Instruction No. 09-17382

19/06/2001

Air Conditioning Fitting Instructions (6VD1 Models)

2001 Rodeo

(Including LT Sport)

Kit No. 92144363 (4 x 2 & 4 x 4) AS-36-GR60P

Division of GM Holden Ltd

ABN 84 006 893 232

CONTENTS
 PREPARATION 
 POINTS TO CHECK 
 INSTALLATION PRECAUTIONS 
 LABELS 
 SPECIFICATIONS 
 TIGHTENING TORQUES 
 PARTS TO BE REMOVED (INTERIOR) 
 AIR CONDITIONER SWITCH INSTALLATION 
 EVAPORATOR INSTALLATION 
 EVAPORATOR DRAIN HOSE INSTALLATION 
 PARTS TO BE REMOVED (ENGINE COMPARTMENT) 
 COMPRESSOR MOUNT INSTALLATION 
 COMPRESSOR INSTALLATION - PART ONE 
 CONDENSER FITMENT 
 FDR BRACKET, FDR AND
PRESSURE SWITCH WIRING INSTALLATION 
 DISCHARGE AND SUCTION HOSE INSTALLATION 
 COMPRESSOR INSTALLATION - PART TWO 
 COMPRESSOR CLUTCH CONNECTOR 
 COMPRESSOR DRIVE BELT INSTALLATION 
 LIQUID TUBE INSTALLATION 
 RELAY INSTALLATION 
 WIRING DIAGRAM 
 EVACUATION AND CHARGING PROCEDURE 

Preparation

Before starting the installation, read these

fitting instructions through, then follow the

sequence from Page 1 through to the

evacuation and charging procedure.

Points to check

a. Check and note any damage to the

vehicle interior or exterior.

b. Check and note operation of all

accessories, horn, lights, etc.

c. Check operation of engine cooling

system.

d. Inspect the kit for damaged parts

before starting the installation.

Installation Precautions

a. This system has been designed to suit

standard wiring by the vehicle manufac-

turer, the wiring of non-approved

accessories could result in malfunction

of the unit or damage to the vehicle.

b. Disconnect the negative lead from

the battery.

c. Route all refrigerant hoses, tubes

and wiring harnesses to avoid fouling.

d. To prevent entry of moisture or foreign

material into the system do not remove

shipping plates or plugs until

immediately before installation of

components.

SIZE TUBE THREAD TORQUE

O.D. -UNF N.M.

No. 5 5/16 9/16-18 13-15.0

No. 6 3/8 5/8-18 11.0-16.0

No. 8 1/2 3/4-16 18.0-23-0

No. 10 5/8 7/8-14 24.0-30.0

No.12 3/4 1-1/6-12 30.0-38.0

Note: This system uses a

specific Lubricating oil-

Polyalkylene Glycol (PAG). This oil

is highly hygroscopic, adhere

to Step D

e. O-Rings do not require lubrication as

they are pre-fitted to most tubes/hoses

and pre-lubricated with silicon at the

manufacturer.

Use two spanners when tightening fittings.

g. Use torques specified.

h. As this R134a Air Conditioning system

uses no sightglass in the filter drier,

refrigerant must be filled by weight

scales or dial-a-charge to the specified

amount only quoted in the rear section

of these instructions.

i. Use only specific R134a charging

equipment and leak detector.

Torque Chart - Hose & Tube Fittings

Labels

A/C Kit Part

Number:

Location —

Glove box

interior (The kit

number on this

label is to be

used for

reference when ordering A/C spare parts.

Warning

Label:

Location —

Radiator

support

Panel.

Warranty

Plate:

Location —

1 x Owners

Manual

1 x Firewall

(Use ball

point

pen-mark label with relative information).

Refrigerant

Label:

Location —

Radiator

support panel

- top LH side.

Specifications

Compressor — Delphi SP 10 (10 piston)

Clutch — 12 Volt, 6 Poly Vee

A/C Belt Size — 2300mm.

Condenser — Dual Pass Serpentine.

Evaporator — Laminated plate and fin design.

TX Valve — 1.5 ton externally equalised with charcoal dampening.

Pressure Switch — High Pressure Compressor Off 2940 ± 196kpaG.

Low Pressure Compressor Off 205 ± 19.6kpaG.

Refrigerant Capacity — R134a 750 ± 25 grams.

Filter Drier Receiver (FDR) — XH9 Desiccant - No sight glass.

Lubricating Oil — Sanden SP 10

‘O’ Ring Material — HNBR Colour - Green.

Compressor Oil Charge

(when first installed new) — 150cc (total system capacity).

Tightening Torques

Condenser Pad Fitting Bolts — 7 - 10NM

Filter Drier Pipe Connections — 13 - 15NM

Liquid Tube to Evaporator Pipe Connection — 13 - 15NM

Suction Tube to Evaporator Pipe Connection — 24 - 30NM

Suction Hose to Compressor Pad Fitting Bolt — 20 - 30NM

Discharge Hose to Compressor Pad Fitting Bolt — 20 - 30NM

Compressor Mount Bracket to Engine Bolts — 40 - 50NM

Compressor Mounting Bolts — 40 - 50NM

Wheel Nuts (Aluminium Wheels) — 125NM

Wheel Nuts (Steel Wheels) — 125NM

1Parts to be Removed (Interior)

a. Glove box (2 screws).

b. Glove box support (2 bolts).

c. Upper glove box panel (4 screws).

d. Air transfer duct (unclip).

e. Resistor (discard transfer duct, metal

resistor backing plate and 2 screws).

f. Remove plastic wire retainer from R/H

lower 6mm stud.

g. Upper dash surround (7 screws, 2

plugs).

Heater Bezel

Knobs

Resistor

Discard

Air

Transfer

Duct

Glove Box

2Air Conditioner Switch Installation

a. Unclip heater control bezel and knobs

and push out and discard the A/C

blanking plug from the heater control

bezel.

b. Clip air conditioner switch into vacant

position in dash.

c. Reinstall heater control bezel and

knobs (4).

A/C

Switch

Heater

Control Bezel

Upper Glove

Box Panel

Glove Box

Support

Upper Dash Surround

;;;

;;

Evaporator Installation

a. Remove and discard (2) firewall rubber

blanking plugs.

b. Fit the original blower resistor to evaporator

case with (2) new self tapping screws.

c. Remove right lower blower case 6mm

nut and retain.

Evaporator Drain Hose Installation

a. From the engine bay install the drain hose

to the evaporator drain tube. Route drain

hose away from the exhaust manifold and

behind the brake tube as shown.

b. Re-install all parts.

CAUTION

Do not

overtighten

evaporator

mounting

nuts as stud

damage will

occur.

d. Install evaporator assembly into position

and retain with (1) supplied 6mm nut, (1)

original 6mm nut and (1) 6mm PAINT

STRIPPING nut and 7mm flat washer for

the upper mounting.

e. Connect evaporator wiring electrical plug

to original harness in vehicle, then

reconnect blower resistor electrical plug.

(2) Self

Tapping

Screws

Blower

Resistor

(1) 6mm Nut

(1)

Original

6mm Nut

Evaporator

(1) 7 x 25mm

Flat Washer

(1) 6mm Paint

Stripping Nut

Original

Harness

Evaporator Pipe

Blanking Grommet

Evaporator Drain

Hose Plug

Evaporator

Wiring Plug

Blower

Resistor Plug

Brake

Tube

Drain

Hose

Chassis

Rail

Exhaust

Manifold

g. Remove and discard the front bracket

and bolt used to secure the wiring

harnesses to the L/H side of the engine

block (as shown). Retain rear bracket

and retaining bolt.

5Parts to be Removed

(Engine Compartment)

a. Grille (8) clips and (1) screw

b. Bonnet lock support (3) bolts.

c. Drive belt (discard).

d. Place vehicle on hoist or jack up front

and place on stands.

e. Left hand front wheel.

f. Detach LH side wheel arch rubber splash

panel.

Drive Belt

(Discard) Left Hand

Front Wheel

Grille

Bonnet

Lock

Support

Discard

M6 Bolt

Retain

Wiring Harness

Front Bracket

(Discard)

Wiring Harness

Rear Bracket

(Retain)

6Compressor Mount Installation

b. Secure the compressor mounting

bracket through the left hand side wheel

arch opening to the engine block using

(2) M10 x 30 washer faced bolts and (1)

M10 x 80 washer faced bolt.

Torque to 40-50Nm.

b. Fit wiring harness bracket to

compressor mounting bracket using

original bolt.

7Note: DO NOT secure the upper

compressor mounting bolt at this stage.

Later in the fitting procedure you will be

required to fit the suction and discharge

hoses then swing the compressor into

position and secure upper mount.

Compressor Installation - Part One

a. Assemble the compressor to the

compressor mounting bracket through

the left hand front wheel arch.

b. Fit the (2) M8 x 30 washer faced bolts to

the lower mounting lugs Leave loose at

this stage.

(1) M10 x 80

Washer Faced Bolt

Compressor

Mounting Bracket

Compressor

Mounting Bracket

Compressor

(2) M8 x 30

Washer Faced Bolts

Lower

Mounting Lugs

DO NOT

SECURE UPPER

MOUNTING

BOLT AT THIS

STAGE

Wiring Harness

Bracket

Original

Bolt

(2) M10 x 30

Washer

Faced Bolts

CAUTION

Be careful

not to

cause

radiator

face

damage

when

installing

condenser

Condenser Fitment

a. Insert condenser into position ensuring

mounting cushions are in position and

secure with (2) 6 x 30mm bolts in the

position shown.

6 x 30mm Bolt

Condenser

Mounting Cushions

6 x 30mm

Bolt

9FDR Bracket, FDR and Pressure

Switch Wiring Installation

a. Fit FDR bracket to radiator support panel

using (1) M6 x 12mm washer faced bolt

and (1) existing 8mm washer faced nut.

b. Insert filter drier into bracket, position as

indicated below and fit (1) M6 x 30mm

washer faced clamping bolt.

NOTE: Do not tighten FDR clamping bolt

at this stage.

c. Connect pressure switch to loom plug.

NOTE: Ensure that the filter drier is fitted

with the pressure switch facing back

towards the engine.

FDR

Bracket

Existing Nut M6 x 30

Washer

Faced Bolt

M6 x 12

Washer

Faced Bolt

Pressure Switch Plug

(Facing Back Towards Engine)

Pressure Switch

Connection

OUT

10 Discharge & Suction Hose

Installation - 4 x 2 & 4 x 4 Vehicles

a. Pass the discharge tube through the

radiator support panel.

b. Connect the discharge hose to the

condenser using (1) M6 x 60mm washer

faced bolt.

c. Secure the discharge tube to the

radiator support panel using (1)

mounting bracket, (1) clamp, (2) M6 x 12

bolts and (1) M6 nut.

NOTE

Tube

tightening

torques are

indicated

on Page 1

All 'O' rings

are pre

lubricated

at the

manufacturer

d. Connect the suction hose to the

evaporator outlet tube and route to

compressor.

e. Remove the compressor discharge (D)

port cover (discard cover and bolt).

Install the discharge hose pad fitting to

the compressor and secure with (1) M8 x

30 washer faced bolt.

f. Remove the compressor suction port (S)

cover (discard cover and bolt). Install the

suction hose pad fitting to the

compressor and secure with (1) M8 x 30

washer faced bolt.

Suction Hose

(to Evaporator Outlet)

Suction Hose

Discharge

Hose

Discharge

Hose

M6 x 12

Bolt

‘P’ Clamp

M6 x 60

Washer Faced Bolt

Discharge Tube

Mounting Bracket M6 x 12

Bolt &

M6 Nut

Discharge Hose

(to Condenser)

(1) M8 x 30

Washer Faced

Bolt

(1) M8 x 30

Washer Faced Bolt

D D

12 Compressor Clutch Connector

a. Connect compressor clutch wire to the

vehicle harness. The vehicle harness

connector is taped back on vehicle

wiring harness.

Cable tie to avoid fouling.

Compressor Installation - Part Two

4 x 2 & 4 x 4 Vehicles

a. Swing compressor towards top

compressor mounting bracket lug and

secure as shown using (1) M8 x 30

washer faced bolt. Torque to 20 - 30Nm.

b. Tighten lower compressor mounting

bolts (previously loosely fitted).

Torque to 20 - 30Nm.

Vehicle Harness

Connector

(1) M8 x 30

Washer Faced Bolt

Compressor

Lower Compressor

Mounting Bolts

Compressor

Vehicle Harness

Connector

14 Compressor Drive Belt Installation

a. Fit new drive belt and route as shown.

13 Breather Tube Harness

Re-location - 4 x 4 Vehicles Only

a. Re-locate the breather tube harness, by

hand, to under the chassis mounting as

shown.

Idler Pulley

Alternator

Pulley

Tensioner

Pulley

Crankshaft

Pulley

Compressor

Pulley

Power Steering

Pulley

Water Pump

Pulley

Breather Tube

Harness

(Over Bracket) Chassis

Mounting

Bracket

Viewed from

Underneath

Vehicle

Breather Tube

Harness

(Under Bracket)

Chassis

Mounting

Bracket

15 Liquid Tube Installation

a. Install liquid tube (A) between the FDR

inlet fitting and the condenser pad

fitting. Secure to the condenser using (1)

M6 x 60 washer faced bolt.

Note: Ensure liquid tube ‘A’ is parallel to

the condenser tubes as this tube is seen

through the grille.

b. Install liquid tube (B) from the engine

bay through the radiator support panel

and connect to the FDR outlet fitting and

the evaporator inlet tube.

c. Fit the plastic retaining clip into the

existing bracket on the LH side inner

guard to secure liquid tube (B).

d. Fit the liquid tube support bracket behind

the washer bottle lug using existing bolt.

Secure liquid tube (B) to the mounting

bracket using (1) clamp and (1) M6 x 12

bolt.

e. Tighten the FDR bracket retaining bolt.

NOTE

All 'O' rings

are pre

lubricated

at the

manufacturer

NOTE

Tube

tightening

torques as

indicated

on Page 1

Liquid Tube (A)

(Ensure tube is

parallel with

condenser

tubes) Liquid Tube (B)

Liquid Tube (B)

Plastic Clip

Liquid Tube

Retaining

Bracket

(1) M6 x 12

Bolt

Existing Bolt Clamp

Existing

Bracket

FDR

(1) M6 x 60

Washer Faced Bolt

16 Relay Installation

a. Locate fuse and relay panel, RHS inner

guard, remove cover and fit (2) relays

(large and small) supplied to positions

shown.

Fuse/Relay

Panel

Relay (Small)

Relay (Large)

Wiring Diagram

CEFG

LOW HIGH

REFRIGERANT

RECOVERY

UNIT VACUUM

PUMP

SPECIFIED CHARGE 750 +/- 25 GRAMS

NOTE: 1. Gloves and safety glasses

must be warn.

2. Work in a well ventilated

area.

3. Do not smoke near

refrigerant.

4. Aviod PAG oil contacting

paint work. Wash off

immediatly.

5. Do not smoke near

refrigerant.

Start vacuum pump, open valve F,

open valves A & C low pressure

filling hose.

High side

gauge reads

below zero

High side

gauge not

below zero

Blockage or leak

evident in system.

find cause and

rectify.

Leave valves A, C, & F open. Slowly

open high side valves B & D.

Evacuate system to 6 kpa

absolute.

Close valves A, B & F.

System must maintain 6 kpa

-absolute for a minimum

of 15 mins.

Low pressure gauge

needle steady

Recover refrigerant from

system, open valves A, B, C,

D, E and H. After the recovery

procedure close valve E. Open

valve F and continue the evacuation

procedure for a minimum of 15 mins

then close valves A, B & F. Turn

pump off. (Refer Fig. 1)

Low pressure gauge

needle rises.

Continue evacuation

for 15 mins.

Partially charge system

with 200 grams of

refrigerant

Partially charge system with

200 grams of refrigerant

through high filling hose.

Locate leakage using an

electrical leak detector.

Check on the underside of

all fittings and components

Recover refrigerant from

system open valves A, B, C,

D, E, & H. (Refer Fig. 1)

Repair leak source

Continue with evacuation

and charging procedure

as per steps 1-3

NOTE: Indicates stop tap or valve-fit these

whenever a hose has to be removed

Fig. 1

Check for leakage using

an electronic leak

detector

STEP 1

EVACUATION

STEP 2

LEAK TESTING

EFG

LOW

HIGH

REFRIGERANT

RECOVERY

UNIT

VACUUM

PUMP

LOW

HIGH

REFRIGERANT

RECOVERY

UNIT

First Aid: In the event of R134a contacting the

eye, carry out the folllowing procedure:-

1. Do not rub eye

2. Splash large quantities of water into the eye to

raise the temperature.

3. Continue to irrigate the eye for 15-20 mins.

4. Take patient without delay to hospital or

physician.

5. Do not attempt to treat yourself.

Start engine set to fast idle.

Activate A/C switch. Set

controls to maximum cooling

and high fan speed.

Open low side valves, A & C

slowly and complete the

charging process (If required).

Caution: do not allow more than

275 kpa to register on the low

side gauge during charging.

Close all valves and taps.

Remove high and low filling hoses,

make sure valves C & D are closed.

Connect high side filling hose to

recovery unit inlet side. Open valves

A, B & D. Switch on recovery machine

and remove all refrigerant in filling

hoses. (Refer Fig. 3)

Carry out performance testing.

Refer appropriate workshop

manual for specifications.

Fig. 3

Fig. 2

Warning: Never run compressor

without refrigerant in

system as the compressor

relies on refrigerant/oil flow.

Any oil displaced during the

refrigerant recovery process

must be replaced in the

system before charging can

commence. The R134a

system uses P.A.G. (poly-

alkaline glycol) lubricating

oil. Use specified oil type.

Warning: Never charge system

through the high side

with the compressor

running.

Open high side valves B, D & G.

Allow as much refrigerant as

possible to enter system, but

do not let more than the specified

amount enter the system.

Close valves B & D. rotate

compressor front plate 12

revolutions to ensure no

liquid is trapped in the

compressor.

STEP 3

CHARGING

SYSTEM