Discovery 2. Manual — part 297
AIR CONDITIONING
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING
82-27
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING
Refrigerant recovery, recycling and
recharging
$% 82.30.02
Recovery
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.
Operate the refrigerant station in accordance
with the manufacturers instructions.
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 design certified by
Underwriter Laboratory Inc. for compliance
with SAE J1991. 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 connectors high and low pressure
hoses from 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
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 evacuate system.
AIR CONDITIONING
82-28
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING
Recharging
NOTE: When recharging, always make
allowance for refrigerant in the line between the
charging station and the vehicle. This is
calculated at 30 grammes/metre of charging
line. System charge weights are 700
±
25
grammes for front A/C system only and 900
±
25 grammes for combined front and rear A/C
system.
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 same quantity of refrigerant oil into oil
charger as collected during recovery. If the
following components have been renewed, add
the following additional quantity of lubricating
oil:
l
Condenser = 40 cm
3
l
Evaporator = 40 cm
3
l
Pipe or hose = 5 cm
3
/metre
l
Receiver/dryer = 15 cm
3
.
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 charge quantity.
LUBRICANTS AND SEALANTS, Capacities.
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.
12. Turn Main switch to 'OFF'.
13. Close valves on connectors.
14. Disconnect high and low pressure hoses from
connectors.
15. Fit dust caps to connectors.
AIR CONDITIONING
REPAIRS
82-29
REPAIRS
Compressor - diesel
$% 82.10.20
Remove
1. Remove engine acoustic cover.
2. Depressurise air conditioning system.
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
3. Remove auxiliary drive belt.
REPAIRS, Belt - auxiliary drive.
4. Drain cooling system.
ADJUSTMENTS, Drain and refill.
5. Disconnect multiplug from compressor.
6. Remove 2 bolts securing air conditioning pipes
to compressor and discard 'O' rings.
CAUTION: Always fit plugs to open
connections to prevent contamination.
7. Release clips and disconnect top hose from
coolant elbow and heater pipe.
8. Remove 4 bolts securing compressor to
mounting bracket.
9. Remove compressor.
Refit
1. Calculate the quantity of refrigerant oil required.
Conditioning Compressor Replacement.
2. Position compressor to mounting bracket and
tighten bolts to 25 Nm (18 lbf.ft).
3. Remove caps from compressor and pipe
connections.
4. Clean compressor and pipe connections.
5. Lubricate new 'O'rings with refrigerant oil and
fit to compressor.
6. Position A/C pipes to compressor and tighten
bolts to 10 Nm (7 lbf.ft) .
7. Connect multiplug to compressor.
8. Position top hose and secure with clips.
9. Refill cooling system.
ADJUSTMENTS, Drain and refill.
10. Fit auxiliary drive belt.
REPAIRS, Belt - auxiliary drive.
11. Recharge air conditioning system.
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
12. Fit engine acoustic cover.
AIR CONDITIONING
82-30
REPAIRS
Compressor - V8
$% 82.10.20
Remove
1. Depressurise air conditioning system.
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
2. Remove auxiliary drive belt.
REPAIRS, Belt - auxiliary drive.
3. Disconnect multiplug from compressor.
4. Remove 2 bolts securing air conditioning pipes
to compressor and discard 'O' rings.
CAUTION: Always fit plugs to open
connections to prevent contamination.
5. Remove 4 bolts securing compressor to
mounting bracket.
6. Remove compressor.
Refit
1. Calculate the quantity of refrigerant oil required.
Conditioning Compressor Replacement.
2. Clean compressor dowels and dowel holes.
3. Position compressor to mounting bracket and
tighten bolts to 25 Nm (18 lbf.ft).
4. Remove caps from compressor and pipe
connections.
5. Clean compressor and pipe connections.
6. Lubricate new 'O' rings with refrigerant oil and
fit to compressor.
7. Position A/C pipes to compressor and tighten
bolts to 10 Nm (7 lbf.ft).
8. Connect multiplug to compressor.
9. Fit auxiliary drive belt.
REPAIRS, Belt - auxiliary drive.
10. Recharge air conditioning system.
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
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