HVAC System (Heating, Ventilation & A/c): Other Saab 9-2X I

HEATER COOLING UNIT

AUTO A/C MODEL

Scheme 40

1. Unit cover
2. Mode actuator
3. Side link
4. Mode actuator lever
5. Foot lever
6. Spring
7. Mode actuator link
8. Defroster lever
9. Foot nozzle
10. Unit duct cover
11. Heater core
12. Drain hose
13. Mix actuator
14. Mix actuator lever
15. Unit assembly
16. Aspirator hose
17. Aspirator
18. Foot duct
19. Packing
20. Cooling unit block
21. O-ring
22. Expansion valve
23. Evaporator
24. Evaporator cover
25. Thermistor

Tightening torque: Nm (kgf-m, ft-lb)

T: 7.4 (0.75, 5.4)

MANUAL A/C MODEL

Scheme 41

1. Unit cover
2. Side link
3. Mode lever
4. Foot lever
5. Spring
6. Mode link
7. Defroster lever
8. Foot nozzle
9. Unit duct cover
10. Heater core
11. Drain hose
12. Mix lever
13. Unit assembly
14. Foot duct
15. Clip
16. Packing
17. Cooling unit block
18. O-ring
19. Expansion valve
20. Evaporator
21. Evaporator cover
22. Thermistor

Tightening torque: Nm (kgf-m, ft-lb)

T: 7.4 (0.75, 5.4)

BLOWER MOTOR UNIT

AUTO A/C MODEL

Scheme 42

1. Upper case
2. Servo motor
3. Blower link
4. Blower link lever A
5. Blower link lever B
6. Blower link lever C
7. Filter cover
8. Filter
9. Blower motor assembly
10. Hose
11. Power transistor
12. Power transistor cover

Tightening torque: Nm (kgf-m, ft-lb)

T: 7.4 (0.75, 5.4)

MANUAL A/C MODEL

Scheme 43

1. Upper case
2. Blower link
3. Blower link lever A
4. Blower link lever B
5. Clip
6. Filter cover
7. Filter
8. Blower motor assembly
9. Hose
10. Blower resistor

Tightening torque: Nm (kgf-m, ft-lb)

T: 7.4 (0.75, 5.4)

CONTROL UNIT

AUTO A/C MODEL

Scheme 44

1. Panel
2. Control dial
3. Control case

MANUAL A/C MODEL

Scheme 45

1. Dial
2. Fan control plate
3. Temperature control plate
4. Mode control plate
5. FRESH/RECIRC switching knob
6. Heater control panel
7. A/C switch
8. Rear window defogger switch
9. Heater control base
10. Intake cable
11. Mode cable
12. Temperature cable
13. Bulb
14. Fan switch ASSY
15. Harness

Scheme 46

1. Condenser
2. High-pressure hose
3. Low-pressure hose
4. Bracket
5. Compressor
6. O-ring
7. Clamp A
8. Clamp B
9. Tube (To condenser)
10. Tube (To evaporator)

Tightening torque: Nm (kgf-m, ft-lb)

T1: 7.4 (0.75, 5.4)

T2: 15 (1.5, 10.8)

Scheme 47

1. Idler pulley bracket
2. Idler pulley adjuster
3. Idler pulley
4. Compressor upper bracket
5. Compressor
6. V-belt
7. Compressor belt cover
8. Compressor bracket

Tightening torque: Nm (kgf-m, ft-lb)

T1: 7.4 (0.75, 5.4)

T2: 22.6 (2.3, 16.6)

T3: 23.0 (2.35, 17.0)

T4: 28.9 (2.95, 21.3)

T5: 35 (3.6, 26)

Scheme 48

1. Front defroster nozzle
2. Side defroster duct (LH)
3. Side defroster duct (RH)
4. Side ventilation duct (LH)
5. Side ventilation duct (RH)
6. Rear heater duct (LH)
7. Rear heater duct (RH)
8. Rear heater duct cover (LH)
9. Rear heater duct cover (RH)

PREPARATION TOOL

Note. For special tool view (Scheme 49)- (Scheme 58).

PREPARATION TOOL DESCRIPTION

TOOLS AND EQUIPMENT DESCRIPTION

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

Scheme 54

Scheme 55

Scheme 56

Scheme 57

Scheme 58

HEATER SYSTEM

HEATER SYSTEM SPECIFICATION

AUTO A/C MODEL

A/C SYSTEM SPECIFICATION (AUTO A/C MODEL)

Scheme 59

MANUAL A/C MODEL

A/C SYSTEM SPECIFICATION (MANUAL A/C MODEL)

Scheme 60

Scheme 61

1. Unlike the old conventional CFC-12 system components, the cooling system components for the HFC-134a system such as the refrigerant and compressor oil are incompatible.
2. Vehicles with the HFC-134a system can be identified by the label (A) attached to the vehicle. Before maintenance, check which A/C system is installed in the vehicle.

COMPRESSOR OIL

1. HFC-134a compressor oil has no compatibility with that for R12 system.
2. Use only the manufacturer-authorized compressor oil for the HFC-134a system; only use DH-PR.
3. Do not mix multiple compressor oils. If CFC-12 compressor oil is used in a HFC-134a A/C system, the compressor may become stuck due to poor lubrication, or the refrigerant may leak due to swelling of rubber parts. On the other hand, if HFC-134a compressor oil is used in a CFC-12 A/C system, the durability of the A/C system will be lowered.
4. HFC-134a compressor oil is very hygroscopic. When replacing or installing/removing A/C parts, immediately isolate the oil from the atmosphere using a plug or tape. In order to avoid moisture, store the oil in a container with its cap tightly closed.

REFRIGERANT

1. The CFC-12 refrigerant cannot be used in the HFC-134a A/C system. The HFC-134a refrigerant, also, cannot be used in the CFC-12 A/C system.
2. If an incorrect or no refrigerant is used, poor lubrication will result and the compressor itself may be damaged.

Scheme 62

1. The refrigerant boils at approx. - 30°C (- 22°F). When handling it, be sure to wear safety goggles and protective gloves. Direct contact of the refrigerant with skin may cause frostbite. If the refrigerant gets into your eye, avoid rubbing your eyes with your hands. Wash your eye with plenty of water, and receive medical treatment from an eye doctor.
2. Do not heat a service can. If a service can is directly heated, or put into boiling water, the inside pressure will become extremely high. This may cause the can to explode. If a service can must be warmed up, use hot water in 40°C (104°F) max.
3. Do not drop or impact a service can. (Observe the precautions and operation procedure described on the refrigerant can.)
4. When the engine is running, do not open the high-pressure valve of the manifold gauge. The high-pressure gas will back-flow resulting in an explosion of the can.
5. Provide good ventilation and do not work in a closed area.
6. In order to prevent global warning, avoid releasing HFC-134a into the atmosphere. Using a refrigerant recovery system, discharge and reuse it. Goggles Gloves Avoid open flame No direct heat on container Do not discharge Loosen

Scheme 63

Scheme 64

Scheme 65

1. Use new O-rings.
2. In order to keep the O-rings free of lint which will cause a refrigerant gas leak, perform operations without gloves and shop cloths.
3. Apply the compressor oil to the O-rings to avoid sticking, then install them.
4. Use a torque wrench to tighten the O-ring fittings: Over tightening will damage the O-ring and tube end distortion.
5. If the operation is interrupted before completing a pipe connection, recap the tubes, components, and fittings with a plug or tape to prevent contamination from entering. Seal
6. Visually check the surfaces and mating surfaces of O-rings, threads, and connecting points. If a failure is found, replace the applicable parts.
7. Install the O-rings at right angle to the tube beards. O-ring OK NG Bead
8. Use the oil specified in the service manual to lubricate the O-rings. Apply the oil to the top and sides of the O-rings before installation. Apply the oil to the area including the O-rings and tube beads.
9. After tightening, use a clean shop cloth to remove excess oil from the connections and any oil which may have run on the vehicle body or other parts.
10. If any leakage is suspected after tightening, do not retighten the connections, Disconnect the connections, remove the O-rings, and check the O-rings, threads, and connections.

PROCEDURE

Perform the compressor oil return operation.

Stop the engine.

Make sure the valves on low/high pressure sides of manifold gauge set are fully closed.

Scheme 66

1. Low-pressure gauge (Compound pressure gauge)
2. High-pressure gauge
3. Close

Install the low/high pressure hoses to the service ports on the low/high pressure sides of the vehicle respectively.

Scheme 67

1. Low-pressure gauge (Compound pressure gauge)
2. High-pressure gauge
3. Close
4. Low-pressure side service port
5. High-pressure side service port

Connect the center hose to the refrigerant recovery system.

Follow the operation manual to activate the refrigerant recovery system.

Close the valves on low/high pressure sides of the manifold gauge.

Scheme 68

1. Low-pressure gauge (Compound pressure gauge)
2. High-pressure gauge
3. Close

Install the low/high pressure hoses to the corresponding service ports on the vehicle respectively.

Connect the center hose of the manifold gauge set with the vacuum pump.

Carefully open the valves on the low/high pressure sides to activate the vacuum pump.

Scheme 69

1. Low-pressure gauge (Compound pressure gauge)
2. High-pressure gauge
3. Slowly open
4. Vacuum pump turn on

After the low-pressure gauge reaches 100.0 kPa (750 mmHg, 29.5 inHg) or higher, evacuate the system for approx. 15 minutes (Continue evacuation).

Scheme 70

After 15 minutes of evacuation, if the reading shows 100.0 kPa (750 mmHg, 29.5 inHg) or higher, close the valves on the both sides to stop the vacuum pump.

Scheme 71

1. Low-pressure gauge (Compound pressure gauge)
2. High-pressure gauge
3. Close
4. Vacuum pump turn off

Note the low-pressure gauge reading.

Scheme 72

Leave it at least 5 minutes, and then check the low-pressure gauge reading for any changes.

When a gauge indicator shows near to zero point, this is a sign of leakage. Check pipe connector points, repair them, make sure there is no leakage by air bleeding.

Following the can tap operation manual instructions, install it to the refrigerant can.

Scheme 73

1. Tap valve
2. Center manifold hose

Disconnect the center manifold hose from the vacuum pump, and connect the hose to the tap valve.

When a 13.6 kg (30 lb) refrigerant container is used, measure the refrigerant amount in use using a weighting scale.

Scheme 74

1. Refrigerant container (HFC-134a)
2. Weight scale

Confirm that all the 3 hoses are tightly connected to the manifold gauge set.

Scheme 75

1. Low-pressure gauge (Compound pressure gauge)
2. High-pressure gauge
3. Close

Open the valve on the HFC-134a source.

Loosen the center hose connection on the manifold gauge set (if applicable, press a purge valve on the manifold gauge set) only for a couple of seconds to allow the air in the center hose to escape by the refrigerant.

Carefully open the high-pressure valve with the engine stopping.

Scheme 76

1. Low-pressure gauge (Compound pressure gauge)
2. High-pressure gauge
3. Close
4. Ignition switch OFF
5. Slowly open

Close the high-pressure valve when the low-pressure gauge reaches 98 kPa (1 kg/cm 2 , 14 psi). Using a leak tester, check the system for leaks.

If any leakage is found after the refrigerant recovery is completed, repair the applicable area.

After confirming that there are no leaks with the leak test, charge the required amount of refrigerant.

Close the high-pressure valve when

Scheme 77

1. the readings of low/high pressure gauges become almost equal, after the charging speed is reduced
2. the HFC-134a source becomes empty, or the system is filled with the gas.

If the HFC-134a source is empty, close the high-pressure valve, close the valve on the can tap, and replace the HFC-134a source with a new one to restart the operation.

Scheme 78

1. Low-pressure gauge (Compound pressure gauge)
2. High-pressure gauge
3. Close

Confirm that both the low/high pressure valves can be closed. Start the engine with the A/C switch OFF.

Quickly repeat ON-OFF cycles a few times to prevent initial compressor damage.

Set up the vehicle to the following status

1. A/C switch ON
2. Engine running at 1,500 RPM
3. Blower speed setting to "HI"
4. Temperature setting to "MAX COOL"
5. Air inlet setting to "RECIRC"
6. Windows open

While reading the low-pressure gauge, carefully open the low-pressure valve with the refrigerant source connected and the service hose purged.

Scheme 79

Adjust the refrigerant flow to maintain the pressure on the low-pressure side at 276 kPa (2.81 kg/cm 2 , 40 psi) max.

After the system is fully charged, close the low-pressure valve.

Close the valve on the refrigerant source.

REFRIGERANT AMOUNT SPECIFICATION

Disconnect the hose from the service port, and install the service port cap.

Note. Before making repairs, conduct the oil return operation to return the compressor oil in circulation with the refrigerant to compressor.

Increase engine to 1,500 RPM.

Turn the A/C switch to ON.

Turn the temperature control switch to MAX COOL.

Put in RECIRC position.

Turn the blower control switch to HI.

Leave in this condition for 10 minutes.

MAGNETIC CLUTCH CLEARANCE

Check the clearance of the entire circumference around the drive plate and pulley.

Standard

0.45+/-0.15 mm (0.0177+/-0.0059 in)

CENTER GRILLE

Disconnect the ground cable from battery.

Remove the console front panel.

Remove the center console panel.

Loosen the three screws to remove the center air vent grille (A).

Scheme 80

SIDE GRILLE

Disconnect the ground cable from battery.

Remove the heater vent duct.

Loosen the screws to remove the side air vent grille.

Scheme 81