inrelation to the temperature of the low pressure high temperature R12 vapour (F5) at the outlet. The atomisedR12 then passes through the evaporator (5). Ram air or fan blown air (A2) passes through (A3) the matrix of theevaporator and is cooled by absorbsion due to the low temperature R12 passing through ~he evaporator.A thermistor is fitted to the bas~ of the. evaporator to sense the temperature of the exterior fins. Should icebegin to form due to a too cold condition it will signal t h ' e ' electro - mechanical clutch on the compressor (1) todisengage. . '.From the evaporator, low pressure high temperature R12 vapour (F5) passes to the compressor to complete thecycle.


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. :AIR CONDITIONINGDESCRIPTION AND OPERATION

XM0789

16 Description clnd Operation

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AIR CONDITIONINGDESCRIPTION AND OPERATION ~';A/CI

AIR CONDITIONING SYSTEM ELECTRICAL CONNECTIONS1. Compressor2. Temperature switches3. Cooling fans'4. Receiver/drier5. Dual pressure switch6. High presswe switch ,7. Relay. electro~ineChanicaJ clutch8. Relay. fan changeover . 1 . :9. Relay, fan C~Mg,eover'lI ' .10. Blower assem"ly' .' ....":"f ...

l ~_.~~ .. .~

11. Mode motor - fresh re - circulatedair12. Evaporator13. Thermistor14. Heater distribution and blend unit15. Relay - fan speed interface16. Amplifier, heater control

17. Mode motor - air distribution18. Switch panel19. Air conditioning switch. , ; . : r,.,,'

AIR CONDITIO.~UT - OUTS~"" " l_' . ".7

Hightemperature 'c~;_'outA temperature sensor iil ,e radiator top hose register~ coolant temperature and is input to the high temperatureE.C.U.When coolant~ , ature rescnes 12 30 to 1.25 Cthe E.C.U.breaks the cooling fan relay earth paththrough the air conditio 'plifier. Because the cooling fan and condenser fan switch in the radiator are bothclosed at this temp thlU:;ooling fans will continue to operate at high speed. However, because the fuelE.C.U.does not rioW,.l~.el~~i ~ J g , - " a lfrom the relay it will switch off the earth path for the compressor clutchrelay. Air conditi9niri~i" be r~-~fMtated when the coolant temperature falls below 1200 C.' , ' . ' " , ' _ ' . . _ " , , ; _ - . , . ; ' _ . J. . ~ -< 1The blower v.:illcontinue t&o,., becal,l$;e!'e fan speed interface is still receiving a signal either through theclosed AlC switch or thefah""s "d"co(ltrol ~ClJit.f, , . . '..1 .t'f"Jl

Lowvoltage cut - out (If fltted~ . ! . ' " ,~t~,:.! :~~~~~.".The low voltage E.C.U.may be fitted I n are8$.~here~,Qeav.y.de.mandsre made on the battery. Battery voltageis monitored by the E.C.U. If the voltage IsbelGW 11.1-V, the)o.w voltage E.C.U.will break the earth path for thecooling fan relay and, as the temperafure switches'j" the'radl~tor ."ill usually be open, the cooling fans will beswitched off. The fuel E.C.U will react to the tans switching off and so switch off the earth path for thecompressor clutch relay. The low voltage E.C.U. also switches off the earth path for the blower motor, switchingoff the blower. Air conditioning will be re- instated when battery voltage rises above 12.4 V.


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~';A/C AIR CONDF{IONINGDESCRIPTION AND OPERATIONAIR CONDITIONING CONTROL SYSTEMThe air conditioning electrical and electronic control system comprises relays, mode motors, thermistors,pressure switches, ECU's and a switch panel. Inputs from outside the air conditioning system comprisetemperature information from the engine cooling and lubricating systems. Together these controls, inconjunction with the cooling fans, compressor clutch, blower and heater distribution and blend unit enableminimal input to maintain the required environment inside the vehicle.

1. Air conditioning switch 7. Defrostifeet mode switch2. Fan speed control lever .8. .Defrost mode switch3. Temperature control lever ~9. Fresh air/recirculated air mode4. Vent mode switch switch5. Fe"t lvent mode switch 10. Heated rear window switch6. Feet mode switch 11. Panel i llumination control leverWf\en air conditioning is not selected, air is supplied by ram effector blower to the areas selected by the modeswitches. The air mix flap on the b'lend unit controls the temperature ofthe air being supplied. No cooled air isavailable. "Selecting air conditioning provides the added facility 'O f cooled air available to be mixed as before. Whenrequired a fully cold condition can be selected which automatically closes the heated coolant access to theheater matrix. Mixtures of cooled, fresh, and hot air can be selected to give required interior environmentalconditions by selection at the switch panel.Dual pressure switchThe dual pressure switch. located in the high pressure line between the receiver drier and the evaporator,monitors R12 pressure and by means of the ECU controls the following system functions:1. Engine idle speed increased, if required, when R12 pressure exceeds 2.3 kg/cm2, 33 Ibflin2.2. R12 pressure drops below 2.3 kg/cm2, 33 Ibflin2 due to possible leakage, compressor electro - mechanicalclutch is dis - engaged. When pressure rises above control pressure the clutch is re - engaged.3. R12 pressure rises above 24 kg/cm2, 340 Ibflin2 due to possible blockage even with both cooling fansrunning at full speed. compressor electro - mechanical clutch is dis - engaged.


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' . r - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Pressure switchPressure switch in the high pressure line monitors R12 pressure and by means of an ECU controls the followingsystem function:1. R12 pressure exceeds 2 O _ j 5 kglcm2, 292 Ibflin2, the COOlingfans change over relays are activated connectingboth fans in parallel to ope'ite at high speed.Blower control 'Two relays. fitted on the lower casing of the blower unit,switch the battery supply to the blower motor andcontrol the speed of the motorwhich supplies air to the evaporator. One relay connects the battery supply tothe blower motor when the ignition .is switched on. The e a r t h path for the motor is completed either through thesecond relay for high blower speed, or through power switching transistors for variable for variable speed. Thetransistors are fitted jn the blower u..'t . , lower casing. An interface unit, fitted to the front of the heater, controlsthe transistor switching rate in res~.,. to the resistance value set by the fa n speed slide control on the fascia.An electric mode motor. fitted to .. '" 'de of the case, moves the fresh! recirculated air flap. The motor iscontrolled by an air conditlonin~ I _""plifier 0 , , the back of the blower motor. The fresh air/recirculationflap can move to two positlon4l . o~el'$ the outside air inlet. leaving open an inlet from the inside ofthe car, when recirculated aldr .~.. 'd.J"tile Other pOsition it will cover the inlet from the inside of the carleaving open the outside air ~'~tf,wtTenfresh air is required. .

,.; .'.""}, !Heater dlstrtbutlon and' "', .",:unit control

Blower unit ail flow. having.: .', through the evaporator passes into the heater bl~n

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, I

AIR CONDITIONINGADJUSTMENTS ~;A/C

GENERAL PRECAUTIONSThe refrigerant used in the air conditioning system is Oi - Chloro - Di - Fluoromethane. FREON (RefrigerantR12). FREON R11 is used as a system flushing agent.~ WARNING; Refrigerant R12 and refrigerant R11 s,.. hazardous liquids and when handled Incorrectlywill cause serious inJury." SuitAble prot~tlile" clothing must be worn when carrying out servicingoperations on the air cOl1dltlon!ng ~ t _ ~ .'~ WARNING; R t2 /S Odour ,e ss an t) c olo ur le sS . Do:nothand/e or discharge In an enclosed area, or Inany area where the vapour or liquid C 8 n come In~cofJtact"with naked flame or hot metal. R12 Is notflammable but can form PHOSGENEa highly toxic 'gas... WARNING: Do not sm ok e or weld In areas w , , ' . i W ~ R 1 21$ In use. Inhalation of concentratlons of th evapour can cause dizziness, disorientation. Incoordination, narcosis, nausea or vomiting.a WARNING; Do not allow fluids other than R12 or specified 'flushlng agent or compressor lubricant toenter the conditioning system. Spontaneous combustion will occur.~ WARNING: R12 splashed on any part of the body will cause Immediate freezing of that area. Alsorefrigerant cylinders and replenishment trolleys when dIscharging wl/l freeze slcln to them If contact ismade." CAUTION: The battery must always be disconnected prior to servicing or component replacement. Plug orcap open pipes and fittings to preveRt moisture or dust contaminating the system.' : i - ~ ' : , ' '' : 'A Note: Suitable protective clothing c,Qfllpr(ses:Wrap around safety glasses or helmet, heatproof gloves,rubber apron or waterproof overalls a n d rubber boots.REMEDIAL ACTIONS "1, If liquid R12 strikes the eye. d9 not rub it: Gently run large quantities of eyewash over the eye to raise thetemperature. If eyewash is not available cool. clean water may be used. Cover eye with clean pad and 'seek immediate medical attention.2. If liquid R12 is splashed'on the skin run large quantities of water over the area as soon as possible to raisethe temperature. Carry out the same actions if skin comes into contact with discharging cylinders. Wrapaffected parts in blankets or similar material and seek immediate medical attention.3. If suspected of being overcome by inhalation of R12 vapour seek fresh air. If unconscious remove to freshair. Apply artificial respiration and/or oxygen and seek immediate medical attention.

A Note: Due to its low evaporating temperature of - 30 "C, - 22" F R12 should be handled with care.~ WARNING; Do not allow a refrigerant container to be heated by a direct flame or to be placed nearany heating appliance. A refrigerant cont./ner must not be heated above s O G e , 122F.~ WARNING; Do not leave a c.onta/ner of refrigerant without the heavy metal cap fitted. Do not carry acontainer of refrigerant In.unauthorlsed transport especially In the boot of a car .

Adjustments 1

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AIR CONDITIONINGADJUSTMENTS

SERVICING PRECAUTIONSCare should be taken when handling components of the refrigeration system. Units must not be lifted by theirhoses. pipes or capilliary lines. Hoses and lines must not be subjected to any twi.st or stress. ensure that nosesare positioned in their correct run before fully tightening the couplings, and ensure that all clips and supportsare used. Torque wrenches of the correct type must be used when tightening refrigerant connections to thestated value. An additional spanner must be used to hold the union to prev~flt twisting of the pipe.Before connecting any hose or pipe ensure that refrigerant oil is applied to the seat of the new '0' ring seal.When discharging the system do not allow the refrigerant to escape too fast as it may draw the compressor oilout of the system. Use an oil trap to check if any oil is lost.All protective plugs must be left in place until immediately prior to connection.The receiver/drier contains dessicant which absorbs moisture. It must b8~OSitiveIY sealed at all times.Use alcohol and a clean cloth to clean dirty connections.Only refrigerant FREON R11 should be used for the flushing proce.dlJre:Never use R1l for a permanent~~. ~ . .

- ::~',.Use an approved refr igerant lubricating oil:BP Energol LPT 68Texaco Copella EShell Claus 33Suniso 5GS ,~. : < ~ :. .Refrigerant oil must not be stOred for Ip~g ~O?AS'~ ~~~attempt to pour unused oil back into the container.When renewing system component$;~d'cf~GlrOwing quantities of refrigerant oil:

~ . . . . \

",-. ':

Compressor V6 53cc .2.0 flozCompressor 2.0 25cc l.(ill. o~Condenser 30ce 1.0 fl ozEvaporator 60cc 2.0 fl ozPipe or hose lOce 0.3 fl ozReceiver/drier lOce 0.3 fl oz Note: When a new compressor is to be instalJ6d:gravity drain and messu;e the amount of existing oil andadd that amount of NEWrefrigerant oil through the suction union on the compressor, unless any of the abovecomponents are also being renewed. Should this occur add the .conea amount of oil for the compressor plusthe amount stated for the other components. When.the system has been flushed. add 153cc, 5.0" oz ofrefrigerant oil. .

2 Adjustments

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.'


PORTABLE TEST EQUIPMENTAir conditioning portable test equipment incorporates all the features necessary to carry out an air conditioningsystem analysis, discharging, evacuating and removal of moisture. accurate recharging and performancetesting.When storing the test equipment. ensure that all pipes connected with the system are sealed from theatmosphere. Where the pipe ends are not connected they should be screwed onto dummy mountings to sealthe pipe ends thus minimising the possibility of moisture ingress..AII the valves should be turned OFF duringstorage. Periodical checks should be made to mQnltor.~y .pressure build - up within the test equipment~~. '.The test equipment comprises:High and low pressure pipes. :..: .; .Usually about 1.8 m long so that a clearance ~an;~~ntained between the test equipment and the vehicle,thus minimising the possibility of damaglnQ'"~,~l:t@le paintwork. The end connection to the vehicle systemhas a Schrader type valve depressor bui.1tnto.a:.'There is a hose gasket fitted to provide~Ood 'seal between the vehicle system and the test equipment, thisshould be inspected for wear or dam~' fairly often. The sealing properties of this gasket can be prolongedwith the application of a small amount"of~(etrigerantoil.before use.. .",';J'Manifold a~embly , ~! . . ..This unit allows the test equiemEf't t9~evacuate,recharge and test the vehicle air conditioning system withoutdisconnecting any hose,$ ,f] :o.argepurposes the pipe connecting the manifold to the test equipment mustbe disconnectedso.tf l.; lt.~ ." '. . t~fU~can be ~ischar9~d !nto a receptac~e.This ~nables the ope~atortomeasu~ethe ~o~n~. 9f"'~.)fng~.Wtt.-..J~':!~~....'~~ the air condltlonmg system dunng the.discharge oper.atlon.To avoid the POSSibilitYi)trt/i. ~eotenng the vacuum pump dUring the system discharge operation, ensurethe vacuum pump valve i'sclo~i ......""' . : ~.The manifold is designed so t h a i the~th~)li9h and low pressure pipes are connected to the vehicle airconditioning system, with both of the .vaJve~n'the ~OFF' position, the gauge will read the vehicle systempressure. When the manifold is set to this positl~n. the'test equipment is isolated from the vehicle airconditioning system. The valve positions would depend upon which operation is being performed by the testequipment. . .Low pressure gaugeMeasures the low pressure side of the air conditioning system.It will also give a n indication of the vacuum depression when the system is being evacuated but although it issufficient for most vehicle~applications this gauge may not be able to detect very slight leaks.A separate vacuum gauge is necessary to accurately measure the degree of vacuum, this can be either a dialtype normally calibrated in 'TORR', or an electroniC type normally calibrated in 'MICRONS', (1 TORR = 1000MICRONS). There are approximately 760 TORR or 760,000 MICRONS pressure at sea level.High pressure gaugeMeasures the high pressure side of the air conditioning system, when the air conditioning system operation isbeing checked, the various t:nodes~an be seen to operate on this gauge with the different pressure alterationsindicating as they are selected. The relationship between the pressure readings on the two gauges provide areliable guide to the functioning of the system an~ an indication of when problems exist.Charging cylinder pressure gaugeIs connected to the top of the ch.argingcylinder sight glass. Its function is to measure the pressure variationsmade to the refrigerant R12 in the charging cylinder.

Adjustments 3

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. ,,L. 0v/A/C

... ~---

..A~RCOND1TIONINGADJUSTMENTS

' .~Jt. : u . ? f Vacuum pump valve'f 'Ie Function is to switch the vacuum pump depression to the manifold, and to isolate the vacuum pump from thetest equipment. . .; , Refrigerant control valve to the charging cylinderFunction is to connect the refrigerant drum, to the test equipment. It can be finely controlled so that refrigerantcan be slowly measured into the charging cylinder.

Refrigerant control valve to the manifold assemblyThis valve must be treated with the same consideration as the other valves. Its function is to control therefrigerant flow to the vehicle, via the manifold. If refrigerant is allowed to flow too quickly it will boil andvapourize, reducing the depression, which is required to draw the refrigerant into the vehicle system,Vacuum pump to manifold connecting pipe . ',':. " ,"Connects the vacuum pump to the vacuum pump valve on the maf\ifold. It:requiresa good seal so that thereare no leaks between the vacuum pump and the manifold. The connf3Qtionss,tlouldbe periodically checked fortightness. .

'I.t ..

1. Low pressure valve - BLUE ..2. Low pressure gauge - BLUE3. High pressure gauge - RED. ' ,',4. High pressure valve- REO' .,;"." ! ' z , . : ~ ~ >5. Charging cylinder vent,valve. ' ,",

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AIR 'CONDITIONINGADJUSTMENTS ~';A/C

CHARGING CYLINDER FILLING~ -WARNING: Ensure all safety precautIons are observed - goggles, protective gloves, apron andboots must b. worn. R.t.r to tft. GENERALPRECAUTIONSat ",. beginning of this s.ctlon.. Note: Carry out this operation at normal workshop temperature. ~.

Ref. Detailall valves closed ;charging pipe - o ' c~linder'cylinder upside down.':. .cylinder valve '.control valV! i:mPAif91drefrigerant ftQ~:",.,":,1$eYlfnder-cylinder V!tlt'~';~~~ l\ ~;re~g~f.an~:-:'. -.r&~ervoircyfinderveQt v a l v econtrol 'v a lv e : - : . manifold,c)'linder valv~ctt~ging pipe -. cylinder. ,!.'

,.....

' ; ' ; " _ f > } ''''f cllar:ging cylinder heater. cYllria'er.pres$ure'gauge'.;'!' i * ~ l f l J r n system lQ r leaks.: ~lir9irig ..~l iAder heater' - c Y . ~ e r , gresaure'gauge reading~u~, ~!"g .~ sight'glasssight;gla\s~~I,' . .

" ..~

Special InstructionsTest equipmentRefrigerant R12SlowlySlowlyn 1020 grm 360zAllow refrigerant. level to risen 425 grm 16 ozRefrigerant at required level& CAUTION: Unscrew connection slowly togradually release pressureFor up to 10 minutesn 690 to 830 kPa 100 to 120 Iblin2Rectify as necessaryRotate plastic shroud R12 band

ActionCheckConnectPoslttonOpenObserveSlowly open:Add Clos.HDisconnectSwttch-onObserveCheckSwitch-offNoteAlignCheck

Adjustments 5

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AIR CONDITIONINGADJUSTMENTS YSTEMFLUSHING

A WARNING: R12 and R11 are hazardous. refer to the GENERALPRECAUTIONSgiven at the beginningof this section. Note: The system must be flushed if refrigerant has leaJt.eddue.to component or pipe failure or wherecomponent failure has possibly contaminated the system or the system has been uncapped for longer thaneight hours.Use Freon(arcton) Rll as'e flusHin agent.

"Ref. Detail .ction

CheckDisconnect

system fullydiacl)argedcompressor nosesreciever/~rier pipesreCieve(ldrier pipes

Bridge

DisconnectWarmConnectPlaceH'oldOpenClose

compre5.$Or pipesA11 cy,!inderoutlet hose - A11 cylinderiniet,.hoSe - ,drainage bottleAll cylinder. above engineAll valveAll v~veRll cylinderA12 cylinderR12 valveR12 valveliquid in bottle

DisconnectConnectOpenCloseInspectReplaceReconnectEvacuateCharge

componentsall pipes and hosessystemsystem '"", "._

,J;

6 Adjustments

;t Special Instrudtions";'i20ff.. ,:i,;'ji! off., .J!' Reciever/Drier.......;. CAUTION: If system contains debris,

. 7;)rir;gethe thermostatic expansion valve. .. . tof t Ii 25 Nm, .\. "Water at 50C

C~ear'glasst o . . . . . - ' ; ~Slowly until.Rll flows into bottle

Allow R11 to drain through system tor 2 - 3minutes ,.

Slowly until Rll flows into bottle3~rs'eCbnas after R12 flows into bottleIf dirty;'rep8at flushing using new R1l and aclean bottle

;~.Smear seals with Refrigerant OilSee AdjustmentsSee AdJustments

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AIR CONDITIONING,~;'.-- . . ; . . A _ D _ J _ U _ S T _ M _ E _ N T _ _ S _ ~,;A/C

AIR' CONDITIONING SYSTEM - DISCHARGtl

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.


AIR CONDITIONING SYSTEM;": EVACUATE~ WARNING: R12 Is hazardous, rater to the GENERAL PRECAUTIONS given at the beginning of thissection.Do not tighten charging trolleyh9se connections. to systein pipelines more than 3 - 4 Nm otherwise Itwill cause distortion and may I '8sun In failure of the weld.& CAUTION: The battery must always be disconnected prior to servicing or component replacement.~ , . , "A Note: When the system has been opened to the atmosphere due to damage. installation or repair it mustbe evacuated. If the system has been open fOr:-several days the receiver/drier must be renewed. Add amountof Oil lost during discharge. VB at su

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AIR CONDITIONINGADJUSTMENTS ~;A/C

Stop vacuum pump Low pressure gauge should indicate above750 mm Hg, 30 in Hg and remain steady for10 minutes.A CAUTION: If low pressure does notreach more than 680 mm Hg. 27 in Hg in 15minutes there is a leal

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StartSwitch onOpenSetSelectOpen

CloseSwitch offStopTest

'AIR CONDITIONINGADJUSTMENTS igh pressure valve

engineAlC systemdoors or windowstemperature lever - coldblower - max speedvent mode

6. low pressure valve

low pressure valvecharging valveAlC systemenginesystem performance .

>~

,. " .

"

When charged with correct amount.ANote:" a full charge of 1020grm, 36OZhas not been accepted. continue withp;ocedure by stBrling the engine.Run at 1500 r.p.m.

,Switch panel, Slowly allow remainder of R12 to be drawninto system.& CAUTION: This procedure must becil.rried out slowly otherwise liquid R12 willd amage the compressori.""

""

", ': T - Return controls to normal,,.."!-!~~

S e e Fault DIagnosis Manual

..~ ~f..l.1"

, -

Adjustments

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AIR CONDITIONING; ~ . { . . , . . . ; A _ D _ J U _ S _ T _ M _ E _ N _ T _ S _'~iI< ~~.~~O~DENSER COOLING FANS -~NEW 'ActionDisconnectRemove

PositionDisconnectRemove. .CleanInspectTestReassembleFill

2 RepaIrs

Ref. Detail , , Special Instructions' , < .earth.lead '~~batteryfiller cap - coolant reservoir Ii. WARNING: System hot, protect handsagainst sieam or boiling water, remove

filler cap slowly '0\ gr.dually releasepressure. \rdrain tray

1. connectors switches 3 off. condenser switch has inhibitedconnector2 off bayonet fi)(ing2 off2 off

2. retaining rings - radiator3. switches - radiator4. seals - radiatorcomponentssealsthermostatic switchescomponentscooling system

Renew if damaged or deterioratedSee Fault Diagnosis ManualSee Cooling 2.0 or Cooling 2.7

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AIR CONDITIONINGREPAIRS

. ,.,,

CONDENSER - RENEWActionSwitch onDisconnectDischarge

Ref. Detail'. .. . . .,; .~ , Special InstructionsTo circulate R12 refrigerantystem

.I .e 8l'tt\ :Ie ad .- ' battery" . '... system . j. ". ~ WARNING: R12 Is hazardous, wearprotective clothing. See AdJustmentsSee Body2 off f iJ 6 NmSee Cooling 2.0 or Cooling 2.7m 20Nm~ CAfJTION:Use backing spanner toprevent pipes distortingm 12Nm~ CAfJTION: Use backing spanner toprevent pipes distortingR.H. drive only m 12Nm& CAfJTION: Use backing spanner toprevent pipes distorting2 off. R.H. drive onlyR.H. drive only2 off f! Lubricate refrigerant oil

Remove front grille1. nuts - condenser2. bonnet platform3. union- condenser

to

Disconnect. . 4. union - condenser

5. union - pipe

MoveRemovePlug

6. bolts - pipe clipspipe asideo ring seals - pipe unionspipe unionscondenser.

Continued ...Repairs 3

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~;A/CRemove

CheckReassembleEvacuate

ChargeTeat


7. condenser 4- body Uft upward, Do not damage oil cooler pipefins where fitted. CAUTION: Do not remove plugs fromnew unit unt;1 immediately before assembly.If no plugs are fit ted, reject unitAre in position. rubber mountingscomponentssystem SeeAdjustments.It'' WARNING: R12 Is hazardous, wearproteCtJye clothing. See Adjustmentssystemsystem performance S e , e .F~Ult Diagnosis Manual

PIPES AND HOSES - 'RENEWActionDisconnectDischargeRemove

Check

ReassembleEvacuateChargeTest

4 Repairs

Ref. Detail ., . ~ ,~_pecia ,inst ruct ions. - ~ ', 7 ' . .-3earth lead- batterysystem :~ ,~ i. 't iJRN'NG: R12 Is hazardous, wear.... ", prote~""ve clothing. See Adjustmentssuspect pipe or ho~ ~, .~"~ Ii) 9 7 1 ' 6 in union 12 Nm_ - , . j o ; , ; (i 3 1 4 in union 20 Nm.: (i 7/~ in union 25 NmfJ Lubricate with refrigerant oil onreassembly .

For deteriorationoses '.pi~. I . ! ' . - For GQfr~sionRene\'9iWherenecessaryWherel~olts are used to fix pipes tocorrlPd'ri~nts:M6Ii&.NmM8 ~,NmM10 45 NmM12 80 Nmcomponentssystem It . . ,NG: R12 Is hazardous. wearprot~ clothing. See AdjustmentsCh_.t'6r leakage. s\e Fault DiagnosisMan.See MIt"Dlagnosls Manual

systemsystem'system :perlormance

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AIR CONDITIONINGREPAIRS ~/A/C

COMPRESSOR AND TENSIONER PULLEY - RENEW - 2.0 WITH REAR MOUNTEDPOWER STEERING PUMPActionSwitch on

Ref. Detail Special InstructionsA Note: Only if compressor is operable tocirculate R 12systemDisconnect

Dischargeearth lead - batterysystem ~ WARNING: R72 Is hazardous. wearprotective. See AdJustments.

~ WARNING: Support on safety stands5 off

Raise front of vehiclebolts - front under panelfront under panel - bOdy

1. lock nut - tensioner spindle m 45NmRemoveSlacken

Continued ...Repairs S

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: A - I R CONDITIONINGREPAIRS

R.move 10. lock nut - spindle.. 11. tensioner pulley - spindle.. -12. special washer .. splndler'.", "

Do not carry out furth.rdlsmanUlng I' c o m ! ' - 9 n , h { i : t e ! 9 0 V e d t o r access onlyR.move 13. bo,It_ tensiOl:ter-SQrndle, ',"'" . 14.tenS!6ner'.splri~1~: f J . -ti~~~e(1~ screws,' ..;:'~,nsioAer brackettension.brack't :- bracket17. bolts _.' compressor bracket18. compressor bracket - engine

oil - compressor

SlackenRemove 2. bolt -tensioner pulley3. belt - pulleysalternator assembly4. earth lead - compressor5. wiring plug compressor6. hose union - compressor

. .Disconnect:Unscrew

. . 7. hose union - compressorPlug hose unions.. compressor unionsRemove 8. bolts - compressor 9. compressor - mounting bracketTENSIONER PULLEY

. .

. .Drain-A U compressor with new oilR.... embl.T.nslonEvacuate

componentscompressor drive beltsystemChargeTest systemsystem performance -; .,.'

6 Repairs

Turns clockwiseSee Electrical

m 20.Nm Suction from evaporator& CAUTION: Use backing spanner toprevent compressor union turning.fD 25 Nm Pressure to condenserIi;A~ION: Use backing spanner toP(fJve(lj compressor union turning.

.i ,

; ' 2 . 6 f H i t 2 6 Nm. Retrieve plain washers~/ ". -~._(-

2 off fD 25 Nm4 off fD 47 N mGravity drain for 10 minutes.Measure amount drained 22 to 26 cm3Add amount drained, Refrigerant oilthrough suction port. see Adjustm.ntsSee AdjustmentsA WARNING: R12 Is hazardous, wea,protectl". clothing, see AdjustmentsSee Fault Diagnosis Manual

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AIR CONDITIONINGREPAIRS ~';A/C

COMPRESSOR AND TENSIONER PULLEY - RENEW - V6ActionSwitch on

Ref. Detail Special InstructionsA Note: Only if compressor is operable toCirculate R12systemDisconnectDIscharge earth lead - batterysystem ~ WARNING: R12 Is hazardous, wearprotective. See Adjustments.A t WARNING: Support on safety stands5 off

RaiseRemove front of vehiclebolts - front under panelfront under panel - body

1. lock nut - tensioner pulley2. bolt - tensioner pulley3. belt - pulleys4. plug - compressor5. bolts - compressor6. compressor - bracket7. bolts - hose unionshose unions - compressoro ring seals

4 off f! J 25 NmMove aside2 off f! J 25 NmSuction from evaporator2 off Lubricate with refrigerant oil onreassembly

"Slacken m 45 NmTurn clockwiseQRemoveDisconnectRemove

"Plug hose unions

Continued ...Repairs 7

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compressor unions~.~Do not carry out turther dismantling If component Is removed for acoess onlyRemove 8. bolts - compressor bracket 4 off Ii 47 Nm.

bracket - compressor9. bolts - tensioner pulley bracketbracket - compressoroil - compressorDrainFlIIReassembleTensionEvacuateChargeTeat

8 Repairs


2 off m 25 Nm

compressor with new oilGravity drain for 10 minutes.Meas"lre amount drained 22 to 26 cm3

s. Add amount drained, Refrigerant oilthrough suction port, see Adjustmentscomponentscompressor drive beHsystem 'S~AdJustmentsA .WARNING: R12 Is hazardous, wear: p,ot_otive clothing. see Adjustments.

. ~. . ~.~~i;! . ,. , > : . . r ; . '~ ' , ~ .),..; . ... Fault Diagnosis Manualsystemsystem performance

.,

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Action Ref. Detail Special InstructionsDisconnect e a r t h lead - batteryDischarge system :,t-ot' ~ WARNING: A12 Is hazardous. wearprotective clothing. See AdjustmentsDisconnect 1. multiplug Tie back Remove . 2. high pressure switch pipe Use backing spanner, do not distort pipeIi 12 NmDisconnect 3. lJIultipl~ Tie backRemove 4. dual pressure switch - pipe Use backing spanner, do not distort pipeII 12 NmReal.emble componentsEvacuate system A WARNING: R12 Is hazardous. ...earprotective clothing. See AdjustmentsCharge systemTest system performance See Fault Diagnosis Manual


HIGH PRESSURE AND DUAL PRESSURE SW ITCHES - RENEW

Repairs 9

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BLOWER MOTOR - RENEWActionDisconnectRemoveDisconnectRemove

Ref. Detailearth lead - batteryclosing panel - ':below glovebo)(

1. multi plugs .'.:- .m9tor socketS2. hose - mator and housing3. bolts- 'moto/bracket4. motor - housing

3off CAUTION: Do not damage fan, easefrom housingFor deterioration, renew if necessary

Special Instructions2 off tumbuckles

. .. .CheckReassembleTest

S. sealcomponentsmotor See Fault Diagnosis Manual

10 Repairs

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AIR CONDITIONING. ~ . ; . : : . , ~ R _E _ P _ A _ 'R _ S _

;, ,\."

RECIRCULATED AIR MODE MOTOR - RENEW;ActionDisconnectII

Remove. .DisconnectCleanCheckReassembleTest

~';A/C

"

Ref. Detail Special Instructionsearth lead

1. multiplugblower unit

2. multiplug ~ . mode motor3. screws -..;: hou~ing4. mode motor - housing

battery .~

3 offRun new motor to full range. see FaultDiagnosIs ManualClip retainedBlow throughEase and range of movement set to fullrange

linkage .- leverhousing internallylinkage. flapscomponentsmode motor See Fault Diagnosis Manual

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A IR CONDIT IONINGREPAIRS

EVAPORATOR - RENEWAction Ref. DetailDisconnect earth lead - batteryDischarge systemRemove glovebox - fasciaradio cassette playerclock trip computerglovebox bar - fasciaDisconnect 1. pipe unionsRemove o rings -- unions

12 Repairs

Special Instructions.:. WARNING: Rt2 Is hazardous, wearprotective clothing. See Adjustments5 off screwsSee ElectricalIf fitted. see InstrumentsIf fitted. see Instruments4 off screws2 offIi 25 Nm Use backing spanner2 offB Lubricate with Refrigerant oil

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. ' .Plug. .DisconnectRemoveSlackenRemove

ReassembleEvacuateChargeTest

pipe unionsevaporator pipe ends

2. thermistor multiplug3. screws'_ evaporatorblower unit f ixings4. bolts'_ evaporatorevaporator'_ bulkhead

ImmediatelyImmediately

components~~~_ system

4 off3 off Ii) 25 Nm3 off& CAUTION: If new evaporator does nothaveplug fitted, reiec: unitEnsure drain tube is engaged fullyA WARNING: R12 Is hazardous. wearprotective clothing. See Adjustments

systemsystem performance See Fault Diagnosis Manual

BLOWER UNIT - RENEWAction Ref. DetailDisconnect earth lead - batteryRemove evaporator - vehicleDisconnect 1. multiplugs - socketsRemove 2. bolts - bulkhead3. blower unit - vehicleCheck gasketReassemble componentsFit evaporator - vehicleTest blower

1

Special Instructions

3 off Ii) 25 NmEase away from bulkheadRenew if necessary

See Fault Diagnosis Manual

RepaIrs. 13

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,. ,

AIR CO'NDITIONINGREPAIRS

THERMOSTATIC EXPANSION VALVE - RENEWAction Ref. Detail Special InstructionsDisconnectRemove earth lead - batteryevaporator - vehicle

1. thermistor sensor holder - fins CarefullyNote location for assembly2. screws - housing3. clips - housing4. housing halves5. pipe union - expansion valve6. pipe union - expansion valve7. 0 ring seals - unionsunions and valve

8. insulation tape - sensor9. sensor - pipeoutlet pipe and sensor

SeparateDisconnect Carefully6 J 12 Nm6 J 20 Nm2 off eI Lubricate with Refrigerant oilImmediatelySensor must make full contact with pipeA t . CAUTION: Do not damage capillaty tube

. .PlugRemoveClean

14 Repairs

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:' ;~"~",: :J,;':'. ',-,


CI nR..... mbl.R.flt

evaporatorcomponentsevaporator ~ vehicle

Use compressed air to blow through rnamxUse adhesive tape to fix sensor to pipe

.:. .~.-.:.~.-J~

,~'

XM0819

HEATER DISTRIBUTION AND, BLEND UNIT - RENEWActionDI.connectRemoveDrainDisconnect

Ref. Detailearth leaq - batteryevaporator - vehiclecoolant system

1. coolant hoses - heater unit2. vacuum hoses - pipes3. multiplug - socket4. nuts - supports5. bolts - retainers6. heater unit - bulkheadunitlinkagesmode motors

Special Instructions

See Cooling 2.0 or Cooling 2.1 Note: For assembly. outlet at topPlug and tie back2 of f2 of f2 offCarefully ease unit from under fasciaBlow through with compressed airFor ease of movementOver full rangeSee Fault Diagnosis ManualSee Fault Diagnosis Manual

"Remove. .CleanCheckTest

Reassemble amplifiercomponents

Repatrs 15

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CONDENSER COOLtNG :FAN 'NOTOR - R ENEWActionDisconnectRemove ,_ '

__. .

DisconnectRemoveMoveRemove

CleanReaaaemble

Ref. Detailearth lead - batteryfron~grille

1. bolts - bonnet lock platform

Special InstructionsSee Body4 off iii 25 Nm Note: Earth cable positioniii 6Nmii i 6Nm2. screw - safety catch3. nut - safety catch .

4. straps - r.Iea8e:~leS. bonnet lock platform ,--.body6. multlplug -' fan motor7. screw - .,ip e C l ippipea. nuts - fan cowl9. fan cow l - cond enser

" 2 off. Position cable in channel arrowedE ns ure g lromm ets a re c orre ctly e ng ag ed: + ; '

Aside3off iii 8Nm , CAUTIO N: Fan . m otor and cow l arebalanced assemblycomponents

components

16 Repairs

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"

'~~. '


5

1 . . . . . -1

XM1066

AIR CONDITIONING MODE UNIT - RENEW,

Documents

15 HVAC