Instruction No. 09-17379 Kit AS-38-GR40P
Air Conditioning Fitting Instructions (C22NE Models)
2001 Rodeo
2.2 Litre Petrol
Kit No. 92144691 18/05/2001
HOLDEN SERVICE PARTS OPERATIONS
Division of GM Holden Ltd
ABN 84 006 893 232
CONTENTS
PREPARATIONS
POINTS TO CHECK
INSTALLATION PRECAUTIONS
LABELS
SPECIFICATIONS
TIGHTENING TORQUES
PARTS TO BE REMOVED (INTERIOR)
AIR CONDITIONER SWITCH INSTALLATION
EVAPORATOR INSTALLATION
PARTS TO BE REMOVED (ENGINE COMPARTMENT)
MOUNT AND DRIVE INSTALLATION
MOUNT AND DRIVE INSTALLATION (DRIVE BELT)
CONDENSER FITMENT
FDR BRACKET AND FDR INSTALLATION
DISCHARGE AND SUCTION HOSE INSTALLATION
LIQUID TUBE INSTALLATION
FDR PRESSURE SWITCH CONNECTION
RELAY INSTALLATION
WIRING DIAGRAM
EVACUATION AND CHARGING PROCEDURE
3
Preparation
Before starting the installation, read these
fitting instructions through, then follow the
sequence from Page 1 through to the
evacuation and charging.
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.
f.
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 —SANDEN TRS090 (Scroll Type) with rubber
dampened clutch.
Clutch —12 Volt.
A/C Belt Size —915 13A
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.
Thermal Protection —Compressor cut out at 115°C.
Refrigerant Capacity —R134a 700 ± 25 grams.
Filter Drier Receiver (FDR) — XH9 Desiccant - No sight glass.
Lubricating Oil —PAG Sanden SP10.
‘O’ Ring Material —HNBR Colour - Green.
Compressor Oil Change
(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 Pipe Connection Bolt —20 - 30NM
Discharge Hose to Compressor Pipe Connection 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 (4 bolts).
c. Upper glove box panel (4 screws).
d. Duct (unclip).
e. Resistor (discard transfer duct, metal
resistor backing plate and 2 screws).
f. Remove and discard rubber plugs from
firewall.
g. Remove plastic wire retainer from R/H
lower 6mm stud.
h. Ash Tray (pull out).
i. Lower dash surround (pull out).
j. Upper dash surround (7 screws, 2 plugs).
Heater Bezel
Knobs
Ash Tray
Plugs
Resistor
Discard
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
Lower Dash Surround
Upper Glove
Box Panel
Glove Box
Support
Upper Dash Surround
3Evaporator Installation
a. Fit the original blo wer resistor to evaporator
case with (2) ne w self tapping scre ws .
b. Remove right lower blower case 6mm nut
and retain.
e. Connect evaporator wiring electrical plug
to original harness in vehicle, then
reconnect blower resistor electrical plug.
fRoute drain tube away from exhaust
pipe.
gReinstall all parts.
CAUTION
Do not
overtighten
evaporator
mounting
nuts as stud
damage will
occur.
c. 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.
d. Install drain tube.
(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
Blower Resistor Plug
Original Harness
Evaporator
Wiring Plug
4Parts to be Removed
(Engine Compartment)
a. Grille (8) clips and (1) screw
b. Bonnet lock (2) bolts and bonnet lock
support (3) bolts.
c. Power steering drive belt (retain).
d. Air cleaner cover and intake air transfer
duct (4) clips and (2) clamps.
Power Steering
Drive Belt
(Retain)
Air Cleaner Cover
Intake Air Transfer
Duct (2 Clamps)
Grille
Bonnet
Lock
Support
Bonnet
Lock
5Mount and Drive Installation
a. Assemble the idler pulley to the
compressor mounting brack et using (1)
M8 x 100 bolt and spring washer, (1) idler
(3) M10 x 25 Bolts
Idler Pulley
Spacer
M8 x 100 Bolt &
Spring Washer
Idler Pulley
Adjusting Bolt
Washer
M10 Nut
Compressor
Mounting
Bracket
Compressor
Vehicle Harness
Connector
Patch
Harness
(4) M10 x 35 Bolts
& (4) M10 Nuts
b. Connect patch harness (09-16308)
between compressor and vehicle wiring
connector (located near engine
temperature switches).
a. Install the compressor using (4) M10 x 35
bolts and (4) M10 nuts .
pulley adjusting bolt, (1) spacer, (1)
washer and (1) M10 n ut as shown.
b.
Fit compressor mounting brac ket to the
v ehicle using (3) M10 x 25 washer f aced bolts .
6Mount and Drive Installation (Drive Belt)
a. Fit new driv e belt and route as shown.
b. Refit pow er steering pump drive belt.
Alternator
Pulley
Tensioner
Pulley
Crankshaft
Pulley
Compressor
Pulley
Compressor
Drive Belt
Power Steering
Pump Drive
Belt
Power Steering
Pulley
Water Pump
Pulley
7
10
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
8FDR Bracket, FDR and Pressure
Switch Wiring
a. Fit FDR bracket to radiator support panel
using (1) M6 x 12mm bolt and (1)existing 8mm washer faced nut.
b. Insert filter drier into bracket, position as
indicated below and fit clamping bolt (1)
M6 x 30mm.
NOTE: Do not tighten mounting bolt at
this stagec. Connect pressure switch to loom plug
(Refer to page 14(11) for connectorreplacement).NOTE: Ensure that the filter drier is fittedwith the pressure switch facing back
towards the engine.
FDR
FDR
Bracket
Existing Nut M6 x 30 Bolt M6 x 12
Bolt
Pressure Switch Plug
(Facing Back Towards Engine)
Pressure Switch
Connection
(Refer to
page 14(11)
for connector
replacement)
IN
OUT
9
12
Discharge & Suction Hose
Installation
a. Pass the discharge tube through the
radiator support panel.
b. Connect the suction hose to the
e vapor ator outlet tube and route to
compressor.
c. Secure the suction hose and the
discharge hose to the compressor using
(2) M8 x 38 bolts.
Suction
Tube
Discharge
Tube (2) M8 x 38
Bolts
Compressor
Suction Hose
Discharge
Hose/Tube
Discharge
Hose/Tube
M6 x 12
Bolt & M6
Nut
M6 x 12
Bolt
M6 x 60
Washer
Faced Bolt
Discharge Tube
Mounting Bracket
Clamp
NOTE
Tube
tightening
torques as
indicated on
Page 1
All 'O' rings
are pre
lubricated
at the
manufacturer
d. Connect the discharge tube to the
condenser using (1) M6 x 60mm washer
f aced bolt.
e. Secure the discharge tube to the radiator
support panel using (1) mounting brac k et,
(1) clamp, (2) M6 bolts and (1) M6 nut.
10
NOTE
All 'O' rings
are pre
lubricated at
the
manufacturer
NOTE
Tube
tightening
torques as
indicated on
Page 1
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.
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 brack et 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.
Liquid Tube (A)
Liquid Tube (A)
Liquid Tube (B)
Liquid Tube (B)
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
11 FDR Pressure Switch Connection
a. Locate the pressure switch harness
taped to the engine bay harness behind
the LH front headlamp. Using a pointed
tool release the plastic tabs and carefully
remove the GREEN/WHITE and
GREEN/RED terminals from the
connector as shown.
12 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)
b. Fit the two (2) terminals,GREEN/WHITE
and GREEN/RED to the new
connector (supplied) in the correct
positions as shown.
c. Connect the new connector to the FDR
pressure switch.
d. Cable tie harness and unused connector
to avoid fouling.
Pointed Tool
Pull
Terminal
Out
Pointed Tool
Push
Locking
Tab
Downwards
Green/Red
Terminal
Green/Red &
Green White
Terminals
Green/White
Terminal
Existing A/C Harness
Connector (Not Used)
13 Wiring Diagram
FRAME
IGN
40A
A/C
10A
BLOWER
20A
BLOWER
MOTOR
RESISTOR
METER
CHARGE
A/C
SWITCH
CONTROL
LEVER
THERMO
RELAY
THERMO
MAGNETIC
CLUTCH
ECM
RELAY
A/C CLUTCH
PRESS.
SWITCH
MAIN
80A
IGNITION
SWITCH
HEATER
RELAY
IGN
50A
ENG
BODY
W/B
B/R
B/R
BACK
TURN
15A
METER
15A
FUSE
ENG.
FUSE
CHARGE
A/C
REQUEST
TO
ECM
B
L/R
L/W
L/B
L/RLL/Y
L/W
W/B
B
BR
W
W
B/R
G/R
G/W
G/B
W/B
GR/R
BR
BRBR
B/R
BR
W
W
OFF
M3
M2
H
L
14
CEFG
AB
D
H
LOW HIGH
REFRIGERANT
RECOVERY
UNIT VACUUM
PUMP
EVACUATION AND CHARGING PROCEDURE
SPECIFIED CHARGE 700 +/- 25 GRAMS
NOTE: 1. Gloves and safety glasses
must be worn.
2. Work in a well ventilated
area.
3. Do not inhale refrigerant.
4. Avoid PAG oil contacting
paintwork. Wash off
immediately.
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
Fig. 1
Check for leakage using
an electronic leak
detector
STEP 1
EVACUATION
STEP 2
LEAK TESTING
14
C
EFG
A
B
D
H
LOW
HIGH
REFRIGERANT
RECOVERY
UNIT
VACUUM
PUMP
C
A
B
D
H
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
— WARNING —
As the R134a systems run higher pressures
DO NOT exceed the specified amount as
component destruction will occur.