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Climate System: Other Saab 9-5 II

Automatic HVAC System 37 illustrations ~3761 words

Parking Heater Inside Air Temperature Sensor

TemperatureInside Air Temperature Sensor
°C°F(kohms)
0329
10505.48
20683.44
30862.22
401041.47
501220.993

Parking Heater Coolant Temperature and Overheat Temperature Sensors

TemperatureCoolant Temperature Sensor and Overheat Temperature Sensor
°C°F(kohms)
03232.54
105019.87
206812.48
30868.06
401045.33
501223.6
601402.48
701581.75
801761.25
901940.91
1002120.67
1102300.5
1202480.38

Parking Heater Combustion Temperature Sensor

TemperatureCombustion Temperature Sensor
°C°F(kohms)
50580.803
0321
10501.022
20681.062
30861.097
501221.194
801761.309
901941.347
1002121.385
1302661.498
1503021.573
2003921.758
2504821.941
3005722.12
3506622.297
4007522.47

Radio Remote Control

The radio remote control has an easy control structure. The radio remote control can be used to set all functions, change them as necessary, preprogram times and read or clear DTCs. With direct visual contact, the radio remote control has an outdoor range of up to 1000 m (3280 ft). External interference, local conditions and dense building development in the surrounding area shorten the range. The radio remote control should always be pointed towards the vehicle when activated for data transmission. If the radio remote control is out of range, the preset mode is then available as an alternative.

Parking Heater

The parking heater work independently of the engine and thus offer a double plus: preheating the vehicle passenger compartment and the engine. The parking heater is integrated in the water cooling system of the engine. The thermal energy gained is absorbed by the vehicles own heat exchanger and distributed into the interior through their existing air vents. The engine is warmed up with the residual heat in the water cooling system of the engine.

Preheating Mode, Switching On

When the parking heater is switched on, the water pump starts up. After that the combustion air fan, glow plug and fuel dosing pump starts the combustion procedure according to a certain program, with pre-rinsing and preheating. Once a stable flame has formed, the time control switches the glow plug off.

Heating Mode

Depending on the heat requirements the parking heater is controlled in the stages: HIGH, ECO, OFF (control pause). The temperature thresholds are permanently programmed in the parking heater control module. If the cooling water temperature reaches 85°C (185°F) in the ECO stage, the parking heater control module switches to the control pause. This is followed by approx. 130 s after running. The operating display is still on and the water pump also continues to run during the control pause.

Preventing With Changeover Switch Heating/Venting

Preventing means triggering the vehicle fan directly by the heater preselection timer or, even more possible, by a remote control bypassing the heater. In this way in summer months when the insides of a vehicle get heated up when standing in the sunshine, it is possible to allow fresh air to vent the vehicle.

Control and Safety Features

  1. If the parking heater fails to ignite within 90 s after the parking heater fuel pump starts, the start procedure is repeated as described. After a further 90 s of fuel pumping and the parking heater still fails to ignite again, the parking heater is switched off in a fault mode. The controller is locked after a certain number of failed starts. For fault displaying and clearing refer to «FUEL OPERATED HEATER DIAGNOSTIC TROUBLE CODE (DTC) DISPLAYING AND CLEARING»(ref-653641-S07332478372014090100000) .
  2. If the flame is cut off during operation, a new start is activated. If the parking heater fails to ignite within 90 s after fuel pumping has started again, or ignites but does not run again within 15 min, the heater is switched off in a fault mode. The fault mode can be cancelled by switching off and on again. Do not repeat this procedure more than 2 times.
  3. If the parking heater is overheated (lack of water, poorly vented cooling circuit), the parking heater overheat sensor triggers, the fuel supply is interrupted and the parking heater is switched off. A DTC is set. Once the cause of overheating has been eliminated, the parking heater can be switched on again by switching off and on again (on condition that the parking heater has cooled down sufficiently, cooling water temperature less than 70°C (158°F)). The controller is locked after a certain number of overheating shutdowns. For fault displaying and clearing refer to «FUEL OPERATED HEATER DIAGNOSTIC TROUBLE CODE (DTC) DISPLAYING AND CLEARING»(ref-653641-S07332478372014090100000) .
  4. The parking heater is switched off in fault mode if the lower or upper voltage limit is reached.
  5. The parking heater does not start when the glow plug is defect or electrical lead to the dosing pump is interrupted.
  6. The fan motor speed is monitored continuously. If the fan motor does not start up, is blocked or if the speed falls below 40% of the nominal speed, the parking heater is switched off in fault mode after 60 s.
DTCDescription
DTC 10Parking Heater Overvoltage - Shutdown
DTC 11Parking Heater Undervoltage - Shutdown
DTC 12Parking Heater Overheating - Software
DTC 14Parking Heater Possible Overheating Detected
DTC 17Parking Heater Overheating Detected - Hardware
DTC 15Operation Lock - Heater Overheated More than 10 Times
DTC 20Parking Heater Glow Plug Circuit Open
DTC 21Parking Heater Glow Plug Circuit Low or Circuit High
DTC 30Parking Heater Blower Motor Speed Out of Tolerance
DTC 31Parking Heater Blower Motor Circuit Open
DTC 32Parking Heater Blower Motor Circuit Low or Circuit High
DTC 41Parking Heater Water Pump Circuit Open
DTC 42Parking Heater Water Pump Circuit Low or Circuit High
DTC 47Parking Heater Fuel Pump Circuit Low or Circuit High
DTC 48Parking Heater Fuel Pump Circuit Open
DTC 50Parking Heater Start Counter Overrun
DTC 51Parking Heater Cold Blow Time Exceeded
DTC 52Parking Heater Safety Time Exceeded
DTC 53Parking Heater Combustion Aborted - Control Stage Large
DTC 56Parking Heater Combustion Aborted - Control Stage Small
DTC 60Parking Heater Coolant Sensor Circuit Low or Circuit High
DTC 61Parking Heater Coolant Sensor Circuit Open
DTC 64Parking Heater Combustion Sensor Circuit Open
DTC 65Parking Heater Combustion Sensor Circuit Low or Circuit High
DTC 71Parking Heater Overheat Sensor Circuit Open
DTC 72Parking Heater Overheat Sensor Circuit Low or Circuit High
DTC 90Parking Heater Controller Defect
DTC 92-103Parking Heater Controller Defect
DTC 91Parking Heater External Interference Voltage

CLIMATE SYSTEM DTC INDEX

Electrical Information Reference

  1. «CIRCUIT TESTING»(ref-653659-S30091259062014090100000)
  2. «CONNECTOR REPAIRS»(ref-653659-S33681896522014090100000)
  3. «TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS»(ref-653659-S19761557662014090100000)
  4. «WIRING REPAIRS»(ref-653659-S03227166852014090100000)

Circuit/System Verification

Ignition OFF, command the parking heater ON and OFF with the remote control. Verify the parking heater turns ON and OFF with no DTCs.

Repair Instructions

Perform the DIAGNOSTIC REPAIR VERIFICATION after completing the diagnostic procedure.

  1. «CIRCUIT TESTING»(ref-653659-S30091259062014090100000)
  2. «CONNECTOR REPAIRS»(ref-653659-S33681896522014090100000)
  3. «TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS»(ref-653659-S19761557662014090100000)
  4. «WIRING REPAIRS»(ref-653659-S03227166852014090100000)

Ignition OFF, command the parking heater ON and OFF with the remote control. Verify the parking heater turns ON and OFF with no DTCs.

Perform the DIAGNOSTIC REPAIR VERIFICATION after completing the diagnostic procedure.

  1. «CIRCUIT TESTING»(ref-653659-S30091259062014090100000)
  2. «CONNECTOR REPAIRS»(ref-653659-S33681896522014090100000)
  3. «TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS»(ref-653659-S19761557662014090100000)
  4. «WIRING REPAIRS»(ref-653659-S03227166852014090100000)

Ignition OFF, command the parking heater ON and OFF with the remote control. Verify the parking heater turns ON and OFF with no DTCs.

Perform the DIAGNOSTIC REPAIR VERIFICATION after completing the diagnostic procedure.

  1. «CIRCUIT TESTING»(ref-653659-S30091259062014090100000)
  2. «CONNECTOR REPAIRS»(ref-653659-S33681896522014090100000)
  3. «TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS»(ref-653659-S19761557662014090100000)
  4. «WIRING REPAIRS»(ref-653659-S03227166852014090100000)

Ignition OFF, command the parking heater ON and OFF with the remote control. Verify the parking heater turns ON and OFF with no DTCs.

Perform the DIAGNOSTIC REPAIR VERIFICATION after completing the diagnostic procedure.

  1. «CIRCUIT TESTING»(ref-653659-S30091259062014090100000)
  2. «CONNECTOR REPAIRS»(ref-653659-S33681896522014090100000)
  3. «TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS»(ref-653659-S19761557662014090100000)
  4. «WIRING REPAIRS»(ref-653659-S03227166852014090100000)

Ignition OFF, command the parking heater ON and OFF with the remote control. Verify the parking heater turns ON and OFF with no DTCs.

Perform the DIAGNOSTIC REPAIR VERIFICATION after completing the diagnostic procedure.

  1. «CIRCUIT TESTING»(ref-653659-S30091259062014090100000)
  2. «CONNECTOR REPAIRS»(ref-653659-S33681896522014090100000)
  3. «TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS»(ref-653659-S19761557662014090100000)
  4. «WIRING REPAIRS»(ref-653659-S03227166852014090100000)

Ignition OFF, command the parking heater ON and OFF with the remote control. Verify the coolant pump turns ON and OFF with the heater.

Perform the DIAGNOSTIC REPAIR VERIFICATION after completing the diagnostic procedure.

  1. «CIRCUIT TESTING»(ref-653659-S30091259062014090100000)
  2. «CONNECTOR REPAIRS»(ref-653659-S33681896522014090100000)
  3. «TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS»(ref-653659-S19761557662014090100000)
  4. «WIRING REPAIRS»(ref-653659-S03227166852014090100000)

Ignition OFF, command the parking heater ON and OFF with the remote control. Verify the fuel pump turns ON and OFF with the heater.

Perform the DIAGNOSTIC REPAIR VERIFICATION after completing the diagnostic procedure.

  1. «CIRCUIT TESTING»(ref-653659-S30091259062014090100000)
  2. «CONNECTOR REPAIRS»(ref-653659-S33681896522014090100000)
  3. «TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS»(ref-653659-S19761557662014090100000)
  4. «WIRING REPAIRS»(ref-653659-S03227166852014090100000)

Ignition OFF, command the independent heater ON and OFF with the remote control. Verify the independent heater turns ON and OFF with no DTCs.

Perform the DIAGNOSTIC REPAIR VERIFICATION after completing the diagnostic procedure.

  1. «CIRCUIT TESTING»(ref-653659-S30091259062014090100000)
  2. «CONNECTOR REPAIRS»(ref-653659-S33681896522014090100000)
  3. «TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS»(ref-653659-S19761557662014090100000)
  4. «WIRING REPAIRS»(ref-653659-S03227166852014090100000)

Ignition OFF, command the parking heater ON and OFF with the remote control. Verify the parking heater turns ON and OFF with no DTCs.

Perform the DIAGNOSTIC REPAIR VERIFICATION after completing the diagnostic procedure.

  1. «CIRCUIT TESTING»(ref-653659-S30091259062014090100000)
  2. «CONNECTOR REPAIRS»(ref-653659-S33681896522014090100000)
  3. «TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS»(ref-653659-S19761557662014090100000)
  4. «WIRING REPAIRS»(ref-653659-S03227166852014090100000)

Ignition OFF, command the parking heater ON and OFF with the remote control. Verify the parking heater turns ON and OFF with no DTCs.

Perform the DIAGNOSTIC REPAIR VERIFICATION after completing the diagnostic procedure.

  1. «CIRCUIT TESTING»(ref-653659-S30091259062014090100000)
  2. «CONNECTOR REPAIRS»(ref-653659-S33681896522014090100000)
  3. «TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS»(ref-653659-S19761557662014090100000)
  4. «WIRING REPAIRS»(ref-653659-S03227166852014090100000)

Ignition OFF, command the parking heater ON and OFF with the remote control. Verify the parking heater turns ON and OFF with no DTCs.

Perform the DIAGNOSTIC REPAIR VERIFICATION after completing the diagnostic procedure.

  1. «CIRCUIT TESTING»(ref-653659-S30091259062014090100000)
  2. «CONNECTOR REPAIRS»(ref-653659-S33681896522014090100000)
  3. «TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS»(ref-653659-S19761557662014090100000)
  4. «WIRING REPAIRS»(ref-653659-S03227166852014090100000)

Ignition OFF, command the parking heater ON and OFF with the remote control. Verify the parking heater turns ON and OFF with no DTCs.

Perform the DIAGNOSTIC REPAIR VERIFICATION after completing the diagnostic procedure.

  1. «CIRCUIT TESTING»(ref-653659-S30091259062014090100000)
  2. «CONNECTOR REPAIRS»(ref-653659-S33681896522014090100000)
  3. «TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS»(ref-653659-S19761557662014090100000)
  4. «WIRING REPAIRS»(ref-653659-S03227166852014090100000)

Ignition OFF, command the parking heater ON and OFF with the remote control. Verify the parking heater turns ON and OFF with no DTCs.

Perform the DIAGNOSTIC REPAIR VERIFICATION after completing the diagnostic procedure.

Independent Heater

  1. «CIRCUIT TESTING»(ref-653659-S30091259062014090100000)
  2. «CONNECTOR REPAIRS»(ref-653659-S33681896522014090100000)
  3. «TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS»(ref-653659-S19761557662014090100000)
  4. «WIRING REPAIRS»(ref-653659-S03227166852014090100000)

Ignition OFF, command the independent heater ON and OFF with the remote control. Verify the independent heater turns ON and OFF with no DTCs.

Perform the DIAGNOSTIC REPAIR VERIFICATION after completing the diagnostic procedure.

Symptoms - Heating, Ventilation, and Air Conditioning

Note. The following steps must be completed before using the symptom tables. Perform the DIAGNOSTIC SYSTEM CHECK - VEHICLE before using the symptom tables in order to verify that all of the following are true: There are no DTCs set The control modules can communicate via the serial data link Review the system operation in order to familiarize yourself with the system functions. Refer to FUEL OPERATED HEATER DESCRIPTION AND OPERATION .

Intermittent

Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS .

  1. For DTC 10 or 11 refer to «DTC 10 OR 11»(ref-653641-S29179436822014090100000) .
  2. For DTC 12, 14, 17 refer to «DTC 12, 14, OR 17»(ref-653641-S10085072472014090100000) .
  3. For DTC 15 refer to «DTC 15»(ref-653641-S16263349412014090100000) .
  4. For DTC 20 or 21 refer to «DTC 20 OR 21»(ref-653641-S16404213262014090100000) .
  5. For DTC 30-32 refer to «DTC 30-32»(ref-653641-S37547537992014090100000) .
  6. For DTC 41 or 42 refer to «DTC 41 OR 42»(ref-653641-S35718035262014090100000) .
  7. For DTC 47 or 48 refer to «DTC 47 OR 48»(ref-653641-S20568649822014090100000) .
  8. For DTC 50-52 refer to «DTC 50-52»(ref-653641-S10805216092014090100000) .
  9. For DTC 53 or 56 refer to «DTC 53 OR 56»(ref-653641-S26978134142014090100000) .
  10. For DTC 60 or 61 refer to «DTC 60 OR 61»(ref-653641-S18416555222014090100000) .
  11. For DTC 64 or 65 refer to «DTC 64 OR 65»(ref-653641-S35129324082014090100000) .
  12. For DTC 71 or 72 refer to «DTC 71 OR 72»(ref-653641-S06606258522014090100000) .
  13. For DTC 90 or 92-103 refer to «DTC 90 OR 92-103»(ref-653641-S02697201522014090100000) .
  14. For DTC 91 refer to «DTC 91»(ref-653641-S30290142332014090100000) .

Perform the DIAGNOSTIC REPAIR VERIFICATION after completing the diagnostic procedure.

Fuel Operated Heater Remote Control Malfunction

The radio remote control is equipped with a self diagnostic. If an error occur the display of the radio remote control shows the data which is explained below.

Display Shows: cobA

Poor communication between the radio remote control and the parking heater remote control receiver. Data is received. However, it is faulty.

  1. Check the distance between the radio remote control and vehicle.
  2. If greater than the specified range change the position relative to vehicle e. g. hold the radio remote control higher or move it to the side, reduce the distance to the vehicle.
  3. Check for dense buildings between the radio remote control and vehicle.
  4. If greater than the specified range reduce the distance, if possible, reinstate visual contact with the vehicle.
  5. Check for several parking heater radio remote controls are operated simultaneously. Reactivate the radio remote control after a pause.
  6. If a reactivation of the radio remote control is not possible replace the radio remote control.
  7. If all test normal, replace the parking heater remote control receiver.

Display Shows: conP

Communication between the radio remote control and the parking heater remote control receiver is not possible.

  1. Check the distance between the radio remote control and vehicle.
  2. If greater than the specified range reduce the distance to the vehicle.
  3. Check for several parking heater radio remote controls are operated simultaneously. Reactivate the radio remote control after a pause.
  4. If a reactivation of the radio remote control is not possible replace the radio remote control.
  5. Check if the radio remote control has not been learned. Learn the radio remote control as described in the installation instructions.
  6. If not possible replace the radio remote control.
  7. If all test normal, replace the parking heater remote control receiver.

Note. If the messages cobA and conP are displayed, no control/operation is possible. A running heater can only be switched OFF using the OFF button mounted in the glove box of the vehicle.

Display Shows: Err

A fault occurs in the parking heater during operation. Refer to FUEL OPERATED HEATER DIAGNOSTIC TROUBLE CODE (DTC) DISPLAYING AND CLEARING .

Display Shows: Add or AddE

The radio remote control is in learn mode.

Check if the radio remote control is in learn mode. Learn the radio remote control as described in the installation instructions.

Display Shows: bAlo

The radio remote control battery is very weak. Data transmission is not possible.

  1. Check the battery of the radio remote control.
  2. If not within the specified range replace the battery of the radio remote control.
  3. If all test normal, replace the radio remote control.

Display Shows: 12:00

The display "set timer" appears after the radio remote control is activated.

  1. The parking heater remote control receiver has been disconnected from the vehicle battery. All programmed preset times have been deleted.
  2. Connect the battery and set the time at the radio remote control as described in the installation instruction.
  3. If not possible replace the radio remote control.
  4. If all test normal, replace the parking heater remote control receiver.

Display OFF

The display of the radio remote control cannot be activated.

  1. Check the battery of the radio remote control.
  2. If not within the specified range replace the battery of the radio remote control.
  3. If all test normal, replace the radio remote control.

Display LED flashing

The parking heater remote control receiver is in learn mode.

  1. Check if the parking heater remote control receiver is in learn mode.
  2. The display switches off after 30 seconds, if not possible learn the radio remote control as described in the installation instruction.
  3. If is not possible to learn the radio remote control, replace it.
  4. If all test normal, replace the parking heater remote control receiver.

Display Battery Symbol is Flashing

  1. Check the battery of the radio remote control.
  2. If not within the specified range replace the battery of the radio remote control.
  3. If all test normal, replace the radio remote control.
  1. «CIRCUIT TESTING»(ref-653659-S30091259062014090100000)
  2. «CONNECTOR REPAIRS»(ref-653659-S33681896522014090100000)
  3. «TESTING FOR INTERMITTENT CONDITIONS AND POOR CONNECTIONS»(ref-653659-S19761557662014090100000)
  4. «WIRING REPAIRS»(ref-653659-S03227166852014090100000)

Perform the DIAGNOSTIC REPAIR VERIFICATION after completing the diagnostic procedure.

Fluorescent Leak Detector

Fluorescent dye will assist in locating any leaks in the A/C system.

  1. NOTE: PAG oil is water soluble. Condensation on the evaporator core or the refrigerant lines may wash the PAG oil and fluorescent dye away from the actual leak. Condensation may also carry dye through the HVAC module drain.
  2. Leaks in the A/C system will be indicated in a light green or yellow color when using the leak detection lamp. Use the leak detection lamp in the following areas: All fittings or connections that use seal washers or O-rings All of the A/C components The A/C compressor shaft seal The A/C hoses and pressure switches The HVAC module drain tube, if the evaporator core is suspected of leaking The service port sealing caps The sealing cap is the primary seal for the service ports.
  3. Follow the instructions supplied with the detection lamp.
  4. To prevent false diagnosis in the future, thoroughly clean the residual dye from any area where leaks were found. Use a rag and an approved fluorescent dye cleaner.

Fluorescent Dye Injection

Note. Use only fluorescent dye approved by General Motors.

  1. Not all of the fluorescent dyes are compatible with PAG oil. Some types of dye decrease the oil viscosity or may chemically react with the oil.
  2. NOTE: Do NOT overcharge the A/C system with dye. R-134A leak detection dye requires time to work. Depending upon the leak rate, a leak may not become visible for between 15 minutes and 7 days.
  3. To prevent false diagnosis, thoroughly clean any residual dye from the service port with a rag and an approved fluorescent dye cleaner.

Halogen Leak Detector

WARNINGDo not operate the detector in a combustible atmosphere since its sensor operates at high temperatures or personal injury and/or damage to the equipment may result.

Ensure that the vehicle has at least 0.45 kg (1 lb) of refrigerant in the A/C refrigeration system in order to perform a leak test. Refer to REFRIGERANT RECOVERY AND RECHARGING .

Note. Halogen leak detectors are sensitive to the following items: Some adhesives used in the vehicle Many solvents and cleaners Windshield washing solutions

Clean and dry all surfaces in order to prevent a false warning. Liquids will damage the detector.

Note. Follow a continuous path in order to ensure that you will not miss any possible leaks. Test all areas of the system for leaks.

Follow the instructions supplied with the halogen leak tester.

Time studies - Heating and ventilation

Object code - IDDescriptionVariantModel yearCorrectionPosMarketTime (hrs)
85410-01Air filter, cab2010010.1
85415-01Blower Motor2010010.2
85421-01Heat exchangerRHD201001AU EU GB LA ME PA SE0.7
85421-02Heat exchangerLHD2010010.7
85422-01Heat exchanger housing2010014.6
85439-01Drainage hoseLHD2010010.4
85439-02Drainage hoseRHD201001AU EU GB LA ME PA SE0.3
85442-01Vent201001030.1
85442-02Vent201001040.1
85443-01Fresh air outlet, centre201001020.3
85444-01Fresh air outlet, outer201001042.0
85444-02Fresh air outlet, outer20100103070.3
85446-01Branch duct, floor duct201001010.6
85446-02Branch duct, floor duct201001010.6
85446-03Branch duct, floor duct201001020.5
85455-01Branch pipe, defroster2010012.0
85458-01Air evacuation unit20100103040.3
85463-01Fresh air hose20100101030.1
85485-01Adjustment shaft/wire2010010.9
85486-01Cranked selector2010010.8
85487-01Toothed rod selector2010010.9

Correction

  1. 01 - Replacement
  2. 02 - Removal - Refit
  3. 03 - Renovate
  4. 04 - Paint
  5. 05 - Adjust
  6. 06 - Change comp. unit
  7. 07 - Lubricate - Clean - Polish
  8. 08 - Check/Fault search
  9. 09 - Expose
  10. 10 - Install new
  11. 11 - Transfer

Refrigerant Recovery and Recharging

WARNINGTo prevent personal injury, avoid breathing A/C Refrigerant and lubricant vapor or mist. Work in a well ventilated area. To remove refrigerant from the A/C System, use service equipment designed for recovery that is certified to meet the requirements of the appropriate SAE Standards. If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant, refrigerant recovery, and lubricant manufacturers.
WARNINGFor personal protection, goggles and lint-free gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If refrigerant comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained.
WARNINGYou must replace the desiccant if the A/C refrigerant system has been open to atmosphere for more than four hours, or if the A/C refrigerant oil has been contaminated. Failure to replace the desiccant will result in damage to the A/C refrigerant system.
WARNINGTo avoid system damage use only R-134a dedicated tools when servicing the A/C system.
WARNINGR-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure.
WARNINGUse only polyalkylene glycol (PAG) synthetic refrigerant oil for circulation inside the R-134a A/C system, and only mineral oil of viscosity 525 on threads and O-rings. Use of lubricants other than those specified can lead to the compressor and/or connections seizing.
WARNINGR-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing.

The A/C service station is a complete air conditioning service center for refrigerant. The service station recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that has a function control and displays recommendations that guide the technician through the operations recovery, recycling, evacuating and recharging. The A/C refrigerant is recovered to and filled to and from an internal storage vessel.

The A/C service station has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the station will not recover the refrigerant from the A/C system.

For information on the actual equipment, please refer to the manual of the equipment in question.

Always recharge the A/C System with the proper amount of refrigerant. Refer to REFRIGERANT SYSTEM SPECIFICATIONS for the correct amount.

A/C Refrigerant System Oil Charge Replenishing

If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system. For the proper quantities of oil to add to the A/C refrigerant system, refer to REFRIGERANT SYSTEM SPECIFICATIONS .

Scheme 72

Scheme 72: Draining Procedure
Scheme 72: Draining Procedure
  1. NOTE: Drain and measure as much of the refrigerant oil as possible from the removed compressor. Remove the compressor crankcase oil drain plug and drain the crankcase into a clean, graded container.
  2. Drain the oil from both the suction and discharge ports of the removed compressor into the same container. Rotate the compressor shaft to assist in draining the compressor.
  3. Measure and record the amount of oil drained from the removed compressor. This measurement will be used during installation of the replacement compressor.
  4. Inspect oil drained from removed compressor. Refer to «AIR CONDITIONING COMPRESSOR OIL DIAGNOSIS»(ref-653641-S25338145432014090100000) .
  5. Properly discard the used refrigerant oil.

Scheme 73

Scheme 73: Balancing Procedure
Scheme 73: Balancing Procedure
  1. NOTE: The refrigerant oil in the A/C system must be balanced during compressor replacement. NOTE: Check the oil volume in the replacement compressor. The replacement compressor is shipped partially filled with refrigerant oil. The amount of oil has to be balanced according to below.
  2. Before installing the compressor, the refrigerant oil will have to be drained: Drain the replacement compressor completely from oil as described above, Draining procedure - item 1 and 2, into a clean, graded container.
  3. Add the same amount of oil into the new compressor as was drain and recorded from the replaced compressor + 20 ml. If no oil (or very little amount = equal or less than 10 ml) was drained from the replaced compressor, fill 50 ml of oil in the new compressor.

Scheme 74

Scheme 74: Air Conditioning Compressor Replacement (LBS/A20DTH)
Scheme 74: Air Conditioning Compressor Replacement (LBS/A20DTH)
CalloutComponent Name
Preliminary Procedure Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING . Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE . Remove the tire and wheel assembly. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION . Remove the right front liner. Remove the engine shield. Refer to ENGINE SHIELD REPLACEMENT . Remove the drive belt. Refer to DRIVE BELT REPLACEMENT .
1A/C Compressor and Condenser Hose Assembly Bolt Refer to FASTENER CAUTION . Tighten 22 Nm (16 lb ft)
2Sealing Washer Procedure Remove and discard the sealing washer. Refer to AIR CONDITIONING SYSTEM SEAL REPLACEMENT .
3A/C Compressor Bolt (Qty: 3) Procedure Tighten the bolts in sequence. Tighten 22 Nm (16 lb ft)
4A/C Compressor Assembly Procedure Perform compressor oil balancing. Refer to AIR CONDITIONING COMPRESSOR OIL BALANCING .

Scheme 75

Scheme 75: Air Conditioning Compressor Replacement (LAU/A28NER)
Scheme 75: Air Conditioning Compressor Replacement (LAU/A28NER)
CalloutComponent Name
Preliminary Procedure Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING Disconnect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION Remove the air cleaner outlet duct. Refer to AIR CLEANER OUTLET DUCT REPLACEMENT Remove the front bumper fascia assembly. Refer to FRONT BUMPER FASCIA REPLACEMENT Remove the charge air cooler outlet hose assembly. Refer to CHARGE AIR COOLER OUTLET HOSE REPLACEMENT (LAU/A28NER) Remove front compartment splash shield. Refer to FRONT COMPARTMENT SPLASH SHIELD REPLACEMENT Remove front wheelhouse front liner - right side. Refer to FRONT WHEELHOUSE FRONT LINER REPLACEMENT Remove the power brake booster pump. Refer to POWER BRAKE BOOSTER PUMP REPLACEMENT (LAU/A28NER) Release the drive belt. Refer to DRIVE BELT REPLACEMENT . Disconnect the A/C compressor electrical connector.
1A/C Compressor Hose Fastener Refer to FASTENER CAUTION . Procedure Remove the A/C compressor hose from the A/C compressor and cap hose. Tighten 20 Nm (15 lb ft)
2Sealing Washer (Qty: 2) Procedure Remove and discard sealing washers. Refer to AIR CONDITIONING SYSTEM SEAL REPLACEMENT .
3A/C Compressor Fastener (Qty: 3) NOTE: Tighten the A/C compressor mounting fasteners in the sequence shown in graphic. Tighten 22 Nm (16 lb ft)
4A/C Compressor Assembly Procedure When replacing the A/C compressor, balance the compressor oil. Refer to AIR CONDITIONING COMPRESSOR OIL BALANCING
NOTE
Tighten the A/C compressor mounting fasteners in the sequence shown in graphic.

Scheme 76

Scheme 76: Air Conditioning Compressor Replacement (LLU/A16LET)
Scheme 76: Air Conditioning Compressor Replacement (LLU/A16LET)
CalloutComponent Name
Preliminary Procedure Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING . Remove front compartment splash shield. Refer to FRONT COMPARTMENT SPLASH SHIELD REPLACEMENT . Release the drive belt. Disconnect the A/C compressor electrical connector.
1Charge Air Cooler Inlet Air Hose Procedure Remove charge air cooler inlet air hose from turbocharger.
2A/C Compressor Hose Fastener Refer to FASTENER CAUTION . Procedure Remove the A/C compressor hose from the A/C compressor and cap hose. Tighten 20 Nm (15 lb ft)
3Sealing Washer (Qty: 2) Procedure Remove and discard sealing washers. Refer to AIR CONDITIONING SYSTEM SEAL REPLACEMENT .
4A/C Compressor Fastener (Qty: 3) NOTE: Tighten the A/C compressor mounting fasteners in the sequence shown in graphic. Tighten 22 Nm (16 lb ft)
5A/C Compressor Assembly Procedure When replacing the A/C compressor, balance the compressor oil. Refer to AIR CONDITIONING COMPRESSOR OIL BALANCING .
NOTE
Tighten the A/C compressor mounting fasteners in the sequence shown in graphic.

Scheme 77

Scheme 77: Air Conditioning Compressor Replacement (LBY/A20DTR)
Scheme 77: Air Conditioning Compressor Replacement (LBY/A20DTR)
CalloutComponent Name
Preliminary Procedure Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING . Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE . Remove the tire and wheel assembly. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION . Remove the right front liner. Remove the engine shield. Refer to, CHARGE AIR COOLER INLET HOSE REPLACEMENT (LBY/A20DTR) . Remove the drive belt. Refer to DRIVE BELT REPLACEMENT .
1Clip (Qty: 4)
2A/C Compressor and Condenser Hose Assembly Bolt Refer to FASTENER CAUTION . Procedure Remove and discard the sealing washer. Refer to AIR CONDITIONING SYSTEM SEAL REPLACEMENT . Tighten 22 Nm (16 lb ft)
3A/C Compressor Bolt (Qty: 3) Procedure Tighten the bolts in sequence. Tighten 22 Nm (16 lb ft)
4A/C Compressor Heat Shield Procedure Remove heat shield. Disconnect the electrical connector.
5A/C Compressor Assembly Procedure Perform compressor oil balancing. Refer to AIR CONDITIONING COMPRESSOR OIL BALANCING .

Scheme 78

Scheme 78: Air Conditioning Compressor Replacement (LHU/A20NFT)
Scheme 78: Air Conditioning Compressor Replacement (LHU/A20NFT)
CalloutComponent Name
Preliminary Procedure Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING . Remove the front compartment splash shield. Refer to FRONT COMPARTMENT SPLASH SHIELD REPLACEMENT . Release the drive belt. Disconnect the A/C compressor electrical connector.
1A/C Compressor Hose Fastener Refer to FASTENER CAUTION . NOTE: Remove the A/C compressor hose from the A/C compressor and cap hose. Tighten 20 Nm (15 lb ft)
2Sealing Washer (Qty: 2) Procedure Discard the sealing washers. Refer to AIR CONDITIONING SYSTEM SEAL REPLACEMENT .
3A/C Compressor Fastener (Qty: 3) NOTE: Tighten the A/C compressor mounting bolts in the sequence shown in graphic. Tighten 22 Nm (16 lb ft)
4A/C Compressor Assembly Procedure When replacing the A/C compressor, balance the compressor oil. Refer to AIR CONDITIONING COMPRESSOR OIL BALANCING .
NOTE
Remove the A/C compressor hose from the A/C compressor and cap hose.
NOTE
Tighten the A/C compressor mounting bolts in the sequence shown in graphic.

Scheme 79

Scheme 79: Compressor Pressure Relief Valve Replacement (LAU/A28NER)
Scheme 79: Compressor Pressure Relief Valve Replacement (LAU/A28NER)
CalloutComponent Name
Preliminary Procedure Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING . Remove Charge Air Cooler Outlet Hose assembly. Refer to CHARGE AIR COOLER OUTLET HOSE REPLACEMENT (LAU/A28NER) .
1Compressor Pressure Relief Valve Refer to FASTENER CAUTION . Tighten 10 Nm (89 lb in)

Scheme 80

Scheme 80: Compressor Pressure Relief Valve Replacement (LHU/A20NFT)
Scheme 80: Compressor Pressure Relief Valve Replacement (LHU/A20NFT)
CalloutComponent Name
Preliminary Procedure Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING .
1Compressor Pressure Relief Valve Refer to FASTENER CAUTION . Tighten 10 Nm (89 lb in)

Scheme 81

Scheme 81: Air Conditioning Compressor Bracket Replacement (LAU/A28NER)
Scheme 81: Air Conditioning Compressor Bracket Replacement (LAU/A28NER)
CalloutComponent Name
Preliminary Procedure Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING . Remove air conditioning compressor. Refer to AIR CONDITIONING COMPRESSOR REPLACEMENT (LAU/A28NER) .
1A/C Compressor Bracket Fastener (Qty: 4) Refer to FASTENER CAUTION . Tighten 42 Nm (31 lb ft)
2A/C Compressor Bracket

Scheme 82

Scheme 82: Air Conditioning Compressor Bracket Replacement (LHU/A20NFT)
Scheme 82: Air Conditioning Compressor Bracket Replacement (LHU/A20NFT)
CalloutComponent Name
Preliminary Procedure Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING . Remove air conditioning compressor. Refer to AIR CONDITIONING COMPRESSOR REPLACEMENT (LHU/A20NFT) . Remove belt idler pulley. Refer to BELT IDLER PULLEY REPLACEMENT .
1A/C Compressor Bracket Fastener (Qty: 3) Refer to FASTENER CAUTION . Tighten 22 Nm (16 lb ft)
2A/C Compressor Bracket

Scheme 83

Scheme 83: Removal Procedure
Scheme 83: Removal Procedure
  1. Remove the seal washer from the A/C refrigerant component.
  2. NOTE: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. Inspect the seal washer for signs of damage to help determine the root cause of the failure.
  3. Inspect the A/C refrigerant components for damage or burrs. Repair as required.
  4. NOTE: DO NOT reuse sealing washer. Discard the sealing washer.

Scheme 84

Scheme 84: Installation Procedure
Scheme 84: Installation Procedure
  1. NOTE: Flat washer type seals do not require lubrication. Inspect the new seal washer for any signs of cracks, cuts, or damage. Do not use a damaged seal washer.
  2. Remove the cap or tape from the A/C refrigerant components.
  3. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components.
  4. Carefully install the new seal washer onto the A/C refrigerant component. The washer must completely bottom against the surface of the fitting.
  5. NOTE: After tightening the A/C components, there should be a slight sealing washer gap of approximately 1.2 mm (3/64 in) between the A/C line and the A/C component. Assemble the remaining A/C refrigerant components.

Scheme 85

Scheme 85: Air Conditioning Compressor and Condenser Hose Replacement (LAU/A28NER)
Scheme 85: Air Conditioning Compressor and Condenser Hose Replacement (LAU/A28NER)
CalloutComponent Name
Preliminary Procedure Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING . Remove the front bumper fascia assembly. Refer to FRONT BUMPER FASCIA REPLACEMENT Remove the air cleaner outlet duct. Refer to AIR CLEANER OUTLET DUCT REPLACEMENT .
1A/C Compressor and Condenser Hose Fastener Refer to FASTENER CAUTION . NOTE: Remove the A/C compressor and condenser hose from the A/C evaporator hose and cap hose. Tighten 20 Nm (15 lb ft)
2Sealing Washer Procedure Remove and discard the sealing washer. Refer to AIR CONDITIONING SYSTEM SEAL REPLACEMENT .
3A/C Compressor Hose Fastener Procedure Remove the A/C compressor hose from the A/C compressor and cap hose. Tighten 20 Nm (15 lb ft)
4Sealing Washer Procedure Remove and discard the sealing washer. Refer to AIR CONDITIONING SYSTEM SEAL REPLACEMENT .
5A/C Condenser Hose Fastener Tighten 20 Nm (15 lb ft)
6Sealing Washer Procedure Remove and discard the sealing washer. Refer to AIR CONDITIONING SYSTEM SEAL REPLACEMENT .
7A/C Compressor and Condenser Hose Assembly
NOTE
Remove the A/C compressor and condenser hose from the A/C evaporator hose and cap hose.

Scheme 86

Scheme 86: Air Conditioning Compressor and Condenser Hose Replacement (LHU/A20NFT)
Scheme 86: Air Conditioning Compressor and Condenser Hose Replacement (LHU/A20NFT)
CalloutComponent Name
Preliminary Procedure Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING . Remove the front bumper fascia assembly. Refer to FRONT BUMPER FASCIA REPLACEMENT
1A/C Compressor and Condenser Hose Fastener Refer to FASTENER CAUTION . Procedure Remove the A/C compressor and condenser hose from the A/C evaporator hose and cap hose. Tighten 20 Nm (15 lb ft)
2Sealing Washer Procedure Remove and discard the sealing washer. Refer to AIR CONDITIONING SYSTEM SEAL REPLACEMENT .
3A/C Compressor Hose Fastener Procedure Remove the A/C compressor hose from the A/C compressor and cap hose. Tighten 22 Nm (15 lb ft)
4Sealing Washer Procedure Remove and discard sealing washers. Refer to AIR CONDITIONING SYSTEM SEAL REPLACEMENT .
5A/C Condenser Hose Fastener Tighten 20 Nm (15 lb ft)
6Sealing Washer Procedure Remove and discard the sealing washer. Refer to AIR CONDITIONING SYSTEM SEAL REPLACEMENT .
7A/C Compressor and Condenser Hose Assembly

Scheme 87

Scheme 87: Air Conditioning Evaporator Hose Assembly Replacement (LAU/A28NER)
Scheme 87: Air Conditioning Evaporator Hose Assembly Replacement (LAU/A28NER)
CalloutComponent Name
Preliminary Procedure Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING . Remove the front bumper fascia assembly. Refer to FRONT BUMPER FASCIA REPLACEMENT Remove the fuel injector sight shield. Refer to UPPER ENGINE COVER REMOVAL Remove the Headlamp - Right Side. Refer to HEADLAMP REPLACEMENT . Remove the engine mount. Refer to ENGINE MOUNT BRACKET REPLACEMENT - RIGHT SIDE . Remove the A/C Compressor and Condenser Hose from the A/C Evaporator Hose. Refer to AIR CONDITIONING COMPRESSOR AND CONDENSER HOSE REPLACEMENT (LAU/A28NER) .
1AC Evaporator Thermal Expansion Valve Heat and Brake Pipe Shield Fastener (Qty: 2) Procedure Remove the A/C TXV heat and brake pipe shield. Release the brake pipes.
2A/C Evaporator Hose Fastener Refer to FASTENER CAUTION . Tighten 20 Nm (15 lb ft)
3A/C Evaporator Hose Stud Bolt Tighten 15 Nm (11 lb in)
4A/C Evaporator Hose Assembly Procedure Remove the A/C Evaporator hose from the thermal expansion valve (TXV). Remove and discard the sealing washer. Refer to AIR CONDITIONING SYSTEM SEAL REPLACEMENT .
5A/C Evaporator Hose Fastener Procedure Remove the A/C Evaporator Hose from the A/C Condenser and cap hose. Tighten 20 Nm (15 lb ft)
6Sealing Washer Procedure Remove and discard the sealing washer. Refer to AIR CONDITIONING SYSTEM SEAL REPLACEMENT .
7Air Conditioning Evaporator Hose Assembly Procedure Release the A/C Evaporator Hose from the attaching clips. When the installation is postponed, close the off lines and connections.

Scheme 88

Scheme 88: Air Conditioning Evaporator Hose Assembly Replacement (LHU/A20NFT)
Scheme 88: Air Conditioning Evaporator Hose Assembly Replacement (LHU/A20NFT)
CalloutComponent Name
Preliminary Procedure Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING . Remove the front bumper fascia assembly. Refer to FRONT BUMPER FASCIA REPLACEMENT Remove the Headlamp - Right Side. Refer to HEADLAMP REPLACEMENT . Remove the engine mount. Refer to ENGINE MOUNT REPLACEMENT - RIGHT SIDE . Remove the A/C Compressor and Condenser Hose from the A/C Evaporator Hose. Refer to AIR CONDITIONING COMPRESSOR AND CONDENSER HOSE REPLACEMENT (LHU/A20NFT) .
1AC Evaporator Thermal Expansion Valve Heat and Brake Pipe Shield Fastener (Qty: 2) Procedure Remove the A/C TXV heat and brake pipe shield. Release the brake pipes.
2A/C Evaporator Hose Fastener Refer to FASTENER CAUTION . Tighten 20 Nm (15 lb ft)
3A/C Evaporator Hose Stud Bolt Tighten 15 Nm (11 lb in)
4A/C Evaporator Hose Assembly Procedure Remove the A/C Evaporator hose from the thermal expansion valve (TXV). Remove and discard the sealing washer. Refer to AIR CONDITIONING SYSTEM SEAL REPLACEMENT .
5A/C Evaporator Hose Fastener Procedure Remove the A/C Evaporator Hose from the A/C Condenser and cap hose. Tighten 20 Nm (15 lb ft)
6Sealing Washer Procedure Remove and discard the sealing washer. Refer to AIR CONDITIONING SYSTEM SEAL REPLACEMENT .
7Air Conditioning Evaporator Hose Assembly Procedure Release the A/C Evaporator Hose from the attaching clips. When the installation is postponed, close the off lines and connections.

Scheme 89

Scheme 89: Receiver and Dehydrator Replacement
Scheme 89: Receiver and Dehydrator Replacement
CalloutComponent Name
Preliminary Procedure Remove the air conditioning condenser. Refer to, AIR CONDITIONING CONDENSER REPLACEMENT (LAU/A28NER) or AIR CONDITIONING CONDENSER REPLACEMENT (LHU/A20NFT) .
1Condenser Cap
2Condenser Snap-Ring Procedure Remove and discard the snap-ring.
3Condenser Plug
4Receiver and Dehydrator O-Ring (Qty: 2) Procedure Remove and discard the O-rings.
5Receiver and Dehydrator

Scheme 90

Scheme 90: Air Conditioning Evaporator Thermal Expansion Valve Replacement (LAU/A28NER)
Scheme 90: Air Conditioning Evaporator Thermal Expansion Valve Replacement (LAU/A28NER)
CalloutComponent Name
Preliminary Procedure Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING . Remove the fuel injector sight shield. Refer to UPPER ENGINE COVER REMOVAL Remove the heater inlet hose from the heater core tube. Refer to HEATER INLET HOSE REPLACEMENT (LAU/A28NER) . Remove the heater outlet hose from the heater core tube. Refer to, HEATER OUTLET HOSE REPLACEMENT (LAU/A28NER)
1AC Evaporator Thermal Expansion Valve Heat and Brake Pipe Shield Fastener (Qty: 2) Procedure Remove the A/C TXV heat and brake pipe shield.
2A/C Evaporator Hose Fastener Refer to FASTENER CAUTION . Tighten 20 Nm (15 lb ft)
3A/C Evaporator Hose Stud Bolt Tighten 15 Nm (11 lb ft)
4A/C Evaporator Hose Assembly Procedure Remove the A/C Evaporator hose from the thermal expansion valve (TXV) and cap the hose. Remove and discard the sealing washer. Refer to AIR CONDITIONING SYSTEM SEAL REPLACEMENT .
5A/C Evaporator Thermal Expansion Valve Fastener (Qty: 2) Tighten 7 Nm (62 lb in)
6Air Conditioning Evaporator Thermal Expansion Valve Procedure Remove and discard sealing washers. Refer to AIR CONDITIONING SYSTEM SEAL REPLACEMENT .

Scheme 91

Scheme 91: Air Conditioning Evaporator Thermal Expansion Valve Replacement (LHU/A20NFT)
Scheme 91: Air Conditioning Evaporator Thermal Expansion Valve Replacement (LHU/A20NFT)
CalloutComponent Name
Preliminary Procedure Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING . Remove the turbocharger heat shield: Refer to TURBOCHARGER HEAT SHIELD, REPLACEMENT .
1AC Evaporator Thermal Expansion Valve (TXV) Heat and Brake Pipe Shield Fastener (Qty: 2) Procedure Remove the A/C TXV heat and brake pipe shield from the thermal expansion valve.
2A/C Evaporator Hose Fastener Refer to FASTENER CAUTION . Tighten 20 Nm (15 lb ft)
3A/C Evaporator Hose Stud Bolt Tighten 15 Nm (11 lb ft)
4A/C Evaporator Hose Assembly Procedure Remove the A/C Evaporator hose from the thermal expansion valve (TXV) and cap the hose. Remove and discard the sealing washer. Refer to AIR CONDITIONING SYSTEM SEAL REPLACEMENT
5A/C Evaporator Thermal Expansion Valve Fastener (Qty: 2) Tighten 7 Nm (62 lb in)
6Air Conditioning Evaporator Thermal Expansion Valve Procedure Remove and discard sealing washers. Refer to AIR CONDITIONING SYSTEM SEAL REPLACEMENT .

Scheme 92

Scheme 92: Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement (LAU/A28NER)
Scheme 92: Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement (LAU/A28NER)
CalloutComponent Name
Preliminary Procedure Remove the front bumper fascia assembly. Refer to FRONT BUMPER FASCIA REPLACEMENT
1Power Steering Fluid Cooling Pipe Retainer (Qty: 2) Procedure Loosen the power steering fluid cooling pipe from the bracket and secure the pipe with cable strap.
2Power Steering Fluid Cooling Pipe Bracket Fastener Refer to FASTENER CAUTION . Tighten 9 Nm (80 lb in)
3Power Steering Fluid Cooling Pipe Bracket
4Air Conditioning (A/C) Refrigerant Pressure Sensor Procedure Disconnect the electrical connector from A/C refrigerant pressure sensor. Remove the A/C refrigerant pressure sensor from the A/C condenser. Remove and discard the O-rings. Tighten 7.4 Nm (66.4 lb in)

Scheme 93

Scheme 93: Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement (LHU/A20NFT)
Scheme 93: Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement (LHU/A20NFT)
CalloutComponent Name
Preliminary Procedure Remove the front bumper fascia assembly. Refer to FRONT BUMPER FASCIA REPLACEMENT
1Air Conditioning (A/C) Refrigerant Pressure Sensor Refer to FASTENER CAUTION . Procedure Disconnect the electrical connector from A/C refrigerant pressure sensor. Remove the A/C refrigerant pressure sensor from the A/C condenser. Remove and discard the O-rings. Tighten 7, 4 Nm (66 lb in)

Scheme 94

Scheme 94: Air Conditioning Condenser Replacement (LAU/A28NER)
Scheme 94: Air Conditioning Condenser Replacement (LAU/A28NER)
CalloutComponent Name
Preliminary Procedure Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING . Remove the front bumper fascia assembly. Refer to FRONT BUMPER FASCIA REPLACEMENT Remove the front bumper fascia support - right side. Refer to FRONT BUMPER FASCIA SUPPORT REPLACEMENT (LEFT SIDE) or FRONT BUMPER FASCIA SUPPORT REPLACEMENT (RIGHT SIDE) . Remove the air cleaner inlet duct. Refer to AIR CLEANER INLET DUCT REPLACEMENT . Disconnect the A/C refrigerant pressure sensor electrical connector.
1Front Intake Air Duct Splash Shield
2Radiator Air Upper Baffle
3Radiator Air Lower Baffle
4A/C Evaporator Hose Fastener Refer to FASTENER CAUTION . Procedure Remove the A/C Evaporator Hose from the A/C Condenser and cap hose. Tighten 20 Nm (15 lb ft)
5Sealing Washer Procedure Remove and discard the sealing washer. Refer to AIR CONDITIONING SYSTEM SEAL REPLACEMENT .
6A/C Compressor and Condenser Hose Fastener Procedure Remove the A/C Compressor and Condenser Hose from the A/C Condenser and cap hose. Tighten 20 Nm (15 lb ft)
7Sealing Washer Procedure Remove and discard the sealing washer. Refer to AIR CONDITIONING SYSTEM SEAL REPLACEMENT .
8Air Conditioning Condenser Assembly Procedure Release both upper condenser support brackets.

Scheme 95

Scheme 95: Air Conditioning Condenser Replacement (LHU/A20NFT)
Scheme 95: Air Conditioning Condenser Replacement (LHU/A20NFT)
CalloutComponent Name
Preliminary Procedure Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING . Remove the front bumper fascia assembly. Refer to FRONT BUMPER FASCIA REPLACEMENT Remove the front bumper fascia support - right side. Refer to FRONT BUMPER FASCIA SUPPORT REPLACEMENT (LEFT SIDE) or FRONT BUMPER FASCIA SUPPORT REPLACEMENT (RIGHT SIDE) . Remove the air cleaner inlet duct. Refer to AIR CLEANER INLET DUCT REPLACEMENT . Disconnect the A/C refrigerant pressure sensor electrical connector.
1Front Intake Air Duct Splash Shield
2Radiator Air Upper Baffle
3Radiator Air Lower Baffle
4A/C Evaporator Hose Fastener Refer to FASTENER CAUTION . Procedure Remove the A/C Evaporator Hose from the A/C Condenser and cap hose. Tighten 20 Nm (15 lb ft)
5Sealing Washer Procedure Remove and discard the sealing washer. Refer to AIR CONDITIONING SYSTEM SEAL REPLACEMENT .
6A/C Compressor and Condenser Hose Fastener Procedure Remove the A/C Compressor and Condenser Hose from the A/C Condenser and cap hose. Tighten 20 Nm (15 lb ft)
7Sealing Washer Procedure Remove and discard the sealing washer. Refer to AIR CONDITIONING SYSTEM SEAL REPLACEMENT .
8Air Conditioning Condenser Assembly Procedure Release both upper condenser support brackets.

Scheme 96

Scheme 96: Heater and Air Conditioning Evaporator and Blower Module Replacement
Scheme 96: Heater and Air Conditioning Evaporator and Blower Module Replacement
CalloutComponent Name
Preliminary Procedure Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING . Remove the heater inlet hose from the heater core tube. Refer to HEATER INLET HOSE REPLACEMENT (LAU/A28NER) or HEATER INLET HOSE REPLACEMENT (LHU/A20NFT) . Remove the heater outlet hose from the heater core tube. Refer to HEATER OUTLET HOSE REPLACEMENT (LAU/A28NER) or HEATER OUTLET HOSE REPLACEMENT (LHU/A20NFT) . Remove the evaporator hose assembly from the thermal expansion valve. Refer to AIR CONDITIONING EVAPORATOR THERMAL EXPANSION VALVE REPLACEMENT (LAU/A28NER) or AIR CONDITIONING EVAPORATOR THERMAL EXPANSION VALVE REPLACEMENT (LHU/A20NFT) . Remove the plenum water deflector. Refer to PLENUM WATER DEFLECTOR REPLACEMENT . Remove the instrument panel assembly. Refer to INSTRUMENT PANEL ASSEMBLY REPLACEMENT . Remove the instrument panel tie bar. Refer to INSTRUMENT PANEL TIE BAR REPLACEMENT .
1Heater and Air Conditioning Evaporator and Blower Module Procedure With the aid of an assistant, remove the heater and air conditioning evaporator and blower module from the vehicle.

Scheme 97

Scheme 97: Air Conditioning Evaporator Core Replacement
Scheme 97: Air Conditioning Evaporator Core Replacement
CalloutComponent Name
Preliminary Procedure Remove the instrument panel assembly. Refer to INSTRUMENT PANEL ASSEMBLY REPLACEMENT . Remove the instrument panel tie bar. Refer to INSTRUMENT PANEL TIE BAR REPLACEMENT . Remove the Heater and Air Conditioning Evaporator and Blower Module. Refer to HEATER AND AIR CONDITIONING EVAPORATOR AND BLOWER MODULE REPLACEMENT . Disconnect the Heater and Air Conditioning Evaporator and Blower module assembly electrical connectors.
1Heater Core brackets
2Heating Element Procedure Pull out the heater core.
3Heater and Blower and Air Conditioning Control Module
4A/C Evaporator Thermal Expansion Valve Fastener (Qty: 2) Refer to FASTENER CAUTION . Tighten 7 Nm (62 lb in)
5Air Conditioning Evaporator Thermal Expansion Valve Procedure Remove and discard sealing washers. Refer to AIR CONDITIONING SYSTEM SEAL REPLACEMENT .
6Heater and Air Conditioning Evaporator and Blower Module Case Screw (Qty: 11)
7Heater and Air Conditioning Evaporator and Blower Module Lower Case
8Air Conditioning Evaporator Core

Scheme 98

Scheme 98: Heater Inlet Hose Replacement (LAU/A28NER)
Scheme 98: Heater Inlet Hose Replacement (LAU/A28NER)
CalloutComponent Name
Preliminary Procedure Drain the cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING (LAU/A28NER) . Remove the fuel injector sight shield. Refer to UPPER ENGINE COVER REMOVAL . Remove the air cleaner assembly. Refer to AIR CLEANER ASSEMBLY REPLACEMENT .
1Hose Clip (Qty: 2)
2Heater Inlet Hose Procedure Release the clip and remove the heater inlet hose from the heater core tube. Remove the heater inlet hose clamp. NOTE: The quick-connect coupling for the heater inlet hose are equipped with an anti-twist protection. The hose has to be in correct position to audible engage when connecting to the heater core tube.
NOTE
The quick-connect coupling for the heater inlet hose are equipped with an anti-twist protection. The hose has to be in correct position to audible engage when connecting to the heater core tube.

Scheme 99

Scheme 99: Heater Inlet Hose Replacement (LHU/A20NFT)
Scheme 99: Heater Inlet Hose Replacement (LHU/A20NFT)
CalloutComponent Name
Preliminary Procedure Drain the cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING (LHU/A20NFT) .
1Heater Inlet Hose Procedure Release the clip and remove the heater inlet hose from the heater core tube. Remove the heater inlet hose clamp.

Scheme 100

Scheme 100: Heater Outlet Hose Replacement (LAU/A28NER)
Scheme 100: Heater Outlet Hose Replacement (LAU/A28NER)
CalloutComponent Name
Preliminary Procedure Drain the cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING (LAU/A28NER) . Remove the fuel injector sight shield. Refer to UPPER ENGINE COVER REMOVAL . Remove the air cleaner assembly. Refer to AIR CLEANER ASSEMBLY REPLACEMENT .
1Hose Clip
2Heater Outlet Hose Assembly Procedure Release the clip and remove the heater outlet hose from the heater core tube. Remove the heater outlet hose clamp. NOTE: The quick-connect coupling for the heater inlet hose are equipped with an anti-twist protection. The hose has to be in correct position to audible engage when connecting to the heater core tube.
NOTE
The quick-connect coupling for the heater inlet hose are equipped with an anti-twist protection. The hose has to be in correct position to audible engage when connecting to the heater core tube.

Scheme 101

Scheme 101: Heater Outlet Hose Replacement (LHU/A20NFT)
Scheme 101: Heater Outlet Hose Replacement (LHU/A20NFT)
CalloutComponent Name
Preliminary Procedure Drain the cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING (LHU/A20NFT) .
1Heater Outlet Hose Assembly Procedure Release the clip and remove the heater outlet hose from the heater core tube. Remove the heater outlet hose clamp. NOTE: The quick-connect coupling for the heater outlet hose are equipped with an anti-twist protection. The hose has to be in correct position to audible engage when connecting to the heater core tube.
NOTE
The quick-connect coupling for the heater outlet hose are equipped with an anti-twist protection. The hose has to be in correct position to audible engage when connecting to the heater core tube.

Scheme 102

Scheme 102: Heater Core Tube Replacement
Scheme 102: Heater Core Tube Replacement
CalloutComponent Name
Preliminary Procedure Remove the Heater and Air Conditioning Evaporator and Blower Module. Refer to HEATER AND AIR CONDITIONING EVAPORATOR AND BLOWER MODULE REPLACEMENT .
1Heater Core Tube Clamp (Qty: 2)
2Heater Core Tube Seal (Qty: 2)
3Heater Core Tube Bracket Bolt
4Heater Core Tube Bracket
5Heater Core Tube Assembly

Scheme 103

Scheme 103: Passenger Compartment Air Filter Replacement
Scheme 103: Passenger Compartment Air Filter Replacement
CalloutComponent Name
Preliminary Procedure Remove instrument panel outer trim cover. Refer to INSTRUMENT PANEL OUTER TRIM COVER REPLACEMENT - RIGHT SIDE . Remove the instrument panel compartment. Refer to GLOVE COMPARTMENT, REPLACEMENT .
1Passenger Compartment Air Filter Service Lid Retainer (Qty: 3) Procedure Release the retainer and open the service lid.
2Passenger Compartment Air Filter

Scheme 104

Scheme 104: Removal Procedure
Scheme 104: Removal Procedure
  1. Remove the Heater and Air Conditioning Evaporator and Blower Module. Refer to «HEATER AND AIR CONDITIONING EVAPORATOR AND BLOWER MODULE REPLACEMENT»(ref-653641-S17990587092014090100000) .
  2. Remove the air inlet housing (2) from the heater and air conditioning evaporator and blower module (1). Disconnect the electrical connectors. Remove the 4 air inlet housing bolts (3).
  3. Remove the air inlet valve actuator. Refer to «AIR INLET VALVE ACTUATOR REPLACEMENT (RIGHT HAND DRIVE)»(ref-653671-S26913508282014090100000) or «AIR INLET VALVE ACTUATOR REPLACEMENT (LEFT HAND DRIVE)»(ref-653671-S32295918882014090100000) .
  4. Remove the air inlet valve and inside air valve control cam. Refer to «AIR INLET VALVE AND INSIDE AIR VALVE CONTROL CAM REPLACEMENT»(ref-653671-S33308067642014090100000) .

Scheme 105

Scheme 105: Installation Procedure
Scheme 105: Installation Procedure
  1. Install the air inlet valve and inside air valve control cam. Refer to «AIR INLET VALVE AND INSIDE AIR VALVE CONTROL CAM REPLACEMENT»(ref-653671-S33308067642014090100000) .
  2. Install the air inlet valve actuator. Refer to «AIR INLET VALVE ACTUATOR REPLACEMENT (RIGHT HAND DRIVE)»(ref-653671-S26913508282014090100000) or «AIR INLET VALVE ACTUATOR REPLACEMENT (LEFT HAND DRIVE)»(ref-653671-S32295918882014090100000) .
  3. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Install the air inlet housing (2) to the heater and air conditioning evaporator and blower module (1). Connect the electrical connectors. Install the 4 inlet housing bolts (3) and tighten to 2.5 Nm (23 lb in).
  4. Install the heater and air conditioning evaporator and the blower module. Refer to «HEATER AND AIR CONDITIONING EVAPORATOR AND BLOWER MODULE REPLACEMENT»(ref-653641-S17990587092014090100000) .

Scheme 106

Scheme 106: Blower Motor Replacement
Scheme 106: Blower Motor Replacement
CalloutComponent Name
Preliminary Procedure Remove the instrument panel compartment. Refer to GLOVE COMPARTMENT, REPLACEMENT . Remove the floor air outlet duct. Refer to FLOOR AIR OUTLET DUCT REPLACEMENT - RIGHT SIDE . Disconnect the blower motor electrical connector.
1Blower Motor Fastener (Qty: 3)
2Blower Motor

Scheme 107

Scheme 107: Side Window Defogger Outlet Grille Replacement
Scheme 107: Side Window Defogger Outlet Grille Replacement
CalloutComponent Name
1Side Window Defogger Outlet Grille NOTE: Use a flat bladed plastic trim tool in order to release the window defogger outlet grille.
NOTE
Use a flat bladed plastic trim tool in order to release the window defogger outlet grille.

Scheme 108

Scheme 108: Body Air Outlet Deflector Replacement
Scheme 108: Body Air Outlet Deflector Replacement
CalloutComponent Name
Preliminary Procedure Remove the rear bumper fascia. Refer to REAR BUMPER FASCIA REPLACEMENT .
1Body Air Outlet Deflector NOTE: Use a small flat-bladed tool to release the body air outlet deflector.
NOTE
Use a small flat-bladed tool to release the body air outlet deflector.

VEHICLES CONCERNED

Saab 9-3 MY03-, 9-5 MY98- and New 9-5 MY10-.

BACKGROUND

Review of replaced AC compressors due to noise shows that they are in many cases without fault.

CONDITIONS

Workshop environment and AC in low fan speed.

ACTION

Perform AC leak test in engine bay according to WIS. If no leak is found perform leak test of expansion valve also in the compartment side.

  1. Repair the leakage
  2. Fill up the refrigerant to specified level according to WIS.
  3. Check the compressor sound after running the system for 5 minutes.

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