Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual — part 1658
1-18 HEATING AND AIR CONDITIONING
LEAK AT REFRIGERANT LINE
CONNECTIONS
1) Check the torque on the refrigerant line fitting and, if too
loose, tighten to the specified torque.
•
Use two wrenches to prevent twisting and damage to the
line.
•
Do not over tighten.
2) Perform a leak test on the refrigerant line fitting.
3) If the leak is still present, discharge and recover the
refrigerant from the system.
4) Replace the O-rings.
•
O-rings cannot be reused. Always replace with new
ones.
•
Be sure to apply specified compressor oil to the new O-
rings.
5) Retighten the refrigerant line fitting to the specified torque.
•
Use two wrenches to prevent twisting and damage to the
line.
6) Evacuate, charge and retest the system.
LEAK IN THE HOSE
If the compressor inlet or outlet hose is leaking, the entire hose
must be replaced. Refrigerant hose must not be cut or spliced
for repair.
1) Locate the leak.
2) Discharge and recover the refrigerant.
3) Remove the hose assembly.
•
cap the open connections at once.
4) Connect the new hose assembly.
•
Use two wrenches to prevent twisting or damage to the
hose fitting.
•
Tighten the hose fitting to the specified torque.
5) Evacuate, charge and test the system.
COMPRESSOR LEAKS
If leaks are located around the compressor shaft seal or shell,
replace the compressor.
REPLACEMENT OF COMPONENT PARTS
When replacing system component parts, supply the following
amount of oil to the component parts to be installed.
cc (lmp fl oz)
Component parts to be installed
Amount of oil
Evaporator
50 (1.4)
Condenser
30 (0.8)
Receiver /drier
30 (0.8)
Refrigerant line (one piece)
10 (0.3)
HEATING AND AIR CONDITIONING 1-19
RECOVERY, RECYCLING, EVACUATION
AND CHARGING
Handling Refrigerant 134a
Air conditioning systems contain R-134a.
This is a chemical mixture which requires special handling
procedures to avoid personal injury.
•
Always wear safety goggles and protective gloves.
•
Always work in a well-ventilated area. Do not weld or steam
clean on or near any vehicle-installed air conditioning lines
or components.
•
If R-134a should come in contact with any part of the body,
flush the exposed area with cold water and immediately
seek medical help.
•
If it is necessary to transport or carry any container of R-
134a in a vehicle, do not carry it in the passenger
compartment.
•
If it is necessary to a fill a small R-134a container from a
large one, never fill the container completely. Space should
always be allowed above the liquid for expansion.
•
R-134a and R-12 should never by mixed as their
compositions are not the same.
•
R-134a PAG oil tends to absorb moisture more quickly than
R-12 mineral oil and, therefore, should be handled more
carefully.
•
Keep R-134a containers stored below 40
°
C (100
°
F).
WARNING
•
SHOULD R-134a CONTACT YOUR EYE(S), CONSULT A
DOCTOR IMMEDIATELY.
•
DO NOT RUB THE AFFECTED EYE(S). INSTEAD,
SPLASH QUANTITIES OF FRESH COLD WATER OVER
THE AFFECTED AREA TO GRADUALLY RAISE THE
TEMPERATURE OF THE REFRIGERANT ABOVE THE
FREEZING POINT.
•
OBTAIN PROPER MEDICAL TREATMENT AS SOON AS
POSSIBLE. SHOULD THE R-134a TOUCH THE SKIN,
THE INJURY MUST BE TREATED THE SAME AS SKIN
WHICH HAS BEEN FROSTBITTEN OR FROZEN.
1-20 HEATING AND AIR CONDITIONING
REFRIGERANT RECOVERY
The refrigerant must be discharged and recovered by using the
ACR
4
(R-134a Refrigerant Recovery/Recycling/Recharging/
System) or equivalent before removing or installing air
conditioning parts.
ACR
4
(115V 60Hz) :5-8840-0629-0 (J-39500-A)
ACR
4
(220-240V 50/60Hz)
: 5-8840-0630-0 (J-39500-220A)
ACR
4
(220-240V 50/60Hz Australian model)
: 5-8840-0631-0 (J-39500-220ANZ)
1) Connect the high and low charging hoses of the ACR
4
(or
equivalent) as shown.
2) Recover the refrigerant by following the ACR
4
Manufacturer's Instructions.
3) When a part is removed, put a cap or a plug on the
connecting portion so that dust, dirt or moisture cannot get
into it.
REFRIGERANT RECYCLING
Recycle the refrigerant recovered by the ACR
4
or equivalent.
For the details of the actual operation, follow the steps in the
ACR
4
Manufacturer's Instructions.
ACR
4
(115V 60Hz) :5-8840-0629-0 (J-39500-A)
ACR
4
(220-240V 50/60Hz)
: 5-8840-0630-0 (J-39500-220A)
ACR
4
(220-240V 50/60Hz Australian model)
: 5-8840-0631-0 (J-39500-220ANZ)
EVACUATION OF THE REFRIGERANT
SYSTEM
Note:
Explained below is a method using a vacuum pump. Refer
to the ACR
4
(or equivalent) Manufacturer's Instructions
when evacuating the system with ACR
4
(or equivalent).
Air and moisture in the refrigerant will cause problems in the air
conditioning system.
Therefore, before charging the refrigerant, be sure to evacuate
air and moisture thoroughly from the system.
1) Connect the gauge manifold.
•
High-pressure valve (HIGH)-Discharge-side
•
Low-pressure valve (LOW)-Suction-side
2) Discharge and recover the refrigerant.
3) Connect the center hose of the gauge manifold set to the
vacuum pump inlet.
HEATING AND AIR CONDITIONING 1-21
4) Operate the vacuum pump, open shutoff valve and then
open both hand valves.
5) When the low-pressure gauge indicates approx. 750 mmHg
(30 ln.Hg), continue the evacuation for 5 minutes or more.
6) Close both hand valves and stop the vacuum pump.
7) Check to ensure that the pressure does not change after 10
minutes or more.
•
If the pressure changes, check the system for leaks.
•
If leaks occur, retighten the refrigerant line connections
and repeat the evacuation steps.
8) If no leaks are found, again operate the vacuum pump for
20 minutes or more. After confirming that the gauge
manifold pressure is at 750 mmHG (30 ln.Hg), close both
hand valves.
9) Close positive shutoff valve.
Stop the vacuum pump and disconnect the center hose
from the vacuum pump.
CHARGING THE REFRIGERANT SYSTEM
There are various methods of charging refrigerant into the air
conditioning system.
These include using the ACR
4
(R-134a Refrigerant Recovery/
Recycling/Recharging/System) or equivalent and direct
charging with a manifold gauge charging station.
ACR
4
(115V 60Hz) :5-8840-0629-0 (J-39500-A)
ACR
4
(220-240V 50/60Hz)
: 5-8840-0630-0 (J-39500-220A)
ACR
4
(220-240V 50/60Hz Australian model)
: 5-8840-0631-0 (J-39500-220ANZ)
Charging procedure
•
ACR
4
(or equivalent) method
For the charging of refrigerant recovered by ACR
4
, follow the
Manufacturer's Instruction.
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