Precautions when working with the air conditioning system (Freelander 2)

The air conditioning system contains working fluids and components that, if handled incorrectly, pose a danger to the operating personnel and the environment. The following instructions are intended to familiarize the operating personnel with the hazards of the air conditioning system and to demonstrate the consequences of improper handling of this system.

Additional safety precautions are provided in the relevant sections of this manual and in the Health and Safety section. These precautions should be read before attempting any repairs.

The air conditioning system uses HFC-134a (fluorinated hydrocarbon) refrigerant R134a.

Only personnel familiar with the system and special equipment for filling and servicing it are allowed to service the air conditioning system. All operations must be carried out in well-ventilated areas, away from open flames and heat sources.

Refrigerant R134a is a potentially hazardous liquid and can cause serious injury if handled carelessly. To work with the air conditioning system, you must have special protective clothing: heat-resistant gloves, face protection, rubber boots and a rubberized apron or special gown.

First aid measures

WARNING: Due to its low evaporation temperature, R134a must be handled with care. If R134a refrigerant comes into contact with unprotected skin, it will cause immediate frostbite. Refrigerant recovery cylinders and trolleys used during refrigerant recovery may also cause frostbite.

If an accident occurs involving R134a refrigerant coming into contact with unprotected areas of the body:

• If R134a refrigerant gets into your eyes, do not rub them with your hands. Gently flush the affected eye with plenty of eye wash to raise the temperature. If there is no special eye wash, flush the eye with clean, cold water. After flushing the eye, apply a clean swab to the eye and seek medical attention immediately.
• If R134a refrigerant comes into contact with your skin, wash the area with plenty of water to raise the temperature. If you touch the refrigerant release cylinders, also wash the area with plenty of water. Wrap the affected areas of skin in woolen (or similar) blankets and seek medical attention.
• If you feel weak and suspect that you have been exposed to R134a vapors, immediately go to fresh air. If the person is unconscious, immediately take them outside the contaminated area to fresh air, perform artificial respiration and/or give them oxygen. After providing first aid, seek medical attention.

Precautions when performing maintenance

When working with air conditioning system components, follow these instructions:

• Do not pull or lift system components by hoses, pipes or capillary tubes.
• Hoses and pipelines must not be subjected to small radius bends and mechanical stress; the cooling capacity of the system will be reduced if there are nodes or any additional resistance. Before tightening the nuts, make sure that the hoses are positioned correctly, the components must be secured with all the provided fastening elements.
• Flexible hoses should not be located near the exhaust manifold (closer than 100 mm) if there are no heat shields.
• After installation, make sure there are no loose contacts between the pipes and the metal panels. Loose contact points can cause noise, so there should be no such points.
• A special torque wrench should be used to tighten the pipeline connecting nuts. An additional wrench should be used to hold the pipeline or unit from turning while tightening the nuts.
• Before connecting a hose or pipe, lubricate the O-ring seats with special oil, but DO NOT lubricate the connection threads.
• The safety plugs should only be removed before the components are actually connected.
• To avoid condensation from air entering the system when disconnecting pipes, make sure the units are warmed up to room temperature before disconnecting.
• When disconnecting air conditioning system lines, immediately install plugs or caps on all lines to prevent dirt and moisture from entering the system.
• Do not leave the openings unplugged for more than 20 minutes, otherwise a new receiver/dryer will need to be installed.
• The receiver/dryer contains a desiccant that absorbs moisture. It must be kept sealed at all times. A receiver/dryer that is left unsealed for more than 20 minutes must not be used again; it should be replaced.
• The receiver-dryer should be connected to the system last. This will ensure maximum protection of the system from moisture.
• Whenever any air conditioning system components are removed, the receiver/dryer must be replaced.
• To clean contaminated connections, use a clean, lint-free cloth dampened with alcohol.
• Components used for repairs must be labelled for use with R134a refrigerant.
• After a major overhaul of the system, it is necessary to conduct a leak test, the procedure for which is discussed in the "Repair Work" section of this manual.

Special oil used in air conditioning systems

CAUTION: The special oil used in the air conditioning system is very hygroscopic. It cannot be stored for a long time. Do not pour unused oil back into the container. Use only the recommended compressor oil.

When replacing air conditioning system components, drain the special lubricating oil into a graduated container. When installing new components, pour the same amount of oil into them - see the section "Replacing the air conditioning system compressor".

Air conditioning compressor

New compressors supplied as spare parts are hermetically sealed and filled with nitrogen. When installing a new compressor, carefully unscrew the sealing plug. At this time, you should hear the noise of escaping gas.

CAUTION: New compressors supplied as replacement parts must be sealed and may be pressurized with nitrogen. To avoid oil spillage, remove the sealing plug(s) slowly and carefully. Remove the sealing plug(s) immediately before installing the compressor on the vehicle.

Rapid refrigerant leak

If the air conditioning system is depressurized as a result of an accident, the refrigerant will evaporate completely. This happens spontaneously within a very short time. As a result, most of the lubricating oil is carried away along with the refrigerant. In this case, the compressor should be removed and all the oil drained from it. Then refill the system with oil as described in the "Air Conditioning System" section of this Manual.

Precautions for removing refrigerant, preparing it for further use and charging the system


Before filling the air conditioning system with refrigerant, the existing refrigerant must be removed from the system and prepared for reuse. After this, the system must be filled with the required amount (by weight) of refrigerant and lubricating oil (by volume).

WARNING: Refrigerant must be purified before reusing. The refrigerant purification technology must comply with regulatory requirements and ensure the required degree of purity. Refrigerant processing must be performed on equipment certified by Underwriter Laboratory Inc. to SAE J1991. If the equipment used does not meet this requirement, there is no guarantee that the refrigerant will be purified to the required degree of purity.

The R134a A/C service station is not designed to work with any other type of refrigerant. Commercially available R134a refrigerant intended for home use is not suitable for use in a car's A/C system.

Removal of the refrigerant must be performed immediately before charging the system. It is prohibited to leave the system uncharged.

Replacing the air conditioning compressor

The new compressor is supplied fully charged with lubricating oil (X cm³).

Before installing a new compressor, the calculated amount of oil must be drained from it. To calculate how much oil must be drained from a new compressor, follow these instructions:

• Unscrew the drain plug on the removed compressor.
• Turn the compressor over and drain the oil by gravity into a calibrated container. Turn the compressor shaft by the coupling to make sure that the oil has been completely drained from the compressor.
• Record the amount of oil drained (Y cm³).
• Determine how much oil should be drained from a new compressor using the following formula: X cm³ - (Y cm³ + 20 cm³) = Q cm³
• Remove the drain plug from the new compressor and drain Q cm³ of oil. Insert and tighten the compressor drain plug.

[The original article is located on the website www.LRman.ru]