N e w s l e t t e r 04

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Dear VCS Member,

Welcome to the latest edition of the Valeo Clim Service Newsletter.

Included in this edition:

NEWS

SERVICE - Flushing a contaminated system

TECHNICAL TIPS - Repairing and Servicing a Toyota Previa (2003)

COMMUNICATION

Please feel free to provide us with your feedback and suggestions for future publications

News

Welcome to our new Valeo Clim Service members:

DISTRIBUTOR GARAGE TOWN OWNER

AUTOEQUIP PIECES CITROEN SERVICES Glasgow Tony McShane BARUM AUTOPARTS BRIAN PHILLIPS Tiverton Brian Phillips BARUM AUTOPARTS MIKE ACKLAND MOTORS Tiverton Mike Ackland BARUM AUTOPARTS A.P.S. Wellington Rob Alpin BARUM AUTOPARTS SHILLINGFORD GARAGE Tiverton Roy Totterdell CAT AUTOMOTIVE SITTINGBOURNE MOT CENTRE Sittingbourne Shane Coull D A FACTORS LTD. BALMORAL GARAGE Blairgowrie Alistair DISCOUNT CAR SPARES TUTTS OF DORKING Dorking Arthur Tutt DISCOUNT CAR SPARES LEATHERHEAD MOTOR COMPANY Leatherhead Bob Butcher DISCOUNT CAR SPARES ELTON PARK MOTORS Surbiton Eric DORSET AUTOSPARES BICKERLEY GARAGE Ringwood Richard Forward DORSET AUTOSPARES PURBECK FORD Wareham Rob Lee FOREIGN MOTOR PARTS RHOS MEADOW GARAGE Pontardawe Colin Thomas FOREIGN MOTOR PARTS GARDEN CITY GARAGE Neath Gareth Stokes KEVIN COOPER ALEXANDRA MOTORS DEVONPORT LTD. Devonport Paul Worthmore KEVIN COOPER CAR SERVICES Plymouth Nick Baverstock KEVIN COOPER UNI FIT Plymouth Martin Wallis MIDWEST MOTOR FACTORS BROXWOOD VEHICLE SPECIALIST AUTO CENTRE Wolverhampton Lee Wesley

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November 2007

www.valeoservice.comValeo Service (UK) Ltd, Heming Road, Washford, Redditch, Worcestershire, B98 0DZTel : 01527 838300 Fax : 01527 523732 www.valeo.com

Be comfortablein all seasons

4 Communication

We would like to present a new product in our Air Quality

range: CLIM SPRAY™, the Valeo cabin purifi er. Due to its double

action formula, CLIM SPRAY™ purifi es the air inside the vehicle

and neutralises bacteria and odours (bacterial growth, smoke,

pets, …) on the covered surfaces: carpet, seats, roof…

CLIM SPRAY™ is simple and friendly to use, ideal for second

hand vehicles. It can be used for Cars, LCV, Trucks, Bus and Coaches.

There is no risks of condensation or stains in the cabin after

treatment. CLIM SPRAY™ leaves the car smelling clean and fresh

on the inside.

Complete treatment of the vehicle in less than 15 minutes.

With bumper-removed push, battery to one side lift radiatorback and condenser can be removed. With condenser outand radiator lifted back, it is easier to gain access to compressor. Disconnect pipes, then with a 19mm socket on tensioner plate just above water pump, relieve tension from tensioner and remove belt from compressor pulley.It is necessary to remove the fan cowl to give enough room for the compressor to be lifted out. Once on bench the new compressor can be emptied of oil and fi lled with the correct grade of Pag oil. It is suggested that half the full charge of oil is put directly into the compressor, turn the compressor a few times this will ensure that the compressor is primed with oil. The rest of the oil charge can be delivered by the ClimFill with the refrigerant recharge.into the compressor, turn the compressor a few times this will ensure that the compressor is primed

The front expansion valve (like on many Japanese vehicles) can be found under the dash behind the glove box. The bolts retaining the fan motor and recirculation unit need to be removed, the fan housing can then be pulled to one` side to allow access to the TXV (Thermal Expansion Valve). Remove valve leave pipes open to allow fl ushing. The rear A/C has an L-type TXV in line this should be removed to allow fl ushing. The way the system is fl ushed will depend upon the equipment available, as seen in the Service part before. Once the system has been fl ushed the pipes can be refi tted. The compressor now charged with new oil and rotated a couple of times should be refi tted with new O’rings to all connections. When the components are refi tted, the entire system should be charged with OFN oxygen free nitrogen and each joint checked for leaking. It is advisable to do this before the car is reassembled. If solvent type fl ushing agent is used ensure the system is vacuumed for longer than normal to ensure any trace of vapor is removed.

Once the system has been pressure tested and proven leak free (this is normally done with soapy solution on joints whilst pressurized with nitrogen) the ClimFill can be used to regas the system and to inject the remainder of the oil and UV dye as normal. A full system performance test should be carried out, cut in temperature as well as cut out temperature of the compressor monitored and recorded.

Valeo P/N: 698899

Recommended Retail Price: £8.99

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1 Clean the interior of the vehicle

2 Start the engine

3 Turn on the air conditioning

4 Program the air con to the coolest temperature

5 Choose interior air recycling mode

6 Open the vents (adjust the ventilation system to the maximum)

7 Check that the windows are closed

8 Push the passenger seat back as far as possible

9 Shake the aerosol and place it on the fl oor next to the passenger seat 50 cm away from the dashboard

10 Activate the spray (automatic mode), pointing in the direction of the cabin

11 Close the vehicle, leave and let the spray work for 10 minutes

12 DON’T FORGET TO AIR THE VEHICLE AFTER SPRAYING

CLIM SPRAY FOR A FRESH, CLEAN AND PLEASANT DRIVING EXPERIENCE!

Layout of rear A/C system in O/S rear quarter panel

NOW

IN STOCK!

VCS Newsletter Issue 4 Aug07.indd 1-3 13/11/07 17:16:09

Flushing a contaminated system These pictures are examples of contamination that require the system to be dismantled and fl ushed. This type of contamination is common after a compressor failure. If the system is put back in to service with a new compressor and without fl ushing it is almost certainly going to cause a failure of the new compressor and possibly other components. When fi xed to the A/C loop, orifi ce tubes, accumulators, expansion valves, receiver driers (as well as compressors) cannot be fl ushed so these components must be removed for fl ushing. If a new compressor is fi tted, it is normal practice to replace the

expansion valve and receiver drier or orifi ce tube and accumulator depending on the system. Whilst these are removed, we can fl ush the pipes, evaporator and condenser. If the old compressor is to be refi tted, empty out the old oil and refi ll with fresh pag oil of the correct viscosity PAG 46 (Valeo P/N: 699935), PAG 100 (Valeo P/N: 699936) or PAG 125 (Valeo P/N: 699937). Put half the oil charge directly into the compressor and the remainder can be charged with the ClimFill machine but it is important to rotate the compressor several times before fi tting back to the vehicle.

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Flushing using ClimFill

An optional fl ushing kit is available for the ClimFill. The Valeo machine already comes fl ushing prepared, that means the fl ushing kit is ready to be fi tted. It uses R134a as a fl ushing medium supplied with all bridges, adapters and full instruction on how to use. Closed loop fl ushing with liquid refrigerant is a quickeffective and more professional method of fl ushing which does not introduce anyforeign chemicals into the system that may lead to further problems. By allowing the A/C system to be split into two halves (high side and low side) an effective forward/backward fl ush can be achieved. Anyrestrictions in the system, such as the receiver drier, expansion valve, accumulator or orifi ce tube are bypassed by using the fl ushing adaptors. Reassemble the system using new o-rings and seals as required, pressure test system using oxygen free nitrogen (Valeo P/N: 699990) then recharge using ClimFill. It is advisable to extend the vacuum period to at least forty-fi ve minutes after fl ushing to ensure all vapors are removed from system before regassing.

Once regassed a system performance check should be carried out. To do so we recommend that you use the Valeo ClimTest 2, this will instantly indicate the temperatures, pressures and if the system is working correctly or not.

N e w s l e t t e r • N e w s l e t t e r • N e w s l e t t e r • N e w s l e t t e r • N e w s l e t t e r • N e w s l e t t e r

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Service

33 Technical Tips: Repairing and Servicing a Toyota Previa (2003)

Whenever a new compressor is fi tted, it is very important to replace the receiver drier and the expansion valve. On a system where the compressor has failed causing debris to enter the loop, the system must be fl ushed. It is convenient to do this at the same time as the receiver drier and expansion valve are removed for replacement.The reason for replacing the expansion valve with a new compressor is to ensure the correct control of the new compressor if the original valve was the cause of the compressor failure or contaminated by debris from the original failure. It could result in a second compressor failing with a good chance that this would not be covered by warranty.

We are now going to look at the repair and service of Toyota Previa (2003) fi tted with front and rear air conditioning systems. The vehicle in question had been fi tted with a new compressor by a third party but was presented to have the system not fl ushed. Unfortunately the system had been run and the debris from the original failed compressor had been circulated around the system.

Another name for the receiver drier is the fi lter drier as this name implies the unit contains a fi lter element to clean the refrigerant as it passes through. Like the expansion valve this cannot be fl ushed and if contaminated it must be replaced. The normal life of a receiver drier is two years, it is a service item.If the system is opened or any major componentis replaced then the receiver drier should be replaced. On this type of vehicle the receiver drier is part of the condenser often referred to as sub cooled. The two units being together as an assembly helps to dissipate the heat more effi ciently. On closer inspection the condenser had suffered a small impact and appeared to be partially blocked, the decision was taken to replace the condenser and drier assembly. To do this it is fi rst necessary to remove the bumper this is retained in place by two screws on the wheel arch each side and apron 20 screws along front edge with four clips on each side along the front.

E6000194

EVAPORATOR ASSEMBLY

CONDENSER ASSEMBLY

COMPRESSOR RECEIVER DRIER

Expansion Valve

Flushing using a portable bottle

This picture shows one method of fl ushing using a portable bottle and an airline to motivate the fl ushing fl uid. This is the simplest way to fl ush a system. It is pictured showing a condenser removed but it can be fl ushed in situation. The pipes can be fl ushed separately or when the receiver drier is removed, the pipes can be connected together and the system fl ushed in sections. Access to the various components will be the factor that dictates how each vehicle is fl ushed. It is likely that every fl ushing job will require a different approach and method.

With a portable system, you can use fl ushing solvent or fl ushing oil this is a personal choice. Fill the fl ushing fl ask with the chosen fl ushing fl uid and regulate the airline

down to about 40psi, with one end of the component or loop connected to the drain tube fl ush the section of the loop or component. For heavy contamination it may be necessary to fl ush in both directions. When the system is clean the fl ushing kit can be used with no fl uid in to remove the last traces of solvent or oil from the system it is permissible to increase airline pressure for this.

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DISTRIBUTOR GARAGE TOWN OWNER

MOTOR FACTORS GROUP PERFORMANCE CARS Plymouth Stuart Day MOTOR FACTORS GROUP MILL ROAD MOTORS Christchurch M Roberts MOTOR FACTORS GROUP SPRINT SERVICES Amesbury P Gill PCS HIGH STREET AUTOCENTRE Tibshelf David Richardson PCS MOTOR FACTORS BTS AUTO Melboorne Roger Frazier PEARLCASTLE MASTER TRAVEL Welwyn Garden City Steve Goulden STOCKWELL ARCHWAY MOTORS London Martin Herbert SUREPARTS WOODYARD GARAGE Redditch Richard Williams TMS MOTOR SPARES APPLETONS OF CARLISLE Carlisle Steven Appleton TMS MOTOR SPARES AUTOSPARKS Stranraer Steven Magee

News continued

P/N: 699992 and 699993

VCS Newsletter Issue 4 Aug07.indd 4-6 13/11/07 17:16:29