A/C - Proper Parts Installation Procedure

Classification:
HA95-02

Reference:
ITB95-005

Date:
March 10, 1995

AIR CONDITIONING (A/C) PARTS PROPER INSTALLATION PROCEDURE

APPLIED VEHICLES:
All

SERVICE INFORMATION

The procedure outlined below shows how to properly handle and install A/C system components during an A/C repair or kit installation.

1. CLEAN WORKING AREA SURFACE

Clean all working area surfaces which may come in contact with A/C components. Dirt particles, metal chips, dirty oil, moisture, etc. can contaminate and damage the "O" rings and joint connectors. In addition, ensure that your hands are clean when handling A/C components.

2. SEAL CAPS




After disconnecting tubes, immediately plug all connector openings with seal caps to prevent entry of dirt and moisture. Do not remove the seal caps of pipes and other components until just before connecting the components. The caps prevent contaminants and moisture from entering and damaging the system (refer to figure A).

3. "O" RINGS AND JOINT CONNECTORS

A. Always replace used "O" rings with new ones. Always install the same size "O" ring.

B. Inspect new "O" rings and joint connectors before installation.

C. Make sure the "O" ring(s) are not scratched or cut. If the "O" ring has a cut or scratch do not use it.

D. Be sure the "O", ring is on the tube end. Apply a small amount of refrigerant oil to the "O" ring. Be careful not to apply lubricant to the threaded portion (see figure B).

E. Inspect mating surfaces of components. Make sure there are no contaminants, burrs, scratches or damage especially at sealing surfaces.

4. MAKING THE CONNECTIONS

Tighten joint connections by hand first. Confirm the tubes are mated correctly. Then tighten the fittings using a torque wrench and a backup wrench to prevent twisting. Twisting can damage tubes and result in a leak later in the life of the vehicle (see figure C).

5. TORQUING

Torque the fittings to specification. Do not over torque. Over torque will damage the sealing surfaces and result in a leak. Be especially careful when installing plastic components such as switches and sensors. These components can be easily damaged due to mishandling or over torquing.

6. LEAK CHECK

After completing all connections, evacuate and charge the system with the specified amount of refrigerant. Conduct a leak check to confirm there are no leaks from the connections. For more information on the detection of refrigerant leaks refer to ITB95-004.