Air Conditioning System Precautions
General
The air conditioning system contains fluids and components which could be potentially hazardous to the technician or the environment if not serviced and handled correctly. The following guidelines are intended to alert the technician to potential sources of danger and emphasize the importance of ensuring the integrity of the air conditioning operating conditions and components fitted to the vehicle.
Where necessary, additional specific precautions are detailed in the relevant sections of this Manual which should be referred to prior to commencing repair operations.
The refrigerant used in the air conditioning system is R134a or R1234yf.
Remedial actions
If an accident involving refrigerant should occur, conduct the following remedial actions:
- If liquid refrigerant enters the eye, do not rub it. Gently run large quantities of eye wash over affected eye to raise the temperature. If an eye wash is not available, cool, clean water may be used to flush the eye. After rinsing, cover the eye with a clean pad and seek immediate medical attention.
- If liquid refrigerant is splashed onto the skin, run large quantities of water over the affected area to raise the temperature. Implement the same action if the skin comes in contact with discharging cylinders. Wrap the contaminated body parts in blankets (or similar materials) and seek immediate medical attention.
Service precautions
Observe the following precautions when handling components used in the air conditioning system:
- Air conditioning units must not be lifted by their hoses, pipes or capillary lines.
- Hoses and lines must not be subjected to any twist or stress; the efficiency of the system will be impaired by kinks or restrictions. Ensure that hoses are correctly positioned before tightening couplings, and ensure that all clips and supports are utilized.
- Completed assemblies must be checked for refrigeration lines touching metal panels. Any direct contact of components and panels may transmit noise and so must be eliminated.
- The appropriate torque wrench must be used when tightening refrigerant connections to the stipulated value. An additional wrench must be used to hold the union to prevent twisting of the pipe when tightening connections.
- All protective plugs must remain in place to seal the component until immediately prior to connection.
- Ensure components are at room temperature before uncapping, to prevent condensation of moisture from the air that enters it.
- Components must not remain uncapped for longer than 15 minutes. In the event of a delay, the caps must be fitted.
- When disconnecting, immediately cap all air conditioning pipes to prevent ingress of dirt and moisture into the system.
- The receiver/drier contains desiccant which absorbs moisture. It must be positively sealed at all times. A receiver/drier that has been left uncapped must not be used.
- The receiver/drier should be the last component connected to the system to ensure optimum dehydration and maximum moisture protection of the system.
- Use alcohol and a clean, lint-free cloth to clean dirty connections.
- Ensure that all new parts fitted are suitable for use with the specified refrigerant.
HVAC line installation
Always carry out the following procedure before connecting any hose or pipe:
- All refrigeration fittings require oiling with the recommended refrigerant oil before installation. Refer to .
- When connecting refrigeration fittings, ensure that the O-ring is positioned correctly. Push the joint together until the O-ring disappears before attempting to tighten the nut. The nut should start by hand; if a wrench is required then the joint is misaligned. Tighten the joint to the torque shown.
- The refrigeration system must be kept clean and capped at all stages. At no time must any hoses be left open to atmosphere as the oil in the system is hygroscopic (absorbs moisture). The connection to the drier should only be completed just prior to commissioning (or at least the system should be vacuumed to keep the system dry so any moisture generally in the pipe work does not affect the oil or ‘wet’ the receiver drier).
- Keep the lid on oil containers such that a small amount can be dispensed at any time and then at the end of the week, the whole can is disposed of to avoid using contaminated oil. Oil containers kept to lubricate O-rings should not be used to top up oil in systems due to potential contamination.
Use the HVAC machine to perform a leak test after a major repair has been completed.
Refrigerant oil
The compressor contains a lubricant, which has greater electrical insulating properties than the A/C lubrication oil normally used for standard mechanical belt driven A/C pumps. It is important that the compressor is kept upright at all times to retain the lubricant in the compressor’s sump.
Compressor
A new compressor is sealed. Ensure that no foreign material is allowed to enter the compressor.
Rapid refrigerant discharge
If the air conditioning system is involved in accident damage and the system is punctured, the refrigerant will discharge rapidly. The rapid discharge of refrigerant will also result in the loss of most of the oil from the system. The compressor must be removed and all the remaining oil in the compressor drained and refilled as instructed in the air conditioning section of this manual.
Refrigerant evacuation and recharging
The HVAC and battery coolant circuits are sealed to prevent the discharge of refrigerant. The refrigerant must be recovered before any removal of system components using the recommended equipment.
Two ports are provided on the HVAC system and are accessible under the hood.
High pressure remote charging port
This port is fitted onto the pipe directing the high pressure refrigerant gas from the supermanifold to the compressor. It can be accessed under hood at the LH side of the vehicle adjacent to the A/C compressor. A Schraeder valve forms the port in the pipe allowing the connection of charging/discharging equipment for servicing purposes. The connection is a 16 mm quick coupler. The valve is fitted with a screw-on cap to prevent seepage of refrigerant through the valve and also to exclude dirt.
Low pressure remote charging port
This pipe leads back from the HVAC assembly. It can be accessed under hood, on the pentaline assembly near the LH side of the bulkhead. A port is on a pipe which allows the connection of recovery/charging equipment for servicing purposes. The connection is a 13mm quick coupler. The valve is fitted with a screw-on cap to prevent seepage of refrigerant through the valve and also to exclude dirt.
HVAC system service mode
With the vehicle in HVAC Thermal Fiill/Drain Mode, the refrigerant can be recovered or recharged. The HVAC system will stay in HVAC Thermal Fiill/Drain Mode until the mode is exited using Toolbox or the touchscreen.
Debris or moisture in the A/C system
Internally or externally damaged components can cause debris and moisture to enter the A/C system. Perform the following procedures if debris or excessive moisture ingress is suspected.
A/C components damaged in a collision, no refrigerant leakage
- Evacuate the refrigerant.
- Replace damaged components.
- Use the HVAC machine to perform a leak test.
- Recharge the refrigerant.
A/C components damaged in a collision, refrigerant leakage
- Evacuate the refrigerant.
- Replace the A/C compressor, the condenser, and all components between them.
- Replace damaged components.
- Use the HVAC machine to perform a leak test.
- Recharge the refrigerant.
A/C system was left open to the environment for an extended time
- Replace the components that have end connections that were left open.
- Replace the receiver/drier desiccant bag.
- Recharge the refrigerant.
Precautions for refrigerant recovery, recycling and recharging
When the air conditioning system is discharged/recharged, any existing refrigerant is recovered from the system and recycled. The system is then charged with the required weight of refrigerant and new oil equal in volume to the oil recovered.