Work with the air conditioning system

Refueling the air conditioning system

1. With the valve handles turned out to the stop (valves closed) install a transfer valve to the low pressure connection of the gauge manifold.

2. Connect the charging hose (blue) to the adapter valve.

3. Connect the quick coupler (low pressure lines) to the filling hose (blue).

Attention:

• Use only special equipment and tools suitable for R-134a refrigerant.
• To install the quick coupling, firmly press on the coupling part "A" towards the service valve until it clicks. When connecting a quick coupler, while pressing on the coupler, run your hand along the hose to make sure there are no kinks.

4. Connect the quick coupler (low pressure lines) with a hose to the low pressure service valve of the air conditioning system.

Note: The low pressure service valve must be connected to the low pressure hose (leading to the compressor).

5. Close the high and low pressure valves on the measuring instrument.

6. Connect the vacuum pump adapter to the vacuum pump.

7. Connect the type and power cable to the adapter.

8. Connect the charging hose (yellow) to fitting "R-134a" vacuum pump adapter.

9. Screw on the adapter valve handle (valve open).

10. Open the low pressure gauge manifold valve.

11. Set the vacuum pump switch to position "ON" (ON).

Note: even if the vacuum pump is turned off, it is in the "ON" (ON), the vacuum pump and will work until the power supply is connected (see paragraph "7").

12. Turn on the adapter switch to start the vacuum pump! vacuum pump towards the fitting "R-134a".

Attention: do not use a compressor to pump out the refrigerant.

13. Pump down to a vacuum of 100 kPa or more (the process takes about 10 minutes).



14. Set the vacuum pump adapter switch to "OFF" (OFF) and wait 5 minutes. Attention: do not turn on the air conditioning compressor if there is a cut in the system. Otherwise, it may be damaged.

15. Check the system for leaks (the system is healthy if the vacuum does not decrease).

Attention: if the vacuum drops, then tighten all connections more tightly and then repeat the pumping procedure, starting from point "12".

16. Unscrew the adapter valve handle (valve closed), remove it from the gauge manifold and install the filling bottle.



17. To charge the system with refrigerant, unscrew the charging valve handle (valve open) and turn the handle (adapter valve (valve open).

Caution: If the charging cylinder is upside down, liquid refrigerant may enter the compressor and cause damage. Always install the cylinder in an upright position to ensure that refrigerant is charged in the gaseous state.

18. If the refrigerant does not enter the system, then unscrew the adapter valve handle (valve closed).


19. Using a leak detector, check the tightness of the air conditioning system. If refrigerant leaks are found, re-tighten all connections and repeat the charging procedure, starting with the refrigerant recovery operation at "12".

Attention: To check the tightness of the system, it is necessary to use a special leak detector for R-134a refrigerant.

20. Start the engine.

21. Turn on the air conditioner and set the temperature control switch to "MAX COOL" (maximum cooling).

22. Keep the engine running at 1500 rpm.

23. To charge the required amount of refrigerant, turn the adapter valve handle (valve open).

Attention: do not overturn the filling bottle, otherwise liquid refrigerant may enter the compressor and damage it. Only installation of the cylinder in a vertical position (valve at the top) will charge the system with gaseous refrigerant.

24. After finishing charging the system with refrigerant, unscrew the handle of the adapter valve as far as it will go (valve closed).

25. Turn the filling valve handle all the way (valve closed).

26. Disconnect the quick coupler (low pressure lines) from the low pressure service valve.

Note: If there is some refrigerant remaining in the charging cylinder, leave the charging valve and adapter valve handles closed until the next charge.

Topping up the air conditioning system in case of low refrigerant level

1. Unscrew the adapter valve handle until it stops (valve closed) and insert it into the filling valve.



2. Connect the charging hose (blue) to the adapter valve.


3. Connect to the charging hose (blue) quick coupler (low pressure lines).

4. Turn the filling valve handle all the way (valve closed) for punching a hole in a balloon. Unscrew the filling valve handle until it stops (valve open).

5. Turn the adapter valve knob and bleed the air.

6. Connect the quick coupler (low pressure lines) to the low pressure service valve.

Note: The service valve must be connected to the low pressure hose.

7. Start the engine.

8. Turn on the air conditioner and set the temperature control switch to "MAX COOL" (maximum cooling).

9. Keep the engine running at 1500 rpm.

10. Screw on the adapter valve handle (valve open) and fill the system with the required amount of refrigerant. Check the filling process on the sight glass.

Attention: do not overturn the charging cylinder, as this may cause liquid refrigerant to enter the compressor and damage it. Only installation of the cylinder in a vertical position (valve at the top) will charge the system with gaseous refrigerant.

11. After completing refrigerant charging, unscrew the adapter handle until it stops (valve closed) and remove the quick coupler.

Note: If there is refrigerant left in the charging cylinder, close the charging valve and adapter valve fully, then store the cylinder until the next charge.

Pumping out refrigerant from the air conditioning system

Note: This procedure is performed if there is no special device for refrigerant disposal.

1. Start the engine and let it run for 5 minutes at 1200-1500 rpm with the air conditioner running to evenly distribute the compressor oil throughout the system.

Note: The circulation of compressor oil through the air conditioning system is more efficient if it is done while the vehicle is moving.

2. Stop the engine.

3. Unscrew the adapter valve handle until it stops (valve closed) and connect the charging hose to it (blue).

4. Connect to the charging hose (blue) quick coupler.



5. Connect the quick coupler to the system's low pressure service valve.

Note: The low pressure service valve must be connected to the low pressure hose (leading to the compressor).

Attention:

• - To install the quick coupling, firmly press on the coupling part "A" towards the service valve until it clicks.
• - When connecting a quick coupler, while pressing on the coupler, run your hand along the hose to make sure there are no kinks.

6. Install the adapter valve inside the drain tank and, by gently opening the valve, gradually release the refrigerant from the air conditioning system so that the compressor oil does not splash.

Note: Remaining compressor oil in the drain tank must be returned to the A/C system when refrigerant is charged.

Filling compressor oil into the air conditioning system

1. Insufficient amount of compressor oil in the air conditioning system will not provide the necessary lubrication of the compressor, which will lead to its failure. Excess oil in the system will cause the temperature of the cooled air to rise.

2. When the compressor is installed at the factory, 140±10 ml of special compressor oil is poured into it.

Compressor oil - SUN PAG 56

3. During the operation of the air conditioner, oil is distributed along with the refrigerant to all elements of the system, while a certain amount of oil remains in various parts of the system. When replacing one part of the air conditioning system (evaporator, condenser, receiver-drier, compressor hoses) add to it the amount of oil that was removed along with the removed part (in order to maintain the oil balance in the system).

Checking the efficiency of the air conditioner

1. The test vehicle must not be exposed to direct sunlight. Outside air temperature 16-30°С at humidity 60-100%.

2. Close the low and high pressure valves on the gauge manifold.

3. Connect the charging hose (blue) to manifold low pressure valve and charging hose (red) to the high pressure valve.

4. Install on the charging hose (blue) quick coupler (for low pressure) and on the filling hose (red) - quick coupler (for high pressure).



5. Connect the appropriate quick couplers to the system's low and high pressure service valves.

Note: The high pressure service valve is located on the high pressure tube (outlet from the compressor), and the low pressure service valve on the low pressure hose (leading to the compressor).

Attention:

• - To install the quick coupling, firmly press on the coupling part "IN" towards the service valve until it clicks.
• - When connecting a quick coupler, while pressing on the coupler, run your hand along the hose to make sure there are no kinks.

6. Start the engine.

7. Set the following air conditioner operation mode:

• Air conditioner switch: position "ON" (ON);
• Air mode selection lever: "FACE" (to the head area);
• Temperature controller switch: "MAX COOL" (maximum cooling);
• Air intake mode selection lever: "RECIRC" (recycling);
• Heater fan switch: position "4" (high speed).

8. Keep the engine running at 1500 rpm with the air conditioner on (the included magnetic clutch of the compressor).

9. Verify that the pressure in the high pressure line is between 1667 - 1765 kPa.

Note: if the pressure is higher than the specified one, then cool the condenser, if the pressure is lower than the specified one, then cover the condenser.

10. Warm up the engine with the doors and windows closed, the car hood should be open.

11. Install the thermometer and psychometer as shown in the illustration and let the engine run for 20 minutes.

Attention:

• - Install "dry" thermometer so that it shows the temperature of the air leaving the deflector.
• - Install the psychometer so that it does not interact directly with the air coming out of the deflectors.

11. Record the temperature of the air entering the passenger compartment.

Note: If the compressor magnetic clutch is in ON/OFF mode, record the temperature before it is turned off.

12. Check the operation of the air conditioner according to the schedule.

Checking the electronic control unit for the engine and variator

Disconnect the connector from the ECM and CVT and check the connector on the wiring harness side according to the table "Checking the voltage at the terminals of the electronic control unit for the engine and the variator".

Checking the electronic control unit of the compressor (built into the air conditioning control panel)

Disconnect the connector from the compressor electronic control unit and check the connector on the wiring harness side according to the table "Checking the voltage at the terminals of the electronic control unit for the compressor".

Attention: To avoid damage to the servo drive, the duration of the voltage test on the corresponding terminals should not exceed 40 seconds.

Elimination of leaks

Total loss of refrigerant

If there is no refrigerant in the system as a result of a leak, perform the following operations:

• 1. Pump out the refrigerant from the system (see related procedure).
• 2. Charge the system with approximately 0.550 kg of refrigerant.
• 3. Check the system for refrigerant leaks.
• 4. Pump out the refrigerant from the system.
• 5. Repair any leaks found.
• 6. Replace receiver dryer.

Attention: when storing the receiver-drier must be hermetically closed and sealed. The dryer used in the receiver-drier unit, when opened, is very quickly saturated with water vapor from the atmosphere. In this regard, replace the receiver-drier as soon as possible, having previously prepared all the necessary tools and accessories so that the open receiver-drier is exposed to air as little as possible.

• 7. Extract the refrigerant (evacuation) from the system and then fully charge the air conditioning system with refrigerant.

Insufficient amount of refrigerant in the system

In the event of a partial refrigerant leak, locate the leaks and repair them. If it is necessary to pressurize the system to locate a leak (due to insufficient refrigerant in the system), then recharge the system.

If it is possible to repair leaks without completely removing the refrigerant from the system, use the procedure "Topping up the air conditioning system in case of low refrigerant level".

Eliminate compressor noise

1. Find out the noise conditions. These are: weather conditions, vehicle speed, whether the transmission is in gear or in neutral, engine temperature, or other specific conditions.

2. Air conditioner noises can often be misleading. For example, a noise like a failed front bearing or connecting rod rattling could be caused by loose bolts, nuts, brackets, or a loose (increased wear) air conditioning compressor clutch.

3. Check up also a tension of belts of a drive of the generator and the pump of the hydraulic booster of a steering.

4. Incorrectly tensioned accessory drive belts can cause noise that is mistaken for the noise generated by the compressor during operation. This noise disappears when the compressor is turned off.

5. The noise from the drive belts depends on the frequency of their rotation. Therefore, depending on the belt tension, at different engine speeds, the drive belts can make strange noises, which are often mistaken for the sounds of a faulty compressor.

Adjustment

1. Select a quiet area for the test. If possible, repeat the conditions for the occurrence of extraneous noise as completely as possible. To clearly distinguish the sound of the compressor, turn it on and off several times.

Note: To reproduce high altitude conditions, limit the air flow through the condenser. Install a gauge manifold assembly to monitor the discharge pressure, which should not exceed 2070 kPa.

2. Tighten all the compressor mounting bolts, the A/C compressor clutch mounting bolt and adjust the tension of the compressor drive belt. Check the reliability of the installation of the winding of the magnetic clutch of the compressor (no rotation or wobble).

3. Check that the air conditioning hoses are not touching or rubbing against neighboring parts, which may cause extraneous noise.

4. Check the coolant level.

5. Listen again to the sound of the compressor running, as indicated in paragraph "1".

6. If the extraneous noise has not disappeared, then loosen the compressor mounting bolts and re-tighten them. Repeat check for item "1".

7. If extraneous noise remains, then replace the compressor, and then repeat the check according to paragraph "1".

Table. Checking the voltage at the terminals of the electronic control unit for the engine and the variator.

Table for checking the voltage at the terminals of the electronic control unit of the compressor (manual air conditioner).