tran DAEWOO LACETTI 2004 Service Repair Manual

POWER STEERING GEAR 6C – 7
DAEWOO V–121 BL4
SPEED SENSITIVE POWER STEERING SYSTEM
OPERATING WITH FULL ASSIST AT ALL TIMES
StepActionValue(s)YesNo
1Perform an initial inspection of the power steering
system.
Is the system operational?–Go to Step 2Go to
Section 6A,
Power Steering
System
2Check the speedometer.
Is the speedometer inoperative?–Go to
Section5,
TransaxleGo to Step 3
3Check the diagnostic trouble codes at the engine
control module (ECM).
Is the ECM code 24 set?–Go to
Section1F,
Engine
ControlsGo to Step 4
41. Turn the ignition ON.
2. Disconnect the electronic variable orifice (EVO)
solenoid actuator electrical connector at the
power steering pump.
3. Probe terminal 1 of the EVO actuator connec-
tor with a voltmeter.
Does the voltmeter display the specified value?–Go to Step 6Go to Step 5
5Repair the open or short in the circuit between termi-
nal 1 of the EVO solenoid actuator electrical connec-
tor and terminal 2 on the speed sensitive power
steering (SSPS) control module connector.
Is the repair complete?–System OK–
61. Remove the EVO solenoid actuator from the
power steering pump.
2. Turn the actuator upside down to position the
pintle.
3. Stimulate the actuator by connecting it to the
battery.
Does the actuator click?–Go to Step 8Go to Step 7
7Replace the EVO solenoid actuator.
Is the repair complete?–System OK–
81. Turn the ignition OFF.
2. Remove the SSPS control module from the
control module bracket.
3. Disconnect the SSPS control module connec-
tor.
4. Connect a test light from terminal 8 on the
SSPS control module connector to the ground.
5. Turn the ignition ON.
Is the test light on?–Go to Step 14Go to Step 9
9Check the ignition fuse.
Is the ignition fuse open?–Go to Step 10Go to Step 11
10Replace the ignition fuse.
Is the repair complete?–System OK–
11Check for an open or short in the circuit between ter-
minal 8 of the control module connector and the I/P
fuse block.
Is the connection faulty?–Go to Step 12Go to Step 13

POWER STEERING GEAR 6C – 9
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
23Repair the open, short to ground, short to B+, or poor
terminal contact between terminal 14 of the SSPS
control module connector and terminal 2 of the
steering wheel rotation sensor connector.
Is the repair complete?–System OK–
241. Turn the ignition OFF.
2. Connect the SSPS control module.
3. Connect the steering wheel rotation sensor.
4. Turn the ignition ON.
5. Backprobe with a voltmeter from terminal 5 on
the control module connector to the ground.
6. Rotate the steering wheel quickly in both direc-
tions.
Does the voltage show an increase and decrease
from the specified value?
3 VGo to Step 25Go to Step 26
25Replace the SSPS control module.
Is the repair complete?–System OK–
26Replace the steering wheel rotation sensor.
Is the repair complete?–System OK–
SPEED SENSITIVE POWER STEERING SYSTEM
OPERATING WITH DECREASED ASSIST AT ALL TIMES
StepActionValue(s)YesNo
1Check the speedometer.
Is speedometer inoperative?–Go to
Section5,
TransaxleGo to Step 2
2Disconnect the EVO solenoid actuator at the power
steering pump.
Is the symptom still present?–Go to
Section 6A,
Power Steering
SystemGo to Step 3
3Replace the speed sensitive poser steering (SSPS)
control module.
Is repair complete?–System OK–
General Operation
The control module self–diagnoses SSPS system. If there
is any malfunction, the warning lamp comes ON and at the
same time a trouble code is set. The trouble code can be
retrieved or cleared only by SCANTOOL.
In normal condition, If the ignition is turned on, the warning
lamp comes on for the first 2 sec and out. During this 2 sec,
the control module is diagnosing SSPS system, so a driver
can feel a little heavy steering effort.
If the warning lamp stays on after the 2 sec or comes on
afterward, it means there is a malfunction and a related
trouble code is recorded.
The warning lamp once come on does not go off even if the
malfunction is cleared. It goes off after ignition is turned off
and on without a malfunction.However the trouble code still remains in the control mod-
ule.

6C – 12IPOWER STEERING GEAR
DAEWOO V–121 BL4
9. Remove the outer tie rod nuts and disconnect the
tie rod ends from the strut assembly using the ball
joint remover KM–507–B.
10. Remove the crossmember assembly. Refer to Sec-
tion 2C, Front Suspension.
11. On vehicles equipped with an automatic transaxle,
remove the transaxle center bracket. Refer to Sec-
tion 5A, Automatic Transaxle.
12. On vehicles equipped with a manual transaxle, re-
move the bolts securing the transaxle center brack-
et to the transaxle and the engine. Move the trans-
axle center bracket out of the way.
13. Remove the nuts and bolts from the steering gear
mounting bracket.
14. Remove the return line from the clip on the cross-
member.
15. Disconnect the rack and pinion assembly from the
crossmember assembly.
Installation Procedure
1. Install the rack and pinion assembly on the cross-
member. The steering gear must be in a straight–
ahead position, and the steering wheel spokes
must be vertical and pointing to the left. Align the
marks on the shafts to ensure proper positioning.
Seat the stub shaft into the intermediate shaft.

POWER STEERING GEAR 6C – 13
DAEWOO V–121 BL4
2. Install the bolts and nuts on the steering gear
mounting bracket.
Tighten
Tighten the steering gear mounting bracket bolts and
nuts to 60 NSm (44 lb–ft).
3. Install the return line into the clip on the crossmem-
ber.
Tighten
Tightem the return line clip bolt to 8 NSm (71 lb–in).
4. On vehicles equipped with a manual transaxle,
position the transaxle center bracket in place and
install the bolts securing the bracket to the engine
and the transaxle.
Tighten
Tighten the transaxle center bracket–to–transaxle
bolts and the transaxle center bracket–to–engine bolt
to 80 NSm (59 lb–ft).
5. On vehicles equipped with an automatic transaxle,
install the transaxle center bracket. Refer to Section
5A, Automatic Transaxle.
6. Install the crossmember. Refer to Section 2C, Front
Suspension.
7. Connect the tie rod ends to the strut assembly.
8. Install the outer tie rod nuts.
Tighten
Tighten the outer tie rod nuts to 50 NSm (37 lb–ft).

POWER STEERING GEAR 6C – 33
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
POWER RACK AND PINION
The power rack and pinion steering system has a rotary
control valve that directs hydraulic fluid coming from the
hydraulic pump to one side or the other side of the rack pis-
ton. The integral rack piston is attached to the rack. The
rack piston converts hydraulic pressure to a linear force
that moves the rack left or right. That force is then trans-
mitted through the tie rods to the steering knuckles, which
turn the wheels.
If power rack and pinion steering is not available, manual
rack and pinion control is used; however, with this system,
more steering effort is required. The movement of the
steering wheel is transferred to the pinion. The rotary
movement of the pinion is then transferred through the pin-
ion threads, which mesh with teeth on the rack, thereby
causing the rack to move in a linear direction.
A vane–type of hydraulic pump provides hydraulic pres-
sure for both steering systems.
SPEED SENSITIVE POWER
STEERING SYSTEM
The speed sensitive power steering (SSPS) system varies
the driver effort required to steer as the vehicle speed
changes. At low speeds, the system provides maximum
power assist for easy turning and parking maneuvers. At
higher speeds, the steering power is reduced to provide
the driver with firmer steering and directional stability. The
SSPS system accomplishes this by reducing the amount
of power steering fluid flow from the power steering pump
to the power steering gear as the vehicle speed increases.
When the vehicle is stationary, the SSPS system provides
maximum fluid flow to the steering gear. As the vehicle
speed increases, the fluid flow to the steering gear is de-
creased.
Control Module
The SSPS control module processes the vehicle speed in-
formation from the engine control module (ECM) and uses
the steering wheel rotation sensor to provide a control sig-
nal to the electronic variable orifice (EVO) actuator located
on the power steering pump.
Electronic Variable Orifice (EVO) Actuator
The electronic variable orifice (EVO) actuator is located on
the power steering pump and contains a solenoid– oper-
ated pintle valve. Fluid leaving the pump passes through
an orifice in the actuator tip. When the EVO actuator is
powered by the SSPS control module, the pintle moves
into the orifice and reduces the power steering fluid flow.As the vehicle speed increases, current from the SSPS
control module increases, and the pintle blocks more and
more of the orifice.
Steering Wheel Rotation Sensor
The steering wheel rotation sensor is located at the end of
the steering column housing and is used to send a signal
to the controller when abrupt or evasive steering maneu-
vers are needed.
Power Steering Pressure Hose
SSPS vehicles have a specific pressure hose assembly
which includes an in–line check valve in the rack and pin-
ion assembly. This reduces the amount of steering wheel
”kick” when driving over irregular road surfaces while oper-
ating at speeds with reduced flow rate and pressure.
Power Rack and Pinion
Except for differences in valve machining, the design of
the SSPS power rack and pinion assembly is the same as
for the a non–SSPS system. The steering wheel move-
ment is transferred to the pinion via the intermediate shaft.
The pinion moves the rack left or right through meshing the
pinion and the rack teeth. The force is then transmitted
through the tie rods and steering knuckle to steer the
wheels.
The power rack and pinion steering system has a rotary
control valve which directs the hydraulic fluid from the
power steering pump to one side or the other side of the
rack piston. The piston is attached to the rack and uses hy-
draulic pressure to move the rack left or right. The rotary
control valve regulates the degree of assist by responding
to the driver’s torque input.
If hydraulic assist is not available, manual control is main-
tained. However, under this condition, more steering effort
is required.
Power Steering Pump
The standard vane–type pump, which provides hydraulic
pressure for the system, incorporates a special discharge
fitting to hold the EVO actuator.
System Operation
System operation originates with input from the vehicle
speed sensor via the engine control module to the SSPS
control module. The SSPS control module sends a signal
to the SSPS actuator to vary the rate of fluid flow output
by the power steering pump.
Circuit Operation
The SSPS system uses inputs from the speed sensor and
steering wheel rotation sensor to the SSPS controller to
determine the desired amount of power steering assist.
The SSPS control module constantly compares the
amount of current flowing through the EVO actuator to the
desired current it has calculated. The EVO actuator has a
pintle that moves in and out of an orifice, regulating power

7A – 28IHEATING AND VENTILATION SYSTEM
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
HEATING AND VENTILATION
SYSTEMS
The base heater system is designed to provide heating,
ventilation, windshield defrosting, side window defogging,
and on some vehicles, heating directly to the rear seat
area.
The heater and fan assembly blower regulates the airflow
from the air inlet for further processing and distribution.
The heater core transfers the heat from the engine coolant
to the inlet air.
The temperature door regulates the amount of the air that
passes through the heater core. The temperature door
also controls the temperature of the air by controlling the
mix of the heated air and the ambient air.
The mode door regulates the flow and the distribution of
the processed air to the heater ducts and to the defroster
ducts.
This console–mounted heating and ventilation panel con-
tains the following:
The Rotary Temperature Control Knob
1. The Rotary Temperature Control Knob
S Actuates by cable.
S Raises the temperature of the air entering the
vehicle by rotation toward the right, or the red
portion of the knob.
2. The Rotary Blower Control Knob
S Turns ON to operate the blower motor at four
speeds.
S Turns OFF to stop the blower.
S Operates completely independently both from
the mode control that regulates the defroster
door and from the temperature control knob.S Changes the fan speed in any mode and at any
temperature setting.
3. The Rotary Mode Control Knob
S Actuates by cable.
S Regulates the air distribution between the wind-
shield, the instrument panel, and the floor vents.
Two Push Knobs
1. The Rear Window Defogger Push Knob
S Controls the rear window defogger.
S Turns ON the rear window defogger when the
push knob is pressed and the indicator lamp is
illuminated.
2. The A/C Push Knob (if the vehicle is equipped with
air conditioning)
S Controls the A/C.
S Turns the A/C ON when the push knob is down.
However, if the blower control knob is OFF, the
A/C system is OFF, regardless of the position of
the A/C knob.
Fresh Air Control Level Or Push Knob
1. The Fresh Air Control Level
S Operates by cable.
S Switches between recirculating passenger
compartment air and bringing outside air into the
passenger compartment.
S Draws in outside air when the lever is moved to
the right.
S Recirculates inside air when the lever is moved
to the left.
2. The Fresh Air Control Push Knob
S Operates by cable.
S Switches between recirculating passenger
compartment air and bringing outside air into the
passenger compartment.
S Draws in outside air when knob is off.
S Recirculates inside air when the knob is down
with the indicator lamp illuminated.

SECTION : 7B
MANUAL CONTROL HEATING, VENTILATION
AND AIR CONDITIONING SYSTEM
CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool
or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help
prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
TABLE OF CONTENTS
SPECIFICATIONS7B–2 . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 7B–2. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 7B–2. . . . . . . . . . .
SPECIAL TOOLS7B–3 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 7B–3. . . . . . . . . . . . . . . . . . . . . . . .
SCHEMATIC AND ROUTING DIAGRAMS7B–6 . . . . .
A/C System – Typical 7B–6. . . . . . . . . . . . . . . . . . . . . .
Manual Control A/C Diagram 7B–7. . . . . . . . . . . . . . . .
DIAGNOSIS7B–8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DIAGNOSIS 7B–8. . . . . . . . . . . . . . . . . . . . . .
Testing the Refrigerant System 7B–8. . . . . . . . . . . . . .
Insufficient Cooling ”Quick Check” Procedure 7B–8. .
A/C Performance Test 7B–9. . . . . . . . . . . . . . . . . . . . . .
Pressure–Temperature Relationship of
R–134A 7B–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leak Testing Refrigerant System 7B–11. . . . . . . . . . . .
V5 SYSTEM AIR CONDITIONING DIAGNOSIS 7B–12
Insufficient Cooling Diagnosis 7B–12. . . . . . . . . . . . . .
SYMPTOM DIAGNOSIS 7B–16. . . . . . . . . . . . . . . . . . . .
Pressure Test Chart (R–134A System) 7B–16. . . . . .
Low and High Side Pressure Relationship
Chart 7B–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR7B–19 . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 7B–19. . . . . . . . . . . . . . . . . . . .
GENERAL A/C SYSTEM SERVICE
PROCEDURES 7B–19. . . . . . . . . . . . . . . . . . . . . . . . . .
O–Ring Replacement 7B–19. . . . . . . . . . . . . . . . . . . . .
Handling Refrigerant 7B–19. . . . . . . . . . . . . . . . . . . . . .
Handling of Refrigerant Lines and Fittings 7B–19. . . .
Maintaining Chemical Stability in the Refrigeration
System 7B–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Discharging, Adding Oil, Evacuating, and Charging
Procedures for A/C System 7B–20. . . . . . . . . . . . . .
SERVICEABLE COMPONENTS 7B–23. . . . . . . . . . . . . Components Used In Non–A/C Systems 7B–23. . . . .
A/C Pressure Transducer 7B–24. . . . . . . . . . . . . . . . . .
A/C Compressor Relay 7B–24. . . . . . . . . . . . . . . . . . . .
Air Filter 7B–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A/C Expansion Valve 7B–25. . . . . . . . . . . . . . . . . . . . . .
A/C High–Pressure Pipe Line 7B–26. . . . . . . . . . . . . . .
Evaporator Core 7B–29. . . . . . . . . . . . . . . . . . . . . . . . . .
A/C Suction Hose Assembly 7B–30. . . . . . . . . . . . . . .
A/C Discharge Hose Compressor to
Condenser 7B–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receiver–Dryer 7B–32. . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor 7B–33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condenser 7B–35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR 7B–37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPONENT LOCATOR 7B–37. . . . . . . . . . . . . . . . . . .
V5 Compressor 7B–37. . . . . . . . . . . . . . . . . . . . . . . . . . .
V5 AIR CONDITIONING COMPRESSOR
OVERHAUL 7B–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Plate and Hub Assembly 7B–38. . . . . . . . . . . .
Clutch Rotor and Bearing 7B–40. . . . . . . . . . . . . . . . . .
Clutch Coil 7B–42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft Seal Replacement 7B–44. . . . . . . . . . . . . . . . . . .
Control Valve Assembly 7B–46. . . . . . . . . . . . . . . . . . .
Rear Head, Gasket, Valve Plate, Reed Plate,
and O–ring 7B–47. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder to Front Head O–ring 7B–48. . . . . . . . . . . . . .
Leak Testing (External) 7B–50. . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION7B–51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION 7B–51. . . . . . . . . . . . . . . . . .
The V5 A/C System 7B–51. . . . . . . . . . . . . . . . . . . . . . .
System Components – Functional 7B–51. . . . . . . . . .
System Components – Control 7B–52. . . . . . . . . . . . .
V5 Compressor – General Description 7B–52. . . . . . .
V5 Compressor – Description of Operation 7B–52. . .

7B – 2IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
DAEWOO V–121 BL4
SPECIFICATIONS
GENERAL SPECIFICATIONS
ApplicationUnitDescription
Compressor–V5
Receiver–Dryer–AL R/DRIER
RefrigerantType–R–134a System
Capacityg640±20 (RHD : 680±20)
Refrigerant Oil in A/C SystemType–Union Carbide 488 PAG OIL
Capacitycc (ml)220
Evaporator Capacity (Airflow rate 8.7 kg/min)Kcal/h6000±10%
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Pressure Transducer7–62
Expansion Valve Stud Bolts8–71
Liquid Pipe Support Clamp Bolts4–35
Liquid Pipe Block–to–Receiver Dryer Retaining Nut1410–
Liquid Pipe Block–to–Expansion Valve Retaining Nut1410–
Refrigerant Discharge Hose Block–to–Condenser Retaining Nut1612–
Refrigerant Discharge Hose Block–to–Compressor Retaining Nut3324–
Evaporator Core Cover Screws1.2–11
Heater Core Housing–to–Evaporator Housing Retaining Screws1.2–11
Suction Hose Block–to–Compressor Retaining Nut3324–
Suction Hose Support Clamp–to–Longitudinal Member Bolt8–71
Suction Hose Support Clamp–to–Engine Bracket Bolt (1.4D, 1.6D only)4–35
Suction Hose Support Clamp–to–Engine Bracket Bolt (1.8D, 2.0D only)1410–
Suction Hose Block–to–Expansion Valve Retaining Nut1410–
(Receiver Dryer) Band Clamp Bolt5–44
Receiver Dryer–to–Condenser Pipe Block Bolt5–44
Upper Compressor–to–Bracket Mounting Bolts (1.4D, 1.6D only)2518–
Lower Compressor–to–Bracket Mounting Bolts (1.4D, 1.6D only)4533–
Front Compressor–to–Bracket Mounting Bolts (1.8D, 2.0D only)3526–
Rear Compressor–to–Bracket Mounting Bolts (1.8D, 2.0D only)2015–
Condenser Mount Bolts4–35
(Compressor) Clutch Plate and Hub Assembly Retaining Nut1713–
(Compressor) Through Bolts10–89

7B – 10IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
DAEWOO V–121 BL4
PRESSURE–TEMPERATURE RELATIONSHIP OF R–134A
Temperature
°C (°F)*Pressure
kPa (psi)*Temperature
°C (°F)*Pressure
kPa (psi)*
–8 (17.6)113.1 (16.4)9 (48.2)296.2 (43.0)
–7 (19.4)121.5 (17.6)10 (50.0)309.6 (44.9)
–6 (21.2)130.2 (18.9)15 (59.0)383.7 (55.7)
–5 (23.0)139.1 (20.2)20 (68.0)467.7 (67.8)
–4 (24.8)148.4 (21.5)25 (77.0)567.5 (82.3)
–3 (26.6)157.9 (22.9)30 (86.0)667.8 (96.9)
–2 (28.4)167.6 (24.3)35 (95.0)785.6 (113.9)
–1 (30.2)177.8 (25.8)40 (104.0)916.4 (133.0)
0 (32.0)188.2 (27.3)45 (113.0)1 062.2 (154.0)
1 (33.8)198.8 (28.8)50 (122.0)1 222.1 (177.2)
2 (35.6)209.9 (30.4)55 (131.0)1 398.2 (202.8)
3 (37.4)221.2 (32.1)60 (140.0)1 589.6 (230.5)
4 (39.2)232.9 (33.8)65 (149.0)1 799.0 (260.9)
5 (41.0)245.0 (35.5)70 (158.0)2 026.6 (293.9)
6 (42.8)257.4 (37.3)75 (167.0)2 272.2 (329.5)
7 (44.6)269.8 (39.1)80 (176.0)2 544.0 (369.0)
8 (46.4)282.9 (41.0)––
* All calculated values are rounded to one decimal place.
Evaporator Range: From –7 to 7°C (19.4 to 44.6°F), the temperatures represent the gas temperatures inside the coil
and not on the coil surfaces. Add 2 to 6°C (4 to 11°F) to the coil and air–off temperatures.
Condenser Range: From 45 to 70°C (113°to 158°F), the temperatures are not ambient. Add 19 to 22°C (34 to 40°C)
to the ambient temperatures for proper heat transfer. Then refer to the pressure chart.
Example:
32°C (90°F) Ambient temperature + 22°C (40°F) = 54°C (130°F)
Condenser temperature, which yields 1 379 kPa (200 psi), based on 50 km/h (31 mph) airflow.

MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B – 19
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
GENERAL A/C SYSTEM SERVICE PROCEDURES
O–RING REPLACEMENT
Important : Even though O–rings may look identical, it is
extremely important that only recommended service re-
placement air conditioning O–rings be used or excessive
leakage of refrigerant may occur.
Important : Always slip the O–ring onto the flange tube to
ensure proper locating and sealing.
Install new Daewoo–approved service replacement air
conditioning (A/C) O–rings whenever a joint or a fitting is
disassembled, except when the O–rings are provided on
new components.
When replacing O–rings on an A/C component or a joint
connection, the fitting design should be identified to en-
sure installation of the correct air conditioning service re-
placement O–ring. Some joint connections and compo-
nents will implement a ”captured” O–ring design fitting that
uses a groove to retain the O–ring. Others do not have a
groove and use a ”non–captured” or ”standard” O–ring.
Assembly and tightening procedures are the same for
both designs, but the O–rings are different.
Notice : Before installation, verify that both O–rings and
fittings have not been nicked or deformed. Deformed or
nicked parts must be replaced. Failure to use the proper
service replacement parts and procedures may result in
excessive refrigerant leakage.
HANDLING REFRIGERANT
CAUTION : Always work in a well–ventilated area and
avoid breathing any refrigerant fumes. If you have dif-
ficulty with breathing, seek medical attention immedi-
ately. If refrigerant comes in contact with any part of
your body, flush the exposed area with water. If a rash
or pain develops, seek medical attention.
Air conditioning systems contain refrigerant. This is a
chemical mixture which requires special handling proce-
dures to avoid personal injury.
Always wear goggles and wrap a clean cloth around the
fittings, the valves and the connections when performing
work that involves opening the refrigerant system. Do not
weld or steam clean on or near any vehicle–installed air
conditioning lines or components.
All refrigerant drums are shipped with a heavy metal screw
cap. The purpose of the cap is to protect the valve and the
safety plug from damage. It is good practice to replace the
cap after each use of the drum.If it is necessary to transport or carry any container of re-
frigerant in a vehicle, do not carry it in the passenger
compartment.
HANDLING OF REFRIGERANT LINES
AND FITTINGS
Notice : Using too low or too high torque when tightening
a fitting can result in loose joints or deformed joint parts.
Both conditions can result in refrigerant leakage.
S Keep all metal tubing lines free of dents or kinks.
Any line restrictions will cause the loss of system
capacity.
S Never bend a flexible hose line to a radius of less
than four times the diameter of the hose.
S Never allow a flexible hose line to come within 65
mm (2–1/2 inches) of the exhaust manifold.
S Inspect flexible hose lines regularly for leaks or
brittleness.
S Replace flexible hose lines with new lines if you find
signs of deterioration or leaking.
S Discharge all refrigerant of the refrigeration system
before disconnecting any fitting in the refrigeration
system.
S Proceed very cautiously regardless of the gauge
readings.
CAUTION : Keep your face and your hands away from
the fitting so that you will not be injured if there hap-
pens to be liquid refrigerant in the line.
S Open the fittings very slowly.
S If you notice pressure when you loosen a fitting,
allow the pressure to bleed off as described under
”Discharging, Adding Oil, Evacuating, and Charging
Procedures for A/C System” in this section.
S Cap or tape any refrigerant line immediately after it
is opened. This will prevent the entrance of mois-
ture and dirt, which can cause internal compressor
wear or plugged lines in the condenser, the evapo-
rator core, the expansion valve, or the compressor
inlet screens.
Important : Use two proper wrenches to connect the O–
ring fittings.
S Back up the opposing fitting to prevent distortion of
the connecting lines or the components.
S Back up both the swagged fitting on the flexible
hose connections and the coupling to which it is
attached with two wrenches to prevent turning the
fitting and damaging the ground seat.
S Keep the O–rings and the seats in perfect condi-
tion. A burr or a piece of dirt may cause a refriger-
ant leak.