412-00 Climatização – informações gerais

412-00-1 Climate Control System - General Information 412-00-1 . SECTION 412-00 Climate Control System - General Information VEHICLE APPLICATION: 2011.50 Ranger CONTENTS SPECIFICATIONS Specifications...................................................................................................................... GENERAL PROCEDURES Air Conditioning (A/C) Clutch Air Gap Adjustment............................................................. Air Conditioning (A/C) System Recovery, Evacuation and Charging................................. Refrigerant Oil Adding........................................................................................................ Contaminated Refrigerant Handling................................................................................... Electronic Leak Detection................................................................................................... Fluorescent Dye Leak Detection........................................................................................ Vacuum Leak Detection...................................................................................................... PAGE 412-00-2 412-00-3 412-00-4 412-00-6 412-00-7 412-00-8 412-00-9 412-00-10

412-00-2 Climate Control System - General Information 412-00-2 SPECIFICATIONS Lubricants, Fluids, Sealers and Adhesives Refrigerant R134a Refrigerant oil Refrigerant Capacities (When Charging) Air Conditioning Refrigerant Oil Capacities (When Charging) Air Conditioning Addition of Refrigerant Oil (When a new compressor is installed) Air conditioning compressor if the amount of refrigerant oil taken from the faulty compressor is 50 to 90 ml Air conditioning compressor if the amount of refrigerant oil taken from the faulty compressor is 91 to 120 ml Air conditioning compressor if the amount of refrigerant oil taken from the faulty compressor is more than 121 to 150 ml Addition of Refrigerant Oil (When new components are installed) Condenser Evaporator Every time refrigerant is evacuated. When all new components are installed (including compressor). When A/C system is flushed. Clutch air gap Compressor clutch air gap Torque Specifications Item Compressor drive plate retaining bolt Specifications WSH-M17B19-A WSH-M1C231-B Grams 650 ± 10 Milliliters 150 Milliliters Drain 70 from new compressor. Drain 40 from new compressor. Drain 0 from new compressor. Milliliters add 80. add 40. as taken from the system add 0. 150 mm 0,35 - 0,65 Nm lb-ft lb-in 13 10 ±

412-00-3 Climate Control System - General Information 412-00-3 GENERAL PROCEDURES Air Conditioning (A/C) Clutch Air Gap Adjustment 1. Check the gap A (measure the difference between the engaged and disengaged positions of the air conditioning clutch) at 60° intervals around the circumference of the pulley. Operate the air conditioning clutch several times with the aid of a 5 A fused cable. Refer to the relevant wiring diagram for the correct electrical connection. Refer to: Specifications (412-00 Climate Control System - General Information, Specifications). $ E92144 2. E68442 3. If necessary correct the gap A using spacer washers. E68470 4. Refer to: Specifications (412-00 Climate Control System - General Information, Specifications). E68442 5. Check the gap A as described in step 1. If necessary, repeat steps 2-5.

412-00-4 Climate Control System - General Information 412-00-4 GENERAL PROCEDURES Air Conditioning (A/C) System Recovery, Evacuation and Charging General Equipment Air Conditioning Service Unit Automatic Calibration Halogen Leak Detector Electronic Leak Detector Refrigerant Identification Equipment UV Leak Detector 1. Refer to: Air Conditioning (A/C) System Health and Safety Precautions (100-00 General Information, Description and Operation). 2. CAUTION: The refrigerant analyzer must be used before recovery, otherwise the refrigerant center may become contaminated. Contaminated refrigerant must be disposed of as hazardous waste. Always follow the manufacturer's instructions when using the refrigerant center and the refrigerant analyzer. Unscrew and remove the protective caps from the A/C charging connections. General Equipment: Air Conditioning Service Unit General Equipment: Refrigerant Identification Equipment 3. 1. Low-pressure connection 2. High-pressure connection 1 2 E104869 4. Connect the service unit lines to the filling connection of the air conditioning system. VFE0031288 5. Drain the air conditioning system via the low-pressure port in accordance with the service unit manufacturer instructions. 6. CAUTION: Make sure that the specified amount of refrigerant oil is added. NOTE: This step is only required when installing a new component.

412-00-5 Climate Control System - General Information 412-00-5 GENERAL PROCEDURES Fill up with refrigerant oil. Refer to: Specifications (412-00 Climate Control System - General Information, Specifications). Refer to: Refrigerant Oil Adding (412-00 Climate Control System - General Information, General Procedures). 7. Evacuate the air conditioning system in accordance with the service unit manufacturer instructions. 8. NOTE: The system is leak-tight if the pressure increase does not exceed 20 mbar. Perform the leak test, by closing the hand valves on the gauge set, switching off the service unit vacuum pump and observing the low pressure gauge. 9. NOTE: This step is only necessary if the pressure increase exceeds 20 mbar. Locate and rectify any leaks in the A/C refrigerant circuit using a leak tester. General Equipment: UV Leak Detector General Equipment: Electronic Leak Detector General Equipment: Automatic Calibration Halogen Leak Detector 10.Add refrigerant oil to the air conditioning system. Refer to: Specifications (412-00 Climate Control System - General Information, Specifications). Refer to: Refrigerant Oil $GGLQJ (412-00 Climate Control System - General Information, General Procedures). 11. Fill the air conditioning system with liquid through the high-pressure connection. Refer to: Specifications (412-00 Climate Control System - General Information, Specifications). 12. 1. Open the shut-off valve on the high-pressure side. 2. Switch the service unit to "Fill" mode and fill the system with the specified quantity of liquid refrigerant (R134a). 13.Fill the air conditioning system with gas through the low-pressure connection. Refer to: Specifications (412-00 Climate Control System - General Information, Specifications). 14. 1. Open the shut-off valve on the low-pressure side. 2. Switch the service unit to "Fill" mode and fill the system with the specified quantity of gaseous refrigerant. 3. Add the remaining amount of refrigerant with the air conditioning switched on. To do so run the engine at about 1200-1500 rev/min. Set the air conditioning system to full cooling power and fresh air mode. Set the blower motor to the highest setting. Fill with the remainder of the specified fill capacity. 15.Disconnect the service unit. 16. 1. Close the shut-off valve. 2. Switch off the service unit. 3. Disconnect the service unit lines from the filling connections of the air conditioning system. 4. Screw the protective caps onto the charging connections. 17.Install all components in reverse order.

412-00-6 Climate Control System - General Information 412-00-6 GENERAL PROCEDURES Refrigerant Oil Adding CAUTION: Collect the refrigerant oil in a clean measuring cylinder. 1. NOTE: This step only needs to be carried out when removing the A/C compressor. NOTE: Rotate the compressor shaft at least 6 to 8 turns when draining the refrigerant oil. Drain the refrigerant oil from the defective A/C compressor and dispose of it. 2. CAUTIONS: The refrigerant oil top-up quantity must not exceed the refrigerant oil fill quantity. If other A/C components are being renewed in addition to the A/C compressor, there is no need to top up with additional refrigerant oil, apart from filling the compressor. Top up with the calculated quantity of new refrigerant oil. See: Specifications (412-00 Heating, Ventilation, Air-Conditioning - General information, Specifications).

412-00-7 Climate Control System - General Information 412-00-7 GENERAL PROCEDURES Contaminated Refrigerant Handling 1. CAUTION: Any R134a or R12 refrigerant which is contaminated with unsuitable refrigerant should be extracted only by means of a suitable servicing unit designed for the purpose of collecting and storing contaminated refrigerant, so that the spread to other vehicles can be prevented. Use refrigerant identification equipment to check that there is contaminated refrigerant in the air conditioning system. 2. Inform the customer about the additional costs involved to repair the system because of the contamination. 3. Extract the contaminated refrigerant.

412-00-8 Climate Control System - General Information 412-00-8 GENERAL PROCEDURES Electronic Leak Detection Leak detection 4. Refer to: Air Conditioning (A/C) System Health and Safety Precautions (100-00 General Information, Description and Operation). 5. WARNINGS: Before starting leak detection, make sure that the area where it is to be done is well ventilated. If the surrounding air is contaminated with refrigerant gas, the leak detector will indicate this gas all the time. Odors from cigarette smoke and other chemicals such as antifreeze, diesel fuel, disc brake cleaner, or other cleaning solvents can cause the same problem. Prevent air movement while performing leak detection. The refrigerant identification equipment must be used before attaching the manifold gauge set. Otherwise the manifold gauge set may become contaminated. Contaminated refrigerant must be disposed of as special waste. Follow the manufacturer's instructions when working with the service unit. NOTE: At 24°C with the engine switched off, both manifold gauges should show 4.1 to 5.5 bar. Attach the manifold gauge set to the service gauge port valves. 6. For the leak test, close the manual valves on the gauge set. 7. If little or no pressure is indicated, charge the system with approx. 300g of refrigerant. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures). 8. WARNING: Make sure that the surface is clean and free of foreign material. NOTE: Make sure that the leak detector is calibrated and set in accordance with the operating instructions. Use the R-134a automatic calibration halogen leak detector to leak test the refrigerant system. Follow the instructions included with leak detector for handling and operation techniques. 9. CAUTION: Do not let the detector sensing tip contact any substance as this could cause a false reading and may damage the sensor. Position the sensor about 5mm from the point to be checked. Circle each fitting completely. 10.If a leak is detected, repeat the leak detection process after blowing away the chemical detected with compressed air. 11. If a leak is detected again, extract the refrigerant under suction. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures).

412-00- Climate Control System - General Information 412-00- GENERAL PROCEDURES Fluorescent Dye Leak Detection General Equipment UV Leak Detector Leak detection CAUTION: Make sure that the vehicle is in a low sunlight area before performing any actions. 12.Refer to: Air Conditioning (A/C) System Health and Safety Precautions (100-00 General Information, Description and Operation). 13.NOTE: The exact location of leaks can be pinpointed by the bright yellow - green glow of the tracer dye. Since more than one leak can exist, always inspect each component. ‡ Locate the leaks. Check all components, fittings and lines of the A/C system for leaks. General Equipment: UV Leak Detector 14.After the leak is found and rectified, remove any traces of dye with a general purpose solvent. 15.Check the repair by operating the system for some minutes and inspecting with the UV lamp again.

412-00-10 Climate Control System - General Information 412-00-10 GENERAL PROCEDURES Vacuum Leak Detection 1. Carry out the air conditioning (A/C) system recovery procedure. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures).