Drain, evacuate and recharge air conditioning, check for proper operation and check for leaks

AR83.30-S-1760S

Drain, evacuate and recharge air conditioning, check for proper operation and check for leaks

20.05.2015

Model

636, 639

with code HH4 (THERMOTRONIC automatic climate control)

Model

636, 639

with code HH9 (Air conditioner, automatic heater control)

Modification notes

12.08.2014

Refrigerant compressor oil top-off quantity when replacing refrigerant compressor with filter/drier

BF83.00-N-1002-01F

1

Air conditioning service unit

1.1

Manometer battery

1.2

Schrader valve

 Danger !

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

 Danger !

Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant.

Do not perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been drained.

AS83.00-Z-0001-01A



Procedure for a damaged or leaky air conditioning system

AH83.30-N-0004-01A



Protect air conditioning circuit and components from moisture when carrying out repair work

AH83.30-N-0005-01A



Notes on handling refrigerant R134a

AH83.30-N-0003-01A

Draining

1

Connect air conditioning service unit (1) with the connectors to the Schrader valves (1.2) of the refrigerant lines

 Attach manometer battery (1.1) at an appropriate location. For all operation steps, note operator's manual for respective air conditioning service unit (1).

 Commercially available devices/tools
Air conditioning service unit

2

Drain air conditioning system

 Note operator's manual for respective air conditioning service unit (1).

3

Drain separated compressor oil for refrigerant compressor from the inspection glass of the air conditioning service unit (1) and determine exact quantity

 Drained quantity must be replaced by fresh compressor oil for refrigerant compressor.

4

Install new desiccant cartridge

Only perform if the refrigerant circuit was opened.

AR83.30-S-6521S

Clean/evacuate

5

Clean and evacuate air conditioning system

6

Add compressor oil for refrigerant compressor



Compressor oils (specification 362.0)

BB00.40-P-0362-00A

 The exact quantity determined when drained must be used.

 MODEL 636, 639Total filling capacity for refrigerant compressor oil for new system (in A/C compressor)

*BF83.00-N-1001-01F

 MODEL 636, 639Refrigerant compressor oil refill quantity when replacing A/C compressor with filter or drier

*BF83.00-N-1002-01F

 MODEL 636, 639Refill quantity of refrigerant compressor oil when replacing condenser

*BF83.00-N-1003-01F

 MODEL 636, 639Refill quantity of refrigerant compressor oil when replacing front evaporator

*BF83.00-N-1004-01F

 MODEL 636, 639Refill quantity of refrigerant compressor oil when replacing rear evaporator

*BF83.00-N-1005-01F

 MODEL 636, 639Refrigerant compressor oil refill quantity when replacing filter or drier

*BF83.00-N-1006-01F

 MODEL 636, 639Refill quantity of refrigerant compressor oil when replacing a refrigerant line

*BF83.00-N-1007-01F

 MODEL 636, 639Refrigerant compressor oil refill quantity for suddenly drained A/C system (line break)

*BF83.00-N-1008-01F

Filling

7

Charge air conditioning system

 MODEL 636, 639Total filling capacity - refrigerant

*BF83.00-N-1009-01F



Remove

8

Remove lower engine compartment paneling

MODEL 636 MODEL 639.7##/8## ## as of 055347

AR61.20-S-1105S



Check

9

Check air conditioning system for leaks with leak detector



Install

10

Attach lower engine compartment paneling

MODEL 636 MODEL 639.7##/8## ## as of 055347

AR61.20-S-1105S



Check

 Danger !

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

11

Check air conditioning for proper operation

 Run engine for about 4 minutes at idle speed and check all the component functions which are of relevance for proper operation of the air conditioning.

 Air conditioning

Number

Designation

MODEL 636, 639 with CODE HH4 MODEL 636, 639 with CODE HH9

MODEL 636, 639.7/8 with CODE HZ7

BF83.00-N-1001-01F

Total filling capacity for refrigerant compressor oil for new system (in A/C compressor)

cm3

190

190

Sheet

BB00.40-P-0362-00A

BB00.40-P-0362-00A

 Air conditioning

Number

Designation

MODEL 636, 639 with CODE HH4 MODEL 636, 639 with CODE HH9

MODEL 636, 639.7/8 with CODE HZ7

BF83.00-N-1002-01F

Refrigerant compressor oil refill quantity when replacing A/C compressor with filter or drier

cm3

20

20

Sheet

BB00.40-P-0362-00A

BB00.40-P-0362-00A

 Air conditioning

Number

Designation

MODEL 636, 639 with CODE HH4 MODEL 636, 639 with CODE HH9

MODEL 636, 639.7/8 with CODE HZ7

BF83.00-N-1003-01F

Refill quantity of refrigerant compressor oil when replacing condenser

cm3

20

20

Sheet

BB00.40-P-0362-00A

BB00.40-P-0362-00A

 Air conditioning

Number

Designation

MODEL 636, 639 with CODE HH4 MODEL 636, 639 with CODE HH9

MODEL 636, 639.7/8 with CODE HZ7

BF83.00-N-1004-01F

Refill quantity of refrigerant compressor oil when replacing front evaporator

cm3

40

40

Sheet

BB00.40-P-0362-00A

BB00.40-P-0362-00A

 Air conditioning

Number

Designation

MODEL 636, 639 with CODE HH4 MODEL 636, 639 with CODE HH9

MODEL 636, 639.7/8 with CODE HZ7

BF83.00-N-1005-01F

Refill quantity of refrigerant compressor oil when replacing rear evaporator

cm3

–

20

Sheet

BB00.40-P-0362-00A

BB00.40-P-0362-00A

 Air conditioning

Number

Designation

MODEL 636, 639 with CODE HH4 MODEL 636, 639 with CODE HH9

MODEL 636, 639.7/8 with CODE HZ7

BF83.00-N-1006-01F

Refrigerant compressor oil refill quantity when replacing filter or drier

cm3

10

10

Sheet

BB00.40-P-0362-00A

BB00.40-P-0362-00A

 Air conditioning

Number

Designation

MODEL 636, 639 with CODE HH4 MODEL 636, 639 with CODE HH9

MODEL 636, 639.7/8 with CODE HZ7

BF83.00-N-1007-01F

Refill quantity of refrigerant compressor oil when replacing a refrigerant line

Front line

cm3

10

10

Rear line

cm3

–

15

Sheet

BB00.40-P-0362-00A

BB00.40-P-0362-00A

 Air conditioning

Number

Designation

MODEL 636, 639 with CODE HH4 MODEL 636, 639 with CODE HH9

MODEL 636, 639.7/8 with CODE HZ7

BF83.00-N-1008-01F

Refrigerant compressor oil refill quantity for suddenly drained A/C system (line break)

cm3

65

65

Sheet

BB00.40-P-0362-00A

BB00.40-P-0362-00A

 Air conditioning

Number

Designation

MODEL 636, 639 with CODE HH4 MODEL 636, 639 with CODE HH9

MODEL 636, 639.7/8 with CODE HZ7

BF83.00-N-1009-01F

Total filling capacity - refrigerant

Body length A1

g

550

840

Body length A2

g

550

840

Body length A3

g

550

870

Sheet

BB00.40-P-0361-00A

BB00.40-P-0361-00A