GENERAL SERVICING PROCEDURES Article Text 2001 Volvo V40

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1 GENERAL SERVICING PROCEDURES Article Text 2001 Volvo V40 ARTICLE BEGINNING GENERAL SERVICING General Servicing Procedures For additional general serving information, see MITCHELL(R) AUTOMOTIVE AIR CONDITIONING BASIC SERVICE TRAINING MANUAL or MITCHELL(R) DOMESTIC CARS, LIGHT TRUCKS & VANS AIR CONDITIONING & HEATING SERVICE & REPAIR supplement. USING R-12 & R-134a REFRIGERANT HANDLING/SAFETY PRECAUTIONS 1) Always work in a well-ventilated, clean area. Avoid breathing refrigerant vapors. Exposure may irritate eyes, nose and throat. Refrigerant is colorless and is invisible as a gas. Refrigerant is heavier than oxygen and will displace oxygen in a confined area. 2) The A/C system high pressure can cause severe injury to eyes and skin if a hose were to burst. Always wear eye protection, gloves and other protective clothing when working around A/C system and refrigerant. 3) Refrigerant evaporates quickly when exposed to atmosphere, freezing anything it contacts. If liquid refrigerant contacts eyes or skin (frostbite), DO NOT rub eyes or skin. Immediately flush affected area with cool water for 15 minutes and consult a doctor or hospital. 4) Never use R-134a in combination with compressed air for leak testing. Pressurized R-134a in the presence of oxygen (air concentrations greater than 60 percent by volume) may form a combustible mixture. DO NOT introduce compressed air into R-134a containers (full or empty), A/C system components or service equipment. 5) DO NOT expose A/C system components to high temperatures, steam cleaning for example, as excessive heat will cause refrigerant/system pressure to increase. Never expose refrigerant directly to open flame. If refrigerant needs to be warmed, place bottom of refrigerant tank in warm water. Water temperature MUST NOT exceed 125 F (52 C). CAUTION: When R-134a is exposed to an open flame, drawn into engine, or detected with a Halide (propane) leak tester, a poisonous gas is formed. Keep work areas well ventilated. 6) Use care when handling refrigerant containers. DO NOT drop, strike, puncture or incinerate containers. Use Department Of Transportation (DOT) approved, DOT 4BW or DOT 4BA refrigerant containers. 7) Never overfill refrigerant containers. The safe filling level of a refrigerant container MUST NOT exceed 60 percent of the container's gross weight rating. Store refrigerant containers at temperature less than 125 F (52 C). 8) R-134a refrigerant is sold and stored in 30- or 50-pound Light Blue containers, while Freon (R-12) is stored in White colored containers. 9) Refrigerant R-12 and R-134a must never be mixed, as they and their desiccants and lubricants are not compatible. If refrigerants are mixed, system cross-contamination or A/C system component failure may occur. Always use separate servicing and refrigerant recovery/recycling equipment. 10) Follow equipment manufacturer instructions of all service equipment to be used. The Material Safety Data Sheet (MSDS), provided by refrigerant manufacturer/suppliers, contains valuable information regarding the safe handling of refrigerants. 11) Before connecting refrigerant lines always lubricate "O" rings with refrigerant oil. 12) Always plug or cap A/C system refrigerant lines and component connections as soon as possible to protect components from moisture and/or dust. DO NOT remove plugs or caps until ready to install component. 13) Always use a back-up wrench when tightening or loosening fittings. IDENTIFYING R-134a SYSTEMS & COMPONENTS To prevent refrigerant cross-contamination, use the following methods to identify R-134a based systems and components. Fittings & "O" Rings All R-134a based A/C systems use 1/2" - 16 ACME threaded fittings (identifiable by square threads) and quick-connect service couplings. See Fig. 1. Besides the use of these fittings, most

2 manufacturers will use Green colored "O" rings in R-134a systems. Fig. 1: Identifying R-134a Fittings & Quick-Connect Service Couplings Courtesy of Audi of America, Inc. Underhood A/C Specification Labels Most R-134a based systems will be identified through the use of underhood labels, or with R-134a refrigerant clearly printed on labels. See Figs. 2 and 3. Labels may be located on underside of hood, compressor, firewall and/or strut supports. The underhood label used on Ford Motor Co. vehicles is Yellow. Before servicing an A/C system, always determine which refrigerant is being used. Fig. 2: Underhood A/C Specification Label (Typical) Courtesy of Nissan Motor Co., U.S.A.

3 Fig. 3: A/C Specification Labels Located On Compressor (Typical) Courtesy of Nissan Motor Co., U.S.A. Other Means Of Identification Refrigerant R-134a, when viewed through a sight glass, may have a "milky" appearance due to the mixture of refrigerant and lubricating oil. As the refrigerant and oil DO NOT exhibit a "clear" sight glass on a properly charged A/C system, most R-134a systems have no sight glass. Audi, Mercedes-Benz and Volkswagen use Green bands/labels on condenser, refrigerant lines, receiver-drier and expansion valve. On Lexus A/C systems, hoses and line connectors have a groove, a White line and "R-134a" marked on them. See Fig. 4. GENERAL SERVICING PROCEDURES Article Text (p. 3)2001 Volvo V40For NONE Fig. 4: Identifying R-134a Hose & Line Connectors (Lexus) Courtesy of Toyota Motor Sales, U.S.A., Inc. REFRIGERANT OILS PAG oils absorb moisture very rapidly, percent by weight, as compared to a mineral oil absorption rate of percent by weight. Use ONLY the specified oil for the appropriate system or A/C compressor. Always check vehicle underhood A/C specification label or A/C compressor label before adding refrigerant oil to A/C compressor/system. See Figs. 2 and 3. Most of the common refrigerant

4 oils are listed below. Always use refrigerant oil specified in underhood A/C specification label or A/C compressor label. Acura Use DENSO ND-Oil 8 (Part No PR7-A01). Audi Use SP-10 PAG oil (Part No. G A2) on Nippondenso compressors and SP-10 PAG oil (Part No. G A2) on Zexel compressors. Honda On Harrison HD6/HT6 compressor, use PAG oil specified on underhood A/C specification label or A/C compressor label. On Keihin compressor, use SP-10 Oil (Part No P13-A01AH). On Nippondenso compressor, use DENSO ND-Oil 8 (Part No PR7-A01AH or PR7- A01). On Zexel DKV-14D compressor, use AIPDN Oil (Part No ). Hyundai Use Daphne Hermetic FD46XG PAG oil. Infiniti & Nissan Use Type "F" Refrigerant Oil (Part No. KLH00-PAGQU) on Ford compressors. Use Type "R" Refrigerant Oil (Part No. KLH00-PAGR0) with Zexel rotary vane compressors. Use Type "S" Refrigerant Oil (Part No. KLH00-PAGS0) with Calsonic V6 compressors. Isuzu On Harrison compressors use PAG oil specified on underhood A/C specification label or A/C compressor label. On Nippondenso compressor, use DENSO ND-Oil 8 (Part No PR7-A01AH). On Zexel DKS-17CH compressor, use PAG Oil (Part No ). On Zexel DKV-14D compressor, use AIPDN Oil (Part No ). Jaguar Use specified PAG refrigerant oil. See underhood A/C specification label and/or A/C compressor label. On S-Type use PAG (WSH-MIC231-B) refrigerant oil. Kia On Sportage, use ZXL 200 PG PAG oil. For other Kia models, check underhood A/C specification label and/or A/C compressor label. Kia Optima, although not specified by manufacturer, may use a Halla compressor and Daphne Hermetic FD46XG PAG oil. Land Rover Use ND-Oil 8 refrigerant oil. Check underhood A/C specification label and/or A/C compressor label. Lexus & Toyota Use Denso/ND-Oil 8 refrigerant oil (Part No PR7-003 or ). Check underhood A/C specification label and/or A/C compressor label. Mazda Use ATMOS GU-10, DENSO/ND-Oil 8, DENSO Oil 9, SP-10 or SP-20 PAG refrigerant oil. Use SUN ISCO 5GS on Ford FS-10 compressors. Check underhood A/C specification label and/or A/C compressor label. Mercedes-Benz Use PAG oil (Part No ). Check underhood A/C specification label and/or A/C compressor label. Mitsubishi Use DENSO/ND-Oil 8 refrigerant oil on Nippondenso compressors. Use SUN PAG 56 refrigerant oil on Sanden compressors. Porsche Use ND-Oil 8 refrigerant oil. Check underhood A/C specification label and/or A/C compressor label. Saab Use DENSO/ND-Oil 8 refrigerant oil on Nippondenso compressors. Use PAG Oil ISO 46 (Part No ) refrigerant oil on Sanden compressors. Check underhood A/C specification label and/or A/C compressor label. Subaru Use ZXL200PG (DH-PR) type "R" (Part No. K0010FS100) refrigerant oil. Check underhood A/C specification label and/or A/C compressor label.

5 Suzuki Use PAG oil. Check underhood A/C specification label and/or A/C compressor label. Volkswagen On Nippondenso compressors, use PAG Oil (Part No. G A2). On Sanden compressors, use SP-10 PAG Oil (Part No. G A2). On Zexel compressors, use PAG Oil (Part No. G A2 or G A2). Volvo Use PAG Oil (Part No ) on Zexel compressors. Check underhood A/C specification label and/or A/C compressor label. SERVICE EQUIPMENT A/C systems using R-134a refrigerant and PAG lubricants cannot use R-12 refrigerant or mineral oil lubricants. R-134a refrigerant is NOT compatible or interchangeable with R-12 refrigerant. Separate sets of hoses, manifold gauge sets and recovery/recycling equipment are required to service the different systems. This is necessary to avoid cross-contaminating and damaging A/C system. A single set of A/C service equipment cannot be cleaned thoroughly enough to be used with both types of refrigerant. All equipment used to service A/C systems using R-134a must be U.L. listed and certified to meet SAE standard J2210. The service hoses on the manifold gauge set must have manual (turn wheel) or automatic backflow valves at the service port connector ends. This will prevent refrigerant from being released into the atmosphere. For identification purposes, R-134a service hoses must have a Black stripe along its length and be clearly labeled SAE J2196/R-134a. The low pressure test hose is Blue with a Black stripe. The high pressure test hose is Red with a Black stripe, and the center test hose is Yellow with a Black stripe. R-134a manifold gauge sets can be identified by one or all of the following: Labeled FOR USE WITH R-134a on set, labeled HFC-134a or R-134a on gauge face, or by a Light Blue color on gauge face. In addition, pressure/temperature scales on R-134a gauge sets are different from R-12 manifold gauge sets. SYSTEM SERVICE VALVES SCHRADER-TYPE VALVES Although similar in construction and operation to a tire valve, NEVER replace a Schrader-type valve with a tire valve. Schrader valve is similar in construction and operation to a tire valve. When a test gauge hose with built-in valve core depressor is attached, Schrader stem is pushed inward to the open position and allows system pressure to reach gauge. If test hose does not have a built-in core depressor, an adapter must be used. Never attach hose or adapter to Schrader valve unless it is first connected to manifold gauge set. Refrigerant R-12 Schrader-type valve cores have TV5 thread size. Refrigerant R-134a Schrader-type valve cores use M6 (Metric) threads. See Fig. 1. SERVICE VALVE LOCATIONS SERVICE VALVE LOCATIONS Vehicle High Low Acura Integra... (1)... (2) MDX... (8)... (9) 3.2CL... (1)... (4) 3.2TL... (1)... (4) 3.5RL... (6)... (4) Audi Except TT... (7)... (7) TT... (8)... (9) Honda Accord... (1)... (4) Civic... (10).. (10) CR-V... (11).. (9)

6 Insight... (8)... (9) Odyssey... (10).. (10) Passport... (13).. (14) Prelude... (1)... (2) S (1)... (9) Hyundai Accent... (8)... (5) Elantra... (8)... (9) Santa Fe... (8)... (9) Sonata... (8)... (9) Tiburon... (8)... (9) XG (8)... (9) Infiniti... (15).. (4) Isuzu Amigo & Rodeo... (13).. (14) Hombre... (3)... (4) Trooper... (3)... (4) Vehi-CROSS... (12).. (14) Jaguar... (6)... (4) Kia... (3)... (4) Land Rover Discovery... (3)... (4) Range Rover... (8)... (4) Lexus ES 300, GS 300, GS 400, GS 430, IS 300, SC 300 & SC (17).. (4) LS 400 & LS (6)... (4) LX (8)... (9) RX (17).. (9) Mazda B2300, B2500, B3000 & B (15).. (6) Millenia... (15).. (4) MPV... (15).. (9) MX-5 Miata... (8)... (4) Protege... (3)... (4) Tribute... (15).. (18) (16).. (4) Mercedes-Benz... (17).. (6) Mitsubishi Diamante... (8)... (9) Eclipse... (8)... (9) Galant... (8)... (9) Mirage... (8)... (9) Montero & Montero Sport 2000 Models... (11).. (6) 2001 Models... (8)... (9) Nissan Altima... (3)... (4) Frontier & Xterra... (15).. (4) Maxima... (15).. (4) Pathfinder... (15).. (4) Quest... (12).. (18) Sentra... (8)... (9) Porsche Boxster... (8)... (9) (8)... (9) Saab... (6)... (2) Subaru... (19).. (19) Suzuki Esteem... (15).. (4) Vitara & Grand Vitara... (6)... (2) Swift... (3)... (4) Toyota Avalon... (1)... (4) Camry, Camry Solara & Celica... (17).. (4) Corolla... (15).. (4) ECHO... (8)... (9) Highlander... (8)... (9) Land Cruiser... (10).. (4) MR2... (8)... (9) Prius... (8)... (9) RAV4... (8)... (14) Sequoia... (17).. (14) Sienna... (6)... (2) Tacoma... (7)... (7) Tundra... (17).. (14) 4Runner... (17).. (7) Volkswagen Beetle... (8)... (9) Cabrio, Golf, GTI & Jetta... (1)... (9) EuroVan... (8)... (9) Passat... (8)... (9) Volvo... (8)... (9)

7 (1) - On high pressure line, near receiver-drier. (2) - On low pressure line, near top of condenser. (3) - On high pressure line, between accumulator/receiver-drier and evaporator. (4) - On low pressure line, between evaporator and compressor. (5) - On low pressure line, on or near compressor. (6) - On top of accumulator/receiver-drier. (7) - On thin evaporator inlet (high pressure) line or thick outlet (low pressure) line. (8) - On high pressure hose/line. For Volvo, see Fig. 7. (9) - On low pressure hose/line. For Toyota MR2, see Fig. 6. (10) - On top of condenser, on right side. (11) - On high pressure outlet at compressor. For Honda CRV, see Fig. 5 (12) - On high pressure (thin) line, at rear of engine compartment. (13) - On high pressure outlet at compressor. (14) - On low pressure (thick) line, at rear of engine compartment. (15) - On high pressure line, between compressor and condenser. (16) - On high pressure hose/line between condenser and evaporator. (17) - In front/back of condenser. (18) - On low pressure line, between accumulator and compressor. (19) - On high and low pressure lines, near compressor Fig. 5: Locating A/C System Components (Honda CR-V) Courtesy of American Honda Motor Co., Inc. Fig. 6: Locating Service Valves (Toyota MR2) Courtesy of Toyota Motor Sales, U.S.A., Inc.

8 Fig. 7: Locating Service Valves (Volvo S60 & S80 Shown; Other Models Similar) Courtesy of Volvo Cars of North America. REFRIGERANT RECOVERY/RECYCLING Refrigerant recovery/recycling equipment is used to remove refrigerant from vehicle's A/C system without polluting atmosphere. To remove and recycle refrigerant, connect the recovery/recycling equipment and following the equipment manufacturer's instructions. Removed refrigerant is filtered, dried and stored in a tank within the recovery/recycling equipment until it is ready to be pumped back into vehicle A/C system. With refrigerant stored in the recovery/recycling equipment, A/C system can be opened without polluting atmosphere. Separate sets of hoses, gauges and refrigerant recovery/recycling equipment MUST be used for R-12 and R-134a based systems. DO NOT mix R-12 and R-134a refrigerants, as their refrigerant oils and desiccants are not compatible. It is NOT possible to clean equipment thoroughly enough to prevent cross-contamination of A/C systems. On systems with R-134a refrigerant, use Polyalkylene Glycol (PAG) wax-free refrigerant oil.

ATTACHMENT 4 (p.1 of 5) 2003 PASSENGER VEHICLE MODELS WITH SIDE AIRBAGS

ATTACHMENT 4 (p.1 of 5) 2003 PASSENGER VEHICLE MODELS WITH SIDE AIRBAGS ATTACHMENT 4 (p.1 of 5) ACURA 3.2 CL / 3.2 TL / 3.5 RL Front Torso only Standard MDX / RSX Front Torso only Standard AUDI A4 except Cabriolet Front Curtain/torso Standard A4 Cabriolet Front Torso/head