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.