Filling the air conditioning
Precondition
The engine is switched off.
Heating and air conditioning system is switched off.
The refrigerant circuit is evacuated and tight.
Vehicle must be positioned on the ground.
Injury hazard!
- Note and follow safety instructions on containers.
- Avoid contact with refrigerant; wear safety goggles and hand protection.
- For additional information see: SAFETY INSTRUCTIONS FOR HANDLING REFRIGERANT and NOTES FOR REPAIR WORK ON AIR CONDITIONING .
Filling a raised vehicle will result in insufficient filling levels.
In some cases, Sanden SP-A2 refrigerant oil must be injected into the refrigerant circuit. See additional information.
- Determine the quantities of new refrigerant oil to be refilled:
In addition to the drawn off and recorded coolant oil level, add the following quantities (if applicable):
- Replenish refrigerant oil losses that have occurred over time according to the table:
TABLE 1 indicates the permitted loss of refrigerant after a specific period of time. There are no leaks. Refrigerant oil must not be topped up.
TABLE 2 indicates the coolant oil level which must be topped up after a specific period of time with an impermissible loss of refrigerant due to a leak.
Case 1: Loss of refrigerant as shown in TABLE 1 is not exceeded:
- Top up missing refrigerant
- Topping up of refrigerant oil is not permitted
Case 2: Loss of refrigerant as shown in TABLE 1 is exceeded:
- Top up missing refrigerant
- Refrigerant oil must be topped up additionally as per TABLE 2 .
| Table 1/case 1 | |||||
|---|---|---|---|---|---|
| Number of years since last filling | 0-1 | 1-2 | 2-3 | 3-4 | 4-5 |
| Permissible loss [g] → do not top up refrigerant oil | ≤ 30 | ≤ 60 | ≤ 90 | ≤ 120 | ≤ 150 |
| Table 2/case 2 | ||
|---|---|---|
| Number of years since last filling | Loss of refrigerant [g] | Top up quantity refrigerant oil |
| 0-1 | < 120 | 0 |
| 0-1 | 120-150 | 10 |
| 0-1 | > 150 | 20 |
| 1-2 | < 180 | 0 |
| 1-2 | 180-210 | 10 |
| 1-2 | > 210 | 20 |
| 2-3 | < 240 | 0 |
| 2-3 | 240-270 | 10 |
| 2-3 | > 270 | 20 |
| 3-4 | < 300 | 0 |
| -3-4 | 300-330 | 10 |
| 3-4 | > 330 | 20 |
| 4-5 | < 360 | 10 |
| 4-5 | > 360 | 20 |
- Add refrigerant oil as per the table if parts of the refrigerant circuit have been replaced:
Case 1: Part exchange as preliminary work for further work and part exchange due to creeping leakage (minor leak e.g. hairline crack)
Case 2: Part exchange due to sudden leakage (major leak, e.g. line disconnection caused by accident)
| Case 1 | Case 2 | |||
|---|---|---|---|---|
| Air conditioning compressor(1). | (1). | (1). | ||
| Evaporator | 10 ml | 35 ml | ||
| Air conditioning condenser without integrated desiccant insert | 20 ml | 35 ml | ||
| Air conditioning condenser with integrated desiccant insert | 40 ml | 55 ml | ||
| Desiccant insert/dryer flask | 20 ml | 55 ml | ||
| Per replaced refrigerant line | 10 ml | 35 ml | ||
| Safety pressure switch, gaskets | 0 ml | 0 ml | ||
|
||||
- Fill the determined coolant oil quantity into the refrigerant circuit.
- Fill the amount of refrigerant into the refrigerant circuit according to the nameplate.
- Disconnect the high pressure line and low pressure line on the vehicle.
- Drain the high pressure line and low pressure line.
- Once again close the refrigerant filler neck on the vehicle with the sealing caps.
Precondition
The service function must be active.
The engine is switched off.
Heating and air conditioning system is switched off.
The refrigerant circuit is evacuated and tight.
Vehicle must be positioned on the ground.
Injury hazard!
- Note and follow safety instructions on containers.
- Avoid contact with refrigerant; wear safety goggles and hand protection.
- For additional information see: SAFETY INSTRUCTIONS FOR HANDLING REFRIGERANT and NOTES FOR REPAIR WORK ON AIR CONDITIONING .
Filling a raised vehicle will result in insufficient filling levels.
In some cases, Sanden SP-A2 refrigerant oil must be injected into the refrigerant circuit. See additional information.
Check
- Check whether the rate of refrigerant loss as per TABLE 1 is exceeded.
TABLE 1 indicates the permitted loss of refrigerant after a specific period of time.
The system is not leaking.
| Table 1 | |||||
|---|---|---|---|---|---|
| Number of years since system last filled | 0-1 | 1-2 | 2-3 | 3-4 | 4-5 |
| Permissible loss [g] | ≤ 30 | ≤ 60 | ≤ 90 | ≤ 120 | ≤ 150 |
Result
» The rate of refrigerant loss as per Table 1 is not exceeded.
Measure
- Top up lost refrigerant.
Do not top up refrigerant oil.
Result
» The rate of refrigerant loss as per Table 1 is exceeded.
Measure
- Top up lost refrigerant.
Top up refrigerant oil according to TABLE 2 .
TABLE 2 indicates the amount of refrigerant oil to be added after a specific period of time in the case of an unacceptable loss of refrigerant due to a leak.
| Number of years since last filling | Loss of refrigerant [g] | Top up quantity refrigerant oil |
|---|---|---|
| 0-1 | < 120 | 0 |
| 0-1 | 120-150 | 10 |
| 0-1 | > 150 | 20 |
| 1-2 | < 180 | 0 |
| 1-2 | 180-210 | 10 |
| 1-2 | > 210 | 20 |
| 2-3 | < 240 | 0 |
| 2-3 | 240-270 | 10 |
| 2-3 | > 270 | 20 |
| 3-4 | < 300 | 0 |
| 3-4 | 300-330 | 10 |
| 3-4 | > 330 | 20 |
| 4-5 | < 360 | 10 |
| 4-5 | > 360 | 20 |
Check
- Check whether and why parts of the refrigerant circuit have been replaced.
Result
» Version A: Parts of the refrigerant circuit have been replaced as preliminary work for further work or due to gradual leakage (minor leak, e.g. hairline crack).
Version B: Parts of the refrigerant circuit have been replaced due to sudden loss of refrigerant (major leak, e.g. broken pipe due to accident).
Measure
- Add refrigerant oil according to table:
| Version A | Version B | |||
|---|---|---|---|---|
| Air conditioning compressor(1). | (1). | (1). | ||
| Evaporator | 10 ml | 35 ml | ||
| Air conditioning condenser without integrated desiccant insert | 20 ml | 35 ml | ||
| Air conditioning condenser with integrated desiccant insert | 40 ml | 55 ml | ||
| Desiccant insert/dryer flask | 20 ml | 55 ml | ||
| Per replaced refrigerant line | 10 ml | 35 ml | ||
| Safety pressure switch, gaskets | 0 ml | 0 ml | ||
|
||||
- Top up determined coolant oil level into the refrigerant circuit.
- Fill the amount of refrigerant as per the nameplate into the refrigerant circuit.
- Disconnect the high pressure line and low pressure line on the vehicle.
- Drain the high pressure line and low pressure line.
- Once again close the refrigerant filler neck on the vehicle with the sealing caps.
| Filling capacities of R134a/1234yf refrigerant (F90/F91/F92/F93/F95/F96/F97/F98/G70/G80 | |
| S58 | 550 g |
| S63 | 650 g |
| S68 | 550 g |