Climate Units - General Information: Other Volvo V40 I рестайлинг

Replacing the compressor

Special tools

9995474

Preparations

Note. Read the instructions about slow and large leaks. See Oil air conditioning (A/C) system, filling .

Note. Always use new O-rings lubricated with air conditioning (A/C) compressor oil.

Note. Always plug pipes and connectors when working on the climate control system.

Scheme 428

1. Note the anti-theft radio code if the car is equipped with an anti-theft radio
2. Switch off the ignition
3. Disconnect the battery negative lead.

Scheme 429

Drain the refrigerant from the system according to Refrigerant, draining .

Remove

1. the air baffle according to «The front bumper»(ref-461599-S42605160282012040200000)
2. the auxiliaries belt according to «Replacing Poly V-belts»(ref-461607-S10189092342012040200000) .

Protect the radiator using radiator protection 9995474 .

Scheme 430

Remove the bolts.

Disconnect the hoses.

Seal the openings carefully.

Scheme 431

Disconnect the connector from the compressor.

Remove

1. the screws
2. the compressor
3. the support for the connector.

Note. If the compressor is replaced, the oil volume must be determined. See Oil in the A/C system .

Install new O rings on the filler plug (lubricate using A/C compressor oil).

Tighten the filler plug. Tighten to 15 Nm .

Change the oil even if the compressor is not replaced.

Scheme 432

Install

1. the support for the connector
2. the compressor. Tighten the bolts. Tighten to 40 Nm .

Connect the connector.

Lubricate the new O-rings using A/C compressor oil.

Install the hoses. Tighten the screws. Tighten to 22 Nm .

Filling with refrigerant

1. Vacuum pump according to «Vacuum pumping»(ref-441397-S27089916782011121500000)
2. Fill the system with refrigerant according to «Filling with refrigerant»(ref-441397-S39380443802011121500000)
3. Fill the system with fluorescent tracing agent according to «Filling with fluorescent tracing agent and refrigerant»(ref-441397-S28572502792011121500000)
4. Leak trace according to «Leak tracing, electronic leak tracer»(ref-441397-S05488723862011121500000) or «Leak tracing, fluorescent tracing agent/UV lamp»(ref-441397-S18102561032011121500000) .

Finishing work

Install

1. the auxiliaries belt according to «Replacing Poly V-belts»(ref-461607-S10189092342012040200000)
2. the air baffle according to «The front bumper»(ref-461599-S42605160282012040200000) .

Scheme 433

Turn the ignition to position II.

Connect the battery negative terminal.

Check that the SRS warning light on the dashboard goes out.

Program the radio code.

Set the clock.

Check the function (ECC system).

Read off the diagnostic trouble codes (DTCs) (ECC system).

Condenser

Special tools

9995474

Read the instructions about slow and large leaks. See Oil in the air conditioning (A/C) system .

Note. Always use new O-rings lubricated with air conditioning (A/C) compressor oil.

Drain the refrigerant from the system according to Draining .

Scheme 434

Remove the clamp from the battery.

Remove the mounting screws.

Carefully remove the pipe.

Seal the openings.

Scheme 435

Remove the upper support for the radiator (4x bolts).

Disconnect the pipe from the condenser. Plug the openings.

Remove the two mounting screws from the condenser.

Position radiator protection 9995474 between the condenser and the radiator on the right side (there is a risk that the radiator will be damaged by the support).

Lift up the radiator slightly and push it towards the cylinder block (press at the bottom of the radiator).

Lift the condenser. Remove it with a twisting movement.

Scheme 436

Transfer the components (foam, rubber etc.) to the new condenser.

Position the condenser. Tighten to 10 Nm .

Secure the radiator at the support. Tighten to 10 Nm .

Remove the seals.

Lubricate the new O-rings with compressor oil.

Install the pipes. Tighten the pipes. Tighten to 25 Nm .

Filling and checking

Fill and check the system according to Filling refrigerant .

Magnetic clutch

Special tools

9995597

9995596

9995598

9995599

9995091

9995087

9995600

9995604

Note. Do not disconnect and drain the air conditioning (A/C) system.

1. Remove the multi-groove V belt
2. Remove the splashguard. Disconnect the wiring.
3. Disconnect the air conditioning (A/C) hoses from the support.
4. Remove the compressor (4x bolts) and hang it up with a steel wire.

Scheme 437

Position counterhold 9995596 over the clutch driven plate and remove the bolt.

Scheme 438

1. Position puller «9995597»(ref-403953-S41787744922011061500000) on the clutch driven plate as shown.
2. Pull off the clutch driven plate.

Note. Do not lose the adjustment washers.

Removing the pulley

1. Remove the snap ring
2. Install the puller «9995598»(ref-403953-S06905847892011061000000) in position as close to the electro magnet as possible
3. Install the bushing «9995599»(ref-403953-S16846945402011061000000) in position on the compressor housing
4. Pull the pulley wheel out of the housing.

Scheme 439

1. Disconnect the wiring from the compressor
2. Remove the three mounting bolts
3. Clean and check all components carefully.

Scheme 440

1. Install a new magnet in position (note the guide pin) and install the bolts
2. Replace the wiring
3. Tighten the bolts to 10 Nm.

Scheme 441

1. Position the pulley
2. Carefully tap the pulley with a plastic hammer
3. Install extractor: «9995598»(ref-403953-S06905847892011061000000) and bushing «9995600»(ref-403953-S29194332992011061000000) on the pulley and press the guide bushing into place
4. Tighten the pulley
5. Install the snap ring with the beveled side upwards.

Scheme 442

1. Install the old spacer washers on the shaft. Install the clutch driven plate
2. HINT: Use a plastic mallet if necessary.
3. Install the center bolt or nut.

Note. Using 9995596 as a counterhold.

Tightening torque: 12 Nm.

1. Check the play between the coupling plate and the pulley with a gauge
2. Measure the height between the plate and the pulley
3. Press the plate and measure the height again
4. The difference in the readings indicates the play
5. Checking and adjusting the value: 0.3-0.6 mm
6. Correct the play with adjustment rings
7. Install the compressor, see «Compressor»(ref-441328-S40325647962011121500000) .

HINT: To replace the sealing ring, see Spacer ring .

Preparation

Note. O-rings must always be replaced when replacing pipes.

Note. Hold the pipe in place with your hand when removing and tightening to avoid damaging couplings and pipes.

Bleed the refrigerant from the system as per Refrigerant, draining .

Oil O-rings with AC compressor oil

Disconnect the connections and seal the openings.

Clean all contact surfaces.

Removing the hose/pipe between the compressor and evaporator

Note. Hold the pipe in place with your hand when removing and tightening to avoid damaging couplings and pipes.

Scheme 443

Disconnect the connections and seal the openings.

Clean all contact surfaces.

Remove the pipe clips.

Fitting the hose/pipe between the compressor and evaporator

Note. Always use new O-rings.

Fit

1. the pipe clips
2. the O-rings

Oil O-rings with AC compressor oil

Remove the seals.

Connect the pipe and tighten the bolts by hand.

Tighten

1. the bolt at the compressor to 22 Nm .
2. the bolt at the evaporator to 10 Nm .

Removing the pipe between the evaporator and the coupling on the bulkhead

Note. Hold the pipe in place with your hand when removing and tightening to avoid damaging couplings and pipes.

Scheme 444

Disconnect the connections and seal the openings.

Clean all contact surfaces.

Remove the coupling from the bulkhead.

Turn only the coupling, holding the pipe with an adjustable wrench (the nut is welded).

Remove the connector support from the bulkhead.

Carefully pull the pipe out of the clips and remove it.

Fitting the pipe between the evaporator and the coupling on the bulkhead

Note. Always use new O-rings.

Fit

1. the pipe clips
2. the support for connectors
3. the O-rings

Fit the coupling on the bulkhead.

Tighten the coupling, holding the pipe with an adjustable wrench (the nut is welded).

Oil O-rings with AC compressor oil

Remove the seals.

Connect the pipe and tighten the bolts by hand.

Tighten

1. the bolt at the evaporator to 10 Nm .
2. the bolt at the coupling to 13 Nm .

Scheme 445

Disconnect the connections and seal the openings.

Clean all contact surfaces.

Remove the coupling on the bulkhead

Tighten the coupling, holding the pipe with an adjustable wrench (the nut is welded).

Carefully pull the pipe out of the clips and remove it.

Fitting the pipe between the coupling and the refrigerant reservoir on the bulkhead

Note. Always use new O-rings.

Fit

1. the pipe clips
2. the O-rings

Fit the coupling on the bulkhead.

Tighten the coupling, holding the pipe with an adjustable wrench (the nut is welded).

Oil O-rings with AC compressor oil

Remove the seals.

Connect the pipe and tighten the bolts by hand.

Tighten

1. the bolt at the coupling to 13 Nm .
2. the bolt at the evaporator to 10 Nm .

Removing the pipe between the refrigerant reservoir and the condenser

Note. Hold the pipe in place with your hand when removing and tightening to avoid damaging couplings and pipes.

Scheme 446

Remove

1. the bolts on the mountings.
2. the battery clamp.
3. the pipe carefully.

Note. Always use new O-rings.

Fit

1. the pipe
2. the battery
3. the O-rings

Oil O-rings with AC compressor oil

Connect the pipe and tighten the bolts by hand.

Tighten

1. the bolt at the refrigerant reservoir to 10 Nm .
2. the bolt at the condenser coupling to 10 Nm .

Removing the hose between the compressor and condenser

Note. Hold the pipe in place with your hand when removing and tightening to avoid damaging couplings and pipes.

Scheme 447

Remove

1. the bolts on the mountings
2. the hose carefully
3. the pipe clip.

Fitting the hose between the compressor and condenser

Note. Always use new O-rings.

Fit

1. the pipe clip
2. the hose
3. the O-rings

Oil O-rings with AC compressor oil

Connect the pipe and tighten the bolts by hand.

Tighten

1. the bolt at the compressor to 22 Nm .
2. the bolt at the condenser to 25 Nm .

Filling refrigerant

Vacuum pump the system as per Vacuum pumping .

Fill the system with refrigerant as per Filling with refrigerant .

Fill the system with fluorescent dye as per Filling with fluorescent tracing agent and refrigerant .

Search for leaks as per Leak tracing, electronic leak tracer or Leak tracing, fluorescent tracing agent/UV lamp .

Scheme 448

Read the safety precautions and instructions according to Introduction .

Drain the refrigerant from the system according to Refrigerant, draining .

Disconnect the connector.

Unscrew the pressure sensor.

Lubricate the new O-rings using A/C compressor oil.

Installing the pressure sensor

Install the pressure sensor.

Tighten the pressure sensor. Tighten to 18 Nm .

Connect the connector.

Fill and check the system according to Filling refrigerant .

Read the safety precautions and instructions according to Introduction .

Disconnect the battery lead.

Drain the refrigerant from the system according to Refrigerant, draining .

Scheme 449

Remove

1. the clamp for the battery
2. the pipe between the drier and the condenser and between the receiver drier and evaporator.

Seal the openings.

Remove

1. the connector for the pressure sensor
2. the two nuts from the support
3. the refrigerant reservoir and support.

Transferring the support to the new refrigerant reservoir

Mark the position of the support on the old refrigerant reservoir.

Remove the screw for the clamp.

Remove the support.

Transfer the marking from the old refrigerant reservoir to the new.

Install the support.

Slide the rubber in between the refrigerant reservoir and the clamp for the support.

Tighten the screw for the clamp by hand.

Transfer the pressure sensor (Pressostat) to the new refrigerant reservoir.

Lubricate the O-rings using compressor oil.

Tighten the screw. Tighten to 18 Nm .

Scheme 450

The refrigerant reservoir must be filled with 20 cm 3 oil when replaced. See Oil air conditioning (A/C) system, filling .

Lubricate the new O-rings using A/C compressor oil.

Position the refrigerant reservoir and the support.

Tighten the two nuts by hand.

Position the pipe.

Tighten

1. the screw at the evaporator. Tighten to 10 Nm
2. the screw at the refrigerant reservoir. Tighten to 10 Nm
3. the nuts. Tighten to 10 Nm .

Install the connector to the pressure sensor.

Fill and check the system according to Filling with refrigerant .

Replacing the spacer ring

Special tools

9995604

Scheme 451

1. Remove the clutch driven plate according to «Magnetic clutch»(ref-441397-S08280013342011121500000)
2. Remove the snap ring
3. Remove the spacer ring from the shaft
4. Install the special tool «9995604»(ref-403953-S16741159712011061500000) in the socket. Turn the tool 90°
5. Pull the spacer ring sleeve out to the right NOTE: Clean all components with compressed air and a lint-free cloth.
6. Check whether any components are worn or dirty. This is particularly important if remnants of the spacer ring remain.

Scheme 452

Note. Do not touch the inner runner section or the carbon section with your fingers.

1. Apply compressor oil on all mating surfaces in the spacer ring
2. First install the spacer ring on special tool «9995604»(ref-403953-S16741159712011061500000)
3. Carefully position the tool and the spacer ring on the shaft. Do not turn it.
4. Press the spacer ring into place.

Scheme 453

Installation

1. The wedge in the shaft
2. The adjustment rings
3. The felt spacer rings and the holder (the holder must be at exactly the same level as the sleeve). Use a drift and a cover.

Compressor

See Compressor

See Condenser

See Magnetic clutch

Pipes and hoses

See Pipes and hoses

Pressure sensor

See Pressure sensor

Refrigerant reservoir

See Refrigerant reservoir

Spacer ring

See Spacer ring

Scheme 454

When draining refrigerant, the recycling unit can be attached to the service valve for both the high pressure side (HP) and the low pressure side (LP). This is the quickest method.

1. The engine must be switched off
2. Check the amount of oil (if any) that has run out when draining the refrigerant.

Note. The recycling unit must be equipped with an oil separator. The oil separator must be of a type that allows the amount of oil in the refrigerant to be measured.

Other information

1. For vacuum pumping, see «Vacuum pumping»(ref-441397-S27089916782011121500000)
2. For visual and physical checks, see «Visual and physical check»(ref-441397-S41652059812011121500000)
3. To fill with refrigerant, see «Filling with refrigerant»(ref-441397-S39380443802011121500000)
4. To fill with fluorescent tracing agent, see «Filling with fluorescent tracing agent»(ref-441397-S16975985852011121500000)
5. To leak trace with an electronic leak tracer, see «Leak tracing, electronic leak tracer»(ref-441397-S08613324792011121500000)
6. To leak trace with fluorescent tracing agent and an UV torch, see «Leak tracing with fluorescent tracing agent and an UV lamp»(ref-441397-S40807323872011121500000) .

Regulations

Filling and leak tracing the climate control system with tracing agent and a UV lamp from Bright Solutions Inc.

Note. The coloring agent may discolor the car paintwork. Therefore extreme caution must be taken when handling the tracing agent.

Note. Carefully follow the manufacturers instructions when handling the UV lamp and the tracing agent.

Note. After filling with the tracing agent, the decal supplied by the manufacturer/supplier must be applied at the point indicated.

When replacing components in the climate control system, the component (for example the drier) can be filled with tracing agent.

Filling an empty climate control system with tracing agent when a leak cannot be localized

1. Fill with 225 g of refrigerant with fluorescent tracing agent according to the manufacturers instructions for leak tracing.

If the climate control system is filled

1. Drain off 225 g of refrigerant, see «Draining»(ref-441397-S42347159362011121500000)
2. Vacuum pump the hose
3. Fill the climate control system with refrigerant with tracing agent according to the manufacturers instructions
4. Leak trace according to «Leak tracing with fluorescent tracing agent and an UV lamp»(ref-441397-S40807323872011121500000) .

If the amount of refrigerant in the climate control unit cannot be determined

1. Empty the climate control system according to «Draining»(ref-441397-S42347159362011121500000)
2. Vacuum pump according to «Vacuum pumping»(ref-441397-S27089916782011121500000)
3. Fill the climate control system with refrigerant with tracing agent according to the manufacturers instructions
4. Leak trace according to «Leak tracing with fluorescent tracing agent and an UV lamp»(ref-441397-S40807323872011121500000) .

Important information about filling with refrigerant

Note. Refrigerant must only be filled via the service valve (TXV system) on the high pressure (HP) side.

HINT: A specification decal in the engine compartment lists the refrigerant capacity of the air conditioning (A/C) system.

Scheme 455

Note. The most common cause of failed filling on the high pressure side is incorrect vacuum pumping or because the pressure in the filling unit is not high enough, or a combination of these two.

Note. The filling unit should preferably have a heating unit for refrigerant. This is so that the pressure in the filling unit is higher than in the system that is to be filled.

Note. When filling with refrigerant, compensate for the volume in the filling hoses before closing the filler valve.

Filling and leak tracing the climate control system with tracing agent and a UV lamp from Bright Solutions Inc.

Note. The coloring agent may discolor the car paintwork. Therefore extreme caution must be taken when handling the tracing agent.

Note. Carefully follow the manufacturers instructions when handling the UV lamp and the tracing agent.

Note. After filling with the tracing agent, the decal supplied by the manufacturer/supplier must be applied at the point indicated.

Leak tracing with a UV lamp

For information about filling with fluorescent tracing agent, see Filling with fluorescent tracing agent .

1. Connect the UV lamp according to the instructions from Bright Solutions Inc
2. Leak trace using the UV lamp
3. Fluorescent tracing agent shows up as a light green color.

Note. This light green color may be mistaken for leaked or spilled coolant which Volvo uses in its products.

Leak tracing, electronic leak tracer

Special tools

9511207

Leak tracing with an electronic leak tracer using refrigerant as a tracing agent

When fault tracing using refrigerant as a tracing agent, it is recommended that leak tracer 9511207 is used.

Note. The engine must always be switched off when leak tracing.

An electronic leak tracer can be used if there is still refrigerant in the climate control system.

If the climate control system is empty and a visual or physical test has not identified the leak.

Leak tracing

1. Fill the climate control system with 200 grams of refrigerant
2. There must not be any strong smells or fumes in the engine compartment. These can affect the leak tracing
3. Leak-trace using a leak tracer.

If no leakage is found

1. Fill with the remaining amount of refrigerant
2. Add fluorescent tracing agent according to «Filling with fluorescent tracing agent»(ref-441397-S16975985852011121500000)
3. If leakage is suspected, ask the customer to drive the car and then return for new leak tracing/repairs.

If leakage is detected

1. Remedy the cause of the leak
2. Vacuum pump according to «Vacuum pumping»(ref-441397-S27089916782011121500000)
3. Add fluorescent tracing agent with the refrigerant according to «Filling with fluorescent tracing agent»(ref-441397-S16975985852011121500000) .

Or

1. Fill with refrigerant according to «Filling with refrigerant»(ref-441397-S39380443802011121500000)
2. Leak trace according to «Leak tracing with an electronic leak tracer using refrigerant as a tracing agent»(ref-441397-S23620455872011121500000) .

Or

1. Leak trace according to «Leak tracing with fluorescent tracing agent and an UV lamp»(ref-441397-S40807323872011121500000) .

Oil in the air conditioning (A/C) system

Corrective actions in the event of slow leakage (longer than 24 hours)

There is not normally a risk of oil loss in event of slow leakage. The following procedures apply when replacing components

Compressor, replacement

Drain off and measure the amount of oil drained from the compressor. Drain the oil from the new compressor and fill it with exactly the same amount of oil as drained from the original compressor (always at least 70 cm 3 ).

Replacing other components

Drain the oil. Make a note of the volume. Fill up the new components with the same amount of oil.

Corrective actions in event of a fast leak (hose breakage for example)

A fast leak often means that oil escapes with the refrigerant.

When replacing components, the following oil volumes apply to the relevant components.

If the system has been completely drained, or flushed out, and it is completely drained of oil the compressor must be filled with 135 cm 3 oil. The remaining 200 cm 3 of oil should be poured into the receiver.

Note. Always read diagnostic trouble codes (DTCs)

Vacuum pumping refrigerant

1. During vacuum pumping, the vacuum pump can be connected to the service valves for both the high pressure (HP) and low pressure (LP) sides
2. Operate the vacuum pump for at least 50 minutes.

Note. The vacuum pump (recycling station) must be capable of maintaining a vacuum lower than 0.1 mbar.

Visual and physical check

Large and slow leaks will often result in air conditioning (A/C) compressor oil being drawn out with the refrigerant.

A visual inspection can localize the point where the oil gathers and identify the source of the leak.

1. Check the system for corrosion which could cause refrigerant to leak
2. Check that there are no loose components.

Fluorescent tracing agent

Volvo has introduced a fluorescent tracing agent manufactured by Right Solutions Inc. for after market use.

Facts about the tracing agent

1. The tracing agent is in liquid form. It is mixed with the A/C compressor oil in the climate control system.
2. The tracing agent is light green in color. It is used to identify any leakage in the climate control system.
3. If an UV lamp is used, it is easier to see where the fluorescent tracing agent is leaking out.

General repair instructions - air conditioning (A/C) system

Any leakage must be repaired immediately in order to prevent moisture entering the system.

Ensure the work area is kept dry and clean. Moisture and dirt will reduce the efficiency of the air conditioning (A/C) system.

Store compressor oil in a sealed container (compressor oil absorbs water).

When working on A/C systems, for example when replacing components, open ends must always be plugged immediately after undoing pipe or hose connections. When installing new components, leave the protective plugs in the holes until the component is actually needed. If dirt may have entered any component it must be inspected and cleaned.

If the car has been damaged in a collision it is important that every component in the system is inspected. Special attention must be paid to brazed joints. Cracked or deformed components must not be repaired.

Desiccant in the receiver

The receiver must be replaced when repairing a major leak or replacing a component, or if moisture is suspected to have entered the system. The receiver does not be replaced more often than on every third occasion if only minor work is carried out under favorable conditions. Favorable conditions are defined, for example, as a slow leak (over 24 hours) which is repaired immediately. When installing new components in a one-year-old car the receiver need not be replaced.

If the car has been left standing for more than 24 hours without refrigerant in the system, the system must be flushed twice with approximately 200 grams of refrigerant. Between the two flushing operations, pump the system completely empty for at least 10 minutes.

Note. Return used refrigerant to the supplier who is responsible for safe disposal of environmentally harmful substances.

Filling and leak tracing the climate control system using fluorescent tracing agent and a UV lamp.

Scheme 456

Note. The coloring agent may discolor the car paintwork. Therefore extreme caution must be taken when handling the tracing agent.

Note. Carefully follow the manufacturers instructions when handling the UV lamp and the tracing agent.

Note. After filling with the tracing agent, the decal supplied by the manufacturer/supplier must be applied at the point indicated.

Note. When leak tracing, always use the protective goggles supplied with the equipment. The goggles make the color more visible.

For information about filling with fluorescent tracing agent, see Filling with fluorescent tracing agent with the refrigerant .

Scheme 457

1. Connect the UV lamp. See the instructions
2. Leak trace using the UV lamp
3. The fluorescent tracing agent is green when leak tracing with a UV lamp.

Note. This light green color may be mistaken for leaked or spilled coolant which Volvo uses in its products.

The method for leak tracing using fluorescent tracing agent is the same for both factory filled and aftermarket filled climate control systems.

Filling with fluorescent tracing agent with the refrigerant

Regulations

Filling and leak tracing the climate control system with tracing agent and an UV lamp from Bright Solutions Inc.

Note. The coloring agent may discolor the car paintwork. Therefore extreme caution must be taken when handling the tracing agent.

Note. Carefully follow the manufacturers instructions when handling the UV lamp and the tracing agent.

Note. After filling with the tracing agent, the decal supplied by the manufacturer/supplier must be applied at the point indicated.

Filling with fluorescent tracing agent

When replacing components in the climate control system, the component (for example the drier) can be filled with tracing agent.

Filling an empty climate control system with tracing agent when a leak cannot be localized

1. Fill with 225 g of refrigerant with fluorescent tracing agent according to the manufacturers instructions for leak tracing.

Scheme 458

If the climate control system is filled

1. Drain off 225 g of refrigerant, see «Refrigerant, draining»(ref-461602-S34177271232012040200000)
2. Fill the climate control system with refrigerant with tracing agent according to the manufacturers instructions
3. Leak trace according to «Leak tracing, fluorescent tracing agent/UV lamp»(ref-441397-S18102561032011121500000) .

If the amount of refrigerant in the climate control unit cannot be determined

1. Drain the climate control system according to «Refrigerant, draining»(ref-461602-S34177271232012040200000)
2. Fill the climate control system with refrigerant with tracing agent according to the manufacturers instructions
3. Leak trace according to «Leak tracing, fluorescent tracing agent/UV lamp»(ref-441397-S18102561032011121500000) .

Air conditioning (AC) system, general instructions

Any leakage must be repaired immediately in order to prevent moisture entering the system.

Ensure the work area is kept dry and clean. Moisture and dirt will reduce the efficiency of the air conditioning (A/C) system.

Store compressor oil in a sealed container (compressor oil absorbs water).

When working on A/C systems, for example when replacing components, open ends must always be plugged immediately after undoing pipe or hose connections. When installing new components, leave the protective plugs in the holes until the component is actually needed. If dirt may have entered any component it must be inspected and cleaned.

If the car has been damaged in a collision it is important that every component in the system is inspected. Special attention must be paid to brazed joints. Cracked or deformed components must not be repaired.

Desiccant in the air receiver/dryer

The dryer must be replaced when repairing a major leak or replacing a component, or if moisture is suspected to have entered the system. The unit need not be replaced more often than on every third occasion if only minor work is carried out under favorable conditions. Favorable conditions are defined, for example, as a slow leak (over 24 hours) which is repaired immediately. When installing new components in a one-year-old car the receiver need not be replaced.

If the car has been left standing for more than 24 hours without refrigerant in the system, the system must be flushed twice with approximately 200 grams of refrigerant. Between the two flushing operations, pump the system completely empty for at least 10 minutes.

Note. Return used refrigerant to the supplier who is responsible for safe disposal of environmentally harmful substances.

Aim

To offer the customer a passenger compartment which is free of bad odors and pollutants.

General

By placing an air quality sensor in the air intake it is possible to measure the amounts of polluted air, primarily from motor vehicles. The signal from the air quality sensor is used to exclude the pollutants by using the recirculation (REC) mode. An activated carbon filter is installed in the heater. This filter takes care of the pollutants in the couple of seconds before the recirculation shutter closes and on those occasions when recirculation cannot be used because of misting. The filter and the sensor are interdependent to provide the customer with as clean a passenger compartment as possible. The climate control system is equipped with a button to activate the system.

The filter

By supplying a particle filter with activated carbon, gases entering the passenger compartment can be absorbed. The focus of exclusion is on the following substances: NO, NO2, HC (benzene, toluene, xylene), CO, ozone.

What can activated carbon absorb?

Cold start: Good absorption of petrol components is usually achieved.

Manure: Ammonia is badly absorbed, however some neutralization can be expected.

Exhausts: Good separation of uncombusted hydrocarbons and "diesel odor" is achieved.

Oil odor: Good.

Water treatment plants: Sulphuric acid cannot be dealt with.

Solvents Good.

Pulp mills: Many odorous substances. Some can be absorbed.

Odours are complicated and are difficult to explain in terms of concentrations and percentages. A filter will reduce odors and minimize strong odor changes and will therefore improve comfort. The car can never be completely odorless. In some cases the odor compounds may seem unexpected because the constituent substance compounds are modified.

Sensor

The sensor registers NOxCO and HC. These are the most prominent compounds produced by motor vehicles. The sensor registers increases in concentrations, for example when a tunnel is entered or when driving behind a truck. The sensor learns the environment it is in and only reacts to the relevant increase in concentration. One point is that the sensor reacts to CO, a compound which activated charcoal filters cannot handle.

Scheme 459

Check whether there is a decal in the engine compartment indicating that there is tracing agent in the climate control system as shown for the location.

Control modules

See Control modules

Filling the climate control system with fluorescent tracing agent and leak tracing using a UV lamp

Note. Check whether there is a decal in the engine compartment indicating that the car is filled with fluorescent tracing agent. See Decal, fluorescent tracing agent .

Note. The coloring agent may discolor the car paintwork. Therefore extreme caution must be taken when handling the tracing agent.

Note. Carefully follow the manufacturers instructions when handling the UV lamp and the tracing agent.

The fluorescent tracing agent can be injected in the following cases

1. when it is not possible to localize the leak using an electronic leak tracer
2. when replacing components
3. for leak tracing where tracing agent has not previously been used in the car
4. when replacing the compressor if tracing agent has previously been used in the car
5. when a majority of the components are replaced and tracing agent has previously been used in the car.

Note. When replacing components for example, do not forget to compensate for the amount of compressor oil in the climate control system. See Oil in the A/C system .

Scheme 460

1. Valves closed
2. The cover for the injector/reservoir
3. Fluorescent tracing agent.

Note. After filling with the tracing agent, the decal supplied by the manufacturer or supplier must be applied.

Filling with fluorescent tracing agent

When replacing a component in the climate control system, the component (for example the drier) can be filled with tracing agent.

Filling an empty climate control system with tracing agent when a leak cannot be localized

1. Add fluorescent tracing agent to the refrigerant according to the manufacturers instructions for leak tracing.

If the climate control system is filled

1. Drain the refrigerant. See «Refrigerant, draining»(ref-461602-S34177271232012040200000)
2. Fill the climate control system with refrigerant and tracing agent according to the manufacturers instructions
3. Leak trace. See «Leak tracing, fluorescent tracing agent/UV lamp»(ref-441397-S18102561032011121500000) .

If the amount of refrigerant in the climate control unit cannot be determined

1. Drain the climate control unit. See «Refrigerant, draining»(ref-461602-S34177271232012040200000)
2. Fill the climate control system with refrigerant and tracing agent according to the manufacturers instructions
3. Leak trace. See «Leak tracing, fluorescent tracing agent / UV lamp»(ref-441397-S18102561032011121500000) .

Injecting tracing agent

Note. On newer filling/draining/vacuum pumping stations there is a reservoir for injecting oil. It can be used for filling with fluorescent tracing agent before filling with refrigerant and after vacuum pumping.

Check that the valves on the draining/recycling station are closed when the vacuum pumping is completed after draining the refrigerant.

Close the valves on both side of the injector as shown

Unscrew the cover on the injector

Pour in the tracing agent. One bottle in the reservoir

Note. Always inject exactly the right amount. Do not inject the tracing agent twice.

Screw on the cover, ensuring that it is secure

Begin filling with the refrigerant

Scheme 461

Open the valves on the injector

Fill the refrigerant in the air conditioning (A/C) system with tracing agent.

Oil in the A/C system

Special tools

9511204

Filling the A/C system with oil

Note. Fill with oil before vacuum pumping.

Filling with PAG oil

When replacing pipes or hoses the oil can be filled through the service valve.

The procedure for topping up PAG oil (P/N 8708581-7) in the car is as follows

1. Remove the needle valve in the service valve using valve tool «9511204»(ref-403953-S29886163752011061000000) .

Scheme 462

Use the filling syringe (without plastic hose) supplied with the unit to top up the oil. Clean the syringe to avoid the possibility of mixing different types of oil.

1. Check according to the table above. Measure how much oil is to be added. After topping up the oil, reinstall the needle valve.

Note. Use only your thumb and index finger when tightening the service valve using valve needle tool 9511204 . This is to prevent damage to the seal on the valve.

See Filling with refrigerant

Volvo has introduced a fluorescent tracing agent for aftermarket use.

Facts about the tracing agent

1. The tracing agent is in liquid form. It is mixed with the A/C compressor oil in the climate control system
2. The tracing agent is light green in color. It is used to identify any leakage in the climate control system
3. If an UV lamp is used, it is easier to see where the fluorescent tracing agent is leaking out.

Volvo has introduced a fluorescent tracing agent into production.

The tracing agent is impregnated in a free standing "Dry-Water" cylindrical filter in the drying agent in the dryer.

The tracing agent dissolves and mixes with the compressor oil in the climate control system. The tracing agent is light green in color. It is used to identify any leakage in the climate control system. If an UV lamp is used, it is easier to see where the fluorescent tracing agent is leaking out.

The receiver drier is supplied without tracing agent for aftermarket orders.

Production receiver driers have a small decal indicating that they contain fluorescent tracing agent.

Cars in production will have a decal in the engine compartment indicating that there is fluorescent tracing agent in the car.

For the location of the decal, see Refrigerant, draining .

The location of the decal is the same for both aftermarket and production.

For information about filling and leak tracing using fluorescent tracing agent, see Refrigerant, draining .

Installing the tracing agent injector

Note. On newer filling/draining/vacuum pumping stations there is a reservoir for injecting oil. It can be used for filling with fluorescent tracing agent before filling with refrigerant and after vacuum pumping.

Instructions for tracing agent injector

Note. On newer filling/draining/vacuum pumping stations there is a reservoir for injecting oil. It can be used for filling with fluorescent tracing agent before filling with refrigerant and after vacuum pumping.

The tracing agent injector is manufactured for use with the draining/recycling station.

The tracing agent injector has two threaded mounting holes to secure it to the draining/recycling station. Once connected, the injector is permanently attached.

To install the tracing agent injector, see Installing the tracing agent injector .

Special tools

9511207

When fault tracing using refrigerant as a tracing agent, we recommend that leak tracer 9511207 is used.

Note. The engine must always be switched off when leak tracing.

An electronic leak tracer can be used if there is still refrigerant in the climate control system.

If the climate control system is empty and a visual or physical test has not identified the leak.

1. Fill the climate control system with 200 grams of refrigerant
2. There must not be any strong smells or fumes in the engine compartment. These can affect the leak tracing
3. Leak-trace using a leak tracer.

1. Fill with the remaining amount of refrigerant
2. Add fluorescent tracing agent according to «Filling with fluorescent tracing agent and refrigerant»(ref-441397-S28572502792011121500000)
3. If leakage is suspected, ask the customer to drive the car and then return for new leak tracing/repairs.

1. Remedy the cause of the leak
2. Vacuum pump according to «Vacuum pumping»(ref-441397-S15248706252011121500000)
3. Add fluorescent tracing agent with the refrigerant according to «Filling with fluorescent tracing agent and refrigerant»(ref-441397-S28572502792011121500000)
4. Leak trace according to «Leak tracing, fluorescent tracing agent/UV lamp»(ref-441397-S18102561032011121500000) .

Or

1. Fill with refrigerant according to «Filling with refrigerant»(ref-441397-S39380443802011121500000)
2. Leak trace according to «Leak tracing with an electronic leak tracer using refrigerant as a tracing agent»(ref-441397-S26513808282011121500000) .

Oil air conditioning (A/C) system, filling

Special tools

9511204

Replacing the receiver drier

Replace the receiver drier in the following cases

1. when replacing the compressor (e. g., compressor breakdown)
2. refrigerant leakage, where nearly 100% has leaked out of the system (the system has no pressure)
3. when replacing any air conditioning (A/C) component outside the warranty period.

Note. On newer filling/draining/vacuum-pumping stations there is a reservoir for injecting oil. This can be used before filling with refrigerant and after vacuum-pumping without needing to remove the needle valve in the service valve.

Note. Fill with oil before vacuum-pumping.

Filling with PAG oil

When replacing pipes/hoses, oil can be filled through the service valve.

When filling the vehicle with PAG oil (for P/N see spare parts catalog), carry out the following

1. Remove the needle valve in the service valve using valve tool «9511204»(ref-403953-S29886163752011061000000) .

Scheme 463

Use the filling syringe (without plastic hose) supplied with the unit to top up the oil. Clean the syringe to avoid the possibility of mixing different types of oil.

1. Check according to the table above. Measure how much oil is to be added. After topping up the oil, reinstall the needle valve.

Note. Use only your thumb and index finger when tightening the service valve using valve needle tool 9511204 . This is to prevent damage to the seal on the service valve.

Vacuum pumping

See Vacuum pumping

See Control modules

Environmental information

Detailed health and environmental information about the chemical products used is available on the product information sheets which are distributed by Volvo Car Corporation Aftersales.

Scheme 464

The additional heater can also operate as a parking heater. It requires Timer type 4 to be installed (accessory).

Installation of connection kit to modify the heater connection to the car's fuel system is required for this function.

Additional heater

Connected to engine fuel return line.

Parking heater

Connected on dedicated fuel line to the tank. Fuel pump is transferred to the tank.

Scheme 465

Examples of preparations which facilitate servicing.

Radio

Make a note of the anti-theft radio code before the battery leads are disconnected. Use the code to lock the radio when work is completed.

Scheme 466

Alarm

Disarm the alarm siren if the alarm has a back-up battery.