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Very small leaks in the air conditioning system cause coolant to be lost over time.
This can lead to reduced air conditioning performance or compressor failure if the leak is not noticed.
Leaks in the system can be attributed to one or more of the following causes:
1. seals at connections cut due to the design of the fitting.
2. assembly error.
3. ageing of the O-rings.
4. minute leaks in the Schrader valves.
These leaks can be extremely small and are often very difficult to detect.
Even the current method of detecting leaks by adding dye to the coolant can lead to loss of coolant.
can lead to loss of coolant gas, as gas can escape when the system is opened.
can escape.
PRODUCTION:
Applies from serial number: See below.
The following improvements have been introduced into production as sequential changes (all improvements from and including serial numbers HFJ036334/HJJ073474):
1. assembly procedure revised; O-rings are lubricated with compressor oil during installation.
2. improved chamfering of edges on connections and fittings.
3. new, improved O-rings made of different material (now green colour).
4. improved fit of the Schrader valve in the connector.
5. new O-rings on the Schrader valves (different material, now green colour).
6. the coolant tank with drier insert now has a dye plate that automatically dissolves in the coolant gas. This dye allows leaks to be detected using black light.
Note: The part number of the coolant reservoir with drier insert has not been changed. The new liquid container with drier insert can be recognised by the sticker "51087 to dye wafer".
SERVICE:
Cross-reference Workshop Manual: Section 50/9000.
If coolant is lost or leaks are detected, perform the procedure described below. 1:
1. use a device to collect the coolant and empty and fill the system. Drain the gaseous coolant from the system and collect it. 2.
Disconnect all hoses from the fittings. To gain access to the evaporator hose fittings, remove the roof panel inside the cabin. 3.
Check the condition of the O-rings and fittings carefully. 4.
The fittings must have a bevelled edge (1, fig. 2). If a fitting does not have a bevelled edge, the fitting should be bevelled using a suitable grinding/cutting tool with a diameter slightly larger than the internal diameter of the fitting. Protect the opening of the hose with a suitable plug or rag to prevent grinding chips from getting into the hose.
Note: The degree of bevelling is not important. It is recommended to use a grindstone with a 33° or 45° angle. 5.
5. install a new coolant tank with dryer insert with the integrated dye plate.
6. replace all O-rings with new O-rings regardless of their condition, lubricate them with air conditioning compressor oil and fit them. Tighten all the fittings. 7.
Check the Schrader valves on the high and low pressure lines. If leaks are detected on a Schrader valve, replace it (available locally) or replace the high pressure hose (1, fig. 3), part no. 5091890, or the low pressure connector (2, fig. 3), part no. 5092979. 8.
Connect the device for collecting the coolant and for emptying and filling the system, and drain the system. 9.
Create a vacuum for at least 30 minutes. Check with a vacuum gauge for another 30 minutes that the system can hold the vacuum. The system must not lose more than 25 mm Hg in 30 minutes. In this case the system is tight. 10.
Refill the system with 1.4 kg of R134A refrigerant gas. 11.
Start the engine and carry out a function test of the air conditioning system as described in section 50 of the workshop manual. 12.
12. use a black light to check the entire air conditioning system and all connections for leaks. The old components can be easily replaced with the new components.
Note: The part numbers for the coolant reservoir with drier insert and the hoses have not been changed.
Replace dryer insert 5165615 every 1200 operating hours
Hose, compressor to condenser (with Schrader valve) 5091890
Connector, low pressure connection of compressor (with Schrader valve) 5092979
Hose, condenser to coolant reservoir with dryer insert 5095483
Hose, coolant tank with dryer insert to evaporator 5091888
Hose, evaporator to compressor 5091891
O-ring If required 14453283
O-ring On demand 14453083
O-ring On demand 89827059
O-ring On demand 82000793
O-ring If required 14452883
The drainage filter (dryer) installed between the condenser and the expansion valve performs two basic functions, as a drainage element and as a container lung for the refrigerant to compensate for different loads. Drainage is a very important function to prevent corrosion in the system.
The 1/4-20G switch has no passage at too little pressure and at too much pressure.
HP 27kg/cm2
LP 2kg/cm2
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